Crossflow AMF TM 201 High Efficiency Media User Manual and
Contents
1. ANCED MEDIA FILTER BY Pg ADW Unit E Filter Technology Centre Blaenau Gwent F 01495 291884 E mail Web Crossflow AMF 201 High Efficiency Media User Manual and Installation Guide Industrial Purification Systems Limited Customer Name Filter model Customer Order Number IPS Contract Number Vessel Serial Numbet Site Location Dispatch date NAH CrossFlow AMF 201 HHH HHH HH HHH HHH NAH Page 1 of 58 ma OF industrial Roseheyworth Business Park Purification Abertillery T 01495 294500 O AN Ltd sales industrial purification co uk www industrial purification co uk Unit E amp Filter Technology Centre A yi Industrial Roseheyworth Business Park o MEDIA FILTER BY Ips 1 Purification Abertillery 01495 294500 oe Systems Ltd Blaenau Gwent 01495 291884 sales industrial purification co uk www industrial purification co uk Components list Taking Delivery Of The Filter CrossFlow AMF Serial Number uon were applicable MA 301 Control Panel n a Pedrollo Pump Automatic Valves Options included No additional options requested TT e The filter will be delivered with the control system BD before the carrier leaves the site ensure there is no obvious damage to the packaging If there is evidence of damage at all note this on the delivery documentation e Allexcess shottages must be reported to Industrial Purification Systems Limite2. ToD BW Sat No Duplicate ToD BW Sat 00 00 NO NOBACK W YES FILTERING STOP I BW int I MBW Unit E Filter Technology Centre Industrial Roseheyworth Business Park 1 DS iii Purification Abertillery 01495 294500 LDS yeu Systems Ltd Blaenau Gwent 01495 291884 sales industrial purification co uk www industrial purification co uk e Press hold button twice to CONFIRM selection the to confirm ToD BW Sun 00 00 V Confirm e After confirming the hours amp then the minutes to zero the display by pressing 0 button The display asks for a final YES button or No button that no backwash is required for that day sun by pressing amp holding the button ToD BW Sun 00 00 NO NOBACK W YES FILTERING STOP I BW int IMBW The next series of displays are associated with the e Valve opening electric actuators only e Valve closing electric actuators only e Delay time time between solenoids in a Spin clean programme e Settling time media settle time CrossFlow programme or CAB vessel re fill time in a Spin clean e Set user PIN from factory default VALVE OPEN time from 0 to 999 seconds in this example 012 seconds to set e To alter the figure between a low of 00 amp a high of 999 press amp hold the button SET OpenT 012 to increment down one or press amp hold the button to increment up one set Confirm to 012 e Press and hold button to CONFIRM selection SET een en e If NO adjustment is
3. Cross Flow Media Filter Press the amp buttons to RUN the filter VR1 ON inlet valve operates to open OPENING TIMER user adjustable VR2 ON outlet valve operates to open OPENING TIMER user adjustable PRI ON 240vac output to start process pump DELAY OR INTERVAL TIMER STARTS unit in filtration mode BACKWASH TRIGGERED FROM TIME Ap OR MANUAL PR1 OFF 240vac output to stop process pump VR1 OFF inlet valve operates to close CLOSING TIMER user adjustable VR2 OFF outlet valve operates to close CLOSING TIMER user adjustable SETTLE TIMER user adjustable time to media bed to settle VR3 ON drain valve operates to open OPENING TIMER user adjustable VR4 ON backwash valve operates to open OPENING TIMER user adjustable PR2 ON 240vac output to start backwash pump BACKWASH TIMER user adjustable PR2 OFF 240vac output to stop backwash pump VR3 OFF drain valve operates to close CLOSING TIMER user adjustable VR4 OFF backwash valve operates to close CLOSING TIMER user adjustable SEQUENCE RETURNS TO START Page 29 of 58 Unit E Filter Technology Centre Industrial Roseheyworth Business Park 1 DS a Purification Abertillery 01495 294500 LPS yeu Systems Ltd Blaenau Gwent 01495 291884 sales industrial purification co uk www industrial purification co uk Starting amp Commissioning the System Please ensure before commissioni
4. The information contained in this Material Safety Data Sheet was the best available at the time of printing The information is provided for guidance only for the purpose of determining health safety and environmental measures The information is given in good faith no warranty is implied with respect to the quality or specification of the product Since the circumstances and conditions in which the product may be used is beyond our control the supplier does not accept liability for any loss or damage however arising that results directly or indirectly from the use of this information The user must satisfy himself herself that the product is entirely suitable for his her purpose The user should check for particular requirements of the region and or country in which the product is to be used Page 43 of 58 Unit E e Filter Technology Centre Roseheyworth Business Park Industrial 1 S Purification Abertillery T 01495 294500 p Systems Ltd Blaenau Gwent F 01495 291884 E mail sales industrial purification co uk Web www industrial purification co uk Documentation e EC Certificate of Conformity e EC Declaration of Incorporation e Safety Notice Page 44 of 58 Unit E m o TM Filter Technology Centre C R h Industrial Roseheyworth Business Park 3 MEDIA F ILTER BY IPs 1j DS a Purification Abertillery 01495 294500 NDNANCE SOT SOUTER Ltd Blaenau Gwent 01495 291884 sales industrial purifi
5. Backwash Press and hold in the until the display indicates that the unit is starting then release In this example the CrossFlow will sequence as follows e Close inlet valve PCB ref VR2 e Close outlet valve PCB ref VR2 e Stop process pump PCB Ref PR1 if fitted 15 33 FILTERING e Open drain valve PCB ref VR3 rea ee e Open backwash valve PCB ref VR4 e Start backwash pump PCB Ref PR2 if fitted 15 33 FILTERING STOP BW int MBW e Time of day in 24 hour format e BACKWASH the unit is in backwash e STOP L HD press amp hold the button e MAN BW indicates a manual backwash cycle 15 32 RUNNING STOP gt gt BW e Close dtain valve PCB ref VR3 e Close backwash valve PCB ref VR4 e Stop backwash pump PCB Ref PR2 if fitted e Open inlet valve PCB ref VR1 T rom e Open outlet valve PCB ref VR2 STOP I gt gt BW e Start process pump PCB Ref PR1 if fitted e Start backwash timer user adjustable 15 33 BACKWASH e Time of day in 24 hour format STOP MAN BW e FILTERING the unit 1s 1n filtration mode e STOP L HD press amp hold the button to stop the unit e BW int indicates backwash is a timed interval user selectable from 1 to 24 hours e MBW R HD press amp hold the button to trigger a manual backwash Timed Interval Activated Backwash If the user has selected the backwash to be via a timed interval BW Int set in hours amp 15 minute steps see the user se
6. Business Park Purification Abertillery T 01495 294500 Systems Ltd Blaenau Gwent 01495 291884 sales industrial purification co uk www industrial purification co uk Operating Manual for the AC 5 Filtration Controller AC 5 Filtration Controller The AC 5 controller is of a printed circuit board design with its logic controlled from a processor chip The PCB is mounted in a 380mm x 300mm x 120mm flame retardant G W T 960 C and IP55 rated enclosure and comes complete with external mounting brackets The AC 5 has a user interface selected from a combination of 3 buttons these allow the user to set a variety of operating parameters which is explained in detail further in the manual The AC 5 controller requires power from a 13 amp 240 vac 50 Hz power supply supply cable not provided as standard It recommended that ISOALTION is provided not provide as standard The unit has two off 240 vac power relays for pump operation designated PR1 Process pump amp PR2 backwash pump which are protected by a 10 amp anti surge fuse Note PR1 amp PR2 is switched LIVE only neutral is not switched The maximum kW rating for a pump would be 3 kW above this an external connector amp overload box would have to be employed The units control circuitry and valve relay outputs are 24 vac and is protected by a 2 amp fuse the PCB has two LED s to indicate Green LED processor supply is ON and healthy Yellow LED 24 vac valve
7. Cra Wie sss scsissccesscsvesseecesescscassvecetecseaccsuccwasarevesesssessuatecsuctesawesdessesencvessavedestesevstecssesessaekes 39 PA OCG DISSE AA UNI I Ud T S INN 40 POCUMENTATION HC TONG eden eq Palme red qr Basaan 44 EC Cernica OF ONO O dee 45 Page 3 of 58 Unit E sales industrial purification co uk www industrial purification co uk TM Filter Technology Centre C R b A Wk Industrial Roseheyworth Business Park MEDIA FILTER BY IPs 1 DS a Purification Abertillery 01495 294500 ail SOT SOUTER Lta Blaenau Gwent 01495 291884 EC Declaration of IncorpordlOLD sssrin AAO 46 Say OU e 47 PONIRONIEN Dos Bl m 48 CROSSFLOW AMF SPARE PARTS eeeeeeeeeeeentenntnennene nennen nnene neenon steterit tttm teste tne tee etre teste testae 49 menge CES NG a NO AA 50 WARRANTY CONDITIONS amp LIMITATIONS eese nnne nnne nnnrnen nennen nennen nnne 51 GENE OL CLIENT ANA PAANAN AAKALA AE HUI MT MINUM MIU 53 BASIC TROUBLESHOOTING ASSISTANGE iseskisttiskssseok iei in au S0 Fon uto Sa ai 54 Trouble Shooting Flowchart sA sad rio pa Ia E PRU RER NAINA NENGKA 55 APEE NID ONERE S 56 FiecincActmator Deras eU B M 56 Electric actuator wiring drawing 111111117700000001 eene nennnnn nnn nnn nnn nnne sess
8. Ltd Unit 10 Lea Green Business Patk St Helens Merseyside WA9 4TR United Kingdom Tel 44 0 1744 811652 Fax No 44 0 1744 833687 E mail sales industrial purification co uk Page 52 of 58 V 7 iy tt ME ILA FILTER EY Ps AWANE General Disclaimer Industrial Purification Systems Ltd Unit E Filter Technology Centre Roseheyworth Business Park Abertillery T 01495 294500 Blaenau Gwent F 01495 291884 sales industrial purification co uk www industrial purification co uk IPS Ltd does not assume responsibility for any loss of profit loss of goodwill loss of use cost of removal and re installation of items or any collateral incidental or consequential damages of any nature any inconvenience or interruption in operation connected to faults or defects in the equipment e No person including IPS LTD s employees agents and dealers may assume on behalf of IPS Ltd any commitment or liability with regards to the equipment which is expressively covered by this warranty exhausts IPS LTD s liability No other warranty expressed or implied applies to this equipment and the warranty herein set out e We remain at your disposal for any information regarding the correct and proper use of the equipment Page 53 of 58 Unit E TM Filter Technology Centre C RO b V Industrial Roseheyworth Business Park p MEDIA FILTER BY jpg 1 DS a Purification Abertillery T 01495 294500 AINA LDS yen Sys
9. Unit E TM Filter Technology Centre C R WA 1 Industrial Roseheyworth Business Park s MEDIA FILTER BY Ips 1 DS a Purification Abertillery 01495 294500 sm O NAE Ltd Blaenau Gwent 01495 291884 sales industrial purification co uk www industrial purification co uk Differential Control The differential pressure input to the controller is received from the factory fitted supplied Bacarra digital AP switch The power required to operate the AP switch is 24 vac with a normally open dry contact and is fed from the control panel terminals Differential Pressure Switch Connection Table TERMINAL BOARD ID CABLE IDENTIFICATION COLOUR DP Sup RED DP Sup BLACK 5V WHITE GREEN Oy The following parameters are factory set and can only be accessed and changed in the FACTORY settings page only see Factory settings page if supplied e AP delay is the time a signal has to be present before it will cause a backwash e AP disable is an additional time after starting or restarting the filter before another AP can be allowed e AP maximum the number adjustable from 2 to 10 of consecutive AP backwashes to cause an a AP fail alarm via the BMS relays see section on BMS signalling BMS Signalling amp Inputs If requited the AC 5 controller can provide three volt free normally open or closed contact signalling relays and two volt free ot switched 5 volt inputs Signalling Relay Output Table DAD Relay m Relay Rela
10. Unit E TM Filter Technology Centre C RO ii 3 A 1 Industrial Roseheyworth Business Park gr MEDIA FILTER BY Ipg 1 DS x Purification Abertillery T 01495 294500 a LDS yen Systems Ltd Blaenau Gwent 01495 291884 sales industrial purification co uk www industrial purification co uk Commisioning Settings This section is completed as a future reference point for customers if the commissioning service is requested Commissioning Date Engineer Customer System CrossFlow AMF 201 Serial Number HHH Micron Rating 0 45 nominal Application Process Water Pump Model CPm130 Timed Backwash 2 minutes min to max undefined 1 hr min to max recommended 7 Cycle Timer Between days Backwashes normal setting 24 hrs Panel Voltage 240 1 50 hz Differential Pressure N A 0 5 0 7 bar recommended Filter Outlet Flow 1 5 5 cubic meters hour max Backwash Volume 26 Litres at 2 min cycle Backwash Pressure 2 5 bar IN THE EVENT OF A NON IPS COMMISSIONING ENGINEER ATTENDING SITE THIS SHEET MUST BE FAXED TO IPS 44 0 1744 833687 IN ORDER TO VALIDATE WARRANTY Page 50 of 58 Unit E TM Filter Technology Centre C RO EN A 1 Industrial Roseheyworth Business Park x9 MEDIA FILTER BY Pg 1 DS x Purification Abertillery T 01495 294500 LDS yen Systems Ltd Blaenau Gwent 01495 291884 sales industrial purification co uk www industrial purification co uk Warranty Conditions amp Limitations A5 is in your interest to
11. e To return to the main display press and holding in the mid 0 followed by pu ps aa jid pressing and holding the and buttons simultaneously or it will FILTERING automatically return after 20 seconds without any key operations STOP I BW int I MBW Page 20 of 58 Unit E hc e Filter Technology Centre V 4 Industrial Roseheyworth Business Park vy MEDIA FILTER BY IPs 1 S Purification Abertillery 01495 294500 i p Systems Ltd Blaenau Gwent 01495 291884 sales industrial purification co uk www industrial purification co uk User Settings The AC 5 filtration controller has two levels of setting both of which are password protected User settings Factory settings Maximum differential activated backwash cycles to activate the alarm The controller has an in built buzzer alarm and a volt free BMS relay output see BMS Signalling Section for further information Backwash duration set in minutes Backwash activation type either timed interval or specific time of day amp days of week TOTAL TIME BWs Valve opening delay time set in seconds LOG 00001 I gt FILTERING STOP I BW int I MBW Valve closing delay time set in seconds Delay time Spin Clean filter Only Settlement timer CrossFlow Filter only Set user PIN Default set to 3344 can be reset by user from original factoty issued passwotd Factoty settings allow the factory authorised engineer to set the following parameters Reset data lo
12. ingestion Material is irritating to mucous membranes and upper respiratory tract To the best of our knowledge the chemical physical and toxicological properties have not been thoroughly investigated Hazardous properties are relatively improbable 12 ECOLOGICAL INFORMATION Considered non hazardous provided the material is handled and disposed of with care and attention No other data available 13 DISPOSAL CONSIDERATIONS As an inert material an approved solid waste disposal or landfill site may be used Observe all local and national environmental regulations 14 TRANSPORT INFORMATION No special precautions required Non hazardous CDG UK IMDG ICAO IATA Page 42 of 58 Unit E TM Filter Technology Centre C R By M Industrial Roseheyworth Business Park nee ia DIA FILTER BY IPs 1 DS a Purification Abertillery 01495 294500 povanc SOT SOUTER Ltd Blaenau Gwent 01495 291884 sales industrial purification co uk www industrial purification co uk 15 REGULATORY INFORMATION Supply Label Information Not classified The following risk and safety phrases are recommended R36 irritating to the eyes R37 irritating to the respiratory system S36 wear suitable protective clothing 16 OTHER Training Advice Wear and use personal protection equipment as appropriate to the situation and quantity of material handled Material Safety Data Sheet complied in accordance with EU Commission Directive 93 112 EC
13. later in the document First make sure the gate valves on the backwash inlet V3 and process outlet V2 are closed Now via the top flange fill half the vessel with clean fresh water This is to ensure no damage O O O O O occurs to the backwash nozzles located within the vessel base Load the base media in the correct order beginning with the largest size first 1 e Grade 3 with the applicable quantities both shown within the media depth table below Level each layer before continuing with loading the next layer Once complete place the top flange back onto the vessel in the same orientation as it was removed remembering to securely screw the vortex feed pipe via union The AMF and other support media needed to fill the vessel is supplied in manageable 25Kg bags and are identified from the base layer upwards by grade 3 coarsest to Reactive media with Zeta potential finest Page 14 of 58 Unit E sales industrial purification co uk www industrial purification co uk TM Filter Technology Centre C RO WAY Industrial Roseheyworth Business Park 7 MEDIA FILTER BY IPs 1 DS a Purification Abertillery 01495 294500 ADVANCE O NAE Ltd Blaenau Gwent 01495 291884 Media Depth Loading Table CrossFlow 125 200 300 600 900 1200 Weights in Kg ee PO Po eee mE s OU oL oL Reactive Media with Zeta Potential Page 15 of 58 Unit E Filter Technology Centre Industrial Roseheyworth
14. or press amp hold the button to increment f up one set to 80 Press and hold 9 button to CONFIRM selection If NO adjustment is required press and hold 0 button to CONFIRM SET MAX DP 03 The display will then move to the next setting 4 CONFIRM FILTERING STOP I BW int I MBW SET BW DUR 020 4 CONFIRM FILTERING STOP I BW int I MBW SET BW DUR 080 4 CONFIRM FILTERING STOP I BW int I MBW Page 23 of 58 Unit E Filter Technology Centre e 1 N WM Industrial Roseheyworth Business Park vy MEDIA FILTER BY IPs 1 S Purification Abertillery 01495 294500 i L Systems Ltd Blaenau Gwent 01495 291884 E sales industrial purification co uk www industrial purification co uk To set backwash activation type or either interval or time amp day e Choose backwash activation type of either interval INT or time of day TOD e To alter between INT and TOD press amp hold the button to toggle between the two Select INT ToD BW Sat 00 00 e Press and hold button to Choose selection 4 PRU T STOP I BW int I MBW e A flashing cursor can now be seen under the first set of digits which sets the hours between 00 to 23 e To alter the hours between 0 23 press amp hold the button to increment down one or press amp hold the button to increment T up one e g set to 12 e Press and hold 0 button to CONFIRM selection the cursor will index to the minutes e If NO hour adjustment is required press and h
15. read fully the following terms of warranty BEFORE calling an engineer on site WARRANTY TERMS e The warranty period is for a period of 12 months from date of commissioning or 13 months from date of delivery Unless agreed otherwise in writing with IPS Ltd in writing prior to dispatch e Warranty is conditional on the system being maintained in accordance with the manufacturer s recommendations which requires a minimum of one service per annum dependant on duty For advice on the service of the CrossFlow AMF 301 filter please contact our Service Department on 44 0 1744 811652 e Warranty does not include normal serviceable parts if these items are replaced during the 12 month warranty period they are chargeable e Call outs resulting in failure of the equipment due to inadequate maintenance will result in a charge for any parts or labour costs incurred e The purchaser shall inspect the equipment immediately upon receipt of goods Any defects are to be reported to IPS Ltd via Tel No 44 0 1744 811652 within 48 hours of receipt of the goods e The purchaser shall deliver the defective equipment or part to IPS Ltd immediately after discovering the defect in accordance with IPS Ltd s delivery instructions unless agreed otherwise with an authorised representative of IPS Ltd and confirmed in writing by that representative e IPS Ltd shall not be liable for any damage nor loss occurring during transportation The responsibi
16. required press and hold 9 button to CONFIRM J CONFIRM e The display will then move to the next setting VALVE CLOSE time FILTERING e VALVE CLOSE time from 0 to 999 seconds in this example 010 seconds to set e To alter the figure between a low of 00 amp a high of 999 press amp hold the button Scr deer t to increment down one or press amp hold the button to increment up one set Confirm 4 to 010 e Press and hold 0 button to CONFIRM selection e If NO adjustment is required press and hold 9 button to CONFIRM 4 CONFIRM e The display will then move to the next setting DELAY TIME FILTERING STOP I BW int 1 MBW SET CloseT 010 Page 26 of 58 Unit E Filter Technology Centre ma GI Industrial Roseheyworth Business Park Purification Abertillery 01495 294500 SOT SOUTER Ltd Blaenau Gwent 01495 291884 E sales industrial purification co uk www industrial purification co uk DELAY TIME Spin Clean Filters Only is the time delay to open the auxiliary CAB or HPBW valve Time from 0 to 999 seconds in this example 010 seconds to set To alter the figure between a low of 00 amp a high of 999 press amp hold the button to increment down one or press amp hold the button to increment f up one set to 010 Press and hold 9 button to CONFIRM selection If NO adjustment is required press and hold 0 button to CONFIRM The display will then move to the next setting SETTLING TIME SETTLING TIME CrossFlow Filter amp
17. suction inlet of the pump It recommended that an isolation valve be installed to facilitate valve maintenance removal e Connect the HP inlet and LP outlet connections on the filter to the differential pressure itch usino 8 lon tubing Backwash Inlet switch using 8mm nylon tubing Valve V3 e All pipe work should be fully supported to ensure no undue mechanical stress is placed on the filter Page 12 of 58 Unit E Filter Technology Centre a e V W Industrial Roseheyworth Business Park p MEDIA FILTER BY Ips Purification Abertillery 01495 294500 Mm Systems Ltd Blaenau Gwent 01495 291884 sales industrial purification co uk www industrial purification co uk Making Electrical Connections CF A competent person must make all electrical connections Ki Refer to control panel wiring drawing in the drawing section of this manual and proceed as follows e Always ensure any connections to the panel are made with suitable cabling and glands Under no circumstances should the equipment be hooked up temporarily e Check all connections of the panel are tight and that no components have become dislodged in transit e Connect a suitable incoming supply to the control panel dependant on your specification to IPS at the time of otdeting e Connect to Earth as per the drawing and also any earth bonding of the filter as required Page 13 of 58 ADVANCED YAM wh Industrial MEDI
18. 1884 sales industrial purification co uk www industrial purification co uk Filter Operation When the control system is powered up the inlet and outlet valves V1 and V2 are open and the backwash drain and backwash inlet V3 and V4 are closed The filter is now on line for filtration The process water is delivered into VALVE 1 via a system pump or specific filter mounted pump the water feed is split so that flow goes via both the tangential inlet and the vortex stabiliser The water is filtered by the media and exits the system via VALVE 2 and on to process the manual valve on the outlet controls the filter throughput The filter continues on line filtration until such time as backwash is initiated this is generally by means of a pressure differential switch supplied as part of the control panel a timer adjustable within the system software or via an optional manual backwash push button optional extra Once backwash is triggered by either of the above Valve 1 and Valve 2 close the filter is no longer producing any process water and this will remain so until the backwash cycle is complete On multiple filter system process flow is maintained during the backwash cycle The media bed is allowed to settle this is called the dwell time and last around 1 1 5 minutes This is to allow the media suspended above the bed to settle out before commencing the backwash After the media has settled the backwash sequence begins Valves 3 op
19. 3 00999 9 _ ad ee L a ee UA a SwahO1sno caisson NG QVAOSZ ki HILIMS LWT NAGO so KK O Ca ae tae YG IVAO XY gt ua ng Vien SHOLIMS VaIX3 Z rr HARD JN C E CSE INIS HOLMS d z Ov N3dO 3lVIO3WH3INI 35019 HOLMS NOLVU3dO HOLMS JTW ONY 3n0N0l Page 57 of 58 Unit E i TM Filter Technology Centre C RO SS l V Industrial Roseheyworth Business Park an MEDIA FILTER BY IPs 1 DS a Purification Abertillery 01495 294500 MT LDS yen Systems Ltd Blaenau Gwent 01495 291884 sales industrial purification co uk www industrial purification co uk Electro Pneumatic Actuators Connection Table Cross Flow Media Filter when using pneumatic actuators Use a 1mm x 5 core YY type cable for the interconnection between the AC 5 controller and filter valves PCB PCB Terminal Inlet Valve Outlet Valve Drain Valve Backwash Valve I d Connection Terminal Terminal Terminal Terminal Note that an earth connection is also need the actuator has an earth termination point which is connected to the AC 5 controller s common earthing block Opening amp closing time is 12 14 seconds Enclosute is rated to IP68 Rated current 0 3 Amp 24 vac Solenoid Valve Specifications amp Connections The AC 5 uses standard Asco 3 port 2 position normally closed brass bodied solenoid Model SCE374A017 Operating Voltage 24 vac Coil wattag
20. A N Dy mo Gp tn iot ge e TM MEDIA FILTER BY Ips ADVANCED H Sooo a odj Control panel electrical drawing Page 39 of 58 Unit E TM e Filter Technology Centre CRO LA NAGA Industrial Roseheyworth Business Park m MEDIA FILTER BY IPs 1 S Purification Abertillery T 01495 294500 ADVANCE Systems Ltd Blaenau Gwent F 01495 291884 E mail sales industrial purification co uk Web www industrial purification co uk Health amp Safety Issues aem NOTE The filter is supplied on the basis it will be operated in a safe manner and located as not to represent a risk to personnel Additional guarding may be required dependent upon a risk assessment carried out by the client For those clients who wish to locate the filter in an area that potentially represents a risk to its employees we recommend the fitting of guarding These are available from IPS Ltd at additional cost Clients should carry out their own risk assessment to establish if the process water used contains any substance microbiological contaminant that constitutes a risk to the health amp safety of its employees ae Care should be taken at all times to ensure the safety of any persons carrying out maintenance on the equipment The pump and actuators rotate during normal operation and is liable to stop start without warning eem Before attempting any maintenance you should insure the filter is electrically isolated and stored ener
21. A FILTER BY Pg Purification Systems Ltd Loading The Vessel If not factory filled Before filling the vessel the following steps should be taken in to account e lt A visual inspection of the inside of the vessel should be undertaken to ensure all the media retaining nozzles are present and fixed in place e In carry out the above inspection O O Ensure that you are wearing the correct PPE Locate the top flange see fig Before detaching the top flange please remove the vortex feed pipe by unscrewing at points A amp B as shown in the Fig Now carefully remove the bolts on the top flange This will then release the blind flange and gasket care should be taken not to damage the flange flange gasket or drop the bolts inside the vessel This will expose the nozzles for inspection Please make sure all of the nozzles are in place If any nozzles are missing please contact IPS before proceeding any further DO NOT FILL THE VESSEL IF NOZZLES ARE MISSING Please make sure vessel interior is free from any debris before following the media filling procedure below Unit E Filter Technology Centre Roseheyworth Business Park Abertillery T 01495 294500 Blaenau Gwent F 01495 291884 E mail sales industrial purification co uk Web www industrial purification co uk Top Flange e Itis strongly recommended to use correct PPE during media installation See Media data sheets which can be found on the bags and
22. IA FILTER BY jp 1 S Purification Abertillery 01495 294500 ae Systems Ltd Blaenau Gwent 01495 291884 m a sales industrial purification co uk www industrial purification co uk Appendix Electric Actuator Details Connection Table Cross Flow Media Filter when using HQ 004 electric actuators Use a 1mm x 5 core YY type cable for the interconnection between the AC 5 controller and filter valves PCB PCB Terminal Inlet Valve Outlet Valve Drain Valve Backwash Valve I d Connection Terminal Terminal Terminal Terminal Note that an earth connection is also need the actuator has an earth termination point which is connected to the AC 5 controller s common earthing block Opening amp closing time 1s 12 14 seconds Enclosure is rated to IP68 Rated current 0 3 Amp 24 vac Page 56 of 58 Unit E Filter Technology Centre T 01495 294500 F 01495 291884 industrial purification co uk Roseheyworth Business Park sales Abertillery Blaenau Gwent E mail Industrial Purification Systems Ltd cep MEDIA FILTER BY pg ADWAN urification co uk www industrial eb W ng drawing 1c actuator wiri Electr 817678 p Xv 697 28 v61O Tal Q11 SNOILMOS G3LVALOV AbZ IV OYYONY1S Wv39vIQ INIYIM OV SYOLVNLIY JHON YO OM N334138 033 15504 INZJAJYd OL SLOVINOD AVT3H MO HOLIMS TWNCIAICNI NIKO S LI HONOYHL Q0343M0d 38 Q TInOHS YOLYNLIY HOV3e gs sp 099 9
23. Spinclean is the time to allow the media bed to settle prior to starting a backwash Time from 0 to 999 seconds in this example 025 seconds is set or in a Spinclean filter the dwell time between modules to allow CAB vessel to re fill To alter the figure between a low of 00 amp a high of 999 press amp hold the button to increment down one or press amp hold the button to increment up one set to 025 Press and hold 9 button to CONFIRM selection If NO adjustment is required press and hold 0 button to CONFIRM The display will then move to the next setting SET USER PIN SET USER PIN this allows the factory set user PIN to either be changed or confirmed The cursor will flash under the first digit To alter the figure between a low of 0 amp a high of 9 press amp hold the button to increment down one or press amp hold the button to increment T up one If the factory set user PIN 3344 is to be retained then simply press the 9 button 4 times each press moves the cursor on to the next digit on the fifth press of the 9 button the display returns to the main display Page 27 of 58 SET DelayT 010 RP Confirm SET OpenT 012 4 CONFIRM FILTERING STOP I BW int I MBW SET Settl T 012 4 CONFIRM FILTERING STOP I BW int I MBW SET Settl T 025 4 CONFIRM FILTERING STOP I BW int MBW SETUser PIN 3344 4 CONFIRM FILTERING STOP I BW int I MBW SETUser PIN 3344 4 CONFIRM FILTERING STOP I BW int I MBW
24. at the same time and hold for 10 seconds until the following display appears DIF SET 01 0 5 V A The pressure differential reading here 0 1 BAR flashes 2 Press the two buttons at the same time for 2 seconds until the auto display appears and will now show 0 0 13 Page 35 of 58 Unit E sales industrial purification co uk www industrial purification co uk ka TM Filter Technology Centre C RO b W Industrial Roseheyworth Business Park MEDIA FILTER BY ps 1 DS a Purification Abertillery 01495 294500 ADVANCE O NAE Ltd Blaenau Gwent 01495 291884 CrossFlow AME Maintenance Recommendations es The CrossFlow AMF 301 system requires maintenance based on utilisation The following is a guide for your reference DESCRIPTION INTERVAL Check inlet amp outlet pressures DIGNIS i Prove sensor functions if fitted Weekly Trigger a manual backwash Monthly AY Prove Dp switch function Monthly Check Media level and top up as required Annually Page 36 of 58 NY P MI ANCED MEDIA FILTER BY Ipg ADNAN Technical Drawings i Industrial Purification Systems Ltd e CrossFlow AMF GA and vessel dimensions e Control panel electrical drawing Actuator Drawings and wiring details may be found in the Apendix Page 37 of 58 Unit E Filter Technology Centre Roseheyworth Business Park Abertillery T 01495 294500 Blaenau Gwent F 01495 291884 E mail sales industr
25. cate the filter in its final position ensuring it is stable and level and suitable for the support of the operational weight Installers should ensure suitable access is available to dismantle top flange of the unit in place in order to carry out any media loading or maintenance that may be necessary Check this by removing and refitting top flange Filter is pre loaded with media prior to dispatch e Check for all round access allowing at least 1m in all directions for ease of access In restricted locations please refer to factory before fixing in place in any areas that are adjacent to fixed objects Once these critetia are satisfied secure the filter down e The filter may be located inside or outside but if outside care should be taken that the filter is not subjected to ambient temperatures of below 2 Celsius without heat tracing If there is any risk of this you should consult with IPS Ltd e Connect Inlet Outlet process pipe work and backwash and drain to the unit as necessary and check all filter connections for tightness as fittings may work loose during transit remembering not to over tighten the connections e Mount control panel if not supplied filter mounted adjacent to the filter unit The control panel should be located so as not to come into direct or sustained contact with water The panel has an IP rating of IP65 Page 10 of 58 Unit E Filter Technology Centre e Industrial Roseheyworth Business Park Purificatio
26. cation co uk www industrial purification co uk EC Certificate of Conformity EC Certificate of Conformity In accordance with Annex 2B of the Machinery Directive 98 37 EC I Andrew Evans Stephen Cupples of Industrial Purification Systems Ltd Unit 10 Lea Green Business Park St Helens Merseyside WA9 4TR being the Responsible Person declare that the machinery detailed below Item Part Number Description Crossflow AMF Media Filter Has been manufactured in accordance with the transposed harmonised European Standards BS EN 292 Part 1 BS EN 292 Part 2 BS EN 294 BS EN 60204 1 BS EN 983 The equipment is in conformity with the health amp safety requirements of the directive Signed Director for and on behalf of Industrial Purification Systems Page 45 of 58 Unit E o TM Filter Technology Centre C R A Wh Industrial Roseheyworth Business Park MEDIA FILTER BY IPs 1j DS a Purification Abertillery 01495 294500 ADVANCE O NAE Ltd Blaenau Gwent 01495 291884 sales industrial purification co uk www industrial purification co uk EC Declaration of Incorporation EC Declaration of Incorporation In accordance with Annex 2B of the Machinery Directive 98 37 EC I Andrew Evans Stephen Cupples of Industrial Purification Systems Ltd Unit 10 Lea Green Business Park St Helens Merseyside WA9 4TR being the Responsible Person declare that the machinery detailed below Item Part Numb
27. d Page 2 of 58 Unit E Filter Technology Centre ma GI Industrial Roseheyworth Business Park Purification Abertillery 01495 294500 O NAE Ltd Blaenau Gwent 01495 291884 sales industrial purification co uk www industrial purification co uk TAING DELIVERY OF THE PUDER ENT 2 A AMNERIS a eegedssussdiesisuium deissnandias usse nu idR D Su Dic s cU AE AN 5 Filter ron ipii AA AA AA M 5 alec AA AA AA AA AA AA AA 6 CEMPA NOT AA MOA AA AA PA AA AA AA AA AA APA 7 CROSSFLOW AMF TM SPECIFICATION anG PAPANG AK AA AG NAA aur aptos RE EU o CrossFlow AMF Data SNEGh iasa GAGA ANGGE ANAND GNG e 9 BG AKIN SELA KA AA PAP BAR 10 Wie YOU NERD TOPROVIDE Pern E EE EEA AA 11 MAKING PIPEWORK CONNECTIONS aiicisekiste eskiitiexkuls n anpi SER PRESE EsAN SNo FR basa GAO NANA 12 MARKING ELECIRICALCONNECIONS kaaa nn N E 13 LOADING THE VESSEL IF NOT FACTORY FILLED Taasan 14 M dia Depth Loading T3DIG oo iere iod ve SRI AA AA AA AA AA AA AA AA 15 OPERATING MANUAL FOR THE AC 5 FILTRATION CONTROLLER a 16 STARTING amp COMMISSIONING THE SYSTEM aa 30 DIFFERENTIAL PRESSURE SWITCH INFORMATION 31 CROSSFLOW AMF MAINTENANCE RECOMMENDATIONS aaa 36 TEGAN ISTRY DISCS AA AA 37 CrossFlow AMF 301 GA and vessel dimensions ccsccscssssssssssssssescsscsssssssssssesssscesscssessssssssssessessessesseses 38 Control panel electrical
28. e 8 W Supply amp outlet Port size 4 Bsp Exhaust port size 1 8 Bsp Operating Media Air ot water Orifice Size 2 7mm Flow coefficient 0 22m h or 3 6 1 min Maximum operating differential pressure 10 bar Operating temperature range 25 c to 60 C Page 58 of 58
29. ectrical supply Most input and control voltage options are available for Primary supply and secondary control supplies dependent site requirements Ki For more information please refer to electrical data sheet Page 8 of 58 Unit E TM Filter Technology Centre e N Industrial Roseheyworth Business Park R BY Ips Purification Abertillery 01495 294500 Systems Ltd E ep MEDIA FILTI A Ty AT Blaenau Gwent 01495 291884 sales industrial purification co uk www industrial purification co uk CrossFlow AMF Data Sheet Stainless Steel 304 built in accordance with PED 5500 Category 3 Hot Dip Galvanised Carbon Steel 460x625x1535 1000x500x 1400 800x600x 1750 1250x 1000x2320 1600x 1500x2500 1745x 1400x2735 1800 2000 2300 3000 3200 3500 sorso 06 2 14 43 s617 sw 23 68 iul m lae A 2 4 minutes Adjustable e ta e foan f osons f an asmmcopper r r ayo r Page 9 of 58 Unit E I i e Filter Technology Centre V 4 Industrial Roseheyworth Business Park cm MEDIA FILTER BY IPs 1 S Purification Abertillery 01495 294500 i p Systems Ltd Blaenau Gwent 01495 291884 sales industrial purification co uk www industrial purification co uk Locating The Filter 9 th Before lifting this unit we recommend a full risk assesment be conducted taking into account the balance on the unit and potential stress and damage caused to piepwork by unsupported lifting e Lo
30. ens shortly followed by Valve 4 this allows backwash water to enter the filter from the bottom connection of the filter vessel this water is distributed equally across the bed area and has the effect of fluidising the AMF media The backwash water lifts the lighter contamination from the media strata and flushes contamination from the system via the backwash drain connection Valve 2 This can be fed to a suitable foul drain or collected for further processing and water recovery The backwash gate valve will be adjusted on commissioning to ensure we cannot over fluidise the bed during backwash as in this event media could be sent to drain reducing filtration efficiency and requiring more frequent media top ups After the backwash is complete usually between 2 4 minutes this is adjusted on commissioning to suit the application but can be confirmed by visually checking that the backwash water is running clear Valves 3 and 4 Close after a dwell time of 30 seconds Valves 1 and 2 open to process filtration again the cycle is repeated as required depending on loading Page 6 of 58 Unit E Filter Technology Centre e HY IM Industrial Roseheyworth Business Park cm MEDIA FILTER BY IPs Purification Abertillery T 01495 294500 ADNANCED UT Systems Ltd Blaenau Gwent F 01495 291884 E mail sales industrial purification co uk el www industrial purification co uk General Notes IMPORTANT e This manual assumes you have ord
31. er Description Crossflow AMF 7 Media Filter Has been manufactured in accordance with the transposed harmonised European Standards BS EN 292 Part 1 BS EN 292 Part 2 BS EN 294 BS EN 60204 1 BS EN 983 The equipment is in conformity with the health amp safety requirements set out in the machinery Directive 98 37 EC This equipment must not be put into service until machinery into which it is to be incorporated has been declared in conformity with the provisions of the Directive and its amendments Signed Director For and on behalf of Industrial Purification Systems Ltd Page 46 of 58 Unit E Filter Technology Centre TM e Industrial Roseheyworth Business Park 1 S Purification Abertillery T 01495 294500 Systems Ltd F 01495 291884 CROS ED MEDIA FILTER BY Pc ADWANI Blaenau Gwent E mail sales industrial purification co uk Wel www industrial purification co uk Safety Notice A Copy of this Notice should be located prominently in the area of the filter system and all personnel operating the equipment should be advised of the nature of the filters operation Warning Pressurised Equipment 1 This equipment is liable to start without prior warning Under no circumstances must anyone attempt to access Of maintain this equipment whilst it is in operation 2 The equipment must be electrically isolated prior to any work being carried out on the plant 3 The filter must be fully isolated fro
32. ered our filter with control system If you have chosen to provide any of the equipment yourselves please use the instruction within this manual for the appropriate section for guidance only and refer to your equipment supplier for specific installation instructions e t is the responsibility of the installer to read this manual in its entirety making sure that all sections ate completed before attempting to install operate the equipment If you have any doubts as to the safe installation of this equipment please contact our technical engineer as detailed later in the manual e Ensure you read and understand the Safety notice supplied with this equipment and detailed in safety section of this manual e If you are in any doubts contact Industrial purification system on 44 0 1744811652 for advice or email sales industrial purification co uk e Discharging waste water to drain it is the responsibility of the user to determine the legal discharge toute for contaminated water from the filter e Electrical connections should be done in accordance with national standards and carried out by competent persons only Page 7 of 58 Unit E 7 m e Filter Technology Centre V W Industrial Roseheyworth Business Park vy MEDIA FILTER BY IPs 1 S Purification Abertillery 01495 294500 id p Systems Ltd Blaenau Gwent 01495 291884 sales industrial purification co uk www industrial purification co uk CrossFlow AMF TM Specificat
33. g m respirable dust No free SiO all components are amorphous non crystalline Respiratory Protection Dust mask as routine If dust concentration exceeds recommended permissible exposure limits use respirators to an approved standard NIOSH MSHA Eye Protection Safety glasses or goggles tight fitting recommended to an approved standard Ensure eye bath is available Skin Protection Protective garments as appropriate Plastic or rubber gloves Ventilation Mechanical exhaust required in situations where dust levels exceed recommended exposure limits Handling No special precautions should be necessary Exposure controls personal protection to be appropriate to the situation and the quantity handled 9 PHYSICAL AND CHEMICAL PROPERTIES Appearance Free flowing brown or green particles Physical state Solid Odour Odourless pH N A Boiling point Range N A Melting Point about 7300C Auto Flammability N A Explosive Properties N A Oxidising Properties N A Vapour Pressure N A Specific gravity approximately 2 5 g ms 200C Flash Point C closed or open cup N A Flammability Gas solid N A Solubility water and fat Insoluble Other None 10 STABILITY AND REACTIVITY Conditions to avoid None Materials to avoid Hydrofluoric Acid fluorosilicic and phosphoric acids and hot strong alkaline solutions Hazardous decomposition products None 11 TOXICOLOGICAL INFORMATION Acute effects May be harmful by inhalation or
34. g history totals Set user PIN Set factory PIN Set differential pressure de bounce delay timer Set differential disable timer input signal is ignored to allow for settlement time between consecutive cycles Set year month day and time Select programme sequence to suit a variety of filter types Once in the settings section you can only scroll forwards through all the options there is no back button If you miss a setting then the complete access procedure must be carried out The next section goes through each display option set by step Page 21 of 58 Unit E Filter Technology Centre Industrial Roseheyworth Business Park 1 S Purification Abertillery T 01495 294500 p Systems Ltd Blaenau Gwent F 01495 291884 sales industrial purification co uk www industrial purification co uk TM CROS 5l MAE L LA L ER B he Al Why ANAL EA To access the user setting press and holding in the mid 9 followed by pressing and holding the and 77 buttons simultaneously this will take you to the log display e Dress and hold the button SET MAX DP 00 4 CONFIRM FILTERING STOP I BW int I MBW e Press and hold the button TOTAL TIME BWs LOG 00001 1 FILTERING STOP I BW int I MBW e Dress and hold the button Na VER NUM 97 e A flashing cursor can now be seen under the first digit SETTING NORMAL FILTERING STOP I BW int MBW e Press amp hold the button to increment down one or press amp h
35. gy released Page 40 of 58 Unit E Filter Technology Centre ma GI Industrial Roseheyworth Business Park Purification Abertillery 01495 294500 O NAE Ltd Blaenau Gwent 01495 291884 sales industrial purification co uk www industrial purification co uk MATERIAL SAFETY DATA SHEET FOR AFM ISSUE 2 REVISION 0 DATE 12 02 07 1 PRODUCT IDENTIFICATION Product Code 5 1 00 00 5 1 00 10 and 5 1 00 20 Trade Name Active Filtration Media AFM 2 PRODUCT COMPOSITION Product Type 100 glass grain from recycled glass Product Grade 0 gt 90 of grains gt 0 25mm lt 0 50mm Grade 1 gt 90 of grains gt 0 50mm 1 00mm Grade 2 gt 90 of grains gt 1 00mm 2 00mm CAS Number 65997 17 3 EINECS Number 226 046 0 Harmonised Customs Code 3207408090 3 HAZARD IDENTIFICATION Nuisance dust concern only Dust in excess of recommended exposure limits may be irritating to respiratory system In case of insufficient ventilation wear suitable respiratory eye and skin protection equipment DO NOT USE AFM FOR DRY SAND BLASTING 4 FIRST AID MEASURES Summary Unlikely to be hazardous if handled correctly Ensure eye bath is available Inhalation Remove to fresh air give water to drink Skin Contact Wash thoroughly with soap in running water Eye Contact Contact with eyes may cause irritation Irrigate eyes with copious amount of water Seek medical attention if irritation persists Ingestion Wash out mouth thoroughly with wate
36. h at least two full cycles or until the backwash water runs clear before putting it online m IMPORTANT If the filter is to be left inoperative for any length of time the system including the pump should be thoroughly flushed with clean water and then drain down It would also be recommended that oil be added to the pump to prevent seizure For guidance on this matter refer to the pump section in this manual NOT APPLICABLE Page 30 of 58 Unit E TM Filter Technology Centre CRO S CN Industrial Roseheyworth Business Park MEDIA FILTER BY TPs 1 DS a Purification Abertillery T 01495 294500 ADVANCE OT AREA Ltd Blaenau Gwent F 01495 291884 E mail sales industrial purification co uk Web Differential Pressure Switch Information Important e Connect High pressure before Low pressute e Disconnect Low pressure before High pressure Digital Differential Pressure Gauge Switch Parts Identification Back view Electric cable Setting Buttons Front view Page 31 of 58 www industrial purification co uk Unit E TM Filter Technology Centre V N Industrial Roseheyworth Business Park paan MEDI FILTER BY ps 1 DS a Purification Abertillery T 01495 294500 ADVANCE OU SRI Ltd Blaenau Gwent F 01495 291884 E mail sales industrial purification co uk Web www industrial purification co uk Digital Differential Pressure Gauge Switch Display Differential Differential Pressure Pressure Tr
37. ial purification co uk Web www industrial purification co uk Unit E Filter Technology Centre e Industrial Roseheyworth Business Park Purification Abertillery T 01495 294500 Systems Ltd Blaenau Gwent F 01495 291884 E mail sales industrial purification co uk Web www industrial purification co uk CrossFlow AME 201 GA and vessel dimensions a q a E n noO p zz O e lt gio usc s 2 5013 IE O 7 d ums I E IO lo 5 2 eo a z E 3 l 3 ii 18 5 A5 E Z a H ili RF HAE HR P f ae e288 a 5 3 TEHE T ole sasg72 2 2 2 3 Pneumatic Actuated 2 S Is 5 O E U 2a c ras ja Pneumatic Actuated 600 Hal Pneumatic Actuated Backwash Outlet Valve PN10 Control Panel Pneumatic Actuated Process Outlet Valve Page 38 of 58 Unit E S x o 2 Ig Sg ot D6 mos eS ol Cc o o N A nin 3 5 YY XD Q Fst Hi Cat e QG coo ct Yu HE SSCA a Lr ow S t eeep ewned rwes ee DIAD dal Se E oe eee uoi RA 40 3 FAD segs Haase cet GEE gt 2 d IDE JHW iem E wy v 2s cos ot o oS c o su 3 2 O O i o2 95 C oeg Rh Co uga ceS 2028s i ccduu dung usow 20g8 ANG dung sseado0ud ING ZHOS 1 Ove Ajdans LT6LOEY P ORO WL ense mog JS LIS HOO jeanuUeD Industrial Purification Systems Ltd M A ON dM ON ON M ON ps i i F0 XUr S
38. igger setting Displays BAR PSI PSI ON M BAR Manual Left Button Right Button Decreases Values Increases Values Low Power Display DIF SET LO P BAR V Page 32 of 58 Unit E TM Filter Technology Centre V A MI A AS industrial Roseheyworth Business Park ED MEDIA F ILTER BY Ips Purification Abertillery T 01495 294500 ADNAN O AN stems Ltd Blaenau Gwent F 01495 291884 E mail sales industrial purification co uk Web www industrial purification co uk Digital Differential Pressure Gauge Switch Programming General Using the Arrow Buttons e To enter settings press and hold both buttons simultaneously Use the left button V for decreasing settings selecting BAR measurements and for turning off the device in the Manual mode e Usethe right button for A increasing settings selecting PSI measurements and for turning on the device in the Manual mode e After making an adjustment holding the two buttons at the same time for 2 seconds sets the adjustment and returns the display to the auto display e If the buttons are not held down for the full 2 seconds until the auto display appears no changes are made to the previous settings e When making an adjustment if the buttons are not pressed for 30 seconds the auto display appears and no changes are made to the previous settings Page 33 of 58 Unit E TM Filter Technology Centre j Industrial Roseheyworth Busi
39. ion The IPS model CrossFlow AMF system process water filtration system is designed to remove suspended particulate from water down to 0 45 micron in size at an efficiency of remove up to 90 by mass at a design flow tate of as stated 1n the data sheet The unit operates at the working pressure of up to that shown in the table and operates fully automatically with an automatic backwash system The backwash control is based on pressure differential and or timer control The backwash water flow loss for the system for a single regeneration for can be seen on the data sheet This filter system is a Patented and consists of a 304 stainless steel filter vessel rated for duty as shown in the table it is generally mounted on its own base plate Unless supplied without The filter vessel comes complete with an internal stainless Steel support plate into which are fixed a set of non metallic diffusers for media retention and the backwash distribution across the filter area This unit is supplied with a charge of several grades of filtration media including a reactive bed of AMF Advanced Media Filter filtration media for 0 45 micron filtration The backwash period is adjustable depending on the nature of the contamination being removed Standard control is housed in an IP65 enclosure to be mounted by the client within 10 m of the filter unless supplied pre fitted to the unit Interconnection between the control panel and the filter is by others El
40. lays total recorded manual activated backwashes e User the button to index to the next log TOTAL DP BWs e To return to the main display press and holding in the mid O followed by LOG 00001 12 pressing and holding the and buttons simultaneously or it will SEES STOP I BW int MBW automatically return after 20 seconds without any key operations To access the data log two press and holding in the mid 9 followed by pressing and holding the and buttons simultaneously followed by pressing the button TOTAL MAN BWs e Displays total recorded timed backwashes activated by either a timed LOG e interval period ora specific time of day STOP I BW int I MBW e Press amp hold the button to index to the next log page e Displays date amp time of the last recorded event LOG 06 02 12 36 e Use the to index to the next previous log in time descending order amp FILTER 15 FILTERING STOP I BW int 1 MBW e Displays date amp time of when the unit was last powered e Use the lt to index to the next or previous log LOG 01 02 08 36 lt 1 POWERON 1 FILTERING STOP I BW int I MBW e Use the to index back to newest event e Displays date amp time of when the unit was last started e Use the to index to the next or previous log LOG 01 02 08 36 START 1 3 FILTERING STOP I BW int I MBW e Displays date amp time of when the unit was last stopped e Use the lt or to index to the next or previous log
41. lity if any for safe delivery shall lie with the freight carrier as of time of dispatch Claims for such damages must be filed with the freight carrier e The warranty registration card must have been fully completed and returned to IPS Ltd Within one month of delivery of the equipment Page 51 of 58 Unit E sales industrial purification co uk www industrial purification co uk Filter Technology Centre C RO ii 3 A 1 Industrial Roseheyworth Business Park sy MEDIA FILTER BY pe 1 DS a Pu rification Abertillery T 01495 294500 m LDS yen Systems Ltd Blaenau Gwent F 01495 291884 AD THIS WARRENTY IS VOID IF e The equipment is not correctly mechanically or electrically installed or not maintained in accordance with the manufacturers instructions The warranty shall not cover defects caused by inappropriate or unapproved application of the product e The equipment is damaged by negligence accident or mishandling or the equipment has not been operated in accordance with the procedures or rated capacities as stipulated in the operating manual The equipment has been altered modified or repaired by anyone other than an IPS Ltd representative or any competent person approved by IPS Ltd e Ifthe commissioning setting sheet has not been completed and returned to IPS e Written Notice of the defect was not forwarded to IPS Ltd within a 7 day period of discovery at the following address Industrial Purification Systems
42. m any water supplies and the vessel drained prior to commencing any works 4 Appropriate safety equipment should be worn whilst maintaining the plant Page 47 of 58 Unit E Filter Technology Centre e Industrial Roseheyworth Business Park Purification Abertillery 01495 294500 i Systems Lid Blaenau Gwent F 01495 291884 sales industrial purification co uk www industrial purification co uk Environmental Issues Control Of Substances e Discharge of trade effluent waste generated The only effluent produced is the material discharged from the backwash process The nature soutce and quantity of this material has not been defined other than generally The composition and rate of solid present in the system will be more familiar to the client The system does not generate any waste other than that removed from the process This will need to be disposed of periodically by the client Unless the plant is operated outside of its design parameters there is no likelihood of uncontrolled release or spillage from the system Page 48 of 58 Unit 10 Lea Green Business Park 1 DS a Industrial St Helens Purification Merseyside 01744 811652 LDS yen Systems Ltd WA9 4TR 01744 833687 sales industrialpurification co uk www industrialpurification co uk 4 FILTER BY Pg p MEDIA ADV ANL CrossFlow AMF Spare Parts Recommended Qty EG 0 media 95 023 25KG EG 1 media 95 009 25KG Page 49 of 58
43. n Abertillery T 01495 294500 Systems Ltd TM g A NI ANCED MEDIA FILTER BY Ips ADNAN Blaenau Gwent F 01495 291884 E mail sales industrial purification co uk Web www industrial purification co uk What You Need To Provide Q e A suitable incoming electrical supply for the control panel based on your order to IPS The standard panel is 240 1 50Hz e Suitable pipe work for interconnection between the following O Process water inlet connection position P1 to connect the dirty water supply o Filter outlet position V2 connection o Filter drains outlet position V4 connection to a suitable receptacle or secondary filtration unit Note that this must allow a flow under gravity without any obstructions 2m min 10 m max e A gate valve on the outlet pipework to provide flow adjustment of the process flow e A gate valve on the drain pipework to provide flow adjustment of the backwash e An isolation valve on the inlet amp outlet process supply is recommended as good engineering practice e lt A by pass to allow for filter maintenance off line is good engineering practice and strongly recommended e All pipe work should be fully supported to ensure no undue mechanical stress is placed on the filter e If Electro Pnuematic Actuators have been ordered an 8mm OD tube for pneumatic control supply from the air compressor to supply point marked on V3 Backwash Outlet Valve V4 Process I
44. ness Park MEDIA F ILTER BY IPs 1 DS a Purification Abertillery T 01495 294500 MDNANCEP aaa stems Ltd Blaenau Gwent F 01495 291884 E mail sales industrial purification co uk Web www industrial purification co uk Digital Differential Pressure Gauge Switch Flow Chart for Settings Hold down both buttons to enter mode Auto Display After making an adjustment hold down Selecting both 4 Seconds Units buttons simultan eously for two seconds to 6 Seconds Time Interval set it between and return measurements bathe 2 Seconds Manual Operation auto 8 Seconds Contact display closed time Time Interval 10 Seconds between contact closure Zero 12 Seconds calibration Page 34 of 58 Unit E mn TM Filter Technology Centre V A M Industrial Roseheyworth Business Park MEDIA F ILTER BY Ips 1 DS a Purification Abertillery T 01495 294500 MDNANCEP CADO AEE Ee Ltd Blaenau Gwent F 01495 291884 E mail sales industrial purification co uk Web www industrial purification co uk Digital Differential Pressure Gauge Switch Zero Calibration Set The pressure sensor should read zero when the pressure differential 1s zero To check the calibration remove the two pipe fittings from H and L The pressure reading when the fittings are open to the atmosphere and there is no pressure differential between them should be O If not set the reading to O as follows Press the two buttons
45. ng to test all the connections flanges and joints for tightness before filling it with water Ideally the filter should be commissioned with clean process water so operating parameter can be set correctly e If incorporating the filter system to a central control panel please refer to the ladder diagram for Operating sequence which can be found in the technical drawing section of this manual NOT APPLICABLE FOR YOUR APPLICATION e Open all isolation valves to the filter system e Open the inlet process water supply to the filter e As water enters the vessel any air can be expelled by opening and closing valve H P marked on the drawing e The outlet process flow will need to be adjusted via the gate valve fitted by the client Adjust the valve to ensure that the process flow does not exceed the system design flow e Start a manual backwash e During the backwash cycle take a sample from the drain to ensure that no FAGM is lost due to excessive flow If this is found to be the case then adjust the backwash flow via the gate valve on the backwash outlet client supply When the correct backwash has been established remove the handle of the drain line gate valve to prevent tampering e Determine the differential pressure drop across the filter after a backwash by reading the difference between inlet and outlet pressure gauges and record the reading for future reference b It is strongly recommended the filter be backwashed throug
46. nlet Valve VI Process Outlet Valve V2 Backwash Inlet Valve V3 Page 11 of 58 Unit E Filter Technology Centre e Industrial Roseheyworth Business Park Purification Abertillery T 01495 294500 Systems Ltd TM g A NM ANCED MEDIA FILTER BY Ipg ADNAN Blaenau Gwent F 01495 291884 E mail sales industrial purification co uk Web www industrial purification co uk Making Pipework Connections e Process inlet is to be connected to the pump at P1 It recommended that an isolation valve be installed to facilitate pump maintenance removal Backwash Outlet Valve V4 e The filtered process water outlet V2 connection from valve 2 must have union to allow for valve are removal A suitable valve gate type is required to allow Inlet Valve flow regulation is e The waste ditty backwash water V4 connection from valve 4 should not create any back pressure on the filter The drain pipe work should be kept to a minimum of 2 meters and have a minimum of bends It should not rise above the filter outlet and again operates under gravity The drain line should be of a minimum 1 diameter or larger and not exceed 10 meters in length If a greater drain length is required it should be done via a tundish arrangement breaking any back pressure build up A suitable valve gate type is required to allow flow regulation Process Outlet Valve V2 e Backwash water V3 supply to be connected to the
47. old 0 button to CONFIRM the CHOOSE BACKWASH cursor will index to the minute adjustment digits V INT gt e i l FILTERING e Cursor will index to second set of digits which sets the minutes between 00 amp STOP I BW int I MBW 45 in increments of 15min e To alter the minutes press amp hold the button to increment down one or press amp hold the button to increment 1 up one e g set to 15 e Press and hold 9 button to CONFIRM selection the display will then move to the next setting BW INTERVAL 00 00 JY CONFIRM STOP I BW int MBW Page 24 of 58 Unit E TM Filter Technology Centre C RO WM Industrial Roseheyworth Business Park zn MEDI FILTER BY IPs 1 DS a Purification Abertillery 01495 294500 or SOT SOUTER Ltd Blaenau Gwent 01495 291884 To Set a Specific Time and Day for Backwashing e Choose backwash activation type of either interval INT or time of day TOD e To alter between INT and TOD press amp hold the button to toggle between the two Select TOD e Press and hold button to Choose selection e Monday is selected and flashing cursor can now be seen under the first set of digits which sets the hours between 00 to 23 e To alter the hours press amp hold the button to increment down one or press amp hold the button to increment f up one e g set to 13 One O clock e Press and hold button to CONFIRM selection the cursor will index to the minutes e To alter the minutes p
48. old the button to increment T up one ENTER PIN 5555 e Release and repeat until correct first PIN number 4 CONFIRM FILTERING STOP I BW int I MBW e Press and hold button to CONFIRM selection e Cursor will index to second digit repeat process until correct four digit PIN is Ciela eee confirmed 4 CONFIRM 4 FILTERING STOP I BW int I MBW ENTER PIN 3555 4 CONFIRM FILTERING STOP I BW int I MBW Page 22 of 58 Unit E e Filter Technology Centre HY IM Industrial Roseheyworth Business Park cm MEDIA FILTER BY IPs 1 S Purification Abertillery 01495 294500 ee p Systems Ltd Blaenau Gwent F 01495 291884 sales industrial purification co uk www industrial purification co uk To set differential alarm set point The number of differential cycles required to activate the alarm is displayed in this example 00 To alter the figure between a low of 02 amp a high of 10 press amp hold the button to increment down one or press amp hold the button to increment up one set to 3 BW INTERVAL 12 15 4 CONFIRM Press and hold 9 button to CONFIRM selection If NO adjustment is required press and hold 9 button to CONFIRM SP LBAN INGATAN The display will then move to the next setting To set the Backwash Duration Set backwash duration from 0 to 999 seconds in this example 20 seconds to set To alter the figure between a low of 00 amp a high of 999 press amp hold the button to increment down one
49. r In severe cases seek medical attention Contaminated clothing Wash before reuse 5 FIRE FIGHTING MEASURES Hazard Non combustible Use extinguishing media suited to surrounding conditions Spillage may result in slippery conditions Special fire fighting procedures In case of excess dust use self contained breathing apparatus amp protective clothing to prevent inhalation and contact with eyes and skin 6 ACCIDENTAL RELEASE MEASURES Personal Precautions Avoid breathing fine dust Wear suitable protective clothing Spillage may result in slippery conditions Environmental Precautions No danger Methods for Cleaning Sweep up with a minimum of dusting If possible use a vacuum system and or spray water to reduce air borne dust Wash spillage site after pick up 7 HANDLING AND STORAGE Handling Assess No special precautions should be necessary Assess manual handling requirements Refer to Accidental Release Measures above Storage Store in cool room temperature dry place Page 41 of 58 Unit E Filter Technology Centre Industrial Roseheyworth Business Park 1 DS a Purification Abertillery 01495 294500 LDS yeu systems Ltd Blaenau Gwent 01495 291884 sales industrial purification co uk www industrial purification co uk 8 EXPOSURE CONTROLS PERSONAL PROTECTION Engineering Controls Dust extraction to comply with COSH Regulations 1988 Exposure Control Limits ACGIH TLV TWA 10 mg m total dust 5 m
50. ress amp hold the button to increment down one or press amp hold the button to increment 1 up one e g set to 30 half past the hour e Press and hold button to CONFIRM selection e Press amp hold the button to choose duplication of the set 13 30 to the next day i e Tues e Press amp hold the button if a different time is required for Tue e Press amp hold the button to choose duplication of the set 13 30 to the next day Tue e Press and hold button twice to CONFIRM e Press amp hold the button to choose duplication of the set 13 30 to the next day i e Wed repeat for the remaining days of the week e If no backwash time is required for example on a Sat amp Sun then set the hours amp minutes to zeto on Sat Press hold 9 button to CONFIRM selection the to confirm e After confirming the hours amp then the minutes to zero the display asks for a final YES F button or No button that no backwash is required for that day sat by pressing amp holding the button e The display asks if duplication of Sat is required to Sun e Press amp hold the button to choose duplication of the set 00 00 to the next day i e Sun e Press amp hold the button if a different time is required for Sun Page 25 of 58 sales industrial purification co uk www industrial purification co uk BW Mon 00 00 TOD FILTERING BW Mon 1 TOD BW Mon TOD ToD BW Mon NO Duplicate ToD BW Tue 13 NO Duplicate
51. rs e MBW R HD press amp hold the button to trigger a manual backwash Viewing the Data logs The AC 5 filtration controller has two data log pages that records the following data Data Log One Totals e Total of recorded timed backed backwash cycles e Total of recorded differential pressure activated backwash cycles e Total of recorded manual activated backwash cycles Data Log Two Time amp Date e Time amp date of last POWER ON e Time amp date of last recorded START e Time amp date of last recorded STOP Time amp date of last recorded FILTER e Time amp date of last recorded MANUAL BACKWASH To access the data log one press and holding in the mid 0 followed by pressing and holding the and buttons simultaneously e Displays total recorded timed backwashes activated by either a timed interval period or a specific time of day maman RE KO S e User the button to index to the next log LOG 00001 1 3 FILTERING STOP I BW int 1 MBW e Displays total recorded differential activated backwashes e User the button to index to the next log TOTAL TIME BWs LOG 00001 1 FILTERING STOP I BW int MBW Page 19 of 58 Unit E ER e Filter Technology Centre HY IM Industrial Roseheyworth Business Park vy MEDIA FILTER BY IPs 1 S Purification Abertillery 01495 294500 i p Systems Ltd Blaenau Gwent F 01495 291884 sales industrial purification co uk www industrial purification co uk e Disp
52. sioning Pipa These can be provided at extra cost if required Backwash Outlet Valve V4 Inlet Valve V1 Backwash Inlet Valve Connection 3 this is the connection at bottom of vessel on the right hand side when viewed from front opposite the process outlet This is NORMALLY connected to the backwash clean water supply backwash water can be either a mains water supply or a pumped external water supply or in some cases we can use the inlet process feed pump to provide this backwash water but this requires a special configuration of pipework Process Outlet Valve V2 2 Valve positions 2 and 3 can be reversed to match plant requirements but if required please consult the factory as programming will need to be amended Backwash Outlet Valve 4 is the topmost connection of the filter located above the tangential inlet pipe but centrally on the filter is the Dirty Backwash Outlet This should be connected to either a collection vessel for backwash OR to a suitable foul water drain it is important that this pipe has no Backwash Inlet restriction other than a flow control valve again a full bore Haba gate valve is recommended but not normally supplied which is used to control the backwash flow rate Page 5 of 58 Unit E ka TM Filter Technology Centre C R N IN Industrial Roseheyworth Business Park o MEDIA FILTER BY Ipc 1 DS a Purification Abertillery 01495 294500 NDNANC LDS yeu Systems Ltd Blaenau Gwent 01495 29
53. sss ss n earn n nnn enne enses nsns senes 57 Ore AB PREUINIATIC A COL PI NN t 58 Page 4 of 58 Unit E Filter Technology Centre e Industrial Roseheyworth Business Park Purification Abertillery T 01495 294500 Systems Ltd TM JNT AIVL go MEDIA FILTER BY Ipg ADVANCED Blaenau Gwent F 01495 291884 E mail sales industrial purification co uk Web www industrial purification co uk System Overview Filter Configuration The CrossFlow AMF is a patented filter system for water which can remove particulate as small as 0 45 micron in size Each unit has a total of four valves connections namely Inlet Valve Connection 1 which is the tangential inlet to the filter system This is the connection from the dirty process water supply and is the inlet connection to the filter This connection is located in the upper section of the vessel near the top entering the vessel on the side tangentially this has an additional pipe already connected to the inlet feeding into the top of the vessel and this is the Vortex Stabilizer Outlet Valve Connection 2 left hand viewed from front at the bottom of the filter on the LHS of the three way valve is the filtered clean water outlet and should be connected to the process system We recommend that you fit a flow control valve full bore manual gate valve at this location to correctly set the flow for your process during commis
54. supply is ON and healthy Note Spark reduction circuits are fitted to all relay contacts These allow a very small current to pass across an open contact this will give an ON reading id measuring with a sensitive voltmeter if there is no load valve connected Page 16 of 58 Unit E Filter Technology Centre Industrial Roseheyworth Business Park 1 DS a Purification Abertillery 01495 294500 LDS yeu Systems Ltd Blaenau Gwent 01495 291884 sales industrial purification co uk www industrial purification co uk After a power interruption the AC 5 controller will return to its last position If in a backwash cycle at the time of power interruption then the backwash cycle runs again on power If time of day has been selected for backwashing and the set time has passed due power interruption then it will be missed If the interval timer has been selected then it will be reset on powering up The AC 5 controller has been designed as a multi functional filtration controller and will cater for either CrossFlow AMF media or Spin clean disc filters combinations Valve operations can either be electrically actuated or electrically pneumatically operated at 24 vac Operating Instructions For Tthe AC 5 Filtration Controller The AC 5 controller is supplied pre programmed ready for operation and only requires a standard 230 vac 50 Hz 13 amp power supply Interconnection for valves and pumps will either be pre wired at the factory or require the end user
55. tems Ltd Blaenau Gwent F 01495 291884 E mail sales industrial purification co uk www industrial purification co u Basic Troubleshooting amp Assistance The majority of faults and problems are associated with the installation rather than the filter system itself We have compiled a flow chart of the most common of these faults in order that your may check them before calling out our service technicians If you are in any doubt or wish to receive further information please do not hesitate to contact our service department Your Customer Support Contacts Are Service Department Contact Mark Hulse Address Unit 10 Lea Green Business Park St Helens Merseyside WAI 4TR United Kingdom Tel Number 44 0 1744 811 652 Fax Number 44 0 1744 833 687 Page 54 of 58 k Unit E Filter Technology Centre FAI Industrial Roseheyworth Business Park a HA FILTER BY ips 1 S Purification Abertillery 01495 294500 we Systems Ltd Blaenau Gwent 01495 291884 mem OO sales industrial purification co uk www industrial purification co uk Trouble Shooting Flowchart PANEL ON PUMP RUNNING OPEN ALL VALVES CONTACT IP LTD PUMP TRIPPED HIGH DP CLEARED HIGH SOLIDS LOADING BED BLINDED CONTACT IP LTD Page 55 of 58 Unit E TM e Filter Technology Centre Industrial Roseheyworth Business Park en MED
56. to complete Please refer to the equipment s operational manual On initial power up the unit emits one beep whilst the display boots up The display now shows e Time of day in 24 hour format e STOPPED the unit is stopped e RUN L HD above the button e CF FLOW indicates CrossFlow programme is selected 15 32 STOPPED e RUN R HD above the button RUN I CR FLOW I RUN Putting the controller to RUN mode Press and hold in the and buttons simultaneously until the display indicates that the unit is starting then release In this example the CrossFlow will sequence as follows e Open inlet valve PCB ref VR2 e Open outlet valve PCB ref VR2 an Paasa e Start pump PCB Ref PR1 f fitted e Time of day in 24 hour format e FILTERING the unit is in filtration mode jud GNE e STOP L HD above the button stops the unit STOP I gt I BW e BW int indicates backwash is a timed interval user selectable from 1 to 24 hours ot BW ToD 7 day timer e MBW R HD press amp hold the button to trigger a manual backwash 15 32 STARTING STOP gt gt I FILTER 15 32 RUNNING STOP gt I FILTER Page 17 of 58 Unit E mn TM Filter Technology Centre C RO b Wk Industrial Roseheyworth Business Park xp MEDIA FILTER BY Ipc 1 DS a Purification Abertillery 01495 294500 KINANG O NAE Ltd Blaenau Gwent 01495 291884 sales industrial purification co uk www industrial purification co uk To activate a Manual
57. tting section in this manual for further information then the display amp sequence is as follows e Close inlet valve PCB ref VR2 e Close outlet valve PCB ref VR2 e Stop process pump PCB Ref PR1 if fitted 15 33 FILTERING e Open drain valve PCB ref VR3 STOP BW int MBW e Open backwash valve PCB ref VR4 e Start backwash pump PCB Ref PR2 if fitted e Start backwash timer user adjustable Page 18 of 58 Unit E t eee Filter Technology Centre Lf y y Industrial Roseheyworth Business Park j m MEDIA FILTER BY I7 1 S Purification Abertillery 01495 294500 swan Systems Ltd Blaenau Gwent 01495 291884 sales industrial purification co uk www industrial purification co uk e Time of day in 24 hour format e BACKWASH the unit is in backwash e STOP L HD press amp hold the button x Aa mi e MAN BW indicates a timed interval backwash cycle e Close drain valve PCB ref VR3 e Close backwash valve PCB ref VR4 e Stop backwash pump PCB Ref PR2 if fitted STOP I gt gt I FILTER e Open inlet valve PCB ref VR1 e Open outlet valve PCB ref VR2 e Start process pump PCB Ref PR1 if fitted 15 32 RUNNING 15 33 FILTERING e Time of day in 24 hour format STOP I BW int MBW e FILTERING the unit is in filtration mode e SIOPL HD press amp hold the button to stop the unit e BW int indicates backwash is a timed interval user selectable from 1 to 24 hou
58. y Signalling Description o ORF OFF o ON OFF ON UNIT IS BACKWASHING IRIGGERED BY TIME or MANUAL AP REMAINS HEALTHY UNIT IS BACKWASHING IRIGGERED BY AP SET POINT AP REMAINS HEALTHY UNIT IS FILTERING BUT AP IS IN FAULT UNIT IS BACKWASHING TRIGGERED BY TIME or MANUAL AP IS IN FAULT Summary BMS relay 1 will be closed energised if the unitis HEALTHY and POWER is On and there is No AP alarm BMS relay 2 will be closed energised when the in FILTERING or when AP has triggered a backwash BMS relay 3 will be closed energised when the unitis BACKWASHING Page 28 of 58 Unit E TM Filter Technology Centre C R A Wk Industrial Roseheyworth Business Park y MEDIA FILTER BY TP 1 DS a Purification Abertillery 01495 294500 ADVANCE O ERR Ltd Blaenau Gwent 01495 291884 sales industrial purification co uk www industrial purification co uk BMS Control Inputs The AC 5 controller has two built BMS input options can be configured either volt free or switched via the on board 5 volt supply BMS input one enable the unit to be remotely started and stopped by the input being high or low The unit can still be locally started and stopped from the controllers function buttons BMS input two enable the unit to be remotely backwashed by making the input go from high to low and back to high BMS I O 1 ACTION BMS I O 2 Cln ACTION UNIT STARTS UNIT STARTS BACKWASH UNIT STOPS REVERTS TO TOD or INT Programme Logic
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