BWT Rondomat HVD Series User manual

Rondomat HVD 400-1550
Softening Unit
Installation and operation manual EN
659997220/EN/4

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Table of contents
1General ................................................................................................... 4
1.1 The Unit - Rondomat HVD ...........................................................................................4
2Function.................................................................................................. 5
2.1 Ion exchange............................................................................................................5
2.2 Regeneration............................................................................................................5
3Installation.............................................................................................. 5
4Commissioning...................................................................................... 5
4.1 Handling and filling the ion exchange resin..................................................................6
4.2 Filing of salt..............................................................................................................6
5Control panel.......................................................................................... 8
5.1 Menu .......................................................................................................................8
5.1.1 Information in menu............................................................................................8
5.1.2 Functions in the menu.........................................................................................8
5.2 Operation.................................................................................................................9
5.2.1 Information in operation.......................................................................................9
5.2.2 Functions in Operation........................................................................................9
5.3 Mimic.....................................................................................................................10
5.3.1 Information in Mimic..........................................................................................10
5.4 Auto/Man................................................................................................................10
5.4.1 Information in Auto/Manuel................................................................................10
5.4.2 Functions in Auto/Manuel..................................................................................10
5.5 Plant type...............................................................................................................11
5.5.1 Information in plant type....................................................................................11
5.5.2 Functions in Plant type......................................................................................11
5.6 Alarm settings.........................................................................................................11
5.6.1 Information in Alarm Settings.............................................................................11
5.6.2 Functions in Alarm Settings...............................................................................11
Changing the parameters:..................................................................................................11
5.7 Reg. Settings ...........................................................................................................12

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5.7.1 Information in Reg. Settings...............................................................................12
5.7.2 Functions in Reg. Settings.................................................................................12
5.8 Alarm.....................................................................................................................12
5.8.1 Information in Alarm..........................................................................................12
5.9 Alarm Log...............................................................................................................13
5.9.1 Information in Alarm Log ...................................................................................13
5.9.2 Functions in Alarm Log......................................................................................13
5.10 Counters ................................................................................................................13
5.10.1 Information in Counters.....................................................................................13
5.10.2 Functions in counters........................................................................................13
5.11 Language...............................................................................................................14
5.11.1 Information in Language....................................................................................14
5.11.2 Functions in Language......................................................................................14
5.12 Time and date.........................................................................................................14
5.12.1 Information in time/date.....................................................................................14
5.12.2 Functions in time/date.......................................................................................14
5.13 Password...............................................................................................................15
5.13.1 Information’s in Password..................................................................................15
6Maintenance ......................................................................................... 15
6.1 Salt container..........................................................................................................15
6.2 Samples.................................................................................................................15
7Periodic inspections............................................................................ 16
7.1 Periodically shut down.............................................................................................16
8Technical data...................................................................................... 17
9Spare part drawing............................................................................... 18
10 Spare parts list..................................................................................... 19
11 P & I Diagram........................................................................................ 20
12 Declaration of Conformity .................................................................. 21
13 Note....................................................................................................... 22

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1 General
BWT's Rondomat HVD –Series of volume
controlled softening units are designed for
industry, municipal waterworks, and
residential complexes and delivers efficient,
reliable and economical softening.
Softened water is used in various reasons.
E.g., BWT’s Rondomat HVD units pre-treat
water to:
▪BWT’s Permaq PRO RO-Units
▪Cooling towers
▪Boilers
The advantages using a quantity-controlled
plant is the good economy, as the plant
always consumes its entire capacity on
column in operation, before it automatically
switches to the standby column and starts
regeneration on the exhausted column.
This causes that the plant supplies soft water
during regeneration, which is necessary for
continuous or varied operation.
The plant has extremely low salt and water
consumption during operation due to the
built-in conductivity measurement.
The system is controlled by a PLC, so it is
always possible to change the operating
parameters. The PLC is connected to a HMI
at the front of the board, where all operating
parameters can be monitored.
The filter columns is made out of glass fibre
reinforced polyester for an overpressure of
max. 10 bar. At max. 40 ° C.
The filter is fitted with an inner plastic jet
system that distributes water evenly
throughout the filter area.
The filter columns, the pipe system and valve
rack in PVC and ABS are pre-assembled and
pressure tested for direct connection to
pipeline at the mounting site.
Appropriate electrical equipment is connected
to 220 V, 10A.
On the side is there a salt container supplied
with a lid. It is made of polyethylene
The plant requires no continuous supervision in
addition to filling the salt container.
1.1 The Unit - Rondomat HVD

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2 Function
2.1 Ion exchange
When the water passes the filter, calcium and
magnesium ions is absorbed by the ion
exchange mass while the corresponding
amount of sodium ions is carried to the water.
This procedure is called ion exchange (in this
case softening).
2.2 Regeneration
When the ion exchange mass is saturated
with calcium and magnesium, it must be
treated so it can soften the water again. This
treatment is called regeneration.
Regeneration begins by adding the diluted
salt solution (brine) with regulated flow to
achieve even distribution and sufficient
contact time in the ion exchange mass.
Calcium and magnesium are consequently
released and rinsed to drain while the ion
exchange mass is again saturated with
sodium.
Once the salt solution is introduced, the
regeneration continues with the first rinse,
which displaces the salt solution through the
ion exchanger.
The regeneration ends with a second flush
that is controlled by the conductivity of the
wastewater.
After 2nd flush, the filter is automatically
switched on for operation.
3 Installation
a. Place the unit on a flat surface, with
the salt container on the side.
b. Connect the top and bottom pipes to
the tanks and the valve rack.
c. Fill both tanks half with water before
filling them with ion exchange
resin.(see chap. 4.1)
d. Connect the inlet to the raw water
supply and the outlet for consumption
–the flange connections is DN50 for
HVD 400, 600, 900 and DN100 for
HVD 1200/1550. Be aware, that the
connected pipes shall be relieved.
e. Connect the waste water –flange size
DN40
f. The dynamical pressure shall be at
min. 3 bar and max 10 bar.
g. Connect the unit to power supply 230
V AC.
4 Commissioning
Please note that during operation of the
filters, ensure that no ion exchange is flushed
out
OPERATION
REGENERATION
Na+
Na+
Na+
Na+
Na+
Ca2+
Ca2+
Ca2+
H2O
Mg2+

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If this is the case, there is a leak in the jet
system at the top of the filter.
There must be mounted an aperture on the
outlet to ensure pressure on the system, if the
treated water goes directly to a reservoir.
It would be advisable to contact BWT before
commissioning, which will assist in answering
any questions.
4.1 Handling and filling the ion
exchange resin
Before the softening unit can go into
operation, fill in the supplied ion exchanger as
follows:
The amount of ion exchange resin should be
divide into two equally.
Remove the upper connection of the filter
column via coupling and screw the remaining
parts of (eg the top sprayer) connected to the
tank. Disassemble the flange connection, by
removing all M8 screws and the PVC adapter
for the tank.
Fill approx. 0.5-1 meters of water in the tank.
Place a funnel in the top of the tank. First, fill
the container with half of the ion exchange
resin. Then fill the rest of the container with
water. It is very important to use a
submersible pump with plastic impeller to fil
the rest of the container.
In the top of the drawing a filling neck is
displayed. This valve is for filling the last part
of the Strong cation and the inert resin.
Firstly, the top pip have to be removed so the
water can over float when the resin is filled
into the container. At the same time the
nozzles have to mounted to makes sure that
resin is not getting out together with the
water.
Now the actual filling of the resin can start.
The water will over float the container has to
be filled up completely
When the container is full, the pipe should be
mounted correctly again. Lubricate the O-ring
with Vaseline or similar and reconstruct the
upper compound. Adjust so that the
connection ends with the link.
Then open the valve for incoming water
slowly to check for any leak.
When this is done and the salt container is
filled, a manual regeneration is performed to
make sure everything is properly executed.
After this check, the filter is set into operation.
It is very important in order to secure good
water quality that the amount of resin is
correct.
After 1 –2 months of operation BWT suggest
that the amount of resin is controlled.
Possibly fill extra if needed.
Spilled ion exchange resin makes
surfaces very slippery.
4.2 Filing of salt
a. Close the valve for the incoming water
to the salt container.
b. Fill the salt container with salt tabs
Figure 1 - Internals of a softening column

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c. Fill the salt container with water, by
opening the valve for incoming water.
Let the valve stay open for operation.
Figure 2 - Salt Container
Keep undissolved salt out
of the tube

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5 Control panel
5.1 Menu
5.1.1 Information in menu
All screen images are designed with a header
with logo, time, menu and alarm keys.
If an alarm occurs, the “alarm” key will flash in
a slow frequency.
Press Alarm
In the Alarm screen, all active alarms will
be displayed.
Press the Menu and return to the shown
screen.
Press the yy/mm/dd. For setting the date
and time.
5.1.2 Functions in the menu
Press Operation
Press Mimic
Press Auto/Man
Press Plant type
Press Alarm settings
Press Reg. settings
On the operating screen it is possible to start and
stop the operation and regeneration.
On the mimic screen is indicated status of
operation and valve/pump..
On the Auto/Man. Screens you can select auto &
manual operation of pumps and valves.
On the plant type screen you select type of filter
This screen image is protected by a Password:
see chapter 5.13
In alarm settings you select settings for set point
and delays of alarm.
This screen image is protected by a Password:
see chapter 5.13
In reg. Settings you select settings for capacity
and regeneration.
This screen image is protected by a Password:
see chapter 5.13

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Press Alarm log
Press Counter
Press Language
5.2 Operation
5.2.1 Information in operation
Start/Stop of the plant (only with reservoir).
Activate with the on/off button
Operation status on each filter is indicated.
Reg. Status:
Indicates which step of the regeneration that
is activated.
Reg. Timer:
Regeneration time in the activated step.
5.2.2 Functions in Operation
Press OFF-ON
Press Start Reg.
Press Step Reg.
Changes to alarm history where all alarm
occurrences are stamped with time and date.
In the counter screen image is shown operating
hours, valve operations and capacities.
In the Language screen image, you can choose
various languages directly on the screens.
Start/stop of the unit
Manual start of a regeneration..
Manual step forward in the regeneration sequence.

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5.3 Mimic
5.3.1 Information in Mimic
-Conductivity in waste water under
regeneration
-Capacity left in each column before
regeneration
-Operation status on valves and
pumps
Pumps:
(Black = OFF, White = ON)
Valves:
(Black = closed, White = open)
5.4 Auto/Man
5.4.1 Information in Auto/Manuel
This function visualize the manual
interference (AUT-MAN)
5.4.2 Functions in Auto/Manuel
Selected Valves & Pumps for Automatic
operation where the equipment is
automatically controlled from the PLC or in
Manual, where it is possible to start / open
the pump & valves directly.

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5.5 Plant type
5.5.1 Information in plant type
-The K-factor of the water meter
-The selected plant type
Selected options:
-Reservoir
-Saturator
-Testomat
5.5.2 Functions in Plant type
Select the filter size that matches the unit.
Set the k-factor for the water meter (number
of impulses pr.m³)
Select options.
5.6 Alarm settings
5.6.1 Information in Alarm Settings
Delay of various alarms and set points for the
conductivity in the second flush.
5.6.2 Functions in Alarm Settings
Setting different alarm time delays and setting
the set point of the conductivity in the second
flush.
Changing the parameters:
To change a value, press the selected field. A
pop up menu with a keyboard will appear.
Type in the selected value and press “ENT”
for confirmation. Password (See chapter
5.13)

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5.7 Reg. Settings
5.7.1 Information in Reg. Settings
The capacity between each regeneration is
shown in ”capacity/ Filter”.
5.7.2 Functions in Reg. Settings
-Change the times in the regeneration
sequence.
-Define the hardness of the raw water
-It´s possible change between °dH, °fH
and ppm CaCO3.
-The capacity in the Ion exchange
resin (preconfigured to 2.8 m3)
Password (See chapter 5.13)
5.8 Alarm
5.8.1 Information in Alarm
See all active alarms by pressing the “Alarm”
button in the top right corner. If an alarm
appears, the alarm button will blink. The
alarm will show date and time when it
occurred.
Reset alarm by pressing “Reset”

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5.9 Alarm Log
5.9.1 Information in Alarm Log
In this picture, the last 128 alarms are
displayed with the date and time of the alarm.
When more than 128 alarms have occurred,
the oldest alarms will be deleted.
5.9.2 Functions in Alarm Log
By pressing the ”START” button, can the
UP/DOWN, buttons be used, to go through
the registered alarms
”CLEAR ALL” Deletes the log.
Password (Se afsnit5.13)
5.10 Counters
5.10.1 Information in Counters
Time for pump P1.
Total time for capacity on filter 1 and 2.
Total amount of regenerations on filter 1 and
2.
5.10.2 Functions in counters
Press the R button to reset all counters.
Password (See chapter 5.13)

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5.11 Language
5.11.1 Information in Language
Displays all the available language options.
5.11.2 Functions in Language
To select a language, Press the preferred
language
5.12 Time and date
5.12.1 Information in time/date
Date and time.
5.12.2 Functions in time/date
Date and time can be changed by pressing
the individual buttons, and set the value and
confirm with”ENT”.

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5.13 Password
5.13.1 Information’s in Password
The password image will automatically
appear if a select feature is password
protected.
If the correct password is entered, the desired
image will appear.
If the correct password is not entered within
10 seconds, the image will automatically
return to Menu.
Password can be given out by calling
BWT Denmark
Tlf. [phone]
6 Maintenance
6.1 Salt container
We recommend to use salt tablets or
granulated vacuum salt if using a Saturator.
The plant is designed for a brine solution of
300g / liter of water.
Frequently empty and rinse the salt container.
The quality of the salt is crucial for the time
interval between these rinses.
NOTE! The minimum level for undissolved
salt must never fall below 10 cm.
Make sure the filter sucks sufficient amounts
of brine during regeneration. See
"TECHNICAL DATA".
6.2 Samples
Check regularly that the water is soft.
Checking the softened water is carried out
with the supplied test kit according to the
instructions with the test kit

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7 Periodic inspections
The HVD Rondomat requires a minimum of
maintenance. However, in order to guarantee
trouble-free operation, must be performed
certain inspections and control of functions.
It is important that the individual parts of the
plant be inspected and maintained according
to the manufacturer's instructions.
Note
Guarantees, etc. Is provided on condition
that inspection / maintenance is carried
out with time intervals as prescribed and
that the results are noted in the operating
record.
Daily:
Weekly:
Each month
Each 6. Months
7.1 Periodically shut down
The cation ion exchanger can be stored in
their container under proper conditions when
the regenerated ion exchanger is left in
contact with 1-2% HCl or H2SO4.
After a prolonged period of closure, take the
following precautions:
Drain the filter containers for liquid and
perform a double regeneration on the ion
exchanger.
BWT Denmark A/S offers various types of
service agreements to ensure a smooth
operation. Inquiry can be made at:
Tel. [phone]
Control the water hardness
Check the salt level in the salt container.
Fill if needed.
Keep record in journal
Monitor a regeneration sequence.
Check times and flow according to set
values.
During the salting and displacement phase,
all the salt solution must be sucked in
according to the markings made.
By the termination of the rapid rinse phase
it must be checked if the water is soft.
Check that the salt tank fills up again with
water to the correct level
Empty and clean the salt tank.
Dismount and clean the salt valve plus the
overflow valve.
Clean the pressure reduction valve.
Clean and wipe off the filter tanks and the
control units.

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8 Technical data
Rondomat HVD
Unit
400
600
900
1200
1550
Max. flow velocity*
m³/t
10/15
18/21
25/30
32/39
41/50
Pressure drop at max. flow
velocity
bar
1,1 / 1,5
Min. flow velocity *
m³/t
0,08
0,35
0,35
3,0
3,0
Capacity at 1°dH
m³
1085
1680
2520
3290
4340
Capacity at 5°dH
m³
217
336
504
658
868
Capacity at 15°dH
m³
72
108
168
220
289
Capacity at 20°dH
m³
54
84
126
165
217
Salt consumption pr.
regeneration
kg.
31
48
72
94
124
Time pr. regeneration
min.
50
55
60
65
70
Max. water temperature
°C
35
Water pressure max.
bar
10
Pipe connection
DN
50
100
Water connection
DN
40
Height [A]
mm
2520
2600
2800
2750
2800
Width [B]
mm
2800
3000
3120
3550
4000
Depth [C]
mm
1400
1500
1600
1800
1900
Height Salt container [D]
mm
1120
Diameter salt container [E]
mm
1350
Capacity salt container
litre
1000
Water consumption pr.
Regeneration*
m³
0,55
0,75
1,05
1,48
2,0
Product number:
422162320
422162470
422162670
422162920
422163220
Product number; hardness test
701995010
Product number; Salt alarm
401528200
*At 15 °C, 3,0 bar before the unit and new clean ion exchange resin. At continually operation should the capacity on
some models be reduced, depending on the condition of the raw water. * Brine is not included in the water consumption
pr. regeneration.

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9 Spare part drawing

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10 Spare parts list
Position
No.
BWT Rondomat HVD
Spare part
No.
Recommended
spare parts
Recommended
replacement
frequency
1
Level switch 5 m. cable.
110851050
2
2-4 years
2
Weight for level switch.
110860000
1
3
Non-return valve 25 mm PVC.
200315025
4
Ball valve 25 mm. PVC.
200712025
5
Ball valve 32 mm. PVC.
200712032
6
Ball valve 25 mm. PVC with
actuator.
200713025
7
3-way ball valve 63 mm. T-drilled.
200718063
1
3-4 years
8
Actuator 230V AC 90-degrees.
200718100
1
9
Sample valve ¼” PVC .
200721020
1
10
Reduc. valve ¾” D06F .
200771006
11
Filter for reduc. valve ½” -¾”.
200772016
1
Once a year
12
Pressure gauge for reduc. valve.
200781108
13
Dist. syst. T/14"-36" flange top.
350244100
1
14
Dist. syst. T/24"flange bottom.
350244108
1
15
Salt hose 5/8.
401528050
1
16
Drain elbow ½”.
405378730
17
Nozzle-pipe 1".
409000480
18
Pressure gauge ¼” 0-10 BAR
stainless steel.
452264000
19
Ejector, size. 3
600101103
1
20
Flow restrictor 40 mm. CPVC.
600220400
Water meter DN50, Q3: 40 m³/h.
puls/10 liter. (HVD 400, 600, 900)
409705050
Water meter DN100, Q3: 160 m³/h.
puls/10 liter. (HVD 1200, 1550)
409705100
Pump CM 3-5 1X200/240V 50Hz
454100950
Jumo ecotrans LF 01
750000391
Conductivity probe, Jumo blackline
K=1,0
750000393
Proface-panel
750001291
Ion exchange resin, inert
By request
10% of the volume
Once a year
Ion exchange resin, active
By request
10% of the volume
Once a year

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11 P & I Diagram