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
AUTOMATIC DEIONIZER SERIES DA/V
INSTRUCTIONS MANUAL
INSTRUCTIONS FOR
COMMISSIONING, INSTALLATION
OPERATION & MAINTENANCE
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 DA/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. via Monfalcone 8 - 20132 Milano - ITALY
tel. +39 02 2827968 fax +39 02 2610839
rev. 3
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INDEX
1. SAFETY...................................................................................................................................3
1.1. General ...............................................................................................................................3
1.2. How to displace the unit ......................................................................................................3
1.3. Hydraulic .............................................................................................................................3
1.4. Electrical..............................................................................................................................3
1.5. How to store, delivery and install ........................................................................................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 & commissioning ....................................................................................................5
3.4. Hydraulic connections .........................................................................................................6
3.5. Pneumatic connections .......................................................................................................6
3.6. Electrical wiring connections ...............................................................................................6
4. PRINCIPLES OF WORKING ...................................................................................................7
4.1. Quality control & end-cycle .................................................................................................7
4.2. Regeneration.......................................................................................................................8
5. CONTROL PANEL DESCRIPTION .........................................................................................9
5.1. How to stop the service, at any moment .............................................................................9
5.2. How to advance manually the phase of the regeneration ...................................................9
5.3. How to rinse the resins during “LONG RINSE” phase ......................................................10
5.4. Cross reference pilot solenoid valves and membrane valves ...........................................10
5.5. Conductivity-meter ............................................................................................................11
6. FUNCTIONS OF OPERATING PANEL TD200 ....................................................................12
6.1. Commands available on the panel....................................................................................12
6.2. Content of the pages.........................................................................................................12
7. PLC : HANDLING OF THE MEMORY ...................................................................................13
8. STARTING UP & ADJUSTMENT ..........................................................................................14
9. MAINTENANCE AND SERVICE ...........................................................................................15
10. TROUBLE-SHOOTING GUIDE .............................................................................................16
11. CHECKING OF THE RESINS ...............................................................................................17
12. HOW TO REPLACE THE RESINS........................................................................................18
13. DISPOSAL.............................................................................................................................18
14. MAIN COMPONENTS LIST...................................................................................................19
14.1. Components commons for all models .............................................................................19
14.2. Special components for model DA/V 14..........................................................................19
14.3. Special components for model DA/V 19..........................................................................19
14.4. Special components for model DA/V 34..........................................................................20
14.5. Special components for model DA/V 50..........................................................................20
15. LIST OF SUGGESTED SPARE PARTS................................................................................20
Annex :
•
•
•
•
•
drawing COMPONENTS
drawing INSTALLATION/DIMENSIONS/WEIGHT
drawing FLOWS SHEET (9 pg)
wiring diagrams (5 pg)
table PHASES & TIMES
•
•
•
•
NOBEL running-test certificate
instructions solenoid valves
instructions conductimeter
instructions valves 024, 025
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1.
SAFETY
1.1.
General
The equipment has been designed and constructed according to D.P.R. n° 459 of 24th July
1996 (regulation for accomplishment of Norms 2006/42/CE, 91/368/CE, 93/44/CE and 93/68/CE
regarding the unification of States members laws in so far as machines are concerned).
It has been designed and constructed according to European Norms UNI EN 292-1, UNI EN
292-2, UNI EN 292-2/A1, UNI EN 418, UNI EN 983, CEI EN 60439-1, CEI EN 60 204-1.
Only authorized and skilled personnel will be allowed to carry out installation, start up as well
as routine and planned maintenance.
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, delivery and install
closed rooms
open space
transport
installation
temperature ºC
humidity rel.
note
5÷45
5÷45
5÷45
5÷45
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.
5÷95% without condensate
protect from sun-light and rain.
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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
pilot air supply
regeneration duration
max. operating pressure
V-ph/Hz-W
bar (kPa)
h
bar (kPa)
< 10 µS/cm
230-1/50-100
5÷7 (500÷700)
3 approx
4 (400)
** the mentioned conductivity of treated water depends on the chemical-physical characteristics
of raw water.
2.3.
MODEL
DA/V 14
DA/V 19
DA/V 34
DA/V 50
Characteristics for each model
RESINS
l
FLOW RATE
l/h
CYCLE
**
MIN
MAX
cation
anion
3
m /H2O
400
600
900
1700
1.400
1.900
3.400
5.000
55
75
125
225
70
110
175
325
6
9
15
27
CONSUMPTION FOR
ONE REGENERATION
kg HCl kg NaOH
30%
30%
18
25
43
75
19
29
47
87
IN/OUT
CONNECTIONS
m3/H2O
ø
1.4
2
3.4
6
3/4"
3/4"
1"
1-1/4"
** cycle calculated according to assumed raw water characteristics (see § 2.1)
2.4.
Dimensions & weights
See drawing “INSTALLATION/DIMENSIONS/WEIGHTS”
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3.
INSTALLATION
3.1.
How to remove packaging
The packaging consist of a wooden crate which contains the deionization plant skidmounted.
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 & commissioning
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).
In some cases, for practical sake, the plant is shipped as sub-assembly, hence the
commissioning of the units is required. The shipped separated parts are marked with
numbered cards.
The operation for commissioning are :
• Place the skid on a perfectly flat surface.
• Put the columns of the resins and the bar with valves on the skid and fix them
according to the directions and the installation diagram (attached) as well as the
numbered cards.
• Load the resins inside the columns (C = cation, A = anion), according to the supplied
quantities. Check that the supplied and available quantities of resins comply exactly
with required quantities for the model, as shown on the attached table "characteristics
for each model" § 2.3.
To load the resins inside the vessel, proceed as follows :
◊ 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 cap with inlet/outlet connections; the distribution
pipe must be inserted inside the proper hole in the lower part of the cap. 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 between cap and vessel is not damaged and
is properly placed. Screw firmly the cap on the vessel just tightening it by hand only.
Do not use any tools.
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3.4.
Hydraulic connections
(see drawing INSTALLATION DIMENSIONS WEIGHT )
• 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 3A valve, to the storage tank of
treated water, using PVC or other suitable material; the DIA of the connecting pipe must
be properly sized. (Ø ≥ the one shown on the drawing INSTALLATION).
• complete the pipes from the drain fittings, mounted on both the columns, to the
neutralization tank, using PVC or other suitable material; the DIA 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), placed on the lower side of
the flow meters, 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 or other suitable material; the DIA of the connecting pipe must
be properly sized. (Ø ≥ the one shown on the drawing INSTALLATION).
NB:
3.5.
• 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
Pneumatic connections
• connect the service air fitting placed on the solenoid valves group to a service air
supply line, equipped with pressure reducer, dehumidifier filter, shut-off valve. The air
must be dry, oil-free and with pressure at least 2,5 bars higher than the pressure of the
inlet water, but not exceeding 7 bar
• connect the outlet fitting of each solenoid valve to the correspondent diaphragm valve,
according to the numbered position (see also § 5.4)
3.6.
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
RL
NL
15
16
+
17
25
42
43
o
o
o
o
o
o
o
o
o
o
o
power supply 100÷240V, 50/60Hz, 100 W
"
"
"
"
"
"
GND
conductivity probe CC
"
"
shield
common to water tank level switches
medium level switch (open without water)
maximum "
"
"
"
"
free voltage contact for remote alarm (max 230V, max 3A, closed on alarm)
"
"
"
"
"
"
"
"
"
"
"
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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 conductivitymeter, 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.
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 “HIGH CONDUCTIVITY” 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. During this feature, named “QUALITY CONTROL”, both
lamps “HIGH CONDUCTIVITY” and “QUALITY CONTROL” are ON, and the outlet valve is
closed.
The time of the phase “QUALITY CONTROL” can be modified by mean of the operating
panel of PLC, as explained at proper chapter (factory set at the shipment, 180”).
Whether the quality of water, during this phase, will turn on a satisfactory value (below the
thre-shold 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 turning ON
of the related lamp.
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.
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4.2.
Regeneration
The regeneration phases run as follow (see “TIME AND PHASES” table) :
0.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
CATION BACKWASH
RESIN SETTLING
HCL INJECTION
HCL DISPLACEMENT
CATION RINSE
ANION BACKWASH
RESIN SETTLING
NAOH INJECTION
NAOH DISPLACEMENT
ANION RINSE **
LONG RINSE (visualized on synoptical panel as “ALARM REGENERATION”)
**
The phase "ANION RINSE" stops when the conductivity of drain water reaches a value
lower than the set-point (K1 set on conductimeter). If this value is not reached within the
maximum pre-set time (60 minutes), the rinse is stopped anyway and the regeneration is
blocked on “LONG RINSE” (“ALARM REGENERATION”) phase.
When regeneration is blocked on this phase, it is possible to run a further rinse, by
opening the drain valve 1A. The valve can be opened mechanically, by driving the
manual command of the solenoid valve 1A; it can also be opened electrically by turning
the mode selector on “0” position and pushing the button "ADVANCE PHASE". By
releasing the button, the valve 1A is closed.
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" (“ALARM REGENERATION”)
phase, it is required to modify temporary the conductivity set-point to a value
appearing satisfactory, by electronic logical only.
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5.
CONTROL PANEL DESCRIPTION
The available commands on control panel are :
“EMERGENCY STOP”
BUTTON
“ADVANCE PHASES”
MODE SELECTORS
“AUT-0-MAN”
on “AUT”:
on “MAN”:
on “0”:
•
•
•
A simple pushing of the red button (placed on the wall-side of the
panel) stops immediately the system. To re-start just rotate the
same button approx 30° clockwise.
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.
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.
The deionizer stops on “REGENERATION REQUIRED” at the end
of service. The regeneration can be started by turning the mode
selector on “AUT” position.
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.
the lamps on the control panel shows the status of the system, as well as the open valves.
the phases of resins settling are not visualized.
the states of “LONG RINSE” (“ALARM REGENERATION”) and REGENERATION
REQUIRED” are joined in only one free voltage contact for remote alarm.
5.1.
How to stop the service, at any moment
When the deionizer is on service, it is possible to force the turning on “REGENERATION
REQUIRED” state, proceeding as follows ;
• Turn the mode selector on "0" position.
• Push the button “ADVANCE PHASES” for 5 consecutive seconds.
The system turns on “REGENERATION REQUIRED” status.
WARNING : the regeneration will start only when the mode selector will be turned, at least
for 2 seconds, on “AUT” position.
5.2.
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”
This features is not working during "LONG RINSE" (“ALARM REGENERATION”) phase;
it must be overpassed only according to the conductivity.
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5.3.
How to rinse the resins during “LONG RINSE” phase
During “LONG RINSE“ (“ALARM REGENERATION”) 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.
5.4.
Cross reference pilot solenoid valves and membrane valves
The table shows the correspondence between the diaphragm valves and correspondent
pilot solenoid valves
PILOT SOLENOID VALVE
E1/6
E2/4
E5
E7
E1A
E2/4/6A
E3A
E5A
E7A
DIAPHRAGM VALVE
1-6
2-4
5
7
1A
2A - 4A - 6A
3A
5A
7A
The diaphragm valves n. 5A e 6A, are Normally Open, all the rest are Normally Closed.
All solenoid valves are 3-ways Normally Closed.
All solenoid valves can be hand-driven by turning the lever placed at the base of each of
them : the action of the lever simulate the excitation of the coil.
So, for the (NC) Normally Closed solenoid valve, the valve is closed when the lever is on
parallel to the base; it is open and is driving the diaphragm valve, when the lever is on
perpendicular to the base.
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AUTOMATIC DEIONIZERS SERIE DA/V - INSTRUCTONS MANUAL
5.5.
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 P07-P08), 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.
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6.
FUNCTIONS OF OPERATING PANEL TD200
6.1.
•
•
•
•
•
•
•
•
•
•
•
Commands available on the panel
Functions F5÷F8 are driven by pushing the buttons SHIFT and F1÷F4 in the same time.
The messages the panel can visualize are folded in pages; each page can be opened by
pushing the correspondent button F…. The opening of a page automatically closes the page
still open.
All pages are automatically closed 5 minutes after the opening, except the page of visualization
of the states.
The pages of visualization of the state of line (F1) is also automatically opened when the
operating panel is switched ON, or also after 5 minutes of visualization of any other page.
Two lines of visualization are available on the display; a blinking arrow at the right end of the
display warns that there are other messages besides the visualized one. Use the arrows
UP/DOWN to scroll the several messages on the same page.
Pushing the button ENTER, during the visualization of a message that allows to modify one or
more numbers, the pointer moves on the first digit on right of the first number that can be
modified.
The digit emphatized can be modified by the UP/DOWN arrows; push both SHIFT and arrow
UP/DOWN in the same time to skip the pointer on another digit.
Push both SHIFT and ENTER in the same time to reset a value to zero.
Push ENTER to confirm the modifications, otherwise push ESC to cancel the modifications not
confirmed yet.
After any confirm of modification, the visualization comes back to the first line of opened page
or to the page of visualization of state, if the maximum allowed opening time (5 minutes) is
already elapsed.
By pushing the button ESC during current visualization, the display shows the main menu. The
access at menu visualization is restricted to operator only and it is protected by a password.
Push again button ESC to cancel the password request form.
6.2.
Content of the pages
F1 = PAGE VISUALIZATION OF STATE
The visualizations that are shown automatically and do not allow any modifications are :
•
•
•
•
•
STAND BY
SERVICE
QUALITY CONTROL, minutes of elapsed time since the starting of the phase and set point
REGENERATION REQUIRED
REGENERATION
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F2 = PAGE VISUALIZATION PHASES OF THE REGENERATION
The visualizations that are shown automatically and do not allow any modifications are all
the ones listed at the paragraph 4.2 page.8, where also the elapsed time (seconds) since
the starting of the phase itself and the set-point, are shown.
F3 = PAGE OF SETTINGS
The available visualization, which can be modified in a range between 0 and 32000, are :
•
•
•
•
•
•
•
•
•
•
•
7.
max running time of the QUALITY CONTROL phase
duration time phase 0 CATION BACKWASH
duration time phase 1 RESINS SETTLING
duration time phase 2 HCl INJECTION
duration time phase 3 HCl DISPLACEMENT
duration time phase 4 CATION RINSE
duration time phase 5 ANION BACKWASH
duration time phase 6 RESINS SETTLING
duration time phase 7 NaOH INJECTION
duration time phase 8 NaOH DISPLACEMENT
duration time phase 9 ANION RINSE
factory set
180 sec
300 sec
180 sec
1500 sec
1500 sec
900 sec
600 sec
180 sec
2100 sec
2100 sec
3600 sec
PLC : HANDLING OF THE MEMORY
The PLC is equipped with an internal EEPROM containing the original software.
The software and the temporary data are kept in the RAM by the power supply or, in case of
power failure, by an high capacity condenser for maximum time of 190 hours approx.
Whether the condenser is charged, the PLC keeps the whole software in the RAM, even in
case of power failure; therefore when the power turns on again, the program is not loaded from
EEPROM.
The PLC loads the program from EEPROM only when the power turns ON afterthat it has
been swicthed OFF and if the high capacity condenser is uncharged.
NOTE :
When the program is loaded from EEPROM, the modifications (if any) made by
operating panel will get lost and they are replaced with the initial values of the
software (therefore all factory set values).
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8.
STARTING UP & ADJUSTMENT
Starting up the unit means allowing a complete regeneration of the resins, and adjusting,
during each phase, the membrane valves to the proper required flow rate for the running phase.
The flow rates and the valves to be adjusted are listed in the TIME & PHASES table.
At the beginning it is suggested to operate by driving manually the solenoid valves (see §
Errore. L'origine riferimento non è stata trovata.).
The above way allows to stop, repeat or running for longer time each phase, adjusting
properly the flow rates according to the value of the attached table.
Proceed according to "PHASES & TIME" table, starting from phase n. 0 (CATION
BACKWASH).
The first part of BACKWASH (both ANION and CATION) allows to fill the columns with water;
the flow rate must be adequately low until the columns will be completely filled.
The time of first backwash (both ANION and CATION) must be extended longer than the
table time (at least 30') until the drain water will be perfectly clean.
For all the other phases it can be operated according to time shown on the tables.
During the phases of regenerant injection, the flow rates of the regenerant chemical and their
dilution water progressively decrease; if it happens, adjust continuously the flow rates at a
correct value until 5'÷10' before the end of the phase.
It is possible that the adjustments of the flow rates at the beginning will not be correct,
furthermore at the low flow rates (that mean high restriction of valve flow), due to the fact that
the membranes, particularly the new ones, are rigid and not easy to be immediately and
properly adjusted.
The manual valves, mounted next to the diaphragm valves, have to be used for adjustment
of flow rates of HCl and NaOH.
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.
When all adjustments and the manual regeneration have been completed, the control panel
can be turned on automatic mode.
However, it is suggested to verify, during the running of the first automatic regeneration, that
the pre-set flow rates and times are correct.
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9.
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 if the pilot air is not perfectly clear.
• 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.
• check that the water pressure and flow rates meet the defined ones.
• check that the air pressure meets the defined ones.
• each regeneration phase must run according to the defined flow rate.
• 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.
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10.
TROUBLE-SHOOTING GUIDE
PROBLEM
POSSIBLE CAUSE
HOW TO SOLVE
• regeneration is stopped on
“ALARM REGENERATION”
See following paragraph. “CHECKING OF THE RESINS”
(high conductivity at the end
of regeneration)
• The quantity of supplied • Quantity of chemicals used for • Run a regeneration adjusting
again the flow rates
water is lower than the
regeneration is lower than the
nominal value
stated values.
• Replace the resins
• The resins are polluted
• Adjust again the flow rate of HCl
• The quantity of HCl used for • The flow rate of HCl is not
valve (valve no 7)
regeneration is lower or
correctly adjusted
higher than the stated one
• Adjust again the flow rate of
• The flow rate of dilution water of
dilution water of HCl (valve no 6)
HCl is not correctly adjusted
• Take out and clean the injector
• The system does not draw • The injector is dirty
HCl
• Adjust again the flow rate of
• The flow rate of dilution water of
dilution water of HCl (valve no 6)
HCl is not correctly adjusted
• Check the correct working of the
• The valve no. 1 does not open
correspondent pilot solenoid
properly
valves; replace them if
• The valve no. 2 does not close
necessary.
properly
• The valve no. 5 does not close
properly
• The valve no. 6 does not open
properly
• The valve no. 7 does not open
properly
• The quantity of NaOH used • The flow rate of NaOH is not
• Adjust again the flow rate of
for regeneration is lower or
correctly adjusted
NaOH valve (valve no 7A)
higher than the stated one
• The flow rate of dilution water of
• Adjust again the flow rate of
NaOH is not correctly adjusted
dilution water of NaOH (valve no
6A)
• Take out and clean the injector
• The system does not draw • The injector is dirty
NaOH
• Adjust again the flow rate of
• The flow rate of dilution water of
dilution water of NaOH (valve no
NaOH is not correctly adjusted
6A)
• Check the correct working of the
• The valve no. 1A does not open
correspondent pilot solenoid
properly
valves; replace them if
• The valve no. 2A does not close
necessary
properly
• The valve no. 5A does not close
properly
• The valve no. 6A does not open
properly
• The valve no. 7A does not open
properly
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11.
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 (using the sampling cocks).
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, in the “LONG RINSE” (“ALARM
REGENERATION”) state.
The causes can be the following :
1. too large quantity of NaOH drawn (the 7A valve is not correctly adjusted)
2. too small quantity of dilution water (the 6A valve is not correctly adjusted or a pressure drop
of the inlet water occurred during the “NaOH DRAWING “ or “ANION RINSE “phases).
In
this case it is suggested to rinse again the anion resins, by handly opening the drain valve
E1A.
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.
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12.
HOW TO REPLACE THE RESINS
Whether the replacement of resins is required, proceed as follows :
•
•
•
•
13.
Switch OFF the main power
Unscrew the top-mounted cap with IN/OUT connections.
Take out the resins using an aspirator or by mean of a siphon.
Be sure that the under-valve nozzle and bottom distribution nozzle are not damaged.
Proceed as explained at § 3.3 to load new resins
Proceed as explained at § 8 for starting-up after replacement of resins.
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.
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14.
MAIN COMPONENTS LIST
14.1. Components commons for all models
Q.ty
1
1
2
1
1
1
9
1
1
DESCRIPTION
cation resins column
anion resins column
internal nozzles NOBEL design
skid NOBEL design
conductivity probe Steiel CCK5 PVC
conductimeter Steiel S503 C 24V cc
pilot solenoid valves BURKERT type 6012-24Vcc/MAN/PA
control panel NOBEL design
PLC Simatic S7-200
PVC fittings several diameters
14.2. Special components for model DA/V 14
n. 1
n. 1
n. 1
n. 6
n. 2
n. 1
n. 1
n. 3
l 55
l 70
flowmeter for H2O
scale l/h
mod.
flowmeter for HCl 30%
scale l/h
mod.
flowmeter for NaOH 30%
scale l/h
mod.
diaphragm valves (n. 1, 2, 7, 1A, 2A, 7A) GF 024 Ø 20 PVC
diaphragm valve (n. 5, 3A) GF 024 Ø 25 PVC
diaphragm valve (n. 6A) GF 025 NA Ø 20 PVC
diaphragm valve (n. 5A) GF 025 NA Ø 25 PVC
diaphragm valve (n. 4, 6, 4A) GF 025 NC Ø 20 PVC
strong cation resins
strong anion resins
14.3. Special components for model DA/V 19
n. 1
n. 1
n. 1
n. 6
n. 2
n. 1
n. 1
n. 3
l 75
l 110
flowmeter for H2O
scale l/h
mod.
flowmeter for HCl 30%
scale l/h
mod.
flowmeter for NaOH 30%
scale l/h
mod.
diaphragm valves (n. 1, 2, 7, 1A, 2A, 7A) GF 024 Ø 20 PVC
diaphragm valve (n. 5, 3A) GF 024 Ø 25 PVC
diaphragm valve (n. 6A) GF 025 NA Ø 20 PVC
diaphragm valve (n. 5A) GF 025 NA Ø 25 PVC
diaphragm valve (n. 4, 6, 4A) GF 025 NC Ø 20 PVC
strong cation resins
strong anion resins
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14.4. Special components for model DA/V 34
n. 1
n. 1
n. 1
n. 2
n. 4
n. 2
n. 1
n. 1
n. 3
l 125
l 175
flowmeter for H2O
scale l/h
flowmeter for HCl 30%
scale l/h
flowmeter for NaOH 30%
scale l/h
diaphragm valves (n. 7, 7A) GF 024 Ø 20 PVC
diaphragm valves (n. 1, 2, 1A, 2A) GF 024 Ø 25 PVC
diaphragm valve (n. 5, 3A) GF 024 Ø 32 PVC
diaphragm valve (n. 6A) GF 025 NA Ø 25 PVC
diaphragm valve (n. 5A) GF 025 NA Ø 32 PVC
diaphragm valve (n. 4, 6, 4A) GF 025 NC Ø 25 PVC
strong cation resins
strong anion resins
mod.
mod.
mod.
14.5. Special components for model DA/V 50
n. 1
n. 1
n. 1
n. 2
n. 3
n. 1
n. 2
n. 1
n. 1
n. 3
l 225
l 325
15.
flowmeter for H2O
scale l/h
flowmeter for HCl 30%
scale l/h
flowmeter for NaOH 30%
scale l/h
diaphragm valves (n. 7, 7A) GF 024 Ø 20 PVC
diaphragm valves (n. 1, 2, 2A) GF 024 Ø 25 PVC
diaphragm valves (n. 1A) GF 024 Ø 32 PVC
diaphragm valve (n. 5, 3A) GF 024 Ø 40 PVC
diaphragm valve (n. 6A) GF 025 NA Ø 25 PVC
diaphragm valve (n. 5A) GF 025 NA Ø 40 PVC
diaphragm valve (n. 4, 6, 4A) GF 025 NC Ø 25 PVC
strong cation resins
strong anion resins
mod.
mod.
mod.
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.
Q.ty
2
1
DESCRIPTION
pilot solenoid valves BURKERT tipo 6012-24Vcc/MAN/PA
membrane for diaphragm valves 024, 020, 021 for each size of installed valve
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