Hellenbrand WM2-IC10-2.0, TF-IC10-2.0, AM4-IC10-2.0, PS4-IC10-2.0, HB-IC10-2.0 Owner's Manual
...
404 Moravian Valley Road • Waunakee, Wisconsin 53597
Web: www.hellenbrand.com • Email: info@hellenbrand.com
Owner’s Manual
©2003‑2006
Manufactured by:
HELLENBRAND, INC.
Phone: 608‑849‑3050 • Fax: 608‑849‑7398
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Congratulations on your purchase of one of the nest water treatment systems available today – the Iron Cur‑
tain System. This patented, non-chemical lter system, when properly applied will remove iron, manganese and/or hydrogen
sulde from your water supply.
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.
Questions? 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 condi‑
INSTALLATION DATA
Date of Installation _____________________________________________
Filter Model Number ____________________________________________
Aeration Model Number __________________________________________
Address of Installation ___________________________________________
Installed By ___________________________________________________
Raw Water Test: Iron_______ Manganese_______ pH_______ Hydrogen Sulde_______
TDS_______ Iron Bacteria_______ yes _______ no Tannins_______
Hardness ______ Alkalinity _______
Automatic Filter Regeneration: Every _______ Days
Frequency of Air Recharge: Every _______ Hours ‑ Factory default is every 24 hours
TABLE OF CONTENTS
Installation Data ........................................................................................................................................................................... 2
Iron Curtain 2.0 Principle of Operation, Operation of Aeration System ....................................................................................... 3
Operating Conditions ................................................................................................................................................................... 4
Pre-Installation Check List ........................................................................................................................................................... 4
Installation Instructions & Start‑Up ..............................................................................................................................................
Specications .............................................................................................................................................................................. 6
Backwash Frequency, Aire Recharge Frequency ........................................................................................................................ 6
Installation Diagram ..................................................................................................................................................................... 7
Iron Curtain 2.0 Assembly ........................................................................................................................................................... 8
Iron Curtain System & Aeration Wiring ........................................................................................................................................ 9
ProMate, WaterMate & AutoMate Filter Valve Options .............................................................................................................. 10
Bypass Valve Operation .............................................................................................................................................................11
Iron Curtain Flow Diagrams .................................................................................................................................................. 12,13
Iron Cutain Aeration Pump ........................................................................................................................................................ 14
Iron Curtain Aeration Pump Repair Instructions ........................................................................................................................ 15
Troubleshooting ....................................................................................................................................................................16‑18
Winterizing Iron Curtain System ................................................................................................................................................ 18
Iron Curtain 2.0 Limited Warranty .............................................................................................................................................. 19
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IRON CURTAIN 2.0
Iron Filtration System
Aeration/precipitation/multi-media ltration for:
1. Iron Reduction/Removal
2. Manganese Reduction/Removal
3. Hydrogen Sulde Reduction/Removal
Principle of Operation
The Iron Curtain System uses a three step process of oxidation, precipitation, and mechanical ltration for the
reduction/removal of iron, manganese, and hydrogen sulde.
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 two main components that make up the Iron Curtain
System. They are:
1. Iron Curtain 2.0 Aeration Assembly
2. Iron Curtain Multi-Media Depth Filter
The rst step in any oxidizing process is to bring the
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raw water into intimate contact with a strong oxidant.
This will begin to convert the dissolved element such as iron
or manganese to a physical particle or nonsoluble precipitate.
A strong, inexpensive, environmentally‑safe oxidant is oxygen,
which makes up about 21% of ambient air. To do this, the
Iron Curtain System sprays water through a regulated head
of air in the aeration tank.
The second step in this three step process is to
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provide adequate reaction or contact
time for the precipitation reaction to go to completion. This
allows time for the iron and/or manganese particles to become
large enough to lter out. The aeration tank with the Iron Curtain
System allows for several minutes of contact time at the rated
service ows, 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.
A low ph can slow the oxidation reaction of the iron. This re‑
action time may also be affected by the presence of organic
material (such as tannins). If tannins are present, eld 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 sulde. Installation
of this system on water supplies with more than 0.5 ppm
of tannins will void warranty.
The third and nal step is ltration for the removal
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of the precipitates from the water. A WQA Water
Filtration Study Guide states:
“The ideal lter 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 lter. This also allows for longer lter
runs and faster ow 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. Caking of the bed and breakthrough turbidity are virtually
eliminated.
3. Much higher service ow rates per square foot.
4. Higher degree of clarity because of the heavier, ner lter
media in the bottom.
The standard Iron Curtain System uses ve layers of lter me‑
dia. 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, smaller in size than the
one above. The fourth layer contains an even heavier media.
The fth layer is a special support bed to retain lter media so
it does not pass through the distribution system, and allows
an even distributed ow of backwash water.
Operation of Aeration System
The Iron Curtain System introduces air into the aeration tank
and bleeds off the old head of air automatically. A timer
controls the air recharge cycle and how frequently it occurs.
The timer turns on the air pump, opening the drain port and
the top air recharge port of the aeration tank. The air pump
runs for a pre‑set amount of time, replenishing the head of
air and discharging excess water and/or air to drain.
Advantages Over
Other Systems
1. The original systems was tested and validated by WQA
under their S‑200 Standard.
2. Uses no chemicals or salt.
3. Eliminates the need for air injectors, venturis, or micron
izers.
4. No oats or air volume controls are used 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 lter.
6. 110V aeration pump to recharge aeration tank.
7. "Piggy‑back" plug allows control valve to be plugged into
same outlet.
8. Can be used on shared wells, municipal water supplies,
or with buried pressure tanks without additional equip‑
ment.
9. Higher service ow rates.
10. Better ltration results.
11. U.S. Patent #B1 5,096,596 and patent pending.
12. Variable settings on air recharge that is independent of
backwash frequency.
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Operating Conditions
The original 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 sulde. The
concentration limits listed below reect the maximum indi‑
vidual limit that each contaminant was tested for separately
without any interference of other contaminants in the inuent
water.
In reality, these contaminants may be present in combination
which may limit the lter’s ability to remove these contami‑
nants 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 reduction/removal of iron,
manganese and/or hydrogen sulde levels that are above
operating conditions listed below, we recommend that you
consult your dealer for proper application. Installation of this
system under these circumstances may void part(s) and/or
all of the system warranty.
pH — The pH level of the inuent water must be 7.0 or higher
for iron oxidation reaction to proceed per the engineering
specications.*
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, 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 to control iron bacteria within the Iron Curtain
is chlorine injection during the regeneration cycle. In
some instances, continuous chlorination of the water
supply may be needed.
Hydrogen Sulde — Sometimes referred to as "rotten
egg" odor. This system is rated for a maximum of 10 ppm
hydrogen sulde. Hydrogen sulde levels vary depending on
barometric pressure.*
Manganese — Limit 2.0 ppm; amounts present over 2.0
ppm may gradually prevent iron removal. Note: For optimum
manganese reduction, pH should be greater than 8.5.*
Organic Matter (Tannins) – The presence of organic matter
such as tannins will prevent the oxidation process of con‑
verting the dissolved element, such as iron or manganese, to
a nonsoluble precipitate or solid substance. In other words,
organics can tie up the iron preventing ltration. The presence of organics such as tannins above 0.5 ppm 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 sup‑
ply 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 interfer‑
ence. Most waters have TDS less than 500 and generally
present no problems to iron reduction. If any ion becomes
excessive, it may cause failure of iron removal. A TDS more
than 750 ppm voids any claims for this system to perform
*For application parameters outside the specied operation conditions or additional information regarding the listed items,
contact your dealer.
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as stated above.*
Pre-Installation Check List
Water Pressure: A minimum of 30 psi at a predetermined
continuous ow rate is required to backwash the lter properly,
with a maximum of 70 psi to be used.*
Actual Inuent Flow Rate: (Water available from well pump,
service inlet, etc.) The actual ow rate must exceed the backwash
rate for the model of lter selected at a minimum of 30 psi for
the entire length of the backwash cycle. See actual backwash
rates in the Specications section on page 6.
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 Figure 1,on page 7.
Location of Aeration and Filter Tank: See Figures 1 on page
7. These two tanks should be installed after the pressure tank
and as close to each other as practical. If you want to lter
outside hosebibs, be sure the lter system is properly sized
to handle the ow rates required for extended periods of time,
in addition to the normal household demand.
Drain Lines: All lter system 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 pos‑
sible. If used, overhead drain lines are not to exceed a height
of ve feet above the control valve and should be no more
than fty feet in length.
Check Valve: On applications where there is a non-ltered
demand for water such as joint wells (where the lter system is
only installed in one of two or more homes), outside hosebibs,
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, on page 7. Install the check valve
in a vertical upow position with a minimum 6" 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‑
ltered and ltered water, the air head in the aeration tank may
escape backwards past the check valve into the non-ltered
water line.
By-Pass Valves: Always provide for a bypass on the lter
system. It is recommended that a bypass be placed on both
the aeration tank and the lter tank.
Filtered Water: Normally, ltered water is furnished to all
household lines; however, outside faucets are typically left on
raw water. If ltered water is provided to outside faucets, the
lter 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; lter system cannot be
subject to freezing conditions; lter system 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 ltration equipment.
Installation Instructions
Your new Iron Curtain™ model IC-2.0 allows for simple instal‑
lation and start up. Installation diagrams are provided to assist
you. Use of these diagrams and the following procedures will
ensure that the system is properly installed.
1. Follow all state and local plumbing and electrical
codes!
2. The one‑inch (1") check valve that is supplied must be
installed in the upow position on the raw water supply
feeding the aeration tank. (See gure 1 page 7 for proper
check valve installation procedures)
3. When installing an Iron Curtain Filter system it is com
mon to provide ltered water to some xtures such as
the kitchen cold faucet. This is typically done as a matter
of personal preference. In rare occassions it has been
noted that the customer may experience some air in the
ltered water line on the morning after regeneration. It
has proven to be benecial to plumb the line for the
ltered only water xture in a downward direction from
the inlet of the softener (12 inches recommended), then
make a reverse turn and go upward toward the xture.
Understanding that air always rises to the highest point
in a water system, and it cannot naturally ow downward.
(Figure 1, page 7)
4. The raw water supply from the outlet of the check valve
must be connected to the down-ow inlet connection on
the aeration tank. Refer to the stickers marked inlet/
outlet for proper connections. A factory by‑pass valve
is available and should be installed on the aeration tank
assembly. (See page 10 for details). Leave the aeration
tank on by‑pass at this time.
5. The outlet from the aeration tank is then connected to the
inlet of the lter tank. A factory by-pass valve is available
and should be installed on the lter tank assembly. (See
page 10 for details).
6. Connect the outlet of the lter system to the water system
lines you are ltering.
7. The IC-2.0 aeration head assembly has a 3/8” drain con
nection that must be run to a drain. This can tee into the
drain line of the lter or to a drain independent of the lter
drain. Drain line emits surges of excess air from aeration
tank and must be secured. Tubing has been supplied
along with a 3/4” male threaded adapter. (See page 10
‑
for details).
8. There is a 1/4” tube size vent port off of the solenoid valve
which is vented to the atmosphere. This will normally ex‑
pel very little moisture unless an internal seal fails within
the valve body. This vent should be run to a drain to
prevent any water damage to the surrounding area,
should the solenoid fail. This must drain downward
to an open atmospheric drain separate from the lter
drain.
9. Recommend 1” diameter pipe between aeration tank and
lter tank.
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Start-Up
1. Once all plumbing is nished and with the unit on bypass,
ush the plumbing system until water is clear and no foreign
material is detected.
2. Plug in electrical power cord. Slowly open the bypass inlet
valve on the aeration tank to the full open position allowing
the tank to ll with water and come up to full pressure. You
do not have to wait for the air recharge cycle (air pump
running) to nish before proceeding to the next step.
3. Open the outlet valve on the by-pass(s) for the aeration
tank and lter.
4. IMPORTANT: Do not backwash your Iron Curtain Filter
for 24 hours.
5. With the lter control valve in the service/ltering position,
slowly open the inlet valve on the by-pass to the lter and
run water at nearest cold ltered water xture until the
water is clear. Slowly open the lter inlet valve fully and
continue to run water at nearest cold ltered water faucet
until water is clear.
6. Start‑up is complete.
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Aeration Control Center
Your new IC-2.0 Aeration Control is factory pre-set to cycle the
air compressor once every 24 hours. To adjust the air recharge
frequency, refer to the wiring schematic on page 9. The timer
has a xed run time, which cannot be adjusted up or down. To
manually initiate an air recharge cycle, unplug the power cord
and plug it back into the electrical outlet. The air pump will
begin to run and will automatically shut off. Off time tolerance
is ±5% which can vary as much as 72 minutes every 24 hours
and not affect the functioning of the Iron Curtain.
Iron Curtain Filter Control
Your Iron Curtain Filter is factory preset to backwash every
third day. Adjust as necessary but never backwash less often
than every three days. See lter control owners manual for
details.
Regeneration Frequency
Your Iron Curtain Filter System contains a special lter media
mixture which allows it to lter iron longer than standard lters
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 higher amounts of iron, iron bacteria,
hydrogen sulde, 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
Backwash Frequency
Iron Applications
0.3 ‑ 3.0 ppm Iron ‑ Every 3rd Day
3.0 - 6.0 ppm Iron - Every Other Day
6.0 ‑ 10.0 ppm Iron ‑ Every Day
10+ ppm Iron - Consult Factory
Air Recharge Frequency
(Settings Based on Average Pressure (50psi) and <500 Gal‑
lons Daily Use)
0.3 - 3.0 ppm Iron - Once Daily (Every 24 hours)
3.0 - 6.0 ppm Iron - Once Daily
6.0 ‑ 10.0 ppm Iron ‑ Twice Daily (Every 12 hours)
10+ ppm Iron - Consult Factory
Hydrogen Sulde Applications
Hydrogen Sulde (H2S) consumes 7 times the amount of oxy‑
gen to oxidize than iron does. Therefore, for Hydrogen Sulde
Applications, we use the following guideline;
0 ‑ 4 ppm H2S ‑Twice Daily (Every 12 hours)
4 ‑ 8 ppm H2S ‑ Three Times Daily (Every 8 hours)
8 ‑ 10 ppm H2S ‑ Six Times Daily (Every 4 hours)
See page 9 to change air recharge frequency on timer.
Specications
Models
IC-10
WM2-IC10-2.0, TF-IC10-2.0, AM4-IC10-2.0, PS4-IC10-2.0, PM1-IC10-2.0,HB-IC10-2.0 10"x54" 1.5 1" 5.0 5.0 26"x68"x16"
IC-10A
WM2-IC10A-2.0, TF-IC10A-2.0, AM4-IC1-A-2.0, PS4-IC10-2.0, PM1-IC1-A-2.0, HB-IC10A-2.0
IC-10+
WM2-IC10+2.0, TF-IC10+2.0, AM4-IC10-+2.0,PS4-IC10+2.0, PM1-IC10+2.0 10"x54" 1.5 1" 5.0 5.0 26"x68"x16
IC-12
WM2-IC12-2.0, TF-IC12-2.0, AM4-IC12-2.0, PS4-IC12-2.0, PM1-IC12-2.0, HB-IC12-2.0 12"x52" 2.0 1" 7.0 8.0 30"x66"x18"
IC-12A
WM2-IC12A-2.0, TF-IC12A-2.0, AM4-IC12A-2.0, PS4-IC12A-2.0, PM1-IC12A-2.0, HB-IC12A-2.0 12"x52" 2.0 1" 7.0 8.0 30"x66"x18"
IC-12+
(1) Aeration Head and Check Valve have 1” Inlet/Outlet.
(2) Water temps above 60° F will require a higher backwash rate. Consult
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Filter &
Aeration
Tank
Size
10"x54" 1.5 1" 5.0 5.0 26"x68"x16"
Media
Cu. Ft
(1)
Inlet/
Outlet
Max.
Service
Flow
GPM
(2)
Backwash
Rate
GPM
Floor
Space
(WxHxD)
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