amiad AMF-36K Installation And Operation Instructions Manual Download Page 63

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AMF² 36K + HMI 08.2013

Page 63 of 71

Installation Requirements:

Pump Electrical Supply Maximum 4
Kw

3 phase/220-400 volt/ 50 Hz or 240-460 volt/60 Hz, other 3
phase supplies by request

Control Electrical Supply Maximum
0.5 Kw

1 phase/ 100 - 240 volt/ 50 or 60 Hz

Compressed Air Supply

6 bar, dry and lubricated

Drainage Facilities

Gravity Flow 0.6 m3/cycle of 36 counts

Flushing water source

Filtered water from filtered water tank

Construction Materials:

Filter Housing and Covers

Epoxy coated carbon steel

Cassette

Polyester thread on plastic body

Cleaning mechanism

316L St/St and plastic

Exhaust Valves

Cast Iron, EPDM, Brass, St/St

Ball Valve

St/St, PTFE

Seals

N.B.R

Pressure Hoses

Rubber

Summary of Contents for AMF-36K

Page 1: ...hical HMI User Guide Serial number _______________ Order number _______________ Catalog number _______________ Filtration degree _______________ Tested by _______________ Installation and Operation Instructions Original Instructions Ref 910101 000592 08 2013 ...

Page 2: ... provided on this file may be used in any form or by any means without permission from Amiad If you received this file in error please notify Amiad immediately reuven amiad com The confidential nature of and or privilege in the file enclosed is not waived or lost as a result of a mistake or error in this file Amiad accepts no liability whatsoever whether it was caused by 1 Accessing or other relat...

Page 3: ...for filter flushing 2 1 4 Drainage system 2 1 5 Compressed air supply 2 1 6 Filter tune up tool 2 2 The Installation Process 2 2 1 Positioning the filter 2 2 2 Pipeline connections 2 2 3 Post shipment inspection 2 2 4 Power Supply Electricity and Pneumatics 3 Description of the control panel Page 29 3 1 Introduction 3 2 Components mounted on the control panel door 3 3 Internal components of the co...

Page 4: ...void danger to the workers the public or to property in the vicinity Please note The filter enters into a flushing mode automatically without prior warning No change or modification to the equipment is permitted without a written notification given in advance by the manufacturer or by its representative on the manufacturer s behalf Always observe standard safety instructions and good engineering p...

Page 5: ...ockable main cut off switch featured with a pressure release mechanism on the compressed air supply line close to the control panel If the control panel is installed far away and there is no eye contact with the filter a lockable compressed air cut off switch featured with a pressure release mechanism should be installed near each filter unit The user should make sure that the compressed air suppl...

Page 6: ...trol Do not operate the filter before reading carefully and being familiar with its operation instructions Observe the safety stickers on the filter and never perform any operation contradicting the instructions given Never operate or use the filter for purposes other than its original design and operational envelope Maintenance Before any maintenance or non regular operation please read the follo...

Page 7: ...ent Manual cleaning of filter media using high water pressure or steam should be performed in accordance with the cleaning system instructions the local standards and regulations and without endangering the operator or the vicinity Manual cleaning of filter element using acid or other chemical agents should be performed in accordance with the relevant material safety instructions the local standar...

Page 8: ...gs and pictures used in this description do not necessarily reflect the actual layout and components of your actual filter they are provided for explaining the technology only 1 3 1 Filter Media Amiad AMF filter is based on Amiad s automated micro fiber technology The basic component of this filtration technology is the Cassette which is a filter media consists of a grooved rigid plastic plate ove...

Page 9: ...lowing to the clean liquid chamber and through the outlet control valve to the customer s system Fig4 5 Figure 4 Figure 5 Larger dirt particles are stopped on the surface of the multiple layers of thread Fig6 and form a filter cake Finer particles that penetrate the surface are trapped deep inside the thread layers Fig7 As dirt is stopped the filter differential pressure gradually increases Figure...

Page 10: ...ighly pressurized clean water The inlet and outlet valves are than closed isolating the filter from the main line A few seconds later the drain valve opens emptying the filter Fig10 Figure 8 Figure 9 Figure 10 The highly pressurized water enters the filter through the flushing control valve into a shuttle pipe fitted with a movable spray unit Fig11 The spray unit Fig12 moves back forth along the e...

Page 11: ...ticles and the filter cake out of the cassettes thread layers and through the open drain control valve to the gravity drain system Fig14 15 Figure 14 Figure 15 After each row of cassettes is cleaned Fig16 the nozzle unit slightly changes position the control unit commands the index assembly to turn the cartridge until the next row is positioned against the nozzle unit Fig17 ready to start cleaning...

Page 12: ...ned Fig21 Figure 20 Figure 21 Raw liquid enters the filter and fills it up and initial filtrate is passed through the filter to waste control valve Fig22 Figure 22 The filter to waste control valve closes Fig23 and afterwards the outlet control valve opens Finally the flushing pump is turned off Fig24 Figure 23 Figure 24 The filter is now back on line The cleaning cycle takes approximately 10 minu...

Page 13: ...pump power supply is not pre connected by the factory connect the pump to the control panel by means of a cable of 4 x 2 5mm for a distance of up to 10m Consult Amiad for cable specifications for distances longer than 10m In any case the user is responsible that this installation meets or exceeds the local or the national electrical codes this is a high voltage connection 2 1 3 Water supply for fi...

Page 14: ...e filter 2 1 5 Compressed air supply Dry and lubricated 6 7 BAR 90 105 PSI standard compressed air supply is needed for the filter operation In case where compressed air supply is not available at the end user s site a portable 8 bar 50 liter compressor should be installed near the filter In cases where the user provides the compressed air supply it is the user s responsibility to install a quick ...

Page 15: ...gineers according to Amiad s Application Engineering Department specifications Please study your Certified Installation Arrangement Drawings and then position the filter and mount it to the floor area according to the drawings please take extra care and exercise the relevant safety instructions The following drawing Fig25 is an example of such Installation Arrangement Drawing It does not replace y...

Page 16: ...Figure 25 ...

Page 17: ...AMF 36K HMI 08 2013 Page 17 of 71 ...

Page 18: ...n return valve at the outlet of the filter It is necessary to protect the filter from excessive line water pressure therefore the user is required to install a quick pressure release valve to ensure that the filter is not exposed to higher than 10 bar water pressure Note Make sure that all pipe connections are bolted and secured properly according to the standards and the good water works practice...

Page 19: ... the sensors from their Mounting block Important note Make sure that the Mounting Blocks stay at their current position Any movement of a block will affect the piston s calibration and will cause damage to the filter Only the sensors should be removed SW1 SW2 Don t Move this Block Do not move this Block Remove this sensor only ...

Page 20: ...AMF 36K HMI 08 2013 Page 20 of 71 3 Unscrew the filter s Intermediate Cover bolts and open the Cover by gently pulling it out together with the Piston Hosing ...

Page 21: ...ling the piston you may need assistants to keep the piston balanced while pulling it out of the filter 5 Using a flashlight inspect the interior of the filter and remove any foreign objects that may entered the filter housing during shipment Inspect the cartridge and in case that loosen or fallen cassettes are found do not proceed with the installation and contact your supplier immediately Inspect...

Page 22: ...y Insert Piston 40 into the filter body and make sure that that the following three points are met i The piston is inserted over the Tail Pipe Assembly located in the center line of the filter 1 ii The piston is inserted in the right direction 2 iii The spray nuzzles are gently inserted in the gaps between the cassette rows 3 and are not hitting the cartridge while the piston is pushed in you may ...

Page 23: ...AMF 36K HMI 08 2013 Page 23 of 71 1 3 ...

Page 24: ... the filter till it slightly sticks out of the filter housing 3 Insert the Piston Housing and the filter s Intermediate Cover over Piston 40 Then re screw the Cover bolts Make sure that these three components are aligned verify that the Cover s O ring is in place ...

Page 25: ...itches SW1 and SW2 to the Piston House Assembly by screwing the sensors to their Mounting blocks SW1 SW2 Note Do not change the position of the mounting blocks It was calibrated in the factory Do not move this Block Reconnect this sensor only Don t Move this Block ...

Page 26: ...o ensure that the spray nozzles are not within the cassette package limits i Remove the plug from the piston inlet located at the left side of the cartridge cover ii Insert a clean and straight 4 5 meter 0 5 pipe or rod the Tune up rod through the opened connection iii Using the rod push the piston all the way in iv Remove the rod out of the filter and reassemble the plug ...

Page 27: ...nit of the filter Connect the compressed air supply to the appropriate terminals in the filter solenoids cabinet Important notes Do not switch on the power and the compressed air supply at this stage Switching on these systems prior to the commissioning procedure of the filter may cause damage Please take extra care when connecting the power and the compressed air to the filter always exercise the...

Page 28: ...AMF 36K HMI 08 2013 Page 28 of 71 Compressed air Connection terminal Main Power Supply Connection terminal The Control Panel The Solenoids Cabinet The PLC Cabinet ...

Page 29: ...ted on the outside of the control panel enclosure Switches MAIN SWITCH used to switch On OFF the main power supply MANUAL OFF AUTO selector switch used to set the flushing pump operation mode Lamps POWER ON lamp indicates the status of the filter s Power Supply FAULT red signal lamp lights on when the system is in Fault Mode ALARM red signal lamp lights on to indicate system s Alarm or Attention S...

Page 30: ...ooks It general the internal components of the control panel include elements such as Power supply elements PLC unit and extension components Fuses Circuit breakers Over loads Relays and Solenoids and other similar control elements The following drawing Fig26 is a general purpose demonstration drawing of the control components This drawing does not replace your certified drawings and it is given h...

Page 31: ...trol system of the filter For the user knowledge only The electronic control system of the AMF filter consists of two major components 1 The PLC Siemens S7 200 PLC this component contains the operational algorithm of the filter and is responsible for its actual operation It is important for the user to understand that once running the PLC software operates the filter independently even without bei...

Page 32: ...reen Whenever a question mark key is shown on the screen a help screen is available Press and hold the key in order to read the help screen Data entry since the HMI panel doesn t have a physical keyboard a virtual keyboard is displayed automatically whenever the user presses a graphical element which requires data entry The following picture shows the virtual keyboard The Virtual keyboard contains...

Page 33: ...ime Interval o Administrator The administrator can see and change all the data elements of the system including changing the very sensitive filter configuration parameters An administrator password is required in order to login as an administrator The following pictures show the main login screen and its operation Your Supervisor user name is super Your Supervisor password is 9876 Your Administrat...

Page 34: ...n a vertical menu list that contains other single operation keys Graphical Screens Screens with pictures showing the filter or its parts These screens show the various filter components in action The color of the components and their motion across the screen is changing according to the operation of the filter in real time Pressing on some graphical elements operate a zoom in and the specific filt...

Page 35: ...rameters to be adjusted by the system s Supervisors and Administrators On Screen Messages These HMI components appear on the Graphical Screens near some filter components The On Screen Messages show o Status data regarding regular filter operation i e Time to next flush or current DP reading o Error messages regarding faulty filter operation or components All the On Screen Messages appear in black...

Page 36: ...AMF 36K HMI 08 2013 Page 36 of 71 Press this To get this Press this To get this Press this To get this ...

Page 37: ...cal screen press the Screens key and choose your desired screen from the list i e Piston Index etc Status This group contains the entry points to all the status table screens of the system In order to jump to a specific status screen press the Status key and choose your desired screen from the list i e System status Messages etc Program This group contains the entry points to all the program table...

Page 38: ...ry under the tools menu and in all the languages its label is Lang The Hebrew language Since the Hebrew language is written from right to left the regular left to right tables are not suitable for Hebrew Therefore when changing the language to Hebrew the system changes the tables direction accordingly Please note that after a power failure the system returns to the last used language If the langua...

Page 39: ... allows the user to Select the user type Press User to login as a regular user Press Supervisor to display the supervisor and the administrator login screen The Login Screen This screen presents The Administrator and Supervisor login window Enter your Administrator or Supervisor user name and password to login The Help Screen This screen presents The help screen Press and hold the question mark ke...

Page 40: ...e system in the upper yellow box The current DP reading in the left yellow box The time to next flush in the lower yellow box The filter drawing shows the status of the various elements of the filter such as valves piston etc Press any filter element to zoom in to the specific detailed screen Press any yellow box to display the detailed relevant screen Press the lower right and left red arrow keys...

Page 41: ...1 WS2 status green or white according to the actual position of the piston The movement of the piston during flushing together with the stroke number and time Attention messages when applicable at the area under the piston drawing Alarm and Fault messages when applicable at the area above the piston drawing Alarm and Fault status appear on the piston in red Index Screen This screen presents A deta...

Page 42: ...g valves The time left till the end of the current flushing step Graphical elements The status of the valves together with a direction arrow green operated black not operated Pump Screen This screen presents A detailed pump drawing that shows the following Text box The current pump status Graphical elements The status of the valves The status of the pump green operated black not operated red fault...

Page 43: ...count of flush cycles System Messages Screen This screen presents System Faults When the system has no faults No Fault is displayed In case of more than one fault message the display alternates the existing fault messages once at every 3 seconds System Alarms When the system has no alarms No Alarm is displayed In case of more than one alarm message the display alternates the existing alarm message...

Page 44: ... SW3 at limit switch SW4 or in movement between them Operating Valves The numbers of the currently operating valves V1 Inlet valve is closed V4 Drain valve is open V5 Flush valve is open V6 Outlet valve is closed V7 Filtering to waste valve is open V9 Filling valve is open Current flushing step one of the following options Close Inlet Outlet Valve Open Drain Valve Open Flush Valve Piston Process E...

Page 45: ...ser to set the span of the trends window Upon entering to this screen the trends span is 4 hours Use the zoom keys to select between 0 5 1 2 4 8 16 and 32 hours The right and left arrows move the trends window one screen to the left or to the right The left most arrow icon key returns the trends to the beginning point Since the left Y axis serves the Inlet and the Outlet Pressure Meters the type o...

Page 46: ...sabling this option DP level for Flushing Set the desired DP value to start flushing Enter 9999 for disabling this option High DP for Additional Flushing The desired HDP High DP value to start a flush cycle Enter 9999 for disabling this option Time Date Screen This screen allows the operator to set the system time There are two clocks in the system the PLC clock and the HMI clock The PLC clock has...

Page 47: ...osing Delay Set the delay for closing the inlet and outlet valves Default value 10 seconds Duration of Filter Draining Set the time required to completely emptying the filter Default value 60 seconds Flush Valve Closing Delay Set the delay for closing the Flush Valve V5 Default value 10 seconds Drain Valve Closing Delay The delay for closing the Drain Valve V4 Default value 10 seconds Duration of ...

Page 48: ...ay between Filters Set the delay in 10 seconds units between the ends of the flush cycle of one unit to the start of the cycle of the next unit Default value 1 X 10 seconds Not applicable in a single filter installation Operations Screen This screen allows the operator to Step by Step Start a Step by Step back flush process of the AMF filter This is a necessary part of the first startup operation ...

Page 49: ...the user would like to flush the filter according to a differential Pressure it is necessary to install two pressure meters Inlet and Outlet In such case this parameter is used to set the maximum range of the Inlet and the Outlet Pressure Meters The DP reading in this case is calculated by the software by subtracting the outlet pressure from the inlet pressure Note Since the meters are of 4 20 typ...

Page 50: ... tis filed must be AMF 36 Number of Piston Steps The user may set the number of piston strokes per flushing cycle For normal operation of the filter this parameter must be 36 Solenoid Type The user may select the type of solenoids installed at the filter s solenoids cabinet Never set this parameter to the wrong type System s Filter Configuration If the filter is an independent single filter this p...

Page 51: ...an extra care is needed in order to ensure the supply of clean water This action ensures that the filtered water volume that stayed in the filter during the pause idle period will not reach the consumer Minimum Inlet Press For Flushing This parameter allows the user to set a minimum inlet pressure for sufficient flushing process This parameter is useful in cases where the filter is flushed with an...

Page 52: ...h Closed 33 A contradictory faulty indication on the main piston location probably due to a short circuit 34 Filter 1 SW3 SW4 Both Closed 34 A contradictory faulty indication on the Index piston location probably due to a short circuit 36 Filter 1 SW4 Not Found at Startup 36 The Index piston is not locked so the main piston is not allowed to move 37 Filter 1 Piston Movement SW1 to SW2 37 The main ...

Page 53: ...eted This fault message is issued only after an unsuccessful second trial to push the piston by the controller This is a fault status of the specific filter since the other filter is still operational the system issues only an alarm message The following table lists and describes the possible system fault messages that may appear on the controller s status screens ID Message Text Remarks 0 No Faul...

Page 54: ...stage connections verification Important notes Before starting the dry stage of the filter start up it is very important to make sure that the filter is empty and isolated from the water system by verifying visually that The upstream and the downstream manual isolation valves are closed The flushing water supply line isolation valve is manually closed Consult your Certified Installation Arrangemen...

Page 55: ...the MAIN POWER SWITCH 3 Make sure that the POWER ON LAMP and the controller s PANEL are lighted up 4 1 3 1 Verify that magnetic switch SW1 led is on This indicates that the main piston is in the right position 2 Return the plug to its place to and tighten it firmly If SW1 led is not ON do not proceed and contact your supplier immediately 1 2 1 2 ...

Page 56: ...re that the manual override handles of all the pneumatic solenoids are at their Automatic position the indicators are vertical 4 Check the position indicator of each one of the filter s valves and verify that it is pointing to the correct position according to the following list Inlet Valve Opened Outlet Valve Opened Drain Valve Closed Flushing Valve Closed Filter to Waste Valve Closed Note In the...

Page 57: ... remain in vertical position Inlet Valve Solenoid SV1 Outlet Valve Solenoid SV6 Drain Valve Solenoid SV4 Flushing Valve Solenoid SV5 Filter to Waste Solenoid SV7 In case that solenoid valve connections mismatch is found change the control tubing connections between the valves In such case after the connections change stages 4 1 4 and 3 1 5 should be performed again 4 1 6 Flushing Pump rotational d...

Page 58: ...lean flushing water supply line and check the filter for leaks 2 Make sure that the air release valve is bleeding air from the pump If not slightly unscrew it release the trapped air and re tighten it once a constant flow of water comes out from the port 4 2 2 Index piston positioning Ensure that the cassette packages are aligned with the spry nozzles and that the index piston is in its locked pos...

Page 59: ...new step starts the green lamp blinks until the pre programmed time length of this step is counted down and ended or until the piston reaches the relevant limit switch By looking at the countdown data on the screen it is possible to know how much time left to complete the current step Once the filter is ready for the next step the lamp stops blinking and remains lighted Moving to the next step is ...

Page 60: ...sufficient water supply Opened bypass valve etc Note the pump s bypass valve must remain closed at all times A you may open it slightly only if the pressure during flushing is higher than 10 bars Check the pressure at pressure meter B on the very beginning of the flushing process before the piston movement starts If the pressure is higher than 10 bar use the bypass to calibrate it Make sure that t...

Page 61: ...ual Isolation Valve the downstream valve The filter starts to filter the process water 4 Check the filter for general leakages and fix any leak found 4 3 2 First complete flushing process 1 Let the filter work and filter the process water for about an hour 2 Initiate a flushing cycle by pressing the START CYCLE push button on the control cabinet door 3 Monitor the empting process of the filter dur...

Page 62: ... cm2 Filtration Element 350 Cassette Units Inlet Outlet Valves 2 Pneumatically Actuated Butterfly Valve Drain Valve 2 Pneumatically Actuated Butterfly Valve Outlet Drain Valve 2 Pneumatically Actuated Butterfly Valve Drain Valve 2 Manually Operated Flush Valve 1 Pneumatically Actuated Ball Valve Full Bore Flush Pump Flow 6 m3 h Flush Pump Discharge Pressure 10 bar Flush Pump Power Maximum 3 Kw Net...

Page 63: ...lt 50 or 60 Hz Compressed Air Supply 6 bar dry and lubricated Drainage Facilities Gravity Flow 0 6 m3 cycle of 36 counts Flushing water source Filtered water from filtered water tank Construction Materials Filter Housing and Covers Epoxy coated carbon steel Cassette Polyester thread on plastic body Cleaning mechanism 316L St St and plastic Exhaust Valves Cast Iron EPDM Brass St St Ball Valve St St...

Page 64: ...m 8 mm 6 mm 6 mm 6 mm 6 mm 6 mm SV 4 A SV 4 B SV 5 A SV 5 B SV 6 B SV 6 A SV 1 B SV 1 A SI 4 SI 3 SV 8 SI 4 SI 3 PILOT CHECK VALVE AIR PRESSURE INLET MIN 6 BAR SV 3 SV 7 A SV 7 B EXHAUST PARTITION Legend SV1 Inlet Valve SV4 DrainValve SV5 FlushingValve SV6 Outlet Valve SV2 IndexPiston SV8 Pilot CheckValve SV7 Outlet DrainValve ...

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Page 71: ...arranty is valid on the condition that the Products are installed according to Amiad s instructions as expressed in Amiad s instruction manuals and according to the technical limitations as stipulated in Amiad s literature or as stated by a representative of Amiad 7 This warranty will not apply to damaged or defective Products resulting from or related to i Fire flood power surges or failures or a...

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