Manual Servicio Pretratamiento

Pretreatment Components BASIC / STANDARD Service Manual Edition: 1/03.11 Part no.: 636 210 1

Fresenius Medical Care

Table of contents 1

Index

2

Important information

3

2.1 2.1.1

Preface........................................................................................................................................ 2-1 Structure of the Service Manual .................................................................................................. 2-1

2.2

How to use the Service Manual................................................................................................ 2-2

2.3 2.3.1 2.3.2 2.3.3

Notes........................................................................................................................................... 2-3 Significance of the warnings........................................................................................................ 2-3 Significance of the note ............................................................................................................... 2-3 Significance of the tip .................................................................................................................. 2-3

2.4 2.4.1 2.4.2 2.4.3

Brief description ........................................................................................................................ 2-4 Operator information.................................................................................................................... 2-5 Guarantee / warranty................................................................................................................... 2-6 Technical documentation............................................................................................................. 2-6

2.5 2.5.1 2.5.2 2.5.3 2.5.4

Warnings .................................................................................................................................... 2-7 Basic warnings ............................................................................................................................ 2-7 Electric hazards ........................................................................................................................... 2-7 Chemical hazards........................................................................................................................ 2-7 Biological hazards ....................................................................................................................... 2-8

2.6

Addresses .................................................................................................................................. 2-9

Component overview 3.1 3.1.1 3.1.2

4

Components of the water pretreatment system ..................................................................... 3-1 Water pretreatment component overview / STANDARD........................................................ 3-2 Water pretreatment component overview / BASIC................................................................. 3-3

Feed water inlet unit 4.1 4.1.1

Component overview – wall-mounted prefiltration unit ........................................................ 4-1 Prefiltration unit 1‘‘, 1 1/4‘‘, 1 1/2‘‘................................................................................................ 4-2

4.2 4.2.1 4.2.2

Installation.................................................................................................................................. 4-3 Installation / start-up requirements .............................................................................................. 4-3 Data reporting.............................................................................................................................. 4-3

4.3 4.3.1 4.3.2 4.3.3

Specifications ............................................................................................................................ 4-4 Specifications / data sheet........................................................................................................... 4-4 Operating conditions.................................................................................................................... 4-5 Configuration options................................................................................................................... 4-5

4.4

Maintenance............................................................................................................................... 4-6

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4.5 4.5.1

4.5.3 4.5.4

Functional description .............................................................................................................. 4-7 Design of components ................................................................................................................. 4-7 4.5.1.1 Water inlet unit ............................................................................................................. 4-7 Component function..................................................................................................................... 4-7 4.5.2.1 Stop valve..................................................................................................................... 4-7 4.5.2.2 Water meter - optional.................................................................................................. 4-7 4.5.2.3 Backwashable prefilter 105 µm .................................................................................... 4-7 4.5.2.4 Solenoid valve .............................................................................................................. 4-8 4.5.2.5 Pipe disconnector ......................................................................................................... 4-9 Prefiltration rack with particle filter (optional) ............................................................................. 4-10 Component description.............................................................................................................. 4-10

4.6 4.6.1 4.6.2 4.6.3

Options ..................................................................................................................................... 4-11 Prefiltration rack with particle filter (option)................................................................................ 4-11 Pressure reducer - optional ....................................................................................................... 4-11 Configuration options (feed water tank)..................................................................................... 4-11

4.5.2

5

Booster pump 5.1

Booster pump assembly CRN5-8 component overview ........................................................ 5-1

5.2 5.2.1 5.2.2

Installation.................................................................................................................................. 5-2 Installation / start-up requirements .............................................................................................. 5-2 Important start-up information...................................................................................................... 5-2 5.2.2.1 Booster pump assembly connection ............................................................................ 5-2 5.2.2.2 Connection to the domestic water supply network ....................................................... 5-3 5.2.2.5 Overview of electrical connections ............................................................................... 5-9 Data reporting ............................................................................................................................ 5-13

5.2.3 5.3 5.3.1 5.3.2

Specifications .......................................................................................................................... 5-14 Specifications / data sheet......................................................................................................... 5-14 5.3.1.1 Performance characteristics ....................................................................................... 5-14 5.3.1.2 Volumetric capacity - diagram .................................................................................... 5-15 Operating conditions.................................................................................................................. 5-15

5.4

Maintenance ............................................................................................................................. 5-16

5.5 5.5.1

Error messages........................................................................................................................ 5-17 Malfunctions, causes and correction ......................................................................................... 5-17

5.6 5.6.1 5.6.2

Functional description ............................................................................................................ 5-18 Design of components ............................................................................................................... 5-18 Component description.............................................................................................................. 5-18 5.6.2.1 Control unit ................................................................................................................. 5-18 5.6.2.2 Base load and peak load pump.................................................................................. 5-19 5.6.2.3 Alternating pressure situations ................................................................................... 5-19 5.6.2.4 Run-dry protection ...................................................................................................... 5-19 5.6.2.5 Tank operation ........................................................................................................... 5-19 5.6.2.6 Automatic turnoff ........................................................................................................ 5-19 Functional description................................................................................................................ 5-20 5.6.3.1 Setting the system to the Standby mode.................................................................... 5-20 5.6.3.2 Selector switch functions............................................................................................ 5-20

5.6.3

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7

Pumps 6.1

Pump CM5-5 – component overview ....................................................................................... 6-1

6.2 6.2.1 6.2.2 6.2.3

Installation.................................................................................................................................. 6-2 Installation / start-up requirements .............................................................................................. 6-2 Important start-up information ..................................................................................................... 6-2 Data reporting.............................................................................................................................. 6-2

6.3 6.3.1 6.3.2

Specifications ............................................................................................................................ 6-3 Specifications / data sheet (CM5-5) ............................................................................................ 6-3 Operating conditions.................................................................................................................... 6-3

6.4

Maintenance............................................................................................................................... 6-4

6.5 6.5.1 6.5.2

Error messages on pumps ....................................................................................................... 6-5 Visual indication on CM5-5.......................................................................................................... 6-5 6.5.1.1 Alarm messages overview ........................................................................................... 6-5 Pump malfunctions overview....................................................................................................... 6-6

6.6 6.6.1

Functional description .............................................................................................................. 6-7 Design of components................................................................................................................. 6-7

Media filters (sand filters / Birm filters) 7.1

Component overview – sand filters S140, S200, S300, S400 ................................................ 7-1

7.2

Component overview – Birm filters B140, B200, B300, B400................................................ 7-2

7.3 7.3.1 7.3.2

7.3.7

Installation of the media filters (sand / Birm).......................................................................... 7-3 Installation / start-up requirements .............................................................................................. 7-3 Important start-up information ..................................................................................................... 7-4 7.3.2.1 Start-up of the sand filters / Birm filters ........................................................................ 7-4 7.3.2.2 Valve heads and drain restrictor................................................................................... 7-5 7.3.2.3 Valves in the control head ............................................................................................ 7-9 Programming the control for sand filters / Birm filters................................................................ 7-11 7.3.3.1 Control / display ......................................................................................................... 7-11 7.3.3.2 Control / control elements .......................................................................................... 7-11 7.3.3.3 Control / programming................................................................................................ 7-11 Data reporting............................................................................................................................ 7-23 Use of Birm for improved water quality..................................................................................... 7-24 7.3.5.1 Removal of iron using "Birm" as filter media in the sand filter.................................... 7-24 7.3.5.2 Alarm limits for water substances............................................................................... 7-24 Birm filter settings ...................................................................................................................... 7-26 7.3.6.1 Weekly / semi-weekly backwash................................................................................ 7-26 Operating conditions.................................................................................................................. 7-28

7.4 7.4.1 7.4.2 7.4.3

Specifications .......................................................................................................................... 7-29 Specifications / sand filter data sheet ........................................................................................ 7-29 Specifications / Birm filter data sheet ........................................................................................ 7-30 Operating conditions.................................................................................................................. 7-31

7.5

Maintenance............................................................................................................................. 7-32

7.6 7.6.1

Error messages ....................................................................................................................... 7-33 Sand filter / Birm filter malfunctions overview............................................................................ 7-33

7.7 7.7.1

Functional description ............................................................................................................ 7-34 Design of components............................................................................................................... 7-34

7.3.3

7.3.4 7.3.5 7.3.6

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7.7.2

8

9

Particle filter (Big Blue) 20" 8.1

Component overview – particle filter....................................................................................... 8-1

8.2 8.2.1 8.2.2

Installation.................................................................................................................................. 8-2 Installation / start-up requirements .............................................................................................. 8-2 Data reporting .............................................................................................................................. 8-2

8.3 8.3.1 8.3.2

Specifications ............................................................................................................................ 8-3 Specifications / data sheet........................................................................................................... 8-3 Operating conditions.................................................................................................................... 8-3 8.3.2.1 Particle filter selection table.......................................................................................... 8-3

8.4

Maintenance ............................................................................................................................... 8-4

8.5 8.5.1 8.5.2

Functional description .............................................................................................................. 8-5 Design of components ................................................................................................................. 8-5 Component description................................................................................................................ 8-5

Softener 9.1

Component overview – softener E080(B), E150(B), E225-T, E300, E400 Magnum .............. 9-1

9.2 9.2.1 9.2.2 9.2.3

Modification of the softener settings in case of high brine concentrations in combination with Kinetico-Autorol retrofit kits............................................................................................. 9-3 Settings for CP 216...................................................................................................................... 9-3 Settings for CP 213...................................................................................................................... 9-3 Settings for CP 210...................................................................................................................... 9-4

9.3 9.3.1

Installation.................................................................................................................................. 9-5 Installation / start-up requirements .............................................................................................. 9-5

9.4 9.4.1 9.4.2

9.4.5

Display and operating elements............................................................................................... 9-6 Display during operation .............................................................................................................. 9-6 Programming the control unit....................................................................................................... 9-7 9.4.2.1 Control / display............................................................................................................ 9-7 9.4.2.2 Programming the control .............................................................................................. 9-7 Important start-up information.................................................................................................... 9-13 9.4.3.1 Softener start-up procedure ....................................................................................... 9-14 Start-up procedure for E080(B),/ E150(B), E225-T, E300, E400............................................... 9-16 9.4.4.3 Brine tank ................................................................................................................... 9-22 9.4.4.5 Triplex operation E225-T............................................................................................ 9-23 9.4.4.6 Alternating or parallel operation ................................................................................. 9-24 Data reporting ............................................................................................................................ 9-44

9.5 9.5.1 9.5.2 9.5.3 9.5.4

Specifications .......................................................................................................................... 9-45 Specifications / data sheet......................................................................................................... 9-46 Restrictor inserts depending on pressure range........................................................................ 9-47 Softener capacities .................................................................................................................... 9-48 Operating conditions.................................................................................................................. 9-49

9.4.3 9.4.4

vi

Component description.............................................................................................................. 7-34 7.7.2.1 Backwash ................................................................................................................... 7-34 7.7.2.2 Flow velocities ............................................................................................................ 7-35 7.7.2.3 Feed water bypass ..................................................................................................... 7-35 7.7.2.4 Efficiency .................................................................................................................... 7-35

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9.5.5

9.5.4.1 Softener selection table.............................................................................................. 9-49 9.5.4.2 Triplex softener (E225-T) ........................................................................................... 9-50 Removal of iron and manganese using a softener .................................................................... 9-50

9.6

Maintenance............................................................................................................................. 9-51

9.7 9.7.1

Error messages ....................................................................................................................... 9-52 Softener malfunctions overview................................................................................................. 9-52

9.8 9.8.1 9.8.2 9.8.3

Functional description ............................................................................................................ 9-55 Design of components............................................................................................................... 9-55 Component description.............................................................................................................. 9-55 Functional description Triplex operation E225-T ....................................................................... 9-56

10 Activated carbon filter 10.1

Component overview – A050, A100, A150, A300, A400 ....................................................... 10-1

10.2 10.2.1 10.2.2 10.2.3

Installation................................................................................................................................ 10-2 Installation / start-up requirements ............................................................................................ 10-2 Important start-up information ................................................................................................... 10-3 Start-up of the activated carbon filter......................................................................................... 10-4 10.2.3.1 Valve heads and drain restrictor................................................................................. 10-4 10.2.3.3 Control unit design ..................................................................................................... 10-8 Programming the control unit .................................................................................................. 10-10 10.2.4.1 Control / display ....................................................................................................... 10-10 10.2.4.2 Control / operating elements .................................................................................... 10-10 10.2.4.3 Control unit ............................................................................................................... 10-11 Data reporting.......................................................................................................................... 10-21

10.2.4

10.2.5 10.3 10.3.1 10.3.2

Specifications ........................................................................................................................ 10-22 Specifications / data sheet....................................................................................................... 10-22 Operating conditions................................................................................................................ 10-24 10.3.2.1 Activated carbon filter (Single) selection table ......................................................... 10-25 10.3.2.2 Activated carbon filter (double) selection table......................................................... 10-25

10.4

Maintenance........................................................................................................................... 10-27

10.5 10.5.1

Error messages ..................................................................................................................... 10-28 Activated carbon filter malfunctions overview.......................................................................... 10-28

10.6 10.6.1 10.6.2

Functional description .......................................................................................................... 10-29 Design of components............................................................................................................. 10-29 Component description............................................................................................................ 10-29

11 USER RELEVANT – Operational data acquisition / maintenance 11.1

Operational data acquisition / daily report............................................................................ 11-2

11.2

System handling instructions report – water pretreatment ................................................ 11-5

11.3 11.3.1

Maintenance............................................................................................................................. 11-9 Maintenance intervals for water pretreatment components....................................................... 11-9 11.3.1.1 Feed water inlet unit ................................................................................................... 11-9 11.3.1.2 Sand filter ................................................................................................................... 11-9 11.3.1.3 Particle filter ............................................................................................................... 11-9 11.3.1.4 Softener.................................................................................................................... 11-10

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11.3.1.5 Activated carbon filter ............................................................................................... 11-11 11.3.1.6 Water leakage indicator............................................................................................ 11-11

12 SERVICE RELEVANT – Reports 12.1 12.1.1 12.1.2 12.1.3 12.1.4 12.1.5 12.1.6

Operational qualification......................................................................................................... 12-1 Start-up report............................................................................................................................ 12-1 Water pretreatment settings reports .......................................................................................... 12-6 Coarse filter and booster pump assembly settings report ......................................................... 12-6 Sand filter settings report........................................................................................................... 12-8 Activated carbon filter settings report ...................................................................................... 12-10 Softener settings report ........................................................................................................... 12-12

12.2 12.2.1 12.2.2 12.2.3

Maintenance ........................................................................................................................... 12-14 Important information on maintenance procedures ................................................................. 12-14 Accessories and supplies for maintenance procedures .......................................................... 12-15 Maintenance report.................................................................................................................. 12-15

12.3 12.3.1

Tools and test equipment ..................................................................................................... 12-19 Test equipment ........................................................................................................................ 12-19

13 Definitions 13.1

Definitions and terms .............................................................................................................. 13-1

13.2

Abbreviations........................................................................................................................... 13-1

13.3

Symbols.................................................................................................................................... 13-1

14 Appendix

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Chapter 1: Index

1

Index

A

I

Abbreviations 13-1

Importance of the instructions 2-2

Activated carbon filter 10-1

Important information 2-1

Activated carbon filter malfunctions overview 10-28

Improved water quality 7-24

Activated carbon filter settings report 12-10

M

Addresses 2-9 Alternating or parallel operation 9-24

Maintenance intervals 11-9 Maintenance report 12-15

Softener selection table 9-49

Manual regeneration 9-14

Softener settings in case of high brine concentration 9-3

Basic warnings 2-7 Biological hazards 2-8

Note, significance 2-3

Brief description 2-4

Softener settings report 12-12 Start-up report 12-1 Symbols 13-1 System handling instructions report – Water pre-treatment 11-5

N

Booster pump 5-1

Softener 9-1 Softener capacities 9-48

Media filters (sand filters / Birm filters) 7-1

B

Selection table activated carbon filter (Single) 10-25

Softener malfunctions overview 9-52

Manually starting the regeneration 9-21

Appendix 11-1, 12-1

Selection table activated carbon filter (double) 10-25

Notes 2-3

T Target group 2-5

C

Technical documentation 2-6

O

Chemical hazards 2-7 Coarse filter and booster pump assembly settings report 12-6

D

Operational data acquisition / daily report 11-2 Operational qualification 12-1

W

Operator information 2-5

Warnings 2-7

Operator responsibility 2-6

Warnings, significance 2-3

Definitions and terms 13-1 Disclaimer of liability 2-6

Water pretreatment / BASIC 3-3

P

Duties of the responsible organization 2-5

Tip, significance 2-3

Particle filter (Big Blue) 20" 8-1 Preface 2-1

E

Prefiltration rack with particle filter 4-10

Electric hazards 2-7

Prefiltration unit 4-2

Error messages on pumps 6-5

Pressure reducer 4-11

F

Pumps 6-1

Water pretreatment / STANDARD 3-2 Water pretreatment component overview 3-2, 3-3 Water pretreatment settings reports 12-6

Pump malfunctions overview 6-6

Feed water bypass 7-35 Feed water inlet unit 4-1

S

G

Sand filter malfunctions overview 7-33

Guarantee / warranty 2-6

Sand filter selection table 7-25, 7-31 Sand filter settings report 12-8

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Chapter 1: Index

1-2

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Chapter 2: Important information

2

Important information

2.1

Preface

2.1.1

Structure of the Service Manual This Service Manual contains a number of individual components or overall concepts that are not products of Fresenius Medical Care Deutschland GmbH. Due to the standardization of documents, the structure for standardized Service Manuals was applied to list the contents for service technicians in their usual workflow. Each component is therefore described in this Service Manual as an individual device using the general structure. When applying the master structure, empty chapters were omitted if the chapter contents were not applicable.

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Chapter 2: Important information

2.2

How to use the Service Manual Identification

The document can be identified by the following information on the title page and on the labels, if any: – Edition of the document – Part number of the technical document

Page identification

The page identification 1-3, for example, refers to Chapter 1, page 3.

Editorial information

The editorial information 1/01.05, for example, refers to: 1st edition, January 2005.

Organization of the chapters

To facilitate the use of documents from Fresenius Medical Care, the organization of the chapters has been standardized in all manuals. There may therefore be chapters within this document without any content. Chapters without content are identified.

Illustrations

The illustrations used in the documents (e.g. screens, photos, etc.) may differ from the original if this does not have any influence on the function.

Importance of the instructions

This document is part of the accompanying documents and is an essential part of the device. It includes information necessary for use, programming and start-up of the device. This document must be studied carefully before attempting to operate the device. Before the responsible organization may begin operating the device, the individual responsible for the operation must have been instructed by the manufacturer on how to use the device and must be thoroughly familiar with the contents of the document. The device may only be operated by individuals certificated to have been instructed on the proper operation and handling of the system.

2-2

Changes

Changes to the technical document will be released as new editions or supplements. In general, this manual is subject to change without notice.

Reproduction

Reproduction, even in parts, only with written approval.

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Chapter 2: Important information

2.3

Notes

2.3.1

Significance of the warnings

Warning Advises the operator that failure to observe this information can result in personal injury. Warning Advises the operator that failure to observe this information can cause damage to the equipment.

2.3.2

Significance of the note

Note Information alerting the operator to the fact that failure to follow the steps as specified may result in the specific function not being executed correctly, not being executed at all, or not producing the desired effect.

2.3.3

Significance of the tip

Tip Information providing useful tips for easy handling.

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Chapter 2: Important information

2.4

Brief description Design BASIC / STANDARD

Components

The water pretreatment may consist of the following individual components – Feed water inlet unit (single components A-F) – Booster pump – Media filter (sand filter / Birm filter) – Particle filter (Big Blue) – Softener – Activated carbon filter If necessary, additional modules can be connected upstream or downstream for improved quality. The water pretreatment components must be installed in a dry, dustfree room. The responsible organization must ensure that the design specifications of the pretreatment components comply with the requirements of the other components used. This applies especially to the following system components such as reverse osmosis system, permeate ring main and dialysis systems. As the complete system consists of separate, individual systems, the responsible organization is responsible for the complete system.

2-4

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Chapter 2: Important information

2.4.1

Operator information Target group

The water pretreatment may only be installed, operated and used by individuals with the appropriate training, knowledge and experience. Assembly, extensions, adjustments, modifications or repairs may only be carried out by the manufacturer or persons authorized by him.

Duties of the responsible organization

The responsible organization assumes the following responsibilities: – Compliance with the national or local installation, operation, use and maintenance regulations – Compliance with the accident prevention regulations – Correct and safe condition of the water pretreatment. – Permanent availability of accompanying documents. The water pretreatment consists of components designed to improve the permeate conductivity and is extended with additional components to a complete water treatment system for use in a dialysis unit by the responsible organization. The water pretreatment must be installed in a dry room not reserved for medical use. The staff call should also be connected. The responsible organization must ensure that the technical adjustments of water pretreatment match the requirements of the other components and that they make up the complete system. This applies especially to the following system components such as: – Rooms with outlets and drains for the installation of the water pretreatment – Leakage protection systems – Sampling site in the soft water supply line – Sampling sites in the ring main system – Alert systems for malfunctions (alarms) – Operational organization The components of the water pretreatment must be easily accessible from all sides. The responsible organization must ensure that its operators have been trained. Operators of the water pretreatment, the reverse osmosis system and the dialysis systems must have received instructions on how to operate the system. The responsible organization should inform the local water supplier of the dialysis operation and insist on early provision of data regarding water composition, availability etc.. This measure does not relieve the responsible organization of its obligation to regularly check the feed water composition. Samples for microbial testing must therefore be collected from the system and from the individual parts of the system in accordance with the applicable regulations.

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Chapter 2: Important information

As the water supply system consists of a series of smaller systems, the responsible organization is responsible for the complete water supply system. Operator responsibility

When entering parameters, the following must be observed: – The parameters entered must be verified by the operator, i.e. the operator must check that the values entered are correct. If the verification reveals a deviation between the desired parameters and the parameters displayed, the setting must be corrected before activating the function. – The actual values displayed must be compared with the desired values specified.

Disclaimer of liability

Should the responsible organization wish to use other consumables and accessories than those listed in the accompanying documents, the responsibility to ensure the correct function of the device lies exclusively with the responsible organization. The applicable legal regulations must be complied with (e.g. in Germany the Medical Device Directive, MDD and the MPBetreibV = German regulation for the operation of medical products). The manufacturer does not assume any responsibility or liability for personal injury or other damage and excludes any warranty for damage to the components of the water pretreatment resulting from the use of non-approved or unsuitable consumables or accessories.

2.4.2

Guarantee / warranty Guarantee

The extent of the guarantee is stipulated in the respective purchase orders.

Warranty

The purchaser's warranty rights are governed by the applicable legal regulations. Proper function of the water pretreatment components is guaranteed for the period specified in the sale contract. Any use of the device which is not in accordance with its intended use will void any liability and warranty.

2.4.3

Technical documentation On request, descriptions and other documents are made available by the manufacturer. These are intended to support trained personnel of the responsible organization in servicing and repairing the device.

2-6

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Chapter 2: Important information

2.5

Warnings

2.5.1

Basic warnings

Warning The design of the water pretreatment components must comply with the requirements of the Fresenius Installation Guideline (IGL)

2.5.2

Electric hazards

,

Warning Danger to life caused by electrical voltage. Touching live parts will cause an electric shock. – Before opening electrical devices, disconnect the power plug. Actuating the ON/OFF switch stops operation of electrical devices, but does not disconnect the system from the supply voltage! Warning The national standards and regulations must be observed when connecting the system to the power supply system.

2.5.3

Chemical hazards

Warning Use of protective equipments Rubber gloves (acrylonnitril latex, cotton-lined) should be worn to avoid contact of chemicals or disinfectant with the skin. When working with acidic substances: Wear goggles! Observe the safety precautions of the concentrated substance used! In the event of contact with acid: Eye: Immediately flush with gently flowing water for 15 minutes. Skin: Use soap under flowing water for neutralization. Ingestion: Do not induce vomiting, but have the person affected drink plenty of still water. Seek medical advice.

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Chapter 2: Important information

Warning The system may only be disinfected after previous consultation with the manufacturer of the system or by personnel authorized by the manufacturer.

2.5.4

Biological hazards

Warning Risk of infection Observe the applicable local laws and regulations concerning handling of potentially infectious material.

2-8

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Chapter 2: Important information

2.6

Addresses Please address any inquiries to: Manufacturer

Fresenius Medical Care AG & Co. KGaA D-61346 Bad Homburg Germany Phone: + 49 (0)6172 609-0 www.fmc-ag.com

International service

Fresenius Medical Care Deutschland GmbH Service Support International Hafenstraße 9 D-97424 Schweinfurt Germany Phone: +49 (0)9721 678-333 (Hotline) Fax: +49 (0)9721 678-130

Local service

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Chapter 2: Important information

2-10

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Chapter 3: Component overview

3

Component overview

3.1

Components of the water pretreatment system The following pages show the two overviews of the BASIC and STANDARD water pretreatment system.

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3-2

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Soft water monitoring unit / AquaSOFT

Prefiltration – Rack with particle filter (optional)

A050 A100 A150 A300 A400

Activated carbon filter

E080 E150 E225-T E300 E400

Birm filter B140 B200 B300 B400

Booster pump

Particle filter Big Blue, 5 µm (20“)

Sand filter S140 S200 S300 S400

Media filter

Tubing

A Stop valve B Water meter (optional) C Backwashable prefilter 105 µm D Solenoid valve E Pipe disconnector F Pressure reducer

Feed water inlet unit

Feed water tank

3.1.1

Softener

Particle filter Big Blue, 5 µm (20“)

Chapter 3: Component overview

Water pretreatment component overview / STANDARD

1/03.11

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Soft water monitoring unit / AquaSOFT

Prefiltration – Rack with particle filter (optional)

A050 A100 A150 A300 A400

Activated carbon filter

E080 E150 E225-T E300 E400

Sand filter S140 S200 S300 S400

Birm filter B140 B200 B300 B400

Media filter

A Stop valve B Water meter (optional) C Backwashable prefilter 105 µm D Solenoid valve E Pipe disconnector F Pressure reducer

Feed water inlet unit

Feed water tank

Booster pump

Tubing

3.1.2

Softener

Particle filter Big Blue, 5 µm (20“)

Chapter 3: Component overview

Water pretreatment component overview / BASIC

3-3

Chapter 3: Component overview

3-4

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Chapter 4: Feed water inlet unit

4

Feed water inlet unit

4.1

Component overview – wall-mounted prefiltration unit

Part number:

Complete assembly – description

F00002261

BASIC Feed water inlet unit 1 1/4" (Inline operation)

F00001403

BASIC Feed water inlet unit 1" (Tank operation)

A

B

C

D

A

INLINE OPERATION

POS

Description

A

Stop valve

B

Backwashable prefilter (105 µm)

C

Solenoid valve

B

C

TANK OPERATION

Note: An additional leakage detector (6328611), which switches the solenoid valve, must be implemented. D

Pipe disconnector (Inline operation)

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Chapter 4: Feed water inlet unit

4.1.1

Prefiltration unit 1‘‘, 1 1/4‘‘, 1 1/2‘‘

Part number:

Complete assembly – description

F00001116

Prefiltration unit complete 1"

F00001117

Prefiltration unit complete 1 1/4“

F00001118

Prefiltration unit complete 1 1/2“

B

C

D

G

H

A

E

F

I

POS

Description

A

Stop valve

B

Backwashable prefilter

C

Solenoid valve (24 V)

D

Pipe disconnector

E

Particle filter (Big Blue) (5 µm); 20“

F

Drain kit

G

Duplex softener (option)

H

Electronics unit

I

Leakage sensor

4-2

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Chapter 4: Feed water inlet unit

4.2

Installation

4.2.1

Installation / start-up requirements



General information

Note Start-up of the system must be performed by a trained technician. The wiring must be adapted to fit the respective field of application. Note Prior to its start-up, check the system for damage caused during transport. If there are signs of damage to the electric components, do not turn the system on.

4.2.2

Data reporting

Note Reports for the items of the operational qualification listed below are available as master copies in chapter 12: – Start-up – Setting – Maintenance

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Chapter 4: Feed water inlet unit

4.3

Specifications

4.3.1

Specifications / data sheet

Rated output of RO system Feed water path Type, size

Tank operation

Inline operation

Rack operation

1“

1 1/4 “

1 1/2 “

Rated flow

1.5m³/h 25 L/min

2.9 m³/h 48 L/min

5.8 m³/h 97 L/min

Peak performance during softener regeneration

2.4 m³/h 40 L/min

4 m³/h 67 L/min

7.8 m³/h 130 L/min

12kg empty;

17kg empty;

22kg empty

~17 kg; operation

~21 kg; operation

~27 kg; operation

Weight ~42 kg

Weight ~46 kg

Weight ~52 kg

Kv

2.2 m³/h

2.5 m³/h

6.0 m³/h

Maximum pressure

8.0 bar

8.0 bar

6.8 bar

Ambient temperature

1–45 °C

1–45 °C

1–45 °C

Water temperature

1-36 °C

1-36 °C

1-36 °C

230 V 50 Hz

230 V 50 Hz

230 V 50 Hz

1700 x 1200 x 800

1700 x 1400 x 800

1700 x 1500 x 800

1 1/4 “ External thread

1 1/4 “ External thread

1 1/4 “ External thread

Weight Weight without rack

Operating weight approx.

Operating data

Voltage supply

Floor space Prefiltration rack (HxWxD in mm)

Connections Inlet and outlet

4-4

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Chapter 4: Feed water inlet unit

4.3.2

Operating conditions For information regarding the operating conditions refer to the latest edition of the Installation Guideline (IGL).

4.3.3

Configuration options Possible configurations: – Configuration with AquaSOFT (see chapter 10) – Automatic backwash function – Timer

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Chapter 4: Feed water inlet unit

4.4

Maintenance Note The information given below is summarized for all water pretreatment components in Chapter 14 (Appendix).: – Important information on maintenance procedures – Accessories and supplies – Test report - maintenance – Overview / maintenance intervals for water pretreatment components – Explanations for the test report

4-6

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Chapter 4: Feed water inlet unit

4.5

Functional description

4.5.1

Design of components

4.5.1.1

Water inlet unit

Water inlet unit Components: A) Stop valve B) Water meter (optional) C) Backwashable prefilter (105 µm) D) Solenoid valve E) Pipe disconnector F) Pressure reducer (optional) F) Drain



Standard configuration The standard configuration of a feed water inlet path consists of the stop valve, a backwashable prefilter, a solenoid valve, a pipe disconnector and a drain connector.

4.5.2

Component function

4.5.2.1

Stop valve The function of the stop valve is to stop the water supply for servicing to perform maintenance procedures. The stop valve is provided with a sampling port for the collection of feed water samples.

4.5.2.2

Water meter - optional An optional water meter can be installed to document the water consumption.

4.5.2.3

Backwashable prefilter 105 µm The backwashable prefilter is installed in the feed water path upstream of the solenoid valve to prevent contamination and therefore an early failure of the solenoid valve.

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Chapter 4: Feed water inlet unit

In its standard version, the backwashable prefilter has 105 µm filter inserts. As an option this prefilter can also be designed with a 50 µm filter insert. As the first filter in the complete water pretreatment system, this insert is usually exposed to a high concentration of particles. Regual backwashing of the filter during non-dialysis hours must therefore be ensured to prevent early pressure drops. This can either be done manually (by turning the rotary pin 180° clockwise) or with the automatic backwashing feature. The automatic backwashing feature is available as an option. It should always be used in combination with a timer to be able to define a fixed backwash time. 4.5.2.4

Solenoid valve Function

The feed water inlet solenoid valve is used to disconnect the water supply in case of a leakage. In case of rack installation it is activated by a single-station leakage detection or in case of wall-mounted installation by a leakage detector.

Usage as tank fill valve

In combination with a feed water tank, the feed water inlet solenoid valve is also used as a tank fill valve. In this case, the solenoid valve is controlled by a float switch which is supplied with the feed water tank.

Manual opening

If necessary, the solenoid valve can be opened manually. If the solenoid valve is manually bypassed, the room must never be left unattended. Otherwise the valve must be left in its original position.

Normal condition (original position)

Valve open (manually bypassed)

In case of a power failure push the lever in and turn it by 90°. In this position it is automatically locked and the valve is permanently open. Water supply is therefore still ensured even without power supply. Note Without power supply, leakage monitoring is not active. After dialysis hours, the valve should be closed again by unlocking to stop the water supply in case of leakage.

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Chapter 4: Feed water inlet unit

4.5.2.5

Pipe disconnector If the inlet pressure drops, the pipe disconnector ensures a disconnection from the system (DIN EN 1717) as requested by the Drinking Water Decree if there is a risk of back-contamination.

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Chapter 4: Feed water inlet unit

4.5.3

Prefiltration rack with particle filter (optional)

Prefiltration rack with particle filter (optional) Components: – Stop valve – Backwashable prefilter – Solenoid valve (24 V) – Pipe disconnector – Particle filter (Big Blue) (5 µm); 20“ – Drain kit – Duplex softener (option) – Electronics unit – Leakage sensor

4.5.4

4-10

Component description Stop valve

(see chapter 4.5.2.1 , page 4-7)

Backwashable prefilter

(see chapter 4.5.2.3 , page 4-7)

Solenoid valve

(see chapter 4.5.2.4 , page 4-8)

Pipe disconnector

(see chapter 4.5.2.5 , page 4-9)

Particle filter (Big Blue) 5 µm

see chapter 8 (particle filter)

Drain kit

The drain kit is used to direct the draining water to the drain in the building.

Duplex softener (option)

see chapter 9 (Softener)

Electronics unit

The electronics unit supplies the connected components with electrical voltage.

Leakage sensor

The leakage sensor detects (inadvertent) water leakage. In this case, the connected valve is closed. An audible alarm and a red LED indicator signal a leakage alarm.

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Chapter 4: Feed water inlet unit

4.6

Options

4.6.1

Prefiltration rack with particle filter (option)

4.6.2

Pressure reducer - optional An optional pressure reducer can be installed in the feed water path. Its function is to avoid pressure peaks and thus to limit the system load. A pressure reducer is recommended if the static pressure at the user points exceeds 5 bar. The installation of a pressure reducer is recommended in case of variations in pressure caused be pressure increases / domestic water supply system. As an option, a domestic water station can be used instead of a backwashable prefilter. It includes the backwashable prefilter and a pressure reducer unit.

4.6.3

Configuration options (feed water tank) If a feed water tank is installed, it will have the requested system disconnection. In this case the installation of a pipe disconnector is not required.

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Chapter 4: Feed water inlet unit

4-12

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Chapter 5: Booster pump

5

Booster pump

5.1

Booster pump assembly CRN5-8 component overview

Part number:

Complete assembly – description

F00001935

Booster pump assembly (vertical pumps CRN5-8)

C

B1

W2

D A

POS

Description

A

Connection to water supply (Possible on both sides. The connection which is not used must be provided with a cap nut)

B1

Pump 1 (vertical pump CRN5-8)

B2

Pump 2 (vertical pump CRN5-8)

C

Control unit

D

Pressurizer vessel

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Chapter 5: Booster pump

5.2

Installation

5.2.1

Installation / start-up requirements



General information

Note Start-up of the system must be performed by a trained technician. The wiring must be adapted to fit the respective field of application. Note Prior to its start-up, check the system for damage caused during transport. If there are signs of damage to the electric components, do not turn the system on.

5.2.2

Important start-up information

Booster pump assembly (CRN5-8)  The pumps must be ventilated prior to start-up of the switching unit.

5.2.2.1

Booster pump assembly connection  The suction line can be connected either on the right or on the outer left of the booster pump assembly. In case of tank operation it is recommended to connect two suction tubes in parallel to avoid pressure drops in the suction line.  The pressure port is located in the center and can be connected using a tubing or a pipe for a fixed connection. A high-pressure tubing is included in the accessories package of the system.  After connection to the water supply, both pumps must be ventilated by opening the vent screws.

5-2

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Chapter 5: Booster pump

5.2.2.2

Connection to the domestic water supply network



Positioning the pressure switch

Note If a pipe separator or a pressure reducer is installed on the outlet side of the booster pump, the pressure sensor must always be installed after these components. For the installation, remove the screw-type adapter in the outlet block and integrate it after the pipe disconnector. The pressure switch installed at the water inlet ensures protection against running dry. Upon delivery, the pressure switch is set to 1 bar. It is recommended to retain this setting. If the pressure in the water inlet drops below 1 bar, the booster pump assembly will be stopped. If this dynamic minimum pressure is not reached, it is recommended to use a feed water tank. State upon delivery: Dismounting the adapter  State upon delivery: When the system is supplied, the pressure sensor is installed with an adapter at the pump outlet, this adapter must be removed and must be installed after the pressure reducer and the pipe separator.  The pressure sensor is installed on the outlet side after the pressure reducer and the pipe separator.



Pressure switch installation position

Pressure switch installation position and connection (run-dry protection)  Pressure switch installation position (run-dry protection)

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Chapter 5: Booster pump

Pressure switch installation position and connection  Pressure switch installation position (after pipe separator and pressure reducer)



Booster pump assembly with pump switching

Pressure switch installation position and connection (run-dry protection)  Electrical connection of the pressure switch for the run-dry protection

Pressure switch installation position and connection  Electrical connection of the pressure sensor

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Chapter 5: Booster pump

Connection of the pressure switch Pressure switch connection  Connection 1: white  Connection 2: brown

Pressure sensor connection Pressure sensor connection  Connection 1: brown  Connection 2: white



Verification / setting of the pressure switch

Reference point on the scale  Locate the reference point.

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Chapter 5: Booster pump

Rotate the selector fully counter-clockwise.  The selector must first be rotated fully counter-clockwise.

Adjust the selector to the reference point.  Rotate the selector approx. ¼ of a turn clockwise until the figure "1" is above the reference point.

Adjust the selector to the reference point.  Adjust the scale reference point.  The pressure switch is now set to 1 bar. This means the operating pressure of the pump is 1 bar.  Due to the pressure switch's hysteresis, the switch-off pressure is slightly below 1 bar (approx. 0.5 bar).

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Chapter 5: Booster pump

5.2.2.3

Connection to a feed water tank

Note In case of tank operation, the tank must be provided with a float switch which will open a contact if the tank is empty. This contact is connected in the pump inlet instead of the pressure switch. Tank connection  The inlet of the booster pump assembly is directly connected to the outlet of the tank using the pump connection set no. 6319211.  The suction line can be connected either on the right or on the outer left of the booster pump assembly.  In case of tank operation it is recommended to connect two suction tubes in parallel to avoid pressure drops in the suction line.  The pressure port is located in the center and can be connected using a tubing or a pipe for a fixed connection. A high-pressure tubing with a length of x cm is included in the accessories package of the system.  The pressure sensor is connected directly to the pump outlet.  The inlet pressure switch on the water inlet side of the pump is not used during tank operation. In its place the float switch (see illustration) must be wired in. This must be done during installation.

Pressure switch installation position and connection (run-dry protection)  A float switch which is installed in the feed water tank ensures rundry protection.

 The brown and white conductor must be connected.

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Chapter 5: Booster pump

Pressure switch installation position and connection  Installation position of the pressure sensor on the pump outlet (state upon delivery)

 Electrical connection of the pressure sensor in the switching cabinet.

5-8

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Chapter 5: Booster pump

5.2.2.4

Power supply A 400 V; 3 N ~; 50 Hz; 16 A three-phase current connection is required to supply the pump switching unit with voltage.



Connection of a leakage detector The floating contact of a leakage detection system can be connected to the booster pressure assembly. The contact must be closed if there is no leakage and must open if a leakage occurs. It is recommended to use the insert of the leakage detecting system. It can be connected directly to the pump control (see illustration )

Connection option for a leakage detection system (jumper must be removed)  Remove the jumper and connect the line to the floating contacts of the leakage detector.

5.2.2.5

Overview of electrical connections

Note When the system is supplied, positions 1 to 6 are wired.  Positions 7 and 8 must be adjusted by the technician depending on the respective situation (feed water tank or direct operation).

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Chapter 5: Booster pump

7

8

1

2

3

4

POS

Connections

1

Pump 1

2

Pump 2

3

Power cable

4

Temperature switch 1

5

Temperature switch 2

6

Pressure sensor

7

Connection for run-dry protection (pressure switch or float switch)

8

Connection option for the floating contact (e.g. leakage detector)

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Chapter 5: Booster pump

5.2.2.6

Settings on the booster pump assembly (CRN5-8) Should the booster pump assembly not operate as desired when it is supplied, the setting of the pressure level and of the delay times can be checked and changed.



Pressure levels

Pressure type

Description

Pmin

Operating pressure for base load and peak load pump (0-10 bar):  Pmin is set to the pressure at which the pump is to start.

Pmax1

Cutoff pressure level for the peak load pump (difference to Pmin), (0-4 bar):  If this pressure is achieved at parallel operation, the peak load pump is turned off. Pmax1 should be set to a value between Pmin and Pmax2.

Pmax2

Cutoff pressure level for the base load pump (difference to Pmax1), (0-2 bar):  If this pressure is reached during operation of one pump, this pump is switched off. Pmax2 should be set to approx. 0.5 bar below the pump's nominal pressure. Caution: If a pressure reducer was installed downstream of the booster pump assembly, the pressure reducer should be set to 6 bar minimum as the pressure on the pressure sensor can otherwise never reach the cutoff pressure.

Note The settings of max1 and Pmax2 are difference values which add to the lower pressure set.

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Chapter 5: Booster pump



Calculation example Setting Pmin: 3 bar Setting Pmax1: 2 bar Setting Pmax2: 1 bar This means

Operating pressure level (Pmin) = 3 bar Cutoff pressure level for peak load pump (Pmax1) = 5 bar Cutoff pressure level for base load pump (Pmax2) = 6 bar



Delay times T = Over-run (0–2 min): Minimum operation time of the pump to prevent permanent start and stop of the pump. Default setting: 2 minutes. When set to "0 minutes", the minimum operation time is approx. 30 seconds. T = run-dry delay (0–2 min): time after which die pumps are turned off in case the pump runs dry. Default setting: 0 minutes. When set to "0 minutes", the delay time is approx. 10 seconds.



Motor protection Potentiometers P1 and P2 are set to the nominal current of the motor. Motor protection setting (nominal current of pump 1 and pump 2) Setting Pmax2: Cutoff pressure level for base load pump (difference to Pmax1) Setting Pmax1: Cutoff pressure for peak load pump (difference to Pmin) Setting Pmin: Operating pressure for base load and peak load pump

Minimum operation time setting Water alarm delay time setting

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Chapter 5: Booster pump

5.2.3

Data reporting

Note Documentation of the settings in the Settings report  As part of the Operational Qualification, the settings must be documented in the Settings reports upon start-up. Note Reports for the items of the operational qualification listed below are available as master copies in chapter 12: – Start-up – Setting – Maintenance

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Chapter 5: Booster pump

5.3

Specifications

5.3.1

Specifications / data sheet

Parameter

Function / specifications

Usage

Pressure increase

Component

Booster pump assembly

Type

CRN5-8

Connection

1 1/4", external thread

Sealing material

Shaft seal carbon silicide, o-ring EPDM

Installation position

Vertical

Operating current

2.5 kW / kVA

Power supply

380–400 V; 3N~ 50 Hz; 16A

Operating pressure, adjustable

1–6 bar (preset to x bar)

Switch-off pressure

1–6 bar (preset to x bar)

Pressure, minimum

2.2 bar (in case of tank operation)

Pressure, maximum

6.5 bar

Water temperature, minimum

1 °C

Water temperature, maximum

40 °C

Flow rate

5.7 m³/h at 3.8 bar (at a nominal pumping head of 37.8m)

Ambient temperature, max. 40°C

5.3.1.1

Performance characteristics

Parameter

Function / specifications

Electrical connection

380–400 V 3N~ 50 Hz

Power consumption

2.5 kW / kVA

Operating pressure

Adjustable 1–6 bar (preset to x bar)

Cutoff pressure

Adjustable 1–6 bar (preset to x bar)

Dimensions (width/ height/depth)

Width / height / depth 101 cm / 92 cm / 45 cm

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Chapter 5: Booster pump

5.3.1.2

Volumetric capacity - diagram

(two pumps active)

Pumping head

(one pump active)

Delivery volume

5.3.2

Operating conditions For information regarding the operating conditions refer to the latest edition of the Installation Guideline (IGL).

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Chapter 5: Booster pump

5.4

Maintenance Note The information given below is summarized for all water pretreatment components in Chapter 14 (Appendix): – Important information on maintenance procedures – Accessories and supplies – Test report – maintenance – Overview / maintenance intervals for water pretreatment components – Explanations for the test report

5-16

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Chapter 5: Booster pump

5.5

Error messages

5.5.1

Malfunctions, causes and correction

Setting the system to the Standby mode Components: A) Operating mode selector switch A B C

B) Operation / malfunction indicator (pump 1 and pump 2) C) Run-dry / leakage indicator D) Main power switch

D

Selection

Description

Green LED flashing.

The motor protection has operated. No automatic confirmation after correction of the problem. Possible causes: – Motor current too high. – The motor temperature is too high, possible defective pressure sensor causing permanent operation and overheating of the pump. Confirmation:  Set the operating mode selector switch to "OFF" and then back to "ON" again. If necessary, allow the motor to cool down first.

Red LED illuminated

Fresenius Medical Care

System was turned off due to lack of water or leakage. Automatic confirmation after correction of the problem.

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Chapter 5: Booster pump

5.6

Functional description

5.6.1

Design of components

Booster pump assembly (CRN5-8) Components: C

B1

B2

A) Feed water connection B1) Pump 1 (vertical pump CRN5-8) B2) Pump 2 (vertical pump CRN5-8) C) Control unit

A

5.6.2

D

D) Pressurizer vessel

Component description The booster pump assembly (CRN5-8) is an assembly which is ready for connection in accordance with the requirements for the minimum flow pressure with normal centrifugal suction pumps. The booster pump assembly in conjunction with the two vertical pumps provides increased operational safety of a water treatment system from Fresenius Medical Care. The booster pump assembly is used for the alternating control of two booster pumps. Automatic switching ensures uniform distribution of stress on both connected pumps and prevents damage to the pump caused by prolonged idle times when it is not in use. To increase the efficiency, the second pump will be turned on additionally in peak situations. The booster pump assembly is intended for the pressure increase in the feed water section of the water pretreatment system. It can be used both for increasing the pressure downstream of a feed water tank and for direct connection to the feed water line.

5.6.2.1

Control unit The electronic control of the booster pump assembly controls and monitors the two connected pumps.

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Chapter 5: Booster pump

5.6.2.2

Base load and peak load pump The control differentiates between a base load and peak load pump. If water requirements are low, only the base load pump will deliver, if water requirements rise the peak load pump will also be switched on. This concept has the advantage that the pumps are always operated in their optimum performance range. This contributes to a high efficiency of the complete system. The base load and the peak load pump will be activated alternating after each restart. This ensures uniform wear of both pumps.

5.6.2.3

Alternating pressure situations If the system is not in operation and the pressure in the system drops below the start-up pressure level (Pmin), the base load pump will start. If the pressure drops again to the start-up pressure (Pmin) caused by an increasing water demand, the peak load pump will also be started. If, with decreasing water demand, the pressure in the system rises above the pressure level (Pmax 1), the peak load pump will be stopped. If water consumption stops, the pressure will rise above the pressure level (Pmax 2) and the basic load pump will be stopped.

5.6.2.4

Run-dry protection The adjustable pressure switch at the booster pump assembly inlet protects the system against running dry and ensures a minimum pressure of 1 bar at the booster pump inlet. If the pressure at the inlet drops below 1 bar, first the peak load pump will stop. If the pressure at the inlet remains below 1 bar after this pump stop, the base load pump will also be stopped.

5.6.2.5

Tank operation When operated with a tank, a float switch will be connected instead of the pressure to ensure protection against running dry.

5.6.2.6

Automatic turnoff The water temperature is also monitored; if the temperature exceeds 60 °C, e.g. by a defect of the control unit and a constantly running pump without water consumption, the respective pump will be stopped.

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Chapter 5: Booster pump

5.6.3

Functional description

5.6.3.1

Setting the system to the Standby mode

Setting the system to the Standby mode Components: A) Operating mode selector switch A B C D

5.6.3.2

B) Operation / malfunction indicator (pump 1 and pump 2) C) Run-dry/leakage indicator D) Main power switch  After turning on the main power switch and after selection of automatic 1 + 2 (position as in illustration), the operating mode switch is used to set the system to the Standby mode.

Selector switch functions

Functions of the selector switch Components: D

E

F

C

A) Test mode pump 2 B) Off A) Test mode pump 1

B

D) Automatic mode pump 1 E) Automatic mode pumps 1 + 2 D) Automatic mode pump 2

A

Selection

Description

Automatic mode pump 1

Only pump 1 runs in the automatic mode (e.g. if pump 2 is defective).

Automatic mode pumps 1+2

Both pumps run in the automatic mode. Depending on the consumption volume the pumps are started and stopped (default setting). The green LED of the active pump is constantly illuminated to indicate operation.

Automatic mode pump 2

Only pump 2 runs in the automatic mode (e.g. if pump 1 is defective).

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Chapter 5: Booster pump

Selection

Description

Test mode pump 1

Pump 1 runs irrespective of the prevailing pressures and safety functions. The test mode will be automatically stopped after approx. 1.5 minutes.

Test mode pump 2

Pump 2 runs irrespective of the prevailing pressures and safety functions. The test mode will be automatically stopped after approx. 1.5 minutes.

Off

Both pumps are off.

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Chapter 5: Booster pump

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Chapter 6: Pumps

6

Pumps

6.1

Pump CM5-5 – component overview

Part number:

Complete assembly – description

F00002253

Booster pump (CM5-5)

631 248 1

Pressure Manager PM1–22 (2.2 bar) for CM5-5

D

C

POS

Description

A

Connection to water supply

B

Stop valve at feed water inlet (optional)

C

Booster pump CM5-5

D

Power connection - not illustrated

E

Pressure Manager PM1 (optional)

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B

A

6-1

Chapter 6: Pumps

6.2

Installation

6.2.1

Installation / start-up requirements



General information

Note Start-up of the system must be performed by a trained technician. The wiring must be adapted to fit the respective field of application. Note Prior to its start-up, check the system for damage caused during transport. If there are signs of damage to the electric components, do not turn the system on.

6.2.2

Important start-up information

Pump CM5-5  The pumps must be ventilated prior to start-up of the switching unit.

6.2.3

Data reporting

Note Reports for the items of the operational qualification listed below are available as master copies in chapter 12: – Start-up – Setting – Maintenance

6-2

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Chapter 6: Pumps

6.3

Specifications

6.3.1

Specifications / data sheet (CM5-5)

Parameter

Function / specifications

Component / use

Booster pump / pressure increase

Type

CM5-5

Connection

– Rp 1 ¼” suction side – Rp 1” delivery side

Material

Stainless steel

Sealing material

FKM

Installation position

Horizontal

Other components

– Pressure control – Leakage sensor – Check valve

Operating current

0.9 kW

Power supply

230 V 16 A grounded mains plug

Pressure, minimum

1 bar

Pressure, maximum

6 bar

Water temperature, minimum

0 °C

Water temperature, maximum

40 °C

Flow rate

6 m³ at 3 bar

Ambient temperature, max. 55°C

6.3.2

Operating conditions For information regarding the operating conditions refer to the latest edition of the Installation Guideline (IGL).

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Chapter 6: Pumps

6.4

Maintenance Note The information given below is summarized for all water pretreatment components in Chapter 14 (Appendix).: – Important information on maintenance procedures – Accessories and supplies – Test report - maintenance – Overview / maintenance intervals for water pretreatment components – Explanations for the test report

6-4

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Chapter 6: Pumps

6.5

Error messages on pumps

6.5.1

Visual indication on CM5-5

6.5.1.1

Alarm messages overview

Pressure-Manager PM1-22 (for CM5-5) 1. Power on / The green indicator lights as soon as the power supply is connected. 2. Pump on / The green indicator is On when the pump is running. 3. Alarm / The red indicator is On or flashing when the pump was turned off due to a failure. See overview. 4. [Reset] / This key is used to reset error messages and to activate /deactivate the "switching operation" function.

Indicator

Alarm

Possible cause

The Alarm indicator is On.

Running dry

The pump was running without water.

The Alarm indicator is flashing.

Switching operation exceeded

The pump has exceeded the admissible number of times for switching on and off. Note: Only indicated of the if the "switching operation" function is activated.

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Chapter 6: Pumps

6.5.2

Pump malfunctions overview

Indication

Possible cause

Action required

The green Power on indicator is not lit.

The fuses of the electrical installation have blown / have tripped.

Replace the fuses / switch on again. If the new fuses blow or trip again, check the electrical connection.

The ground fault interrupter or the voltagecontrolled circuit breaker has tripped.

Switch the circuit breaker on again.

No power supply.

Have the electrical installation checked by an electronics specialist.

The pressure control unit is defective.

Repair or replace the pressure control unit.

The power supply to the pump after the pressure control unit is interrupted.

Check the plug and the cable connections. Check if the circuit breaker installed in the pump has tripped.

The motor protection switch has tripped due to overload.

Check if the motor / the pump is blocked.

The pump is defective.

Repair or replace the pump.

The pressure control unit is defective.

Repair or replace the pressure control unit.

The pump fails to start when water is removed. The Pump on indicator is Off.

Level difference between the pressure control unit and the user point to high.

Adjust the installation or select a pressure control unit with a higher operating pressure.

The pressure control unit is defective.

Repair or replace the pressure control unit.

Frequent switching on and off.

Leakage in the tubing.

Check and repair the tubing.

Check valve leaking.

Clean or replace the check valve.

A valve next to the outlet nozzle of PM 1 has been closed..

Open the valve.

The pump is not able to deliver the required pumping height.

Replace the pump.

The pressure control unit installed has an operating pressure that is too high.

Select a pressure control unit with a lower operating pressure.

The pressure control unit is defective.

Repair or replace the pressure control unit.

The check valve is blocked in "open" position.

Clean or replace the check valve.

The green Power on indicator is On, but the pump fails to start.

The pump fails to switch off.

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Chapter 6: Pumps

6.6

Functional description

6.6.1

Design of components

Pump (CM5-5) Components: – Water supply with stop valve at feed water inlet (optional) – Pump – Power supply – Pressure control

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Chapter 6: Pumps

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Chapter 7: Media filters (sand filters / Birm filters)

7

Media filters (sand filters / Birm filters)

7.1

Component overview – sand filters S140, S200, S300, S400

Part number:

Complete assembly – description

F00001842

Sand filter S140

F00001843

Sand filter S200

F00001328

Sand filter S300

F00001329

Sand filter S400

A B C

D E F

G H

POS

Description

A

Outlet block with sampling port and tube connection

B

Control head

C

Upper sieve

D

Riser tube

E

Filter bed

F

Tank

G

Gravel bed

H

Lower sieve

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Chapter 7: Media filters (sand filters / Birm filters)

7.2

Component overview – Birm filters B140, B200, B300, B400

Part number:

Complete assembly – description

F00002451

Birm filter B140

F00002452

Birm filter B200

F00002453

Birm filter B300

F00002454

Birm filter B400

A B C

D E F

G H

POS

Description

A

Outlet block with sampling port and tube connection

B

Control head

C

Upper sieve

D

Riser tube

E

Filter bed

F

Tank

G

Gravel bed

H

Lower sieve

7-2

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Chapter 7: Media filters (sand filters / Birm filters)

7.3

Installation of the media filters (sand / Birm)

7.3.1

Installation / start-up requirements



General information

Note Start-up of the system must be performed by a trained technician. The wiring must be adapted to fit the respective field of application. Note Prior to its start-up, check the system for damage caused during transport. If there are signs of damage to the electric components, do not turn the system on.

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Chapter 7: Media filters (sand filters / Birm filters)

7.3.2

Important start-up information

Sand filters S140, S200, S300, S400 Birm filters B140, B200, B300, B400 Note  The sand filters / Birm filters must be ventilated upon start-up.  The filter must be filled with the filter material supplied prior to startup. After filling, the filter vessels should be filled completely with water using the immersion tube. This will facilitate ventilation at startup.

7.3.2.1

Start-up of the sand filters / Birm filters  When the filter has been set up and the control has been programmed the system must be carefully ventilated and rinsed. Before this is done, it must be checked that all lines and equipment upstream of the filter have been thoroughly rinsed. To rinse the filter, the outlet adapter of the filter must be removed and discarded to the drain. The water inlet valve must be opened slowly and only partly. Watch the removal of air until water exits.  When water exists, the tank is thoroughly ventilated during the backwash phase C1 by the start of a regeneration.  When all air has been removed, the remaining phases are all skipped after a short rinse by briefly and simultaneously pressing  + . When ventilation is complete, the water inlet valve can be fully opened.  Rinsing should be followed by a manual regeneration to check the drain. In addition, the dynamic pressure of the water supply should be briefly checked.  When the tank has been rinsed sufficiently, i.e. it has been rinsed with 5 times the bed volume, the filter outlet can be re-mounted. The complete water pretreatment system must now be briefly rinsed and can then be connected to the reverse osmosis system.  The programmed values must be documented in the start-up report.

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Chapter 7: Media filters (sand filters / Birm filters)

7.3.2.2

Valve heads and drain restrictor The drains for all filters must be designed as free drains using the lines supplied and ensuring that the distances are as short as possible. The drains are restricted to reduce the flows in the outlet.

S140/ S200

S300 / S400

Sieve for servo flows Drain restrictor Drain

Drain

Sand filter TYPE

S140 / B140

S200 / B200

S300 / B300

S400 / B400

Drain rate

~45 L/min ~2000 L/h

~45 L/min ~2000 L/h

~90 L/min ~5400 L/h

~90 L/min ~5400 L/h

Sand filter and Birm filter restrictor (D)

none

none

10 mm

10 mm

Restrictor for fine-grain ceramic filter medium* (D)

6 mm

6 mm

6.5 mm

6.5 mm

Sand filter design

* applies to fine-grain ceramic filter material Additional restrictor

A reduced drain restrictor is only required for fine-grain ceramic filter media.  On the S140/200 a small additional restrictor with 6 mm is used in the drain connection .  When using the S400, a 6.5mm restrictor must be installed.

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Chapter 7: Media filters (sand filters / Birm filters)

Servo drain line

 The large valves of the S300/400 must be provided with a servo drain line in addition to the drain. The required line is included.  For the rinse time settings, refer to the master copies in the appendix. These are determined specified values and should be checked on site (see Operating phases (Service, Backwash, Fast rinse), page 7-6).  Especially for colloid-forming particles and if no upper sieve is installed, the backwash-time must be set so as to ensure that the draining water is largely clear or has the same turbidity as in the water inlet.



Operating phases (Service, Backwash, Fast rinse) The control initiates a time-controlled backwash of the filters at defined intervals. During the first regeneration phase, the backwash phase, the filter bed media is lifted and separated, and rinsed. This phase is intended to backwash all collected contaminants to the drain.  During the following phase, the Fast rinse, the filter bed settles again and is pre-rinsed to reduce the start-up phase of the filter in service.  The backwash phase generally lasts 5 minutes, but should be extended depending on the quality of the feed water and the condition of the drain water on site, until an acceptable drain water quality is achieved. Note The rinse time should be selected so as to rinse for at least 2-3 tank volumes. The operation cycles of the filter are therefore divided into three phases:

7-6

Betrieb

Backwash

Schnelles Spülen

Service

Backwash

Fast Rinse

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Chapter 7: Media filters (sand filters / Birm filters)

For the rinse time settings, refer to the master copies in the appendix.

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Chapter 7: Media filters (sand filters / Birm filters)



Backwash times The backwash must be timed to occur outside the operation time of the reverse osmosis system. The softener may also not be regenerating. It must also be ensured that the AquaA does not supply or rinse while the backwash is in progress, but that a regeneration of the softener, which may have been initiated by rinsing of the AquaA, can be completed.  2.5 hours before the backwash of the sand filter, an operation of 10 minutes in the Supply mode using the auto-start and auto-stop function, and a rinse interval phase, which lasts at least 4 hours, must therefore be programmed on the AquaA.  Alternatively, the programmed start-stop times and the rinse interval phase can be used for the calculation, so that the last rinse phase occurs approx. 2.5 hours before the backwash of the sand filter:

4 hours rinse interval

AquaA 2.5 hours interval

Softener Sand filter

max. 110 min regeneration Activated

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Chapter 7: Media filters (sand filters / Birm filters)



Configuration of the free flow for drains (e.g. rack) S140/ S200

S300 / S400

7.3.2.3

Valves in the control head The valves in the S140 / S200 are switched directly and can be opened manually for rinsing in case of servicing. In the filter S400 with large valve, the control activates the motor's camshaft which switches the control valve for the actual poppet valves.

S140/ S200

Drain

S300 / S400

Drain 1 Rinse 2

Outlet

Drain 1 Inlet 4

Inlet 4 and 5

inlet

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Chapter 7: Media filters (sand filters / Birm filters)

7.3.2.4

Control unit design On the large valves of the S300/400 and B300 / 400, the housing unit of the control must be secured on the valve.  This is done by removing the protective cover of the camshaft, by pushing the spring lever on the end of the shaft outwards and pulling the shaft a little back so that it is aligned on the front:

 Then remove the housing unit from its box and push it fully onto the rear lugs.

 Then slide the shaft back to the front. This may only be done with the arrow marks being on the top. Refit the protective cover and reconnect the 12 V AC; 150 mA power supply unit to the control unit.

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Chapter 7: Media filters (sand filters / Birm filters)

7.3.3

Programming the control for sand filters / Birm filters

7.3.3.1

Control / display Current display

In the picture shown it is Sunday and the filter is currently regenerating.

During operation, time and day are displayed. The day is indicated by the triangle which moves from the left to the right. A bar will be displayed below the date indicating the days during which a regeneration will take place. In Europe the first day of the week is generally the Sunday. If a regeneration is in progress, the regeneration symbol will be displayed. 7.3.3.2

Control / control elements

Display

manual regeneration Reg.

Down  Save Set 

7.3.3.3

Up 

Control / programming At the start the control must be set to the correct system configuration. When inserting the control, the following screens may be displayed:

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Chapter 7: Media filters (sand filters / Birm filters)



Fig. 1 Example

If 255 A is flashing, the correct system configuration can be selected directly with the  arrow key.  E.g. for S300 / 400 sand filters, 293 F must be selected.  If the correct configuration is flashing, it must be confirmed with Set .

Fig. 1

Filter valve configuration Setting for the following filter valves:



263 F

S140 / S200 / A050 / A100 / A150

293 F

S300 / S400 / A300 / A400

Fig. 2

Fig. 2

The control has already filed a configuration and is in progress of aligning the shaft.  The system configuration must be entered again with a Reset (see level 4).

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Chapter 7: Media filters (sand filters / Birm filters)



Fig. 3

Fig. 3

The display shows only dashes. In this case, there is also a stored configuration, and the control prompts you to enter the current time and day. This setting is lost in case of a prolonged power loss.  Here it is also recommended to enter the system configuration again with a Reset (see level 4).



Level 1 Level 1 can only be accessed with a new control after turning power on or with a Reset (see level 4) for entering basic data.  The arrow keys  or  are used to scroll, Set  is used to release the value for changing it, the arrow keys are used to change the value, and Set  is used to save the value. LEVEL 1

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Select valve 293 (S300/400) or 263 (S140/200) and configuration.

–

Select F for filter mode.

P1

Current time

P2

Current day, identified by the arrow on the upper edge of the display.

P3

Regeneration time

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Chapter 7: Media filters (sand filters / Birm filters)

LEVEL 1



P4

Regeneration days 0.5–99 = interval, days between regenerations, selection of 0 will activate a 7-days timer:

P5

Rinse days can be activated with [  ] and [  ] or [  ]; if P4 = 0 (Europe: 1 = Sunday)

P6

Backwash time in minutes

P7 and P8

not used

Level 2 Level 2 is also used to define basic parameters.  This level is accessed by simultaneously pressing the key Up and Down keys + for 5 seconds. This can only be done from the normal operation display. (Therefore if Error 3 or Error 4 is displayed and the system configuration has not yet been defined or verified,  immediately go to level 4 and make a reset.) The arrow keys  or  are used to scroll, Set  is used to release the value for changing it, the arrow keys are used to change the value, and Set  is used to save the value. LEVEL 2

7-14

P9

Must be set to 1 for the selection of metric units.

P10

Selection of the time display, must be set to 1 for 0–24 hrs.

P11

Maintenance interval in months – recommended 0

P12

Time delay in seconds for remote regeneration – default 60

P13– P19

not used

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Chapter 7: Media filters (sand filters / Birm filters)



Level 3 - Operating phases/times Level 3 is used to display or define the times of the operating phases.  This level is accessed by simultaneously pressing the Set and Down keys + for 5 seconds. This can only be done from the normal operation display, not during a regeneration. LEVEL 3



C1

Backwash in minutes – can be changed

C2–C4

not used

C5

Fast rinse in min (can be changed)

C6–C8

not used

Level 4 – history Level 4 is used to see the history.  (Possibility in H0 for a reset with the Set key  for 5 seconds..  This level is accessed by simultaneously pressing the Set and Up keys  + for 5 seconds. (This can even be done during a regeneration). Example LEVEL 4



H0: F

Filter display (reset by pressing the Set key  for 5 seconds.)

H1: 0

(d) days since last regeneration

H2–– H16

0 not used

H17: 4

(month) months since service

H18 and H19

0 not used

Starting a regeneration When pressing the Reg key, the Reg. symbol will be flashing. This indicates that a delayed regeneration is due which would start at the programmed time P3.

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Chapter 7: Media filters (sand filters / Birm filters)

If the Reg. key is pressed for 5 seconds, the Reg. symbol will be displayed permanently and a regeneration will be started immediately.  Pressing the Set and Up keys  + briefly and simultaneously, will quickly skip a phase. This will set the remaining phase time, which is displayed by briefly pressing the Set key , to 0.  A regeneration which has started can be skipped completely by pressing the Set and Up keys  + for 5 seconds.

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7.3.3.4

Programming table for S140 / S200 or B140 / B200 using the control Logix 762



Level 1 Return to default screen: From each menu after 30 seconds idle phase. Operation screen: Indication of time and current day

Level 1 –

263

Valve and configuration

–

F

Filter

P1

E.g.: 9:30

Current time

P2

 upper edge

Current day, days 1–7 (Europe: 1 = Sunday)

P3

2:00

Backwash time

P4

0

Regeneration days 0.5–99 interval, 0–7 days timer

P5

Rinse days

Rinse days can be activated with  and  or  if P4=0

P6

6 / 8 (Birm 20)

Backwash time in minutes (pure Birm filter, minimum 20 min)

P7

–

Capacity in m3

P8

–



Level 2  and  for 5 seconds. Blocking a value with the Reg. key

LEVEL 2 P9

1

Selection for metric units

P10

1

Selection of time display 0–24 h

P11

0

Maintenance interval in months

P12

60 seconds

Time delay for remote regeneration

P13–19

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Chapter 7: Media filters (sand filters / Birm filters)



Rinse days in P5

Regeneration

1

2

Change

n

...

Yes / No

/

...

Continue

/



3

4

5

6

7

Level 3 +  for 5 seconds. Time in minutes: S300 / S400

Manual start of backwash Time-delayed regeneration

Short regeneration

Immediate regeneration

Regeneration after 5 seconds

Cancel regeneration

+  for 5 seconds

Skip phase

+  briefly During a regeneration, always the remaining time of the complete regeneration will be displayed. Remaining time of the phase displayed with 

LEVEL 3 C1

mod

Backwash 1

S140 / B140 = 6 min / 20 min S200 / B200 = 8 min / 20 min

C2

–

–

–

C3

–

–

–

C4

–

–

–

C5

mod

S140 / B140 = 3 min

Fast Rinse 1

S200 / B200 = 4 min C6/C

–

–

–

C8

–

–

–

Σ

S140 / B140 = 9 min S200 / B200 = 12 min

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Chapter 7: Media filters (sand filters / Birm filters)



Level 4 and  for 5 seconds In H0 : for 5 seconds, reset for control - then Reg. for synchronization.

LEVEL 4 H0

F

Filter display

H1

Days since last regeneration

H6

Total consumption since reset in 1000 000 m3

H17

Months in operation

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Chapter 7: Media filters (sand filters / Birm filters)

7.3.3.5

Programming table for S140 / S200 or B140 / B200 using the control Logix 762



Level 1 Return to default screen: From each menu after 30 seconds idle phase. Operation screen: Indication of time and current day

LEVEL 1 –

293

Valve and configuration

–

F

Filter

P1

e.g.: 9:30

Current time

P2

 upper edge

Current day, arrow 1–7 (Europe: 1=Sunday)

P3

2:00

Backwash time

P4

0

Regeneration days 0.5– 99 interval, 0–7 days timer

P5

Rinse days

Rinse days can be activated with  and  or  if P4=0

P6

7 (Birm 20)

Backwash time in minutes (pure Birm filter minimum 20 min)

P7

–

Capacity in m3

P8

–



Level 2  and  for 5 seconds. Blocking a value with the Reg. key

LEVEL 2 P9

1

Selection for metric units

P10

1

Selection of time display 0–24 h

P11

0

Maintenance interval in months

P12

60 seconds

Time delay for remote regeneration

P13–19

7-20

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

Rinse days in P5

Regeneration

1

2

Change

n

...

Yes / No

/

...

Continue

/



3

4

5

6

7

Level 3 and  for 5 seconds Time in minutes: S300 / S400

Manual start of backwash Time-delayed regeneration

Short regeneration

Immediate regeneration

Regeneration 5 seconds

Cancel regeneration

and  for 5 seconds

Skip phase

 and  briefly During a regeneration, always the remaining time of the complete regeneration will be displayed. Remaining time of the phase displayed with 

LEVEL 3 C1

mod

S300 / B300 = 7 min / 20 min

Backwash 1

S400 / B400 = 9 min / 20 min C2

–

–

C3

–

–

C4

–

–

C5

mod

S300 / B300 = 4 min.

Fast Rinse 1

S400 / B400 = 4 min C6/C

–

C8

–

Σ

S300 / B300 = 11 min. S400 / B400 = 13 min

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Chapter 7: Media filters (sand filters / Birm filters)



Level 4 and  for 5 seconds In H0 : 5 seconds, reset for control - then Regeneration for synchronization.

LEVEL 4 H0

F

Filter display

H1

Days since last regeneration

H6

Total consumption since reset in 1000 000 m3

H17

Months in operation

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Chapter 7: Media filters (sand filters / Birm filters)

7.3.4

Data reporting

Note Documentation of the settings in the Settings report As part of the Operational Qualification, the settings must be documented in the Settings reports upon start-up. Note Reports for the items of the operational qualification listed below are available as master copies in chapter 12: – Start-up – Setting – Maintenance

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Chapter 7: Media filters (sand filters / Birm filters)

7.3.5

Use of Birm for improved water quality

7.3.5.1

Removal of iron using "Birm" as filter media in the sand filter Alternatively iron and manganese can be removed with Birm. The exact amount of filter media will be determined and specified by the project planning team. Note When using alternative filter media, different drain restrictors are used. All other settings are made as specified in the settings table.

7.3.5.2

Alarm limits for water substances

Substance

Alarm limits / range

Iron content

< 4 mg/l

Manganese content

< 0.5 mg/l

Free chlorine

< 0.5 mg/l

pH range / iron removal

6.8-8.0

Iron and manganese removal

8.0-8.5

Manganese removal

8.0-9.0

If iron and manganese are not removed in the softener but in the Birm filter, the following applies: Note – Until the backwash 1.7 mg iron per liter of Birm can be removed from 1 m³ water. – If the water also contains manganese, this value is reduced to 1.2 mg per 1 m³. – Based on this information the backwash interval must be calculated.

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Chapter 7: Media filters (sand filters / Birm filters)

7.3.5.3

Sand filter / Birm filter selection table

Reverse osmosis system rated output

SAND FILTER / BIRM FILTER TYPE S140 / B140

S200 / B200

S300 / B300

S400 / B400

250 500 750 1000 1250 1500 1750 2000 2250 3000 4000 * at a yield of 70 %

Note In principle, it may be said that no additional sand filter must be installed when using a Birm filter since the Birm filter covers the sand filter's function due to its physical characteristics. Note For information regarding sand and Birm layers, backwash times and space requirements, refer to chapter Specifications / Birm filter data sheet.

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Chapter 7: Media filters (sand filters / Birm filters)

7.3.6

Birm filter settings

Note A reduced drain restrictor is only required for ceramic filter media. – For Birm, the backwash time is increased to at least 20 min. – The water's oxygen content must be at least 15 % of the iron content. – All other settings are made as specified in the sand filter settings table. 7.3.6.1

Weekly / semi-weekly backwash



For 80 operating hours - weekly backwash: For a weekly backwash, the following max. contents apply (allocation RO system dimensions to Birm filter): 80 h

B140

Rated output*

B200

B300

B400

max. mg/l Fe (max. mg/l Fe + Mn)

250

4 (3)

500

2.1 (1.5)

750

1.4 (1)

1000

1.1 (0.8)

1250

0.8 (0.6)

1.4 (1)

1500

1.2 (0.8)

1750

1 (0.7)

2000

0.9 (0.6)

2250

0.8 (0.6)

3000

0.8 (0.6) 0.6 (0.4)

4000

0.5 (0.4)

* at 70 % yield and 80 operating hours a week (corresponding to 15 dialysis shifts of 5 h each + rinsing approx. 5 h)

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

For 50 operating hours - approx. semi-weekly backwash: For a semi-weekly backwash the following max. contents apply (allocation RO system size to Birm filter): 50 h

B140

B200

Rated output*

B300

B400

max. mg/l Fe (max. mg/l Fe + Mn)

250

4 (4.5)

500

3.4 (2.4)

750

2.2 (1.6)

1000

1.7 (1.2)

1250

1.3 (1)

2.3 (1.6)

1500

1.9 (1.3)

1750

1.6 (1.2)

2000

1.4 (1)

2250

1.3 (0.9)

3000

0.9 (0.7)

4000

0.8 (0.6)

* at 70 % yield and 50 operating hours between the backwashes (for both tables the following applies: Calculations with 20 % loss for 3 years of operation).

Note Depending on the actual operating hours, the actual utilization (HD consumption) and substances, the backwash interval must be adjusted proportionally.

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Chapter 7: Media filters (sand filters / Birm filters)

7.3.7

Operating conditions For information regarding the operating conditions refer to the latest edition of the Installation Guideline (IGL).

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Chapter 7: Media filters (sand filters / Birm filters)

7.4

Specifications

7.4.1

Specifications / sand filter data sheet

Sand filter TYPE

S140

S200

S300

S400

Sand filter design Support gravel layer Support layer per tank

25 kg 1 bag

25 kg 1 bag

25 kg 1 bag

25 kg 1 bag

Sand bed per tank

140 liters 250 kg 10 bag

203 liters 325 kg 13 bag

203 liters 325 kg 13 bag

250 liters 400 kg 16 bag

Filter tank size

170 liters 16 x 65“ Ø 41 x 162 cm

250 liters 18 x 65“ Ø 47 x 165 cm

250 liters 18 x 65“ Ø 47 x 165 cm

310 liters 21 x 60“ Ø 56 x 172 cm

Freeboard +5 cm

45 cm

41 cm

41 cm

41 cm

Weight without water

300 kg

390 kg

400 kg

490 kg

Operating weight approx.

430 kg

550 kg

560 kg

690 kg

Riser tube Ø Distance above upper edge of tank

Ø 28 20–25 mm

Ø 28 20–25 mm

Ø 48.3 0-5 mm

Ø 48.3 0-5 mm

Backwash Rinse volume

Approx. 450 liters

Approx. 700 liters

Approx. 990 liters

Approx. 1260 liters

Backwash flow*

45 L/min

45 L/min

90 L/min

90 L/min

Backwash time

Individually adjustable

Individually adjustable

Individually adjustable

Individually adjustable

Kv

2.5 m³/h

2.8 m³/h

7.3 m³/h

7.5 m³/h

Minimum pressure

2 bar

2 bar

2 bar

2 bar

Maximum pressure

8 bar

8 bar

6.8 bar

6.8 bar

Ambient temperature

1-40°C

1-40°C

1-45°C

1-45°C

Water temperature

1-40°C

1-40°C

1-36°C

1-36°C

Voltage supply

230 V 60/50 Hz

230 V 60/50 Hz

230 V 60/50 Hz

230 V 60/50 Hz

per power supply unit

12 V~

12 V~

12 V~

12 V~

55x72x200

55x72x200

Space requirements Floor space W x D x H in mm

42x60x187

50x60x192

* the values indicated are real values and depend on the prevailing conditions and the actual available pressure.

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Chapter 7: Media filters (sand filters / Birm filters)

7.4.2

Specifications / Birm filter data sheet

Birm filter TYPE

B140

B200

B300

B400

Birm filter design Support gravel layer Support layer per tank

25 kg 1 bag

25 kg 1 bag

25 kg 1 bag

25 kg 1 bag

Sand bed Sand layer per tank

16.7 liters 25 kg 1 bag

33.5 liters 50 kg 2 bags

33.5 liters 50 kg 2 bags

50 liters 75 kg 3 bags

Birm bed Birm layer per tank

85 liters 75 kg 3 bags

142 liters 125 kg 5 bags

142 liters 125 kg 5 bags

170 liters 150 kg 6 bags

Freeboard +5 cm

68 cm

57 cm

57 cm

60 cm

Other data: Backwash times*, space requirements, etc. identical to the sand filter specifications * The backwash times should generally be adjusted to the local water quality so that the water is largely clear at the end of the backwash time. With the Birm filter, the usual minimum backwash time is 20 minutes.

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Chapter 7: Media filters (sand filters / Birm filters)

7.4.2.1

Sand filter / Birm filter selection table

Reverse osmosis system - rated output

SAND FILTER / BIRM FILTER TYPE S140 / B140

S200 / B200

S300 / B300

S400 / B400

250 500 750 1000 1250 1500 1750 2000 2250 3000 4000 * at a yield of 70 %

Note In principle, it may be said that no additional sand filter must be installed when using a Birm filter since the Birm filter covers the sand filter's function due to its physical characteristics.

7.4.3

Operating conditions For information regarding the operating conditions refer to the latest edition of the Installation Guideline (IGL).

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Chapter 7: Media filters (sand filters / Birm filters)

7.5

Maintenance Note The information given below is summarized for all water pretreatment components in Chapter 14 (Appendix): – Important information on maintenance procedures – Accessories and supplies – Test report - maintenance – Overview / maintenance intervals for water pretreatment components – Explanations for the test report

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Chapter 7: Media filters (sand filters / Birm filters)

7.6

Error messages

7.6.1

Sand filter / Birm filter malfunctions overview

Error

Possible cause

Action required

Outflow outside of regeneration

– Valves contaminated – Valves leaking due to worn spring – Water pressure too low – Sieve for servo flow clogged

– Rinse valves until free and remove dirt – Replace spring – Check inlet pressure – Clean sieve for servo flow

Poor or no automated regeneration

– S300/400 sieve for servo flow clogged.

– – – – –

Regeneration at the wrong time

– Check time setting

– Correct time setting, if necessary.

Insufficient RO water supply due to regeneration.

– Regeneration time not offset to RO rinse time

– Set the times appropriately.

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Check the power supply Check the shaft motor Check the control Replace defective components Clean sieve for servo flow

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Chapter 7: Media filters (sand filters / Birm filters)

7.7

Functional description

7.7.1

Design of components

Sand filter / Birm filter design Components: – Outlet block with sample – ing port and tube connection – Control head – Upper sieve – Riser tube – Filter bed – Tank – Gravel bed – Lower sieve

7.7.2

Component description If the feed water analysis reveals a silt density index of SDI > 3, a sand filter must be installed to reduce suspended solids. The sand filter removes particles from the feed water. The filter media used is garnet which prevents suspended solids from passing through the spacing between the media granules, which formed when the filter was filled, at slow flow velocities. The flow velocity of the water in the sand filter is considerably lower than in the upstream pipes or fixtures. The water is also forced to find its way through the spacing between the sand bed. This permits the suspended solids to settle on the sand, or first to conglomerate before being held back in the spacings. Larger particles settle immediately on the the surface of the filter bed.

7.7.2.1

Backwash A sand filter must be backwashed at regular intervals to remove the retentate. On principle, the filter effect is increased with service life of the system (formation of a so-called filter cake). For reasons of hygiene, it is recommended to perform a backwash once a week. If the pressure drop has increased by 50 %, this is a criteria that a backwash should be performed. The required frequency may therefore vary depending on

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Chapter 7: Media filters (sand filters / Birm filters)

the water. During the backwash process, particles on the surface of the bed, and particles in the spacings are removed and rinsed to drain. Generally the backwash process is the better, the higher the flow velocity. However this is restricted by the settling velocity of the filter material, which may not be removed, and by the practical technical constraints. 7.7.2.2

Flow velocities In practice flow velocities around 30 m/h are used for backwashing. Backwashing can therefore only be done outside operation times. This can only be avoided by the connection of two sand filters in parallel. For setting the backwash times, observe the settings in chapter 5 (backwash time). Note The use of Birm for iron removal in the sand filter requires that the upper sieve be provided. The upper sieve which is supplied with the sand filter is not required if the water contains silicate to improve the rinsing away of conglomerated particles which have been held back.

7.7.2.3

Feed water bypass The sand filters S300 and S400 are provided with a feed water bypass. This ensures a reduced supply flow also during the backwash phase.

7.7.2.4

Efficiency The efficiency of sand filters depends to a large extent on the flow rate. The correct design of the sand filter is determined by the project planning team. To protect the downstream components, it is recommended to use a 20 µm micro-filter in the sand filter's outlet.

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Chapter 7: Media filters (sand filters / Birm filters)

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Chapter 8: Particle filter (Big Blue) 20"

8

Particle filter (Big Blue) 20"

8.1

Component overview – particle filter

Part number:

TYPE / description complete assembly

F00001222

Single filter Big Blue 20“; 5 µm

F00001223

Single filter Big Blue 20“; 20 µm

F00001224

Dual filter Big Blue 20“; 5 µm

F00001225

Dual filter Big Blue 20“; 20 µm

B

C D

F

A E Dual version:

Single version:

POS

Description

A

Particle filter

B

Pressure gauge; inlet / outlet

C

Sampling port

D

Connector 1 1/4“, external thread

E

Retaining plate

F

Drain valve

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Chapter 8: Particle filter (Big Blue) 20"

8.2

Installation

8.2.1

Installation / start-up requirements



General information

Note The pressure gauges on the fine filters must be pre-assembled so that they can be easily read from the front or from the top. Note Start-up of the system must be performed by a trained technician. The electrical connection is to be adjusted to the respective installation environment. Note Prior to its start-up, check the system for damage caused during transport. Do not put the system into operation if components are damaged.

8.2.2

Data reporting

Note Reports for the items of the operational qualification listed below are available as master copies in chapter 12: – Start-up – Setting – Maintenance

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Chapter 8: Particle filter (Big Blue) 20"

8.3

Specifications

8.3.1

Specifications / data sheet

Parameter

Function / specifications

Usage

Fine filtration

Components

– Filter – Pressure gauge; inlet / outlet – Sampling port

Type

Single version / dual version

Connection

1 1/4", external thread

Nominal width

20“

Material

HFPP PVC (tubing)

Sealing material

BUNA – N

Filter mesh

5 µm / 20 µm

Dimensions

675 x 420 (LxH)

Pressure – Maximum – Pressure drop

6.2 bar 0.5 bar

Temperature – Maximum

8.3.2

37.8 °C

Operating conditions For information regarding the operating conditions refer to the latest edition of the Installation Guideline (IGL).

8.3.2.1

Particle filter selection table

≤ 2000 L/h

Permeate volume

≤ 4000 L/h

Single 5 µm Single 20 µm Dual 5 µm Dual 20 µm

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Chapter 8: Particle filter (Big Blue) 20"

8.4

Maintenance Note The information given below is summarized for all water pretreatment components in Chapter 14 (Appendix): – Important information on maintenance procedures – Accessories and supplies – Test report - maintenance – Overview / maintenance intervals for water pretreatment components – Explanations for the test report

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Chapter 8: Particle filter (Big Blue) 20"

8.5

Functional description

8.5.1

Design of components

Particle filter design – single and dual filter Components: – Particle filter – Pressure gauge; inlet / outlet – Sampling port – Connector 1 1/4“, external thread

8.5.2

Component description Particle filter

Particle filters are used to adsorb particles which may be released from water treatment systems and other suspended solids still present in the feed water. A 20 µm particle filter is connected downstream of the sand filter to prevent filter media from entering into th supply path. Another particle filter is installed upstream of the reverse osmosis system. In the last stage before the system, the water is filtered with a filtering efficiency of 5 µm.

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Chapter 8: Particle filter (Big Blue) 20"

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Chapter 9: Softener

9

Softener

9.1

Component overview – softener E080(B), E150(B), E225-T, E300, E400 Magnum

Part number:

Complete assembly – description

F00001119

Softener E080(B) Autotrol

F00001120

Softener E150(B) Autotrol

F00001453

Softener E225-T

F00001121

Softener E300 Magnum; not filled

F00001122

Softener E400 Magnum; not filled

E080(B) / E150(B)

E225-T

A

B C D E F

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Chapter 9: Softener

Application example for the use of E300 Magnum / E400 Magnum:

POS

Description

A

Brine lines

B

Brine tank

C

Brine valve tube

D

Float cup

E

Grid plate

F

Brine valve

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Chapter 9: Softener

9.2

Modification of the softener settings in case of high brine concentrations in combination with Kinetico-Autorol retrofit kits Softener settings in case of high brine concentration

The following tables show the modified settings for the new softener heads. These settings have been selected for problems with high brine concentration. The rinse times are extended by these times to improve rinsing out of the brine. This ensures an optimized operation at locations with problematic operating conditions.

9.2.1

Settings for CP 216

CP 216

9.2.2

Set point

new

C1

8

8

C2

30

30

C3

28

38

C4

6

8

C5

7

14

C8

8

8

T Reg.

87

106

Settings for CP 213

CP 213

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Set point

new

C1

7

7

C2

17

17

C3

24

35

C4

4

4

C5

5

15

C8

5

5

T Reg.

62

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Chapter 9: Softener

9.2.3

Settings for CP 210

CP 210

9-4

Set point

new

C1

4

4

C2

9

9

C3

15

25

C4

4

4

C5

3

10

C8

4

4

T Reg.

39

56

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Chapter 9: Softener

9.3

Installation

9.3.1

Installation / start-up requirements



General information

Note Start-up of the system must be performed by a trained technician. The wiring must be adapted to fit the respective field of application. Note  Prior to its start-up, check the system for damage caused during transport.  If there are signs of damage to the electric components, do not turn the system on.

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Chapter 9: Softener

9.4

Display and operating elements

9.4.1

Display during operation

Time / day Regeneration time Brine volume Capacity Hardness

With alternating operation: – Indication of the number of the tank to be supplied (here: 1 for main) – Remaining system capacity in m³ with < –  or  alternating – Flow in L/min with faucet symbol The following displays alternate in case of parallel operation: – Remaining system capacity of tank 1 with "1" – Remaining system capacity of tank 2 with "2" – Total flow (tanks 1+ 2), with faucet symbol. When the system has been configured, the display will return to the operation display from each menu after 30 seconds.

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Chapter 9: Softener

9.4.2

Programming the control unit

9.4.2.1

Control / display

Display

manual regeneration Reg.

Down  Save Set 

9.4.2.2

Up 

Programming the control  At the start the control must be set to the correct system configuration. When inserting the control, the following screens may be displayed: Fig. 1

Example:

 If 255A is flashing, the correct system configuration can be selected directly with the  arrow key.  For E080 / 150 sand filters, 278 must be selected, for the 278L triplex and for the large valves, 298A must be selected.  When the correct configuration is flashing, confirm with Set .

Fig. 1

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Chapter 9: Softener

Softener valve configuration

Settings for the following filter valves: 278 A

E080(B) / E150(B)

278 L

E225-T

298 A

E300 / E400

Fig. 2

Fig. 2

 The control has already filed a configuration and is in progress of aligning the main head (Error3) or the secondary head (Error4).  The system configuration must be entered again with a Reset (see level4). Fig. 3

Fig. 3

The display shows only dashes. In this case, there is also a stored configuration, and the control prompts you to enter the current time and day. This setting is lost in case of a prolonged power loss.  Here it is also recommended to enter the system configuration again with a Reset (see level 4).



Level 1 Level 1 can only be accessed with a new control after turning power on or with a Reset (see level 4) for entering basic data.  For browsing use the arrow keys  or , use Set  to clear the value for changing.  The value is changed with the arrow keys and set with Set .

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Chapter 9: Softener

LEVEL 1



–

Valve 278A (Performa) or 298A (Magnum) with configuration A (Alternating) for 225-T: 278L

–

Resin volume in liters

P1

Current time

P2

Current day, identified by the arrow on the upper edge of the display, from Sunday to Saturday.

P3

Regeneration time for E225-T: Set tanks time-delayed, e.g. 0:00, 1:30 and 3:00 hours).

P4

Regeneration days 0.5-99 = interval for forced regeneration. Recommended: 2 days!

P5

not used

P6

Regeneration consumption in g/liters; 110 recommended

P7

Estimated capacity in kg CaCO³/liter of water – can be changed

P8

Water hardness in mg CaCO³/liter of water –calculated from °dH *17.86 or *fH*10

Level 2 Level 2 is also used to define basic parameters.  This level is accessed by simultaneously pressing the Up and Down key + for 5 seconds. This can only be done from the normal operation display. (Therefore if Error3 or Error4 is displayed and the system configuration has not yet been defined or verified, immediately go to level 4 and make a reset.)  For browsing use the arrow keys  or , use Set  to clear the value for modification.  The value is changed with the arrow keys and set with Set . LEVEL 1

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P9

Must be set to 1 for the selection of metric units.

P10

Selection of the time display, must be set to 1 for 0–24hrs.

P11

Maintenance interval in months – recommended 0

P12

Time delay in seconds for remote regeneration – default 60

P13

Not used with twin systems - default 0 (optional salt sensor)

P14

Brine flow - refill capacity (Brine Refill) in gpm*100 (gpm = L/min; 3.785 L/g)

P15

Brine flow - suction capacity (Draw Brine) in gpm*100

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Chapter 9: Softener

LEVEL 1



P16

Select 3, reserve type for E225-T

P17

Not used with alternating operation - for E225-T, reserve capacity expressed in % in relation to hardness (- see above)

P18

Selection of the flow sensor for E080(B) / E150(B) /225T = 1 but for E300/E400

P19

Must be set to 1 if a valve sensor is integrated (if P18 = 3, then K-factor)

Level 3 - operating phase times Level 3 is used to display or define the times of the operating phases.  This level is accessed by simultaneously pressing the Set and Down  +  keys for 5 seconds. This can only be done from the normal operation display, not during a regeneration. LEVEL 1



C1

Backwash in min – can be changed

C2

Draw brine in min - defined in P15

C3

Slow rinse in min - can be changed (valve position same as for draw brine)

C4

Repressurize (equals Standby for E080/150) in min - can be changed

C5

Fast rinse in minutes – can be changed

C6– C7

---

C8

Refill in min - defined in P14

Level 4 – history Level 4 is used to see the history.  (Possibility in H0 for a reset with the Set key  for 5 seconds).  This level is accessed by simultaneously pressing the Set and Up keys  + for 5 seconds. (This can even be done during a regeneration).

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Chapter 9: Softener

Example: LEVEL 4

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H0: F

200

liters

Filter display (reset by pressing the Set key  for 5 seconds.)

H1: 0

0

d

Days since last regeneration

H2

0

L/min

Current flow

H3

0

Water today since last regeneration

H4

0

Water since last regeneration

H5

2804

m³

Consumption since reset (in 100 m³)

H6

0

m³

Consumption since reset in 1000 000 m³

H7

3.84

m³

Average consumption on Sundays

H8

17.4

m³

Average consumption on Mondays

H9

22.46

m³

Average consumption on Tuesdays

H10

21.24

m³

Average consumption on Wednesdays

H11

20.78

m³

Average consumption on Thursdays

H12

18.58

m³

Average consumption on Fridays

H13

5.36

m³

Average consumption on Saturdays

H14

0

d

Service cycle

H15

96

L/min

Peak flow / maximum flow

H16

15:19 Fr

H17:

4

Months

Months since service

H18

1.234

liters

Water consumption since last regeneration of tank 1

H19

00

liters

Water consumption since last regeneration of tank 2

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Day and time of peak flow

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Chapter 9: Softener



Starting a regeneration  When pressing the Reg. key, the Reg. symbol will be flashing. This indicates that a delayed regeneration is due which would start at the programmed time P3.  If Reg. is briefly pressed a second time, a factor x2 will be displayed after the flashing Reg. symbol, indicating that both tanks will be regenerated at the set Reg time.  If the Reg. key is pressed for 5 seconds, the Reg. symbol will be displayed permanently and a regeneration will be started immediately.  If the Reg. key is again pressed for 5 seconds immediately thereafter, a factor x2 will be displayed after the Reg. symbol, indicating that both tanks will immediately be regenerated one after the other.  Pressing the Set and Up keys  +  briefly and simultaneously, will quickly skip a phase. This will set the remaining phase time, which is displayed by briefly pressing the Set key , to 0.  A regeneration which has started can be skipped by pressing the Set and Up keys  + for 5 seconds .

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Chapter 9: Softener

9.4.3

Important start-up information

Softeners E080(B),/ E150(B), E225-T, E300, E400  The site of installation must be protected from frost and must be level, the floor load must be sufficient for the weight of the full softener. A floor drain is also required.  The softener must not be exposed to direct sunlight.  A 50 µm particle filter and a pressure gauge for pressure monitoring must be installed upstream of the softener.  The maximum pressure must not be exceeded; if necessary, a pressure reducer must be installed. E080(B) / E150(B)

 The installation must be done in compliance with the local regulations.  The overflow of the brine tank must be directed to the drain and must also be a free flow design.

E225-T

 Apply only small amounts of silicone-based FDA-approved lubricant to seals and valves.  Tighten plastic screw-connections only by hand.  The drain must be designed as a free flow to prevent backcontamination.  To refill the brine tank use only regeneration salt tablets intended for softening of drinking water.  When refilling salt, the salt level must always be higher than the brine level!

E300 Magnum / E400 Magnum:

 The design of the softener must ensure that the operating time of one tank is at least the regeneration time and the time required for the brine to develop (approx. 3 – 4 hours), and that regeneration takes place at least once a day. Make absolutely sure to avoid prolonged standby times, if necessary regeneration of both tanks must be started manually or electrically. Filling on site:  If the softeners are to be filled on site, use the immersion pipe to fill the tanks completely with water after they have been filled with the filter material and before mounting the control heads.

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Chapter 9: Softener

9.4.3.1

Softener start-up procedure Ventilation, rinsing

 When the softener has been set up and the control has been programmed, the system must be carefully ventilated and rinsed. Before this is done, it must be checked that all lines and equipment upstream of the softener has been thoroughly rinsed. To rinse the softener, the outlet of the softener must be dismounted and discarded to the drain. The brine tank should remain empty until rinsing and ventilation are finished. The water inlet valve must be opened slowly and only partly. Watch the removal of air until water exits. When using E300 / 400 softeners, the drain must now be closed or considerably restricted.  When water exits, the tank or the vessel is not actually completely ventilated. The air is actually completely removed with the backwash.

Manual regeneration

 When water exists, the tank is thoroughly ventilated during the backwash phase C1 by the start of a regeneration. When all air has been removed, the remaining phases are all skipped after a short rinse by briefly and simultaneously pressing +  . When the first tank has been ventilated, the second tank will also be thoroughly ventilated during the backwash phase C1 by the start of a regeneration. The remaining phases can be skipped after a short rinse.  After both tanks have been ventilated and if ventilation is complete, the water inlet valve can be fully opened. During rinsing, the dynamic pressure of the water supply should also be checked. If both tanks are sufficiently rinsed, i.e.they have been rinsed with 5 times the bed volume, the softener outlet can be re-mounted. The complete water pretreatment system must now be rinsed briefly and can then be connected to the reverse osmosis system.

Refill Phase C8

 The brine tank must now be filled by starting a manual regeneration with Reg. and fast skipping of the phases (by simultaneously pressing + ) up to the Refill phase C8. It should now be checked if the programmed time for the refill phase is sufficient for refilling. (Caution: the required level applies to a brine tank filled at least up to the brine level with salt). It would be sensible to switch on the consumers to reach to lower operating pressure.  After the time required for the brine to develop, the first tank can be regenerated by restarting a manual regeneration. The draw-brine phase C2 and the slow-rinse phase (phase C3) must now be checked during their common time to ensure that all of the brine is drawn in and the residual brine is rinsed out again.

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Please note that, although the slow-rinse phase C3 has the same effect as the draw-brine phase C2, the system is already rinsed clear to avoid high concentrations of brine in the standby mode.  Especially for softeners E080(B) and E150(B) it must be ensured that any residual brine has been rinsed away at the end of C3. This can easily be verified by taking a taste sample on the drain.  When the first regeneration is complete and the reverse osmosis system to be supplied continues to run in the rinse mode when the second regeneration starts, correct switching to the tanks to be supplied and the programmed times can be checked. Note  The programmed values must be documented in the start-up report.

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Chapter 9: Softener

9.4.4

Start-up procedure for E080(B),/ E150(B), E225-T, E300, E400

Preparation and ventilation 1.

The softener has been set up and the control has been programmed using the programming table.

2.

The brine tank has been correctly positioned, has been connected and filled with salt tablets. The brine tank can then be filed with feed water up to the float cup to allow the brine in the tank to develop.

3.

Caution: The softener system must be carefully ventilated.

 Close the water supply.  Dismount the outlet tubing on the particle filter and direct it to the drain.  Slowly open the water supply. (Important: Do not open completely!

Regeneration of the first tank 4.

Start regeneration with the key [5 sec], the Standby tank 1 is ventilated during the Fast Rinse phase C5. All other phases then are skipped with the key combination  + [5 sec.].

5.

Start regeneration with the key [5 sec], the Standby tank 2 is ventilated during the Fast Rinse phase C5. All other phases then are skipped with the key combination  + [5 sec.].

6.

Rinsing of both softener tanks for approx. 10 minutes per tank.

– Initiation of a manual regeneration with the key [5 sec], switches to the other softener tank and this tank can now also be rinsed for 10 minutes. – After rinsing, close the water supply and connect the tubing to the RO system. – The water supply can then be fully opened. 7.

Start regeneration with the key [5 sec], the Service tank will now be completely regenerated. No phases will be skipped and the times can be checked. (Important: time for the brine to develop, approx 1–1.5 hours)

 Check that brine is drawn in during phase C2.  Check filling of brine during phase C8. When using softeners E080(B) and E150(B), the brine tank will also be filled in the auxiliary position C4, while the other tank is in Service, until the brine valve in the brine tank closes.

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Chapter 9: Softener

Regeneration of the second tank 8.

The first tank is now properly regenerated. For a manual regeneration of the second tank, it is necessary to wait until the brine has developed. (Important: time for the brine to develop approx. 1,5 hours)

9.

Start regeneration with the key [5 sec], the Service tank will now be completely regenerated. No phase will be skipped. This permits a check of the times of the individual phases.

10. Check the water hardness at the softener outlet and thus the softener function. 11. If the water hardness is zero, start-up of the RO system can be started.

Note  Start another manual regeneration during the start-up.  This causes the tanks to switch, and the second tank can be checked for proper service.

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Chapter 9: Softener

9.4.4.1

Valve heads and drain restrictor  The drains for all softeners must be designed as free drains using the lines supplied and ensuring that distances are as short as possible. The drain outlets are restricted to reduce the flows.

E080(B) / E150(B) / E225-T

E300 / E400

Drain restrictor Connection for drain with restrictor

Softener TYPE

Drain

E080(B)

E150(B)

E225-T

E300

E400

8 -15 L/min

10 -20 L/min

10 -20 L/min

15 -30 L/min

20 -40 L/min

Restrictor hole at 4.5-6 bar

4 mm

4 mm

4 mm

Blue 5.0 mm

Red 5.5 mm

Restrictor hole at 3-4.5 bar

4 mm

4.5 mm

4.5 mm

Red 5.5 mm

Green 6.0 mm

Restrictor hole at 2-3 bar

4.5 mm

5 mm

5 mm

Green 6.0 mm

Without insert

Required drain during backwash and fast rinse

Use the appropriate restrictors for the pressures to be reached as specified in the table. The pressure values refer to the pressure indicated at the softener inlet.

Tip Identification of the restrictors (for E080(B), E150(B) and E225-T): – 4 mm has 1 ring – 4.5 mm has 2 rings – 5 mm has no ring Restrictor hole

9-18

 The restrictor hole of E300 and E400 can be adjusted on site to the prevailing pressure. The appropriate color is installed.

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Servo flow line

 The large valves of the E300/E400 must be provided with a servo drain line in addition to the drain. The required lines are included.  If the drain flow during Backwash and Fast Rinse is too high, a smaller restrictor can be installed, if necessary. The times should then be increased accordingly.  For the rinse time settings, refer to the report master copies in the appendix (see chapter l, page 9-20). These are determined specified values and should be checked on site.



Configuration of the free flow for drains (e.g. rack) E080(B) / E150(B) / E225-T

E300 / E400

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Chapter 9: Softener



Regeneration phases for E080(B) / E150(B) / E225-T / E300 / E400

Fast Rinse Operation



9-20

Backwash

Draw brine

Pressure compensation

Filling with brine

Auxiliary and service position for E080(B) and E150(B) / small valve

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

Auxiliary and service position for E300 and E400 / large valve

Auxiliary position

Service position

The tank which was last regenerated (here always tank 1) remained in the auxiliary position. When a regeneration is initiated, this tank is switched from the auxiliary position to the Service position. For small softeners this means: Fast rinsing and Service of the tank. For large softeners this means direct switching from the auxiliary position to the Service position. The Triplex softener regenerates in one go, i.e. without stop at the auxiliary position.



Starting a manual regeneration – applicable for all softener types

Function

Input

Start time-delayed regeneration



key [press briefly]

Start manual regeneration



key [press for 5 seconds]

Complete regeneration. Cancel

 Key combination  +  [press for 5 seconds]

Skip regeneration phase

 Key combination  +  [press briefly]

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Chapter 9: Softener

9.4.4.2

Suction tube - injector The function of the suction tube is to draw in the brine, that of the Refill Control is filling with brine:

E080(B) / E150(B) / E225-T

Refill control

9.4.4.3

Brine connection

E300 / E400

Suction tube

Sieve for servo flows

Suction tube Refill control

Brine connection

Brine tank The brine level listed in the specification is a net value. The gross value takes the offset of the brine valve into consideration.  Depending on the net level X, the brine valves are set to the gross level H:

(

Softener TYPE

E080(B)

E150(B)

E225-T

E300

E400

Brine level, net X value

14 cm

30 cm

30 cm

35 cm

45 cm

Lower offset

4 cm

4 cm

4 cm

12.5 cm

12.5 cm

Upper offset

6 cm

6 cm

6 cm

3.5 cm

3.5 cm

Level

24 cm

40 cm

40 cm

51 cm

61 cm

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Chapter 9: Softener

9.4.4.4

Valves in control head

E080(B) / E150(B) / E225-T

E300 / E400

Inlet 3 Refill 1

Brine

Drain #1

Outlet 4

Rinse 5 and 6

Rinse #2

Outlet #3

Drain 1 Inlet 4

Inlet #4 and #5

Drain 7.8 and 9

Outlet 3 Rinse 2

The valves in the small head are switched directly and can be opened manually for rinsing in case of servicing. The large control heads switch indirectly via servo valves, therefore each time the valve closes, a small servo flow will exit the servo drain. Rinsing clear in case of servicing can only be done indirectly. The servo flow sieve should be regularly checked according the the local conditions. To permit operation of the E080(B) / E150(B) with a brine tank, a refill will be performed in the auxiliary position. This is not required for the E225-T as it performs a complete regeneration. 9.4.4.5

Triplex operation E225-T In triplex operation a reserve is required as the softener tanks may all be empty simultaneously and a tank does not start regenerating before its minimum reserve has been reached. The reserve to be set depends on the size of the RO system and the prevailing hardness. The values specified in the selection table are reference values for a standard consumption profile. An immediate regeneration P16 =3 with a defined reserve is selected in the control. The E225-T is equipped with one control on each tank valve. These controls are interconnected by a cable which they use for mutually signalling if a regeneration can be started or not. With the exception of the regeneration time, the controls all have the same setting.

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Chapter 9: Softener

9.4.4.6

Alternating or parallel operation For alternating operation no reserve is required (apart from C5 and C8 requirements for small softeners) as the exhausted tank can directly switch to the regenerated tank. The softeners are therefore preferably operated alternating! For parallel operation a reserve is mandatory. Selectable in the program mode: Flow

Soft water supply

Efficiency

high medium low



P16 = 0, Time-delayed regeneration with Smart Reserve (Reserve set in P17)

(see diagram above) A regeneration will only start at the regeneration time which is set in P2. A tank will regenerate when its remaining capacity has reached the minimum capacity limit. Calculation of the water consumption volume of the following day is based on the daily average water consumption (which is stored in the history), plus a safety reserve of 20%. If necessary, the tanks are regenerated successively, starting with the tank with the higher consumption. This option allows correction of the reserve to optimize salt consumption.



P16 = 1, time-delayed regeneration with defined reserve.

(see diagram above) Regenerations do not start before the time set in P2. A tank is regenerated when its remaining capacity is below the critical capacity (set in P17). If the capacity of a tank drops below the limit of 50%, this tanks will be regenerated. The 764 control causes successive regeneration of the two tanks, irrespective of the water volume which will be used in the next 24 hours. This option allows improved regeneration of highly exhausted resin.

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

P16 = 2, immediate regeneration. Defined reserve / time-delayed regeneration - smart reserve

(see diagram above) This option combines the advantages of option 0 and option 3. It is the most flexible regeneration option and combines the benefits of the smart reserve (optimized salt consumption) with the ability to react to occasional days with excessive water consumption.



P16 = 3, immediate regeneration - defined reserve

(see diagram above) Regeneration starts as soon as the capacity of a tank is exhausted or as soon as the capacity (tank 1 + tank 2) is below the critical capacity (set in P17). To prevent hard water, this reserve should be set to a value that ensures sufficient soft water while the most exhausted tank is being regenerated.

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Chapter 9: Softener

9.4.4.7

Control unit design On the large valves of the E300/400, the housing unit of the control must be secured on the valve.  This is done by removing the protective cover of the camshaft, by pushing the spring lever on the end of the shaft outwards and pulling the shaft a little back so that it is aligned on the front.

 Take the housing unit out of the carton and fit it onto the rear flaps until it stops.

 Then slide the shaft back to the front. This may only be done with the marker arrow facing up. Refit the protective cover. Then position the flow sensor.

 The control is always located on the master head. Connect the second head to a data cable which is usually provided on the master control. The connector plugs are protected against reverse polarity.  Their orientation can be easily seen from the safety hook. Connect the power supply unit with its 12 VAC 150 mA output to the external power supply and the control.

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

This results in the following circuit diagram:

Small figure Triplex wiring



Wired softener (example E400)

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Chapter 9: Softener

9.4.4.8

Softener E080 programming table – control Logix 764



Level 1 Return to default screen: From each menu after 30 seconds idle phase. Operation screen: Tank number Flow in L/min alternating with remaining capacity in m³ Brief indication of time with []

Level 1 –

278A

Valve and configuration

–

40

liters resin

P1

e.g.: 9:30

Current time

P2

 upper edge

Current day, arrow Sun-Mon-Tues ...

P3

2:00

Regeneration time

P4

2

Regeneration days 0.5–99 interval

P6

110

Regeneration medium consumption in g/L and regeneration

P7

1.9

Estimated capacity in kg CaCO3 - can be changed

P8

180

Water hardness in mg/L CaCO3 (mg CaCO3 = dH x 18)



Level 2 + for 5 seconds. Blocking a value with the Reg. key

Level 2 P9

1

Selection for metric units

P10

1

Selection of time display 0–24 h

P11

0

Maintenance interval in months

P12

60

seconds time delay for remote regeneration

P13

--

Salt check and chlorine processor 0=none; 1=only sensor; 2=chlorine processor and sensor

P14

70

gpmx 100 refill capacity - Brine Refill (change standard 34 to 70)

P15

30

gpmx 100 suction capacity - (gpm = l/min; 3.785 l/g) (change standard 26 to 30)

P16

--

Reserve type (parallel operation only) 0=variable reserve and time-delayed regeneration; 1=invariable reserve, time-delayed regeneration; 2=variable reserve; 3=invariable reserve and immediate regeneration

P17

--

Reserve % capacity (0-70 %, standard 30 %), initial average or defined reserve

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Level 2 P18

1

Selection flow sensor 0=magnetic; 1=1"Autotrol; 3=given K factor; 4 given pulse equivalent

P19

1

P18=3: K factor (p9=1->metric) pulse per liter or P18=4 L/pulse

Pr

0

Preliminary refill 0=none 1=preliminary refill

Pd

0

time-delayed remote regeneration 0=immediate 1=time-delayed



Level 3 +  for 5 seconds Time in minutes

Manually starting the regeneration Time delayed regeneration

Short regeneration

Immediate regeneration

Regeneration 5 seconds

Cancel regeneration

+  for 5 seconds

Skip phase

+  short During a regeneration, always the remaining time of the complete regeneration will be displayed. Indication of the remaining time of the phase by 

LEVEL 3 C1

mod

6

Backwash1

C2

fixed

12

Draw (function of P15)

C3

mod

24

slow Rinse

C4

mod

6

Repressurize / Standby

C5

mod

4

Fast Rinse 1

C6/C

–

–

–

C8

fixed

5

Refill (function of P14)

S



57

Level 4 and  for 5 seconds In H0 : 5 seconds, reset for control - then Reg. for synchronization.

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Chapter 9: Softener

LEVEL 4 H0

Liters resin volume

H1

Days since last regeneration

H2

Current flow

H3

Water consumption of this day in m3 since regeneration

H4

Water consumption in m3 since last regeneration

H5

Total consumption since reset in x 100 m3

H6

Consumption since reset in 1000000 m³

H7

Average consumption in m3 on Sundays

H8

Average consumption in m3 on Mondays

H9

Average consumption in m3 on Tuesdays

H10

Average consumption in m3 on Wednesdays

H11

Average consumption in m3 on Thursdays

H12

Average consumption in m3 on Fridays

H13

Average consumption in m3 on Saturdays

H14

Average service phases in days

H15

Peak flow in L/min

H16

Date and time of peak flow

H17

Months in operation

H18

m3 Water consumption since last regeneration tank 1

H19

m3 Water consumption since last regeneration tank 2

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9.4.4.9

Softener E150(B) programming table – control Logix 764



Level 1 Return to default screen: From each menu after 30 seconds idle phase. Operation screen: Tank number Flow in L/min alternating with remaining capacity in m³ Brief indication of time and []

Level 1 –

278A

Valve and configuration

–

80

liters resin

P1

e.g.: 9:30

Current time

P2

 upper edge

Current day, arrow Sun-Mon-Tues ...

P3

2:00

Regeneration time

P4

2

Regeneration days 0.5–99 interval

P6

110

Regeneration medium consumption in g/L and regeneration

P7

3.8

Estimated capacity in kg CaCO3 - can be changed

P8

180

Water hardness in mg/L CaCO3 (mg CaCO3 = dH x 18)



Level 2  +  for 5 seconds. Blocking a value with the Reg. key

Level 2 P9

1

Selection for metric units

P10

1

Selection of time display 0–24 h

P11

0

Maintenance interval in months

P12

60

seconds time delay for remote regeneration

P13

--

Salt check and chlorine processor 0=none; 1=only sensor; 2=chlorine processor and sensor

P14

137

gpmx 100 refill capacity - Brine Refill (change standard 34 to 137)

P15

40

gpmx 100 suction capacity - (gpm = l/min; 3.785 l/g) (change standard 26 to 40)

P16

--

Reserve type (parallel operation only) 0=variable reserve and time-delayed regeneration; 1=invariable reserve, time-delayed regeneration; 2=variable reserve; 3=invariable reserve and immediate regeneration

P17

--

Reserve % capacity (0-70 %, standard 30 %), initial average or defined reserve

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Level 2 P18

1

Selection flow sensor 0=magnetic; 1=1"Autotrol; 3=given K factor; 4 given pulse equivalent

1. P19

1

P18=3: K factor (p9=1->metric) pulse per liter or P18=4 L/pulse

1. Pr

0

Preliminary refill 0=none 1=preliminary refill

1. Pd

0

time-delayed remote regeneration 0=immediate 1=time-delayed



Level 3 +  for 5 seconds Time in minutes 0

Manually starting the regeneration Time-delayed regeneration

Short regeneration

Immediate regeneration

Regeneration after 5 seconds

Cancel regeneration

+  for 5 seconds

Skip phase

+  short During a regeneration, always the remaining time of the complete regeneration will be displayed. Indication of the remaining time of the phase by 

LEVEL 3 C1

mod

8

Backwash1

C2

fixed

18

Draw (function of P15)

C3

mod

25

slow Rinse

C4

mod

6

Repressurize / Standby

C5

mod

5

Fast Rinse1

C6/C

–

–

–

C8

fixed

5

Refill (function of P14)

S

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

Level 4 and  for 5 seconds In H0 : 5 seconds: reset for control - then Reg. for synchronization.

LEVEL 4 H0

Liters resin volume

H1

Days since last regeneration

H2

current flow

H3

Water consumption of this day in m3 since regeneration

H4

Water consumption in m3 since last regeneration

H5

Total consumption since reset in x 100 m3

H6

Total consumption since reset in 1000 000 m³

H7

Average consumption in m3 on Sundays

H8

Average consumption in m3 on Mondays

H9

Average consumption in m3 on Tuesdays

H10

Average consumption in m3 on Wednesdays

H11

Average consumption in m3 on Thursdays

H12

Average consumption in m3 on Fridays

H13

Average consumption in m3 on Saturdays

H14

Average service phases in days

H15

Peak flow in L/min

H16

Date and time of peak flow

H17

Months in operation

H18

m3 Water consumption since last regeneration tank 1

H19

m3 Water consumption since last regeneration tank 2

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9.4.4.10 Softener 225-Triplex programming table -– control Logix 764

Reserve % **

Hardness [°dH]

RO system

6

8

10

12

14

16

18

20

22

24

26

28

30

32

34

36

38

40

42

44

1500

0

0

0

0

0

0

0

0

0

0

0

5

10

15

15

15

20

20

20

25

1750

0

0

0

0

0

0

0

0

0

5

10

10

10

15

15

15

20

20

20

25

2000

0

0

0

0

0

0

0

0

0

5

5

10

10

15

15

20

25

30

---

---

2250

0

0

0

0

0

0

0

5

10

15

20

20

25

25

30

30

---

---

---

---

3000

0

0

0

0

0

5

10

15

15

15

20

25

30

30

---

---

---

---

---

---

4000

0

0

0

5

10

15

20

25

30

30

---

---

---

---

---

---

---

---

---

---

rated output*

* at a yield of 70% ** reserve to be set as reference value depends on the supply profile



Level 1 Return to default screen: From each menu after 30 seconds idle phase. Operation indicator Tank number Flow in L/min alternating with remaining capacity in m³ Brief indication of time and []

Level 1 –

278L

Valve and configuration

–

80

liters resin

P1

e.g.: 9:30

Current time

P2

 upper edge

Current day, arrow Sun-Mon-Tues ...

P3

00:01 / 01:30 / 3:°°

Regeneration time (0:01 hours and time-delayed by the regeneration period respectively)

P4

2

Regeneration days 0.5–99 interval

P6

110

Regeneration medium consumption in g/L and regeneration

P7

3.8

Estimated capacity in kg CaCO3 - can be changed

P8

180

Water hardness in mg/L CaCO3 (mg CaCO3 = dH x 18)

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

Level 2 +  for 5 seconds. Blocking a value with the Reg. key

Level 2 P9

1

Selection for metric units

P10

1

Selection of time display 0–24 h

P11

0

Maintenance interval in months

P12

60

Seconds time delay for remote regeneration

P13

--

Salt check and chlorine processor 0=none; 1=only sensor; 2=chlorine processor and sensor

P14

22

gpmx 100 refill capacity - Brine Refill (change standard 34 to 22)

P15

40

gpmx 100 suction capacity - (gpm = l/min; 3.785 l/g) (change standard 26 to 40)

P16

3

Reserve type (parallel operation only) 0=variable reserve and time-delayed regeneration; 1=invariable reserve, time-delayed regeneration; 2=variable reserve; 3=invariable reserve and immediate regeneration

P17

35

Reserve % capacity (0-70 %, standard 30 %), initial average or defined reserve

P18

1

Selection flow sensor 0=magnetic; 1=1"Autotrol; 3=given K factor; 4 given pulse equivalent

P19

1

P18=3: K factor (p9=1->metric) pulse per liter or P18=4 L/pulse

Pr

0

Preliminary refill 0=none 1=preliminary refill

Pd

0

time-delayed remote regeneration 0=immediate 1=time-delayed



Level 3 +  for 5 seconds Time in minutes 0

Manually starting the regeneration Time-delayed regeneration

Short regeneration

Immediate regeneration

Regeneration after 5 seconds

Cancel regeneration

+  for 5 seconds

Skip phase

+  short During a regeneration, always the remaining time of the complete regeneration will be displayed. Indication of the remaining time of the phase by 

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Chapter 9: Softener

LEVEL 3 C1

mod

8

Backwash1

C2

fixed

18

Draw (function of P15)

C3

mod

25

slow Rinse

C4

mod

1

Repressurize / Standby

C5

mod

5

Fast Rinse1

C6/C

–

–

–

C8

fixed

30

Refill (function of P14)

S



87

Level 4 and  for 5 seconds In H0 : 5 seconds: reset for control - then Reg. for synchronization.

LEVEL 4 H0

Liters resin volume

H1

Days since last regeneration

H2

Current flow

H3

Water consumption of this day in m3 since regeneration

H4

Water consumption in m3 since last regeneration

H5

Total consumption since reset in x 100 m3

H6

Total consumption since reset in 1000 000 m³

H7

Average consumption in m3 on Sundays

H8

Average consumption in m3 on Mondays

H9

Average consumption in m3 on Tuesdays

H10

Average consumption in m3 on Wednesdays

H11

Average consumption in m3 on Thursdays

H12

Average consumption in m3 on Fridays

H13

Average consumption in m3 on Saturdays

H14

Average service phases in days

H15

Peak flow in L/min

H16

Date and time of peak flow

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Chapter 9: Softener

LEVEL 4 H17

Months in operation

H18

m3 Water consumption since last regeneration tank 1

H19

m3 Water consumption since last regeneration tank 2

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Chapter 9: Softener

9.4.4.11 Programming table softener E300 - Logix 764 control



Level 1 Return to default screen: From each menu after 30 seconds idle phase. Operation indicator Tank number Flow in L/min alternating with remaining capacity in m³ Brief indication of time and []

Level 1 –

298A

Valve and configuration

–

150

liters resin

P1

e.g.: 9:30

Current time

P2

 upper edge

Current day, arrow Sun-Mon-Tues ...

P3

2:00

Regeneration time

P4

2

Regeneration days 0.5–99 interval

P6

110

Regeneration medium consumption in g/L and regeneration

P7

7.2

Estimated capacity in kg CaCO3 - can be changed

P8

180

Water hardness in mg/L CaCO3 (mg CaCO3 = dH x 18)



Level 2  +  for 5 seconds. Blocking a value with the Reg. key

Level 2 P9

1

Selection for metric units

P10

1

Selection of time display 0–24 h

P11

0

Maintenance interval in months

P12

60

seconds time delay for remote regeneration

P13

--

Salt check and chlorine processor 0=none; 1=only sensor; 2=chlorine processor and sensor

P14

40

gpmx 100 refill capacity - Brine Refill (change standard 100 to 40)

P15

55

gpmx 100 suction capacity - (gpm = l/min; 3.785 l/g) (change standard 60 to 55)

P16

--

Reserve type (parallel operation only) 0=variable reserve and time-delayed regeneration; 1=invariable reserve, time-delayed regeneration; 2=variable reserve; 3=invariable reserve and immediate regeneration

P17

--

Reserve % capacity (0-70 %, standard 30 %), initial average or defined reserve

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Chapter 9: Softener

Level 2 P18

0

Selection flow sensor 0=magnetic; 1=1"Autotrol; 3=given K factor; 4 given pulse equivalent

P19

1

P18=3: K factor (p9=1->metric) pulse per liter or P18=4 L/pulse

Pr

0

Preliminary refill 0=none 1=preliminary refill

Pd

0

time-delayed remote regeneration 0=immediate 1=time-delayed



Level 3 +  for 5 seconds Time in minutes 0

Manually starting the regeneration Time-delayed regeneration

Short regeneration

Immediate regeneration

Regeneration 5 seconds

Cancel regeneration

+  for 5 seconds

Skip phase

+  short During a regeneration, always the remaining time of the complete regeneration will be displayed. Indication of the remaining time of the phase by 

LEVEL 3 C1

mod

8

Backwash1

C2

fixed

25

Draw (function of P15)

C3

mod

25

slow Rinse

C4

mod

–

Repressurize / Standby

C5

mod

5

Fast Rinse1

C6/C

–

–

–

C8

fixed

31

Refill (function of P14)

S



94

Level 4 and  for 5 seconds In H0 : 5 seconds: reset for control - then Reg. for synchronization.

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Chapter 9: Softener

LEVEL 4 H0

Liters resin volume

H1

Days since last regeneration

H2

current flow

H3

Water consumption of this day in m3 since regeneration

H4

Water consumption in m3 since last regeneration

H5

Total consumption since reset in x 100 m3

H6

Total consumption since reset in 1000 000 m³

H7

Average consumption in m3 on Sundays

H8

Average consumption in m3 on Mondays

H9

Average consumption in m3 on Tuesdays

H10

Average consumption in m3 on Wednesdays

H11

Average consumption in m3 on Thursdays

H12

Average consumption in m3 on Fridays

H13

Average consumption in m3 on Saturdays

H14

Average service phases in days

H15

Peak flow in L/min

H16

Date and time of peak flow

H17

Months in operation

H18

m3 Water consumption since last regeneration tank 1

H19

m3 Water consumption since last regeneration tank 2

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Chapter 9: Softener

9.4.4.12 Softener E0400 programming table – control Logix 764



Level 1 Return to default screen: From each menu after 30 seconds idle phase. Operation indicator Tank number Flow in L/min alternating with remaining capacity in m³ Brief indication of time and []

Level 1 –

298A

Valve and configuration

–

200

liters resin

P1

e.g.: 9:30

Current time

P2

 upper edge

Current day, arrow Sun-Mon-Tues ...

P3

2:00

Regeneration time

P4

2

Regeneration days 0.5–99 interval

P6

110

Regeneration medium consumption in g/L and regeneration

P7

9.6

Estimated capacity in kg CaCO3 - can be changed

P8

180

Water hardness in mg/L CaCO3 (mg CaCO3 = dH x 18)



Level 2  +  for 5 seconds. Blocking a value with the Reg. key

Level 2 P9

1

Selection for metric units

P10

1

Selection of time display 0–24 h

P11

0

Maintenance interval in months

P12

60

seconds time delay for remote regeneration

P13

--

Salt check and chlorine processor 0=none; 1=only sensor; 2=chlorine processor and sensor

P14

45

gpmx 100 refill capacity - Brine Refill

P15

60

gpmx 100 suction capacity - (gpm = l/min; 3.785 l/g)

P16

--

Reserve type (parallel operation only) 0=variable reserve and time-delayed regeneration; 1=invariable reserve, time-delayed regeneration; 2=variable reserve; 3=invariable reserve and immediate regeneration

P17

--

Reserve % capacity (0-70 %, standard 30 %), initial average or defined reserve

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Chapter 9: Softener

Level 2 P18

0

Selection flow sensor 0=magnetic; 1=1"Autotrol; 3=given K factor; 4 given pulse equivalent

P19

1

P18=3: K factor (p9=1->metric) pulse per liter or P18=4 L/pulse

Pr

0

Preliminary refill 0=none 1=preliminary refill

Pd

0

time-delayed remote regeneration 0=immediate 1=time-delayed



Level 3 +  for 5 seconds Time in minutes 0

Manually starting the regeneration Time delay regeneration

Short regeneration

Immediate regeneration

Regeneration after 5 seconds

Cancel regeneration

+  for 5 seconds

Skip phase

+  short During a regeneration, always the remaining time of the complete regeneration will be displayed. Indication of the remaining time of the phase by 

LEVEL 3 C1

mod

10

Backwash1

C2

fixed

30

Draw (function of P15)

C3

mod

28

slow Rinse

C4

mod

–

Repressurize / Standby

C5

mod

6

Fast Rinse1

C6/C

–

–

–

C8

fixed

36

Refill (function of P14)

S



110

Level 4 and  for 5 seconds In H0 : 5 seconds: reset for control - then Reg. for synchronization.

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Chapter 9: Softener

LEVEL 4 H0

Liters resin volume

H1

Days since last regeneration

H2

Current flow

H3

Water consumption of this day in m3 since regeneration

H4

Water consumption in m3 since last regeneration

H5

Total consumption since reset in x 100 m3

H6

Total consumption since reset in 1000 000 m³

H7

Average consumption in m3 on Sundays

H8

Average consumption in m3 on Mondays

H9

Average consumption in m3 on Tuesdays

H10

Average consumption in m3 on Wednesdays

H11

Average consumption in m3 on Thursdays

H12

Average consumption in m3 on Fridays

H13

Average consumption in m3 on Saturdays

H14

Average service phases in days

H15

Peak flow in L/min

H16

Date and time of peak flow

H17

Months in operation

H18

m3 Water consumption since last regeneration tank 1

H19

m3 Water consumption since last regeneration tank 2

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Chapter 9: Softener

9.4.5

Data reporting

Note Documentation of the settings in the Settings report  As part of the Operational Qualification, the settings must be documented in the Settings reports upon start-up. Note Reports for the items of the operational qualification listed below are available as master copies in chapter 12: – Start-up – Setting – Maintenance

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Chapter 9: Softener

9.5

Specifications

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Chapter 9: Softener

9.5.1

Specifications / data sheet

Softener TYPE

E080(B)

E150(B)

E225-T

E300

E400

Duplex/altern.

Duplex/altern.

Triplex

Duplex/altern.

Duplex/altern.

Support gravel layer (per tank):

12.5 kg / 0.5 bag

12.5 kg / 0.5 bag

12.5 kg / 0.5 bag

25 kg / 1 bag

25 kg / 1 bag

Amount of resin (per tank):

38 L / 1.5 bags

75 L / 3 bags

75 L / 3 bags

150 L / 6 bags

200 L / 8 bags

Capacity per tank (°dH *m³):

96

192

192

360

480

Resin tank size

63 liters 10 x 54“ Ø 26 x 139 cm

105 liters 13 x 54“ Ø 34 x 139 cm

105 liters 13 x 54“ Ø 34 x 139 cm

194 liters 16 x 65“ Ø 41 x 162 cm

257 liters 18 x 65“ Ø 47 x 165 cm

Freeboard regenerated +5 cm

34 cm

33 cm

33 cm

30 cm

43 cm

Brine tank Ø x H [cm]

Ø 45/57 x 90

Ø 45/57 x 90

Ø 45/57 x 112

Ø 59/67 x 115

Ø 59/67 x 115

Salt grid height

12 cm

12 cm

12 cm

38 cm

38 cm

Weight without water

130 kg

210 kg

290 kg

350 kg

450 kg

Operating weight approx.

430 kg

600 kg

150 kg

800 kg

1200 kg

Regeneration volume

Approx. 320 liters

Approx. 575 liters

Approx. 575 liters

Approx. 920 liters

Approx. 1230 liters

Max. regeneration flow

20 L/min*

20 L/min*

20 L/min*

32 L/min*

32 L/min*

Salt per regeneration

4.8 kg

8.7 kg

8.7 kg

17.5 kg

23 kg

(Brine level measure) Setting dimension: upper level of float cup

(14 cm) 24 cm

(30 cm) 40 cm

(30 cm) 40 cm

(35 cm) 51 cm

(45 cm) 61 cm

Regeneration time

60 min*

70 min*

85 min*

90 min*

100 min*

Kv

2.2 m³/h

2.5 m³/h

5.5 m³/h

5.5 m³/h

6.0 m³/h

Minimum pressure

2 bar

2 bar

2 bar

2 bar

2 bar

Maximum pressure

8 bar

8 bar

8 bar

6.8 bar

6.8 bar

Ambient temperature

1-45°C

1-45°C

1-45°C

1-45°C

1-45°C

Water temperature

1-36°C

1-36°C

1-36°C

1-36°C

1-36°C

Voltage supply

230 V 60/50 Hz

230 V 60/50 Hz

230 V 60/50 Hz

230 V 60/50 Hz

230 V 60/50 Hz

W x D x H in mm

see space requirements

see space requirements

see space requirements

see space requirements

see space requirements

On pallet with prefiltration rack W x Dx H in mm

1400 x 800 x 1750

1400 x 800 x 1750

1400 x 800 x 1750

Softener design

* the values indicated are real values and depend on the actual available pressure.

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Chapter 9: Softener

9.5.2

Restrictor inserts depending on pressure range

SOFTENER TYPE E080(B) Required drain during backwash and fast rinse

E150(B)

E225-T

E300

E400

8–15 L/min

10–20 L/min

10–20 L/min

15–30 L/min

20–40 L/min

Restrictor hole at 4.5–6 bar

4.0 mm

4.0 mm

4.0 mm

Blue 5.0 mm

Red 5.5 mm

at 3-4.5 bar

4.0 mm

4.5 mm

4.5 mm

Red 5.5 mm

Green 6.0 mm

at 2-3 bar

4.5 mm

5.0 mm

5.0 mm

Green 6.0 mm

Without insert

The restrictor diameters specified are given for reference and may be optimized to meet the local conditions.

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Chapter 9: Softener

9.5.3

Softener capacities The table lists the softener capacities per tank in cubic meters of water, depending on the hardness of the water entering the softener:

Capacity in m³

SOFTENER E080(B)

E150(B) / E225-T

E300

E400

Hardness [°dH]

Hardness in mg CaCO³/L

1.9*

3.8*

7.2*

9.6*

2

40

48.0

96.0

180.0

240.0

4

80

24.0

48.0

90.0

120.0

6

110

17.5

34.9

65.5

87.3

8

150

12.8

25.6

48.0

64.0

10

180

10.7

21.3

40.0

53.3

12

220

8.7

17.5

32.7

43.6

14

260

7.4

14.8

27.7

36.9

16

290

6.6

13.2

24.8

33.1

18

330

5.8

11.6

21.8

29.1

20

360

5.3

10.7

20.0

26.7

22

400

4.8

9.6

18.0

24.0

24

440

4.4

8.7

16.4

21.8

26

470

4.1

8.2

15.3

20.4

28

510

3.8

7.5

14.1

18.8

30

540

3.6

7.1

13.3

17.8

32

580

3.3

6.6

12.4

16.6

34

620

3.1

6.2

11.6

15.5

36

650

3.0

5.9

11.1

14.8

38

690

2.8

5.6

10.4

13.9

40

720

2.7

5.3

10.0

13.3

* Total capacity of a tank in kg CaCO3 (with 48g capacity/liter of resin) as by P7 (see report master copy)

 Since the hardness frequently varies due to the water supply, a reserve of 1–2°dH should be entered.

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Chapter 9: Softener

9.5.4

Operating conditions For information regarding the operating conditions refer to the latest edition of the Installation Guideline (IGL).

9.5.4.1

Softener selection table

Note The choice of softener depends on the hardness of the feed water supply and on the required volume in L/h.  Use the softener selection table shown below. Hardness [°dH]

SOFTENER TYPE

Reverse osmosis system - rated output*

E080(B)

E150(B)

250

16–82

30–82

500

8–50

16–82

750

6–34

10–68

20–82

1000

4–24

8–50

16–82

1250

4–20

6–40

12–82

1500

4–16

6–34

6–54

10–68

1750

4–14

6–28

6–46

10–58

60–78

2000

4–12

4–24

6–40

8–50

52–68

2250

4–22

6–36

8–46

48–60

3000

4–16*

6–32

6–34

36–46

4–24

(4–24)

6–34

4000

E225-T

E300

E400

* at a yield of 70 % () Values at a flow between 40–60m/h or 1.1 - 1.7 cm/sec

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Chapter 9: Softener

9.5.4.2

Triplex softener (E225-T) The lower minimum hardness values are based on the request that, for microbiological reasons, a regeneration is to be effected every 24 operating hours. If the regeneration days are appropriately programmed in the control, a forced regeneration will be initiated to achieve lower hardness levels however at the cost of higher resources. Note  The set reserve of the Triplex softener must be increased when hardness increases. The following settings are recommended for a 2–3 shift supply profile.

Reserve % **

Hardness [°dH]

Reverse osmosis system

6

8

10

12

14

16

18

20

22

24

26

28

30

32

34

36

38

40

42

44

1500

0

0

0

0

0

0

0

0

0

0

0

5

10

15

15

15

20

20

20

25

1750

0

0

0

0

0

0

0

0

0

5

10

10

10

15

15

15

20

20

20

25

2000

0

0

0

0

0

0

0

0

0

5

5

10

10

15

15

20

25

30

---

---

2250

0

0

0

0

0

0

0

5

10

15

20

20

25

25

30

30

---

---

---

---

3000

0

0

0

0

0

5

10

15

15

15

20

25

30

30

---

---

---

---

---

---

4000

0

0

0

5

10

15

20

25

30

30

---

---

---

---

---

---

---

---

---

---

rated output*

* at a yield of 70 % ** reserve to be set as reference value depends on the supply profile.

9.5.5

Removal of iron and manganese using a softener The basic hardness setting of the softener must be adjusted as follows:

Substance

Hardness to be added

Hard water

Additional hardness level per retentate proportions (mg/l)

Iron (Fe 2+)

+3° dH

Manganese (Mn2+)

+5° dH

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Chapter 9: Softener

9.6

Maintenance Note The information given below is summarized for all water pretreatment components in Chapter 14 (Appendix): – Important information on maintenance procedures – Accessories and supplies – Test report - maintenance – Overview / maintenance intervals for water pretreatment components – Explanations for the test report

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Chapter 9: Softener

9.7

Error messages

9.7.1

Softener malfunctions overview

Problem

Possible cause

Action required

Error 1

– Power supply connected but control is unsure about the operating position.

 Pressing the Up key  should reset the control.

Error 2

– The control does not match the existing power frequency.

 Disconnect the power supply unit again and connect it again; if the problem persists, procure the control matching the frequency.

Error 3

– Control is unsure about the camshaft position and sets it on the master. – Error 3 persists for a prolonged period, and the camshaft does not rotate.

 Wait 2 minutes so the camshaft can be trued.

– Error 3 persists for a prolonged period despite rotating camshaft.

 The motor is not connected or its gear does not engage, check the component position and the cable. If necessary, replace the component.  The visual sensor may be unlatched, a strong light irradiation disturbs the sensor or it is defective.

– The control is unsure about the camshaft position and sets it at the secondary head. – Error 4 persists for a prolonged period despite rotating camshaft.

 Wait 2 minutes so the camshaft can be trued.

Display -- : --

– The control forgot the time due to power failure for a longer period.

 Set the time again with the Set key .

Brine tank overflow

– – – – –

 Check set height of float cup

Error 4

Uncontrolled refill flow Refill valve always open Inlet valve open in C2/3 as well Leaking brine line Drain clogged

 Check the secondary head for error causes same as for Error 3. In addition, check the connection cable.

 Check refill valve  Check function of inlet valve and clean it  Clean brine valve  Check brine line  Check drain valve

Fill operation or refill operation

9-52

– Valves contaminated – Valves leaking, possibly due to worn spring

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 Rinse valves until free and remove dirt  Replace spring

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Chapter 9: Softener

Problem

Possible cause

Action required

Hard water penetration after a regeneration

– Defective regeneration due to lack of salt – Over-estimated capacity – Leakage at the riser tube o-ring – Check brine suction (see below)

 Check salt level and dosage

– – – – –

 Ensure specified water pressure

Incorrect brine suction

Water inlet pressure too low Drain clogged Injector defective or clogged Inlet valve not closed Refill restrictor or brine valve clogged – Check set times

 Check resin volume and programmed volume  Check riser tube seal

 Check if the drain and restrictor are free  Clean injector and replace if necessary  Clean valve and replace if necessary  Check refill restrictor and brine valve  Check brine suction time and refill time  Check set control times

High concentration of brine

– Amount of brine too high – Incorrect brine suction – Minimum pressure not reached

 See problem: Brine tank overflow  See problem: Incorrect brine suction  Install booster pump

Poor or no automated regeneration

– – – –

Check flow indicator and sensor Check the power supply Check the shaft motor S300/400 sieve for servo flow clogged.

 Compare displayed flow and flow at reverse osmosis system  Check flow sensor for correct placement  Replace defective components  Clean sieve for servo flows

Regeneration at the wrong time

– Check time setting

 Correct if necessary

Salt consumption too high

– Check brine level prior to regeneration – Undiscovered brine bottle overflow

 Check brine settings and change if necessary  Check program times and values  Check for "Brine tank overflow"

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Chapter 9: Softener

Problem

Possible cause

Action required

Salt consumption too low

– Check brine level prior to regeneration

 Check brine settings and change if necessary  Check program times and values  Check for "Incorrect brine suction"

RO water shortage at regeneration.

– Water inlet pressure too low – Check drain valve – Check softener in operating position

 Ensure specified water pressure  Insert correct drain valve  Check inlet and outlet valves  Check resin tanks for absence of obstructions

Flow indicator incorrect

– Sensor not engaged – Flow turbine contaminated – Incorrect values lodged in the control

 Check flow sensor for correct position and function  Disassemble and clean flow turbine  Check values set in the control

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Chapter 9: Softener

9.8

Functional description

9.8.1

Design of components

Softener design Intended purpose The softener is an indispensable component of a central water treatment system in a dialysis unit. It replaces all components in the water causing water hardness, such as calcium (Ca++) and magnesium (Mg++), by sodium (Na+). The prevailing concentrations cause the sodium ions, which are attached to the ion exchanger resin, to be substituted by ions causing water hardness. In the course of the operating time the capacity of the ion exchanger resin will be exhausted which means that no more ions will be exchanged. The exhausted resin must therefore be regenerated to be able to use a saturated saline solution (NaCl). To ensure that a regeneration can also be performed during dialysis hours, a softener unit is generally a twin-tank (Duplex) or triple-tank (Triplex) design: While the one tank is in service, the other tank is regenerating. The two resin tanks of a twin-tank unit are controlled by a control head. The brine for regeneration is produced in a brine tank which is connected to the control head and which in turn is periodically refilled with salt tablets. The control head provides the brine tank with the amount of water required to produce the brine. It features an integrated, adjustable float mechanism which controls both the amount of water supplied and the amount of brine required for regeneration.

9.8.2

Component description The scale-forming calcium and magnesium ions in the softener pressure tanks are replaced by sodium ions. As the capacity of the softener is directly proportional to the amount of resin, but this amount is limited, the resin beds must be regenerated. This is done with sodium chloride brine. The brine or sodium-chloride solution is supplied by a brine tank. To ensure production of brine and softening, the salt, i.e. the salt tablets, in the brine tank must always be above the water level. If salt is refilled too late this may lead to high concentrations of brine or hard water.

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The specified, dynamic water pressure must be present to ensure reliable function of the softener. The system consumption and the regeneration flow must be considered in the water flow. Insufficient pressures may delay the regeneration and may also cause a water alarm. As the softeners are designed for continuous operation, at least two tanks are used for alternating operation. The minimum capacity of one tank must be sufficient for the regeneration time of the tank which is regenerating. As the flow velocities must not be too high, but also not be too low, the respective selection table is to be used to select the softener (Softener selection table / see below). The softener control counts the flow and initiates a volume-controlled regeneration. Idle times should be avoided. If the softener is not used for a longer period, a regeneration should be initiated either manually or by a higherlevel control unit. The control unit offers the possibility to enter the local water hardness by simply entering the hardness in milligram calcium carbonate per liter of water. The following applies: mg[CaCO3] = hardness value [.dH] * 17.86 = French degrees [fH.] * 10

9.8.3

Functional description Triplex operation E225-T In triplex operation a reserve is required as the softener tanks may all be empty simultaneously and a tank does not start regenerating before its minimum reserve has been reached. The reserve to be set depends on the system capacity of the reverse osmosis system and the prevailing hardness. An immediate regeneration P16 =3 with a defined reserve is selected in the control. The E225-T is equipped with one control on each tank valve. These controls are interconnected by a cable which they use for mutually signaling if a regeneration can be started or not. With the exception of the regeneration time, the controls all have the same setting.

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10 Activated carbon filter 10.1 Component overview – A050, A100, A150, A300, A400 Part number:

Complete assembly – description

F00001844

Activated carbon filter A050

F00001845

Activated carbon filter A100

F00001846

Activated carbon filter A150

F00001330

Activated carbon filter A300

F00001331

Activated carbon filter A400

A B C

D E F

G H

POS

Description

A

Outlet block with sampling port and tube connection

B

Control head

C

Upper sieve

D

Riser tube

E

Filter bed

F

Tank

G

Gravel bed

H

Lower sieve

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Chapter 10: Activated carbon filter

10.2 Installation 10.2.1 Installation / start-up requirements 

General information

Note Start-up of the system must be performed by a trained technician. The wiring must be adapted to fit the respective field of application. Note Prior to its start-up, check the system for damage caused during transport. If there are signs of damage to the electric components, do not turn the system on.

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10.2.2 Important start-up information

Activated carbon filters A050, A100, A150, A300, A400  The site of installation must be protected from frost and must be level, the floor load must be sufficient for the weight of the full activated carbon filter.  A floor drain is also required.  Do not expose the activated carbon filter to direct sunlight.  A 50 µm particle filter and a pressure gauge for pressure monitoring must be installed upstream of the activated carbon filter.  The maximum pressure must not be exceeded, if necessary, a pressure reducer must be installed.  The installation must be done in compliance with the local regulations.  Apply only small amounts of silicone-based FDA-approved lubricant to seals and valves.  Tighten plastic screw-connections only by hand.  The drain must be designed as a free flow to prevent backcontamination.  The activated carbon filter must be designed to ensure that the dwell time per tank is sufficient to reduce the total chlorine content downstream of a tank to a value of 0.1 mg/L. The flow in the bed should not be below 5 m/h and should not exceed 25 m/h.  The flushing of retained particles and possible coatings achieved by the backwash is negligible; its purpose is preventing tunnel effects in the filter bed.  Therefore the pressure drop cannot be used as a criteria for the backwash time, as it may rise by up to a maximum of 50 %. The standard time interval between two backwashes is one week. This can be adjusted to local conditions.  Long times of no use should be avoided ; this should be ensured by rinsing the reverse osmosis system. When filling the filters:  Both filters must be filled with the supplied filter media prior to startup; after filling, the filter tanks should be filled completely with water by means of the immersion pipe. It facilitates ventilation at start-up.  Please observe the soaking time for activated carbon filters. Otherwise it may cause washing out of fine carbon dust over time.

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10.2.3 Start-up of the activated carbon filter  When the filter has been set up and the control has been programmed the system must be carefully ventilated and rinsed. Before this is done, it must be checked that all lines and equipment upstream of the filter has been thoroughly rinsed. To rinse the filter, the outlet of the filter must be dismounted and discarded to the drain. The water inlet valve must be opened slowly and only partly. Watch the removal of air until water exits.  When water exits, the tank is thoroughly ventilated during the backwash phase C1 by the start of a regeneration.  When all air has been removed, the remaining phases are all skipped after a short rinse by briefly and simultaneously pressing  + . If ventilation is complete, the water inlet valve can be fully opened.  Rinsing should be followed by a manual regeneration to check the drain. In addition to this, the dynamic pressure of the water supply should also be checked.  When the tank has been rinsed sufficiently, i.e. it has been rinsed with 5 times the bed volume, the filter outlet can be re-mounted. The complete water pretreatment system must now be rinsed briefly and can then be connected to the reverse osmosis system.  The programmed values must be documented in the start-up report. 10.2.3.1 Valve heads and drain restrictor The drains for all filters must be designed as free drains using the lines supplied and ensuring that paths are as short as possible. The drain outlets are restricted to reduce the flows. A050 / A100 / A150

A300 / A400

Sieve for servo flows Drain restrictor Drain

Drain

Restrictor inserts depending on pressure range:

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ACTIVATED CARBON FILTER TYPE

Required drain during backwash and fast rinse Restrictor hole



A050

A100

A150

A300

A400

approx. 45 L/min

approx. 45 L/min

approx. 45 L/min

approx. 60 L/min approx. 3600 L/h

approx. 60 L/min approx. 3600 L/h

6 mm

6 mm

6 mm

8 mm

8 mm

Operating phases (Service, Backwash, Fast rinse) The control initiates a time-controlled backwash of the filter at defined intervals. During the first regeneration phase, the backwash phase, the filter bed media is lifted and separated, and rinsed. This phase is intended to backwash all collected contaminants to the drain. During the following phase, the Fast rinse, the filter bed settles again and is pre-rinsed to reduce the start-up phase of the filter in service. The backwash phase generally lasts 5 minutes, but should be extended depending on the quality of the feed water and the condition of the drain water on site, until an acceptable drain water quality is achieved. Note The time should be selected so as to rinse for at least 2-3 tank volumes. The operation cycles of the filter are therefore divided into three phases: Service

Backwash

Service

Backwash

Fast rinse

Fast Rinse

For the rinse time settings, refer to the master copies in the appendix.

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Chapter 10: Activated carbon filter



Backwash times The backwash of sand filters must be timed to occur outside the operation time of the reverse osmosis system. Additionally, the softener may not regenerate during the reverse osmosis operating time. It must be ensured that e.g. an AquaA is not in the Supply or Rinse mode while the sand filter is backwashed. It should be possible to fully run a regeneration of the softener possibly initiated by rinsing of the AquaA. 2.5hours before the backwash of the sand filter, an operation of 10 minutes in the Supply mode using the auto-start and auto-stop function, and a rinse interval phase, which lasts at least 4 hours, should therefore be programmed on the AquaA. Due to the long time intervals, it is recommended not to rinse the activated carbon filter(s) on the same day as the sand filters. At best they can be backwashed subsequently. First the activated carbon filter(s) and then the sand filter.

4 hours rinse interval

AquaA 2.5 hours interval

Softener Sand filter

max. 110 min regeneration Activated

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

Configuration of the free flow for drains (e. g. rack) A050 / A100

S300 / S400

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10.2.3.2 Valves in control head The valves in the A050–150 are switched directly and can be opened manually for rinsing in case of servicing. When filters A300 / A400 with large valve are used, activates the camshaft via the motor. The camshaft switches the control valves for the actual disk valves. A050–A150

Drain

A300 / A400

Drain 1 Rinse 2

Outlet

Outlet 3

Drain 1 Inlet 4

Inlet 4 and 5

Inlet

Outlet 3 Rinse 2

10.2.3.3 Control unit design  On the large valves of the A300 / 400, the housing unit of the control must be secured on the valve.  This is done by removing the protective cover of the camshaft, by pushing the spring lever on the end of the shaft outwards and pulling the shaft a little back so that it is aligned on the front.

 Then remove the housing unit from its box and push it fully onto the rear lugs.

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 Then slide the shaft back to the front. This may only be done with the arrow marks being on the top.  Refit the protective cover and reconnect the 12 V/AC 150 mA power supply unit to the control unit.

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10.2.4 Programming the control unit 10.2.4.1 Control / display

During operation, time and day are displayed. The day is identified by the triangle that moves from left to right. A bar will be displayed below the date indicating the days during which a regeneration will take place. In Europe the first day of the week is generally the Sunday. If a regeneration is in progress, the regeneration symbol will be displayed. Current display: In the picture shown it is Sunday and the filter is currently regenerating. 10.2.4.2 Control / operating elements

Display

manual regeneration Reg.

Down  Save Set 

10-10

Up 

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10.2.4.3 Control unit At the start the control must be set to the correct system configuration. When inserting the control, the following screens may be displayed:



Fig. 1 Example

If 255 A is flashing, the correct system configuration can be selected directly with the  arrow key. E.g. for sand filter S300 / 400 293 F must be selected. When the correct configuration is flashing, confirm with Set .

Fig. 1

Filter valve configuration Settings for the following filter valves:



263 F

S140, S200, A050, A100, A150

293 F

S300, S400, A300, A400

Fig. 2

Fig. 2

The control has already filed a configuration and is in progress of aligning the shaft. The system configuration must be entered again with a Reset (see level 4).

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Chapter 10: Activated carbon filter



Fig. 3

Fig. 3

The display shows only dashes. In this case, there is also a stored configuration, and the control prompts you to enter the current time and day. This setting is lost in case of a prolonged power loss. Here, it is also recommended to enter the system configuration again with a reset (see level 4).



Level 1 Level 1 can only be accessed with a new control after turning power on or with a Reset (see level 4). Basic data is entered in this level.  The arrow keys  or  are used to scroll, Set  is used to release the value for changing it, the arrow keys are used to change the value, and Set  is used to save the value.

LEVEL 1 –

Select valve 293 (S300/400) or 263 (S140/200) and configuration

–

Select F for filter mode.

P1

Current time

P2

Current day defined by arrow at upper display edge from Sunday to Saturday.

P3

Regeneration time

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LEVEL 1 P4

Regeneration days 0.5–99 = interval, days between regenerations, selection of 0 will activate a 7-days timer:

P5

Rinse days can be activated with [  ] and [  ] or [  ]; if P4 = 0 (Europe: 1 = Sunday)

P6

Backwash time in minutes

P7 and P8

not used



Level 2 Level 2 is also used to define basic parameters.  This level is accessed by simultaneously pressing the Up and Down keys + for 5 seconds.  This can only be done from the normal operation display. (Therefore if Error3 or Error4 is displayed and the system configuration has not yet been defined or verified, immediately go to level 4 and make a reset.)  The arrow keys  or  are used to scroll, Set  is used to release the value for changing it, the arrow keys are used to change the value, and Set  is used to save the value.

LEVEL 2 P9

Must be set to 1 for the selection of metric units.

P10

Selection of the time display, must be set to 1 for 0–24 hrs.

P11

Maintenance interval in months – recommended 0

P12

Time delay in seconds for remote regeneration – default 60

P13–P19

not used

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Chapter 10: Activated carbon filter



Level 3 - operating phase times Level 3 is used to display or define the times of the operating phases.  This level is accessed by simultaneously pressing the Set and Down keys  +  for 5 seconds. This can only be done from the normal operation display, not during a regeneration.

LEVEL 3 C1

Backwash in min – can be changed

C2–C4

not used

C5

Fast rinse in min – can be changed

C6–C8

not used



Level 4 – history Level 4 is used to see the history.  (Possibility in H0 for a reset with the Set key  for 5 seconds).  This level is accessed by simultaneously pressing the Set and Up keys  + for 5 seconds. (This can even be done during a regeneration.) Example:

LEVEL 4 H0: F

Filter display (reset by pressing the Set key  for 5 seconds.)

H1: 0

d days since last regeneration

H2–H16

0 not used

H17: 4

months since service

H18 and H19

0 not used

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

Start regeneration  When pressing the Reg. key, the Reg. symbol will be flashing. This indicates that a delayed regeneration is due which would start at the programmed time P3.  If the Reg. key is pressed for 5 seconds, the Reg. symbol will be displayed permanently and a regeneration will be started immediately.  Pressing the Set and Up keys  +  briefly and simultaneously, will quickly skip a phase. This will set the remaining phase time, which is displayed by briefly pressing the Set key , to 0.  A regeneration which has started,can be skipped by pressing the Set and Up keys  + for 5 seconds.

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10.2.4.4 Activated carbon filter A050, 100, 150 programming table - control Logix 762



Level 1 Return to default screen: From each menu after 30 seconds idle phase. Operation indicator Indication of time and current day

Level 1 –

263

Valve and configuration

–

F

Filter

P1

e.g.: 9:30

Current time

P2

 upper edge

Current day, arrow 1-7 (Europe: 1=Sunday)

P3

2:00

Backwash time

P4

0

Regeneration days 0.5 - 99 interval, 0-7 days timer

P5

Rinse days

Rinse days can be activated with  and  or  if P4=0

P6

5 / 8 / 12

Backwash time in minutes

P7

–

Capacity in m3

P8

–



Level 2  and  for 5 seconds. Blocking a value with the Reg. key

LEVEL 2 P9

1

Selection for metric units

P10

1

Selection of time display 0–24 h

P11

0

Maintenance interval in months

P12

60 seconds

Time delay for remote regeneration

P13–19

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

Rinse days in P5

Regeneration

1

2

Change

n

...

Yes / No

/

...

Continue

/



3

4

5

6

7

Level 3 +  for 5 seconds Time in minutes: A300 / A400

Manual start of backwash Time-delayed regeneration

Short regeneration

Immediate regeneration

Regeneration 5 seconds

Cancel regeneration

+  for 5 seconds

Skip phase

+  short During a regeneration, always the remaining time of the complete regeneration will be displayed. Display of the remaining time of the phase with 

LEVEL 3 C1

mod

A50 = 5 min A100 = 8 min

Backwash 1

A150 = 12 min C2

–

–

–

C3

–

–

–

C4

–

–

–

C5

mod

A50 = 3 min A100 = 4 min

Fast Rinse 1

A150 = 5 min C6/C

–

–

–

C8

–

–

–

Σ

A50 = 8 min A100 = 12 min A150 = 17 min

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

Level 4 and  for 5 seconds In H0 : 5 seconds, reset for control - then Reg. for synchronization.

LEVEL 4 H0

F

Filter display

H1

Days since last regeneration

H17

Months in operation

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10.2.4.5 Activated carbon filter A300 / 400 programming table - control Logix 762



Level 1 Return to default screen: From each menu after 30 seconds idle phase. Operation indicator Indication of time and current day

LEVEL 1 –

293

Valve and configuration

–

F

Filter

P1

e.g.: 9:30

Current time

P2

 upper edge

Current day, arrow 1-7 (Europe: 1=Sunday)

P3

2:00

Backwash time

P4

0

Regeneration days 0.5 - 99 interval, 0-7 days timer

P5

Rinse days

Rinse days can be activated with  and  or  if P4=0

P6

8 / 10

Backwash time in minutes

P7

–

Capacity in m3

P8

–



Level 2  and  for 5 seconds. Blocking a value with the Reg. key

LEVEL 2 P9

1

Selection for metric units

P10

1

Selection of time display 0–24 h

P11

0

Maintenance interval in months

P12

60 seconds

time delay for remote regeneration

P13–19

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Chapter 10: Activated carbon filter



Rinse days in P5

Regeneration

1

2

Change

n

...

Yes / No

/

...

Continue

/



3

4

5

6

7

Level 3 and  for 5 seconds Time in minutes: A300 / A400

Manual start of backwash Time-delayed regeneration

Short regeneration

Immediate regeneration

Regeneration 5 seconds

Cancel regeneration

and  for 5 seconds

Skip phase

+  briefly During a regeneration, always the remaining time of the complete regeneration will be displayed. Display of the remaining time of the phase with 

LEVEL 3 C1

mod

A300 = 8 min

Backwash 1

A400 = 10 min C2

–

–

C3

–

–

C4

–

–

C5

mod

A300 = 4 min

Fast Rinse 1

A400 = 6 min C6/C

–

C8

–

S

A300 = 12 min A400 = 16 min

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

Level 4 and  for 5 seconds In H0 : 5 seconds, reset for control - then Regeneration for synchronization.

LEVEL 4 H0

F

Filter display

H1

Days since last regeneration

H6

Total consumption since reset in 1000 000 m3

H17

Months in operation

10.2.5 Data reporting

Note Documentation of the settings in the Settings report As part of the Operational Qualification, the settings must be documented in the Settings reports upon start-up. Note Reports for the items of the operational qualification listed below are available as master copies in chapter 12: – Start-up – Setting – Maintenance

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10.3 Specifications 10.3.1 Specifications / data sheet

Softener TYPE

A050

A100

A150

A300

A400

Support gravel layer (per tank):

25 kg / 1 bag

25 kg / 1 bag

25 kg / 1 bag

25 kg / 1 bag

25 kg / 1 bag

Amount of activated carbon (per tank):

50 L / 25 kg / 1 bag

100 L / 50 kg / 2 bags

150 L / 75 kg / 3 bags

200 L / 102 kg / 4 bags

250 L / 128 kg / 5 bags

Filter tank size

105 liters 13 x 54“ Ø 34 x 140 cm

170 liters 16x65" Ø 41x162 cm

250 liters 18x65" Ø 47 x 165 cm

250 liters 18x65" Ø 47 x 165 cm

310 liters 21 x 60“ Ø 55 x 172 cm

Freeboard +5 cm

55 cm

69 cm

70 cm

43 cm

40 cm

Weight (not filled)

70 kg

100 kg

155 kg

190 kg

220 kg

Weight (filled)

170 kg

290 kg

400 kg

430 kg

540 kg

Riser tube Ø distance above upper edge of tank

Ø 28 20–25 mm

Ø 28 20–25 mm

Ø 28 20–25 mm

Ø 48.3 0-5 mm

Ø 48.3 0-5 mm

Rinse volume

Approx. 350 liters

Approx. 500 liters

Approx. 750 liters

Approx. 720 liters

Approx. 960 liters

Backwash flow*

45 L/min*

45 L/min*

45 L/min*

60 L/min*

60 L/min*

Backwash time

15/20/25 min

15/20/25 min

15/20/25 min

Individually adjustable

Individually adjustable

Kv

2.7 m³/h

2.8 m³/h

3.0 m³/h

6.1 m³/h

6.5 m³/h

Minimum pressure

2 bar

2 bar

2 bar

2 bar

2 bar

Maximum pressure

6 bar

6 bar

6 bar

6.8 bar

6.8 bar

Ambient temperature

1-40°C

1-40°C

1-40°C

1-45°C

1-45°C

Water temperature

1-40°C

1-40°C

1-40°C

1-36°C

1-36°C

Voltage supply

230 V 60/50 Hz

230 V 60/50 Hz

230 V 60/50 Hz

230 V 60/50 Hz

230 V 60/50 Hz

Per power supply unit

12 V~

12 V~

12 V~

12 V~

12 V~

Filter design

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Softener TYPE

A050

A100

A150

A300

A400

35x60x160

42x60x187

50x60x192

55x72x200

55x72x200

Floor space W x D x H in mm

* the values indicated are real values and depend on the actual conditions and available pressure (values given in brackets are theoretical limits for flow velocities of 15-20 m/h)

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10.3.2 Operating conditions For information regarding the operating conditions refer to the latest edition of the Installation Guideline (IGL).

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10.3.2.1 Activated carbon filter (Single) selection table

Dwell time in min Activated carbon filter size

* at a yield of 70 % A050

A100

A150

A300

A400

System capacity (L/h)

250

8 (minimum)

500

4 (minimum)

8 (minimum)

750

6 (minimum)

8 (minimum)

1000

4 (minimum)

6 (minimum)

1250

3 (minimum)

5 (minimum)

8 (minimum)

1500

4 (minimum)

6 (minimum)

8 (minimum)

1750

4 (minimum)

6 (minimum)

7 (minimum)

2000

3 (minimum)

5 (minimum)

6 (minimum)

2250

3 (minimum)

4 (minimum)

5 (minimum)

3 (minimum)

4 (minimum)

3000 4000

3 (minimum)

10.3.2.2 Activated carbon filter (double) selection table

Dwell time in min Size Activated carbon filter

* at a yield of 70 % A050

A100

A150

A300

A400

System capacity (L/h)

250

16 (minimum)

500

8 (minimum)

16 (minimum)

750

12 (minimum)

16 (minimum)

1000

8 (minimum)

12 (minimum)

1250

6 (minimum)

10 (minimum)

16 (minimum)

1500

8 (minimum)

12 (minimum)

16 (minimum)

1750

8 (minimum)

12 (minimum)

14 (minimum)

2000

6 (minimum)

10 (minimum)

12 (minimum)

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Dwell time in min 2250

* at a yield of 70 % 6 (minimum)

3000

8 (minimum)

10 (minimum)

6 (minimum)

8 (minimum)

4000

10-26

6 (minimum)

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Chapter 10: Activated carbon filter

10.4 Maintenance Note The information given below is summarized for all water pretreatment components in Chapter 14 (Appendix): – Important information on maintenance procedures – Accessories and supplies – Test report - maintenance – Maintenance intervals / overview for components of the water pretreatment – Explanations for the test report

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Chapter 10: Activated carbon filter

10.5 Error messages 10.5.1 Activated carbon filter malfunctions overview

Problem

Possible cause

Action required

Outflow outside of regeneration

– Valves contaminated – Valves leaking due to worn spring – Water inlet pressure too low – Sieve for servo flows clogged

– Rinse valves until free and remove dirt – Replace spring – Check inlet pressure – Clean sieve for servo flows

Poor or no automated regeneration

– – – –

– Replace defective components – Clean sieve for servo flows

Regeneration at the wrong time

– Check time setting

– Correct if necessary

RO water shortage due to regeneration.

– Regeneration time not offset to RO rinsing time

– Set the times appropriately

10-28

Check the control Check the power supply Check the shaft motor A300/400 sieve for servo flow clogged.

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Chapter 10: Activated carbon filter

10.6 Functional description 10.6.1 Design of components

Activated carbon filter design Components: – Outlet block with sampling port and tube connection – Control head – Upper sieve – Riser tube – Filter bed – Tank – Gravel bed – Lower sieve

10.6.2 Component description The flow velocity of the water starts to decrease in direction of the activated carbon filter. The water is also forced to find its way through the spacing between the activated carbon bed. Substances in the water attach to the large surface, 300–-1200m² per gram, of the activated carbon which is extremely porous. As only suspended particles and possible layers, but not the adsorbed substances, can be removed by backwashing, the activated carbon must be replaced after a certain time.

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Chapter 10: Activated carbon filter

To permit economic operation, two tanks are connected in series and loading and exhaustion of the first tank are monitored by regular checks. When the limit of a total chlorine content of 0.1 mg/L has been reached after collecting a sample after the first tank, this tank will be filled with new activated carbon and will be returned to operation as the second tank in the flow. A flexible tubing eliminates the need to change its position.

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Chapter 11: USER RELEVANT – Operational data acquisition / maintenance

11 USER RELEVANT – Operational data acquisition / maintenance

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Chapter 11: USER RELEVANT – Operational data acquisition / maintenance

11.1 Operational data acquisition / daily report The following page shows the operational data acquisition report (daily report) for the water pre-treatment system.

11-2

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Chapter 11: USER RELEVANT – Operational data acquisition / maintenance

OPERATIONAL DATA ACQUISITION

DAILY REPORT

Water pretreatment

Site of installation

_____________________________________________________

Address

_____________________________________________________

ZIP code

_____________________________________________________

Place

_____________________________________________________

Responsible technician: Phone: GENERAL NOTES Monitoring of the operating parameters is indispensable to ensure a safe and continuous operation of the reverse osmosis unit. Meticulous recording of the data is also an absolute requirement for potential warranty claims. If values deviate, inform the technical service to be able to take appropriate action before a malfunction occurs.

International service

Fresenius Medical Care Deutschland GmbH Service Support International Hafenstraße 9 D-97424 Schweinfurt Germany Phone: +49 (0)9721 678-333 (Hotline) Fax: +49 (0)9721 678-130

Local service

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Chapter 11: USER RELEVANT – Operational data acquisition / maintenance

OPERATIONAL DATA ACQUISITION / DAILY REPORT Year:_______ Calendar week:_______

Water pretreatment Procedure

Alarm limit

Weekday

Entries (operator)

Unit

Mon

Tue

Wed

Thu

Fri

Sat

Sun

__:__

__:__

__:__

__:__

__:__

__:__

__:__















______

______

______

______

______

______

______

---

















metric) pulse per liter or P18=4 l/pulse

Pr

Preliminary refill 0=none 1=preliminary refill

Pd

Time-delayed remote regeneration 0=immediate 1=time-delayed

Level 3 C1

Backwash1

C2

Draw (function of P15)

C3

slow Rinse

C4

Repressurize / Standby

C5

Fast Rinse 1

C6/C

–

C8

Refill (function of P14)

S

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Chapter 12: SERVICE RELEVANT – Reports

12.2 Maintenance 12.2.1 Important information on maintenance procedures Checks

This chapter includes the required maintenance procedures (MA). The maintenance procedures (MA) are a recommendation of the manufacturer. The maintenance procedures must be carried out every 2 years (24 months) and ensure troublefree operation.

Tester's qualification

The checks must be performed by the technical service of Fresenius Medical Care or a person authorized by them. The checks may only be performed by persons qualified to properly perform the specified checks owing to their educational background, training, knowledge and experience. Furthermore, the persons performing the checks must not be bound by any directives when performing this activity.

Test equipment and accessories

The activities described in this technical document require the availability of the necessary technical test equipment and accessories.

Specifications

Observe the information on the specifications.

Precautions

Before turning power on, repair any visible damage. Prior to opening the system and when working on the open system, the following precautions have to be observed: – Protect the components against ingress of fluids. – Do not touch live parts. – Disconnect and connect all jacks, connectors and components only when the device is turned off.

ESD precautions

12-14

When repairing the system and when replacing spare parts, observe the applicable ESD precautions.

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Chapter 12: SERVICE RELEVANT – Reports

12.2.2 Accessories and supplies for maintenance procedures

Note  The required accessories and supplies are listed in the electronic Spare Parts Catalog eSPC. Note  The required replacement intervals are specified in the maintenance report.

12.2.3 Maintenance report The following page shows the Maintenance report for the Water pretreatment.

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Chapter 12: SERVICE RELEVANT – Reports

MAINTENANCE REPORT Water pretreatment

Manufacturer:

Date:

Technician's name: System:

Technician:

Intervals (every 24 months):

The following inspections must be carried out at no greater than 24 months' intervals.

MA

No.

Description

Desired value / function



1 Water pretreatment - visual inspections MA

1.1

Labels and inscriptions.

Are present and legible.



MA

1.2

Mechanical condition of components.

Permits further safe use.



MA

1.3

Damage or contamination.

Not detectable.



MA

1.4

Power cable.

No signs of damage.



Moisten water sensor; valve closes, audible alarm



Close the stop valve and start a backwash on the coarse filter; the pipe disconnector disconnects. (Green cap is visible)



Perform a backwash.



2 Water sensor MA

2.1

Water sensor.

3 Pipe disconnector MA

3.1

Functional test.

4 Backwashable particle filter MA

4.1

Backwash.

5 Booster pump MA

5.1

Leakage.

No leakage.



MA

5.2

Running noise

No running noise.



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Chapter 12: SERVICE RELEVANT – Reports

MA

No.

Description

Desired value / function



6 Sand filter MA

6.1

Backwash and times

Backwash performed and times checked.



MA

6.2

Time

Corresponds to the current time.



MA

6.3

SDI test.

Specified: SDI < 3



MA

6.4

Replacement interval – sand

Specified: every 4 years.



7 Activated carbon filter MA

7.1

Backwash and times

Backwash performed and times checked.



MA

7.2

Time.

Corresponds to the current time.



MA

7.3

Residual chlorine concentration on the outlet (chlorine strip test)

Collect a sample:



Chlorine: ______________________ mg/L Specified: free chlorine < 0.1 mg/L.

MA

7.4

Replacement interval – activated carbon

Specified: every 4 years.



8 Softener MA

8.1

Hard water sample.

Hardness: ______________________ ° dH



MA

8.2

Check hardness setting.

Hardness setting checked.



MA

8.3

Soft water sample

Hardness: 0 °dH



MA

8.4

Brine valve.

Check and clean if necessary.



MA

8.5

Brine tank

Drain and clean the brine tank.



MA

8.6

Regeneration control and volume flow:

Manual regeneration initiated and times checked.



Initiate manual regeneration and check set times and level in the brine tank.

in C4/C8 - completely filled

in C4 - completely aspirated

Check flushing in C3 (taste test if necessary) MA

8.7

Compare flow on softener display and flow of RO system.

Values OK?



MA

8.8

Replacement interval – softener resin

Desired: every 8 years



6 Particle filter MA

9.1

Filter element.

Replace filter element.



MA

9.1

SDI test.

Desired: SDI < 3



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Chapter 12: SERVICE RELEVANT – Reports

The system has been released for its intended use.

 Yes  No

Comments:

Date:

12-18

Signature:

Stamp:

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Chapter 12: SERVICE RELEVANT – Reports

12.3 Tools and test equipment 12.3.1 Test equipment

HMED case set complete with electronic pressure gauge Part no.: M30 770 1

COND 3210 (part no.: 630 635 1) - without RS232 or COND 3310 (part no.: 630 634 1) - with RS232 Case set complete with CD temperature meter

ESC Service kit, complete Part no.: 630 387 1

Analog test set TKA29 for system separator Part no.: 634 566 1

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Chapter 12: SERVICE RELEVANT – Reports

Flow meter for reverse osmosis systems Part no.: 634 465 1

Visocolor HE Chlor test kit Part no.: 631 688 1

Test kit for determination of the water hardness Type: Visocolor ECO Part no.: 635 091 1

Filter HWP 47 mm, 0.45 µm Part no.: 631 391 1

SDI silt density index measuring device Part no.: 631 811 1

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Chapter 13: Definitions

13 Definitions 13.1 Definitions and terms Dialysate

The exchange fluid used in dialysis.

13.2 Abbreviations Fig.

Figure (diagram)

13.3 Symbols See component documentation.

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Chapter 13: Definitions

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Chapter 14: Appendix

14 Appendix Note Reports required as master copies for use by operators and service technicians are to be found in Chapter 11 (user relevant) and Chapter 12 (service relevant).

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Chapter 14: Appendix

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