Iron Curtain 2.0 Manual (73-#B7
Contents
1. trennen nennen annee neen 15 Troubleshooting 5 2 o pe den ER RUE EE DRM GHI RUE RO HG UU DEEE 16 18 Winterizing Iron Gurtain System let hha Le Pee d 18 IroriGurtain 2 0 Limited Warfanty s aiite eR REED EG ce ERU RERUM E MR RERO ABRE 19 IRON CURTAIN 2 0 Iron Filtration System Aeration precipitation multi media filtration for 1 Iron Reduction Removal 2 Manganese Reduction Removal 3 Hydrogen Sulfide Reduction Removal Principle of Operation The Iron Curtain System uses a three step process of oxidation precipitation and mechanical filtration for the reduction removal of iron manganese and hydrogen sul fide The process of how the Iron Curtain System does each one ofthese separate procedures is the key to the successful results this product has obtained in the market place There are two main components that make up the Iron Curtain System They are 1 Iron Curtain 2 0 Aeration Assembly 2 Iron Curtain Multi Media Depth Filter The first step in any oxidizing process is to bring the raw water into intimate contact with a strong oxi dant This will begin to convert the dissolved element such as iron or manganese to a physical particle or nonsoluble precipitate A strong inexpensive environmentally safe oxi dantis oxygen which makes up about 21 of ambient air To do this the Iron Curtain System sp2. Hellenbrand IRON CURTAIN O system 20 Owner s Manual 2003 Manufactured by HELLENBRAND INC 404 Moravian Valley Road PO Box 187 Waunakee Wisconsin 53597 Phone 608 849 3050 Fax 608 849 7398 Web www hellenbrand com Email info hellenbrand com Congra tula tions on your purchase of one of the finest water treatment systems available today the lron Curtain System This patented non chemical filter system when properly applied will remove iron manganese and or hydrogen sulfide from your water supply This owner s manual is designed to assist owners and installers with the operation maintenance and installation of your new iron removal system It is our sincere hope that this manual is clear concise and helpful to both owner and installer We have included detailed instructions of general operating conditions pre installation installation start up and timer settings Q uestions Should you have any questions regarding the installation operation or servicing of this system please contact the dealer you purchased this system from Your dealer will be familiar with your particular situation your water conditions etc and should be able to address your concerns promptly and efficiently INSTALLATION DATA Date of Installation Filter Model Number Aeration Model Number Address of Installation Installed By Raw Water Test Iron Manganese pH Hydrogen Sulfide TDS lron Bacte
3. D You will need to repeat this step if the air pump shuts off while water is still discharging to the drain To start pump unplug the electrical cord for the Aeration Control Center re plug in Turn off water when only air is discharging to drain Remove the plug installed in the pressure relief valve previously installed Loosen the union nuts on the Aeration Tank Bypass Valve on the Aeration Head Make sure you loosen the nuts between the bypass and the aeration head Move the Aeration Tank to the side You then can proceed with winterizing the rest of the building You will need to make sure there is no water left below the 1 Check Valve Consult your dealer if you have questions Make sure the Aeration Tank Bypass Valve is in the service position System is now winterized When turning the system back on refer to the start up instructions on page 5 Iron Curtain 2 0 Filter Systems Limited Warranty Hellenbrand Inc warrants to the original consumer purchaser against defects in material and or workmanship from the date of the original installation as follows For a Period of THREE YEARS The 3 4 or 1 control valve s including electrical parts internal parts and valve body For a Period of TEN YEARS The fiberglass and or polyglass mineral tanks 6 Diameter 13 Diameter For a Period of FIVE YEARS The fiberglass and or polyglass mineral tanks 14 Diameter Up For a Period of ONE YEAR T
4. in conjunction with or after the complete water distribution system is drained to prevent water from entering the Iron Curtain System after it has been winterized After Iron Curtain System and water distribution system are drained make sure all water shut off valves are open Instructions for winterizing Iron Curtain Systems 1 Before shutting off the water manually shift the filter control valve to the backwash cycle 2 Unplug the electrical cords for the Aeration Control Cen ter and the Filter Control Valve Let unit backwash for 15 minutes 4 Place the Aeration Tank Bypass in shut off mode See page 11 Make sure you leave the filter tank bypass in the service position 5 Plug the electrical cord for the Filter Control Valve back in and manually shift the control valve to the fast rinse cycle 6 Unplug the filter electrical cord 7 You will need to plug the fitting for the 3 8 drain connection on aeration head 3 8 plug available from manufacturer p n 11 P108125 A Consult your dealer if assistance is needed with this step recharge frequency 10 11 12 18 14 15 16 17 18 frequency changes Shorten bleed off tube to 9 Page 8 Plug in the electrical cord for the Aeration Control Center A This will start the Air Recharge Cycle B Water air will drain out the filter drain pipe C You need to leave in this cycle until only air is discharging out of the drain pipe
5. on motor shaft Remove exhaust valve flapper screw valve keeper strip valve flapper valve flapper o ring and piston sleeve o ring from valve plate Lubricate new o rings with silicone lubricant to hold o rings in place and install in valve plate Install new valve flapper valve keeper strip and exhaust valve flapper screw 12 Ibs in valve plate Install valve plate on pump aligning piston sleeve o ring with top of piston sleeve Remove o ring from pump head Place 3 4 small dabs of silicone lubricant in pump head o ring groove to hold o ring in place and install o ring in pump head Install pump head on pump aligning exhaust port with front of pump Install four pump head screws and tighten 48 Ibs Remove any remaining gasket material from front cover and pump front and make sure both surfaces are clean Install new front cover gasket with burr side in Install front cover and four cover screws and tighten screws 20 Ibs Air pumps manufactured after 11 94 use an air filter with a hole in the center and a plastic press in retainer to hold itin place To replace air filter order p n 74 641169 Air Filter and Retainer Place air filter in place and install new retainer 15 16 Troubleshooting Complaint Problem Cause Solution Iron or manganese bleed A Inadequate backwash of filter Plugged drain line flow control 18 Clean or replace drain line flow through or staining control Sulphur odor
6. was tested and validated by WQA under their S 200 Standard 2 Uses no chemicals or salt 3 Eliminates the need for air injectors venturis or micronizers 4 No floats or air volume controls are used to regulate air volume in aeration tank which foul from iron 5 Two tank system consisting of a pressurized aeration tank and multi media depth filter 6 110V aeration pump to recharge aeration tank 7 Piggy back plug allows control valve to be plugged into same outlet 8 Canbe used on shared wells municipal water supplies or with buried pressure tanks without additional equip ment 9 Higher service flow rates 10 Better filtration results 11 U S Patent B1 5 096 596 and patent pending 12 Variable settings on air recharge that is independent of backwash frequency Operating Conditions The original Iron Curtain System has been validated by the WQA under their S 200 Filter Standard for the reduction removal of iron manganese and or hydrogen sulfide The concentration limits listed below reflectthe maximum individual limit that each contaminant was tested for separately without any interference of other contaminants in the influent water In reality these contaminants may be present in combination which may limit the filter s ability to remove these contami nants in higher concentrations In some cases individual sellers of this equipment have had success removing higher concentrations of contamina
7. Basket 6 32 31688 dade 1 67 10631 01439 Grounding Screw 22 D1269 Bleed off Tube ee 1 22 D1130 50 25 Pick Up Tube nenne 1 22 D1267 Cover 67 10631 01439 Screw Cover 22 D1273 Adapter Assembly Kit 22 A3321 51 Solenoid Operator Assembly 22 D1270 01 Shuttle Assembly 4 PI4808215 1 4 Vent Port Adapter cx 22 1220 02 Aeration Head 1 67 28996 Timer Bolt Nut 1 22 D1271 End Cap Assembly 1 22 D1272 Piston Assembly 1 22 D1267 Back Plate Bolt 3 22 D1266 ie Back Plate 1 22 15 1 Inlet Check Valve Not Shown ses 22 800 Complete Aeration Assembly 1 32 ss 15 V3180 O RING be s 1 ure 15V O Ring Pick Up Tube Not Shown 1 Item 23 Shuttle Valve Assembly See Separated Items Below Iron Curtain System FILTERED WATER OUT En Hellenbrand QUON CURTAIN 75 L 3 FIGURE 8 Iron Curtain 2 0 Aeration Wiring Solenoid valv
8. Connecting Rod Valve Plate Eccentric amp Set Screw Assy 1 Screw Cover sud Cover Fan d usan zu Motor End Cap 1 74 641169 Air Filter m 74 669213 504 HOUSING incon 1 74 633562 Gasket Front Cover 1 74 614430 Front Cover vl 74 625107 Screw Slator esuss 2 22 0T snnt a IC Complete Air Compressor 1 74 650465 405 Air Pump Service Kit Not Shown Includes 3 4 5 6 7 9 11 12 29 34 74 650571 405 Air Pump Rebuild Kit Not Shown Includes 22 33 Iron Curtain Aeration Pump Repair Instructions Air pump must be removed from Aeration Tank and have power supply disconnected before proceeding 1 TA Remove four front cover screws and remove front cover and cover gasket Remove four pump head screws and remove pump head Remove valve plate assembly Remove felt air filter on side of pump with a flat screw driver prying under the flat center retainer Remove piston sleeve from connecting rod assem bly Using an 1 8 allen wrench through the air intake hole loosen eccentric bearing and piston connecting rod assembly set screw and remove eccentric bearing and connecting rod assembly If eccentric amp bearing assembly need replacing Us ing a 1 8 allen wrench through air intake hole l
9. Cycle The rinse cycle packs the clean filter bed Raw water enters the control valve through the inlet port and is directed downward through the filter bed into the bottom distributor up the distributor tube into the control valve Water is then directed through a specific flow restrictor and out the drain port to be discharged to drain U S Patent B1 5 096 596 Patent Pending 13 14 Iron Curtain Aeration Pump FIGURE 10 Item Part No No Description Qty des 74 625646 Screw Head suus 4 74 660631 504 Head nitentem 1 74 623121 O Ring Head sul 74 625307 Screw Exhaust Valve Flapper 1 74 617045 Valve Keep Strip sax 74 621102 Exhaust Valve Flapper aad 74 623615 O Ring Valve Flapper zu 74 662150 Valve Plate 74 623537 O Ring Piston Sleeve 1 74 662784 Valve Plate Assembly 1 74 618145 Piston Sleeve 1 74 625160 Screw Ramped Intake Valve Flapper 1 74 621488 Intake Valve Flapper 1 Item Part No No Description Qty 21 74 607604 Connecting Rod Assy 1 22 74 607605
10. alled in one of two or more homes outside hosebibs farms with outbuildings yard hydrants etc a spring loaded check valve is provided and must be installed ahead of the aeration tank See Figures 1 on page 7 Install the check valve in a vertical upflow position with a minimum 6 water column above the check valve This prevents air from escaping past the check valve If the check valve is installed in a horizontal position and there is a simultaneous demand for both non filtered and filtered water the air head in the aeration tank may escape backwards past the check valve into the non filtered water line By Pass Valves Always provide for a bypass on the filter System It is recommended that a bypass be placed on both the aeration tank and the filter tank Filtered Water Normally fillered water is furnished to all household lines however outside faucets are typically left on raw water If filtered water is provided to outside faucets the filter system must be sized accordingly Caution The water pressure is not to exceed 70 p s i water temperature is not to exceed 110 F filter system cannot be subject to freezing conditions filter system cannot be subject to anegative pressure or vacuum On installations where there is the possibility of a negative pressure or vacuum a vacuum breaker or check valve must be installed at the inlet of the conditioner For example if the water service is interrupted due to a water pipe break w
11. ations 0 3 3 0 ppm Iron Every 3rd Day 3 0 6 0 ppm Iron Every Other Day 6 0 10 0 ppm Iron Every Day 10 ppm Iron Consult Factory Air Recharge Frequency Settings Based on Average Pressure 50psi and 500 Gallons Daily Use 0 3 3 0 ppm Iron Once Daily Every 24 hours 3 0 6 0 ppm Iron Once Daily 6 0 10 0 ppm Iron Twice Daily Every 12 hours 10 ppm Iron Consult Factory Hydrogen Sulfide Applications Hydrogen Sulfide H2S consumes 7 times the amount of oxygen to oxidizethan iron does Therefore for Hydrogen Sulfide Applications we use the following guideline 0 4 ppm H2S Twice Daily Every 12 hours 4 8 ppm H2S Three Times Daily Every 8 hours 8 10 ppm H2S Six Times Daily Every 4 hours See page 9 to change air recharge frequency on timer Filter amp Max Aeration 1 Service Tank Media Inlet Flow Size Cu Ft Outlet GPM 10 x54 26 x68 x16 10 x54 i 26 x68 x16 12 x52 i 30 x66 x18 12 x52 i f 30 x66 X18 Installation Diagram FILTERED UNFILTERED NON SOFTENED WATER TO WATER OUTSIDE HOSEBIBS SOFTENED amp FILTERED WATER FA T ZAN Hellenbrand XJ Hellenbrand amp 7 1 I QS MINIMUM MINIMUM s 12 1 Check Valve WATER IRON CURTAIN IRON FILTER SOFTENER FILTER TANK AERATION TANK Figure 1 When installing an Iron Curtain Filter system it is common to provide filtered water to
12. bleed through Insufficient water supply from well 2a Check for minimum specified flow and pressure requirements of filter system Plugged aeration tank inlet 3a Generally will only plug with the diffuser or pick up tube presence of iron bacteria Clean aeration assembly and shock treat the water supply with chlorine as needed to control iron bacteria Media bed fouled 4a Rebed filter and correct the cause of fouling B Fails to regenerate Interrupted electrical service 18 Assure continuous electrical supply See specific control manual check plug breaker fuses etc Faulty timer motor 2a Replace timer motor Faulty skipper wheel on Fleck 3a Replace skipper wheel Control 4a Replace 24 hour gear or timer Faulty 24 hour gear assembly C Water contaminant levels are 18 Consult dealer greater than limits established by It is not uncommon for local water the manufacturer conditions to change D Inadequate aeration 18 Check installation position of check Loss of air through inlet check valve Consult Installation and valve Operation Manual for proper position 1b Check for foreign material in seat of check valve clean or replace as required 2a Check aeration tank assembly and air Loss of air through air leak recharge line and fittings for any air leaks and repair Note soapy water solution works well for locating air leaks Faulty aeration pump due to 3a Assure permanent electrical service a Electrical failure check plug breaker
13. derstand the quality of water supplies may vary seasonally or over a period of time and that your water usage may vary as well Water characteristics can also change considerably if your water conditioner is moved to a new location For these reasons we assume no liability for the determination of the proper equipment necessary to meet your requirements and we do not authorize others to assume such obligations for us UNDER NO CIRCUMSTANCES SHALL HELLENBRAND INC BE LIABLE TO PURCHASER OR TO ANY OTHER PERSON FOR ANY INCIDENTAL SPECIAL OR CONSEQUENTIAL DAMAGES OR FOR ANY OTHER LOSS DAMAGE OR EXPENSE OF ANY KIND INCLUDING LOSS OF PROFITS WHETHER ARISING OUT OF BREACH OF WARRANTY BREACH OF CONTRACT OR OTHERWISE Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state Hellenbrand Inc 404 Moravian Valley Road P O Box 187 Waunakee WI 53597 19 20 73 514 3 03 1000
14. e 120V 7Watts Each green ground wire to be connected directly to backplate Part 22 MC100181H ITEM QTY PART NO REQ D NO DESCRIPTION IC 10 Rebed Mix IC 10A Rebed Mix 10 Rebed Mix C 12 Rebed Mix 12 Rebed Mix 12 Rebed Mix Aeration Assembly 10x54 Polyglass IC 10 Tank 12x52 polyglass IC 12 Tank 1 Check Valve Distributor Tube for IC 10 PM TF HB WM2 Series Distributor Tube for IC 10 PS AM Series Distributor Tube for IC 12 PM TF HB TS WM Series Distributor Tube for IC 12 PS AM Series ProMate HB Control 60 WM2 FLAT 5 0DLFC WM2 TF Control LU 60 263 960F 05DLFC AM PS Control Control Valve Options for Filter Valves IC 12 E nue dedeni 60 PM1FITRVLV 7 5 for PM HB Series EIER 60 WM2 FLAT 8 0 DLFC for TF TS WM2 Series SEM 60 263 960F 08DLFC for AM and PS Series Tmebewsen BWiser 58268 285581 1584 set Ous ON or 5 27 prous jore ov Jor e pros ox o jor o AIR RECHARGE TIME IS FIXED To initiate a manual cycle Disconnect power supply then restore power supply The air recharge pump will start immediately ProMate Filter Valve Option Air Pump T Filter Tank Drain Line Solenoid Vent 1 4 line to atmospheric drain Fil
15. e The solenoid valve then closes the port between the air pump and the shuttle valve The port between the shuttle valve and the atmosphere opens and releases air pressure This allows water pressure to shift the piston to the closed position With the piston in the closed position the air recharge inlet port is closed and direct communication between the bleed off tube and the drain port is also closed Timer Operation Atimer controls the air recharge cycle and how frequently it occurs The timer simultaneously energizes the air pump and the solenoid valve After a preset amount of time the timer shuts off the air pump and de energizes the solenoid valve Solenoid Valve T T1 m A Solenoid Valve Operation The solenoid valve is a three way valve having ports that connect to the air pump shuttle valve and the atmosphere In the service cycle the solenoid valve is de energized and closes the port to the air pump providing a positive shut off to the pump This prevents water from backing up into the air pump and damaging the pump In the air recharge cycle the solenoid valve closes the port to the atmosphere and opens the port from the air pump Shuttle Valve Operation Aeration Tank In the service position water pressure holds the shuttle valve piston in the closed position trapping the airhead in the aeration tank and closes the air recharge inlet port and drain port During air recharge cycle U S Pate
16. e secured Tubing has been supplied along with a 3 4 male threaded adapter See page 10 for details There is a 1 4 tube size vent port off of the solenoid valve which is vented to the atmosphere This will normally expel very little moisture unless an internal seal fails within the valve body This vent should be run to a drain to prevent any water damage to the surrounding area should the solenoid fail This must drain downward to an open atmospheric drain separate from the filter drain Recommend 1 diameter pipe between aeration tank and filter tank With the filter control valve in the service filtering position slowly open the inlet valve on the by pass to the filter and run water at a filtered water fixture until the water is clear Then continue to slowly open the filter inlet valve fully and continue to run water at a filtered water faucet until water is clear Start up is complete IMPORTANT Do not backwash your Iron Curtain Filter for 24 hours Aeration Control Center Your new IC 2 0 Aeration Control is factory pre set to cycle the air compressor once every 24 hours To adjust the frequency for the air pump refer to the wiring schematic The timer has a fixed run time which cannot be adjusted up or down To manually initiate an air recharge cycle unplug the power cord and plug it back into the electrical outlet The air pump will begin to run and will automatically shut off Iron Curtain Filter Control You
17. ell pump being serviced etc a back siphon could occur causing a vacuum or negative pressure on the filtration equipment For application parameters outside the specified operation conditions or additional information regarding the listed items contact your dealer Installation Instructions Your new Curtain model IC 2 0 allows for simple installation and start up Installation diagrams are provided to assist you Use of these diagrams and the following proce dures will ensure that the system is properly installed 1 Follow all state and local plumbing and electrical codes 2 The one inch 1 check valve that is supplied must be installed in the upflow position on the raw water supply feeding the aeration tank See figure 1 page 7 for proper check valve installation procedures 3 Wheninstalling an Iron Curtain Filter system itis common to provide filtered water to some fixtures such as the kitchen cold faucet This is typically done as a matter of personal preference n rare occassions it has been noted that the customer may experience some air in the filtered water line on the morning after regeneration It has proven to be beneficial to plumb the line for the filtered only water fixture in a downward direction from the inlet of the softener 12 inches recommended then make a reverse turn and go upward toward the fixture Under standing that air always rises to the highest point in a water system and it can
18. fuses terminal block on control valve etc 3b Check for adequate pressure and b Pneumatic failure volume production from air pump Repair or replace air pump c Damp environment 3c Clean repair or replace aeration pump ventilate environment or provide external air source Air loss through high demand 4a Increase air recharge frequency of filter See page 9 E Exceeding recommended filter Service flow rate demand is 1a Install a flow control at filter system System flow rate higher than filter system design outlet equal to or less than the design flow rate flow rate of filter system 1b Install additional filter s or a larger single filter system which meets both the service flow demand and backwash flow requirements available F Regeneration during service flow Time of day set incorrectly 1a Reset timer demand G Raw water bleeding through filter Internal control valve leak 18 Assure all adapter base o ring seals See specific control manual are in place 1b Replace seals spacer and piston assemblies Manganese can be slow to oxidize when the pH is less than 8 5 Complaint Water leaking from vent port adapter Problem A Seals failed internally Cause Pressure has exceeded rating on system Solution 1a Check pressure on system Adjust if necessary Replace shuttle assy Water is effervescent A This can be expected when water Water supply has been naturally 1a This natural phenomenon wi
19. he Iron Curtain aeration pumps and any other defective component Any parts used for replacement are warranted for the remainder of the original warranty period If a part described above becomes defective within the specified period you should notify your Hellenbrand Iron Curtain reseller and arrange a time during normal business hours for the Iron Curtain reseller to inspect the water conditioner on your premises Any part found defective within the terms of this warranty will be replaced by him You pay only freight from our factory and local Iron Curtain reseller charges THIS WARRANTY DOES NOT COVER defects caused by accident fire flood Act of God misuse misapplication neglect alteration installation or operation contrary to our printed instructions or repair or service by anyone other than the factory or authorized Hellenbrand Iron Curtain reseller EXCEPT AS EXPRESSLY PROVIDED ABOVE HELLENBRAND MAKES NO OTHER WARRANTY WITH RESPECT TO THE IRON CURTAIN FILTER SYSTEM WHETHER EXPRESS OR IMPLIED INCLUDING IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OR OPERATION OF LAW ALL SUCH WARRANTIES ARE HEREBY EXPRESSLY DISCLAIMED Our performance specifications are furnished with each water conditioning unit As a manufacturer we do not know the charac teristics of your water supply or the purpose for which you are purchasing this water conditioner Please un
20. he outlet of the aeration tank to the inlet of the filter tank Solenoid Shuttle Valve ToS Filter Tank Operation Service Cycle Raw water enters the filter tank through the inlet port of the filter control valve Upon system demand for filtered water water is directed to the top of the tank and flows downward through the multimedia filter bed toward the lower dis tributor Oxidized iron particles are trapped by the filter bed as the water passes through Filtered water enters the lower distributor and travels up the distributor tube to the outlet port on the filter valve U S Patent B1 5 096 596 SERVICE Patent Pending Step 2 Aeration Operation Air Recharge Cycle When energized the air pump sends air through the solenoid valve into one end of the shuttle valve Once Shuttle air pressure in the shuttle valve is greater than the water supply pressure at the other end of the shuttle valve the piston shifts to the open position Inthe open position the bleed off port discharges excess water and old air to the drain port through a flow restrictor Simultaneously the air inlet port opens to provide a direct connection between the air pump and the top of the aeration tank The air pump runs for a preset period of time recharging the head of air in the aeration tank Air Recharge Shut Off The timer turns power off to the air pump and the solenoid valve at the end of the recharge cycl
21. ing first New filter media is shipped in a dry 1a Clean drain line flow control 24 hours after installation condition and must soak for 24 control valve body seals spacers hours to become fully saturated and piston assemblies before a backwash cycle B Air passing through filter during Excess air accumulated in aeration 1a Bleed off valve flow control is backwash tank from aeration pump plugged with foreign material clean or replace Excess air accumulated in filter 2a Repair well pump system system from water supply or well 2b If the cause was due to temporary pump loss of water main pressure the problem will most likely correct itself with the return of continuous pressure Excessive noise during A Howling or whistling noise during Inadequate drain line size la Increase drain line size regeneration regeneration cycle Drain line is vibrating against other 2a Insulate drain line specifically at pipes conduits pipe hangers heat points of contact with other ducts floor joists etc materials Water running to drain continuously A Control valve is stuck in regenera Electrical service to control s has 1a Assure continuous electrical tion cycle See specific control been interrupted service is available check plug manual breaker fuse etc Faulty timer motor 2a Replace timer motor Foreign material lodged in piston 3a Disassemble and clean control valve replace seals spacers and piston assemblies Timer is lodged in rege
22. ll typi is aerated under pressure aerated under well system cally dissipate to the atmosphere in pressure As water is released a matter of seconds If preferred to the atmosphere air molecules water can be drawn and stored in separate from the water an open container prior to use i e fill a pitcher and store in the refrig erator for cool fresh drinking water Loss of pressure A See complaint 1 Page 16 Plugged Inlet 18 See 3a under 1 Solutions pg 16 Fouled Media Bed can also cause 2a See 4a under 1 Solutions pg 16 loss of pressure Air spurting at outside or A Inlet check valve not sealing non filtered water fixtures Improper installation location 1a Seeinstallation and operation manual for proper location of inlet Foreign material preventing check prop valve from sealing check vave 2a Clean or replace check valve Worn or faulty check valve P Air spurting from filtered water A Reduced pressure in distribution 3a Replace check valve fixtures system Service flow demand is greater than water supply available from well pump syster 1a replace well pump Water flow is restricted by supply piping wale treatment 2a Eliminate restrictions in supply equipment L pipings to water treatment equipment such as iron bacteria plugging the upper diffuser assembly etc 2b Install larger water treatment System to provide less pressure drop Loss of media through drain line A New filter backwashed dur
23. neration 4a Check program wheel pins to cycle assure back pins are not catching on timer gears 4b Check to assure timer gears are clean and free from foreign ma terials such as solder or pipe burrs 17 18 Complaint Problem Cause Solution Water running to drain B Did not plug in aeration pump prior 1 Drain port open 1a Plug in aeration pump continuously from 3 8 bleed to filling off drain line C Air pump failed during air recharge 1 Drain port open 1b Replace Repair pump cycle Blue green staining A Corrosive water condition in 1 Low pH condition of the raw water 18 On type A filters add pH copper distribution piping system supply On type A filters the pH correction media to filter tank see correction media may be depleted Installation and Operation manual 2 In rare occasions highly aerated 2a Install a polyphosphate cartridge water in combination with a specific filter after the Iron Curtain Filter water supply can create a slightly System to protect the distribution corrosive condition piping 3 Shorten bleed off tube reduce 3 See page 9 for recharge Winterizing Iron Curtain Systems Optional In certain climates where houses and or cottages are not heated during the winter months Iron Curtain Systems must have the water removed from them to protect from damage due to freezing Following are instructions for winterizing Iron Curtain Systems Draining of the Iron Curtain System should be done
24. not naturally flow downward Figure 1 page 7 4 The raw water supply from the outlet of the check valve must be connected to the down flow inlet connection on the aeration tank Refer to the stickers marked inlet outlet for proper connections A factory by pass valve is available and should be installed on the aeration tank assembly See page 10 for details Leave the aeration tank on by pass at this time Start Up 1 Onceall plumbing is finished and with the unit on bypass flush the plumbing system until water is clear and no foreign material is detected 2 Plugin aeration pump Open the inlet valve on the by pass to the aeration tank and allow the tank to fill with water and come up to full line pressure You do not have to wait for the air recharge cycle air pump running to finish before proceeding to the next step 3 Open the outlet valve on the by pass s for the aeration tank and filter The outlet from the aeration tank is then connected to the inlet of the filter tank A factory by pass valve is available and should be installed on the filter tank assembly See page 10 for details Connect the outlet of the filter system to the water system lines you are filtering The IC 2 0 aeration head assembly has a 3 8 drain connection that must be run to a drain This can tee into the drain line of the filter or to a drain independent of the filter drain Drain line emits surges of excess air from aeration tank and must b
25. nt B1 5 096 596 air pressure is greater than the water pressure and forces the shuttle valve piston in the open piston The Patent Pending shuttle valve has an internal pressure relief valve that will relieve pressure greater than 100 psi that may build up in the aeration tank This precautionary function protects components from failure due to excessive pressure 12 Solenoid Valve Shuttle rane vam av ap apa a 87 NON FILTERED WATER AERATED WATER IN BACKWASH WATER TO DRAIN BACKWASH Step 3 Filter Tank Operation Backwash Cycle Reversing the flow of water through the filter bed and backwashing dirty water to the drain cleans the filter bed Raw water enters the filter control valve through the inlet port and is directed down the distributor tube and out the lower distributor at the bottom of the tank flowing upward through the multi media filter bed toward the top of the tank into the control valve Water is then directed through a specific flow restrictor and out the drain port to be discharged to drain U S Patent B1 5 096 596 Patent Pending Solenoid Valve Shuttle 4 A 7 Aeration Tank NON FILTERED WATER OUT AERATED WATER IN T AN FAST RINSE Step 4 Filter Tank Operation Rinse
26. nts iron for example above the limitations we have listed If you are considering the installation of this system for the reduction removal of iron manganese and or hydrogen sulfide levels that are above operating conditions listed below we recommend that you con sult your dealer for proper application Installation of this System under these circumstances may void part s and or all of the system warranty pH The pH level of the influent water must be 7 0 or higher for iron oxidation reaction to proceed per the engineering specifications Iron This system is rated for a maximum of 10 ppm of ferrous clear water and or ferric red water iron Iron Bacteria If iron bacteria are present more frequent service may result life of the Iron Curtain system may be limited and the system may be unable to properly remove iron By properly controlling the iron bacteria with chlo rine or other approved methods for bacterial reduction thelron Curtain System will function properly One option to control iron bacteria within the Iron Curtain is chlorine injection during the regeneration cycle In some in stances continuous chlorination of the water supply may be needed Hydrogen Sulfide Sometimes referred to as rotten egg odor This system is rated for a maximum of 10 ppm hydrogen sulfide Hydrogen sulfide levels vary depending on barometric pressure Manganese Limit 2 0 ppm amounts present over 2 0 ppm may gradually
27. oosen eccentric amp bearing assembly screw and remove eccentric amp bearing assembly Remove piston sleeve from connecting rod assembly Remove valve flap per screw and valve flapper Remove intake valve plate screws and remove ramped valve plate and piston cup Install new piston cup on connecting rod Place a dab of silicone caulk in the center dimple on bottom side of ramped valve plate and install ramped valve plate and intake valve plate screws 12 lbs making sure the intake hole is aligned in the connecting rod piston cup and ramped valve plate Install new valve flapper and valve screw 12 lbs Slide new piston sleeve upwards over connecting rod assembly starting from the bottom forcing new piston cup to curve upwards inside piston sleeve Note If piston sleeve slides over the top of connecting rod assem bly reinstall starting from the bottom If installing new connecting rod assembly slide new piston sleeve upwards over connecting rod assembly starting from the bottom forcing new piston cup to curve upwards inside piston sleeve Note If piston sleeve slides over top of connecting rod assembly reinstall starting from the bottom 9 10 11 12 13 14 15 16 From the top of the pump insert connecting rod eccen tric bearing assembly with set screw facing air filter holes Install on motor shaft all the way and tighten set screw 8 inch pounds Note Set screw should tighten onto flat spot
28. ow rate must exceed the backwash rate for the model of filter selected at a minimum of 30 psi for the entire length of the backwash cycle See actual backwash rates in the Specifications section on page 6 Electrical Requirements for Filter Control A continuous 110 volts is required to cycle the controls and aeration pump Make certain the electrical supply is always on and cannot be turned off with another switch Existing Plumbing The condition of the existing plumbing should be free from lime and iron build up Piping that is heavily built up with lime and or iron should be replaced Equipment Location See Figure 1 on page 7 Location of Aeration and Filter Tank See Figures 1 on page 7 Thesetwotanks should be installed after the pressure tank and as close to each other as practical If you want to filter outside hosebibs be sure the filter system is properly sized to handle the flow rates required for extended periods of time in addition to the normal household demand Drain Lines All filter system drain lines must be a minimum of 3 4 or equal to the size of the drain line connection at the control valve or larger Avoid overhead drain lines when possible If used overhead drain lines are not to exceed a height of five feet above the control valve and should be no more than fifty feet in length Check Valve On applications where there is a non filtered demand for water such as joint wells where the filter system is only inst
29. prevent iron removal Note For optimum manganese reduction pH should be greater than 8 5 Organic Matter Tannins The presence of organic matter suchastannins will preventthe oxidation process of converting the dissolved element such as iron or manganese to a nonsoluble precipitate or solid substance In other words organics can tie up the iron preventing filtration The presence of organics such as tannins above 0 5 ppm voids any claims for this system to perform as stated above In some applications tannin levels below 0 5 ppm or the presence of other organics may hinder the operation of this system Chlorine The presence of chlorine in the raw water supply ahead of this system should be limited to a maximum of 1 0 ppm residual and preferably 0 5 ppm or less when fed continuously Total Dissolved Solids TDS While TDS does not directly affect iron removal it is a good indicator of potential interference Most waters have TDS less than 500 and gener ally present no problems to iron reduction If any ion becomes excessive it may cause failure of iron removal A TDS more than 750 ppm voids any claims for this system to perform as stated above Pre Installation Check List Water Pressure A minimum of 30 psi at a predetermined continuous flow rate is required to backwash the filter properly with a maximum of 70 psi to be used Actual Influent Flow Rate Water available from well pump service inlet etc The actual fl
30. r Iron Curtain Filter is factory preset to backwash every third day Adjust as necessary but never backwash less often than every three days See filter control owners manual for details Regeneration Frequency Your Iron Curtain Filter System contains a special filter media mixture which allows it to filter iron longer than standard filters between backwash regenerations However it is our recommendation to leave factory settings as is unless you wish to backwash more frequently You will have to backwash more frequently if you have higher amounts of iron iron bacteria hydrogen sulfide and or manganese present in your water supply You will also have to regenerate more frequently if you notice iron bleed through before the end of the normal service run Specifications 1042 0 TF 101042 0 AM4 IC10 2 0 PS4 1C10 2 0 PM1 1C1042 0 1242 0 TF 101242 0 AM4 1C12 2 0 PS4 11242 0 PM1 1C12 2 0 Aeration Head and Check Valve have 1 Inlet Outlet N 10 2 0 TF 1C10 2 0 AM4 1C10 2 0 PS4 1C10 2 0 PM1 1C10 2 0 HB 1C10 2 0 0A 2 0 TF IC10A 2 0 AM4 IC1 A 2 0 PS4 1C10 2 0 PM1 IC1 A 2 0 HB IC10A 2 0 10 x54 26 x68 x16 12 2 0 TF 1C12 2 0 AM4 1C12 2 0 PS4 1C12 2 0 PM1 1C12 2 0 HB IC12 2 0 2A 2 0 TF IC12A 2 0 AM4 IC12A 2 0 PS4 IC12A 2 0 PM1 IC12A 2 0 HB IC12A 2 0 12 x52 i 30 x66 x18 Water temps above 60 F will require a higher backwash rate Consult factory Backwash Frequency Iron Applic
31. r filter runs and faster flow rates Unfortunately such an ideal bed when consisting of a single media is not possible the way to solve this problem is to use layers of media The advantages of a multi media bed are 1 Longer runs between backwash times 2 Caking of the bed and breakthrough turbidity are virtually eliminated 3 Much higher service flow rates per square foot 4 Higher degree of clarity because of the heavier finer filter media in the bottom The standard Iron Curtain System uses five layers of filter media The top layer is made up of large lighter weight particles The second layer contains a slightly heavier media The third layer contains a much heavier media smaller in size than the one above The fourth layer contains an even heavier media The fifth layer is a special support bed to retain filter media so it does not pass through the distribution system and allows an even distributed flow of backwash water Operation of Aeration System The Iron Curtain System introduces air into the aeration tank and bleeds off the old head of air automatically A timer controls the air recharge cycle and how frequently it occurs The timer turns on the air pump opening the drain port and the top air recharge port of the aeration tank The air pump runs for a pre set amount of time replenishing the head of air and discharging excess water and or air to drain Advantages Over Other Systems 1 The original systems
32. rays water through a regulated head of air in the aeration tank The second step in this three step process is to provide adequate reaction or contact time for the precipitation reaction to go to completion This allows time forthe iron and or manganese particles to become large enough to filter out The aeration tank with the Iron Curtain System allows for several minutes of contacttime atthe rated service flows compared to only seconds on other systems It should be noted that this reaction time will also be affected by temperature the warmer the water the faster the reaction A low ph can slow the oxidation reaction of the iron This reaction time may also be affected by the presence of organic material such as tannins If tannins are present field tests have shown that they will not be removed and will also hinder the ability of this system to effectively remove iron manganese and or hydrogen sulfide Installation ofthis system on water supplies with more than 0 5 ppm of tannins will void warranty The third and final step is filtration for the removal of the precipitates from the water A WQA Water Filtration Study Guide states The ideal filter bed would be one with large grains at the top to prevent the formation of a surface cake and to provide large pores for course particles and small grains at the bottom to entrap smaller particles This allows the entire depth of the bed to be used as a filter This also allows for longe
33. ria yes no Tannins Hardness Alkalinity Automatic Filter Regeneration Every Days Frequency of Air Recharge Every Hours Factory default is every 24 hours Continuous Water Supply Flow Rate 9 30 PSI While the pump is running Gallons Per Minute gpm TABLE OF CONTENTS Installation Data m IESU ied ee a Sie 2 Iron Curtain 2 0 Principle of Operation Operation of Aeration System enne nnns 3 Operating GondItions 3 1 re re seve E eel Ge ie aie eee 4 Pr Installation Check List tx RR ERRARE EIL atat ete ius 4 Installation Iristructions amp Start Up doe Ia i oer obe t RERO 5 Specifications tr cedem tete gle tit aia 6 Backwash Frequency Aire Recharge Frequency nnne nnne nennen nnn nenne nennen 6 Installation Diagrami 8 Iron Curtain 2 0 Assembly Iron Curtain System amp Aeration Wiring einen 9 ProMate WaterMate amp AutoMate Filter Valve Options 1 eene nnne nennen nennen rennen nennen 10 Bypass Valve Operation rec ee Eee x ee eee ee Ea oes ea e ce oe y E e YR da EUH re E E e debes Iron Curtain Flow Diagrams Iron Cutain Aeration Pump Iron Curtain Aeration Pump Repair Instructions
34. some fixtures such as the kitchen cold faucet This is typically done as a matter of personal preference In rare occassions it has been noted that the customer may experience some air in the filtered water line on the morning after regeneration It has proven to be beneficial to plumb the line for the filtered only water fixture in a downward direction from the inlet of the softener 12 inches recommended then make a reverse turn and go upward toward the fixture Understanding that air always rises to the highest point in a water system and it cannot naturally flow downward IC 2 0 Assembly Item Part No No Description 405 Series Air Pump 1 IC Pump Feet IC Pump Feet Nut Brass Str L 1 8 NPT x 1 4 Tubing mE with Nut amp Ferrele 1 1 4 Tubing Brass Insert 2 41 1 4 Polypropylene Tubing 1 Penne 3 L 9 required 22 MC1001181H Timer Relay 0 0 1 67 28996 Bolt Timer Mount 10 24x1 3 4 1 25 759400 Conduit Seal 1 65 HA401 Electrical Bushing 1 2 d 65 183SJTW 8B Power Cord 8 ft a 65 1207 Strain Relief Elec Cords 22 01268 Upper Distributor Basket 1 67 71346 Screw Upper Distributor Basket 6 32 x 3 4 8 18SS 1 Nut Upper Distributor
35. ter Tank Bypass a Aeration Tank Bypass A Aeration Tank inlet RO Cm Filter Tank Outlet Filter Tank Intlet eed Off Drain Line 1 Check Valve Installed Vertically WaterMate Filter Valve Option Air Pump Filter Tank Drain Line Solenoid Vent 1 4 line to atmospheric drain Filter Tank Bypass Filter Tank Yolk Aeration Tank Bypass 2 a Filter Tank Outlet Aeration Tank in lon 1 Check Valve Tank Outlet Filter Installed Vertically Tank inlet 3 8 Bleed Off Drain Line AutoMate Filter Valve Option Air Pump Filter Tank b Solenoid Vent 1 4 line 27 to atmospheric drain Filter Tank Bypass Aeration Tank Bypass Aeration Tank inet Aeration Filter Tank Inlet Pam Tank Outlet Filter Drain Line 1 Check Valve Installed Vertically BYPASS VALVE OPERATION NORMAL OPERATION BYPASS OPERATION IRON CURTAIN FLOW DIAGRAMS FILTEREO AERATED WATER WATER Step 1 T OUT IN Aeration Operation Service Cycle In the service cycle raw water enters the inlet port of the aeration tank and is directed through the inlet diffuser The oxidation process begins when the water passes through the inlet diffuser and cascades through a head of air This air water contact oxidizes the iron manganese hydrogen sulfide in the water The water is directed toward the bottom of the tank and travels through the pick up tube It then passes through t
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