Hydrotec HYDROION VAS-CS Series Operating instructions

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Operating and Maintenance Manual
HYDROION® Type: VAS –CS
Serial number: ____________________
HYDROTEC UK Ltd. Telephone [phone]
Hydrotec House
5 Manor Courtyard, Hughenden Avenue
High Wycombe, Bucks. HP13 5RE Fax [phone]
Web: www.hydrotec.co.uk

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Index
The individual chapters are listed in the survey below. More detailed information is shown in
the respective overlays.
Preface
Chapter IGeneral information
Chapter II Transport and storage
Chapter III System description / Technical data
Chapter IV Assembly and installation
Chapter VMicro processor control
Chapter VI Start up / Taking out of service
Chapter VII Troubleshooting
Chapter VIII Monitoring and maintenance
Appendices 1 Installation schematic softener
Appendices 2 Calculation soft water capacity
Appendices 3 Calculation sodium content
Appendices 4 Start up and training record - Softener HYDRO ION®
Appendices 5 Log book
Appendices 6 Commissioning request
Appendices 7 PUROLITE - ION EXCHANGE RESIN - Safety data sheet
Imprint

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Preface
The HYDROION® Softener are constructed and manufactured with respect to and in consideration
of all current standards as well as further technical specifications, and corresponds to the latest
state-of-the-art technology, allowing for maximum safety under all operating conditions.
System safety in operation can only be assured if all necessary measures are taken beforehand. It
is part of the operator’s diligence to plan and monitor such measures and implement them with due
care.
The operating and maintenance manual includes important information for a save installation,
operation and commissioning. Please make yourself familiar with all details prior to start operation.
For any additional information or problems encountered in conjunction with operation, please
contact our Customer Service Department at the following address:
Hydrotec (UK) Ltd
Hydrotec House
5 Manor Courtyard, Hughenden Avenue
High Wycombe, Bucks HP13 5RE
Tel: [phone]
Email: [e-mail]

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Index Chapter I–General information
Page
1. Documentation 5
2. Safety information 5
2.1 Operator’s duty of care 5
2.2 Appropriate use 6
2.3 Basic safety measures 6
Maintenance, repair and electric work 7
Start up after maintenance and repair work 7
Environmental regulations 7
2.4 Risk in the event of safety instructions being disregarded 8
2.5 Operational and ancillary materials 8
2.6 Used safety signs and instruction symbols 8
3. Warranty 9

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1. Documentation
The following information is included for the operator in the operation and maintenance manual:
•Safety information
•Information and instructions for assembly
start-up
operation
maintenance
troubleshooting
•Technical Data
The operation and maintenance manual together with all other technical information and documents
must always be kept readily accessible.
The O&M includes several chapters marked with roman numerals (see global index). The page
reference is shown right below on each page.
Information about the chapter contents see index on page 1 of each chapter.
For any additional information or problems encountered in conjunction with operation, please
contact our Customer Service Department at the following address:
Hydrotec (UK) Ltd.
Hydrotec House
5 Manor Courtyard, Hughenden Avenue
High Wycombe, Bucks HP13 5RE
Tel: [phone]
Email: [e-mail]
2. Safety information
2.1 Operator’s duty of care
The system is constructed and manufactured with respect to and in consideration of all current
standards as well as further technical specifications, and corresponds to the latest state-of-the-art
technology, allowing for maximum safety under all operating conditions.
System safety in operation can only be assured if all necessary measures are taken beforehand. It
is part of the operator’s diligence to plan and monitor such measures and implement them with due
care.
The operator must ensure that:
-The system is used in accordance with the specified purpose
-The system is maintained in a serviceable condition, with the safety facilities being monitored
for correct function in regular intervals
-The operation and maintenance manual is always in a legible condition and available next
to the unit
-The operation, maintenance and repair work is carried out by qualified and authorised
personnel only
-All safety and warning information attached to the system must not be removed and must be
kept in a legible condition

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2.2 Appropriate use
The system is manufactured to the latest German technical safety standards employing the latest
state-of-the-art technology.
If incorrectly treated, not maintained properly at regular intervals or not used for the correct purpose
according to the specifications, the softener may incur risks and/or damage.
Operation of system shall be within the technical parameters and limit values in chapter III.
The softener unit is to be operated and maintained in good working order and according to the
specification it was designed for only.
Important! Any other use of the system, other than described, is deemed to be not in
accordance with the specification.
The manufacturer / supplier does not accept any liability resulting from the
improper use of the system. Such risks are borne by the operator alone.
All regulations and instructions in the operating and maintenance manual and
such regulations as are applicable locally must be strictly adhered to.
Any malfunctions must be corrected immediately.
2.3 Basic safety measures
Prior to starting the system it must be guaranteed that:
-No-one can suffer injury due to the system operation
-All safety facilities are in a perfectly serviceable condition
The system must be operated in perfect condition only. All faults must be notified to the person
responsible immediately after being noticed.
In order to avoid flooding of installation site, there is a drainage and / or leak control with alarm to be
provided locally.

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Maintenance and repair work
-All inspection and maintenance intervals specified in the operation and maintenance manual
must be adhered to
-Prior to any repair work, the system must be disconnected from mains
-Prior any repair and electrical work the system is to be disconnected from the piping system
(the system must be de-pressurised) and shall be protected from accidental restart
-Only suitable and correctly functioning load-supporting devices shall be used when replacing
heavy components or system elements
-Hose lines shall be replaced regularly (preventive maintenance) even if no damage is visible
-During work at the plant suitable and corresponding protective clothing shall be worn (e.g.
when handling with liquids such as acids and bases/alkalis)
Electrical work
-Prior to any work on electric components the system must be disconnected from the mains
-Electric equipment must be checked in regular intervals
-Any possible loose connections must be re-secured and damaged electric cabling replaced
immediately
-Casings of electric equipment and system components must never be cleaned with a water
hose (spray)
-Electric components must never be touched with wet hands
-Valid VDE regulations must be adhered to, especially the regulations for the required
potential equalisation
-EMC interferences must be avoided and if necessary a mains filter protection shall be
applied
-Cable connections shall always be kept as short as possible
-Sensor and low voltage cables shall never be laid parallel to current-carrying wires (230 V or
400 V).
Start-up after maintenance and repair work
-Check screw connections for tight fit
-Ensure that any components removed beforehand (e.g. tank lid, screen or filter) are installed
and restored to their correct operational position
-It is to be ensured that all material, tools and other appliances which were necessary for
maintenance and repair work are removed from the working area of the system
-Any liquid that has leaked is to be removed
-Ensure that all safety equipment is in a perfectly serviceable condition
Regulations in respect of environmental protection
When working on and with the system, all legal regulations in respect of waste minimisation and
proper disposal (if appropriate) must be observed and respected.
The water-endangering substances listed below in particular must not be allowed to contaminate the
soil or enter the drainage system during installation, maintenance and repair work:

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-Grease and lubrication oils
-Hydraulic oils
-Cooling agents
-Acids and alkalis (bases)
-Disinfection agents
-Cleaning materials containing solvents
Such substances must be stored, transported and collected in suitable tanks and disposed
of in accordance with the applicable regulations.
2.4 Risk in the event of safety instructions being disregarded
The consequences of disregarding safety instructions can be dangerous to the system, material and
personnel, and the loss of any warranty claims.
We shall accept no liability for possible water damage caused due to disregard of the safety
instructions.
2.5 Operational and ancillary materials
All materials shall be handled in accordance with the COSHH regulation (the Control of Substances
Hazardous to Health 2002). Material Safety Data Sheets are provided in the Appendices.
Safety datasheets
The operating media used:
-Highly acidic cation exchange resin
-Regeneration salt
are not considered to be hazardous substances in the meaning of the legal provisions.
2.6 Safety and warning symbols
This icon indicates general information which must be observed during the
operation of water treatment systems.
This warning symbol indicates information which shall be observed for the
purpose of your own personal safety and to prevent any cause of damage to the
systems.
This warning symbol indicates work which shall only be carried out by qualified
electricians according to VDE regulations or by responsible institutions or
specialized companies.
This symbol indicates information which must be observed for handling of
environmentally hazardous and water-endangering substances.
This icon indicates information to be observed during any maintenance and repair
work and for maintenance intervals.

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3. Warranty
The warranty period for the system is 12 months, calculated from either the date of commissioning
by Hydrotec (UK) Ltd. or 15 months from the date of supply in the event that commissioning is not
included with the supply agreement, whichever is the shorter. The plant must be operated and
maintained in accordance with Hydrotec (UK) Ltd’s requirements. It is recommended that a service
contract is taken out for the unit.
Claims under warranty will only be accepted in the meaning of our General Conditions of Sale and
Supply subject to the following conditions:
-The system is used and operated in accordance with information and instructions in the
operation and maintenance manual
-The system is treated properly
-Repair work is to be carried out exclusively by authorised specialists
-Original spare parts or parts recommended by Hydrotec (UK) Ltd. shall be used
exclusively
-No modifications are carried out on the system by users themselves
-The stipulated operation parameters (pressures, flow volume) are maintained and a
water temperature of 30°C is not exceeded
-Start-up of the system has been carried out by our service personnel
-That after installation and longer standstill periods a chemical disinfection has been
effected
-A yearly maintenance is carried out by our service personnel
Excluded from warranty claim are all parts subject to wear and tear such as:
- All moving parts, motors, seals, membranes, filter etc.
Warranty claims cannot be accepted in cases of:
- Operation and installation errors
- Faulty maintenance
- Deliberate damage or negligent handling
Any unauthorised modifications are not permitted for safety reasons. Original spare parts and
accessories are especially designed for the softener series HYDROION®.
Original spare parts shall be used exclusively!
Important information for any queries and spare parts orders:
- Softener type (model number)
- Serial number
- Date of manufacture

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Chapter II –Transport and storage
All system parts of the HYDROION®softener unit should be secured against jolting and
falling during transport and storage.
Appropriate means must be used in order to avoid and exclude any damage during transport.
The entire delivery must be checked for completeness and possible transport damage immediately
upon receipt at the warehouse / site.
Any transport damage must be notified to the supplier immediately.
Important!
Pressure tanks get damaged by shock load!
In order to protect the feet, the tanks shall be lifted for transport (not tilted!).
The system and resin must be protected from frost during transport and storage
(recommended temperature 5-40°C). Storage outside these conditions can damage and
destroy the resin and resin vessel.
Components, fittings and pipes shall never be used for fixing of conveyor belts or other
supporting means of transport!
Do not lift the system via the components, fittings or pipes!
If disregarded, system components can easily get damaged and break/crack!
Regeneration material
Common salt (sodium chloride) supplied in tablet form according to EN 973 (DIN19604) is to be
used as the regenerant. Typically the salt is supplied in 25 kg plastic sacks which must be stored in
clean and dry areas only.
Hydrotec (UK) Ltd. is not a salt supplier. Supply of salt is the responsibility of the operator.

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Index Chapter III –System description / Technical Data
Page
1. System description 12
1.1 General 12
1.2 Function 13
1.3 Water pressure 14
2. Technical Data 15
2.1 HYDRO ION®VAS –CS –A 15
2.2 HYDRO ION®VAS –CS –B 16
2.3 Installation schematic 17
2.4 Pressure loss 18
3. Scope of supply 19
3.1 Components 19
- Resin vessel 19
- Resin 20
- Control valve 20
- Micro processor control 21
- Water volume counter 21
- Brine tank 22
- Brine exhaust 22
- Brine lack sensor 22
- Chlorinator 23
- Measuring kit total (permanent) hardness 23
3.2 Accessories 24
- System separator 24
- Assembly mounting 24
- External blending 25
- Flexible hoses 25
- Regenerant 25

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1. System description
1.1 General
Simplex softener HYDRO ION®VAS –CS
HYDROION®VAS softeners are designed and used to chemically transform hard water into soft
water. The treatment process is via the ‘ion-exchange’ method, whereby the hard water flows over
the resin media in the pressure vessel. The elements responsible for hardness, calcium and
magnesium ions present in the water are bound reversibly to the ion exchange resin and in return,
sodium ions are released into the water. The accumulation of calcium and magnesium ions
(hardness) on the resin is periodically removed by a regeneration process using sodium chloride
(common salt) solution or brine.
Plant type: HYDRO ION®VAS - CS –A / B (Salt saving mode)
Treatment normally for
- Drinking water application according to DIN 19636
- Preparation of cooling water according to VDI 3803
Softener designed as Simplex system.
fig.1

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1.2 Function
System HYDRO ION®VAS exclusively suited to soften hard water having drinking water
characteristics.
That means the water must be clear, colourless, free from chlorine, iron, manganese and oil in order
to avoid a damage of the exchange material by blocking.
The feature of hard water is substantial for the efficiency of the ion exchange material and the
operation of the system.
The ambient temperature for the system must be free from frost and not exceed 40°C since
otherwise the ion exchange resin will be irreversibly damaged and/or the pressure resistance of
used materials is reduced.
The HYDRO ION®VAS water softener is controlled by a water meter.
The softening of the water is by means of the ion exchange resin in the pressure vessel. The
process of ion exchange is the exchange of the hard minerals (calcium and magnesium ions) with
sodium ions. Water treated in this manner is called softened water.
The ion-exchange resin becomes exhausted after a certain water volume has passed and at this
point it must be regeneration with sodium chloride (common salt).
Operation / regeneration of the softener in the different stages in accordance with the following
processes:
Operation = soft water production
The water to be treated passes through the iron exchange resin bed from top to bottom and goes to
service as soft water via a riser tube.
Backwash
Water passes through the ion exchange resin bed from bottom to top, to fluidise and aerate the bed.
The back wash is sent to drain.
Brining / slow rinse
Brine is drawn by means of an injector, diluted, and fed through the ion exchange resin from top to
bottom. Whilst the process is taking place, the calcium and magnesium ions attached to the resin
are exchanged for sodium ions, thus regenerating it. Effluent goes to drain.

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Fast rinse
Hard water flows from top to bottom through the ion exchange resin, driving out the excess residues
of brining process. Effluent goes to drain.
Brine tank fill
After brining and rinsing, water is fed to the brine tank, via the brine draw line, filling it again up to
the normal water working level, this is to ensure that concentrated brine available for the next
regeneration process.
The softener is returned to service!
1.3 Water pressure
In order to guarantee optimum and economic operation of the system, the water pressure should be
adjusted to between 2.0 bar and 8.0 bar.
The water pressure should not fall below 2.0 bar, in order not to impair the functional performance of
the softener.
Regular maintenance avoids the increase of pressure loss and guarantees correct system
operation.
The water pressure must not exceed 8 bar, doing so may pose a safety risk and cause operational
problems, it is recommended that a pressure reducing valve be fitted upstream of the water
softener.
Caution!
Pressure booster systems must not be installed in flow direction directly after a water treatment
system into the piping.
In case a pressure booster system is required for the transport to the consumer the system shall
only transport soft water into a pressure-less vessel which is used for the subsequent pressure
booster system.
water
incoming
to the consumer
reservoir
pressure
booster
system
softener
fig.2

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2. Technical Data
2.1 Technical data
HYDROION® VAS –CS –A
Systems with full salting
(Type A)
25-CS
1 - A
50-CS
1 - A
75-CS
1 - A
125-CS
1,5 - A
150-CS
1,5 - A
200-CS
1,5 - A
250-CS
2 - A
375-CS
2 - A
600-CS
2 - A
Connection mains / soft water line
DN 25 (1")
DN 40 (1 1/2")
DN 50 (2")
DN 80
Drain line (mind.)
DN 50
DN 50
DN 70
Mains electrical connection
230 V / 50 Hz AC
230 V / 50 Hz AC
230 V / 50 Hz AC
Electrical connection (secondary)
12 V AC
12 V AC
12 V AC
Water temperature (min./max.)
5 °C / 30 °C
5 °C / 30 °C
5 °C / 30 °C
Ambient temperature (min./max.)
5 °C / 40 °C
5 °C / 40 °C
5 °C / 40 °C
Operational pressure
(min./max.) 2)
2 bar / 8 bar
2 bar / 8 bar
2 bar / 8 bar
Performance data
Nominal flow1)
m³/h
2.5
3.5
4.5
6.5
8.0
10.5
13.5
17.0
24.0
Flow rate at blending
(300 ppm to 60 ppm)
m³/h
3.1
4.4
5.6
8.1
10.0
13.1
16.9
21.3
30.0
Pressure loss at rated flow 1)
bar
0.43
0.66
0.88
0.78
0.65
1.14
1.05
1.34
1.94
Capacity at 300 ppm CaCO31)
m³
5.3
10.8
16.2
27.3
32.2
43.5
54.9
82.8
132.3
Salt consumption
kg
5
10
15
25
30
40
50
75
120
Waste water volume per
regeneration
m³
0.17
0.36
0.55
0.88
1.06
1.40
1.73
2.62
4.20
Volume and weights
Resin vessel volume
Ltr.
38.4
79.5
115
153
277
277
344
473
704
Quantity of resin
Ltr.
25
50
75
125
150
200
250
375
600
Quantity of gravel
kg
4
7
10
17
40
40
40
58
40
Brine tank volume
Ltr.
140
190
340
460
460
670
920
1000
1500
Regeneration salt supply
kg
50
75
125
175
162
250
325
375
525
Operational weight
(complete unit) max.
kg
125
210
325
465
620
740
925
1210
1750
Dimensions
Height (max.)
mm
1235
1530
1600
1600
1700
1700
2000
2200
2220
Ceiling height (min.)
H
mm
1800
1800
1900
1900
2000
2000
2200
2400
2500
Width (max.)
B
mm
910
960
1160
1360
1550
1730
1980
2050
2480
Depth (max.)
T
mm
600
600
725
850
850
1000
1150
1150
1500
Clearance tank/tank (ca.)
A1
mm
510
530
630
760
820
900
1020
1070
1340
Diameter pressure tank
D1
mm
258
310
363
413
555
555
555
635
779
Diameter brine tank
(min. / max.)
D2
mm
460 /
565
460 /
565
594 /
723
703 /
833
703 /
833
847 /
973
997 /
1123
1015 /
1120
1050 /
1150
Height pressure tank
(incl. foot)
H1
mm
897
± 6
1232
± 6
1344
± 6
1341
± 15
1434
± 15
1434
± 15
1721
± 15
1918
± 15
1892
± 15
Height top control valve
H2
mm
1080
1420
1530
1570
1665
1665
1930
2130
2160
Height brine tank
H3
mm
843
1123
1200
1196
1196
1196
1206
1340
1500
Height feed (mains
water) / discharge
(softwater)
H4
mm
960
1295
1400
1430
1520
1520
1810
2010
2040
Control box (W x H x D)
mm
240 x 170 x 110
Mounting board (W x H x D)
mm
330 x 200 x 10
1) Parameters are dependent on operation mode and water input quality.
2) At operating pressure min. the flow pressure is decisive, at operating pressure max. the static
pressure is decisive
For the use in the field of boiler feed water, preliminary treatment and reverse osmosis a project
planning is always required performed by our Applications engineering department!

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2.2 Technical data
HYDROION® VAS –CS –B
Systems with economise
salting (Type B)
25-CS 1
- B
50-CS 1
- B
75-CS 1
- B
125-CS
1,5 - B
150-CS
1,5 - B
200-CS
1,5 - B
250-CS
2 - B
375-CS
2 - B
600-CS
2 - B
Connection mains / soft water line
DN 25 (1")
DN 40 (1 1/2")
DN 50 (2")
DN 80
Drain line (mind.)
DN 50
DN 50
DN 70
Mains electrical connection
230 V / 50 Hz AC
230 V / 50 Hz AC
230 V / 50 Hz AC
Electrical connection (secondary)
12 V AC
12 V AC
12 V AC
Water temperature (min./max.)
5 °C / 30 °C
5 °C / 30 °C
5 °C / 30 °C
Ambient temperature (min./max.)
5 °C / 40 °C
5 °C / 40 °C
5 °C / 40 °C
Operational pressure (min./max.) 2)
2 bar / 8 bar
2 bar / 8 bar
2 bar / 8 bar
Performance data
Nominal flow1)
m³/h
2.5
3.5
4.5
6.5
8.0
10.5
13.5
17.0
24.0
Flow rate at blending
(300 ppm to 60 ppm)
m³/h
3.1
4.4
5.6
8.1
10.0
13.1
16.9
21.3
30.0
Pressure loss at rated flow 1)
bar
0.43
0.66
0.88
0.78
0.65
1.14
1.05
1.34
1.94
Capacity at 300 ppm CaCO31)
m³
3.9
7.8
11.8
19.9
23.4
31.6
39.9
60.2
96.2
Salt consumption
kg
2
4
6
10
12
16
20
30
48
Waste water volume per
regeneration
m³
0.15
0.31
0.46
0.76
0.92
1.22
1.52
2.28
3.66
Volume and weights
Resin vessel volume
Ltr.
38,4
79,5
115
153
277
277
344
473
704
Quantity of resin
Ltr.
25
50
75
125
150
200
250
375
600
Quantity of gravel
kg
4
7
10
17
40
40
40
58
40
Brine tank volume
Ltr.
140
190
190
340
340
460
460
670
920
Regeneration salt supply
kg
50
75
75
125
125
175
175
250
337
Operational weight
(complete unit) max.
kg
125
210
270
410
580
660
765
1080
1550
Dimensions
Height (max.)
mm
1235
1530
1600
1600
1700
1680
2000
2200
2220
Ceiling height (mind.)
H
mm
1800
1800
1900
1900
2000
2000
2200
2400
2500
Width (max.)
B
mm
910
960
1020
1250
1400
1500
1540
1760
2060
Depth (max.)
T
mm
600
600
600
750
750
850
850
1000
1150
Clearance tank/tank (ca.)
A1
mm
510
530
560
700
770
830
870
980
1130
Diameter pressure tank
D1
mm
258
310
363
413
555
555
555
635
779
Diameter brine tank
(min. / max.)
D2
mm
460 /
565
460 /
565
460 /
565
594 /
723
594 /
723
703 /
833
703 /
833
847 /
973
997 /
1123
Height pressure tank (max.)
H1
mm
897
± 6
1232
± 6
1344
± 6
1341
± 15
1434
± 15
1434
± 15
1721
± 15
1918
± 15
1892
± 15
Height top control valve
H2
mm
1080
1420
1530
1570
1665
1665
1930
2130
2160
Height brine tank
H3
mm
843
1123
1123
1200
1200
1196
1196
1196
1206
Height feed (mains water) /
discharge (softwater)
H4
mm
960
1295
1400
1430
1520
1520
1810
2010
2040
Control box (W x H x D)
mm
240 x 170 x 110
Mounting board (W x H x D)
mm
330 x 200 x 10
1) Parameters are dependent on operation mode and water input quality.
2) At operating pressure min. the flow pressure is decisive, at operating pressure max. the static
pressure is decisive
For the use in the field of boiler feed water, preliminary treatment and reverse osmosis is this model
series not suitable!

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2.3 Installation schematic
Height feed (mains water) / discharge (softwater)

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2.4 Pressure loss curve

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3. Scope of supply
3.1 Components
Equipment
Description
HYDRO ION®VAS –CS 1,5
(example)
1 = Resin vessel 1 (pressure tub)
2 = Control valve
3 = Brine tank
4 = Electronic control
5 = Input
6 = Output (softened water)
7 = Wash water drain
Resin vessel
Pressure tank of corrosion-resistant glass-fibre
reinforced plastics with PE-inliner (approved
for foodstuffs) with nozzle (jet) system.
Number: 1
Top threaded connection:
2 1/2“ HYDRO ION®VAS –CS 1
4” HYDRO ION®VAS –CS 1.5
4“ HYDRO ION®VAS –CS 2
6“ flanged HYDRO ION®VAS 600 –CS 2
1
2
3
4
5
6
7
fig.3

20/98
Last change 10/2018 E-P | Subject to technical modifications
Resin media
Strong acid cat-ion exchange resin to be suited
for drinking water application PFC100E grade.
Control valve
Microprocessor controlled, menu driven
system for control of operating modes,
functions and display.
Number: 1
Operating pressure: 2,5 to 8 bar
Operating temperature: 5 to 40 °C
HYDRO ION®VAS –CS 1
Material: Plastics (Noryl)
With top nozzle and
system pcb CB 204
Connections:
Incoming/soft water: 1“ (male)
Brine intake: 3/8“
Waste water: DN 20
Tank connection: 2 1/2“ – 8 NPSM
HYDRO ION® VAS –CS 1.5
Material: Brass with epoxy resin
coating and
system pcb CB 204
Connections:
Incoming/soft water: 1 1/2“ (female)
Brine intake: 1/2“
Waste water: DN 20 / DN 25
Tank connection: 4“ – 8 NPSM
HYDRO ION® VAS –CS 2
Material: Brass with epoxy resin
coating and
system pcb CB 204
Connections:
Incoming/soft water: 2“ (female)
Brine intake: 3/4“
Waste water: DN 25
Tank connection: 4“ – 8 UN
fig.4
fig.5
fig.6