Hydrotec HYDROION VAD 125-CS 1 Operating And Maintenance Manual Download Page 2

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Last change 10/2018 E-P | Subject to technical modifications

Index

The individual chapters are listed in the survey below. More detailed information is shown in
the respective overlays.

Preface

Chapter

General information

Chapter

Transport and storage

Chapter

III

System description / Technical data

Chapter

Assembly and installation

Chapter

Micro processor control

Chapter

Start up / Taking out of service

Chapter

VII

Troubleshooting

Chapter

VIII

Monitoring and maintenance

Appendices 1

Installation schematic softener

Appendices 2

Calculation soft water capacity

Appendices 3

Calculation sodium content

Appendices 4

Start up and training record - Softener HYDRO ION

Appendices 5

Log book

Appendices 6

Commissioning request

Appendices 7

PUROLITE - ION EXCHANGE RESIN - Safety data sheet

Imprint

Summary of Contents for HYDROION VAD 125-CS 1

Page 1: ...ications Operating and Maintenance Manual HYDROION Type VAS CS Serial number ____________________ HYDROTEC UK Ltd Telephone 01494 796040 Hydrotec House 5 Manor Courtyard Hughenden Avenue High Wycombe...

Page 2: ...ata Chapter IV Assembly and installation Chapter V Micro processor control Chapter VI Start up Taking out of service Chapter VII Troubleshooting Chapter VIII Monitoring and maintenance Appendices 1 In...

Page 3: ...es are taken beforehand It is part of the operator s diligence to plan and monitor such measures and implement them with due care The operating and maintenance manual includes important information fo...

Page 4: ...rator s duty of care 5 2 2 Appropriate use 6 2 3 Basic safety measures 6 Maintenance repair and electric work 7 Start up after maintenance and repair work 7 Environmental regulations 7 2 4 Risk in the...

Page 5: ...796 040 Email services hydrotec co uk 2 Safety information 2 1 Operator s duty of care The system is constructed and manufactured with respect to and in consideration of all current standards as well...

Page 6: ...scribed is deemed to be not in accordance with the specification The manufacturer supplier does not accept any liability resulting from the improper use of the system Such risks are borne by the opera...

Page 7: ...aned with a water hose spray Electric components must never be touched with wet hands Valid VDE regulations must be adhered to especially the regulations for the required potential equalisation EMC in...

Page 8: ...azardous to Health 2002 Material Safety Data Sheets are provided in the Appendices Safety datasheets The operating media used Highly acidic cation exchange resin Regeneration salt are not considered t...

Page 9: ...arts recommended by Hydrotec UK Ltd shall be used exclusively No modifications are carried out on the system by users themselves The stipulated operation parameters pressures flow volume are maintaine...

Page 10: ...lifted for transport not tilted The system and resin must be protected from frost during transport and storage recommended temperature 5 40 C Storage outside these conditions can damage and destroy th...

Page 11: ...S A 15 2 2 HYDRO ION VAS CS B 16 2 3 Installation schematic 17 2 4 Pressure loss 18 3 Scope of supply 19 3 1 Components 19 Resin vessel 19 Resin 20 Control valve 20 Micro processor control 21 Water vo...

Page 12: ...nts responsible for hardness calcium and magnesium ions present in the water are bound reversibly to the ion exchange resin and in return sodium ions are released into the water The accumulation of ca...

Page 13: ...e process of ion exchange is the exchange of the hard minerals calcium and magnesium ions with sodium ions Water treated in this manner is called softened water The ion exchange resin becomes exhauste...

Page 14: ...nd 8 0 bar The water pressure should not fall below 2 0 bar in order not to impair the functional performance of the softener Regular maintenance avoids the increase of pressure loss and guarantees co...

Page 15: ...Brine tank volume Ltr 140 190 340 460 460 670 920 1000 1500 Regeneration salt supply kg 50 75 125 175 162 250 325 375 525 Operational weight complete unit max kg 125 210 325 465 620 740 925 1210 1750...

Page 16: ...kg 4 7 10 17 40 40 40 58 40 Brine tank volume Ltr 140 190 190 340 340 460 460 670 920 Regeneration salt supply kg 50 75 75 125 125 175 175 250 337 Operational weight complete unit max kg 125 210 270 4...

Page 17: ...17 98 Last change 10 2018 E P Subject to technical modifications 2 3 Installation schematic Height feed mains water discharge softwater...

Page 18: ...18 98 Last change 10 2018 E P Subject to technical modifications 2 4 Pressure loss curve...

Page 19: ...alve 3 Brine tank 4 Electronic control 5 Input 6 Output softened water 7 Wash water drain Resin vessel Pressure tank of corrosion resistant glass fibre reinforced plastics with PE inliner approved for...

Page 20: ...VAS CS 1 Material Plastics Noryl With top nozzle and system pcb CB 204 Connections Incoming soft water 1 male Brine intake 3 8 Waste water DN 20 Tank connection 2 1 2 8 NPSM HYDRO ION VAS CS 1 5 Mater...

Page 21: ...both vessels takes place in short intervals Stagnated water is minimized in stand by Interval rinsing At this setting the stagnated water defined volume is led directly into the drain line Water refr...

Page 22: ...thread Voltage 12 V AC Cable suited to connect the control to the central control valves 1 Brine tank Storage tank for regeneration salt designed as tank with sieve base brine tube and overflow Numbe...

Page 23: ...VAS CS 1 5 2 The electrodes are activated automatically once the brine intake cycle of the regeneration phase starts Chlorine is produced that starts the disinfection of the resin bed The process is...

Page 24: ...ith external thread Pressure loss 1 0 bar Back flow prevention to be in accordance with local regulations Connection local incoming soft water pipe Assembly mount HYDRO ION VAS CS 1 With blending Art...

Page 25: ...0 C Pressure step PN 10 Connections R 1 1 4 DN 32 Installation length 130 mm Installation length R 2 DN 50 Installation length 139 mm Flexible hose HYDRO ION VAS CS 1 Flexible hose Art No HYDRO ION VA...

Page 26: ...d soft water pipe 28 3 1 Filling of filter vessel with quartz gravel and exchange resin 29 4 Hydraulic connections at control valve 31 Control valve 1 HYDRO ION VAS CS 1 31 Control valve 1 1 2 HYDRO I...

Page 27: ...formation and parameters such as time regeneration status residual capacity water consumption operation days functions and actual state for inputs and outputs are shown in the display of the microproc...

Page 28: ...st not drop below 5 C and not exceed 40 C A free discharge to the drainage system as per EN 1717 DIN 1988 for waste water and overflow of brine tank in accordance with the discharge volume is to be pr...

Page 29: ...d of riser tube 2 resin vessel base Position the riser tube in the resin vessel in such a way that the riser tube stands in the middle of the container base Star type distributor 1 and 2 systems 1 noz...

Page 30: ...ssels are shown in chapter III point 2 1 and 2 2 table with technical data Step 4 Clear any contamination such as resin off the threaded opening to the vessel with clean water Step 5 The closure of th...

Page 31: ...ntrol valve Control valve 1 HYDRO ION VAS CS 1 1 Mains water connection inlet 2 Soft water connection outlet 3 Connection for brine line 4 Waste water connection Control valve 1 1 2 HYDRO ION VAS CS 1...

Page 32: ...on 3 4 The waste water hose that is included in the delivery scope must be connected in an appropriate length and size to the local drain Brine lack sensor The brine lack sensor is mounted already in...

Page 33: ...ol in wall mount casing must be installed at eye level and easily accessible A safety socket must be provided locally next to the mains cable of the micro processor control Permanent voltage must be p...

Page 34: ...YDRO ION VAS CS 1 5 HYDRO ION VAS CS 2 The water meter is installed in the output of the soft water line in case of control valves 1 5 and 2 Electrical connection is realized by means of plug cable at...

Page 35: ...ey 41 3 Alarm 42 3 1 Acknowledge alarm 42 3 2 Alarm records 44 4 Total hardness 45 5 Operation mode 45 6 Protocol settings 46 7 SD Card messaging 46 8 Language 47 9 System time 46 10 System date 47 11...

Page 36: ...ion with a hardness control device that supplies an external contact input in case of hardness break is possible as well Different VFC outputs are given to control the operation of the softener Extern...

Page 37: ...ler is run up The controller is switched on with the ON OFF button left side at casing and supplied with mains voltage The below display is shown when the controller is run up HC Applikation SOFTENER...

Page 38: ...ching automatically Main display with date time and software version Display for filter in operation identical for all plant constructions total capacity that can be treated available residual capacit...

Page 39: ...phase time remaining of regeneration phase At the beginning of regeneration the following messages are shown on display Pre regeneration filter 1 Pre operation filter 1 These messages are displayed on...

Page 40: ...sed lock time active 1 4 Access levels The controller has four access levels to avoid access by unauthorized persons Example for input of password Passwords There are 4 access levels with the below pa...

Page 41: ...turns to any higher menu via the keys F1 or Escape If any setting was modified confirmation is required prior returning to main view that the new setting must be stored The respective necessary releas...

Page 42: ...larm record The alarm is acknowledged via the keys F3 or Enter NOTE Any failure must be eliminated prior being acknowledged Example 1 Alarm brine lack That is caused if regeneration is released but no...

Page 43: ...switched off and on again If power supply was interrupted for a longer time period no flow was determined during such period and the capacity was not reduced Manual regeneration is worthwhile then to...

Page 44: ...th quite high voltage Too low brine saturation add salt tablets possibly check hydraulics of brine intake Alarm Chlorinator Short circuit Hardware error or false terminal charge Check installation Ala...

Page 45: ...nt 4 Total hardness The local mains water hardness is programmed in the menu point total hardness Setting range 5 dH to 80 dH 89 ppm to 1430 ppm 5 Operation mode The main menu item Operation mode is u...

Page 46: ...information will be stored on the SD card at the execution time Logging Protocol Systemtime Date 7 SD Card messaging The menu item SD Card is used for transfer of data of the SD Card to the controller...

Page 47: ...e setting Unit total hardness in German dH Unit total hardness in English ppm Unit resin capacity in German m x dH Unit resin capacity in English m The actual values and figures are converted and show...

Page 48: ...generations Vessel 2 Total volume Total water volume treated in m Volume F1 Water volume treated in Vessel 1 Volume F2 Water volume treated in Vessel 2 Last regeneratioin Date and time of last regener...

Page 49: ...limit Saturation lim Circulation Minimum flow delay Capacity Clack valve Clack type t backwash t brine dr sl t fast rinse t fill t brine format Forced regenerat Lock times Operation valve 1st lock ti...

Page 50: ...ervall New File Interval Single recording SD card All Data SD Card PAR Data SD Card SYS Data SD Card PROC Data SD Card SD Card All Data SD Card PAR Data SD Card SYS Data SD Card PROC Data Calib SD Car...

Page 51: ...al equipment must be carried out by skilled experts only Electric equipment must be controlled in regular intervals Any loose connections must be fixed Damaged cable wiring must be replaced immediatel...

Page 52: ...d the wires clamped inserted with minimum power only The connection clamps without screws are suited to take flexible wiring without wire end sleeve up to 0 5 mm at sensor inputs or flexible wiring wi...

Page 53: ...aximum Unit Nom operating voltage AC 205 230 250 V Mains frequency 47 50 63 HZ Nom apparent power excluding consumer 6 8 15 VA Ambient temperature operation 0 40 C Ambient temperature storage 10 60 C...

Page 54: ...VDC clack board Inputs and Outputs for the control valves Output 24 VDC for the clack board Output 24 VDC for the chlorine board Power supply 230 V 50 Hz Output 230 V 50 Hz Outputs with potential 230...

Page 55: ...1 6 The grounding cable is already clamped 230 V Outputs potential free Relays only operate 230 Volts No Name Function Colour 1 PE 1 PE Connection L board PCB Ground 2 PE 2 housing pipelines 3 PE 3 4...

Page 56: ...oltage levels is not allowed Digital Inputs potential free No Name Function 23 Input Di1 24 GND 25 Input Di2 external regeneration release 26 GND 27 Input Di3 brine sensor 28 GND 29 Input Di4 30 GND 3...

Page 57: ...GND brown 5 14 Increments Analogue output optical detection of piston position blue 6 15 Increments Enable Enabling piston control red 7 16 water meter pulses Water meter pulses black 8 17 LED Product...

Page 58: ...ston motor grey 27 36 5 V Power supply black 26 35 GND red 25 34 Increments Analogue output optical detection of piston position blue 24 33 Increments Enable Enabling piston control brown 23 32 Impuls...

Page 59: ...01 0 V power supply chlorinator brown 2 blue 3 02 0 V 4 5 24 V power supply chlorinator board red 6 GND power supply chlorinator board blue 7 24 V power supply chlorinator board red 8 GND power supply...

Page 60: ...2018 E P Subject to technical modifications Board in the housing cap 13 4 Fine fuses Name Type F 1 5 x 20 mm fuse T 200mA L 250V F 2 5 x 20 mm fuse T 5A L 250V F 1 F 2 Connection for SD memory card U...

Page 61: ...6 8 9 13 9 11 13 15 16 Fill min 9 18 27 45 53 71 17 20 31 Chlorinator Type A Alarm delay 300 seconds Salting min 12 15 23 16 19 18 20 19 20 On delay sec 25 25 25 25 25 25 25 25 25 Period min 11 14 22...

Page 62: ...ssioning 63 2 Start up of softener 64 Preparation 64 Programming of control unit 64 Backwash of softener manual regeneration 65 Brine tank filling 65 Adjusting of soft water hardness 66 Blending at co...

Page 63: ...able and is permanent voltage available Is the water meter connected to the plug connections of the central control valve Is the below equipment connected to the micro processor control unit control v...

Page 64: ...ntrol unit is programmed ex works The mains water hardness is set to 300 ppm Adjustment to local water hardness and water pressure may be necessary Brine filling time of brine tank is to be adjusted t...

Page 65: ...Superior menu on controller Function key or press Escape The backwashed vessel will switch in Operation mode Start up of softener The last pressure vessel having passed the backwash cycle goes automat...

Page 66: ...ve close the adjusting screw anti clockwise until the unit is closed open the stop fittings in mains and soft water pipe until the desired flow is reached open the adjusting screw in clockwise directi...

Page 67: ...f operation the softener must be regenerated completely After regeneration has been concluded the stop valves in the raw and soft water lines must be closed Mains power should be shut off at the spur...

Page 68: ...t to technical modifications Index chapter VII Troubleshooting fault finding Page 1 Malfunction control unit 69 2 No water supplied by softener 69 3 Residual hardness at consumer too high 70 4 Overflo...

Page 69: ...water line Water flows Open service valve leading to consumer No water Proceed with 3 3 Check power supply as far as control system Interrupted power supply Provide power supply Power supply available...

Page 70: ...tting Correct the setting Correct setting but no activation of regeneration Call service 5 Check control valve activate manual regeneration and ensure that all that control valve switches to second ve...

Page 71: ...ult Call service 3 Calculate filling time of brine tank and compare with technical parameters Filling time correct Proceed with 4 Filling time too long Correct filling time 4 Is the brine being drawn...

Page 72: ...n water pressure is 2 0 bar flow pressure f check programming and correct on request 3 Constant regeneration a faulty control b faulty cables a check control and replace on request b replace cables Ca...

Page 73: ...2 Control to be carried out by operator inspection 74 Check permanent hardness mains water 75 Check soft water hardness 75 Check setting of control 75 Check salt level in brine tank 75 Check brine le...

Page 74: ...nspection by the operator A regular visual check of all system components damage leakage etc is necessary for the safe operation of the softener The following parameters must be checked and recorded i...

Page 75: ...per chapter V Check salt level in brine tank Re fill After visual inspection In order to guarantee regeneration of the system the brine tank must always be filled with sufficient regenerant as per DI...

Page 76: ...water quality that can be carried out our service personnel only Call service contact see page 4 3 Maintenance A yearly maintenance is necessary as per DIN EN 806 5 2012 EN 14743 That includes a visu...

Page 77: ...njector and injector sieve must be dismounted and cleaned in regular intervals dependent on purity of mains water during plant maintenance at the latest Control valve HYDRO ION CS 1 Components mains w...

Page 78: ...In order to carry out cleaning and maintenance work at the softener it must be disconnected from the mains water and depressurised Once this has been done the parts can be dismantled and cleaned with...

Page 79: ...es be taken on request Please bear in mind that the annual maintenance should either be carried out by Hydrotec UK Ltd or by an authorised specialist company since otherwise we cannot accept any warra...

Page 80: ...80 98 Last change 10 2018 E P Subject to technical modifications Appendices 1 Installation schematic softener...

Page 81: ...s of a test kit Type of plant VAS CS 25 CS 1 50 CS 1 75 CS 1 125 CS 1 150 CS 1 200 CS 1 250 CS 2 375 CS 2 600 CS 2 Capacity m 300 ppm VAS CS A 5 3 10 8 16 2 27 3 32 2 43 5 54 9 82 8 132 3 Economic sal...

Page 82: ...measured by means of a test kit ppm CaCO3 Mixed water hardness measured value ppm x 0 46 Na Ion sodium ion exchange value ppm Na Increase of sodium contents by softening ppm Na Sodium contents in inco...

Page 83: ...____ bar static pressure Volume flow ____________________ l min Regeneration sequence checked yes no Float valve function checked yes no Note __________________________________________________________...

Page 84: ...ter of brine tank mm to be measured Height of brine tank mm to be measured Setting of control No Designation Actual value 1 Display format 2 Regeneration type 3 Soft water volume to be calculated 4 St...

Page 85: ...on site _____________________________________________________ Time period ________________________________________________________ Date Total hardness incoming water ppm CaCO3 Total hardness soft wate...

Page 86: ...on site _____________________________________________________ Time period ________________________________________________________ Date Total hardness incoming water ppm CaCO3 Total hardness soft wate...

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Page 98: ...erausgeber Publisher HYDROTEC prepared by AL AC All rights reserved 10 2018 by HYDROTEC 17 10 2018 modification Chapter V point 14 Float height adjustment due to a new brine valve 3 4 Water softeners...

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