EHRLE DF400 Duplex Training manual

Assembly and Commissioning Instructions
Water Softener unit
DF400 Duplex, Valve WS1,25CI TT

2| Table of contents
Duplex Water Softener
Programming DF400
Level 2 Next + ᴠfor 5 sec. / 1x
Operating mode
SOFTENING
Press button SET/CLOCK
Level 1 Next + ᴠfor 5 sec. / 2x
Diameter of valve
1.25
Valve configuration
Master – ALT A
Slave – ALT B
Pre Rinse
OFF
External regeneration trigger
dp OFF
HARDNESS
dH
Programm step 1
BACKWASH
Programm step 2
Dn BRINE
Programm step 3
RINSE
Programm step 4
FILL
Programm step 5
END
External power supply / Lo DC
OFF
Level 2 Next + ᴠfor 5 sec. / 1x
Operating mode
SOFTENING
Duration of programm step 1 - BACHWASH
5 min.
Duration of programm step 2 - dn BRINE
99 min.
Duration of programm step 3 - RINSE
10 min.
Duration of programm step 4 - FILL
24 Kg.
CAPACITY on M³
400
Regeneration
Auto
TIME REGEN
on 0
rLY 1 (relay 1)
OFF
rLY 1 (relay 2)
OFF
REMAINING SALT
OFF
Level 3 Next + ᴧfor 5 sec. / 1x
HARDNESS (lokal water hardness) individual
dH 20
HARDNESS 2
dH 0
REGEN DAY (forced regeneration)
OFF
REGEN (not adjustable)
on 0 m³

Operating instructions
| 3
Table of contents
IMPRINT .................................................................................................................................................. FEHLER!TEXTMARKE NICHT DEFINIERT.
TABLE OF CONTENTS.............................................................................................................................................................................. 3
1ABOUT THESE INSTRUCTIONS .................................................................................................................................................... 5
1.1 HAZARDS OF ELECTRICAL ENERGY.........................................................................................................................................................5
1.2 HAZARDS OF HYDRAULIC ENERGY ..........................................................................................................................................................5
1.3 EXPLANATIONS OF SAFETY NOTICES AND GENERAL NOTES .......................................................................................................................6
1.4 WARRANTY AND LIABILITY.....................................................................................................................................................................6
1.5 INFORMATION ON PACKAGING AND TRANSPORT .......................................................................................................................................7
1.6 STORAGE ............................................................................................................................................................................................7
1.7 UNPACKING THE COMPONENTS ..............................................................................................................................................................7
1.8 FUNCTIONAL DESCRIPTION OF THE DUPLEX WATER SOFTENER ..................................................................................................................8
1.9 INTENDED USE......................................................................................................................................................................................8
2TECHNICAL DATA.......................................................................................................................................................................... 9
3SYSTEM ASSEMBLY.....................................................................................................................................................................12
3.1 PRIOR TO ASSEMBLY ..........................................................................................................................................................................12
3.1.1 UNPACKING .......................................................................................................................................................................................12
3.1.2 INSTALLATION SITE.............................................................................................................................................................................12
3.2 FILLING THE PRESSURE TANK ..............................................................................................................................................................13
3.3 MOUNTING THE CENTRAL CONTROL VALVES TO THE PRESSURE TANKS.....................................................................................................13
3.4 INSTALLING THE CONNECTIONS BETWEEN THE CONTROL VALVES.............................................................................................................14
3.5 INSTALLING THE BYPASSES .................................................................................................................................................................15
3.5 INSTALLING THE BSPT CONNECTIONS (WATER OUTLET).........................................................................................................................15
3.6 INSTALLING THE VERTICAL ADAPTER (90°) (WATER INLET) .....................................................................................................................16
3.7 INSTALLING THE MOTOR ALTERNATING VALVE .......................................................................................................................................16
3.9 INSTALLING THE WATER INLET PP PIPE ................................................................................................................................................17
3.10 WATER OUTLET PP CONNECTION.........................................................................................................................................................17
3.11 CONNECTING THE BRINE HOSES ...........................................................................................................................................................18
3.12 CONNECTING THE WASTEWATER LINES .................................................................................................................................................19
4WIRING THE CENTRAL CONTROL VALVES ...............................................................................................................................19
4.1 CONNECTING THE TWO CONTROL VALVES .............................................................................................................................................20
4.2 WIRING THE MOTOR ALTERNATING VALVE .............................................................................................................................................20
4.3 WIRING THE MOTOR ...........................................................................................................................................................................22
4.4 CONNECTING THE CABLE TO THE POWER SUPPLY...................................................................................................................................22
4.5 WIRING THE FLOW METER....................................................................................................................................................................22
5PROGRAMMING INSTRUCTIONS.................................................................................................................................................23
5.1 KEY FUNCTIONS .................................................................................................................................................................................23
5.2 SETTING THE CLOCK (ON BOTH VALVES) ...............................................................................................................................................24
5.3 SETTING THE PROGRAM SEQUENCE (LEVEL 1) .......................................................................................................................................24
5.4 PROGRAM CONFIGURATION (LEVEL 2) ..................................................................................................................................................26
5.5 INSTALLATION /USER DISPLAYS (LEVEL 3) ............................................................................................................................................28
5.6 GENERAL CONTROL DISPLAYS .............................................................................................................................................................29
5.7 DIAGNOSTIC DISPLAYS DURING THE FIRST PHASE...................................................................................................................................29
5.8 DIAGNOSTIC DISPLAYS IN PHASE TWO...................................................................................................................................................30

4| Table of contents
Duplex Water Softener
Table of contents
6COMMISSIONING...........................................................................................................................................................................32
6.1 FILLING THE BRINE TANK.....................................................................................................................................................................32
6.2 FLUSHING PRIOR TO INITIAL USE...........................................................................................................................................................33
6.2.1 FLUSHING THE LEFT PRESSURE TANK (ALT A–MASTER VALVE).............................................................................................................33
6.2.2 FLUSHING THE RIGHT PRESSURE TANK (ALT B–SLAVE VALVE) .............................................................................................................34
6.2.3 IMPORTANT INFORMATION ABOUT BRINE FORMATION TIME ......................................................................................................................34
6.3 NON-STOP OPERATION........................................................................................................................................................................35
7WATER SOFTENER OPERATING CYCLES .................................................................................................................................36
7.1 OPERATION (NON-STOP OPERATION)....................................................................................................................................................36
7.2 BACKWASHING (CLEANING AND LOOSENING THE RESIN BED) ..................................................................................................................36
7.3 BRINE (RESIN BED REGENERATION)......................................................................................................................................................37
7.4 FAST RINSE .......................................................................................................................................................................................38
7.5 FILLING THE BRINE TANK.....................................................................................................................................................................38
8MAIN CONTROL VALVE TECHNICAL DETAILS ..........................................................................................................................39
8.1 IMAGE OF CLACK WS CI CENTRAL CONTROL VALVE ..............................................................................................................................39
8.2 CONTROL AND DRIVE UNIT...................................................................................................................................................................40
8.3 BYPASS VALVE ..................................................................................................................................................................................41
9FEHLERSUCHTABELLE................................................................................................................................................................44
10 WS1 INSTALLATION SPANNER ..................................................................................................................................................44

Operating instructions
1 About these instructions | 5
1 About these instructions
These instructions are for a volume-based duplex water softener.
•Please note, the operating and programming instructions are intended for qualified specialists.
•Please carefully read the operating instructions prior to initial use.
•Observe the basic safety instructions.
•Observe the instructions related to actions.
•Keep all documents included with this system in a location where they can be referenced when
necessary.
•When passing the product along to others, include all documents included with this system.
1.1 Hazards of electrical energy
•Work on the electrical power supply should only be carried out by an electrician.
•Routinely inspect the electrical equipment of the system.
•Immediately repair loose connections and scorched cables.
•If live parts must be worked on, seek the assistance of a second person to switch off the main switch in
an emergency.
1.2 Hazards of hydraulic energy
•Work on hydraulic equipment must be carried out by persons with special hydraulics knowledge and
experience.
•Depressurize sections and pressure lines which must be opened before starting repairs.
EHRLE GmbH assumes no liability
for damages due to failure to observe these instructions.

6| 1.3 Explanations of safety notices and general notes
Duplex Water Softener
1.3 Explanations of safety notices and general notes
General notes are marked as follows:
General note with important information.
Hazards which may result in property damage if damage occurs, meaning
damaging the system or the work piece.
General notes use the following symbols:
This symbol indicates information.
This symbol indicates a general note.
This symbol indicates a potentially dangerous situation
The water softener must be installed in compliance with DIN EN 1988, as well as DVGW work sheet W 503 and
W 504.
During installation, observe the OEM instructions for the WS1.25 CI central control valves.
Only carry out work specified in these instructions.
Do not alter or modify the system.
Always unplug the power plug before working on the valve.
1.4 Warranty and liability
Warranty and liability claims for personal injury and property damage are excluded for one or more of
the following causes:
•Improper system use.
•Improper system assembly, commissioning, operation and maintenance.
•Operating the system with defective safety equipment or incorrectly installed or inoperable safety
devices and guards.
•Failure to observe the information in the operating instructions (regarding; transportation, storage,
assembly, commissioning, operation, maintenance and equipping) the system.
•Unauthorised structural changes to the system.
•Improper monitoring of system parts subject to wear.
•Improper repairs.
•Emergencies due to foreign objects and force majeure.
NOTE
CAUTION

Operating instructions
1 About these instructions | 7
1.5 Information on packaging and transport
•If possible, pack the water softener on an IPPC Euro pallet.
•Protect components from moisture during transport.
•Protect components from frost during transport.
1.6 Storage
•Store exchanger resin in moist conditions and keep from drying out.
•Store exchanger resin frost-free.
•Keep the pressure tank away from sunlight to prevent ageing.
•Keep pressure tank protected from shock.
•Store central control valve and electronic components dry.
•Store hardware in the clean, dry brine tank.
1.7 Unpacking the components
The VAD 100 system is not filled at the factory due to its weight. With this type of system, the ion
exchanger resin, the support gravel, the pressure tank, the riser, the central control valve, the piping and
the brine tank are delivered as separate parts.
Unload the shock-sensitive pressure tanks with care.
Lift the pressure tanks during transport.
Never roll pressure tanks!!
NOTE

8| 1.8 Functional description of the duplex water softener
Duplex Water Softener
1.8 Functional description of the duplex water softener
The duplex filtration system uses the ion exchanger principle. Hardeners in the water, calcium (Ca) and
magnesium (Mg) are replaced with sodium ions (Na+) in the filter bed. This achieved by using a strong acid
cation resin in sodium form (softening resin).
During regeneration, common salt removes the hardeners calcium (Ca) and magnesium (Mg) from the
resin and flushes these out in the wastewater.
1.9 Intended use
•The duplex water softener may only be used to soften drinking and service water.
•The limits in the technical data apply; pressure, temperature and flow rate.
•Intended use also includes observing all information in the operating instructions and
complying with the inspection and service schedule.
•Improper use includes:
Filter (mech. filtration without brine regeneration)
Storage tank (after removing the ion exchanger material)
Pressure reservoir (water or air)
•Do not modify, install add-ons or convert the system without the written approval of the
manufacturer / supplier.
•Immediately replace any parts which are not in excellent condition; only replace these with
original parts. There is no guarantee that third-party parts have been designed properly for
their function, demand and safety.
•Any other use of the duplex water softener is considered improper use.
•EHRLE GmbH assumes no liability for damages due to failure to observe this notice. The user
is solely liable for the risk.
•The operating instructions must be observed to ensure proper operation and warranty claims.
•Therefore, first use the operating instructions, before carrying out any work on the water
softener!

Operating instructions
2 Technical data | 9
2 Technical data
Model VAD TA duplex water softeners with
separate brine tank.
For softening drinking and service water.
Includes:
●2 top quality pressure tanks made from
corrosion-resistant GRP, filled with softening
resin type S1567, for softening water.
●2 fully automatic central control valves by
CLACK, model WS 1.25" CI (volume-based)
made from Noryl®
●1 separate brine tank with sieve bottom.
Image 1. duplex water softener components.
Features & functionality
●Softening resin, Na form, approved
for drinking water and food.
●Full regenerability with NaCl (discharging Ca
and Mg)
●2 central control valves with piping and
central alternating valve
●Programmable cycle times
●Reliable, multi-stage program control
●Extended operating data logging
●Optical sensor for accurate cycle
configuration
●Connection piping with sampling
●Non-stop 24/7 operation through automatic
switchover (multiway switching)
●LCD display for easy programming
●Clock memory during power outages
●Program saved to memory, won’t be lost in
power outages
●Displays remaining capacity / time
before switching over and displays
current flow rate

10 | 1.9 Intended use
Duplex Water Softener

Operating instructions
2 Technical data | 11
Specifications
VAD 100 TA
Weight
(Net weight with resin) in kg
(Operating weight) in kg
[kg]
[kg]
410
780
Softener design
Duplex
Capacity per tank
(°dH × m³)
400
() Values at a flow rate within 40–60 m/h or 1.1–1.7 cm/sec.
Resin tank size
Pressure tank type
H
Ø
[Litre]
[inch]
[mm]
[mm]
140
14x65
1630 - 1660
369
Brine tank
H
Ø
[mm]
[mm]
SBE340
1200
594
Footprint
H1 (tank)
H2 (brine tank) without scale
W
D
[mm]
[mm]
[mm]
[mm]
2100
1200
2100
700
Resin quantity
[Litre]
2x100
Water connections
[inch]
1.25" ET
Control head size
[inch]
1.25" ET
Salt supporting plate height
[mm]
375
Regeneration volume
[Litre]
1850
Regeneration time
[min.]
195
Max. regeneration flow rate
[L/min.]
*42
Kv value
[m³/h]
4.0
Salt per regeneration
[kg]
36
Minimum pressure
[bar]
2
Maximum pressure
[bar]
6
Ambient temperature
[°C]
4 – 43
Water temperature
[°C]
4 - 43
* the specified values are ideals which vary by actual conditions and the available pressure
Power supply
VAD 100 TA
Power supply voltage
220-240V / 50/60Hz.
*100-120V / 50/60 Hz.
* only available with US plug
Operating conditions
pH operating range
6-10
Free chlorine Cl
2
working range
(max.) 0.1 mg/L (continuous duty)
Free chlorine Cl2stability
(max.) 2.0mg/L (temporary load)
Transport and storage conditions
Storage temperature range
+4°C to +43°C (protect from frost!)
Relative humidity
Up to 80% at 20°C (non-condensing)

12 | 3.1 Prior to assembly
Duplex Water Softener
3 System assembly
3.1 Prior to assembly
The fused electrical connection must be installed within range of the mains connection.
Never interrupt the electrical connection.
Never connect the electrical connection to a light cable
The installation site must be level and clean.
The installation room must be frost-free and sufficiently ventilated.
The temperature in the installation room must not exceed 43 °C.
The wastewater connection on site must be a free outlet per DIN EN 1717 with the
recommended usable cross-section (recommended NW 70).
The water system must be located near the wastewater connection.
The untreated water must have a minimum pressure of 2 bar.
The untreated water pressure must not exceed 6 bar.
3.1.1 Unpacking
Unload the shock-sensitive pressure tanks with care.
Lift the pressure tanks during transport, never roll!!
3.1.2 Installation site
Ensure all installation requirements are met.
A level surface is required to ensure the pipes of the system are tension free. If the surface is not level,
build a foundation with a minimum size to fit the pressure tank feet. Remember the brine tank must be
placed near the pressure tank.
CAUTION
NOTE
NOTE

Operating instructions
3 System assembly | 13
3.2 Filling the pressure tank
Fill the pressure tanks successively in the following order:
1. Align the pressure tanks on a level surface.
2. Screw a central control valve onto each tank. Align the two pressure tanks with the attached control valve
so the displays face the same direction you would like them to later be in. Now align the two pressure tanks
so there is enough space between the two control valves to install the connecting pipes with motor
alternating valve (MAV) between the two control valves without strain (see figure 3 under item 3.4)
3. Remove the two control valves from the pressure tanks again. Do not change the position of the pressure
tanks in the process.
4. Ensure the riser is centred in the pressure tank. If necessary, realign the riser so it is centred.
5. Seal the top opening of the riser with a suitable cap or adhesive tape to keep out support gravel or
exchanger resin.
6. Now add water to the tank until it is approx. 20% full of water. Ensure the riser does not shift from the
centre position or float.
7. First add the included support gravel to the tank, pushing the riser onto the bottom of the tank so the tube is
upright in the middle of the tank.
8. Fill the pressure tank with the amount of ion exchanger resin specified for each tank.
9. After filling, slowly fill the water softener with water to approx. 10 cm above the resin bed.
10. Remove the cap or adhesive tape from the top opening of the riser. If necessary, remove ion exchanger
resin from the thread.
3.3 Mounting the central control valves to the pressure tanks
1. Grease the gaskets of the threads on the bottom of the two central control valves with silicone grease.
2. Then attach the upper baskets to the bottoms of the control valves. Take their large opening and insert
these in the opening at the bottom of the central unit and the adapter. Turn anti-clockwise once so the
basket locks into the opening in the opening. This is a so-called bayonet connector, not a screw thread.
The basket cannot be removed once screwed in.
Attach the top
basket
to the bottom of the
control valve.
attached upper basket

14 | 3.4 Installing the connections between the control valves
Duplex Water Softener
Image 2. Attaching the upper basket.
3. Slide the opening at the bottom of the basket over the upper end of the riser and push the control valve
down with a bit of pressure until the threads meet. Screw the control valve onto the thread and tighten.
4. Repeat the steps under item 3 with the second control valve.
3.4 Installing the connections between the control valves
Image 3. Central control valves with alternating valve, bypass and piping

Operating instructions
3 System assembly | 15
3.5 Installing the bypasses
There are two openings with external threads and arrows indicating the water inlet and outlet at the back of the
central control valve. The bypass mounts to these threads for both central control valves. The swivel nut only
needs to be tightened by hand, as the O-ring ensures the joint is tight.
Image 4 water inlet / outlet and 5. Bypass.
3.5 Installing the BSPT connections (water outlet)
An adapter screws onto the threaded outlet of the bypasses, running to the water inlet of the central control
valve, to convert to the European thread (BSPT thread). The two adapters (one for each bypass, or for each
central control valve) are packaged in a plastic bag with instructions for assembling the parts. The description is
titled: WS Fitting 1.25" Plastic BSPT.
Image 6. WS Fitting 1.25" Plastic BSPT.
Fitting 1.25"
Swivel nut
Split ring
O-ring 215
Water inlet
Water outlet
BSPT pieces

16 | 3.6 Installing the vertical adapter (90 ) (water inlet)
Duplex Water Softener
3.6 Installing the vertical adapter (90°) (water inlet)
Screw two connected 90° vertical adapters onto each BSPT piece at
the outlet of the two bypasses as shown under 3.4.
Image 7 Vertical adapter.
3.7 Installing the motor alternating valve
The motor alternating valve (MAV) screws to the vertical adapter
(Image see item 3.4)
Image 8. Motor alternating valve (MAV).
ATTENTION:
The thread marked with the letter A must be connected to the vertical adapters to the central control valve on
the left pressure tank. The thread marked with the letter B must be connected to the vertical adapters to the
central control valve on the right pressure tank.
A BSPT piece (see item 3.5) screws onto the MAV outlet on the bottom.
The outlet at the bottom of the MAV is the outlet for treated water.
A
B
Left
pressure
tank
Right
pressure
tank
Image 9. 1.25 inch BSPT piece.

Operating instructions
3 System assembly | 17
The MAV is used to shut off the water flow from the regenerating central control valve and redirect the water
flow from the central control valve supplying treated water to the outlet.
You will see a thread inside the transparent dome at the top of the MAV. When water flows through inlet B to
the outlet, the thread will not be visible in the transparent dome (retracted), when water flows through inlet A to
the outlet, the thread will be visible (extended).
Image 10. Motor alternating valve (MAV).
3.9 Installing the water inlet PP pipe
The polypropylene (PP) piping (see image below) screws onto the water inlet on the two bypass valves. This
piping supplies the two central control valves with untreated water.
3.10 Water outlet PP connection
A polypropylene (PP) adapter screws onto the BSPT piece at
the water outlet below the motor alternating valve (MAV) (see
image on the right). This adapter has a sampling tap and a
John Guest fitting for connecting a hose.
Image 12. Water outlet PP connection.
Image 11. Water inlet PP pipe.

18 | 3.11 Connecting the brine hoses
Duplex Water Softener
3.11 Connecting the brine hoses
Brine hoses (semi-transparent, 9.5 mm diameter) connect the two control valves to the brine valve on the brine
tank. Both control valves therefore have a brine hose running to a T-piece, from
which a brine hose runs to the brine valve.
1. Firmly insert one end of the brine hose into the designated opening at the
back of both control valves (see image below).
2. Firmly insert the other end of the brine hose into one of the openings in the
T-piece on the other side (see image below).
3. Since the end of the brine hose connecting to the brine valve screws to a thread using a nut, the following
parts need to be attached: (Attention: follow order).
First slide the black plastic nut over the end of the brine hose as shown below. Then first slide the white,
then the black compression ring over the brine hose.
Then firmly insert the hose in the opening on the brine tank and tighten the nut.
Image 13. Brine hose opening on control valve
Image 15. Brine hose connection on brine tank
Image 14. Connecting brine hoses
to the T-piece.
Brine hose for valve A on
control valve
Brine hose connection on
the control valve
Brine hose from T-piece to
brine valve inside brine tank

Operating instructions
3 System assembly | 19
•Use a kink-proof plastic hose as the brine hose from the brine tank to the central
control valve.
•Secure the brine hose against moving.
•Keep the brine line as short as possible.
•Avoid any cross-section constriction.
Please do not add regeneration salt to the brine tank until after commissioning.
Adding regeneration salt to the brine tank sooner prevents proper monitoring of the water
level in the brine tank.
3.12 Connecting the wastewater lines
A drain hose must be used to connect the water outlet of the control valves to a
drain pipe. The hose attaches to the grey 90° angle at the back (left) of the
control valves.
Inside the 90° vertical adapter (DLFC housing) is a rubber seal with a
defined opening (drain line flow control - DLFC). The flow rate for backwashing
is controlled by the DLFC. The table (below) lists the designation of the DLFC
used
Run all wastewater lines from the central control valves and the overflow drain of
the brine tank straight into a drain using a hose.
Run the hose from the top to the bottom so the wastewater can drain well.
Run the hose without narrowing cross-section and without kinking.
Secure the hose with a hose clamp.
Table: Drain line flow control (DLFC) and connection fittings on VAD 150 TA
DLFC housing Channel fitting
Drain line flow
control
Drain line flow
control Backwash capacity
V 3008
19.1 mm (¾")
V3162-090
9 gpm
34.1 L/min
Ensure the hose is secured well to the drain pipe and cannot slip out, as the wastewater is
pressurised as it is discharged and causes somewhat of recoil.
Image 16. Wastewater connection ¾", 13
NOTE
CAUTION
NOTE
NOTE

20 | 4.1 Connecting the two control valves
Duplex Water Softener
If the wastewater connection is so far from the desired installation site that the included
drain hose is not long enough, please use a longer hose of the same diameter or extend
the included hose accordingly. You can also order the required drain hose length by the
metre from your water softener dealer.
4 Wiring the central control valves
The control valve on the left pressure tank is the master valve. In the program settings, it is named ALT A. The
ALT A valve switches over the MAV and controls the second control valve on the right pressure tank (ALT B).
4.1 Connecting the two control valves
A communication cable connects valve A to valve B. Before starting to program the unit, connect the
communication cable to the three-pin connection labelled "COMM CABLE" (communication cable) on the
board for the left and the right control valve. Feed the cables into the openings at the back of the control valve
and lock in place to the side of the board.
Connection cable between control valve A and B
This cable connects the two head valves.
Ensure the cable is connected to 3-wire connection "COMM CABLE" of
both valve heads (ALT Aand ALT B).
4.2 Wiring the motor alternating valve
Feed the connecting cable for the MAV into one of the two openings at the back of the central control valve on
the left pressure tank (valve A = master). At the bottom of the control board (board) is a terminal marked MAV
directly to the left of the threaded rod. Connect the cable to this terminal.