Hellenbrand Iron Curtain System User's Manual
Contents
1. Switch Mounting 49 14007 Decal Time of Day 49 14045 Decal Instructions 49 13864 Skipper Wheel Ring 49 11805 Single Micro Switch Screw 49 12681 EE Wire Connector not shown 49 15066 Ball 1 4 Dia Main Gear 49 15354 01 Ground Wire not shown 49 15320 Air Pump Switch 49 15808 Roll Pin Air Pump Switch not shown 49 12625 1 Long Roll Pin 13 Iron Curtain Control Drive Assembly FIGURE 6 ITEM NO NO REQ D PART NO DESCRIPTION IC Air Pump IC Pump Feet IC Pump Feet Nut not shown 3 8 Brass Elbow 3 8 Delrin Sleeve not shown inside brass nut and elbow 3 8 Tube Insert not shown inside brass nut and elbow 3 8 Brass Nut 3 8 x 1 PVC Tubing 2 1 4 Piece Needed 3 8 Tube x 1 4 FPT White Elbow 1 4 MPT Stainless Steel Check Valve 3 8 Tube x 1 4 FPT White Connector 3 8 x 500 Natural Tubing 8 piece needed IC Air Recharge Plastic Valve IC Air Bleedoff Plastic Valve 3 8 x 500 Black Tubing 9 1 2 piece needed IC Recharge Bleed off Cam Bracket 49 16637 IC Recharge Bleed off Cam 49 15226 3 Terminal Strip 49 10769 Drive Motor 4910774 0 Bracket Motor Mounting 49 10231 Screw Drive Mounting ITEM NO NO REQ D PART NO DESCRIPTION 49 60304 IC IC Timer Assy w Air Pump Switch 49 10338 Roll Pin m Drive Cam As2. AIR PUMP SWITCH Located behind FIGURE 9 program wheel 12 Iron Curtain Timer Assembly 2 3 4 5 A FA l FIGURE 7 ITEMNO NO REQ D PARTNO DESCRIPTION ITEMNO NO REQ D PARTNO DESCRIPTION wade Timer Housing 49 13011 Cycle Actuator Arm 49 49 60519 24 Hour Gear 49 13959 24 Hour Label Silver 49 13886 Knob 49 13296 Screw Timer Knob 8 Motor Mtg Plate 49 11999 Button Decal 49 14381 Skipper Wheel Assembly 12 Day 49 13429 Skipper Wheel Label 12 Day 49 13014 Regeneration Pointer 49 14265 Spring Clip 49 13311 Spring Skipper Wheel Detent 49 13300 Ball 1 4 Dia Skipper Wheel 49 14457 o Spring Main Gear Detent 49 13911 Main Drive Gear 49 13880 Program Wheel 49 15493 00 Roll Pin 49 13901 Program Wheel Decal 49 13018 Idler Shaft 2 4913312 0 0 Spring Idler 49 13017 Idler Gear AOA BP oia Drive Gear 49 13299 Curved Washer 49 13887 Motor Mounting Plate 49 13944 Motor 110V 60 Hz 49 14104 Motor 24V 60 Hz 49 13278 Screw Motor Mounting 49 11384 Screw Timer Hinge 8 Ground Wire See Hinge Bracket 49 14087 Insulator 49 10896 Homing Switch 49 15320 Program Actuator Switch 49 11413 Screw
3. AIR BLEEDOFF VALVE a Ny OUTLET e t MULTI MEDIA FILTER TANK INLET DIFFUSER BLEED OFF TUBE DISTRIBUTOR TUBE PICK UP TUBE AERATION TANK Step 6 Packing the Bed for Filtering The Iron Curtain Control Center automatically closes both the air bleedoff and air recharge valves and shifts the piston into the rapid rinse position Raw water passes thru the aeration system and enters the control valve passes down thru the multi media filter bed into the bottom distribution system up thru the distributor tube and out to the drain At the end of this cycle the Iron Curtain System automatically returns to the service position U S Patent B1 5 096 596 Troubleshooting Complaint Problem Cause Solution Iron or manganese bleed A Inadequate backwash of filter 1 Plugged drain line flow control ta Clean or replace drain line flow through or staining control Sulphur odor bleed through 2 Insufficient water supply from well 2a Check for minimum specified flow and pressure requirements of filter system 3 Plugged aeration tank inlet 3a Generally will only plug with the diffuser or pick up tube presence of iron bacteria Clean aeration assembly and shock treat the water supply with chlorine as needed to contro
4. As you look at the numbered side of the program wheel the group of pins starting at 10 determines the length of time that your Iron Curtain Filter will backwash For example If there are six pins in this section the time of the backwash will be 12 minutes 2 minutes per pin To lengthen backwash time remove 1 long roll pin s from pin storage on timer 1 pin needed for each 2 minutes to be added Beginning at number 8 and counting back remove pin s extended out back of program wheel 1 pin for each long roll pin to be added to extend backwash time Replace with long roll pin s so it extends out back equal distance with existing pins IMPORTANT After installing long roll pin s turn the manual regeneration knob clockwise one revolution to make sure long roll pin s do not touch drive gear Item 22 Figure 7 page 13 How to change the length of air recharge cycle ARC The group of holes between the last pin in the backwash section and the second group of pins determines the length of time that your Iron Curtain Filter is in the air recharge cycle rinse 2 minutes per hole Note This cycle also uses the set of pins on the backside of the program wheel simul taneously with the first set of spaces on the front side of the program wheel Backwash Section pins 10 20 2 min per pin Air Recharge Cycle Section pins 22 38 2 min per hole Rapid Rinse Pin Storage Cycle Advance pins 46 48 Cycle Shu
5. advancing the timer to service position How To Set Regeneration Cycle Program Refer to page 3 for factory settings How to set the regeneration cycle program The regeneration cycle program on your Iron Curtain Filter has been factory preset however portions of the cycle or program may be lengthened or shortened to suit local conditions To expose cycle program wheel grasp timer in upper left hand corner and pull releasing snap retainer and swing timer to the right To change the regeneration cycle program the program wheel must be removed Make sure the timer is in the service position and then unplug the power cord Grasp program wheel and squeeze protruding lugs toward center of wheel Lift program wheel off timer The arm on the program actuator switch may need to be moved to facilitate removal After making the necessary adjustments described in steps 2 3 and 4 install the program wheel on the timer Place program wheel over the protruding lugs and gently push program wheel on until the tabs on the lugs are snapped in place over the wheel The arm on the program actuator switch may need to be moved to facilitate installation Return timer to closed position engaging snap retainer in back plate Make certain all electrical wires are located above snap retainer post Plug in power cord How to change the length of the backwash time The program wheel as shown in the drawing is in the service position
6. assembly 1 After water distribution system is drained place Iron Curtain System on bypass See Figures 1 2 amp 3 page 8 Unplug power cord 2 Openthe bottom drain valve on the Iron Curtain filter tank and allow water to drain out You may want to connect a garden hose to drain valve and run to appropriate drain Leave drain valve open 3 After pressure is relieved disconnect white air recharge line from aeration head 4 With an air compressor blow air through white air recharge fitting in aeration head until air with little or no water discharges from drain valve Caution Use only enough air pressure to force water in tank to discharge Do not exceed 30 psi 5A If aeration tank IS NOT equipped with optional bottom drain It is recommended at this point to disconnect the inlet outlet of aeration tank and remove the aeration head assembly Dump remaining water If aeration head assembly has a buildup of iron bacteria the well should be shock treated with chlorine when the water system is reactivated Consult your local dealer for more informa tion regarding shock treating well Clean aeration head assembly of any buildup and reassemble aeration tank 5B If aeration tank IS equipped with optional bottom drain Open the bottom drain valve on the Iron Curtain aeration tank and allow water to drain out You may want to connect a garden hose to drain valve and run to an appropriate drain Leave drain valve open 6 Plug in pow
7. driver prying under the flat center retainer Remove piston sleeve from connecting rod assem bly Using an 1 8 allen wrench through the air intake hole loosen eccentric bearing and piston connecting rod assembly set screw and remove eccentric bearing and connecting rod assembly If eccentric amp bearing assembly need replacing Us ing a 1 8 allen wrench through air intake hole loosen eccentric amp bearing assembly screw and remove eccentric amp bearing assembly Remove piston sleeve from connecting rod assembly Remove valve flap per screw and valve flapper Remove intake valve plate screws and remove ramped valve plate and piston cup Install new piston cup on connecting rod Place a dab of silicone caulk in the center dimple on bottom side of ramped valve plate and install ramped valve plate and intake valve plate screws 12 lbs making sure the intake hole is aligned in the connecting rod piston cup and ramped valve plate Install new valve flapper and valve screw 12 lbs Slide new piston sleeve upwards over connecting rod assembly starting from the bottom forcing new piston cup to curve upwards inside piston sleeve Note If piston sleeve slides over the top of connecting rod assem bly reinstall starting from the bottom If installing new connecting rod assembly slide new piston sleeve upwards over connecting rod assembly starting from the bottom forcing new piston cup to curve upwards inside piston sleeve N
8. lt a Hellenbrand WON CURTAIN YSTEM 5 A 6 3 For systems manufactured after October 1997 Owner s Manual 2003 Manufactured by HELLENBRAND INC 404 Moravian Valley Road PO Box 187 Waunakee Wisconsin 53597 Phone 608 849 3050 Fax 608 849 7398 Web www hellenbrand com Email info hellenbrand com Congra tula tions on your purchase of one of the finest water treatment systems available today the Iron Curtain System This patented non chemical filter system when properly applied will remove iron manganese and or hydrogen sulfide from your water supply The Iron Curtain has been third party tested by the Water Quality Association An optional Type A filter also corrects low pH water This owner s manual is designed to assist owners and installers with the operation maintenance and installation of your new iron removal system It is our sincere hope that this manual is clear concise and helpful to both owner and installer We have included detailed instructions of general operating conditions pre installation installation start up and timer settings Q uestions Should you have any questions regarding the installation operation or servicing of this system please contact the dealer you purchased this system from Your dealer will be familiar with your particular situation your water conditions etc and should be able to address your concerns promptly and efficiently TABLE OF
9. the filter system See Figures 1 2 amp 3 on page 889 Optional Filter Inlet Shut Off This valve allows for servicing of the filter tank and or filter control valve without draining the aeration tank See Figures 1 2 amp 3 on page 889 Filtered Water Normally filtered water is furnished to all household lines however outside faucets are typically left on raw water If filtered water is provided to outside faucets the filter system must be sized accordingly Caution The water pressure is not to exceed 70 p s i water temperature is not to exceed 110 F conditioner cannot be subject to freezing conditions conditioner cannot be subject to a negative pressure or vacuum On installations where there is the possibility of a negative pressure or vacuum a vacuum breaker or check valve must be installed at the inlet of the conditioner For example if the water service is interrupted due to a water pipe break well pump being serviced etc a back siphon could occur causing a vacuum or negative pressure on the filtration equipment Installation Instructions See Page 3 for Special Factory Connections Assembly 1 Follow all local and state plumbing and electrical codes 2 Ajumper ground wire should be installed where the metallic continuity of a water distribution piping system is interrupted 3 Turn the water supply off 4 Ifyou have a water softener place the water softener on bypass and close the shut off valve to the wat
10. 5 3 4 5 0 5 0 26 x70 x16 IC 12 12 x52 20 1 7 0 8 0 30 x68 x18 IC 12A 12 x52 2 0 1 7 0 8 0 30 x68 x18 IC 12 12 x52 2 0 1 7 0 8 0 30 x68 X18 1 Aeration Head and Check Valve have 1 Inlet Outlet 2 Water temps above 60 F will require a higher backwash rate Consult factory TYPE A IRON CURTAIN SYSTEMS Optional When supply water has a pH between 6 0 and 6 9 a Type A filter system with sacrificial media is generally used To insure top performance this media needs to be replenished periodically depending on water characteristics and usage patterns generally every 6 to 18 months This can be determined by testing the pH of the water at a cold filtered tap or by physically measuring the amount of freeboard See Figure 8 page 4 If the pH is 7 0 or greater media does not need to be added If the pH is below 7 0 and or the amount of freeboard is greater than 18 for IC 10A or 17 for IC 12A see step 5 media needs to be added If media needs to be added contact your dealer and ask for the following Part Number 1 A8011 66 cubic foot IC pH Correction Media 50 Ib bag Instructions for Adding IC pH Correction Media See Figures 1 2 amp 3 on page 8 1 2 2A Place Iron Curtain System on bypass Close inlet and outlet valves and open bypass valve Relieve pressure by manually advancing timer to back wash position see page 10 Unplug control valve after valve is shifted into backw
11. CONTENTS Installati n RT EE 3 Air Recharge amp Air Bleed Off Valve Fitting Connection ASSY c oococccnccnncccnncononcnnnccnonn cnn cnn coronar rra 3 Aeration Head Fitting GOnMeCtion sirere a ata 3 Principle of Operations it deat a Wa Ae oe a et ee A ee idea 4 Operation of Aeration PUMP a ahi eel anne ae ee las 4 Advantages e 4 Operating Ben ed ain nde aa A a ees ee a ee eaS 5 General Application Guidelines ic festa sde eatin data 5 Pre Installation Check let sic ria A o a ee 6 Installation INStruCtiOnS EE 6 CT El E 6 7 Regeneration Frequentdy irni A AU A A ee E a 7 Specific OS ee o o a e eo e eli ee ro el e e da tdo E 7 Type A Iron Curtain Systems iii a A A di 7 Instructions for Adding IC pH Correction Media 7 8 EEN NR Le 8 9 HOW O Set IMO e a Es a a A EE 9 Howto Set Regeneration Time ici bib 10 How to Manually Regenerate Your Water Filter AAA 10 How To Manually Advance Control Center coococcccnncccnnccnoccconccnonnnono cono cnn cnn nn n rn nannnins 10 How to Set Regeneration Cycle Program E 11 Iron Gurtain System Dia Mii ti id 12 Irom Gurtain Wiring DIAG Mita ai iia aera side sezechageniensasteande 12 lrom Gurtain Timer ASSEM Dy a eaa e a a a a e a a e a E a aaa a ae E aee AT n aT aao EEA T A a T 13 Iron Curtain Control Drive e UE 14 lron Gurtain Aeration dall le E 15 Iron Curtain Aeration Pump Repair Instructions e cecceeeceeeeeeeeeeeeeeeceeeeeeeeseeeeeaeesaeecaeeseaeeeaeeseaeeseeseeseaeeseeeseeesieeseaees
12. F AERATION FILTER ASSEMBLY PRESSURE TANK E FIGURE 1 A MIA Due to existing plumbing conditions you may want to choose an alternate installation configuration Refer to Figures 2 and 3 below for alternate installation diagrams FILTERED UNSOFTENED FILTERED UNSOFTENED WATER TO_KITCHEN SINK WATER TO KITCHEN SINK TO OUTSIDE TO OUTSIDE HOSEBIBBS HOSEBIBBS THREE VALVE THREE VALVE BY PASS BY PASS d INLET OPTIONAL H OPTIONAL H D SHUT OFF FILTER INLET FILTER INLET SHUT O SHUT OFF SHUT OFF FILTERE JATER TO WATER SOFTENER PRESSURE RELIEF VALVE CHECK IRON IRON DRAIN LINE VALVE CURTAIN CURTAIN EAS AERATION FILTER ASSEMBLY FILTERED WATER TO WATER SOFTENER PRESSURE RELIEF VALVE CHECK VALVE LCN PRESSURE TANK IRON CURTAIN A AERATION ASSEMBLY DRAIN LINE PRESSURE Mna TANK LD NLET SHUT OFF 11 FIGURE 2 H REA FIGURE 3 KEN How To Set Timer How to set days on which water Service conditioner is to regenerate Position 24 Bate a bestet Rotate the skipper wheel until the number 1 is at the red Indicator andar nego neraton ine pointer Set the days that regeneration is to occur by aa sliding tabs on the skipper wheel outward to expose trip SON LARGE DAL UNTIL fi
13. No floats or air volume controls to regulate air volume in aeration tank which foul from iron 5 Two tank system consisting of a pressurized aeration tank and multi media depth filter 6 110V aeration pump to recharge aeration tank 7 Canbe used on shared wells municipal water supplies or with buried pressure tanks without additional equip ment 8 Higher service flow rates 9 Better filtration results 10 U S Patent B1 5 096 596 w Operating Conditions The Iron Curtain System has been validated by the WQA under their S 200 Filter Standard for the reduction removal of iron manganese and or hydrogen sulfide The concentration limits listed below reflect the maximum individual limit that each contaminant was tested for separately without any interference of other contaminants in the influent water In reality however we know that these contaminants may be present in combination which may limit the filter s ability to remove these contaminants in higher concentrations In some cases individual sellers of this equipment have had success removing higher concentrations of contaminants iron for example above the limitations we have listed If you are considering the installation of this system for the reduc tion removal of iron manganese and or hydrogen sulfide beyond the printed operating conditions below we recommend that you consult the manufacturer for proper application Installation of this system un
14. O Ring 17 18 IC 12 Series Control Valve Assembly NO REQ D PART NO DESCRIPTION 1 49 14749 02NP Nickel Valve Body se End Spacer Seal Ring Spacer Seal Spacer Kit Piston sr OO Joo EF G bh SERVICE TOOLS needed for removing and replacing piston seals and spacers for both IC 10 amp IC 12 49 13061 49 PICK 49 11098 Spacer Puller O Ring and Seal Pick Spacer Stuffer FIGURE 12 10 RE Mia 49 60090 HF 2750 Piston Assembly 49 11710 Inside Tube O Ring 49 10381 Adapter Base Tank O Ring 49 12461NP Nickel Adapter Base 49 11208 Adapter Base Seal O Ring 49 15137 Flat Cap Screw 49 11893 Flat Cap a 49 11475 oonan Injector Body Gasket 49 11224 a Adapter Base Screw 49 60700 8 0 IC 12 8 gom DLFC Assembly Instructions for Replacing Piston Assembly and Seal Kit Replacing Piston Assembly See pages 17 and 18 for Parts Diagrams 1 Place Iron Curtain System on bypass Close inlet and outlet valves and open bypass valve See Figures 1 2 8 3 on page 8 2 Relieve pressure by manually advancing timer to back wash position See page 10 Unplug control valve after valve is shifted into backwash position piston all the way in and piston has stopped moving After pressure is relieved proceed 3 With a 5 8 wrench e Loosen fitting nuts on back of air recharge valve and air bleedoff valves 3 8 white and black polytubi
15. Ring Valve Flapper 74 662150 Valve Plate ee 74 623537 O Ring Piston Sleeve 1 74 662784 0 Valve Plate Assembly ocooccc cc 1 a 74 618145 oe PISTON SICOVE oo ee ee eeeeeeeeereeeeeeee 1 74 625160 oe Screw Ramped Intake Valve Flapper 1 74 621488 oe Intake Valve Flapper ooooicccccncoo 1 Item Part No No Description Qty a Perens 74 607604 ue Connecting Rod Assy ccocccccoccooo 1 E 74 607605 eee Connecting Rod Valve Plate Eccentric amp Set Screw Assy bel 74 625449 woe crew over 68 74 614609 oe Cover Oir 1 74 633504 A CMA e oro 1 74 614425 504 Motor End Cap sen 1 74 641169 oe APR te avec sateen 1 74 669213 504 HOUSING E 1 74 633562 Gasket Front Cover Seel 74 614430 oo Front Cover aviat 1 GREMIEN Screw SlatOr 2 2 cece 2 22 01 IC Complete Air Compressor 1 405 Air Pump Service Kit Not Shown Includes 3 4 5 6 7 9 11 12 29 WE 74 650571 cee 405 Air Pump Rebuild Kit Not Shown Includes 22 33 15 16 Iron Curtain Aeration Pump Repair Instructions Air pump must be removed from tank and have power supply disconnected before proceeding 1 Remove four front cover screws and remove front cover and cover gasket Remove four pump head screws and remove pump head Remove valve plate assembly Remove felt air filter on side of pump with a flat screw
16. UTOR TUBE Step 4 Recharge of Aeration Tank with New Air After approximately 2 4 minutes a specially mounted switch in the Iron Curtain Control Center turns the air compressor pump on for approximately 10 minutes Water and or air continue to run to the drain thru the air bleedoff valve and the compressor pumps air thru the air recharge valve directly into the aeration tank At the end of this cycle the aeration tank has been recharged with fresh air and will have approxi mately an 18 inch head of air U S Patent B1 5 096 596 23 CHECK VALVE AIR RECHARGE VALVE AIR BLEEDOFF VALVE MULTI MEDIA BED OUTLET FILTER TANK INLET DIFFUSER DISTRIBUTOR TUBE BLEED OFF TUBE TR A PICK UP TUBE A AERATION TANK Step 5 Bleeding Off Excess Air The Iron Curtain Control Center automatically turns the air com pressor pump off and allows both valves to remain open The air bleedoff valve will bleed off any excess air which was pumped in during the previous step and the check valve in the recharge line prevents any backflow into the air compressor system U S Patent B1 5 096 596 D CHECK VALVE AIR RECHARGE VALVE
17. and Drain Lines All drain lines must be a minimum of 3 4 or equal to the size of the drain line connection at the control valve or larger Avoid overhead drain lines when possible If used overhead drain lines are not to exceed a height of five feet above the control valve and should be no more than fifty feet in length Pressure Relief Valve A pressure relief valve is installed in the aeration tank manifold and it is recommended that a separate drain line be extended toward the floor or to a drain recepticle NOTE Do not plumb to a common drain line with filter backwash discharge Check Valve On applications where there is a non filtered demand for water such as joint wells where the filter system is only installed in one of two or more homes outside hosebibbs farms with outbuildings yard hydrants etc a spring loaded check valve is provided and must be installed ahead of the aeration tank See Figures 1 2 amp 3 on page 8 amp 9 It is recommended to install the check valve in a vertical upflow position with a minimum 12 water column above the check valve This prevents air from escaping past the check valve If the check valve is installed in a horizontal position and there is a simultaneous demand for both non filtered and filtered water the air head in the aeration tank may escape backwards past the check valve into the non filtered water line and cause air spitting By Pass Valves Always provide for a three valve bypass on
18. arge and air bleed off valves and tighten fitting dealer nuts Reconnect inlet and outlet plumbing and Cover the distributor tube use a plastic cap or masking tighten the union nuts on inlet and outlet duct tape so media will not get into the distributor tube IC 12A Reconnect the tubing to the air recharge Using a funnel add IC pH correction media until it and air bleed off valves and tighten fitting nuts reaches the maximum fill line Reconnect inlet outlet and drain plumbing and Rinse the powdery fines from the funnel covered dis tighten unions tributor tube and tank threads Remove the funnel and 11 Slowly open the inlet valve and allow filter to fill at a slow uncover distributor tube rate After a steady stream of water is running to drain Place the adapter base back on tank and thread into completely open inlet valve Open outlet valve and close place until snug Be careful not to cross thread the bypass valve adapter base in tank threads You may need to back 12 Plug the control valve in and reset time of day see page 9 thread the adapter base to get it started correctly 13 Allow the system to finish the regeneration cycle and return to service FILTERED UNSOFTENED WATER TO KITCHEN SINK TO OUTSIDE HOSEBIBBS THREE VALVE BY PASS D OPTIONAL FILTER d INLET MOSHUT OFF FILTERED WATER TO WATER SOFTENER PRESSURE RELIEF VALVE An CHECK VALVE i Ny IRON DRAIN IRON CURTAIN CURTAIN Z
19. ash position and piston has stopped moving After pressure is relieved proceed If your type A Iron Curtain filter is equipped with an optional dome hole and bottom drain proceed as fol lows otherwise advance to step three a After pressure is relieved remove the dome plug by turning counter clockwise Open the bottom drain andallow approximately 15inches of water to drain out b Measure down through the dome hole to deter mine media level The media level may be as low as 1 2 of the total tank height or as high as 2 3 of the total tank height c Add pH correction media and fill to a maximum level of 2 3 of the total tank height Approximately 17 18 inches down from the top of the tank on an IC 12 or IC 10 respectively d Replace the dome hole plug being cautious not to cross thread Check the o ring seal to be sure it is clean from foreign debris Hand tighten only plus approximately 1 8 of a turn with a wrench Be careful not to overtighten causing damage to the threads e Proceed to step 11 Remove the control valve from tank see page 14 Determine if plumbing is rigid and able to support the weight of the control valve assembly If the plumbing is rigid and able to support the weight of the control valve assembly Remove the two adapter base screws and slide the tank away from the control valve and plumbing so it is easier to work on If the plumbing is unable to support the weight of the control valve ass
20. ated water to appear effervescent Stuffer to Replace Spacers and Seals Replacing Spacer in Valve Body Removing Stuffer from Valve Body after Inserting Seal 21 MULTI MEDIA BED IRON CURTAIN FLOW DIAGRAMS CHECK VALVE AIR RECHARGE VALVE AIR BLEEDOFF VALVE FILTER TANK INLET DIFFUSER BLEED OFF TUBE d PICK UP TUBE ae uw DISTRIBUTOR TUBE AERATION TANK Step 1 Service Position Raw water enters the aeration tank inlet flows thru the inlet diffuser thru a head of air down thru the aeration tank thru the pick up tube out the aeration head into the filter control inlet and down thru the multi media bed Filtered water is collected by the bottom distributor flowing up thru the distribution tube and out the top of the filter control U S Patent B1 5 096 596 MULTI MEDIA BED 22 H CHECK VALVE AIR RECHARGE VALVE AIR BLEEDOFF VALVE DRAIN OUTLET FILTER TANK INLET DIFFUSER DISTRIBUTOR TUBE BLEED OFF TUBE PICK UP TUBE AERATION TANK Step 2 Backwashing the Multi Media Filter Bed The Iron Curtain Control Center automatically shifts the c
21. dditional contact time is recommended Consult Factory For application parameters outside the specified operating conditions or additional information regarding the listed items contact your dealer Pre Installation Check List Water Pressure A minimum of 30 psi at a predetermined flow rate is required to backwash the filter properly with a maximum of 70 psi to be used Actual Influent Flow Rate Water available from well pump service inlet etc The actual pumping rate must exceed the backwash rate for the model of filter selected at a minimum of 30 psi See actual backwash rates in the Specifications section on page 7 Electrical Requirements for Filter Control A continuous 110 volts is required to cycle the controls and aeration pump Make certain the electrical supply is always on and cannot be turned off with another switch Existing Plumbing The condition of the existing plumbing should be free from lime and iron build up Piping that is heavily built up with lime and or iron should be replaced Equipment Location See Figures 1 2 8 3 on page 889 Location of Aeration and Filter Tank See Figures 1 2 amp 3 on page 8 amp 9 These two tanks should be installed after the pressure tank and as close to each other as practical If you want to filter outside hosebibbs be sure the filter system is properly sized to handle the flow rates required for extended periods of time in addition to the normal household dem
22. der these circumstances may void part s and or all of the system warranty pH ThepHlevelofthe influentwater mustbe 7 0 orhigherunless you have a Type A filter which will work on a pH of 6 0 to 7 0 Iron This system is rated for a maximum of 10 ppm of ferrous clear water and or ferric red water iron Iron Bacteria If iron bacteria are present more frequent service may result the life of the Iron Curtain system may be limited and the system may be unable to properly remove iron By properly controlling the iron bacteria with chlo rine or other approved methods for bacterial reduction the Iron Curtain System will function properly One option is to control iron bacteria within the Iron Curtain is chlorine injection during the regeneration cycle In some instances continuous chlorinaton of the water supply may be needed Hydrogen Sulfide Often referred to as rotten egg odor hydrogen sulfide will be reduced significantly on water supplies containing less than 10 ppm Past installations have shown that hydrogen sulfide levels from 2 0 10 00 ppm will require use of the Iron Curtain Remote Control Center and or larger aeration assembly The Iron Curtain Remote Control Center has an independent timer program which recharges the aeration assembly with fresh oxygen up to six times per day with the filter s being regenerated with their own independent timer Manganese Limit 2 0 ppm amounts present over 2 0 ppm will graduall
23. dissipate to the atmosphere in pressure As water is released a matter of seconds If preferred to the atmosphere air molecules water can be drawn and stored in separate from the water molecules an open container prior to use i e fill a pitcher and store in the refrig erator for cool fresh drinking water Loss of pressure See complaint 1 problem A 8 B Air spurting at outside or non Inlet check valve not sealing 1 Improper installation location la See installation and operation filtered water fixtures manual for proper location of inlet check valve 2 Foreign material preventing check 2a Clean or replace check valve valve from sealing 3 Worn or faulty check valve 3a Replace check valve Air spurting from filtered water Reduced pressure in distribution 1 Service flow demand is greater than 1a Repair or replace well pump fixtures system water supply available from well system pump system 2 Water flow is restricted by supply 2a Eliminate restrictions in supply piping and or water treatment pipings to water treatment equipment equipment such as iron bacteria plugging the upper diffuser assembly etc 2b Install larger water treatment system to provide less pressure drop Loss of media through drain line New filter backwashed during first 1 New filter media is shipped in a dry 1a Clean drain line flow control 24 hours after installation condition and must soak for 24 control valve body seals spacers hours to become fully saturated and p
24. eeeenaeene 16 IC 10 Series Control Valve Assembly s 2 c2i2tsscc8saceveas caceennyieniceiescenusnasace ave tases A E E dees E AE aaa aTa a Toa aAa ER RTAS 17 IC 12 Series Control Valve Assembly EE 18 Instructions for Replacing Piston Assy amp Seal Kit oooiocnnccincccicccnonaconccnonnnoncnnnnnconnnnnnc con cnn nono 19 21 Irom Curtain Flow Diagram S iia RAE E Apiaceae ast 22 24 Brel Let ME 25 26 Winterizing Iron Gurtain SyStems iii Raices 27 iron Gurtain E Tu RE 28 INSTALLATION DATA Date of Installation Model No Address of Installation Installed By Raw Water Test Iron Manganese pH Hydrogen Sulfide TDS lron Bacteria yes no Tannins Automatic Regeneration Every Days Influent Flow Rate 25 PSI Gallons Per Minute gpm Regeneration Program Settings Factory Number Program Wheel Customized Cycle Preset Setting Pins Spaces Location Setting Backwash 12 minutes 6 pins 10 20 minutes Air Recharge Cycle 18 minutes total 9 spaces 22 38 minutes Pre Bleed off 4 minutes 2 spaces 22 24 minutes Air Recharge Bleed off 10 minutes 5 spaces 26 34 minutes Air Pump Run Time 10 minutes 5 pins extending out back of program wheel 0 8 minutes Post Bleed off 4 minutes 2 spaces 36 38 minutes Rapid Rinse 6 minutes 3 pins 40 44 minutes Cycle Advance 4 minutes 2 spaces 46 48 Cycle Shut Off 4 minutes 2 pins 50 52 Refer to page 11 for instructions if altering factory settings Note Five pins extending out back of progra
25. embly IC 10A Loosen the union nuts on the inlet and outlet and disconnect plumbing Loosen the fitting nuts on back of air recharge and air bleed off valves and remove tubing Loosen the fitting nut on drain line flow control housing and remove tubing Loosen the screw holding the drain line flow control and disconnect the drain Slide the tank unit away from the plumbing so it is easier to work on IC 12A There must be a union installed on the inlet outlet and drain line of control valve to proceed If not they must be installed prior to proceeding Loosen the union on the inlet outlet and drain and disconnect plumbing Loosen the fitting nuts on back of air recharge and air bleed off valves and remove tubing Slide the unit away from the plumbing so it is easier to work on Remove the two adapter base screws and remove the control valve assembly from the tank Remove the adapter base Place the two adapter base screws back in the adapter base and thread in until they are flush with the bottom of the adapter base but not touching the top of the tank Carefully place a pry bar long screwdriver wrench etc between the screws and Carefully place a pry bar long screwdriver wrench etc apply pressure counterclockwise to loosen the adapter between the screws and apply pressure clockwise until base Be careful not to crease or tear the o rings in tight Be careful not to crease or tear the o rings in the the adapter base Unscrew
26. epeated with step 4 IRON CURTAIN Iron Filtration System Aeration precipitation multi media filtration for 1 Iron Reduction Removal 2 Manganese Reduction Removal 3 Hydrogen Sulfide Reduction Removal A special Type A filter also provides pH adjustment on water supplies with a pH from 6 0 or greater Principle of Operation The Iron Curtain System uses a three step process of oxidation precipitation and mechanical filtration for the reduction removal of iron manganese and hydrogen sul fide The process of how the Iron Curtain System does each one of these separate procedures is the key to the successful results this product has obtained in the market place There are three main components that make up the Iron Curtain System They are 1 IC Control Center w Aeration Pump 2 Aeration Tank 3 Multi Media Depth Filter The first step in any oxidizing process is to bring the raw water into intimate contact with a strong oxi dant This will begin to convert the dissolved element such as iron or manganese to a physical particle or nonsoluble precipitate The least expensive environmentally safe oxi dant is oxygen 0 air To do this the Iron Curtain System makes the water spray through a regulated head of air in the aeration tank The second step in this three step process of oxida tion precipitation filtration is to provide adequate reaction or contact time for the precipitation to go to completion T
27. er cord and manually advance timer to backwash position then to air recharge position See page 10 Unplug power cord 7 Openinlet and outlet shut off valves Leave bypass valve open System is now winterized 9 Whenturning system back on follow start up instructions on page 6 Note The bottom drain valve on Iron Curtain aeration tank and filter tank must be closed prior to start up CAUTION Always be certain that the distribution piping including but not limited to the bypass piping arrangement typically just above the Iron Curtain System does not trap water that may consequently drain into the filter after the filter draining procedure is complete and all pressure is relieved If optional drain valve s are used it is suggested they be left open 27 28 IRON CURTAIN FILTER SYSTEMS LIMITED WARRANTY Hellenbrand Inc warrants to the original consumer purchaser against defects in material and or workmanship from the date of the original installation as follows For a Period of FIVE YEARS The 3 4 or 1 control valve s including electrical parts internal parts and valve body For a Period of TEN YEARS The fiberglass and or polyglass mineral tanks 6 Diameter 13 Diameter For a Period of FIVE YEARS The fiberglass and or polyglass mineral tanks 14 Diameter Up For a Period of ONE YEAR The Iron Curtain aeration pumps and any other defective component Any parts used for replacement are
28. er heater Drain down the plumbing system Mountthe control valve and aeration pump on the filter tank Do all necessary plumbing as shown in Figures 1 2 amp 3 on page 8 If you want to filter outside hosebibbs be sure the filter system is properly sized to handle the flow rates required for extended periods of time in addition to the normal household demand Use a PVC compatible thread sealer when connecting fittings to the aeration tank manifold Care must be taken not to overtighten fittings into aeration tank manifold 8 Run the drain line from the filter control in accordance with local plumbing codes The drain line will emit surges of excess air from the aeration tank and therefore must be secured Models IC 10 amp IC 10A have a 1 2 Male NPT Drain Connection Models IC 12 amp IC 12A have a 3 4 Female NPT Drain Connection For all models use a minimum 3 4 LD Drain Line 9 Connect the 3 8 white polytubing from the white fitting on the aeration tank manifold to the air recharge valve on the Iron Curtain Control Center Connect the 3 8 black polytubing from the black fitting on the aeration tank manifold to the air bleedoff valve on the Iron Curtain Control Center The 3 8 white and black tubing are located in the Control Center box Cut tubing off to minimal necessary length after aeration tank and filter tank are in place Secure tubing to the plumbing with cable ties provided Connect drain discharge line to pressure
29. haft on the upper left side of drive motor and pulling outwards While holding the motor shaft out the drive cam can be turned clockwise to move connecting link to align connecting link hole with piston rod hole Tighten the two capscrews and plug in control valve powercord Manually advance the timerto service position and allow control valve to cycle until in the service position See page 10 for instructions on manually advancing timer Manually advance the timer to the backwash position and allow to stop Then advance timer to the beginning of the air recharge cycle Unplug the control valve powercord Puller to Remove Spacers Removing Spacer from Valve Body FIGURE 16 Stuffer Placing Seal in Brass Sleeve of Stuffer FIGURE 18 24 25 26 27 FIGURE 19 Open inlet valve no more than 1 4 turn and allow system to fill slowly After a steady stream of water is seen at the drain without excess air proceed to the next step Close the bypass valve and open the inlet valve all the way Plug in the control valve powercord In approximately four minutes the aeration pump will automatically turn on and begin to pump air into the aeration tank Allow the Iron Curtain Control Center to finish the remaining cycles Set time of day Open the outlet valve on the filter then open the nearest cold water faucet and allow the water to run until the air stops spurting and discoloration is gone Note It is normal for aer
30. he nearest cold water faucet and allow the water to run until the air stops spurting and discoloration is gone Note It is normal for aerated water to appear effervescent Piston Assembly End Plug Piston Rod lt A eS lt Connecting Link Pin FIGURE 13 19 20 Replacing Seal Kit 1 To replace seal kit the follow special tools are needed A Seal Hook Used to remove piston seals Wire hook with finger loop B Puller Used to remove piston spacers e Has 3 retractable pins retained by a rubber ring at one end They are retracted or pushed out by pulling or pushing the center button on the opposite end C Stuffer Used to install rubber seals and plastic spacers e Double purpose tool with brass sleeve on one end Place Iron Curtain System on bypass Close inlet and outlet valves and open bypass valve See Figures 1 2 amp 3 on page 8 Relieve pressure by manually advancing timer to back wash position See page 10 Unplug control valve after valve is shifted into backwash position piston all the way in and piston has stopped moving After pressure is relieved proceed With a 5 8 wrench e Loosen fitting nuts on back of air recharge valve and air bleedoff valves 3 8 white and black polytubing connecting the control valve to aeration head and disconnect tubings from air recharge and air bleedoff valves e Loosen remaining fitting nut on air bleedoff valve and discon
31. his allows time for the iron and or manganese particles to become large enough to filter out The aeration tank with the Iron Curtain System allows for several minutes of contact time at the rated service flows compared to only seconds on other systems It should be noted that this reaction time will also be affected by temperature the warmer the water the faster the reaction This reaction time may also be affected by the presence of organic material such as tannins f tannins are present feld tests have shown that they will not be removed and will also hinder the ability of this system to effectively remove Iron manganese and or hydrogen sulfide Installation of this system on water supplies with more than 0 5 pom of tannins will void warranty The third and final step is the removal of the precipi tates from the water The WQA Water Filtration Study Guide states The ideal filter bed would be one with large grains at the top to prevent the formation of a surface cake and to provide large pores for course particles and small grains at the bottom to entrap smaller particles This allows the entire depth of the bed to be used as a filter This also allows for longer filter runs and faster flow rates Unfortunately such an ideal bed when consisting of a single media is not possible the way to solve this problem is to use layers of media The advantages of a multi media bed are 1 Longer runs between backwash times 2 Ca
32. hten screws until connecting link pin is installed Caution Be careful not to scratch exposed piston rod Install connecting link pin connecting piston rod to the connecting link on drive cam Note If connecting link pin hole and piston rod hole are not aligned the drive motor can be disengaged by grasping the motor shaft on the upper left side of drive motor and pulling outwards While holding the motor shaft out the drive cam can be turned clockwise to move connecting link to align connecting link hole with piston rod hole Tighten the two capscrews and plug in control valve powercord Manually advance the timer to service position and allow control valve to cycle until in the service position See page 10 for instructions on manually advancing timer Manually advance the timer to the backwash position and allow to stop Then advance timer to the beginning of the air recharge cycle Unplug the control valve powercord Open inlet valve no more than 1 4 turn and allow system to fill slowly After a steady stream of water is seen at the drain without excess air proceed to the next step Close the bypass valve and open the inlet valve all the way Plug in the control valve powercord In approximately four minutes the aeration pump will automatically turn on and begin to pump air into the aeration tank Allow the Iron Curtain Control Center to finish the remaining cycles Set time of day Open the outlet valve on the filter then open t
33. igure A 5 Turn the time plate so the desired regeneration time aligns next to the raised arrow Figure A 6 Push the red buttom in and rotate the 24 hour dial Tighten each of the three screws 7 Push the red button and locate the pointer one more time to ensure the desired regeneration time is correct 8 Reset the time of day and restore power to the unit How To Manually Regenerate Your Water Filter At Any Time Slowly turn the manual regeneration knob clockwise until the drive motor starts running The movement of the manual regeneration knob engages the program wheel and starts the regeneration program The black center knob will make one revolution in approximately the following three hours and stop in the service position as shown in the drawing Even though it takes three hours for this center knob to complete one revolution the regeneration cycle of your unit is generally set for only one third of this time In any event conditioned water may be drawn after rinse water stops flowing from the water conditioner drain line How To Manually Advance Control Center to a Specific Cycle See Figure 5 on page 11 for location of specific cycles To manually advance the Iron Curtain Control Center to a specific cycle you must start with unit in the service position service position indicator aligned with time of day arrow as shown in Figure 4 Page 9 Advance the timer from one cycle to the next pausing be
34. in 11 Iron Curtain System 9 23 Cir 4 te E IRON CURTAIN FILTER DRAIN LINE ITEM NO NO REQ D PART NO DESCRIPTION BE RE 1 010 1 10 Rebed Mix 8 8 Freeboard Area 1 010A 1C 10A Rebed Mix A ean ie 1 010 1C 10 Rebed Mix Maximum Fill Line 1 012 10 12 Rebed Mix IRON 1 012A IC 12A Rebed Mix CURTAIN 1 012 IC 12 Rebed Mix Consult factory for larger systems pees Bigfoot MMU Aelia 11 P6ME4 3 8 Tube x 1 4 Male Elbow 7 Black Air Bleedoff Fitting Baste se caste E 2920 3 8 Tube x 1 4 Male Elbow White Air Recharge Fitting 1 2 Relief Valve 1 Check Valve not shown 1 Aeration Head Assembly for the IC 10 and IC 10A 22 36 12 1 Aeration Head Assembly for the IC 12 and IC 12A Includes Machined Aeration Head Inlet Diffuser Pick up Tube Bleedoff Tube 1 2 Relief Valve 1 Check Valve Air Recharge Fitting Air Bleedoff Fitting Misc Labels SE IN 9 93154 1 050x54 Distributor Assy IC 10 9 93152 1 050x52 Distributor Assy IC 12 Bee ea EE 19 PG1054BG 10 x54 Polyglass Tank IC 10 19 PG1252BG 12 x52 Polyglass Tank IC 12 AA Misato 2342 IC 10 Valve amp Pump Assy Complete FIGURE 8 EEN 22 47 nn IC 12 Valve 8 Pump Assy Complete Iron Curtain Wiring Diagram TO AIR PUMP PROGRAM ACTUATOR SWITCH TIMER MOTOR 7 HOMING SWITCH PROGRAM SWITCH
35. iston assemblies before a backwash cycle Air passing through filter during 1 Excess air accumulated in aeration 1a Bleed off valve flow control is backwash tank from aeration pump plugged with foreign material clean or replace 2 Excess air accumulated in filter 2a Repair well pump system system from water supply or well 2b If the cause was due to temporary pump loss of water main pressure the problem will most likely correct itself with the return of continuous pressure Excessive noise during Howling or whistling noise during 1 Inadequate drain line size la Increase drain line size regeneration regeneration cycle 2 Drain line is vibrating against other 2a Insulate drain line specifically at pipes conduits pipe hangers heat points of contact with other ducts floor joists etc materials Water running to drain Control valve is stuck in regenera 1 Electrical service to control s has 1a Assure continuous electrical continuously tion cycle been interrupted service is available check plug breaker fuse etc 2 Faulty timer motor 2a Replace timer motor 3 Foreign material lodged in piston 3a Disassemble and clean control valve replace seals spacers and piston assemblies 4 Timer is lodged in regeneration 4a Check program wheel pins to cycle assure back pins are not catching on timer gears 4b Check to assure timer gears are clean and free from foreign ma terials such as solder or pipe burrs Blue green staining A Corrosi
36. king of the bed and breakthrough of turbidity are virtually eliminated 3 Much higher service flow rates per square foot 4 Higher degree of clarity because of the heavier finer filter media in the bottom The standard Iron Curtain System uses five layers of filter media The top layer is made up of large lighter weight particles The second layer contains a slightly heavier media The third layer contains a much heavier media The fourth layer contains an even heavier media The fifth layer is a special support bed to retain filter media so it does not pass through the distribution system and allows an even distrib uted flow of backwash water Operation of Aeration Pump The Iron Curtain System introduces air into the aeration tank and bleeds off the old head of air automatically Following the backwash cycle both the air recharge valve and the air bleed off valve open allowing water and or air to bleed out of the aeration tank After approximately 4 minutes the aeration pump automatically starts pumping a fresh head of air into the aeration tank for approximately 10 minutes After the pump shuts off the air recharge and air bleed off valves remain open for an additional 4 minutes to allow any excess air and or water to bleed off to drain Advantages Over Other Systems 1 Tested and validated by WQA under their S 200 Stan dard 2 Uses no chemicals or salt Eliminates need for air injectors venturis or micronizers 4
37. l iron bacteria 4 Media bed fouled 4a Rebed filter and correct the cause of fouling B Fails to regenerate 1 Interrupted electrical service la Assure continuous electrical supply check plug breaker fuses etc 2 Faulty timer motor 2a Replace timer motor 3 Faulty skipper wheel 3a Replace skipper wheel 4 Faulty 24 hour gear 4a Replace 24 hour gear or timer assembly C Water contaminant levels are 1 Itis not uncommon for local water 1a Consult factory greater than limits established by conditions to change the manufacturer D Inadequate aeration 1 Loss of air through inlet check ta Check installation position of check valve valve Consult Installation and Operation Manual for proper position 1b Check for foreign material in seat of check valve clean or replace as required 2 Loss of air through air leak 2a Check aeration tank assembly and air recharge line and fittings for any air leaks and repair Note soapy water solution works well for locating air leaks 3 Faulty aeration pump due to a Electrical failure 3a Assure permanent electrical service check plug breaker fuses terminal block on control valve etc b Pneumatic failure 3b Check for adequate pressure and volume production from air pump Repair or replace air pump c Faulty air line check valve 3c Repair or replace check valve and allowing water to back up clean repair or replace aeration through aeration pump during pump regeneration cycle d Damp e
38. l out of the stuffer and leave it in place in the valve body Remove the stuffer from the valve body turn it end for end and push the center on the brass female end to expose the pilot on male end and hold Place a spacer on the pilot and insert the spacer and stuffer into the valve body While the stuffer is still in the valve press another seal into the inside diameter of the exposed brass female end Remove the tool turn it end for end and insert it into the valve body bore Alternately repeat steps 13 through 15 until all seals and spacers have been pushed into the valve Lubricate the piston and piston seals with silicone lubricant Start the piston into the valve body and slowly push the piston assembly with end plug into the valve body Push piston rod in all the way leaving only the connecting hole end without teflon coating exposed Place two capscrews through holes in backplate align with female threads in valve body and turn capscrews a couple turns to support powerhead assembly Do not completely tighten screws until connecting link pin is installed Caution Be careful not to scratch exposed piston rod Seal Hook to Remove Seals Removing Seal from Valve Body FIGURE 15 20 21 22 23 Install connecting link pin connecting piston rod to the connecting link on drive cam Note If connecting link pin hole and piston rod hole are not aligned the drive motor can be disengaged by grasping the motor s
39. m wheel 0 8 program wheel location are synchronized with bleed off spaces 26 34 Air Recharge amp Air Bleed Off Aeration Head Fitting Connection Valve Fitting Connection Nut O Ring Tubing X 3 y A Ka Assembly TUBE NUT GRIPPER FERRULE INSERT VALVE BODY Spacer Grab Ring RING 1 Cut the tube squarely and remove E Fast amp Tite Fittings Pictures 1 5 Spe Ge Ree Y 2 Mark from end of tube the length of Si insertion See Table 3 Loosen nut on fitting until three A i threads are visible Fittings for aa Insertion length Insertion length glass tubes must be disassembled W D Size Tube Support Tube Support and the grab ring removed 1 4 0 D 9 16 5 8 Body O Ring gt Grab Ring 5 When using clear vinyl tubing it is necessary to use a TS tube support Disassemble the fitting A Iron Curtain Bleed Off Valve PN 22 55 4 Moisten end of the tube with water Push tube and prace me E B Iron Curtain Air Recharge Valve PN 22 54 STRAIGHT into fitting unit it bottoms on the fitting s Oring in the body then proceed shoulder Tighten nut by hand Additional tightening should not be necessary but 1 4 additional turn may be added if desired DO NOT OVER TIGHTEN nut or threads will strip and the fitting will not function properly A proper assembly will not show the inser tion mark extending beyond the nut If the insertion mark is visible then steps 1 thru 4 must be r
40. nect tubing 3 8 black polytubing connecting air bleedoff valve to drain fitting Remove the two capscrews holding powerhead backplate to valve body and remove the powerhead and piston assemblies CAUTION Be careful not to scratch the exposed piston rod Note Some piston seals and or spacers may come out of the valve body with the piston assembly Remove connecting link pin that connects piston rod to the connecting link on drive cam assembly and remove piston assembly Using the seal hook remove the first seal Back Plate Removing Power Head FIGURE 14 10 11 12 13 14 15 16 17 18 19 Using the puller remove the first spacer Alternately remove the remaining seals and spacers in accordance with steps 7 and 8 The last or end spacer does not have any holes for the pins of the puller to engage therefore if the end spacer does not come out on the first try try again using the seal hook With your thumb press the button on the brass sleeve end of the stuffer and hold Place the end spacer on the male end of the stuffer with the lip on end spacer facing the stuffer and push the stuffer into the valve body bore until it bottoms While the tool is in the valve body take a piston seal and press it into the inside diameter of the exposed brass female end Remove the tool turn it end for end and insert it into the valve body bore until it bottoms then push the center button to push sea
41. ng connecting the control valve to aeration head and disconnect tubings from air recharge and air bleedoff valves e Loosen remaining fitting nut on air bleedoff valve and disconnect tubing 3 8 black polytubing connecting air bleedoff valve to drain fitting 4 While holding the powerhead assembly firmly remove the two capscrews holding powerhead backplate to valve body and remove the powerhead and piston assemblies Note Some piston seals and or spacers may come out of the valve body with the piston assembly If so see Seal Kit Replacement instructions for re installing them 5 Remove connecting link pin that connects piston rod to the connecting link on drive cam assembly and remove piston assembly 6 Inspectthe inside of the valve to make sure that all piston seals and spacers are in place If piston seals and or spacers need to be re installed or replaced see Seal Kit Replacement instructions 7 Lubricate the piston and piston seals with silicone lubricant Connecting Link Pin Capscrews 10 11 12 13 14 15 16 17 Start the piston into the valve body and slowly push the piston assembly with end plug into the valve body Push piston rod in all the way leaving only the connecting hole end without teflon coating exposed Place two capscrews through holes in backplate align with female threads in valve body and turn capscrews a couple turns to support powerhead assembly Do not completely tig
42. ngers Each tab is one day Tab at red pointer is tonight Moving clockwise from the red pointer extend or retract START CYCLE fingers to obtain the desired regeneration schedule GO Make certain the tab aligned with red pointer is not extended outward The filter must not regenerate within 24 hours of installation to allow the filter media to absorb water and not be backwashed out Red 2 How to set the time of day Pointer Press and hold the red button in to disengage the drive gear Turn the large gear until the actual time of day is aligned with the time of day pointer Release the red button to again engage the drive gear Red Time 12 Day Skipper Wheel Set Button Shows every other The Iron Curtain is preset to regenerate at 12 00 a m day regeneration provided the time of day is correct FIGURE 4 10 How to set Regeneration Time The 24 hour dial of the 3200 Timer has been redesigned so that the regeneration time can be field adjusted To adjust follow these easy steps 1 Disconnect the power source 2 Locate the three screws behind the manual regen eration knob by pushing the red button in and rotating the 24 hour dial until each screw appears in the cut out portion of the manual regeneration knob Figure B 3 Loosen each screw slightly to release the pressure on the time plate from the 24 hour gear 4 Locate the regeneration time pointer on the inside of the 24 hour dial in the cut out F
43. nvironment 3d Clean repair or replace aeration pump ventilate environment or provide external air source 4 Air loss through high demand 4a Increase regeneration frequency of filter or Iron Curtain Remote Control Center E Exceeding recommended filter 1 Service flow rate demand is ta Install a flow control at filter system system flow rate higher than filter system design outlet equal to or less than the design flow rate flow rate of filter system 1b Install additional filter s or a larger single filter system which meets both the service flow demand and backwash flow requirements available F Regeneration during service flow 1 Time of day set incorrectly ta Reset timer demand G Raw water bleeding through filter 1 Internal control valve leak la Assure all adapter base o ring seals are in place 1b Replace seals spacer and piston assemblies Manganese can be slow to oxidize when the pH is less than 8 5 25 Complaint Problem Cause Solution Water leaking from relief valve A Dirt lodged under seat of valve 1 Pressure has exceeded rating on 1a Check pressure on system Adjust relief valve and caused valve to if necessary Clean or replace open relief valve Faulty or defective relief valve la Replace valve Water is effervescent This can be expected when water 1 Water supply has been naturally ta This natural phenomenon will typi is aerated under pressure aerated under well system cally
44. ontroller into the backwashing cycle Raw water enters the filter valve inlet from the aeration system flows down thru the distribution system and up thru the multi media bed and out the drain line The oxi dized contaminants which were removed during the service cycle are backwashed out to the drain U S Patent B1 5 096 596 CHECK VALVE AIR RECHARGE VALVE AIR BLEEDOFF VALVE E DRAIN N wae INLET OUTLET INLET A INLET DIFFUSER AN Jr DISTRIBUTOR TUBE y S Y S S S BLEED OFF TUBE MULTI MEDIA a i PICK UP TUBE BED a a Ms A PL FILTER TANK AERATION TANK Step 3 Bleeding Off the Aeration System The Iron Curtain Control Center automatically shifts the controller into the Aeration recharge cycle The air bleedoff valve opens up and allows raw water and or air to pass thru the bleed off tube in the aeration tank to the drain The air recharge valve is also open during this time however a check valve prevents any backflow toward the compressor U S Patent B1 5 096 596 CHECK VALVE AIR RECHARGE VALVE NN AIR BLEEDOFF VALVE INLET DIFFUSER DISTRIB
45. ote If piston sleeve slides over top of connecting rod assembly reinstall starting from the bottom 9 10 11 12 13 14 15 16 From the top of the pump insert connecting rod eccen tric bearing assembly with set screw facing air filter holes Install on motor shaft all the way and tighten set screw 8 lbs Note Set screw should tighten onto flat spot on motor shaft Remove exhaust valve flapper screw valve keeper strip valve flapper valve flapper o ring and piston sleeve o ring from valve plate Lubricate new o rings with silicone lubricant to hold o rings in place and install in valve plate Install new valve flapper valve keeper strip and exhaust valve flapper screw 12 lbs in valve plate Install valve plate on pump aligning piston sleeve o ring with top of piston sleeve Remove o ring from pump head Place 3 4 small dabs of silicone lubricant in pump head o ring groove to hold o ring in place and install o ring in pump head Install pump head on pump aligning exhaust port with front of pump Install four pump head screws and tighten 48 lbs Remove any remaining gasket material from front cover and pump front and make sure both surfaces are clean Install new front cover gasket with burr side in Install front cover and four cover screws and tighten screws 20 Ibs Air pumps manufactured after 11 94 use an air filter with a hole in the center and a plastic press in retainer to hold i
46. r every other day If you wish to reset any of these factory settings see page 9 6 Make sure the filter will not regenerate within 24 hours of installation to allow the filter media to absorb water and not be backwashed out 7 Open the outlet valve on the filter then open the nearest cold water faucet and allow the water to run until the air stops spurting and discoloration is gone Note It is normal for aerated water to appear effervescent 8 If the water softener was placed on bypass close the bypass valve and place the softener in service 9 Open the shut off valve to the water heater Regeneration Frequency Your Iron Curtain Filter System contains a special filter media mixture which allows it to filter iron longer than standard filters between backwash regenerations However it is our recom mendation to leave factory settings as is unless you wish to backwash more frequently You will have to backwash more frequently if you have iron bacteria hydrogen sulfide and or manganese present in your water supply You will also have to regenerate more frequently if you notice iron bleed through before the end of the normal service run Specifications Filter amp Max 2 Back Aeration 1 Service wash Floor Tank Media Inlet Flow Rate Space Model Size Cu Ft Outlet GPM GPM WxHxD IC 10 10 x54 15 3 4 5 0 5 0 26 x70 x16 IC 10A 10 x54 1 5 3 4 5 0 5 0 26 x70 x16 IC 10 f 10 x54 1
47. relief valve Start Up NOTE The control valve is shipped in the air bleed off position see step 3 in flow diagrams page 20 1 Close all valves that were previously opened to drain the plumbing system Close the inlet and outlet valves on the Iron Curtain Filter System and open the filter system bypass valve If you have a water softener leave it on bypass also 2 Turnonthe main water supply valve and flush the water distribution system Run water at the nearest cold water faucet until all the airis relieved lines are flushed and the water is clear 3 Opentheinletvalve to the filter no more than 1 4 turn and allow excess air in the filter tank to escape to drain After a steady stream of water is seen at the drain without any air proceed to the next step 4 Close the bypass valve and open the inlet valve all the way Leave the outlet valve closed NOOO 5 Plug in the electrical cord from the Iron Curtain Control Center In approximately four minutes the aeration pump will automatically turn on and begin to pump air into the aeration tank Allow the Iron Curtain Control Center to finish the remaining cycles automatically approximately 25 minutes Make certain that the filter control is in the Service Position piston all the way out Do NOT backwash filter at this time Set time of day Time of regeneration is preset for 12 00 a m Regeneration frequency is preset for every three days Type A Filters are preset fo
48. sembly 49 10909 Connecting Link Pin 49 10872 Screw Motor Mounting 49 14923 Screw Switch Mounting Motor Lead Wires Insulator Micro Switch IC Backplate IC Check Valve Replacement Kit IC Wire Harness Drive IC Wire Harness Timer leas 49 13296 Screw Terminal Block not shown Seeche Not Used 49 60232 Designer Cover not shown Sech 49 15742 Designer Cover Screw not shown a 49 15833 Spacer Designer Cover Screw not shown EA 49 10250 Retaining Ring Designer Cover Screw not shown sities 72 A1008 Iron Curtain Cover Label not shown Model No Label not shown C Powerhead Assembly C Power Cord not shown Speed Nut for Cover Screw not shown To replace brass IC Air Recharge and Air Bleedoff valves on systems manufactured prior to October 1997 order p n 22 56 IC Plastic Air Recharge Bleedoff Retrofit Kit which includes both valves and machined cover to accommodate the larger plastic valve holding nuts Iron Curtain Aeration Pump 10 FIGURE 10 Item Part No No Description Qty L ns 74 625646 conoccconccnno Screw Head coccococcccacccnnaniccnanicnnanon 4 Ds 74 660631 504 Deeg AAA A O RP EE 1 74 623121 O Ring Head vee 74 625307 Screw Exhaust Valve Flapper 1 74 617045 Valve Keep Strip 0 1 74 621102 Exhaust Valve Flapper 74 623615 O
49. set to regenerate every other day 6 0 10 0 ppm Iron Standard IC System sized for application service flow rate set to regenerate every day 10 ppm Iron Consult Factory Note Manganese will also be reduced if the pH of the water is 8 5 or greater Hydrogen Sulfide Applications Hydrogen Sulfide H2S consumes 7 times the amount of oxygen to oxidize than iron does Therefore for Hydrogen Sulfide Applications we use the following guidelines 0 1 ppm H2S Standard IC System Aeration tank sized for 2 minutes contact time 2 4 ppm H2S IC System using Remote Control Center with Pump Aeration tank sized for 2 minutes contact time Standard IC System could be used for these applications however the system must be set to regenerate every day to replenish air in aeration tank During high usage times available oxygen in the aeration tank could be consumed allowing bleed through of H2S By using the Remote Control Center with Pump the air in aeration tank is replenished every 4 hours and filter s can be set to regenerate everyday every other day or every three days 5 8 ppm H2S IC System using Remote Control Center with Pump Aeration tank sized for 3 minutes contact time Use an Iron Curtain Plus bed for optimum results 8 10 ppm H2S IC system using Remote Control Center with Pump Aeration tank sized for a minimum of three minutes contact time Iron Curtain Plus bed Also note that with TDS over 750 ppm a
50. t Off pins 50 52 Program Wheel Retainer Lugs Air Pump Run Time pins 0 8 extending out back 2 min per pin FIGURE 5 To lengthen the air recharge time remove 1 long roll pin s from pin storage on timer 1 pin needed for each 2 minutes to be added Beginning at number 10 and counting up remove pin s 1 pin for each long roll pin to be added to extend air recharge time Replace with long roll pin s so it extends out back equal distance with existing pins For each long roll pin added move the rapid rinse pin to the higher numbered end of wheel After the rapid rinse pins leave two holes then place two pins IMPORTANT After installing long roll pin s turn the manual regeneration knob clockwise one revolution to make sure long roll pin s do not touch drive gear Item 22 Figure 7 page 13 How to change the length of rapid rinse time The second group of pins on the number side of the program wheel determines the length of time that your Iron Curtain Filter will rapid rinse 2 minutes per pin To lengthen the rapid rinse time add pins at the higher numbered end of this section as required After the rapid rinse pins leave two holes then place two pins The regeneration cycle is complete when the program actua tor microswitch drops off the last pin The program wheel however will continue to rotate until the homing microswitch drops into the notch on the program wheel Section pins 40 44 2 min per p
51. ter usage may vary as well Water characteristics can also change considerably if your water conditioner is moved to a new location For these reasons we assume no liability for the determination of the proper equipment necessary to meet your requirements and we do not authorize others to assume such obligations for us UNDER NO CIRCUMSTANCES SHALL HELLENBRAND INC BE LIABLE TO PURCHASER OR TO ANY OTHER PERSON FOR ANY INCIDENTAL SPECIAL OR CONSEQUENTIAL DAMAGES OR FOR ANY OTHER LOSS DAMAGE OR EXPENSE OR ANY KIND INCLUDING LOSS OF PROFITS WHETHER ARISING OUT OF BREACH OF WARRANTY BREACH OF CONTRACT OR OTHERWISE Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state Updated January 2003 73 510 7 03 2500
52. the adapter base from tank adapter base Remove the two screws from adapter base and remove Be careful not to pull up the distributor 10 Reattach the control valve to the tank tube with adapter base If distributor tube does pull If the control valve was supported and connected to the up with the adapter base consult your dealer At this plumbing slide the tank underneath the control valve and point it is recommended to remove some of the water align Be careful not to dislodge or cut o rings Install from the tank This can be done by placing asmall hose the two adapter base screws and tighten inside the distributor tube and creating a siphon or by Gg f If the control valve was disconnected from plumbing carefully tipping the tank sideways pouring out water place control valve on adapter base and align Be care only not media ful not to dislodge or cut o rings Install the two From the top of the tank measure down approximately adapter base screws and tighten 1 3 the overall height of the tank 18 for IC 10A 17 for IC 10A Reconnect the drain and tighten the screw IC 12A and mark the tank This is the amount of free that holds the flow control housing Reconnect the board and the maximum fill height that should not be bleed off tubing to flow control housing and tighten exceeded when adding media If media is at correct the fitting nut Reconnect the tubing to the air height and pH is below 7 0 do not add Consult your rech
53. tin place To replace air filter order p n 74 641169 Air Filter and Retainer Place air filter in place and install new retainer IC 10 Series Control Valve Assembly FIGURE 11 ITEMNO NO REQ D PARTNO DESCRIPTION 49 11212NP Nickel Valve Body 49 10757 End Spacer 49 10545 Seal Ring 49 11451 0 Spacer 49 60121 Seal Spacer Kit 49 15168 Piston 49 14309 Piston Rod Retainer 49 14452 Piston Rod 49 10209 Seal Quad Ring 49 10234 End Plug O Ring 49 10598 End Plug 49 60090 2500 Piston Assembly 49 11180 Flow Control Retainer Screw 49 12092 5 0 gpm DLFC Button SERVICE TOOLS needed for removing and replacing piston seals and spacers for both IC 10 amp IC 12 49 13061 Spacer Puller 49 PICK O Ring and Seal Pick 49 11098 Spacer Stuffer 49 11183 DLFC Fitting O Ring 2 49 12619 00 0 2500 SVO Drain Fitting 49 12619 5 IC 10 5 gom DLFC Assembly 49 11475 Injector Body Gasket 49 11893 Flat Cap 49 15137 Flat Cap Screw 49 11224 Adapter Base Screw aun 49 11206 Inlet Outlet Fitting Gasket aun 49 11205 Inlet Outlet Tube Fitting 49 11207NP Inlet Outlet Nickel Nut mun 49 11710 0 Inside Tube O Ring E E 49 11208 Adapter Base Seal O Ring E 1 49 12461NP Nickel Adapter Base OS 1 49 10381 Adapter Base Tank
54. tion system is drained place Iron Curtain System on bypass See Figures 1 2 amp 3 on page 8 2 Manually advance the timer to rapid rinse position See page 10 Unplug power cord 3 After pressure is relieved disconnect white air recharge line from aeration head 4 With an air compressor blow air through white air re charge fitting in aeration head until air with little or no water discharges to drain Caution Use only enough air pressure to force water in tank to discharge Do not exceed 30 psi 5 It is recommended at this point to disconnect the inlet outlet of aeration tank and remove the aeration head assembly Dump remaining water If aeration head assembly has a buildup of iron bacteria the well should be shock treated with chlorine when the water system is reactivated Consult your local dealer for more information regarding shock treating the well Clean aeration head assembly of any buildup and reassemble aeration tank 6 Plug in power cord and manually advance the timer to service position and allow control valve to reset to service position Manually advance timer to backwash position then to air recharge position See pages 10 Unplug power cord 7 Open inlet amp outlet shut off valves Leave bypass valve open System is now winterized 9 Whenturning system back on follow start up instructions on page 6 Instructions for Iron Curtain Systems with filter tank equipped with optional bottom drain
55. tween each cycle until the drive motor stops running If you do not wait until the drive motor stops running the timer and the drive motor will become out of synch If that happens advance the timer to the service position and the control valve piston will return also to the service position They are now resynchronized The first cycle is the backwash cycle Slowly turn manual regeneration knob clockwise until backwash pins engage microswitch arm and drive motor begins running Wait until drive motor stops before proceeding to next cycle The second cycle is the a r recharge cycle Slowly turn the manual regeneration knob clockwise until backwash pins drop off microswitch arm and drive motor begins running Wait until drive motor stops before proceeding to next cycle The third cycle is the sao drinsecycle Slowly turn the manual regeneration knob clockwise until rapid rinse pins engage microswitch arm and drive motor begins running Wait until drive motor stops before proceeding to next cycle The fourth cycle is the cyc e advance cycle Slowly turn the manual regeneration knob clockwise until rapid rinse pins drop off microswitch arm and drive motor begins running Wait until drive motor stops before proceeding to next cycle The final cycle is the cycle shut off cycle Slowly turn the manual regeneration knob clockwise until cycle shut off pins engage microswitch arm and drive motor begins running Wait until drive motor stops before
56. ve water condition in copper 1 Low pH condition of the raw water 1a On type A filters add pH distribution piping system supply On type A filters the pH correction media to filter tank see correction media may be depleted Installation and Operation manual 2 In rare occasions highly aerated 2a Install a polyphosphate cartridge 26 water in combination with a specific water supply can create a slightly corrosive condition filter after the Iron Curtain Filter System to protect the distribution piping Winterizing Iron Curtain Systems Optional In certain climates where houses and or cottages are not heated during the winter months Iron Curtain Systems must have the water removed from them to protect from damage due to freezing Following are instructions for winterizing Iron Curtain Systems Prior to draining water distributor system and Iron Curtain System manually initiate regeneration of Iron Curtain System see page 10 and allow system to com plete regeneration and return to service position auto matically Draining of the Iron Curtain System should be done in conjunction with or after the complete water distribution system is drained to prevent water from entering the Iron Curtain System after it has been winterized After Iron Curtain System and water distribution system are drained make sure all water shut off valves are open Instructions for winterizing Iron Curtain Systems 1 After water distribu
57. warranted for the remainder of the original warranty period If a part described above becomes defective within the specified period you should notify your Hellenbrand Iron Curtain reseller and arrange a time during normal business hours for the Iron Curtain reseller to inspect the water conditioner on your premises Any part found defective within the terms of this warranty will be replaced by him You pay only freight from our factory and local Iron Curtain reseller charges THIS WARRANTY DOES NOT COVER defects caused by accident fire flood Act of God misuse misapplication neglect alteration installation or operation contrary to our printed instructions or repair or service by anyone other than the factory or authorized Hellenbrand Iron Curtain reseller EXCEPT AS EXPRESSLY PROVIDED ABOVE HELLENBRAND MAKES NO OTHER WARRANTY WITH RESPECT TO THE IRON CURTAIN FILTER SYSTEM WHETHER EXPRESS OR IMPLIED INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OR OPERATION OF LAW ALL SUCH WARRANTIES ARE HEREBY EXPRESSLY DISCLAIMED Our performance specifications are furnished with each water conditioning unit As a manufacturer we do not know the characteristics of your water supply or the purpose for which you are purchasing this water conditioner Please understand the quality of water supplies may vary seasonally or over a period of time and that your wa
58. y prevent iron removal If manganese is present a larger filter should be installed with more frequent backwashing Note For optimum manganese reduction pH should be greater than 8 5 Organic Matter Tannins The presence of organic matter such as tannins may tie up iron or manganese prevent ing the oxidation filtration process from occuring Je pres ence of organics such as tannins above 0 5 pom voids any claims for this system to perform as stated above In some applications tannin levels below 0 5 ppm or the presence of other organics may hinder the operation of this system Chlorine The presence of chlorine in the raw water supply ahead of this system should be limited to a maximum of 1 0 ppm residual and preferably 0 5 ppm or less when fed continuously Total Dissolved Solids TDS While TDS does not directly affect iron removal it is a good indicator of potential interference Most waters have TDS less than 500 and gener ally present no problems to iron treatment If any ion becomes excessive it can possibly cause failure of iron removal A TDS more than 750 ppm voids any claims for this system to perform as stated above General Application Guidelines for Residential Iron Curtain Systems Iron Applications 0 3 3 0 ppm Iron Standard IC System sized for application service flow rate set to regenerate every three days 3 0 6 0 ppm Iron Standard IC System sized for application service flow rate
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