Amiad Arkal Spin Klin™ 2" with Air Aid Flushing (AAF) User Guide

1. Introduction

Amiad Water Systems congratulates you on purchasing the Arkal Spin Klin Filtration System. These filters are designed for easy installation, use, and service, requiring no special skills. This manual provides instructions for operation and maintenance. The Arkal Spin Klin battery system is an automatic self-cleaning filter suitable for non-hazardous liquids and operates within the pressure framework detailed in the specifications table.

2. Safety Instructions

2.1 General Safety Instructions

• Filtration products operate as components within larger systems; adhere to all relevant safety standards.
• Read all instructions before installation, operation, or maintenance.
• Observe all conventional safety instructions to avoid danger to personnel, the public, or property.
• The system is designed for non-hazardous liquids only.
• The filter enters a flushing mode automatically without prior warning.
• No modifications are permitted without written manufacturer approval.
• Always follow standard safety instructions and good engineering practices.
• Use the filter only for its intended purpose; misuse may void the warranty. Consult the manufacturer for non-regular use.
• System cleaning and maintenance should only be performed when an explosive atmosphere is not present.

2.2 General Installation

• Install the filter according to the provided instructions and this manual.
• Ensure sufficient clearance for future treatments and safe maintenance.
• Provide adequate lighting for good visibility and safe maintenance.
• Arrange suitable platforms and safety barriers for easy and safe access. Ensure all equipment complies with relevant local standards.
• Check and re-tighten all bolts during commissioning and after the first week of operation.
• Use only appropriate tools operated by qualified personnel.
• For installations in hazardous environments, ensure site design and auxiliary equipment are appropriate and follow relevant standards.
• Ensure walking areas are slip-free when wet.
• It is recommended to stabilize the drain pipe to prevent vibration during flushing.

2.3 Shipment and Transporting

• Ship and transport the filter safely and stably, adhering to relevant standards and regulations.
• Use only approved lifting equipment and authorized personnel for lifting and positioning.

2.4 Electricity

• All electrical wiring must be performed by a qualified electrician using standardized components.
• Install suitable electrical grounding to prevent electrostatic discharge.
• Install a lockable main power cut-off switch near the control panel.
• If the control panel is not in line-of-sight of the filter, install an additional lockable power disconnect switch near each filter unit.
• Install the filter to avoid direct water splashing on electrical components or the control panel.

2.5 Pneumatics

• Install a lockable main cut-off switch with a pressure release mechanism on the compressed air supply line near the control panel.
• Install a non-return valve before the compressed air valve on the accumulator tank.
• If the control panel is not in line-of-sight, install a lockable compressed air cut-off switch with a pressure release mechanism near each filter unit.
• Ensure the compressed air supply does not exceed the filter's maximum designated pressure. Install an air-pressure reduction valve upstream of the pneumatic inlet port.

2.6 Hydraulics

• Install extra safety devices for hot water applications to prevent burns.
• Install a manual Water Cut-off Valve next to the filter's inlet port.
• If downstream piping is pressurized, install an additional manual Water Cut-off Valve next to the filter's outlet port.
• Ensure the system includes a Pressure Release / Drainage Valve to release residual pressure before maintenance.
• Never expose the filter to pressure exceeding its maximum designated pressure. Install a Pressure Reduction Valve if necessary.
• The maximum working pressure includes effects from fluid hammer and pressure surges.

2.7 Civil Engineering

• Ensure installation is performed by qualified manufacturer technicians.
• Ensure all civil engineering work is done by qualified personnel and in accordance with local standards.
• Securely chain lifting equipment. Avoid working below lifted equipment. Wear a safety helmet.
• Ensure flooring is sloped for drainage to prevent liquid accumulation.

2.8 Commissioning

• Read the Commissioning and First Start-up Operation instructions carefully before operating the filter.
• Follow startup procedures precisely for optimal performance.
• Commissioning should be done by an authorized technician; do not attempt it alone to avoid damage and warranty issues.

2.9 Operation and Control

• Read and understand the operation instructions before operating.
• Observe safety stickers and instructions.
• Use the filter only for its intended design and operational envelope.
• The system is for non-hazardous liquids only.
• System cleaning and maintenance must be performed in a non-explosive atmosphere.

2.10 Maintenance

• Servicing should only be performed by authorized technicians.
• Cleaning and maintenance must be performed in a non-explosive atmosphere.
• Disconnect power and lock the Main Power Switch.
• Disconnect compressed air, release pressure, and lock the Pneumatics Main Valve.
• Disconnect from the water system by closing and securing the manual inlet valve. If the downstream network is pressurized, also close and secure the manual outlet valve.
• Release residual water pressure using the pressure release / drainage valve.
• Empty the filter via the drainage valve.
• For hot water systems, allow components to cool before maintenance.
• Post warning signs as required by local standards.
• Inspect and replace any damaged or faded safety stickers.
• ATTENTION! Before opening the filter lock, ensure there is no pressure in the filter and accumulator tank.

3. Description & Operation

3.1 Disc Filtration Technology

Amiad Filtration Systems utilizes a disc filtration technology where thin, color-coded polymeric discs are diagonally grooved on both sides to a specific micron size. These discs are stacked and compressed on a spine. The grooves on adjacent discs are oriented oppositely, creating a filtration element with numerous grooves and traps for solids. The assembly is housed in corrosion and pressure-resistant material. During filtration, the discs are compressed by a spring and differential pressure, ensuring high efficiency. Water percolates from the outer to the inner diameter of the element. Depending on the micron rating, there are 18 to 32 stopping points per track, providing in-depth filtration.

Table of Filtration Grades of the Discs and Color Code

*PP discs are standard Arkal, PA discs available on request.

3.2 Spin Klin Technology

Spin Klin Spine - The Core of the Spin Klin Filtration System

The Spin Klin discs are stacked on the Spin Klin Spine, color-coded by micron size and assembled to meet water filtration requirements. The spine assembly includes a spring compression unit and an internal piston that operate during filtration and back-flush modes. Within the housing, a spring and pressure difference compress the discs tightly during filtration, forcing water through the grooves to trap solids.

Spin Klin Automatic Back-flush Operation

Activated by an external command (differential pressure or time), alternate units of the Spin Klin system enter back-flush mode. During back-flush, the compression spring is released, and the pressure difference is eliminated. The spine piston rises, releasing disc pressure. Tangential jets of clean water spray from the spine nozzles onto the discs at high pressure. The discs spin freely, loosening trapped solids, which are then efficiently washed out through the drain.

Diagrams illustrating the Spin Klin Spine and Back-flush Operation are present.

3.3 Back-flush Valves Operation Mode

Filtration Position:

• Inlet valve: Water flows from port [2] (main supply) to port [C] (filter connection). Port [1] (drain water outlet) is sealed.
• Outlet valve: Water flows from port [C] to port [2]. Port [1] is sealed.

Back-flush Position:

• Inlet valve: Command pressure applied to the diaphragm's control chamber via port [D] moves the sealed shaft. Port [2] closes, preventing flow to the filter. Port [C] opens, allowing flushing water to flow from port [C] to the drain [1].
• Outlet valve: Command pressure applied to the diaphragm's control chamber via port [D] moves the sealed shaft. Port [2] closes, port [1] opens, allowing flushing water to flow to port [C].

Diagrams illustrating the Inlet and Outlet Valve Filtration and Back-flush Modes are present.

3.4 Mode of Operation

Filtration Process:

• Water flows through the Inlet Manifold, distributing via the Straight flow Valve to the 2" Spin Klin Filter.
• Water passes through the filtration elements, is cleaned, and exits through the Straight flow Valve to the Outlet Manifold.
• The Accumulator Tank fills with clean water from the Outlet Manifold via its Check Valve.

Back-flushing Process:

1. The Controller/PLC sends a signal to solenoid No.1 (based on differential pressure, time, or manual activation).
2. Command from solenoid No. 1 simultaneously activates the valves for filter No.1:
• INLET VALVE switches from filtration to back-flush mode.
• OUTLET VALVE switches from filtration to back-flush mode.
3. After a pre-set delay, the Controller/PLC signals the Valve Delay Solenoid.
4. Command from the Valve delay solenoid activates the Accumulator Tank valves:
• Air Valve opens, allowing compressed air into the Accumulator Tank.
• Check Valve closes the connection to the outlet manifold.
5. Compressed air enters the Accumulator Tank, increasing water pressure to the level of the compressed air.
6. Air mixes with clean water and is directed to Filter No.1 for back-flushing. The air-to-water ratio increases, with minimal water at termination (air alone does not spin discs).
7. At the end of the back-flush cycle, the Controller/PLC deactivates the Valve delay Solenoid first, followed by Solenoid No.1 after a similar delay.
8. The Accumulator Tank refills with clean water (approx. 20-25 seconds) before the next filter can be back-flushed.
9. The controller initiates back-flushing of the next filter until all filters are clean.

4. Technical Data

* Maximum operating pressure and temperature are interdependent and given for general reference. Consult your authorized Amiad representative for application-specific parameters.

Construction Materials

• Filter Housing & Lid: RPA (Reinforce Polyamide) or RPP (Reinforce Polypropylene)
• Disc elements: PP (Polypropylene) or PA (Polyamide)
• Backwash valves: RPA (Reinforce Polyamide) or RPP (Reinforce Polypropylene)
• Manifolds: PP (Polypropylene)
• Seals: NBR or EPDM, (Viton optional)
• Control Tubing: PE or PA

Air Volume and Flow Rate at Different Pressures

Air Pressure: 6-8 Bar (85-115 PSI)

**Recommendation Air Compressor: 3/4 H.P. + 80L/21GI Tank.

5. Dimensional Drawing

Diagrams showing the dimensions of 2-unit to 8-unit batteries are present.

6. Installation & Start-up

Installation

1. Check for any transport damage (System operates under pressure).
2. Ensure inlet and outlet orientations are correct (indicated by arrows).
3. Connect inlet, outlet, and drain valves to the main manifolds.
4. Verify all covers and clamps are properly closed.
5. Connect and check the pressure source for the PLC/Controller solenoids.
6. Connect the air pressure source to the accumulator.

Start-up Operation

• Perform a dry test run to ensure all connections and wiring are correct.
• Slowly open the inlet valve, allowing air to vent from the Air Release Valve on the inlet manifold.
• Once air vents, check for leaks.
• If pressure difference is high, verify flow rate is not excessive, as this can cause pressure loss.
• Open the air supply and check the air pressure in the accumulator tank.
• Manually initiate a back-flush cycle to confirm correct operation of all system components.
• If pressure difference is not reduced after back-flush, check if flow rate is too high or air supply is too low.

Note: PLC/Controllers vary based on the order.

PLC/Control

• Refer to the manufacturer's handbook before installing the PLC/Controller.
• Ensure correct voltage before connecting.
• Verify that the AP hydraulic switch HIGH and LOW pressure tubes are correctly connected.
• Set the DP switch to the required AP (Recommended AP: 5m/7PSI, depending on site conditions).
• Set the PLC/Controller: Back-flush Time to 7 seconds, Valve Delay to 1 second, and Dwell time to 25 seconds. Adjust settings as needed for local water conditions.
• A typical interval between back-flush cycles is 1-3 hours.
• The Back-flush Cycle Time acts as a backup for the DP switch; whichever condition is met first resets the timer. Manual override also resets the timer.

7. System Maintenance

General

Before any maintenance, read safety and instructions. Ensure all personnel are aware of and comply with safety instructions and any local safety requirements.

7.1 General Inspection of the filter module operation

Perform a visual inspection of the filter for proper operation regularly and before any scheduled maintenance. Initiate a self-cleaning cycle and inspect the filters.

7.2 Weekly maintenance

Visual Check:

• Verify proper system operation as per the General Inspection.
• Visually check the filter housing for leaks.
• Check for loose bolts.

7.3 Maintenance prior to long term cessation of filter operation

Perform these steps if the system will be inactive for over two weeks:

• Run a Back-flushing cycle.
• Release pressure from the filter system using the outlet manifold ball valve.
• Close and release air pressure from the Accumulator tank.
• Perform a dry back wash (no water, no air supply to the accumulator).
• Close and disconnect the air supply to the controller.

7.4 Maintenance prior to re-operation

• Reconnect the system to water and air supply; open the air supply to the controller.
• Run a back-flush cycle and check for proper system operation.

7.5 Periodical

Before any maintenance, read safety and instructions. Ensure all personnel are aware of and comply with safety instructions and any local safety requirements.

1. Perform a General Inspection of system operation and visually inspect the filter for:
   • Proper operation
   • Leakage from housing or accessories
   • Unusual noises
   • Loose bolts
   • Corrosion on housing or accessories
   • Unusual vibrations
   • Non-smooth operation of air release and drainage valves
2. Drain the system and release any remaining water and pressure.
3. Disassemble the filter lids (refer to 'Open the Filter for Service' section).
4. Inspect internal components and seals for wear and tear.
5. Check filter housing and lid for mechanical damage.
6. Replace any damaged components.
7. Ensure maintenance engineers are aware of any damage to the filter housing, lid, or accessories. Contact your Amiad representative immediately if damage is found.
8. Re-assemble the filter lids (refer to 'Open the Filter for Service' section).
9. Perform a complete COMMISSIONING, START-UP AND FIRST OPERATION as described earlier in this document.

7.6 Service & Opening the Filter Lid

Before any maintenance, read safety and instructions. Ensure all personnel are aware of and comply with safety instructions and any local safety requirements.

Tools & Accessories needed:

• Socket Wrench 1/2"
• Torque Meter Wrench set to 70 N-m
• Amiad Spin Klin Butterfly Nut Socket/Wrench
• Amiad Spin Klin Filtration Element Socket
• Silicon Grease

7.7 Cleaning Recommendations

Cause for clogged Filtration Discs:

Water-formed deposits can clog filtration discs. Deposit formation depends on water source quality and environmental conditions (temperature, pH, light, filtration duration).

Common water-formed deposits:

• Biological or organic deposits (mucous, oily; beige, brown, or green).
• Iron oxide (rust) or other metal oxides.
• Carbonates (white or gray deposit).
• Combinations of the above.

If deposits persist after pretreatment, follow this cleaning procedure:

Material and Equipment:

• Well-ventilated workspace.
• 2 small (1 liter) and 2 large (15 liter) containers resistant to chemicals (preferably polypropylene).
• Plastic rope for tying discs.
• Sodium Hypochlorite (NaOCI) - 10% commercial concentration (oxidizes and removes organic/biological deposits).
• Hydrochloric Acid (HCI) - 30% commercial concentration (dissolves and removes carbonates, iron oxide, and other deposits).
• Safety equipment: safety glasses, gloves, long pants, long-sleeved shirt, and shoes.

ATTENTION! Wear safety equipment and work in a well-ventilated area. Follow manufacturer's instructions when working with chemicals.

Cleaning Organic and Biological Deposits:

• Open the filter and remove dirty discs.
• Attention: Never open the filter before pressure is released.
• Arrange discs loosely on the plastic rope.
• Prepare a 5% Sodium Hypochlorite solution: Mix 5 liters of water with 5 liters of 10% Sodium Hypochlorite in a large container.
• Soak discs in the solution, ensuring both sides are covered. Agitate discs periodically for maximum cleaning (up to 8 hours contact time).
• Carefully remove discs, rinse thoroughly with clean water, and place in the second large container before reassembling in the filter.
• Wash cleaned discs again in the filter to remove chemical residues. The cleaning solution can be reused for multiple sets of discs, but may require longer soaking times as its activity decreases.

Cleaning Carbonates and Iron Deposits:

• Open the filter and remove dirty discs.
• Attention: Never open the filter before pressure is released.
• Arrange discs loosely on the plastic rope.
• Prepare a 5% Hydrochloric Acid solution: Add 2 liters of 30% Hydrochloric Acid to 10 liters of water in a large container.
• Soak discs in the solution, ensuring both sides are covered.
• NOTE: Carbonates react vigorously with hydrochloric acid (foaming, gas evolution).
• Agitate discs periodically for maximum cleaning (1-8 hours contact time).
• Remove discs, rinse well with clean water, and place back in the filter.
• Wash cleaned discs again in the filter to remove chemical residues. The cleaning solution can be reused, but may require longer soaking times as its activity decreases.

Cleaning Complex Deposits:

If deposit composition is unknown, perform the following test:

• Take 5 discs.
• Soak 2 discs in a 5% Sodium Hypochlorite Solution (1 cup water + 1 cup 10% NaOCl).
• Soak 2 discs in a 5% Hydrochloric Acid Solution (2.5 cups water + 0.5 cup 30% HCl).
• Keep one disc as a control.
• Observe cleaning: If one solution removes all deposits, clean all discs using that solution as per instructions.
• If neither solution works completely, proceed to the next step.
• Remove discs from both solutions, rinse with running water, and soak the discs from the Sodium Hypochlorite solution in the Hydrochloric Acid solution, and vice versa.
• Check cleaning: If one treatment removes all deposits, clean all discs using this two-step procedure in the same order. Rinse discs well between treatments.
• If deposits are not completely removed, send untreated discs to the laboratory for examination.

8. Troubleshooting

Continuous or Non-stop Backwashing

Flowchart for troubleshooting continuous or non-stop backwashing is present.

• Continuous Backwash: Disconnect control tube from valve -> Command transfer -> Check Controller -> No command transfer -> Contact Amiad local Distributor.
• Continuous Backwash: Disconnect control tube from valve -> Command transfer -> Check Controller -> No command transfer -> Check Solenoids -> No command transfer -> Contact Amiad local Distributor.
• Continuous Backwash: Disconnect control tube from valve -> Command transfer -> Check Controller -> Command transfer -> Replace Control Panel.
• Continuous Backwash: Disconnect control tube from valve -> Command transfer -> Check Controller -> Command transfer -> Check Solenoids -> Command transfer -> Replace Solenoid if needed.
• Non-stop Backwash cycle: Check Inlet/Outlet pressure, Check DP gauge -> Disconnect the Drain Manifold -> Locate the faulty valve and repair.

No Backwash Operation

Flowchart for troubleshooting no backwash operation is present.

• Check Inlet/Outlet pressure -> Check Command pressure -> Check Controller, manually initiate Backwash cycle.
• From 'Check Controller':
• Note of the Solenoid worked -> Check the Controller, connections, power source.
• All of the Solenoid worked -> Check the Valves -> Note of the Valves worked -> Check the Command pressure.
• All of the Solenoid worked -> Check the Valves -> All the Valves Worked -> Check the valve Actuator -> Check and clean the Drain Manifold & pipe.
• Some of the Solenoid worked -> Check the Solenoids, connections & power source.
• If issues persist, contact your Amiad local Distributor.

9. Control Scheme

Diagram illustrating the control scheme with components like Solenoid AC 24v, Flushing controller, P.D. Electronic Sensor, and recommended setup parameters is present.

Recommended Setup:

• FLUSHING TIME: 7 sec.
• DWELL: 15-25 sec.
• V.D.: 1 sec.
• BETWEEN FLUSHING: 1-2 hour.
• ΔΡ: (3-4.5)m, (4-6) p.s.i.

10. FILTER PARTS SCHEDULE AND PARTS LIST

Detailed parts list with descriptions and SAP P/N for the filter components is provided, along with an exploded view diagram.

11. VALVES - PARTS SCHEDULE AND PARTS LIST

Parts list and diagrams for 350 Series Plastic Back-flush Filter Valves (Straight/Angle & Reverse Flow) are provided.

STRAIGHT FLOW 2X2 350 BSP RPA BLACK BERMAD

STRAIGHT REVERSE FLOW 2X2 350 BSP RPA BLACK BERMAD

11.1 STANDARD VALVES PARTS LIST

STRAIGHT FLOW 2X2 350 BSP RPA BLACK AGRESSIVE WATER BERMAD

STRAIGHT REVERSE FLOW 2X2 350 BSP RPA BLACK AGRESSIVE WATER BERMAD

11.2 DW VALVES PARTS LIST

STRAIGHT FLOW 2X2 350 BSP RPA BLACK BERMAD DW

STRAIGHT REVERSE FLOW 2X2 350 BSP RPA BLACK BERMAD DW

11.3 AW VALVES PARTS LIST

STRAIGHT FLOW 2X2 350 BSP RPA BLACK AGRESSIVE WATER BERMAD

STRAIGHT REVERSE FLOW 2X2 350 BSP RPA BLACK AGRESSIVE WATER BERMAD

11.4 SW VALVES PARTS LIST

STRAIGHT FLOW 2X2 350 BSP RPA/DUPLEX BLACK SW BERMAD

STRAIGHT REVERSE FLOW 2X2 350 BSP RPA/DUPLEX BLACK SW BERMAD

12. SYSTEM DRAWINGS

System drawings with dimensions and component details are provided.

13. AMIAD LIMITED WARRANTY

This warranty applies to Amiad Water Systems Ltd. ("Amiad") products purchased from Amiad, unless otherwise agreed in writing. It extends only to the original purchaser and is non-transferable. Amiad warrants products against defects in material and workmanship under normal use and service. This warranty is enforceable for 12 months from the delivery date (the "Warranty Period").

If a defect is discovered during the Warranty Period, the Buyer must submit a written complaint to Amiad using the standard Buyer Complaint Form. For the form, submission, or questions, contact your service representative. Upon Amiad's written request, the Buyer shall return the defective product or a sample to Amiad at Amiad's cost. Amiad assumes no liability for loss or damage during shipment. If Amiad determines the warranty does not apply, the Buyer will reimburse Amiad for shipping and customs costs. Returned products must include the warranty certificate and purchase invoice. Returns must be coordinated and approved by Amiad.

Amiad's obligation is limited to repairing or exchanging, free of charge, any product or part found defective under normal use and service during the Warranty Period. An extended warranty period of 12 months applies to repaired or replaced products, with a maximum total warranty period of 18 months from the original delivery date. This warranty is valid only if products are installed according to Amiad's instructions and within technical limitations specified in Amiad's literature or by an Amiad representative.

This Warranty does not cover defects resulting from:

• Fire, flood, power surges, unforeseen occurrences, or force majeure events.
• Buyer's fault, abuse, or negligence.
• Intake water not meeting agreed standards or improper storage.
• Improper or unauthorized use, failure to operate according to instructions, operation by untrained personnel, or improper installation by an unauthorized third party.
• Maintenance or operation not conforming to Amiad's instructions, or services provided by non-authorized personnel.
• Alterations, modifications, foreign attachments, or repairs performed by anyone other than Amiad or its authorized representatives.

Amiad is not liable for damages to property, intangible or economic loss, including lost profits, loss of customers, or damage to reputation, including indirect, special, consequential, or punitive damages, arising from or in connection with this Warranty or the product's performance or failure to perform, even if Amiad has been advised of the possibility of such damages.

Amiad is excused from failure or delay in performance due to causes beyond its reasonable control or force majeure.

This Warranty is the sole contractual warranty provided by Amiad and replaces all other warranties. Amiad makes no warranty for accessories or parts not supplied by Amiad. Amiad may correct non-warranted products or parts for an additional fee.

Parties will endeavor to settle disputes amicably. If an amicable settlement is not reached, any claim or lawsuit related to the Warranty will be brought before the courts of Tel-Aviv, Israel. Israeli law governs the Warranty, excluding conflict of law rules.