AFB24-180 - IBC Water
Contents
1. Pipe Valves Solenoids Water Meter with isolating valves supplied by others External Backwash 1 Micronizer All pipework connections to be flanged Note arrow flow direction or barrel union for ease of removal and maintenance Flow Controller supplied separate must be fitted before Connecting Drain Line USE PIPEWORK SIZES SHOWN IN PERFORMANCE DATA TABLE 2 Inlet Isolating Valve Manual Outlet Isolating Valve Manual Bypass Valve Manual optional Water Meter optional fit only where metering of supply is required Solenoid Valve optional fit only where raw water to service is not required during REGENERATION Valve must be 240V 50Hz operation normally open and equal to pipeline size connect to terminals 2 and 5 inside valve cover Refer Fig 17 Inlet Air Regulating Valve Manual Inlet Outlet Pressure Gauges moov Hou n o m O TI FIG 5 INSTALLATION MULTIPLE UNITS ueq oL Page 3 Page 4 25mm BSPF BACKWASH FLOW CONTROLLER 40mmBSPF OUTLET P 1 rm 40mmBSPF fe INLET RUBBER SEAL SIDE VIEW TANK ADAPTER ON TANK C L REAR VIEW 180 TOP MOUNT VALVE 240 VOLT 50 Hz FIG 1 Page 5 MEDIA INSTALLATION Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Remove the tank and riser tube assembly from the carton and make sure the softener tank is empty and clean Cover the distributor pipe with a clean2. Minimum of two pins down SET FAST RINSE TIMING Pull pins as shown for desired fast rinse time see chart Adjustable Cycle Pin e Switca Topi Service Switch i Bottom Regenesation Cycle Cam Page 10 0 E oc lt o LU LU O lt 1 o LU oc yg ATBWASSY HAMIL A quiassy JAPA Page 11 VALVE ASSEMBLY PARTS LIST Item Description No Item Description No Required Required 12G Valve Body NPT 1 49G Screw 2 13G Valve Body BSPP 1 50G Nut 2 14G Injector Assy small 1 51G Limit Switch 3 15G Injector Assy Med 1 52G Machine Screw 2 16G Injector Assy Large 1 53G Cam Screw 1 17G 1 2 Brass Pipe Plug 1 54G Cam 1 18G Cap Screw 5 55G Lock Washer 2 32G Backwash Assy BSPP 1 56G Drive Motor 100v 1 33G Ring 1 120v 50Hz 60Hz 34G Cap Screw 4 57G Drive Motor 240v 50Hz 1 Drive Motor 240v 35G Piston Assy 1 58G 50Hz 60Hz 1 36G Lower Cap Assy 1 59G Motor Screws 4 37G Cotter Pin 1 60G Wiring Harness 1 38G Manifold Gasket 1 61G Drive Link Assy 1 39G Timer Lock 1 62G Drain Shut off Valve 1 40G Motor Plate Assy 1 63G ORing 1 41G Hex Head Screw 10 64G Cover 1 42G Ground Screw 1 65G Window Cover w Fasteners 1 Cover Window Cover 43G Lock Washer 1 66G Fasteners 1 44G Nut 1 67G Top Mount Adaptor O Ring 1 4
3. AFB 57 87 114 180 338 24 180 Valve 180 Operating Pressure 280 690 kPa Inlet Temperature 5 C 48 C Electrical 240V 50Hz 3 watts maximum 40 mm om Warning A pressure reduction valve should be installed if water hammer prevails 40 mm Table at left shows recommended MINIMUM plumbing sizes 40 FAILURE TO OBSERVE WARNING WILL VOID WARRANTY Page 2 INSTALLATION Check the equipment upon arrival for damage or shortages and report same to our Office or Agent before commencing installation Locate the unit on a clean firm level foundation preferably concrete with sufficient space for operation and maintenance Level with shims if necessary Position the tank in the correct position before loading the Media The filter should be fitted with inlet and outlet pressure gauges to monitor the pressure loss through the filter It is recommended that the filter be backwashed when the pressure differential increases by 35 kPa The control system is sometimes shipped as a sub assembly to avoid damage in transit The water filter should be assembled piped and wired according to the following recommendations The following instructions are provided as a general guide The filter requires a 10amp 240 volt GPO The filter installation must be protected from the elements FIG 4 INSTALLATION SINGLE TANK BIRM IRON REMOVAL FILTER INSTALLATION Pipework Layout suggestive only mE Unit only supplied Jot 25 amp bypass line
4. Filter PROBLEM UNIT WILL NOT BACKWASH AUTOMATICALLY UNFILTERED WATER TO SERVICE LEAK TO DRAIN INSUFFICIENT SERVICE FLOW RATE Page 17 REF PAGE Page Seventeen Page Seventeen Page Eighteen Page Eighteen 1 Unit will not Backwash Automatically IS THERE POWER TO THE UNIT IS THE POWER CORD PLUGGED IN IS THERE A REMOTE SWITCH IN THE LINE ISOLATED check these possibilities and correct if necessary D IS THE TIMER MOTOR RUNNING if the timer motor is running the small driven gear on the timer motor will be turning If not replace the timer motor E BACKWASH DRIVE GEAR NOT ENGAGED check gear behind push button on timer for proper alignment and time of day lever is down and fully engaged F VALVE MOTOR MICRO SWITCH NOT OPENING OR CLOSING adjust micro switch stack Fig 19 VALVE MOTOR MICRO SWITCH BURNED OUT replace micro switch H VALVE MOTOR MICRO SWITCH NOT OPENING OR CLOSING replace micro switch TIMER MOTOR SWITCH BURNED OUT replace micro switch 2 Unfiltered Water to Service A RUBBER SLEEVE MISALIGNED OR MISSING AT TOP OF DISTRIBUTOR PIPE remove valve head and replace rubber sleeve B UNIT INSTALLED BACKWARD check arrow markings on top of valve head for correct inlet outlet plumbing C REFER SECTION 1 FOR FURTHER INFORMATION 3 Leak to Drain Page 18 A CH
5. rag or plastic so that NO gravel or media enters the distributor pipe Load the media Refer Media Placement instructions a Pour in the underbed gravel No 6 Refer Table 1 80kg b Level out the underbed gravel using a broom handle PVC pipe The underbed gravel should cover the bottom distributor by about 25mm CAUTION Do not raise the distributor pipe If gravel is allowed to get under the distributor empty and start again b After loading and levelling the No 6 Gravel underbed half fill the tank with water and add the Birm Refer Table 1 126kg Slowly fill the tank To obtain optimum performance from your unit exercise particular care in ensuring that each grade of media is levelled evenly over the previous layer Fill the tank with water to 50mm from the top Clean top of tank neck amp threads of all traces of media Remove the rag or plastic fitted in Step 2 taking care not to raise the riser pipe Unpack the valve remove the cap screws and separate the adaptor Store gasket safely Check that the tank O ring seal is in place Remove the rubber sleeve and using a little silicone O ring lubricant lubricate the inside surface only Place rubber sleeve into tank adaptor Refer Fig 1 Fit the adaptor to the tank carefully to allow the riser pipe to locate centrally Screw down firmly by hand Do not over tighten Place the gasket on the tank adaptor fit the valve body with cap screws provided Tighten cap
6. screws evenly Refer valve assembly Page 6 Page 6 COMMISSIONING Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Check plug is dry first then connect lead into power outlet switch on Remove clear cover from timer face by pulling the two black lock pins outward Depress the red knob Fig 14 and rotate anti clockwise to backwash position release red knob wait for valve drive to index to backwash position if not already in this position spindle fully out Fig 1 1 Just open inlet isolating valve approximately 1 1 2 turns Allow unit to fill slowly water will issue to drain continue to run until the unit automatically indexes to Pause position which may take up to 20 minutes All air must be removed Depress the red knob and turn anti clockwise until the microswitch trips into the fast rinse position Allow the valve to move fully into this position Fig 13 Further rotate the red knob anti clockwise so that the arrow tip is pointing at about a seven o clock position Then allow the red knob to advance electrically around to the Service position This may take up to 10 minutes Depress the red knob and turn anti clockwise to start release the unit will now go through each cycle Backwash purge and back to service automatically NOTE Asmall amount of media may pass to drain during the initial backwash this is considered normal Check with site supervisor that unit can go o
7. 5G Screw 2 68G Side Mount Adaptor NPT 1 46G Switch Bracket 1 69G Side Mount Adaptor BSPP 1 47G Terminal Strip 1 70G Distributor Seal 1 48G Marker Strip 1 71G ORing 1 Page 12 SEVEN DAY 440 TIMER LIST OF PARTS Item Description No Item Description No Required Required 14A Cam Screw 1 89F Day Dial Washer 1 16A Timer Mounting Screw 3 99F4 7 Day Tripper Assy 1 Limit Switch 2 1G Timer Bracket 1 14F7 Skipper Wheel 7 Day 1 2G Adjustable Cam 1 15F Friction Washer 1 3G Timing Pin 36 18F Motor Mounting Screw 2 4G O Ring 1 19F Wire Nut 2 5G Retaining Washer 1 84F Cover Plate 1 Switch Insulator 2 85F Screw 4 7G Switch Spacer 2 87F Compression Spring 1 8G Switch Mounting Screw 2 88F Gear Retainer 1 9G Wiring Harness 1 Seven Day 440 Timer TY zl D x la is aa M maar eee WIRING DIAGRAM 440 F 4 als 2 25 SIX DAY SEVEN DAY TIMER i be FIG 17 1 NEUTE Page 13 IR 195 a 4 B 2 D MODEL 180 VALVE CAM POSITION GENERAL MAINTENANCE For correct operation the cam should be set to stop the position at the point of each function This is done at the factory and rotation checked at this time However resetting may
8. COMMERCIAL WATER FILTER INSTALLATION amp OPERATING INSTRUCTIONS Model AFB24 180 Serial No Manufacturer and Supplier of FILTRATION amp WATER TREATMENT PRODUCTS gt Water for commercial industrial and residential application Quality F AUS Telephone 07 3219 2233 Facsimile 07 3219 2266 Email sales Oibewater com au Website www ibcwater com au Page 1 OPERATING PRINCIPLE Iron Removal Birm Iron is removed by catalytic oxidation and filtration in the media bed both soluble and Insoluble iron is removed in one operation under most conditions The unit normally only requires Backwashing periodically to restore the filter bed Chemical regeneration is not normally required Operating Parameters Water Temperature 5 C 48 C Water pH 6 8 8 5 Water Pressure 280 690 kPa Oil amp Hydrogen Sulphide To be absent Colloidal Iron To be absent Suspended Solids 5 mg l Alkalinity 4 mg l for each 1mg l of Iron and or manganese Max 4 5 mg l organic matter as indicated by dissolved oxygen consumed value 1596 dissolved oxygen of iron level NOTE If fitted with a micronizer to induce oxygen into the water prior to the filter install the micronizer on a valved by pass as indicated in figure 4 AF SERIES FILTERS Table 2 TYPE MODEL CONTINUOS PEAK FLOW BACKWASH VALVE APPROX FLOW RATE RATE L P M FLOW RATE WEIGHT KG L P M L P M Multi Media
9. ECK PLUNGER POSITIONING refer Fig 12 B CHECK DRAIN SHUT OFF O RING located in upper cap refer Part No 35G 4 Insufficient Service Flow Rate A UNIT MAY BE FOULED WITH SUSPENDED SOLIDS backwash and check again B SERVICE INLET OR OUTLET VALVE NOT FULLY OPENED ensure they are opened C PISTON OUT OF POSITION reposition refer Fig 12 Page 19
10. ast START to BACKWASH Disconnect electrical power and leave in position for desired time Reconnect electrical power b Pushin RED KNOB and repeat for all desired cycles Step 2 MANUAL INITIATION OF REGENERATION a Reconnect electrical power Page 9 b Push in RED KNOB and turn counterclockwise to the START position Release Unit will then go through a complete regeneration as programmed BACKWASH CYCLE TIME INSTRUCTIONS PIN TIME CHART TYPICAL FILTER APPLICATION CYCLE BACKWASH OR PAUSE FAST RINSE Backwash 20 min 5 pins outward NO OF TIME NO OF TIME Pause 1 5 min 2 pins inward PINS PINS IN Fast Rinse 11 min 2 pins outward OUT 1 8min 2 1 5 min 2 11 min 3 4 5 min Rotatior 3 14 min 4 7 5 min 4 17 min 5 10 5 5 20 6 13 5 min 6 23 7 16 5 min 7 26 8 19 5 min 8 29 min 9 22 5 min 9 32 min 10 25 5 min 10 35 min 11 28 5 min 11 38 min 12 31 5 min 12 41 min 13 34 5 min 13 44 min 14 37 5 min 14 47 min 15 40 5 min MN Pins Outward 15 50 min 16 43 5 min Pins Inward Each additional pin either pulled out or pushed in equals 3 minutes TIMER REAR VIEW SET BACKWASH TIMING Pull pins as shown for backwash time desired see chart SET PAUSE TIMING Depress pins as shown for desired brine rinse time see chart
11. be necessary from time to time should the unit fail to draw brine Setting is simple index position to service position fully in switch off power loosen screw A adjust cam to position shown above Switch on power MICRO SWITCH STACK ad SCREW L Wess CAM a sa jx SCREW A nh SHAKEPROOF WASHER FIG 19 Page 14 WATERITE MICRONIZER HOW TO INSTALL REPLACEMENT PARTS The Waterite micronizer consists of high impact ABS plastic body containing two water passages The water passages closest to the check valve M 005 contain built in convergent and divergent cones forming a venturi The venturi causes air to be drawn into the water stream when water is flowing The second water passage acts as a by pass The percentage of water flow allowed through the by pass is regulated by the valve gate M 003 gate retainer M 002 assembly This in turn regulates the amount of air drawn into the water stream through the venturi Turning the valve gate screw clockwise into the by pass serves to restrict water flow in the by pass and at the same time force more water through the venturi passage This in turn causes more air to be drawn into the water stream In the event that parts must be replaced this can be accomplished by following a few simple instructions 1 To replace the rubber check valve M 005 wet the check valve with water or silicone oil and install itin the main body Thread the cap
12. down snugly by hand Do not over tighten Failure to lubricate the rubber properly will cause the valve to twist inside the cap and will result in leakage of water through the valve If this should occur remove the valve re lubricate and re install it 2 To replace the O ring or valve gate gate retainer assembly start by wetting the rubber O ring with water or a silicone oil Carefully insert the O ring into its seat in the bottom of the hole in the main body Thread the valve gate fully into the gate retainer Thread the gate retainer into the main body by hand to a snug fit With use of a suitable tool wrench or pliers turn the gate retainer another 1 4 turn into the main body Do not over tighten NOTE To prevent leakage through the 1 NPT threads use teflon tape during assembly Care should be taken when wrapping the tape over the threads to ensure that no tape enters the micronizer and clogs the venturi CAP kumi s le ae 4 M608 Sy CHECK VALVE 05 MA N BODY MICRON ZER no W 288 VALVE GATE M C93 GASE RETAINEA l M 202 mem f ET ja SN Pee 2 12 52 MN PAINAT jo e i H RING fa MOT N aer Page 15 MEDIA PLEACEMENT BIRM FILTER Table 1 Sequence in Tank AFB24 1 st 80kg 6 gravel in bottom of tank 4 x 20kg 126kg Birm and 7 x 18kg Page 16 TROUBLE SHOOTING GUIDE AFB20 180 Birm
13. n line If so slowly open outlet isolating valve fully check that manual bypass valve is fully closed This unit is now on line Check for and report any leaks Set the backwash frequency to Tuesday and Saturday for Carbon Filter if frequency of backwash has not already been calculated To set PUSH the skipper pins IN on the skipper wheel on days Backwashing is required Note This is only a guide for initial setting and should be altered to suit each individual installation in accordance with load conditions Turn the dial to the correct day of the week on which you are setting the dial Now depress the pins for the desired day s for backwash required Page 7 Step 9 Step 10 Step 11 Step 12 Set time of day pull timer knob Fig 14 and set arrow to the time of day time of your watch release make sure that the knob has re engaged gear knob right in Backwash will take place at approximately 2 am If this time is not convenient it will be necessary to offset the time of day setting to make allowance for the desired time of backwashing eg if 4 am is desired it will be necessary to set the time of day two hours earlier than actual time Replace the timer cover depress the lock pins and wipe over unit Check that the micronizer is injecting oxygen into the feed stream check that the side valve gate is screwed all the way in and that the vacuum is occurring at the barbed fitting To do this place a finger over the
14. open end of the fitting and check for vacuum effect If a vacuum can not be felt it will be necessary to restrict the main inlet valve to the filter so as to force more flow through the micronizer Make sure the micronizer bypass loop valve is fully open Do final check for leaks etc Ensure instruction book is kept with relevant personnel Run the unit and check the water quality produced Page 8 DRIVE PISTON POSITIONING Fi IZH Zo wn far e mM 2 9 1 SERVICE POSITION 2 n e 2 ie Pr jen gu a 2 BACKWASH POSITION 4 FAST RINSE POSITION SKIPPER SKIPPER SET TIMER WHEEL PINS Determine a regeneration schedule for the conditioner and adjust the automatic timer as follows 1 Pull all SKIPPER PINS out away from control 2 Rotate SKIPPER WHEEL until DAY ARROW points to day of week or number 1 3 Depress SKIPPER PIN S for day s regeneration is required 4 Pull TIMER KNOB out away from timer face and rotate until BLACK ARROW on tripper arm points to correct time of day on Face Plate 5 Timer will automatically initiate regeneration on preset days at 2 30AM To alter time simply reset TIMER KNOB to an earlier or later time which will change the time of regeneration by the same number of hours Time indicated as BLACK ARROW will no longer be correct MANUAL OPERATION Step 1 START UP OR INSPECTION REGENERATION a Pushin RED KNOB and turn counterclockwise p
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