AUTOMATIC DEIONIZERS SERIE WD/V INSTRUCTIONS MANUAL
AUTOMATIC DEIONIZERS SERIE WD/V INSTRUCTIONS MANUAL WARNING ! The equipment must be used only for the utilizations for which they have been designed, as shown in the technical documentation. Read carefully this leaflet until the end before starting any operation. Proceed according strictly to all directions included in this manual. Deionizers models WD/V 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 REL. 2 Page 1 of 21 wdv_mi-r2.doc INSTRUCTIONS MANUAL AUTOMATIC DEIONIZERS SERIE WD/V INDEX 1. SAFETY...................................................................................................................................3 1.1. CE mark, declaration of conformity .....................................................................................3 1.2. How to displace the unit ......................................................................................................3 1.3. Hydraulic .............................................................................................................................3 1.4. Electrical..............................................................................................................................3 1.5. How to store and delivery....................................................................................................3 2. TECHNICAL CHARACTERISTICS..........................................................................................4 2.1. Assumed raw water characteristics.....................................................................................4 2.2. Technical characteristics (general) .....................................................................................4 2.3. Characteristics for each model............................................................................................4 2.4. Dimensions & weights.........................................................................................................4 3. INSTALLATION .......................................................................................................................5 3.1. How to remove packaging...................................................................................................5 3.2. How to move and lift the unit...............................................................................................5 3.3. Placing ................................................................................................................................5 3.4. Hydraulic connections .........................................................................................................5 3.5. Electrical wiring connections ...............................................................................................6 4. PRINCIPLES OF WORKING ...................................................................................................7 4.1. Quality control & end-cycle .................................................................................................7 4.2. End-cycle by volume ...........................................................................................................8 4.3. Manual end-cycle ................................................................................................................8 4.4. Regeneration.......................................................................................................................8 4.5. How to advance manually the phase of the regeneration ...................................................9 4.6. How to rinse the resins during “LONG RINSE” phase ........................................................9 4.7. Conductivity-meter ..............................................................................................................9 5. DESCRIPTON OF THE CONTROL PANEL..........................................................................10 5.1. Commands and visualizations ..........................................................................................10 5.2. Logical programmer ..........................................................................................................13 5.2.1. Reports on the display of the programmer ..............................................................14 5.2.2. How to set language .................................................................................................14 5.2.3. How to set current time and day ...............................................................................14 5.2.4. How to set times and delays.....................................................................................15 5.2.5. How to use the function buttons of the programmer.................................................15 5.2.6. How to set parameters switch (ON/OFF)..................................................................15 6. STARTING-UP ......................................................................................................................16 7. MAINTENANCE AND SERVICE ...........................................................................................17 8. HOW TO REPLACE THE RESINS........................................................................................18 9. DISPOSAL.............................................................................................................................18 10. MAIN COMPONENTS LIST...................................................................................................19 10.1. Components commons for all models .............................................................................19 10.2. Special components for WD/V 10 ...................................................................................19 10.3. Special components for WD/V 14 ...................................................................................19 10.4. Special components for WD/V 19 ...................................................................................19 10.5. Special components for WD/V 34 ...................................................................................19 11. LIST OF SUGGESTED SPARE PARTS................................................................................20 12. CHECKING OF THE RESINS ...............................................................................................20 13. TROUBLE SHOOTING GUIDE .............................................................................................21 Annex: • • • • drawing COMPONENTS drawing INSTALLATION, DIMENSIONS AND WEIGHT drawing PILOTING CONNECTIONS (S132) wiring diagrams (3 pg) • • • • NOBEL running-test certificate instructions solenoid valves data sheets membrane valves declaration of conformity s.r.l. - ITALY Page 2 of 21 wdv_mi-r2.doc - r2 INSTRUCTIONS MANUAL AUTOMATIC DEIONIZERS SERIE WD/V 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. The heavy components must be lifted and displaced by lifting or hooking them up only by the points and facilities shown on the attached drawings. It is strictly recommended to use only proper sized and suitable ropes, chains or hooks. (see DIMENSIONS & WEIGHT drawing). 1.3. Hydraulic 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), according to safety regulations for working areas. The operators must be aware of the hazards and danger of the chemicals used in the process. In case of leakage of chemicals and/or in case of accident (contact with skin, eyes, etc.) follow strictly the directions mentioned on the safety bulletins of the chemicals themselves. 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, using proper tools and personal protection devices if required (CE marked), according to safety regulations for working areas. In case of liquid leakage, switch off the main power supply before operation. Before the switching ON, be sure all the parts of the system are perfectly dry. Check that the available electrical power is correct, as shown on technical data, before connection. Do not make preliminary wiring connections. 1.5. • • • • How to store and delivery closed rooms open space transport installation t = ºC t = ºF humidity rel. 5÷40 5÷40 5÷40 5÷40 41÷104 41÷104 41÷104 41÷104 5÷95% without condensate protect from sun-light and rain. note 5÷95% without condensate protect from sun-light and rain. 5÷95% without condensate protect from sun-light and rain. 5÷95% without condensate protect from sun-light and rain. s.r.l. - ITALY Page 3 of 21 wdv_mi-r2.doc - r2 INSTRUCTIONS MANUAL AUTOMATIC DEIONIZERS SERIE WD/V 2. TECHNICAL CHARACTERISTICS 2.1. • • • • • • • • ºC bar (kPa) operating temperature min÷max operating pressure min÷max bacteria total hardness Na + K TAF bicarbonate silica 2.2. • • • • Assumed raw water characteristics ppm CaCO3 ppm CaCO3 ppm CaCO3 ppm CaCO3 ppm SiO2 10÷40 2.5÷4.0 (250÷400) nil 350 50 150 250 10 Technical characteristics (general) treated water conductivity ** power supply regeneration duration max. operating pressure V-ph/Hz-W h bar (kPa) < 10 µS/cm 230-1/50(60)-100 3 approx 4 (400) ** the mentioned conductivity of treated water depends on the chemical-physical characteristics of raw water. 2.3. MODEL WD/V 10 WD/V 14 WD/V 19 WD/V 34 Characteristics for each model FLOW RATE l/h RESINS l CYCLE ** MIN MAX cation anion 3 m /H2O 200 400 600 900 1.000 1.400 1.900 3.400 35 55 75 125 50 70 110 175 4 6 9 15 CONSUMPTION FOR ONE REGENERATION kg HCl kg NaOH 30% 30% 12 18 25 42 13 19 29 47 IN/OUT CONNECTIONS m3/H2O ø 0.9 1.4 2 3.4 1/2" 3/4" 3/4" 1" ** cycle calculated according to assumed raw water characteristics (see § 2.1) 2.4. Dimensions & weights See drawing “INSTALLATION/DIMENSIONS/WEIGHTS” s.r.l. - ITALY Page 4 of 21 wdv_mi-r2.doc - r2 INSTRUCTIONS MANUAL AUTOMATIC DEIONIZERS SERIE WD/V 3. INSTALLATION 3.1. How to remove packaging The packaging consist of a wooden crate which contains the deionization plant skid-mounted. Open the wooden crate removing, first, the cover and, then, the wall sides. Keep the cards and everything contained inside the packaging. 3.2. How to move and lift the unit The pipes of the plant are made in plastic material, hence they can be easily damaged. Do not lift and/or move the unit by any part of the plant. To lift the unit, use only fork-lift or other equipment suitable for the weight and dimensions to be lifted/displaced. Take care to correct balance the weight in order to avoid rolling of the load during displacements. Insert the forks under the pallet-type side of the skid of the unit (see “INSTALLATION/DIMENSIONS/WEIGHT” drawing). 3.3. Placing Place the unit on a perfectly flat surface. 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 (see “INSTALLATION/DIMENSIONS/WEIGHT” drawing). 3.4. • • • • Hydraulic connections (see “INSTALLATION/DIMENSIONS/WEIGHT“ drawing) connect the pipe of the water to be treated to the fitting of the main flow meter of water. It is recommended that the water pressure should be constant (between 2,5 and 4 bar); the installation of a pressure reducer on the inlet line should be provided. The inlet pipe of raw water should be properly sized. (Ø ≥ the one shown on the drawing INSTALLATION). complete the line from the outlet fitting, placed on the VU valve, to the storage tank of treated water, using PVC or other suitable material; the Ø of the connecting pipe must be properly sized. (Ø ≥ the one shown on the drawing INSTALLATION). complete the pipes from the drain fittings, one for each automatic control valve and for the valve VS, to the neutralization tank, using PVC or other suitable material; the Ø of the connecting pipe must be properly sized. (Ø ≥ the one shown on the drawing INSTALLATION). connect the drawing fittings of the chemicals (HCl and NaOH), to the chemical storage tanks. The HCl drawing fitting is mounted on the cation column, the NaOH drawing fitting is mounted on the anion column. It is recommended to use PVC, PE or other suitable material. NB: • The pipe unions are complete with O-ring seals, hence they have to be only handling tightened, using no tools. • Use PTFE tape for the thread connections • It is recommended to hold and support the plastic pipes with suitable brackets. s.r.l. - ITALY Page 5 of 21 wdv_mi-r2.doc - r2 INSTRUCTIONS MANUAL AUTOMATIC DEIONIZERS SERIE WD/V 3.5. Electrical wiring connections Run the electrical wiring connections to the terminal board of the control panel, as below explained (see also “WIRING DIAGRAM“) o o o o o o o o o o o o o 6 7 8 9 10 11 1 19 20 o o o o o o o o o o o o o Power supply 230V, 50÷60 Hz, directly to the inlet clamps of the main switch GND Conductivity cell CC " " “ GND Free voltage contact for remote alarm (max 24V, max 3A, closed on alarm) " " " " " " " " “ " " “ " Free voltage contact for start regeneration pump (max 24V, max 3A, closed on regeneration) " " " " " " " " “ “ " " “ " common medium level switch of storage tank (NO = open without water) maximum level switch of storage tank (NO = open without water) Whether an external enabling signal to start regeneration and/or a water meter are available, they must be connected as described in the annex wiring diagram. s.r.l. - ITALY Page 6 of 21 wdv_mi-r2.doc - r2 INSTRUCTIONS MANUAL AUTOMATIC DEIONIZERS SERIE WD/V 4. PRINCIPLES OF WORKING The process of deionization is featured by ion exchange. The resins contained in the cation column exchange all the metal cations against H ions, of which they are charged. When the resins are exhausted, they are fully charged of metal ions (cations), while they do not have any more H ions available for exchanging and they need to be regenerated. The anion exchanger completes the process of deionization. The resins contained in the anion column exchange all the acid anions against OH ions, of which they are charged. When the resins are exhausted, they are fully charged of acid ions (anions), while they do not have any more OH ions available for exchanging and they need to be regenerated. Regeneration means exchanging back H and OH ions available from chemicals regenerants (HCl and NaOH) against metals and acids ions which are carried away to waste treatment. The starting of regeneration of exhausted line is usually programmed according to the conductivity of treated water. The control panel handles the working of the regeneration. The regeneration consists of a backwashing, an injection of the chemicals regenerants followed by a rinsing of the resins. These operations run for both exchangers (cation-anion) The complete regeneration (backwashing- chemical drawing- rinse) of both exchangers takes approx 180 minutes. 4.1. Quality control & end-cycle The conductivity of treated water is continuously checked and visualized by conductivity-meter, built-in the control panel. Two adjustable set-points (K1 and K2) are available in the conductivity-meter, allowing to set the end-cycle of the deionizer (see particular paragraph further on, for setting/modification of set points) The set-point K1 has been adjusted, during the running test of the system, at a value of 10 µS/cm (factory-set), while the set-point K2 is not used. Therefore, the set-point K1 is the threshold value of conductivity to switch the end-cycle; when this value is reached, the red lamp “ALARM” turns ON; in the same time the outlet valve of the deionizer is closed, in order to avoid to supply water of not-satisfactory quality. If water does not flush inside the resins bed, i.e. when the treated water is not required, a reionization of the still water can occur. Therefore, the first water supplied after the interruption of service could be of an unsatisfactory quality, although it is not depending on the exhausting of the resins. The system is arranged in order that, when the conductivity exceeds the pre-set value, the drain valve automatically opens, featuring a “test-drain” for a pre-fixed time, in order to check if the unsatisfactory quality is caused by the exhausting of the resins or by a too long standing of the water itself inside the resin bed. This feature is named “QUALITY CONTROL” and the time of this can be modified as explained at next pages, while the factory set is 8’. Whether the quality of water, during this phase, will turn on a satisfactory value (below the threshold value of set-point), the system turns on service again; otherwise, the end-cycle is featured and the system turns on "REGENERATION REQUIRED”, indicated by the visualization on the display of PLC. The regeneration can be started by simply turning, for at least some seconds, the mode selector on “AUT” position. The regeneration will be automatically completed. Obviously, whether the mode selector is already on “AUT” position, the regeneration will automatically start, without any manual operation. Whether the regeneration have not been cmpleted correctly, the red lamp "ALARM" will be still ON at the end of the regeneration. It can be turned OFF by pushing the button RESET, or starting manually a new regeneration. s.r.l. - ITALY Page 7 of 21 wdv_mi-r2.doc - r2 INSTRUCTIONS MANUAL AUTOMATIC DEIONIZERS SERIE WD/V 4.2. End-cycle by volume The end-cycle by volume can be enabled by mean of parameter switch ACT. VOL (B11) End-cycle is reached when the preset volume of water has been supplied; in the same time the system turns on “WAITING FOR REGENERATION”, until the mode selector of the line is turned on AUT position. Naturally, if the mode selector is already on AUT position, the regeneration will automatically start, without any manual operation; in this case, the status of “WAITING FOR REGENERATION” will be only temporary. Whether the end cycle by volume is enabled and the end-cycle by conductivity is reached before that the pre-set volume is reached, the alarm “SHORT CYCLE” is driven. The meaning of the unit of volume entered and visualized depends on the unit value of the pulse from the installed meter. As standard setting the unit of setting and reading are hectolityers, according to the installation of water meter series CD (1 pulse every 100 liters). 4.3. Manual end-cycle When the deionizer is on service or on stand-by, it is allowed to force the shift to status of to he status “WAITING FOR REGENERATION”, proceeding as follows : • Turn the mode selector on "0" • Push the button of “ADVANCE PHASE” for 5 consecutive seconds. The unit shift on “WAITING FOR REGENERATION”. WARNING : The regeneration will start only when the mode selector is turned on AUT (for at least 2 seconds) and there is not any regenration inhibit. 4.4. Regeneration The regeneration phases run as follow (see “TIME AND PHASES” table) : FASE • • • • • • • • • CATION BACKWASH HCL INJECTION HCL DISPLACEMENT CATION RINSE ANION BACKWASH NAOH INJECTION NAOH DISPLACEMENT ANION RINSE ** LONG RINSE ** The minimum duration of the phase "ANION RINSE" of the regeneration is fixed at 5 minutes; then the phase is completed when the conductivity of drain water is below the pre-fixed value . If this value is not reached within the maximum pre-set time (45 minutes), the rinse is stopped anyway and regeneration is blocked on "LONG RINSE" phase. WARNING : Regeneration can be completed only whether the value of conductivity goes down below the thre-shold value of set-point K1. In order to repeat the regeneration, when the regeneration is blocked on "LONG RINSE" phase, it is required to modify temporary the conductivity set-point to a value appearing satisfactory, by electronic logical only. s.r.l. - ITALY Page 8 of 21 wdv_mi-r2.doc - r2 INSTRUCTIONS MANUAL AUTOMATIC DEIONIZERS SERIE WD/V 4.5. How to advance manually the phase of the regeneration During the regeneration, the phases can be manually advanced, by turning the mode selector on "0" position and pushing the button "ADVANCE PHASE”. The phase is actually advanced when it is completed the rotation of the motor in order to place correctly the cam shaft for the following phase. This features is not working during "ANION RINSE" and "LONG RINSE" phases; they must be overpassed only according to the conductivity. 4.6. How to rinse the resins during “LONG RINSE” phase During “LONG RINSE“ phase, it is possible to run a further rinse, by turning the mode selector on “0” position and pushing the button "ADVANCE PHASE". By releasing the button, the rinse is stopped. 4.7. Conductivity-meter The main functions of the conductivity-meter are the following : • • • • The pushing of the button ON disables the outputs related to set-points K1 and K2; in the same time, the light ON blinks to warn that the set-points have been manually disabled The light ON is continuously lit up to indicate the correct working The blinking of the light ON warns of a current faulty condition. The pushing of the button NEXT, during the normal working, alternates the visualization of the conductivity and the one of the temperature of water (only if the temperature sensor is installed, otherwise a fixed value is shown). In order to visualize and/or modify the parameter of configurations of the instrument, (included the set-point K1 value, parameters P06-P07, the shipping value are P06=10 - P07=10) it is necessary to enter the programming mode, according to the following directions : • • • • • • • push and keep pushed for at least 2 seconds the button CAL; the notice CAL appears. push the button NEXT, the notice EDIT appears on the top and left side of the screen, while the notice P01 appears in the center. by pushing the buttons + or -, select the desired parameters (P01, P02, or else) when the desired parameter is visualized on the screen, push the button CAL; the current value of the selected parameter appears and it is possible to modify it by pushing the buttons + or -. push the button CAL to confirm the modifications proceed the same way for other parameters to modify, if any or push the button NEXT to conclude the programming session. If not any button is pushed for several seconds, the programming mode is automatically closed. For further details about the functions of the instrument, see the directions of the attached manual of the instrument manufacturer. s.r.l. - ITALY Page 9 of 21 wdv_mi-r2.doc - r2 INSTRUCTIONS MANUAL AUTOMATIC DEIONIZERS SERIE WD/V 5. DESCRIPTON OF THE CONTROL PANEL The control panel QE, handled by a logical programmer, controls the automatic and/or manual working of the whole system. 5.1. Commands and visualizations The instruments available on the control panel are : CONDUCTIVITY-METER the instrument continuously shows the conductivity of the treated water. When the conductivity of treated water overpasses the set-point value (set-point K1), the high conductivity alarm is switched on. LOGICAL PROGRAMMER LOGO the programmer that handles the logical working of the unit. Its display shows the status of the inputs and outputs and allows to modify the pre-set time of the used timers (see special chapter for details). The commands available on the front of control panel QE are : MODE SELECTORS “AUT-0-MAN” on “AUT”: Referred to the mode of starting of regeneration and service : The deionizer automatically turns on regeneration at the end of service and on service at the end of regeneration. on “MAN”: The deionizer stops on “REGENERATION REQUIRED” at the end of service. The regeneration can be started by turning the mode selector on “AUT” position. on “0”: The deionizer stops on “REGENERATION REQUIRED” at the end of service, or in stand-by at the end of regeneration, avoiding to turn on service. The service can be started by turning the mode selector, even temporarly, on “AUT” or also on “MAN” position. LIGHTING BUTTON “ALARM - RESET” The button blinks if one or more alarms are driven. The running alarms are reset by pushing the button. BUTTON “ADVANCE PHASES” Every pushing of the button allows to advance at the following phase of regeneration, when the mode selector of the correspondent line is on “0” position. s.r.l. - ITALY Page 10 of 21 wdv_mi-r2.doc - r2 INSTRUCTIONS MANUAL AUTOMATIC DEIONIZERS SERIE WD/V The visualizations available on the display of the programmer are : "SERVICE" "VOLUME" "STAND-BY" "NO WATER REQUEST" "QUALITY CONTROL" "WAITING REGENERATION" "REGENERATION RUNNING" "CATION BACKWASH" "SUCTION HCl" "DISPLACEMENT HCl" "CATION RINSE" This visualization is available only when the deionizer is running on SERVICE The current date and time of day is also shown. This visualization is available only when the end-cycle by volume is enabled. The report visualizes the volume of water (in hl) already supplied during the running service (elapsed) and the pre-set limit of volume (set). The memory of volume is reset to zero at the end of the following regeneration. This visualization is available only when the deionizer has completed the regeneration, but it cannot turn on service, since there is neither signal AUT nor the signal MAN. (the mode selector is not turned on AUT or MAN position) The current date and time of day is also shown. When this visualization appears, it indicates that there is not any request of water supplying by level switches. This visualization is available only when the deionizer is running the QUALITY CONTROL phase. This report visualizes also the time (in seconds) elapsed during the running phase (elaps.) and the pre-set time of the phase itself (set). This visualization appears only when the deionizer reaches the end-cycle, but the regeneration cannot start , since there is neither signal AUT nor the signal MAN. (the mode selector is not turned on AUT or MAN position) This visualization is available only when the regeneration is running. This visualization is available only when the deionizer is running the CATION BACKWASH phase. This report visualizes also the time (in seconds) elapsed during the running phase (elaps.) and the pre-set time of the phase itself (set). This visualization is available only when the deionizer is running the SUCTION HCl phase. This report visualizes also the time (in seconds) elapsed during the running phase (elaps.) and the pre-set time of the phase itself (set). This visualization is available only when the deionizer is running the DISPLACEMENT HCl phase. This report visualizes also the time (in seconds) elapsed during the running phase (elaps.) and the pre-set time of the phase itself (set). This visualization is available only when the deionizer is running the CATION RINSE phase. This report visualizes also the time (in seconds) elapsed during the running phase (elaps.) and the pre-set time of the phase itself (set). s.r.l. - ITALY Page 11 of 21 wdv_mi-r2.doc - r2 INSTRUCTIONS MANUAL AUTOMATIC DEIONIZERS SERIE WD/V "ANION BACKWASH" "SUCTION NaOH" "DISPLACEMENT NaOH" "ANION RINSE" "PHASE ADVANCE" "RETURN TO SERVICE POSITION" "MICRO-SWITCH MOTOR ALARM" "LONG RINSE ALARM" "SHORT CYCLE ALARM" This visualization is available only when the deionizer is running the ANION BACKWASH phase. This report visualizes also the time (in seconds) elapsed during the running phase (elaps.) and the pre-set time of the phase itself (set). This visualization is available only when the deionizer is running the SUCTION NaOH phase. This report visualizes also the time (in seconds) elapsed during the running phase (elaps.) and the pre-set time of the phase itself (set). This visualization is available only when the deionizer is running the DISPLACEMENT NaOH phase. This report visualizes also the time (in seconds) elapsed during the running phase (elaps.) and the pre-set time of the phase itself (set). This visualization is available only when the deionizer is running the ANION RINSE phase. This report visualizes also the time (in seconds) elapsed during the running phase (elaps.) and the pre-set time of the phase itself (set). This visualization is available only when the cam shaft is rotating between one phase and the following one This notice of the counting-down of time to the start of following phase is also visualized. This visualization is available only when the cam shaft rotates back to the service position. The alarm is driven when the cam shaft cannot rotate back to the service position. The notice of the day and time when the alarm is driven, is also visualized. The alarm is driven when the deionizer is running the LONG RINSE phase. The notice of the day and time when the alarm is driven, is also visualized. The alarm is driven when the end-cycle by conductivity is reached before the end-cycle by volume (if enabled). The notice of the day and time when the alarm is driven, is also visualized. The above listed alarm are joined in a free voltage contact for remote report. s.r.l. - ITALY Page 12 of 21 wdv_mi-r2.doc - r2 INSTRUCTIONS MANUAL AUTOMATIC DEIONIZERS SERIE WD/V 5.2. Logical programmer The logical programmer Siemens serie LOGO controls the logical working of the whole system. The display of the programmer shows the status of the logical input signals (marked as I), the status of the logical output signals (marked as Q), current time and date, the several messages enabled by the programme. It is also possible to modify the setting of the entered numerical parameters (marked as B). The numbering of the inputs and outputs is written on several lines, each of them is related to ten (I1÷I9, I10÷I19 etc.) By pushing the buttons or the display shows, alternatively, the visualizations of the service : current time and date, inputs, outputs, merker (M, to be ignored), function buttons (ESC+C..) By pushing the buttons and the messages enabled by the programme are visualized. The used functions are the following : MARK DESCRIPTION I1 I2 I3 I4 I5 I6 I7 I8 I9 I10 Q1 Q2 Q3 Q4 Q5 Q6 input for automatic working input for manual working input for phase advance input high conductivity alarm (activated = alarm) input of the motor microswitch (activated = service) input for medium level of water tank (open without water) input for maximum level of water tank (open without water) input pulses from water meter WM input for “RESET” button input for regeneration inhibit output for the motor output for the out solenoid valve EU output for the drain solenoid valve ES output for the alarms joined lamp (flashing) output for the alarms joined signal (remote alarm) output for the regeneration pump BW CAT. ASP. HCl DISP.HCl WASH.CAT BW ANION ASP. NaOH DIS. NaOH WASH. AN QUALITY LONG RIN ACT. VOL VOL. (hl) ENG-ITA time of CATION BACKWASH phase time of HCl SUCTION phase time of HCl DISPLACEMENT phase time of CATION RINSE phase time of ANION BACKWASH phase time of NaOH SUCTION phase time of NaOH DISPLACEMENT phase time of ANION RINSE phase time of QUALITY CONTROL phase time of LONG RINSE phase ON = switching end-cycle by volume counting pulses of water meter WM (hl) ON = message in ITALIAN OFF = message in ENGLISH Factory settings 8m 20 m 20 m 10 m 10 m 25 m 25 m 45 m 5m OFF 999999 8m OFF All adjustment of automatic programmer are factory set, before shipment. Refer to following paragraphs to read how to modify them. s.r.l. - ITALY Page 13 of 21 wdv_mi-r2.doc - r2 INSTRUCTIONS MANUAL AUTOMATIC DEIONIZERS SERIE WD/V 5.2.1. Reports on the display of the programmer The report messages enabled by the programmer are visualized on the display one at a time, with a determinate priority. The buttons and are used to scroll the messages. The button is used to turn back to service visualizations. 5.2.2. How to set language The programmer LOGO allows to select the language of menu and of messages : - To set the language of menu, proceed as follows: 1. 2. 3. 4. 5. 6. 7. 8. push the button ESC push the button until the pointer > indicates "Set …" push the button OK . push the button or until the pointer > indicates "Menu language" push the button OK . push the button or until the pointer > indicates the language desired push the button OK to confirm (save) the modifications push twice the button ESC to go back to the visualization of service The programmer is already factory set on “english”. - Set the parameter “B100” on position “ON” to select the italian language of the messages; set on position “OFF” to select english language of the messages (proceed as described at chapter 5.2.6). 5.2.3. How to set current time and day The programmer is equipped with internal clock, keeping exact time for 80 hours in case of power failure. To set the current time and day, proceed as follows : 1. 2. 3. 4. 5. 6. 7. push the button ESC push the button until the pointer > indicates "Set …" push the button OK the pointer indicates “Clock..”, push the button OK the pointer indicates “Set Clock..”, push the button OK push the button to point the day or the number to be modified when the pointer blinks on the day or the number to be modified, push the buttonor until the new desired day or value is shown (symbols related to days of week are explained at following chapter) 8. repeat the same operation with other values, if required 9. push the button OK to confirm (save) the modifications 10.push twice the button ESC to go back to the visualization of service. The programmer is already factory set for automatic updating with european summer time (S/W Time ON = EU) s.r.l. - ITALY Page 14 of 21 wdv_mi-r2.doc - r2 INSTRUCTIONS MANUAL AUTOMATIC DEIONIZERS SERIE WD/V 5.2.4. How to set times and delays Proceed as follows, to make any modification : 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. push the button ESC push the button until the pointer > indicates "Set param" push the button OK push several times the button until the parameter to be modified is visualized (B1 or other) push the button OK push the button to point the number to be modified when the pointer blinks on the day or the number to be modified, push the button until the new desired value is shown repeat the same operation with other values, if required push the button OK to confirm (save) the modifications proceed with other modifications, if any, or push the button ESC to quit the modification menu. push the button ESC to go back to the visualization of service NOTES : • during modification operations the normal current service is NOT interrupted • In modifications menu, related to timers, the digits visualized on the line (marked as Ta) underneath the one on the time settings, marked as T, (TH and TL for alternation timers) indicate the status of the running counting of the time of the selected timer s = seconds (00,00 ÷ 99,95) • the time bases are : m = minutes (00:00 ÷ 99m:59s) h = hours (00:00 ÷ 99h:59m) • symbols related to days of week : Mo Tu We Th Fr Sa Su Monday Tuesday Wednesday Thursday Friday Saturday Sunday 5.2.5. How to use the function buttons of the programmer The 4 buttons can have special functions if enabled by the programmer for these purposes. Proceed as follows to use them: • push several times the button until the notice ESC+C…is visualized on the display. • push and keep pushed the button ESC and immediately after that the desired function button () WARNING : by pushing the button ESC and not the function button within 2 seconds, the display skips to the visualization of modification menu; release and then push again the button ESC to go back to visualization ESC+C… 5.2.6. How to set parameters switch (ON/OFF) Proceed as follows to make any modifications of the parameters allowing only ON/OFF selection. 1. 2. 3. 4. 5. 6. 7. 8. 9. push the button ESC push several times the button until the pointer > indicates "set param" push the button OK . push several times the button until the required parameter (B74 or other) is visualized. push the button OK , the pointer blinks on the notice "switch" push the button to change selection between ON and OFF push the button OK to save/confirm the modifications. proceed with other modifications, if any, or push the button ESC to quit the modification menu. push the button ESC to go back to the visualization of service s.r.l. - ITALY Page 15 of 21 wdv_mi-r2.doc - r2 INSTRUCTIONS MANUAL AUTOMATIC DEIONIZERS SERIE WD/V 6. STARTING-UP • DISCONNECT ELECTRIC POWER • Close the inlet and outlet valves • Turn clockwise the cam shaft of the pilots group, until the first piston is pressed. (CATION BACKWASH). • Open slowly and not completely the inlet valve. Water will enter from the bottom into the cation column as air will be expelled from the top to the drain. • When only water will come out from drain, open completely the inlet valve and allow the water flush until the drain water looks clear. • Turn again clockwise the cam shaft, until the second piston is pressed too (HCl INJECTION). Check that some water flows to the drain line, while, in the same time, the acid flows from its own tank to the unit. • Turn again clockwise the cam shaft, until only the second piston is pressed, while the first one is released. (CATION RINSE). The water flows to the drain line; allow the water flowing until the drain water looks perfectly clear. • Close the inlet valve . • Turn again clockwise the cam shaft, until the second piston is released and the fourth one is pressed (ANION BACKWASH). • Open slowly and not completely the inlet valve. Water will enter from the bottom into the anion column as air will be expelled from the top to the drain. • When only water will come out from drain, open completely the inlet valve and allow the water flush until the drain water looks clear. • Turn again clockwise the cam shaft, until the fifth piston is pressed too (NaOH INJECTION). Check that some water flows to the drain line, while, in the same time, the chemical (NaOH) flows from its own tank to the unit. • Turn again clockwise the cam shaft, until only the fifth piston is pressed, while the fourth one is released. (ANION RINSE). The water flows to the drain line; allow the water flowing until the drain water looks perfectly clear. • Turn again clockwise the cam shaft, until the fifth piston is released as well (SERVICE). • Switch on again electrical power. • Open the outlet valve. It is now requested to start an automatic regeneration of the resins, checking that the correct quantities of chemicals are injected (sucked) within the times listed in the programming table, related to each model of deionizer (see “Characteristics for each model” page 4). When the regeneration is completed, the unit is on service, if the quality of the product water meets the desired value. At the shipment, the new resins are totally exhausted, hence another regeneration could be required. ¾ In order to adjust the injected quantity of chemicals, drive manually the ball valves mounted along the injection line of the chemicals themselves. ¾ During the phases CHEMICAL (HCl OR NaOH) INJECTION and CHEMICAL (HCl OR NaOH) DISPLACEMENT, the multifunction top-mounted control valves are in the same position; the difference between one phase and the (following) other one is made by mean of the automatic closing of the diaphragm valves mounted along the chemical injection lines (the opening/closing of the diaphragm valves is controlled by the pilot pistons no. 3 and 6). s.r.l. - ITALY Page 16 of 21 wdv_mi-r2.doc - r2 INSTRUCTIONS MANUAL AUTOMATIC DEIONIZERS SERIE WD/V 7. MAINTENANCE AND SERVICE Generally speaking, this kind of plant does not require any scheduled maintenance operations. Indeed, the only parts that could be damaged, during the working, are the electrical components and the moving parts; in details : • membranes of the automatic valves, that can aged after years and hair-cracked. • solenoid valves, that can be electrically failed or dirty.. • common electrical components (relays, lamps, etc.). It is important to note that the plant and all area around should be kept clean, in order to realize immediately any mechanical or hydraulic dysfunction. Indeed, dust or wet part can hide leakages or crackings, that otherwise should be immediately noted. The correct handling of the plants requires the following points: • the water to be treated must be free of suspended particles; a proper filtration should be provided. • the best condition of service are a continuous flow of water at a constant flow rate; too long stillness of the water inside the resins bed should be avoided. • before starting a regeneration, check that proper quantity of chemicals are available in the regenerant tanks. WARNING : The piping of the system contains dangerous chemicals. The operators must be aware of the hazard and danger of the chemicals used in the process. The maintenance operations must be performed only by skilled and authorized operators, using proper tools and CE marked personal protection devices (gloves, masks, cloths, etc). It is also required to follow strictly the directions mentioned on the safety bulletins of the chemicals themselves. s.r.l. - ITALY Page 17 of 21 wdv_mi-r2.doc - r2 INSTRUCTIONS MANUAL AUTOMATIC DEIONIZERS SERIE WD/V 8. HOW TO REPLACE THE RESINS Whether the replacement of resins is required, proceed as follows : • • • • • • Switch OFF the main power Take off all tubing and pipes connected to the multifunction top-mounted valves. Unscrew the top-mounted valves. Take out the resins using an aspirator or by mean of a siphon. Withdraw the resins pipe with related bottom distribution nozzle Be sure that the under-valve nozzle and bottom distribution nozzle are not damaged; in the case replace the pipe with the distribution nozzle. • Proceed to load the new resins : 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 lubricated 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. • Complete the commissioning of the unit by connecting all the tubing and pipes to the multifunction top-mounted valves, previously taken off. Proceed as explained at § 9 for starting-up after replacement of resins. 9. 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. s.r.l. - ITALY Page 18 of 21 wdv_mi-r2.doc - r2 INSTRUCTIONS MANUAL AUTOMATIC DEIONIZERS SERIE WD/V 10. MAIN COMPONENTS LIST 10.1. Components commons for all models Q.ty DESCRIPTION n. 2 n. 1 n. 1 n. 1 n. 1 n. 1 n. 1 n. 1 n. 1 n. 1 n. 1 n. 1 n. 2 Internal diffusers manufactured NOBEL skid manufactured by NOBEL multifunction valve type S132/deionization (cation) multifunction valve type S132/deionization (anion) diaphragm valve (HCl) Aquamatic Ø 20 PVC/NORYL/VITON with regulator diaphragm valve (NaOH) Aquamatic Ø 20 PVC/NORYL/BUTYL with regulator diaphragm valve (VS) Aquamatic Ø 20 PVC/NORYL/BUTYL with regulator conductivity probe Steiel CCK5 PVC conductimeter Steiel S504 C 230 Vac PLC Siemens LOGO 24RC expansion card DM 8 24R group 6 pilots pilot solenoid valves BURKERT type 6014-24Vac/MAN type NA PVC fittings, different dia 10.2. Special components for WD/V 10 n. 1 n. 1 n. 1 n. 1 flowmeter for H2O mod. column for cation resins 10x54" column for anion resins 10x54" diaphragm valve (VU) Aquamatic Ø 20 PVC/NORYL/BUTYL 10.3. Special components for WD/V 14 n. 1 n. 1 n. 1 n. 1 flowmeter for H2O scale l/h mod. column for cation resins 13x54" column for anion resins 13x54" diaphragm valve (VU) Aquamatic Ø 32 PVC/NORYL/BUTYL 10.4. Special components for WD/V 19 n. 1 n. 1 n. 1 n. 1 flowmeter for H2O scale l/h mod. column for cation resins 14x65" column for anion resins 14x65" diaphragm valve (VU) Aquamatic Ø 32 PVC/NORYL/BUTYL 10.5. Special components for WD/V 34 n. 1 n. 1 n. 1 n. 1 flowmeter for H2O scale l/h mod. column for cation resins 16x65" column for anion resins 18x65" diaphragm valve (VU) Aquamatic Ø 32 PVC/NORYL/BUTYL s.r.l. - ITALY Page 19 of 21 wdv_mi-r2.doc - r2 INSTRUCTIONS MANUAL AUTOMATIC DEIONIZERS SERIE WD/V 11. LIST OF SUGGESTED SPARE PARTS The following parts are of high importance for the correct working of the plant; it is suggested to provide them for a quick replacement in case of incidental failure. 12. Q.ty DESCRIPTION n. 2 n. 1 n. 1 pilot solenoid valves BURKERT type 6014-24Vac/MAN type NA diaphragm valve (HCl) Aquamatic Ø 20 PVC/NORYL/BUTYL with regulator diaphragm valve (NaOH) Aquamatic Ø 20 PVC/NORYL/BUTYL with regulator CHECKING OF THE RESINS If the conductivity of the product water is not satisfactory, it is possible to check quickly the conditions of the resins, by testing the Hardness and the pH values of the outlet water from the cation and anion columns. In order to check the quality of outlet water from cation column, turn temporarily the column in the phase "CATION RINSE" (see § 9) and sample the water from the drain line of the column. The sampling of water outlet from the anion column is made directly from the sampling cock on the outlet line of the unit. 1. The Hardness of the outlet water from the cation column must be NIL, and the pH must be very low (2-3 according to the quality of the treated water). An higher pH value and/or the presence of Hardness means that the resins is not regenerated properly, hence a regeneration is required. 2. After checked that the quality of the outlet water from the cation column meets the above mentioned standard, proceed to test the outlet water from the anion column : its Hardness must be NIL, and the pH between 7 and 9. The presence of Hardness means a fouling of the anion resins, that could be caused by a flowing of hard water through it. According to this condition, a washing of the anion resins with HCl followed by a double regeneration with NaOH could be required. 3. A pH value lower than 7 means a failing regeneration (or the exhausting) of the anion resins, hence that a regeneration is required. 4. A pH value higher than 9, together with hardness NIL, means that the anion resins is still impregnated with NaOH regenerant, and a new rinse should be provided. This situation can be often found at the end of the regeneration cycle (hence, when the signal "LONG RINSE ALARM" appears). The causes can be the following : 1. A too high quantity of NaOH has been drawn off, or the correct quantity has been drawn off in too short time (in any case a too high concentration of NaOH through the resins). 2. during the phases of NaOH suction and/or following rinses, a pressure drop in inlet water line occurred. It is suggested, in this case, to rinse again the resins, opening manually the drain valve VS. WARNING : The mentioned pH values are average values: they are strictly depending on the chemical composition of the water to be treated. I.e. an high value of sodium in the water to be treated causes an increase in the pH value of the product water, quite apart from the presence of regenerant NaOH. In this situation, the presence of NaOH is inevitably caused by a natural leakage of the Na from the cation resin. Therefore, it is suggested, for further reference and comparation, to use the values already verified with the same water to be treated. s.r.l. - ITALY Page 20 of 21 wdv_mi-r2.doc - r2 INSTRUCTIONS MANUAL AUTOMATIC DEIONIZERS SERIE WD/V 13. TROUBLE SHOOTING GUIDE PROBLEM • The electronic programmer does not switch ON. • The regeneration starts electrically but it does not start hydraulically • The alarm “MICRO-SWITCH ALARM” is switched ON • During regeneration the unit does not draw HCl • the unit does not draw NaOH • Regeneration is blocked on “LONG RINSE ALARM” (i.e. high conductivity at the end of regeneration) • • • • CAUSE HOW TO SOLVE • electrical power is disconnected • the programmer is defected • The geared motor of the pilots group is defected • connect electrical power • replace the programmer • replace the geared motor • the microswitch of pilot group is defected or disconnected • drawing of air along the brine suction line • too low water pressure • injector dirty • filter of injector dirty • drain line of the control valve clogged even partially or, however of too small size • the membrane valve of the chemical does not open correctly • reconnect or replace the microswitch • check the connections and the integrity of the suction line • increase the water pressure • clean the injector • clean the injector filter • re-built correctly the drain line • Chemical suction not featured • Lack of water during the regeneration • Resins spoiled • The resins pipe inside the vessel come out of its proper seat below the control valve featuring an internal by-pass line The alarm “SHORT CYCLE” is • the quantity of chemicals switched ON regenerant used is lower than the one stated. Quantity of treated water is lower than nominal value • the resins are polluted or deteriorate There is a leakage of water to • internal pistons of the control valve drain during service blocked • O-ring of internal pistons spoiled • internal pistons spoiled • pilot pistons spoiled or broken The unit does not feed water • Pistons blocked during regeneration • la valvola di uscita VU non si apre • check the integrity and correct working of the correspondent solenoyd valve; if required, replace it. • See above • Run a new regeneration • Replace the resins (see also part “CHECKING OF THE RESINS) • place the resins pipe in correct position or replace it if damaged. • run the regeneration adjusting again the flow rates. • replace the resins • clean or replace the pistons • • • • replace O-rings replace the pistons of the valve replace pilot pistons Clean or replace the pistons • controllare l’efficienza della elettrovalvola pilota corrispondente; se non funziona sostituirla • There is a leakage of resins to • the nozzle of distribution pipe is • replace the nozzle the drain or to outlet line damaged or broken • replace under-valve filter • the under-valve filter is broken or detached s.r.l. - ITALY Page 21 of 21 wdv_mi-r2.doc - r2 s.r.l. via G.Galilei, 5 20090 Segrate (MI) - ITALY AZIENDA CON SISTEMA QUALITÁ CERTIFICATO DA DNV UNI EN ISO 9001/2008 TEL. +39 02 2827968 FAX +39 02 2610839 e-mail [email protected] 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 DICHIARAZIONE DI CONFORMITÀ DECLARATION OF CONFORMITY La Nobel srl dichiara che l’apparecchiatura (vedi etichetta in prima pagina) della serie Nobel srl hereby declares that the equipment (see label on first page) of serie WD/V 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) – UNI EN ISO 4414 :2012 CEI EN 61439-1 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) – UNI EN ISO 4414 :2012 CEI EN 61439-1 The technical manager is authorized to manage the technical folder. Direttore Tecnico Technical Manager Giorgio Da Dalt M3.6-r2 Milano, 6 marzo 2012 sede legale : via Monfalcone 8 20132 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
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