Softener OM.pdf

Water Treatment Equipment For Commerce & Industry

7869 North 73rd Street · Milwaukee, WI 53223 · Telephone 414-365-0787 · FAX 414-365-0248 www.lakesidewater.com

INSTALLATION AND OPERATION MANUAL

NANCREDE ENGINEERING CO.

INDIANAPOLIS, IN.

1-317-257-7201

FOR

FREITAG-WEINHARDT

TERRE HAUTE PRISON

TERRE HAUTE, IN.

WATER SOFTENER

JOB NO. L-02495A

TWIN INDUSTRIAL

WATER TREATMENT SYSTEM

MODEL # XLWT-9750-6" TWIN

Shipped October, 2002

INDEX

1.0 GENERAL SYSTEM DESCRIPTION

2.0 EQUIPMENT INSTALLATION

2.1 Twin Softener & Brine Skid

2.2 Electrical Requirements

2.3 Control Tubing Requirements

3.0 START-UP PROCEDURE

3.1 System Operating Specifications

3.2 Loading Vessels

3.3 Initial Regeneration

4.0 PROCESS SEQUENCE OF OPERATIONS

5.0 TROUBLESHOOTING

6.0 EQUIPMENT AND INSTRUMENT OPERATING AND MAINTENANCE

MANUALS

7.0 RECOMMENDED SPARE PARTS

8.0 ELECTRICAL SEQUENCE OF OPERATIONS

9.0 ELECTRICAL DRAWINGS

D-02495-14 Main Control Panel D-02495-13 Elementary Schematic Diagram D-02495-15 Brine Transfer Pump Starter Enclosure D-02495-16 Brine Tank Pressure Switch Enclosure

10.0 PLUMBING AND TUBING DRAWINGS

D-02495-01 XLWT-9750-6" P & I Diagram D-02495-02 Softener L/O D-02495-11 Valve Timing & Sequence Chart D-02495-03 Brine Transfer Pump L/O D-02495-21 Brine System Float & Operation D-02495-10 Valve Tubing Soft.

A-02495-01 Valve & Instrument Sched

1.00 GENERAL SYSTEM DESCRIPTION

Sodium Cycle Softener System and Brine Transfer

The Sodium Cycle Softener system consists of two (2) 120" diameter by 84" sideshell 100 PSIG ASME Code Cation exchange columns, each containing 325 cu. ft. of Strong Acid Cation resin in the sodium form. Maximum system flow rate is 1800 GPM. The exchange capacity of the softeners is 9,750,000 grains per vessel, based on maximum salting. The system uses a flow totalizer(FET-1ZA/B) to initiate the automatic regeneration. The system uses saturated Sodium Chloride salt brine to regenerate the Strong Acid Cation exchange resin. Only one (1) unit may be in regeneration at a time. The brine is prepared in a Brine Lixator and is transfer to the Brine Measuring Tank. The Brine Measuring Tank has an automatic brine measuring level control(LC-1Z) and a refill valve(FV-8Z). The saturated brine is diluted and pumped to the exhausted exchanger via a brine transfer pump(P-1ZA/B). Control of the Backwash and Rinse flow rates is accomplished through the use of a variable orifice type automatic flow controls(FC-1ZA/B & FC-2ZA/B). The electrical controls permit manual operation of the system in service and regeneration if power to the control system is lost. The butterfly valves(FV-1ZA/B...FV-6ZA/B) are pneumatically controlled by stagers with individual shuttle valves. The butterfly valves(FV-2ZA/B) are pneumatically controlled by stagers with individual shuttle and solenoid valves.

The mode of operation during the service cycle is on demand, with units placed in service based on flow demand. The system starts with one unit placed in service, and as the flow rate increases, the additional unit is automatically placed in service. As the system demand changes, units are placed in stand-by or service based on the total system flow rate required. The Programmable Logic Controller (PLC) totals the gallons treated by each softener unit. Regeneration of a softener unit automatically starts when the softener unit reaches a preset throughput gallons.

The Brine Measuring Tank is supplied with a refill valve(FV-8Z) and level control(LC-1Z).

During regeneration, brine is pumped(P-1ZA/B) from the brine measuring tank through the brine valve(FV-7Z) based on a preset level and time. After the brine injection/slow rinse step has been completed, the brine tank refill valve(FV-8Z) opens until the tank has reached the preset refill level.

DESIGN WATER ANALYSIS

The following water analysis was used as the basis for the projected capacities and water quality for this ion exchange system. Any variations in the actual water composition will directly affect the values presented in this proposal.

Element or Compound Design Value

Total Hardness (As CaCO3) Unknown Temperature 40° to 100° F

EQUIPMENT PERFORMANCE - SODIUM ZEOLITE SYSTEM

If the design water analysis is accurate, and the equipment is operated in accordance with the manufacturer’s ongoing recommendations each Sodium Cycle Softener will deliver the following to service per regeneration:

Water Quality: < 1 GPG Total Hardness (per ASTM Soap Test) Capacity: 30.0 KGR per FT3, 9750 KGR Total

Throughput Based On Water Analysis

Any variation in the following will directly effect the throughput and effluent quality of the system:

A. The design water analysis as supplied is accurate and consistent.

B. The cation exchange resin will be regenerated with 10% to 15% by weight brine at a chemical dosage equivalent to 15# of 100% sodium chloride per cubic foot of resin.

C. The flow rate for the system will be maintained at a minimum of two (2) GPM (7.5 l/m)per square foot of cross sectional area of the ion exchange vessel.

D. Influent Iron will be less than 0.3 PPM Iron as Iron.

E. Influent Turbidity will be less than 6 NTU.

F. Influent Suspended Solids will be less than 5.0 PPM.

G. Influent Color will be less than 5 APHA units.

H. Influent Organics will be less than 1.0 PPM Oxygen Demand, and less than 2.0

PPM TOC.

I. The influent free Chlorine level will be less than 0.3 PPM chlorine as chlorine.

J. The purity of the salt used to regenerate the softener meets or exceeds the standards outlined in the ASME Performance Test Codes for ion exchange equipment (PTC31).

2.0 INSTALLATION OF EQUIPMENT

Reference Drawings:(SMS DEMAG DRWG NO.)

D-02495-01 P & I Diagram D-02495-02 Softener Layout & Assembly D-02495-11 Valve Sequence and Timing Chart D-02495-10 Valve Tubing Diagram-Twin Softeners D-02495-21 Brine System Float & Operation D-02495-03 Brine Transfer Pump Skid Layout D-02495-13 Elementary Electrical Schematic D-02495-14 Main Control Enclosure D-02495-15 Brine Transfer Pump Starter Enclosure D-02495-16 Brine Pump Pressure Switch Enclosure

2.1.1 INSTALLATION OF THE SOFTENER UNITS

2.1.1.1 Place each Softener unit on a firm foundation, preferably concrete, and level. Caution! Tank may be unstable until loaded with media. Brace tank to prevent tipping during installation. An open floor drain should be located near the Softeners to receive the regenerant waste piping.

2.1.1.2 Reassemble all components removed for shipping to be field installed(Refer to Installation Drawing.)

2.1.1.3 Place the Brine Transfer Pump skid and Brine Measuring tank on a firm foundation, preferably concrete, and level. An open floor drain should be located near the Brine Measuring tank to receive the overflow piping. Assemble the Brine Measuring tank outlet to the Brine Transfer pump inlet connection.

2.1.2 CUSTOMER PIPING CONNECTIONS

2.1.2.1 Connect Softeners service inlet water piping to the 6"-150# Flanged Service Water Inlet connections 1ZA & 1ZB. Provide an isolation valve on the inlet of each softener (not furnished).

2.1.2.2 Connect waste outlet piping and fittings to the 6"-150# Flanged softener waste outlet connections 3ZA & 3ZB. This piping must run to an open drain with an air break. DO NOT reduce the size, valve, or elevate this piping. The regenerant chemical injection can be adversely affected.

2.1.2.3 Connect Softener service outlet piping, manual valves and Service

Outlet Flow Sensor w/installation fittings (FE-1ZA & FE-1ZB) to the 6"-150# Flanged Service Outlet connections 2ZA & 2ZB. Proper lengths of straight pipe must be installed per manufacturer’s instructions upstream and downstream of these flow sensors.

Install manual by-pass valve (not furnished) between service inlet & outlet common piping.

2.1.2 CUSTOMER PIPING CONNECTIONS (Cont.)

2.1.2.4 Connect the 4"-150# Lug Stlye Dilute Brine Outlet to Softener connection 5Z located on the Brine Pump Transfer skid to the 4"-150# Lug Style Dilute Brine Inlet connections 4ZA & 4ZB located on the Softeners. Install a dilute brine sample valve on this piping.

2.1.2.5 Connect raw water piping to the 2 1/2" Lug Style Brine Dilution Water

Inlet connection 6Z.

2.1.2.6 Provide Strong Brine Transfer piping from the Brine Lixator Outlet connection to the 2" F.N.P.T. Brine Measuring Tank Refill connection 9Z.

2.1.2.7 Assemble all components removed for shipping from the Brine

Measuring Tank. Connect the control tubing from the Brine Measuring Tank level controller LC-1Z to valve FV-8Z, Level Switches PS-1Z & 2Z and Pressure Gauges PI-5Z & 6Z per the Brine System Float & Operation tubing diagram (D-02495-21).

2.1.2.8 Connect a Brine Measuring Tank overflow to drain piping from the 2"

F.N.P.T. Brine Measuring Tank overflow connection to an open drain.

2.2 ELECTRICAL REQUIREMENTS

2.2.1 Insure that the electrical power circuit to the Control enclosures is de-energized. Open the enclosures and insure that the Stager dials are in the No. 4 position, "Service".

2.2.2 Bring 120V., 60 HZ, 5 AMP min. single phase power supply wiring to the Softener Main Control Panel (MCP). Ground in accordance with local requirements.

2.2.3 Provide interconnecting wiring between the Main Control Panel and the flow sensors and the Brine Tank Pressure Switch Enclosure per the Electrical Schematic.

2.2.4 Bring 480V., 60 HZ, 15 AMP min. three phase power supply wiring to the Brine Pump Starter Enclosure. Ground in accordance with local requirements.

2.3 CONTROL TUBING REQUIREMENTS

2.3.1 The pneumatic tubing that controls the butterfly valves for the softeners was installed at the factory. Reinstall any tubing removed for shipment.

2.3.2 Connect a source of clean, dry oil-free instrument quality air to the pressure regulators PCV-1Z A/B. Adjust the regulators per the Valve Tubing Diagrams D-02495-10.

3.0 START-UP PROCEDURE

3.1 SOFTENER SYSTEM OPERATING SPECIFICATIONS

REGENERATION SCHEDULE- XLWT-9750

STEP

Backwash @ 60° F

Brine Injection @ Maximum Salting

Displacement Rinse

Fast Rinse

TOTAL

TIME

(Minutes)

≈24

≈36

WATER

FLOW

GPM

CHEMICAL

FLOW

GPM

TOTAL

Gallons

19128

3.1.1 EXCHANGE MEDIA (per Vessel)

325 cu. ft. C-100 Strong Acid Cation Resin = 325 bags 153 cu. ft. 1/8 x 1/16 Quartz Subfill = 15300 lbs. = 153 bags Media Bed Depth = 50" Freeboard - 64% (34" from top of bed to tangent line of tank head)

3.1.2 REGENERATION SALT (NaCl) USAGE

Design: Minimum Salting - 6,500,000 Grains Exchange Capacity per Vessel 6 lbs. of NaCl per cubic foot of C-100 resin 1950 lbs. of NaCl (˜780 gallons 100° Salometer Brine) per regeneration Design: Maximum Salting - 9,750,000 Grains Exchange Capacity per Vessel 15 lbs. of NaCl per cubic foot of C-100 Resin 4875 lbs. of NaCl (˜1950 gallons 100° Salometer Brine) per regeneration

3.1.3 MISCELLANEOUS

Inlet Water Pressure = 40 PSIG Min., 100 PSIG Max.

Inlet Water Temperature = 35°F Min., 100°F Max.

Brine Draw From Brine Measuring Tank = 49 1/4" FE-1ZA/B set point = Based On Water Analysis LL-1Z set point* = 0"(turns “OFF” P-1ZA/B) LH-1Z set point* = 49 3/4"(closes FV-8Z) LL-2Z set point = switch closes when dilution water pressure drops during flow condition LH-2Z set point = switch opens when dilution water pressure increases during no flow (static) condition *set point levels are measured from bottom of tank

3.2 LOADING SOFTENER PRESSURE VESSELS

3.2.1 Close all manual isolation valves on inlet and outlet water lines. The butterfly/diaphragm valves which are controlled by individual solenoid valves have manual operators. The controls are designed to open the butterfly/diaphragm valve when the solenoid valve is energized. To manually open the butterfly/diaphragm valves for this procedure, rotate manual operator stem at the bottom of solenoid valve and turn clockwise until it stops. The solenoid valve will be in the same position as when the solenoid valve is energized. Rotate manual operator stem on the solenoid valve fully counterclockwise until until it stops to close butterfly/diaphragm valve, and before operating valve electrically. The butterfly/diaphragm valves which are controlled by stagers and also operate manually, by rotating the stager dial clockwise thru the different stager positions.

3.2.2 Carefully remove the access manways to the top head of the vessels. TO AVOID DAMAGE TO TANK INTERIOR WITH YOKE

TYPE ELLIPTICAL MANHOLES IT IS WISE TO SECURE A LINE

TO THE MANHOLE COVER AND AN EXTERIOR PIPE OR LIFT

LUG PRIOR TO LOOSENING THE MANHOLE YOKES. Do not drop anything into the vessels that may damage the internals.

Inspect internal distributors and lining for shipment damage.

3.2.3 Rotate the stager dial for "A" Softener to position No. 1, "Backwash"

(Note: Stager Position numbers are visible from the inside of the stager enclosure). Slowly open the raw water inlet manual isolation valve. Allow the Softener vessel to fill 1/3 full of water. Close the raw water inlet manual isolation valve.

3.2.4 Carefully load the quartz sub-fill. The bags themselves do not go into the vessel. Avoid pouring quartz into the inlet distributor. Level the quartz as required. Failure to do this may result in poor system performance. The quartz should completely and evenly cover the underdrain distributor.

3.2.5 Carefully pour small quantities of the Cation resin into the vessel.

The bags themselves do not go into the vessel. Do not allow resin to get into the inlet distributor.

3.2.6 Slowly open the raw water inlet manual isolation valve. Allow the vessel to fill to near the top. Close the raw water inlet manual isolation valve. Replace the manhole cover in the top opening of the tank. Open the raw water inlet manual isolation valve.

3.2.7 As the vessel pressurizes the water will flow out through the auto flow control device FC-1Z, backwashing the newly installed resin.

Completely open the raw water inlet manual isolation valve to insure proper backwash flow rate is achieved (See Regeneration Schedule 3.1).

3.2 LOADING SOFTENER PRESSURE VESSELS cont.

3.2.8 Allow the "A" Softener to backwash until the waste effluent is clear.

This should take 15-20 minutes.

3.2.9 Rotate the Stager dial to position No. 3, "Fast Rinse". Allow the softener to continue rinsing for 10 minutes. The waste effluent should test soft (< 10 ppm Hardness). Rotate the Stager dial to position No. 4, "Service".

3.2.10 Repeat above steps for Unit "B".

3.3 INITIAL REGENERATION

The following procedure assumes that the resin has been backwashed and rinsed.

The Softener resin is shipped in the fully regenerated (sodium) form and no initial regeneration is required. This procedure is to check the operation of the Brine Transfer Pump(P-1ZA/B) and Brine Measuring Tank Level Control(LC-1Z) system.

All manual inlet isolation valves should be completely open. The vessel should be vented to remove any trapped air.

3.3.1 Open manual isolation valve (V-19Z) on the Brine Measuring tank.

3.3.2 Allow the Brine Measuring Tank to fill with saturated brine until the liquid level is at the 53" level and the float for LC-1Z is in the UP position. At this time Brine Measuring Tank Refill Inlet Valve FV-8Z should close, adjust if needed.

3.3.3 Open manual isolation valves V-12Z (Brine Dilution Water Inlet) & V-13Z

(Dilute Brine Outlet). Rotate the Stager dial of Unit "A" Softener to the No. 2, "Brine/Rinse" position. Valves FV-5ZA & FV-6ZA on Unit “A” softener will open. Open manual valves V-17ZA/B, V-18ZA/B and V-14Z on the Brine Transfer Pump skid. Manually open the Strong Brine inlet valve(FV-7Z) & turn “ON” the Brine Transfer pump (P-1ZA/B) and adjust the Brine Transfer Pump discharge manual rate set valve (V-14Z) until a flow of 77GPM is indicated on the Brine Transfer Pump Discharge Flow Meter (FI-2Z).

Observe that the brine level in the Brine Measuring Tank begins to drop.

The level should drop appox. 2" every minute. After a few minutes of Brine Injection, manually close the Strong Brine inlet Valve(FV-7Z) & turn “OFF” the Brine Transfer Pump(P-1ZA/B).

3.3.4 Unit “A” Softener is in the "Brine Displacement Rinse" position. Allow Unit

“A” Softener to rinse for 36 minutes. After displacement rinse is completed, rotate the Stager dial to the No. 3, "Fast Rinse" position. The brine tank will start refilling until the liquid level is at the 53" level and the float for LC-1Z is in the UP position.

3.3.5 Rotate the Stager dial to the No. 4, "Service" position. Open the manual inlet and outlet isolation valves. The unit is now in Service.

3.3.6 Place the Softener Main Control Panel Control Power selector switch in the "AUTO" position. All timers and set points have been set at the factory, and should not have to be adjusted. To shorten or extend a regeneration step or change set points refer to Section 8 of this manual. Close the panels and secure all hinges. The system is now in the normal operating mode.

4.0 PROCESS SEQUENCE OF OPERATION

4.1 Water Softener (Sodium Cycle)

STEP: Service

VALVES OPENED: FV-1ZA/B & FV-2ZA/B

PUMPS RUNNING:

FLOW RATE: 700 GPM Normal @ 100°F Max./Softener

1800 GPM Peak @ 100°F Max./Softener

TIME:

REMARKS: Raw water enters the top of the Softener through valve

FV-1Z. The water flows downward through the Softener resin, where calcium, magnesium and other trace ions (such as iron and manganese) which contribute "hardness" to the water are removed and replaced with "soft" sodium ions. The treated water exits through the bottom of the Softener vessel, through valve FV-2Z, to service.

4.2 Water Softener (Sodium Cycle)

STEP: Backwash

VALVES OPENED: FV-3ZA/B & FV-4ZA/B

FLOW RATE: 390 GPM (1474 lpm) Controlled ±10%

TIME: 12 minutes

REMARKS: The Softener is backwashed to expand the resin, remove suspended material and fines from the resin, and prepare the resin for regeneration. Water passes through valve FV-4Z, enters the bottom of the Softener vessel, and flows upward through the resin bed. The water exits out of the top of the Softener tank through valve FV-3Z, Automatic Flow Control FC-1Z, and then to drain.

4.3 Water Softener (Sodium Cycle)

STEP: Brine Injection

VALVES OPENED: FV-5ZA/B, FV-6ZA/B & FV-7Z

PUMPS RUNNING: Brine Measuring Tank Transfer Pump (P-1ZA or

P-1ZB)

FLOW RATE: 187 GPM Dilute Brine, 110 GPM Dilution Water, 77 GPM Saturated Brine

TIME: 24 Minutes

REMARKS: Raw water flows through the brine dilution water flow controller (FC-3Z) and mixes with the saturated brine that is being pumped by the brine measuring tank transfer pump through strong brine valve FV-7Z and flow meter FI-2Z forming a dilute brine regenerant solution.

The dilute brine solution concentration range is relatively wide at 10-16% wt. This is equivalent to 38° to 62° Salimeter or a Specific Gravity of 1.074 to 1.122 @ 60° F.

Dilute brine enters the Softener vessel through valve FV-5Z. The dilute brine proceeds downward through the cation resin removing "hardness" ions that were exchanged during the service cycle, replacing them with sodium ions.

The dilute brine exits through the bottom of the Softener vessel, flows through valve FV-6Z, automatic flow control FC-2Z, and then to drain.

4.4 Water Softener (Sodium Cycle)

STEP: Displacement Rinse

VALVES OPENED: FV-5ZA/B & FV-6ZA/B

FLOW RATE: 110 GPM Controlled ±10%

TIME: 36 Minutes

REMARKS: Raw water continues to flow through brine dilution water flow controller(FC-3Z), valve FV-5Z and into the top of the Softener vessel. The water continues downward through the cation resin, displacing the dilute brine remaining in the cation resin bed from brine regenerant injection.

The brine displacement rinse water exits through the bottom connection of the Softener vessel, flows through valve FV-6Z, flow controller FC-2Z, and then to

4.5 Water Softener (Sodium Cycle)

STEP: Fast Rinse

VALVES OPENED: FV-1ZA/B & FV-6ZA/B

FLOW RATE: 500 GPM Controlled ±10%

TIME: 12 Minutes

REMARKS: Raw water flows through valve FV-1Z, enters the top of the Softener unit, and proceeds downflow through the resin bed. The increased water flow removes the remaining traces of brine in the resin bed. The water flows through the bottom connection on the Softener vessel, valve FV-6Z, and Auto Flow Control FC-2Z to

4.6 Water Softener (Sodium Cycle)

STEP: Brine Measuring Tank (BMT) Refill

VALVES OPENED: FV-8Z

PUMPS RUNNING: -

FLOW RATE: 25 GPM

TIME: Approx. 74 min.

REMARKS: Saturated brine is pumped from the Brine

Maker/Storage Silo through the Brine Silo forwarding pumps to the BMT Refill Valve FV-8Z. Refill of the BMT continues until the level reaches a pre-set level, 53" (LH-1Z) terminating BMT refill.

5.0 TROUBLESHOOTING

6.0 EQUIPMENT AND INSTRUMENT OPERATING AND MAINTENANCE MANUALS

6.1 AquaMatic- Diaphragm Valves, Stager & Level Controller

6.2 ASCO - Solenoid Valves

6.3 Bellofram - Air Pressure Regulator

6.4 Blue/White - Flow Indicator

6.5 Flo-Controlet- Flow Controller

6.6 Keystone - Butterfly Valve & Actuator

6.7 Purolite - Resin

6.8 Signet - Flow Sensor

6.9 Goulds - Pump

6.10 U-1A Pressure Vessel ASME Forms

7.0 RECOMMENDED SPARE PARTS LIST L-02495A

Item Quantity

7.1 Aqua-Matic Valves

7.1.1 Diaphragm and Seal Kit 425RA 2

7.2 Gould

7.2.1 Softener Brine Transfer Pump - NPE 2ST1G5D6

7.2.1.1 Impeller, 4-5/8" Dia., PN 2L52 1

7.2.1.2 Mechanical Seal, PN 10K62 1

7.2.1.3 Case “O”-Ring, Viton, PN 5K2D4 1

7.2.1.4 “O”-Ring, PN 5K270 1

7.3 Asco Solenoid Valve, 3-Way, 110 V/60

7.3.1 Solenoid Valve, #8320-G1MS 2

7.4 Keystone Butterfly Valve

7.4.1 4" Fig. 222-786

7.4.1.1 EPDM Liner 3

7.4.1.2 Inboard Bearings, Bronze 6

7.4.1.3 Upper Bushing, Acetal 3

7.4.1.4 Torque Plug 3

7.4.1.5 Upper Stem Seal 3

7.4.1.6 Primary Stem Seal 3

7.4.1.7 Secondary Stem Seal 3

7.4.2 6" Fig. 222-786

7.4.2.1 EPDM Liner 1

7.4.2.2 Inboard Bearings, Bronze 2

7.4.2.3 Upper Bushing, Acetal 1

7.4.2.4 Torque Plug 1

7.4.2.5 Upper Stem Seal 1

7.4.2.6 Primary Stem Seal 1

7.4.2.7 Secondary Stem Seal 1

7.5 Signet

7.5.1 Rotor-X Low Flow Sensor PN 3-2536-P0 1

7.6 Ashcroft

7.6.1 Press. Ind., 2 1/2" Dial, Bronze Tube & Socket, 20-1005-02L-0-160PSI 3

8.0 Electrical Sequence Of Operation

Job # 02495A Rev. 1

8.1 System Description

8.2 Operational Modes

8.2.1 Operational Mode 1 (Manual)

8.2.2 Operational Mode 2 (Semi-Auto)

8.2.3 Operational Mode 3 (Auto)

8.3 System Operation

8.3.1 One unit in service - Service (1)

8.3.2 Two units in service - Service (2)

8.3.3 Unit in Stand-by

8.3.4 Alternate Units

8.4 Operator Interface

8.4.1 General Description

8.4.2 Function Keys

8.4.2.1 Alarm Silence

8.4.2.2 Unit "A" flow rate thru-put

8.4.2.3 Unit "B" flow rate thru-put

8.4.2.4 Reset TMR CNT Reg

8.4.2.5 Shift + F1 (keys)

8.4.2.6 Sys-flow thru-put

8.4.2.7 Shift + Reset T (keys)

8.4.2.8 Set "A" Batch

8.4.2.9 Shift + Reset AB (keys)

8.4.2.10 Set "B" Batch

8.4.2.11 Shift + Reset BB (keys)

8.4.2.12 Alternate Units

8.4.2.13 Shift + F2 (keys)

8.4.2.14 System Status

8.4.2.15 Shift + Regen Status (keys)

8.4.2.16 Start "A" Regen

8.4.2.17 Shift + Reset AR (keys)

8.4.2.18 Start "B" Regen

8.4.2.19 Shift + Reset BR (keys)

8.4.2.20 Hold Regen

8.4.2.21 Shift + Restart (keys)

8.5 Exhausted on Thru-put

8.6 Regeneration

8.6.1 Manual Start of Regeneration

8.6.2 Auto Start of Regeneration

8.6.3 Auto Start Before Exhausted (two units in service)

8.6.4 Advance Regeneration Step

8.6.5 Hold/Restart Regen

8.6.6 Reset from Regeneration

8.7 Change Register, Timer Value

8.8 Register, Timer Value Chart

8.9 Wrong Values in Register-Fault Message

8.10 Low Brine Tank Level Fault

8.11 Low Brine Dilution Water Flow Fault

8.1 System Description (hardware)

The electrical system consists of one main control panel, and a flow sensor for each unit.

The main control panel has an operator interface, fault alarm and a three-position selector switch mounted on the front door.

The control power three-position selector switch should be in the "Auto" mode for normal operation. In the "Manual" position, the outputs from the programmable controller are turned off. In the "Off" position, power to the electrical system is turned off. To "Manually" operate the stagers, the selector switch must be placed in the "Manual" position.

The operator interface is used to access data registers in the programmable controller. The flow rate and gallons remaining in each units thru-put batch can be displayed. The system flow rate and total gallons passed through the system can also be displayed. Regeneration can be started, advanced or reset by using the operator interface.

For additional functions and features, see the section which describes the operator interface in detail.

Located inside the main control panel is a Mitsubishi programmable controller (PLC). The system is pre-programmed at the factory. The only change that may be required is an adjustment to a regeneration step time, thru-put gallonage, operational mode or flow rate, at which the second unit is placed in service. The above changes can be made by using the operator interface.

The local stager/amplifier enclosure contains a multi-port valve (stager) , which is used to control the individual valves located on the face piping. Mounted on the bottom of the enclosure is a solenoid valve. The solenoid valve is used to control the service outlet valve. The solenoid valves are equipped with manual overrides.

NOTE: To manually override a solenoid and close the valve, turn the operator on the bottom of the solenoid clockwise until fully closed.

For normal operation, the override must be turned fully counter clockwise.

The stager can be manually rotated to perform a manual regeneration if necessary. The service outlet valve can be controlled by using the manual override on the solenoid valve.

8.2 Operational Modes

The system is programmed to operate in three of different modes. The modes are selectable by changing the value of the "Opera Mode" register.

The value can be changed by using the operator interface. See section 8.8 for a listing of the items that can be changed and section 8.7, for a detailed description on how to change a value. The following section describes the three different modes of operation.

8.2.1 Operational Mode 1 - Manual

Operational Mode 1 is established by placing a value of "1" in the "Operat Mode" register. See section 8.7 for a complete description on how to change a register value. Once placed in an operational mode the system will remain in that condition until changed by the operator.

Mode 1 is a manual mode of operation. When the a unit exhausts on gallonage thru-put, the alarm horn is actuated. The alarm can be silenced by depressing the alarm silence key. The operator interface will flash a message indicating which unit is exhausted. The unit that is exhausted will remain in service. The units can be alternated, by depressing the "Alternate Units" key, the stand-by unit will be placed in service and the exhausted service unit will be placed in stand-by.

A regeneration of the exhausted stand-by unit, can be started by depressing the start regeneration key of the exhausted unit. Once a regeneration is started, the unit advances through each step of regeneration automatically, and after completion of regeneration, is automatically returned to stand-by.

8.2.2 Operational Mode 2 - Semi Auto

Operational Mode 2 is established by placing a value of "2" in the "Operat

Mode 2 is a semi-auto mode of operation. When the a unit exhausts on gallonage thru-put, the alarm horn is actuated. The alarm can be silenced by depressing the alarm silence key. The operator interface will flash a message indicating which unit is exhausted. The unit that is exhausted will be placed in stand-by and the unit that was in stand-by will be placed in service.

A regeneration of the exhausted stand-by unit, can be started by depressing the start regeneration key of the exhausted unit. Once a regeneration is started, the unit advances through each step of regeneration automatically, and after completion of regeneration, is

8.2.3 Operational Mode 3 - Auto

Operational Mode 3 is established by placing a value of "3" in the "Operat

Mode 3 is a completely automatic mode of operation. When the service unit exhausts on gallonage thru-put, the stand-by unit is placed is service and the exhausted unit is placed in stand-by and a regeneration of the exhausted unit is started automatically. The unit advances through each step of regeneration automatically, and after completion of regeneration, is

8.3 System Operation

The system is programmed to have one unit in service at all times. The system can also be setup for progressive flow. If the flow thru the system increases beyond the setpoint for a pre-determined amount of time, the second unit is automatically placed in service. The second unit can be placed in or removed from service, depending on the flow rates.

Note: For alternating mode of operation, the flow rates to place the second unit in service, are set at a high value that can never be achieved. The second unit will then, never be placed in service with the first unit, in effect making the system a permanent alternator.

In normal operation (mode 3), when the unit in service exhausts on thru-put gallonage, it is removed from service and placed in regeneration automatically.

The unit that was in stand-by is then placed in service. The unit that was placed in regeneration automatically advances thru each step of regeneration. After completion of regeneration, the unit is returned to stand-by.

A manual regeneration of any unit can be started, as long as another unit is not in regeneration, by depressing the appropriate start regeneration key.

The unit can also be operated manually by placing the "Control Power" "OFF" - "MAN" - "AUTO" selector switch to the "MANUAL" position. In the manual position, all the outputs from the PLC are "OFF". The stager can then be rotated through the steps of regeneration manually without returning to the service position. The manual override on the solenoid valve can be used to open the service outlet valve.

Any unit can be in any one of the following conditions: Service (1), Service (2), Stand-By, or in Regeneration. See the following sections for a detailed description of each.

8.3.1 One Unit in Service - Service (1)

One unit is always in service. The unit that is in service is identified as Service (1).

In normal operation the Service (1) unit will be the first unit to exhaust on gallonage thru-put.

The unit will remain in Service (1) until it exhausts on gallonage thru-put or a regeneration is started manually.

If a unit is in Service (1) and it exhaust on thru-put gallonage, it is removed from service and placed in regeneration automatically, provided another unit is not in regeneration. After completion of regeneration, it is placed in the Stand-by position.

If a unit is in Service (1) position, a regeneration of that unit can be started manually before it exhausts on thru-put gallonage, by depressing the "Start Regen" key for that unit. After regeneration, it is placed in the Stand-by position.

8.3.2 Two Units in Service - Service (2)

One unit is always in service. If the system flow rate rises above the setpoint for the pre-determined amount of time, a second unit is placed in service and identified as Service (2) when the "System Status" key is depressed.

The unit that is placed in Service (2) was previously in Stand-by position.

Note: For alternating mode of operation, the flow rates to place the second unit in service, are set at a value that never can be achieved. The second unit will then, never be placed in service with the first unit, in effect making the system a permanent alternator.

The operator can adjust the flow rate or the length of time, the second unit will remain in service. There are five parameters that can be changed by using the operator interface, to place or remove the second unit from service. The operator adjusts these points by changing the value of a register in the PLC. See Section

8.7 for a description on how to access and change the register.

The following is register synonym identification and description of each:

Register Register Number Synonym Description

D0185 F/R 2nd ON Flow rate in GPM at which the second unit is placed in service.

D0186 F/R 2nd OFF Flow rate in GPM at which the second unit will be removed from service.

D0187 T DLY ON 2d Time in seconds; flow rate must be above value in Register D0185 before second unit is placed in service.

D0189 MIN T 2nd ON Minimum time in seconds; second unit will remain in service if flow rate is not above value in D0186.

D0191 MIN T 2nd OF Minimum time in seconds; system flow rate is below value in Register D0193 before second unit is removed from service.

8.3.2 Two Units in Service - Service (2) (continued)

Register D0185

When the systems flow rate rises above the value set in the register, the second unit will be placed in Service (2) after the time delay period established by the value in Register D0187.

Register D0186

When the system flow rate falls below the value set in this register for the time delay period established by the value in Register D0191 and the minimum of time of Register D0189 the second unit will be removed from Service (2) and placed in Stand-by position.

Register D0187

The system flow rate must be above the value in Register D0185 for the time set in this register, before the second unit is placed in Service (2). The purpose of this time delay is to avoid placing the second unit in Service (2) with just a momentary increase in flow rate. The value displayed is in seconds.

Register D0189

Once the second unit is placed in Service (2), it will remain on line as a minimum, the time set in this register. After the time delay, if the flow rate falls below the value set in Register D0186 for the time set in Register D0191 the second unit will be removed from service. The purpose of this delay is to avoid having the second unit banging on and off. The value displayed is in seconds.

Register D0191

The system flow rate must fall below the value set in Register D0186 for the time set in this register, before the second unit is removed from Service (2).

This time delay starts after the minimum "On" time set in Register D0189.

The purpose of this time delay is not to have a momentary drop in flow, remove the second unit from service. The value displayed is in seconds.

8.3.3 Unit in Stand-by Position

The unit that is in Stand-by position will be the next unit to be placed in service, if the system flow demand requires it, or if the existing service unit exhausts on thru-put.

8.3.4 Alternate Units

When the alternate key is depressed, the units will alternate provided a unit is not in regeneration. If the alternate key is depressed again, the unit alternates back. A two second delay is built into the alternating logic.

The alternating logic is also reset if a regeneration is started on either unit.

The alternating logic can also be reset by depressing the "Shift" + "F2" keys simultaneously.

8.4 Operator Interface

8.4.1 General Description

8.4.2 Function Keys

8.4.2.1 Alarm Silence

8.4.2.2 Unit "A" flow rate thru-put

8.4.2.3 Unit "B" flow rate thru-put

8.4.2.4 Reset Tmr Cnt Reg

8.4.2.5 Shift + F1 (keys)

8.4.2.6 Sys-flow Thru-put

8.4.2.7 Shift + Reset T (keys)

8.4.2.8 Set "A" Batch

8.4.2.9 Shift + Reset AB (keys)

8.4.2.10 Set "B" Batch

8.4.2.11 Shift + Reset BB (keys)

8.4.2.12 Alternate Units

8.4.2.13 Shift + F2 (keys)

8.4.2.14 System Status

8.4.2.15 Shift + Regen Status (keys)

8.4.2.16 Start "A" Regen

8.4.2.17 Shift + Reset AR (keys)

8.4.2.18 Start "B" Regen

8.4.2.19 Shift + Reset BR (keys)

8.4.2.20 Hold Regen

8.4.2.21 Shift + Restart (keys)

8.4.1 General Description

The operator interface is a two line, twenty character display with function keys allowing the operator to interface with the programmable controller. The operator interface and PLC are preprogrammed at the factory.

The operator interface will display system status, flow rate, thru-put gallonage, flow rate and thru-put gallonage remaining in the batch for each unit. By using the keys on the operator interface, a regeneration can be started and steps advanced or reset from regeneration. The batch thru-put can also be changed or reset. For a detailed description of each keys function, see the following sections.

The memory in the operator interface is battery backed SRAM. The battery life is 10 years (calculated).

The operator interface is password protected.

8.4.2 Function Keys

The function keys are used to perform various operations of the unit. After depressing a key, a message should appear indicating that the key has been depressed. If the message does not appear, the key was not pressed hard enough.

The keys that have an horizontal line in them are dual function keys. Pressing the key actuates the lower function. To enable the upper function, the "Shift" key and desired function key must be depressed simultaneously.

The following sections describe the operation of each of the function keys.

8.4.2.1 Alarm Silence Key

The alarm silence key is used to silence the fault alarm. When the system is in operational mode 1 or 2 and a unit exhausts on thru-put gallonage, the fault alarm is initiated. The fault condition will continue to be displayed, but the alarm will be silenced after the key is depressed.

8.4.2.2 Unit "A" Flow Rate Thru-put Key

Depressing the "Unit A Flow Rate Thru-put" key will display the flow rate of Unit "A" and the gallons remaining in the thru-put batch. The display will continue to show Unit "A" status until another status key is depressed, or a regeneration is started.

If a regeneration is started, either manually or automatically, the display will switch to the regeneration status until manually changed. After completion of regeneration, the system flow and total thru-put gallonage is displayed.

8.4.2.3 Unit "B" Flow Rate Thru-put Key

Depressing the "Unit B Flow Rate Thru-put" key will display the flow rate of Unit "B" and the gallons remaining in the thru-put batch. The display will continue to show Unit "B" status until another status key is depressed, or a regeneration is started.

regeneration, the system flow and total thru-put gallonage is displayed.

8.4.2.4 Reset TMR CNT REG Key

If a timer, counter or register value is changed, (see Section 8.7), the "Reset TMR CNT REG" key has to be depressed before the values are transferred to the program.

NOTE: If a unit is in regeneration, and the key is depressed, the transfer does not take place. Wait until the regeneration is completed and then depress the reset key to transfer the values. The mode of operation cannot be changed if a unit is exhausted on thru-put, or in regeneration.

8.4.2.5 Shift +F1 (Keys)

The "Shift" + "F1" keys depressed simultaneously can be used to start a manual compare. If the controls don't seem to be sequencing correctly, depress the above keys to reset the unit.

8.4.2.6 Sys-Flow Thru-put Key

When the "Sys-Flow Thru-put" key is depressed, the system flow rate and total thru-put gallonage is displayed. The display will continue to show the system status until another status key is depressed or a regeneration is started.

regeneration, the system flow and total thru-put gallonage is displayed again.

The total thru-put gallonage is the systems total gallonage. The gallonage will continue to add until a value of 9,999,999 is reached. It will then reset to "000" and continue counting again. The total can be reset to zero. See the following section.

8.4.2.7 Shift + Reset T (Keys)

The "Shift" + "Reset T" keys, depressed simultaneously, can be used to "manually" reset the total gallonage thru-put register to zero.

The total thru-put gallonage is the system total gallonage. The gallonage will continue to add until a value of 9,999,999 is reached. It will then reset to "000" and continue counting again.

8.4.2.8 Set A Batch Key

The "Set A Batch" key is used to set the gallonage thru-put for Unit "A". To change the thru-put or check existing batch size use the following procedure.

1) Depress the "Set "A" Batch" key

The following message appears:

ENTER BATCH FOR A

**** GALLONS

The number on the lower left is the existing batch size. If no changes are required depress the enter key.

2) To change the value, depress the "CLR" key, located in the lower left corner of the display. The displayed value should turn to zero's.

3) Enter the new batch size and depress the "ENT" key.

NOTE: The batch thru-put value will take effect after the next regeneration.

To reset the existing batch to the value just entered, depress the "Shift" and "Reset AB" keys simultaneously. A message will flash indicating the "Reset AB" key has been depressed. The new batch can be checked by depressing the "Set A Batch" key again.

8.4.2.9 Shift + Reset AB (Keys)

The "Shift" + "Reset AB" keys, depressed simultaneously, are used to reset Unit A thru-put to the existing preset batch size.

The manual rest of the thru-put gallonage can be used if the size of the batch has been changed and the operator doesn't want to wait until the next regeneration.

The batch is automatically reset when a unit is placed in regeneration.

8.4.2.10 Set B Batch Key

The "Set B Batch" key is used to set the gallonage thru-put for Unit "B". To change the thru-put or check existing batch size use the following procedure.

1) Depress the "Set "B" Batch" key

The following message appears:

ENTER BATCH FOR B

**** GALLONS

The number on the lower left is the existing batch size. If no changes are required depress the enter key.

2) To change the value, depress the "CLR" key, located in the lower left corner of the display. The displayed value should turn to zero's.

3) Enter the new batch size and depress the "ENT" key.

NOTE: The batch thru-put value will take effect after the next regeneration.

To reset the existing batch to the value just entered, depress the "Shift" and "Reset BB" keys simultaneously. A message will flash indicating the "Reset BB" key has been depressed. The new batch can be checked by depressing the "Set B Batch" key again.

8.4.2.11 Shift + Reset BB (Keys)

The "Shift" + "Reset BB" keys, depressed simultaneously, are used to reset Unit B thru-put to the existing preset batch size.

The manual rest of the thru-put gallonage can be used if the size of the batch has been changed and the operator doesn't want to wait until the next regeneration.

The batch is automatically reset when a unit is placed in regeneration.

8.4.2.12 Alternate Units Key

When the alternate key is depressed, the units will alternate provided a unit is not in regeneration. If the alternate key is depressed again, the unit alternates back. A two second delay is built into the alternating logic.

The alternating logic is also reset if a regeneration is started on either unit.

The alternating logic can also be reset by depressing the "Shift" + "F2" keys simultaneously.

8.4.2.13 Shift + F2 (Keys)

The "Shift" + "F2" keys depressed simultaneously can be used to reset the alternate units logic to normal.

8.4.2.14 System Status

When the "System Status" key is depressed, the display will list for two seconds, the status condition of each unit, whether in service, stand-by or in regeneration. After displaying the status of each unit, it will return to the System Flow and Thru-put display.

If the unit was in regeneration and the "System Status" key is depressed, the status of each unit is displayed, then the display will revert back to displaying system status. To return the display to show regeneration status, the Shift + "Regen Status" keys must be depressed.

8.4.2.15 Shift + Regen Status (keys)

The "Regen Status" key is used to return the unit to displaying the regeneration step, if another status key was used while the unit was in regeneration.

After regeneration is completed, the display automatically returns to displaying the system flow and thru-put gallonage.

8.4.2.16 Start A Regen Key

The "Start A Regen" key is used to start a manual regeneration of Unit A. A regeneration can be started at any time, provided another unit is not in

Once a unit is in regeneration, the "Start Regen" key can be used to advance through the regeneration steps. See Advance Regeneration step section for more details.

8.4.2.17 Shift + Reset AR (Keys)

The "Shift" + "Reset AR" keys, depressed simultaneously are used to reset Unit "A" from regeneration.

NOTE: Caution should be taken when resetting a unit from regeneration.

The unit is returned to stand-by or possibly service if required, and may not have quality water.

8.4.2.18 Start B Regen Key

The "Start B Regen" key is used to start a manual regeneration of Unit B. A regeneration can be started at any time, provided another unit is not in

Once a unit is in regeneration, the "Start Regen" key can be used to advance through the regeneration steps. See Advance Regeneration step section for more details.

8.4.2.19 Shift + Reset BR (Keys)

The "Shift" + "Reset BR" keys, depressed simultaneously are used to reset Unit "B" from regeneration.

NOTE: Caution should be taken when resetting a unit from regeneration.

The unit is returned to stand-by or possibly service if required, and may not have quality water.

8.4.2.20 Hold Regeneration

The "Hold Regen" key is used to hold a regeneration in the step it is in.

If the unit is in regeneration, and the hold key is depressed, a message is flashed indicating the regeneration is stopped.

REGENERATION

ON HOLD

When a regeneration is placed on hold, the valves remain in the position they were in, but the timing for the step is stopped. The display will also show which step of regeneration the unit was in, and how much time is remaining in that step.

The system will remain in that condition until the "Shift" + "Restart" keys are depressed again. At that point the timer will continue to time from the point it was stopped.

If a regeneration is on hold, the regeneration steps cannot be advanced.

8.4.2.21 Shift +Restart (Keys)

Once a regeneration is placed on hold, it will remain in that condition until it is restarted by the operator.

To restart the regeneration, depress the "Shift" + "Restart" keys simultaneously.

The regeneration will start timing from the point it was stopped.

8.5 Exhausted on Thru-put Gallonage

When the preset gallonage has passed through the unit, it is removed from Service

(1) and placed in regeneration automatically, provided another unit is not in regeneration. If another unit is in regeneration, it will wait until that unit completes regeneration before switching.

The number of gallons remaining in a batch can be monitored by depressing the "Unit "*" Flow Rate Thru-put" key. When the value reaches "0", the unit is exhausted.

8.6 Regeneration

8.6.1 Manual Start of Regeneration

A regeneration of the unit can be started manually, provided another unit is not in regeneration at that time. Regeneration of a unit can be started if a unit is in service or stand-by.

Once a regeneration is started, the unit advances through each step automatically.

After completion of regeneration, it is returned to stand-by.

8.6.2 Auto Start of Regeneration

In normal operation, when a unit exhausts on gallonage thru-put, it is removed from service and placed in regeneration, provided another unit is not in

If a unit is in regeneration when one exhausts, the exhausted unit will wait until regeneration is completed before removing the exhausted unit from service and starting regeneration.

8.6.3 Auto Start Before Exhausted (two in service)

If two units are in service, the service unit will start a regeneration before it becomes exhausted. The regeneration is started early to permit sufficient time to regenerate the service unit before the other units become exhausted.

This feature can be inhibited by placing value "0" in Register D0193. The register is presently set at 0 gallon. The value placed in the register is the number of gallons at maximum flow rate of the system that it takes to regenerate in time.

8.6.4 Advance Regeneration Step

Once a regeneration has been started, it can be advanced one step at a time by depressing the "Start * Regen" key of the unit that is in regeneration.

When the "Start * Regen" key is depressed, the unit advances to the next step of regeneration. At the beginning of the step, a delay is programmed into the advance function, inhibiting it until the stager has a chance to move to its next position. A regeneration cannot be advanced if the regeneration is on "Hold".

If the unit is in Fast Rinse, advancing one more step would remove it from regeneration and place it in stand-by.

8.6.5 Hold/Restart Regeneration

A regeneration step can be placed on "Hold" or "Restarted" by depressing the "Hold" or Shift + "Restart" keys.

While a regeneration is on hold, the following message is flashed:

REGENERATION

ON HOLD

When a regeneration is placed on hold, the valves remain in the position they were in, but the timing for the step is stopped. The system will remain in that condition until the "Shift" + "Restart" keys are depressed again. At that point the timer will continue to time from the point it was stopped.

If a regeneration is on hold, the regeneration steps cannot be advanced.

8.6.6 Reset from Regeneration

The unit can be reset from regeneration in two ways.

During any step of regeneration, the "Shift" + "Reset" keys (of the unit regenerating), depressed simultaneously, can be used to reset the unit from

If the unit is in "Fast Rinse", depressing the "Start * Regen" key of the appropriate unit will reset the unit from regeneration.

NOTE: Caution should be taken when resetting the unit from regeneration.

The unit is returned to service or stand-by and may not have quality water.

8.7 Change Register, Timer Value

To change the length of a regeneration step, delay timer or flow rate, use the following procedure.

1) Press the "Arrow" key and a message will be displayed of a time or register value that can be changed.

BACKWASH CT <-/->

D0195 12.0

1.1) The upper left corner is the timer register synonym label.

1.2) The upper right means to use either arrow key to scroll through the registers.

1.3) The lower left is the register number.

1.4) The lower right is the current value in the register.

NOTE: See Section 8.8 for regeneration step, timer and register chart identification.

2) After scrolling through the timer registers and finding the step that has to be changed:

2.1) Press the "New Data" key. The arrow "<-/->" symbol in the upper right corner is replaced by "Data?"

2.2) Depress the "Clr" key. The current value is replaced by "0".

2.3) Enter the new value and depress the"Enter" key. The present value of the timer is changed.

2.4) After changing the value, the "Reset TMR CNT REG" key must be depressed.

2.5) If more changes are required,…