SOFTENERS SERIES: AC/T AS/S AC/SV AS/T AS/SV …€¦ · SOFTENERS SERIES: AC/T AC/SV AS/S AS/T AS/SV AS/V ... All operations must be performed by and/or under direct supervision

REL. 2 Page 1 of 15 as_stvm_mi-r2.doc

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SOFTENERS SERIES: AC/TAC/SV

AS/SAS/TAS/SVAS/VAS/METER

INSTRUCTIONS MANUAL

WARNING!

The equipment must be used only for the utilization for which they have been designed, as shown in the technical documentation.

Read carefully this leaflet until the end before starting any operation.Proceed strictly according to all directions included in this manual.

Automatic softeners series AC & AS are designed to treat raw water supplied from municipalities or from well.

ANY OTHER APPLICATIONS OF THE EQUIPMENT DIFFERENT THAN THE MENTIONED ONES IS MADE UNDER THE ONLY RESPONSIBILITY OF THE USER.

For any assistance concerning the installations, maintenance or utilization of the equipment apply the NOBEL Service Center closest to you or directly:

NOBEL S.r.l.e-mail: [email protected]

tel. +39 02 2827968 fax +39 02 2610839

AUTOMATIC SOFTENERS INSTRUCTIONS MANUAL AC/T AC/SV AS/S AS/T AS/SV AS/V AS/METER

s.r.l. - ITALY Page 2 of 15 as_stvm_mi-r2.doc - r.2

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INDEX1. Safety ......................................................................................................................................3

1.1. CE mark, declaration of conformity.....................................................................................31.2. How to displace the unit......................................................................................................31.3. Hydraulics ...........................................................................................................................31.4. Electrical .............................................................................................................................31.5. How to store and delivery ...................................................................................................3

2. Principles of working................................................................................................................43. Technical characteristics .........................................................................................................4

3.1. Assumed raw water characteristics ....................................................................................43.2. Technical characteristics (general) .....................................................................................43.3. Characteristics for each model ...........................................................................................53.4. Dimensions .........................................................................................................................53.5. Weight.................................................................................................................................6

4. Installation ...............................................................................................................................64.1. Room conditions .................................................................................................................64.2. How to remove packaging ..................................................................................................74.3. How to move and lift the unit...............................................................................................74.4. Placing ................................................................................................................................74.5. Hydraulic connections.........................................................................................................84.6. Electrical wiring connections...............................................................................................8

5. End cycle and regeneration.....................................................................................................95.1. End cycle ............................................................................................................................95.2. How to select the end-cycle ................................................................................................95.3. Regeneration ....................................................................................................................10

6. Starting-up and settings.........................................................................................................117. Service & Maintenance..........................................................................................................12

7.1. Disposal ............................................................................................................................128. Components ..........................................................................................................................13

8.1. Programmers ....................................................................................................................139. Trouble shooting guide..........................................................................................................14

Annex:

• DRAWING 1a: components AC series • DRAWING 1b: components AS series • DRAWING 2a: installation and dimensions AC series • DRAWING 2b: installation and dimensions AS series • DRAWING 3: automatic valve S132 & S132/SV • DRAWING 4: automatic valve S230 • DRAWING 5: automatic valve S250 • Special instructions membrane valves. • Programmer special instructions • declaration of conformity



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1. Safety

1.1. CE mark, declaration of conformity The equipment is designed to meet state-of-the-art safety requirements, has been

tested and left the factory in a condition in which it is safe to operate. The equipment complies with the applicable standards and regulations as listed in the

CE declaration of conformity and thus complies with the statutory requirements of the CE Directives.

NOBEL confirms the successful testing of the equipment by sticking to it the CE mark.

1.2. How to displace the unit Particular care and attention should be put in during moving and displacing of heavy

items, in order to avoid injuries to persons or damage properties. (see § 3.5 page 6).

1.3. Hydraulics All operations must be performed by and/or under direct supervision of skilled and

authorized operators, using proper tools and personal protection devices if required (CE marked).

Before any operation of taking out pipes or part of hydraulic system, it is required to release the pressure inside and empty the part of the system.

1.4. Electrical Before starting any operation on electrical devices, be sure that main power supply is

OFF. All operations must be performed by skilled and authorized operators. In case of liquid leakage, switch off the main power supply before operate. Before the

switching ON, be sure all the parts of the system are perfectly dry. Check that the available electrical power is correct, (see § 3.2 page 4) before connection. Do not make preliminary wiring connections.

1.5. How to store and delivery = ºC t = ºF humidity rel. notes

• closed rooms 5÷45 41÷113 5÷95% without condensate

• open space 5÷45 41÷113 5÷95% without condensate protect from sun-light and rain. • transport 5÷45 41÷113 5÷95% without condensate protect from sun-light and rain.



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2. Principles of working

Softening is the process that allows to remove calcium and magnesium from water. These two elements, together with bicarbonate, are the main cause of the scale inside thermal plant and domestic appliances (heating system, laundry machines, etc.). They also can cause big trouble in many industrial process.

The process of softening is featured by ion exchange. The resins contained in the column exchange the ions calcium and magnesium (Ca++ and Mg++) against sodium ions (Na+), of which they are charged. When the resins are exhausted, they are fully charged of calcium and magnesium (Ca++ e Mg++) while they do not have any more sodium ions (Na+) available for exchanging and they need to be regenerated.

Regeneration means re-built the charge of sodium ions (Na+) available from sodium chloride (NaCl), common salt used in kitchen. During regeneration an exchanging back is performed of sodium ions (Na+) against ions calcium and magnesium (Ca++ e Mg++) which are carried away to drain. The equipment prepares automatically the brine from the salt (NaCl) in grain or tablets.

AC and AS series softeners are used for water treatment for residential and industrial applications as well. All the materials, resins included, are food grade and approved for drinking water.

The range of models includes systems with capacity from 1 up to 20 m³/h and capacity from 90 up to 4300 m³ x ºF. The working of the system is controlled by an automatic programmer, allowing to schedule the frequency and the hour for the regeneration. Then the system automatically starts the regeneration that proceed automatically. During regeneration, (except for "fast rinse" phase) the system supplies non softened water thanks to a by-pass inside the automatic valve; for AS/METER models, water supply during regeneration is completely inhibited by means of a membrane valve mounted on the outlet.

These system can be equipped with automatic sterilizing device (Nobel CL 90 or CL180), according to the local laws of some countries for the treatment of drinking water.

3. Technical characteristics

3.1. Assumed raw water characteristics • organics NIL • water temperature (min÷max) ºC (ºF) 5÷40 (41÷104) • water pressure (min÷max) bar (kPa) 2÷6 (200÷600)

3.2. Technical characteristics (general) • hardness of treated water (with raw water up to 30°Fr) ºFr < 0.5 • power supply V ph/Hz W 230 1/50 10 • regeneration time min. 40÷70



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3.3. Characteristics for each model MODEL connections flow max. cycle brine tank capacity consumption for

regenerationIN/OUT drain mm m³/h m³ x ºFr l tot ≅ kg salt salt kg water l

AC 90 1" 22 1.8 90 55 2.25 120 AC 150 1" 22 2.4 150 75 3.75 200 AS 90 1" 22 1.6 90 100 2.25 120 AS 150 1" 22 2.4 150 100 3.75 200 AS 210 1" 22 2.8 210 100 5.25 280 AS 300 1" 22 3.2 300 150 7.5 400 AS 450 1" 22 4.1 450 150 11.25 600 AS 600 1" 22 4.5 600 150 15.0 800 AS 800 1¼" 22 5.0 800 200 19.5 1040 AS 1050 1¼" 22 5 1050 300 26.25 1400 AS 1055 1½" 22 8 1050 300 26.25 1400 AS 1345 1¼" 22 5 1350 300 33.75 1800 AS 1350 1½" 22 9 1350 300 33.75 1800 AS 1355 1½" 1¼"F 11.5 1350 300 33.75 1800 AS 1650 1½" 22 9 1650 300 41.25 2200 AS 1655 1½" 1¼"F 11.5 1650 300 41.25 2200 AS 1950 1½" 22 9 1950 300 48.75 2600 AS 1955 2" 1¼"F 16 1950 300 48.75 2600 AS 3000 2" 1¼"F 18 3000 520 75.0 4000 AS 4300 2" 1¼"F 20 4300 850 108.75 5800

3.4. Dimensions

See DRAWING 2a or 2b installation & dimensions



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3.5. Weight WEIGHT (approx)

MODEL vessel with resins

brine tank shipping weight

on service

kg kg kg vessel kg brine tank (fill) kg AC 90 / / 35 110 / AC 150 / / 50 150 / AS 90 25 5 35 45 110 AS 150 35 5 45 65 110 AS 210 45 5 55 85 110 AS 300 60 6 75 120 160 AS 450 85 6 105 170 160 AS 600 115 6 140 230 160 AS 800 145 7 170 290 210 AS 1050 190 12 210 385 320 AS 1055 190 12 210 385 320 AS 1345 250 12 270 495 320 AS 1350 250 12 270 495 320 AS 1355 250 12 270 495 320 AS 1650 305 12 320 595 320 AS 1655 305 12 320 595 320 AS 1950 355 12 370 695 320 AS 1955 355 12 370 695 320 AS 3000 530 20 550 1060 540 AS 4300 750 30 800 1515 880

4. Installation

4.1. Room conditions These units do not include visible moving or specially noising parts. There are not any

high temperature points. In cold countries, whether the room temperature is below 15 °C (59°F), the salt requires longer time to be dissolved, even up to 10 hours; this feature must be considered in designing and selecting the correct system. Apply Nobel Technical Dept. for further information.

Room & climate conditions.

• room temperature 5÷45ºC (41÷113ºF) • humidity rel. 5÷95 % without condensate • sun-light protection required • rain, snow etc protection required



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4.2. How to remove packaging The packaging consist of one wooden crates that contain the vessel with resins, on

which the automatic valves have been already mounted; the brine tanks is shipped as separated, already assembled and protected by a plastic foil wrapped around.

Open the wooden crate removing, first, the side cover, then withdraw carefully the contents. Keep the cards and everything contained inside the packaging.

For models AC, which have the brine tank integrated in main structure, the packaging consist of one carton box.

For models AS 1050 and following, the vessel is empty and is packed in a single carton box, pallet-sized for the largest model. The resins are shipped as separated in bags of 25 liters each.

4.3. How to move and lift the unit The vessel containing the resins can be easily moved until it is in original packaging;

after removed the packaging it can be moved for short stretches by rotating it around their base, very carefully, to avoid the breaking of the plastic end.

The empty vessel and the brine tank can be moved avoiding bump or crashing which can seriously damage them.

Always do not move the vessel handling them by the top-mounted control valve.

4.4. Placing (see DRAWING 2a or 2b installation & dimensions)

• Follow the directions of the dimensional drawing for the correct placing of the unit, according to the dimensions of the available room and the required room for service and maintenance.

• Place the column of resins and the brine tank on a perfectly flat surface. NOTE : AC models, have the brine tank integrated in main structure.

For models AS 1050 and following, the resins are shipped separately.

The resins must be loaded according to the shipped quantity, and proceeding as follows:

Check that the shipped and available quantity complies exactly with the quantity listed in the Components Table (see § 8 page 13).

Keep the distribution pipe with bottom nozzle, exactly in the center of the vessel, while loading the resins. Take care that the resins do not fall inside the pipe; it can be useful to put on the hole a scotch tape or something else, during the loading.

After the loading has been completed, remove the scotch tape, if used, and clean perfectly the thread hole of the vessel, taking off the spheres of resins that could be there. Proceed in screwing on the control valve; the distribution pipe must be inserted inside the proper hole in the lower part of the control valve. In order to make this operation easier, it is suggested to lubricate the end of the pipe or to wet it with water.

After that, check that the O-ring seal from control valve and vessel is not damaged and is properly placed. Screw firmly the control valve on the vessel just tightening it by hand only. Do not use any tools.



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4.5. Hydraulic connections (see DRAWING 2a or 2b installation & dimensions, DRAWING 3, 4 or 5 automatic valves )

• connect the inlet and outlet fittings, placed on the back side of automatic valve, to the untreated water line. In order to avoid shut-off during maintenance operations, an emergency by-pass line should be provided.

The fittings of automatic valve type S132 (black plastic ones) have to be inserted just pushing them inside the connections of body valve and then fixed with proper pins. The fittings of valves type S230 and S250 are thread union type (bronze ones).

• MODELS AS/V only: insert pulse sender water meter, horizontally downstream the softener, along the outlet piping.

• MODELS AS/METER only: insert, pulse sender water meter - membrane valve unit, horizontally downstream the softener, along the outlet piping. Run the plastic tubes, already connected to the front of the automatic valve, to the fitting placed on the diaphragm valve.

CAUTION: It is recommended to hold the pipes with adequate brackets, to avoid breaking on the plastic connections.

• complete the line from the injector fitting placed on the top of the control valve to the fitting of the float valve mounted inside the regenerant tank, using the supplied plastic tube. For AC models such connection is already done.

• complete the line from the drain hose connection (placed on the side of automatic valve), to a floor drain, using a proper sized common flexible rubber or plastic tube (see § 3.3 page 5).

• for models AS1355, AS1655, AS1955, AS3000, AS4300 only : the plastic tubing already connected to the drain fitting of the pilots on rear side of the programmer, must be connected to the main drain line.

• connect the overflow fitting of the brine tank to a floor drain; this line must run separately from the above mentioned drain connection.

4.6. Electrical wiring connections • Connect the power feeder of the programmer to a power socket; check that the

available power is correct as listed in technical characteristics (see § 3.2 page 4). • MODELS AS/V and AS/METER only: Connect the DIN plug from the pulse sender

water meter on the socket placed on the side of the electronic programmer.



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5. End cycle and regeneration

5.1. End cycle The softeners are equipped with an electronic programmer that allows to schedule the

automatic regeneration (end of cycle). The regeneration runs according to the following modes :

• SERIES AS/S : electro-mechanic time programmer: (24 h, 7 days, max 1 regeneration per day)

• SERIES AC/T ed AS/T : electronic time programmer : selected time and day (24 h, 14 days, max 1 regeneration per day)

• SERIES AC/SV and AS/SV :

end-cycle by time/volume (pulse sender inside automatic valve); regeneration runs at selected time and day (24 h, 14 gg, max 1 regeneration per day), or after the preset volume of water has been supplied but only at a pre-set time.

• SERIE AS/V : as for AS/SV series but with external pulse sender water meter

• SERIE AS/METER : end-cycle by volume; regeneration runs after the preset volume of water has been supplied, with membrane valve to shut off the flow during regeneration

The end-cycle programming has to be adjusted according to the quality of available water and the consumption of water.

The max. quantity of available soft water the equipment can supply between two following regeneration is to be calculated as follows:

=

where 1°Fr = 10 ppm CaCO3 = 0.56° German

The cycle of all NOBEL softeners are expressed by the number identifying the model (i.e. AS 1350/V, the cycle is 1350 m3 x °Fr).

The regeneration can also be started manually at any time (see instruction of the programmer).

5.2. How to select the end-cycle The programmer installed on the AS/V and AS/METER series allows also working

mode time only, besides volume only and time/volume modes. Whether it is desired to use the equipment with working mode different than the

standard one, it is possible to select an end-cycle mode different than the pre-set one; it is required to select the new mode, according to the explanation in the special instruction of the programmer (mod. AQUA TIMER).

m³ of available soft water per cycle cycle of the softener (m³ ∗ ºFr)total hardness of raw water (°Fr)



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5.3. Regeneration

The regeneration phases run one after one, as follows :

1. Backwash: during this phase, the water flush from the bottom to the top of the column, lifting the resins which are mixed together and release the solids trapped on surfaces of the resins bed during the service. The backwashing water flows to drain from the top of the column. This is the only phase, during which the water crosses through the column from the bottom to the top. During this phase, it is very important to check that there is no leakage of resins to the drain.

2. brine drawing: during this phase, a concentrated solution of water and sodium chloride (common kitchen salt, in grain or, better, tablet) is drawn from the brine tank to the resins column, by an injector. The brine crosses through the column from the top to the bottom.

3. slow rinse: it is the first step of the rinse, during which the ion exchanges between sodium chloride and resins is featured. The time of this phase is not adjusted, since it starts when the brine tank is completely empty (all brine has been drawn); a special device built-in the brine float valve avoids the air drawing.

4. fast rinse: it is the phase during which the residual of salt is flushed away through the resins; at the end of this phase the resins column is ready to start again a new service cycle.

NOTE: During the fast rinse phase the unit supplies the water to the brine tank, in order to prepare the brine for the following regeneration. The brine tank refill will be automatically completed when the level mark of water reaches the float valve inside the tank.

NOTE: During regeneration, (except for fast rinse phase), an internal by-pass line allows the system to supply un-treated water; for AS/METER models, the water supplying during regeneration is completely inhibited by means of a membrane valve mounted on the outlet line.

See programmer manual for the time of each phase of regeneration.



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6. Starting-up and settings

The starting-up of the unit consists of running a first regeneration cycle, during which the column of resins and brine tank will be filled of water, all automatic features will be checked and the unit will be prepared to start the service.

During the starting-up is not required that salt is available inside the brine tank. At the end of the first regeneration, fill the brine tank with salt.

See § 3.3 page 5 for recommended quality of salt to be used.

To start-up the unit, proceed as follows :

• DISCONNECT ELECTRIC POWER • Open the by-pass valve, keeping the inlet and outlet ones shut. • Turn clockwise the eccentric disk (or cam shaft for models with S250 automatic

valve) located on the back of the programmer, until the first piston is pressed (BACKWASH).

• Open slowly and not completely the inlet valve. Water will enter from the bottom of the column as air will be expelled from the top to the drain.

• Using a pail, add water in the brine tank, until the water mark is approx. 30 cm (12 inches) from the bottom (this is required for the initial regeneration only and is automatically filled thereafter).

• When only water will come out, open completely the inlet valve and allow the water flush until the water looks clear.

• Turn again clockwise the eccentric disk (or cam shaft), until both pistons are pressed (BRINE DRAWING AND RINSE). Check that some water flows to the drain line, while, in the same time, the water flows from the brine tank to the unit. Check the water mark diminution in the brine tank (BRINE DRAWING).

• Turn again clockwise the eccentric disk (or cam shaft), until only the second piston is pressed. The first piston must be released (FAST RINSE). The water flows to the drain line; allow the water flowing until the drain water looks perfectly clear. In the same time the water flows to the brine tank, too, in order to prepare the brine for the following regeneration cycle. The water level inside the brine tank is automatically adjusted according to the float valve.

• Turn clockwise the eccentric disk (or cam shaft), until both pistons are released and not pressed (SERVICE).

• Switch on electrical power. • Put the salt into the brine tank (it can also be completely filled). Take care not to put

salt inside the protection pipe. • open the outlet valve and close the by-pass valve

Starting now the unit is on service and feeds treated water.

WARNING (for models AS1355, AS1655, AS1955, AS3000, AS4300 only) : It can happen a hydraulic misfunction of the control valve (S250), due to special operating situations (usually caused by high pressure drop through the inlet Iine of water). Whether it happens, it is possible to solve the problem just closing partially (reducing the flow of) the gate valve mounted on the drain of the valve. Please, take note that if the gate valve is closed too much, it can compromise the correct function of the brine suction during regeneration.



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7. Service & Maintenance

Softeners are equipment designed to treat raw water supplied from municipalities or from well.

ANY OTHER APPLICATIONS OF THE EQUIPMENT DIFFERENT THAN THE MENTIONED ONES IS MADE UNDER THE ONLY RESPONSIBILITY OF THE USER.

The correct handling of the equipment requires:

• take off the raw water suspended solids, if any, by an adequate filtration. • check that the water pressure is within the stated values. • check the salt level in the brine tank. A salt lack will cause the incomplete

regeneration of the resins, or not any regeneration at all. • it is suggested to use clean salt, better in the shape of tablets, available almost

everywhere, in order to avoid residuals of sand or dirties in the tank and along the brine lines.

Not any further special maintenance operations are required. The only consumption material is salt. The average life of the ion exchange resins is approx. 5÷8 years, according to the

quality of raw water and how often regeneration is featured.

7.1. Disposal In case of disposal of the unit or parts of it, it must be made according to local laws

concerning the waste of the materials. It should be taken in consideration that resins are usually listed as plastic materials and not as toxic or harmful material (the safety bulletin of resins are available upon request).



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8. Components

MODEL automaticvalve

resinvessel resins

distribution pipe

brinetubing float valves

water meter ***

diaphragmvalve **

type Ø x h (inches) l Ø mm Ø ext mm Ø (inches) Ø (inches) Ø(inches) & type

AC 90 S132* 8x30 15 32 9.5 ³/8" / /

AC 150 S132* 10x35 25 32 9.5 ³/8" / /

AS 90 S132* 7x35 15 32 9.5 ³/8" 1" 1"NA

AS 150 S132* 8x44 25 32 9.5 ³/8" 1" 1"NA

AS 210 S132* 10x44 35 32 9.5 ³/8" 1" 1"NA

AS 300 S132* 10x54 50 32 9.5 ³/8" 1" 1"NA

AS 450 S132* 13x54 75 32 9.5 ³/8" 1" 1"NA

AS 600 S132* 14x65 100 32 9.5 ³/8" 1" 1"NA

AS 800 S132* 16x65 130 32 9.5 ³/8" 1¼" 1¼"NA

AS 1050 S132 18x65 175 32 9.5 ³/8" 1¼" 1¼"NA

AS 1055 S230 18x65 175 50 9.5 ³/8" 1½" 1½"NA

AS 1345 S132 21x60 225 32 9.5 ³/8" 1¼" 1¼"NA

AS 1350 S230 21x60 225 50 9.5 ³/8" 1½" 1½"NA

AS 1355 S250 21x60 225 50 9.5 ³/8" 1½" 1½"NA

AS 1650 S230 21x69 275 50 9.5 ³/8" 1½" 1½"NA

AS 1655 S250 21x69 275 50 9.5 ³/8" 1½" 1½"NA

AS 1950 S230 24x69 325 50 9.5 ³/8" 1½" 1½"NA

AS 1955 S250 24x69 325 50 9.5 ³/8" 2" 2"NA

AS 3000 S250 30x72 500 50 Øi 16 ¾" 2" 2"NA

AS 4300 S250 36x72 725 50 Øi 16 ¾" 2" 2"NA

* AC/SV ed AS/SV series S132SV valve with built in pulse sender ** AS/METER series only *** AS/V and AS/METER series only

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repl

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unde

r-va

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filte

r

s.r.l.TEL. +39 02 2827968 FAX +39 02 2610839 e-mail [email protected]

via G.Galilei, 5 20090 Segrate (MI) - ITALY

AZIENDA CON SISTEMA QUALITÁ CERTIFICATO DA DNV

UNI EN ISO 9001/2008 www.nobelitaly.it

società italiana per lo studio e la realizzazione di apparecchiature ed impianti per il trattamento acqua engineering and manufacturing of equipments and plants for water treatment

M

3.6-

r4 sede legale : via dell’Unione 3 20122 Milano

C.C.I.A.A. 1250687 - EXPORT MI 044905 - Reg. Trib. Milano nº 272528 vol.7032 fasc.28 società a responsabilità limitata - cap. soc. € 99.000 i.v. - C.F. e P.I. : IT 08829620155

rev. 1

DICHIARAZIONE DI CONFORMITÀ DECLARATION OF CONFORMITY

La Nobel srl dichiara che l’apparecchiatura (vedi etichetta in prima pagina) delle serie

Nobel srl hereby declares that the equipment (see label on first page) of seriesAC – AS

è conforme alle seguenti Direttive Europee:

2006/42/CE – 2006/95/CE – 2004/108/CE

Principali Norme armonizzate osservate durante la progettazione e costruzione:

UNI EN ISO 12100:2010 – UNI EN 60204-1 (CEI 44-5)

Il direttore tecnico è autorizzato alla costituzione del fascicolo tecnico.

complies to the requirement of the following European Directives :

2006/42/CE – 2006/95/CE – 2004/108/CE

Besides, the main regulations followed for the design and manufacturing are :

UNI EN ISO 12100:2010 – UNI EN 60204-1 (CEI 44-5)

The technical manager is authorized to manage the technical folder.

Direttore Tecnico Technical Manager Giorgio Da Dalt

Milano, 18 febbraio 2013

Documents

SOFTENERS SERIES: AC/T AS/S AC/SV AS/T AS/SV …€¦ · SOFTENERS SERIES: AC/T AC/SV AS/S AS/T AS/SV AS/V ... All operations must be performed by and/or under direct supervision