IBC Water AS30400 Manual

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COMMERCIAL
WATER SOFTENER
INSTALLATION
&
OPERATING
INSTRUCTIONS
Model : AS30400
Serial No: ………………………..
Telephone:[phone] Facsimile:[phone]
Email: [e-mail] Website: www.ibcwater.com.au
FILTRATION &WATERTREATMENTPRODUCTS
forcommercial, industrial andresidential application
Manufacturerand Supplierof

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Check the equipment upon arrivalfordamage orshortagesand report sametoourOfficeor
Agent beforecommencing installation.
Locatethe unit and brine tankon afirmlevelclean foundation, preferablyconcrete, with
sufficient spaceforoperation and maintenance. Position the tanks intheircorrect position
beforeloading the media.
Step 1:Removethe top tankflange/strainerassemblybyunscrewing out the larger
diameterflange and makesurethe softenertankisemptyand clean. It is
recommended toutilisespecial‘C’ type spannersavailablefromI.B.C.
Step 2:Bottomdistributorassemblyispre-assembled and installed inthe SoftenerTank.
Step 3:Placea40mm or50mm plasticpipe through the top hand holethat will reachto
the bottomof the softenertank. Carefullypourthe underbed gravelthrough this
pipe soasnot todamage the distributorassembly.
Step 4:Pourinthe underbed gravel(No.6)evenlyaround the tank, 120kg.
Step 5:Levelout the underbed gravelusing abroomhandle/PVCpipe. The underbed
gravelshouldcoverthe bottomdistributorbyabout 25mm.
Step 6:Fill the tankwithwatertoabout 1/2full of water.
Step 7:Load the 400 litresof C100Eresin. The resinisshipped in25L bags.
Step 8:Completelyfill the tankwithwater.
Step 9:Clean top of tankof all tracesof resin.
Step 10:Unpack the valveand pipe work, check that eachunion hasits‘O’ring.
INSTALLATION
MEDIAINSTALLATION

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Step 11:Replacetop tank/flange/strainerassembly(removed inStep 1)and tighten. Fit
pipe worksupplied and hand tighten eachunion. Check that mainvalveand pipe
workisvertical, tighten all unions. Fit airreleasevalvetothe Tee at the top of the
pipe work. Check all jointsand flangesaretight. Donot overtighten.
Step 12:Removethe lidof the brine tankand removethe brine tube (black polyflexible
tubing). Connect the brine tube tothe throttle/stop valveon the maincontrol
valve.
Step 13:Removethe brine valvefromthe brine well of the brine tank. Ensurebrine tankis
free fromforeign matterand set brine valveand float height asfollows:-
Determine if wet salt ordrysalt isrequired, using the formula
shownin“Determining Frequency of Regeneration”. If sufficient
information isnot availabletodo the calculationsshownin
“Determining Frequency of Regeneration”, contact ouroffice. The
brine valveissupplied factoryfitted withadrysalt riser, awet salt
riserisalsosupplied (short black screwed riserpipe -referFig.
19). Storethe risertube not used, DO NOTDISCARD it maybe
needed at commissioning.
Step 14:Replacethe brine valveinthe brine well and connect brine tube -thistube is
supplied long and can be cut tothe desired length.
Step 15:Nowadd the No4graveltothe brine tank(120kg-6bags)and level. Ensureno
gravelentersbrine well -add salt tothe tank(referTable7forcorrect quantity),
replacelid.
Step 16:Plumbthe unit, noting the following:-
a) Check arrowmarkingson the valveforcorrect inlet/outlet plumbing (Fig.1).
b) Useminimum50mm pipe size.
c) Fit apipe union todrainline foreaseof access formaintenanceorcleaning.
d) Install inlet and outlet isolating valvesand aManualBypass Valve(if
desired).
e) Install optionalwatermeterif required.
f) Connecting pipe workand valves MUST be supported toprevent loading on
the valveand pipe work. Beforeconnecting pipe work, flushall lines, close
inlet, outlet and bypass valve.

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g) The drainline must discharge intoan open pipe at least 80mm diameterno
morethan 3metresfromthe unit. Anairgap of 100mm shouldbe allowed
forinspection and toconformtosanitarycodes. Connect the 172 Valve
actuatordrainline tothe wastewith10mm tubing.
h) Powersupplyisrequired not morethan 0.5metresfromthe unit and should
be a3pin10a 240v50HzGPO preferablyearthleakage protect.
Totalpowerdraw, 13 wattsmaximum.
i) Minimumoperating pressure205 kPa(30psi), maximumoperating pressure
690 kPa(100psi). If supplypressureisabove690 kPa, fit pressurereducing
valve. Thismust be anon-fluctuating supply. Maximumtemperatureof 58°C
j) Slowlyfill SoftenerTankwithwaterbyplacing controlvalveinbackwash
position, turnoff inlet isolating valvewhen tankfullyvented of air. Referto
start up procedurePage 4, of 172 ValveInstallation, Operation &
MaintenanceManual.

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Afterlocating and installing the brine tankinthe required position, it isnecessarytoknow
whetherawet ordrysalt systemisbeing used. Thisisdone bycalculation asfollows:-
NOTE: Less salt isrequired toregenerateapartiallyexhausted bed pergramof
hardness removed, than that required foramoreexhausted bed. Foreconomy
sake, regeneratebeforefull exhaustion.
Calculatetimebetween regenerationsthus:-
C
----------- =N
HxQ
WhereC = maximumcapacityof unit asgramsof CaCO3
=28000 grams.
H = hardness of wateramg/lorppm.
Q = amount of waterpassed through the unit inkilolitresperday.
N = maximumtimebetween regenerationsindays.
The calculated value of Nshouldbe taken downtothe nearest wholenumber. Thisisthe
maximumnumberof days, whichcan be achieved between regenerations.
The amount of salt needed perregeneration, iscalculated thus:-
Totalhardness removed = NxHxQ =A
WhereA = the totalhardness removed asgramsof CaCO3
The salt dosage isfound on Table4.
DETERMINE FREQUENCYOFREGENERATION

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EXAMPLE
Unit AS30400
Litresof resin“400”fromTable4
Hardness of water90 mg/l
Flow15kl/hrfor18 hours/day.
Q = 15 x18 = 270 kl/day
H = 90 mg/lorppm
C = 24300 grams(=270 x90)
Frequency of regeneration -
C
N = -------------
HxQ
24300
=-------------
90 x270
=1.0day
Always go downtothe nearest wholenumber(say1day).
Totalhardness removed -
A = NxHxQ
=1x90 x270
= 24300 grams
The mediumand maximumcapacitiesof asingleunit fromTable4are21000 and 28000
respectively. The calculated capacityfallsclosertothe maximumand sothe highervalue
shouldbe used.
Salt dosage required persinglesoftenerfor28000 gis96 kg(fromTable4).
Nowlooking at Table5wefind that onlywet salt can be used. However, if yourcalculated
salt dosage allowsyou the choiceof eitherdryorwet salt always choosedrysalt.
Inthe caseof the examplethe salt dosage is96 kgsothe float setting is350mm (referBrine
TankSet-up forfloat setting details), brine tanksizeis1070 x1220.
Install the brine valveasshowninBrine TankSet-up.
The initialsalt load asshowninTable7shouldbe loaded intothe brine tank.

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IMPORTANTNOTE:
The watersoftener, assupplied, hasthe brine riserpipe assembled tosuit drysalt
brine system. If, however, on referencetoTable5you find that wet salt must be
used, then wet salt brine risepipe (short black pipe piecesupplied)must be fitted to
the brine valve.
Note: Forwet salt it isveryimportant that the salt levelbe maintained inline withthe
brine valve. Asillustrated inthe brine tanksetup sheet, the salt used per
regeneration must be replenished at least 4hoursbeforethe next regeneration.

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Step 1:Check plug isdryfirst, then connect lead intopoweroutlet and switchon. Check
that the brine throttle/stop valveisclosed.
Step 2:Fullyopen the controlvalveelectricalcabinet coverand holdinthisposition with
atemporarytiecord. Depress the red knob (Fig. 5)and rotateanti-clockwiseto
backwashposition, releasered knob, wait forvalvedrivetoindextobackwash
position. (if not alreadyinthisposition).
Depress red knob and rotateanti-clockwisetobrine position, release, wait for
valvedrivetoindextobrine position. Depress red knob and rotatetobrine refill
purge position and release.
Step 3:Just open inlet isolating valveapproximately1.1/2turns. Allowunit tofill slowly
(waterwill issue todrain)continue torun until the unit automaticallyindexesto
Serviceposition whichmaytakeup to10 minutes. All airmust be removed.
Step 4:Open brine throttle/stop valveapproximately1.1/2turns, fullyopen inlet isolating
valve. Open the coldwaterisolating valveand allowbrine tanktofill until brine
float valveshutsoff. Aperiod of four(4)hourssoaking shouldelapseafterfilling
withwaterbeforecommissioning toallowthe brine tosaturate. Depress the red
knob and turnanti-clockwisetostart, release, the unit will nowgo through each
cycle-Backwash, brine rinse, purge and back toserviceautomatically, the full
cyclewill takeapproximately90 minutes.
NOTE: Asmall amount of mediamaypass todrainduring the initialbackwash,
thisisconsidered normal. Whenunitcommences brineandrinse cycle, adjust
brinethrottle/stop valvetothecorrectdraw downrate.
The drawdownrateisdetermined bydividing the float setting height, selected
fromTable5, by20. eg if 300mm isthe float height selected, the drawdownrate
is15mm perminute. Drawdownismeasured withatape measureinthe brine
well, and isthe distancein‘mm’that the brine leveldropsinone minute.
Step 5:Check withsitesupervisorthat unit can go on line. If so-slowlyopen outlet
isolating valvefully, check that manualbypass valveisfullyclosed. Thisunit is
nowon line.
Step 6:Check forand report anyleaks. Gotonearest tap, nowon soft water, open and
allowtoflowforafewminutes. Using test kit totest forsoft water-refertesting in
back of theseinstructions. It maytakeseveralminutesforthe soft watertopass
tothe tap. If hardwaterpersistsrefertothe Servicehintsintheseinstructions.
Check that the brine tankisfull and that the float hasshut off.
COMMISSIONING

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Step 7:Inthe calculationsyou havedone (determining regeneration frequency)you
found the value for(N)-maximumtimebetween regeneration indays. Toset the
skipperwheelup asrequired, pull all the skipperwheelpins(Fig. 5)out.
Turnthe dialtothe correct dayof the weekon whichyou aresetting the dial. Now
depress the pinsforthe desired day/sforregeneration/srequired. If no datais
availabletodo the calculationsat thisstage then set regeneration forevery
second day.
When setting the regeneration frequency you shouldtakeintoaccount the
working days, forinstanceif the installation will onlyworkweekdays,
regeneration on Fridayand Mondaywouldbe aneedless wasteof salt. Always
set inaccordancewiththe dutyconditionsformaximumeconomy.
NOTE: Thisisonlyaguide forinitialsetting and shouldbe altered tosuit eachindividual
installation inaccordancewithload conditions-do the calculationsindetermining
frequency of regeneration, it will helpyou inunderstanding the softener.
Step 8:Set timeof day, pull timerknob (Fig. 5)and set arrowtothe timeof day(timeof
yourwatch)release, makesurethat the knob hasre-engaged gear, knob right in.
Step 9:Replacethe timercover, wipe overunit.
Dofinalcheck forleaks etc.

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1.Watertobe tested shouldbe taken fromatap afterthe watersoftener
2.Measure10mlof waterintoplasticbottlesupplied (approximately1/3full)
3.Add one Yes/Notablet tosamplewater, replacecap and shakeuntil tablet
hascompletelydissolved.
(NOTE:do nothandleYes/Notabletwithfingers)
4.The finalcolourtobe obtained forsoft waterisgreen. (Note: The shade of
green mayvary.)If the colourturnsred, the waterisabove20mg/lhardness,
thereforeanotherregeneration isrecommended.
5.Rinseplasticbottleaftereachtest hasbeen completed.
6.When used asabove, the tabletschange the colourfromgreen tored at a
hardness of approximately20ppmbased on asamplevolumeof 10mls.
Otherhardness test kitsareavailableformoreaccuratetesting eg.
Hardness Tablets
Directions: Takea50mlsampleof waterinascrewcapped bottle. Add one (1)
tablet tosample, shakeorcrushtodisintegrate. Repeat until last trace
of reddishtinge disappears. The finalcolourisusuallyblue but with
somewateragreyishcoloured end point isobtained.
Using 50mlsample-
Hardness ppm=(numberof tabletsx40)-20
LR(BW)Tablets
Directions: Takea100mlsampleof waterinascrewcapped bottle. Add one (1)
tablet tosample, shakeorcrushtodisintegrate. Repeat until last trace
of reddishtinge disappears. The finalcolourisusuallyblue but with
somewateragreyishcoloured end point isobtained.
Using 100mlsample-
Hardness ppm=(numbertabletsx2)-1
Contact IBCWaterTreatment if furtherdetailsarerequired.
HARDNESS TEST

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Peakflownot recommended forextended periodsof time.
BrineTank: 1000 litreL.D.P.E. moulded construction
completewithlid.
BrineValve: Plasticconstruction.
OperationPressure: 210 -600 kPa
Temperature: 5-50 degreesC
Electrical: 240v50Hz3wmaximum
WARNING: Apressurereduction valveshouldbe installed inareasof high water
pressure(above690 kPa).
Awaterhammerarrestershouldbe installed if waterhammerprevails.
FAILURETO OBSERVE WARNINGSWILL VOIDWARRANTY
Table3
Model
No.
Capacity
&
SaltDosage
Service Flow
Rate PipeSize Resin
Volume
Approx.
Shipping
Weight
Space
Requirements
Minimum Maximum Peak
Flow Continuous Flow Inlet Outlet Drain Litres wt/kg WxDxH
grams/kg grams/kg l/m l/m mm mm metres
AS30400 14000/26 28000/96 350 265 50 40 400 830 1.8x1.2x2.6
PERFORMANCE DATA
MEDIALOADING
Model UnderbedGravel No.6 ResinContent BrineTankGravel No.4
kg litres kg
AS30400 120 400 120

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Table4
Gramscapacityand salt dosage -gramsasCaCO3/ salt kg
Table5
Float settings(mm)
Table6
Specification flowrate-lpm-nominalonly.
Table7
Model Resin Minimum Medium Maximum
litres grams/kg grams/kg grams/kg
AS30400 400 14000/26 21000/53 28000/96
SaltDosage BrineTankSize
(kg) 1070 x1220
Dry Wet
32 270 110
40 335 135
50 420 170
55 460 185
65 545 215
75 625 250
80 670 270
90 - 300
95 - 320
110 - 370
120
-
405
Model Backwash Brine Slow Rinse FastRinse
AS30400 95 33 25 95
Model Initial SaltLoading-Kgs
Dry Wet
AS30400
800
275

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BRINE TANK SETUP

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Series 172
Commercial/ Industrial
ControlSystem
Water Softener

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Includes procedures to pressurise softener tank
and fill brinetank
Withall piping and installation completed, and with
mineralinthe tank, proceed asfollows:
1.Disconnect electricalpowertotimer.
2.Removevalvecovertoexposetimerand
mechanism.
3. Open manualbypass valve, close manualinlet
and outlet valves(see Figure2).
4.Pushinon REDKNOBon timer, turncounter-
clockwiseuntil arrowon the camshaft/timer
support pointstothe BACK-WASHposition
indicated on #1 cam(see Figure5).
5.Slowlyopen manualinlet supplyvalve. DO NOT
open fully. Waterwill enterfromthe bottomof
filtertankasairisexpelled fromthe top tothe
drain. Full flowofwatercouldcauseloss of
media. Continue tofill slowlyuntil airisexpelled
and onlywaterflowstodrain.
NOTE: Iftop coverofsoftenertankcan be removed
tovent air, the tankmaybe filled morequickly.
Observethe leveland replacecoverbeforetank
overflows.
6.When ONLYwaterflowstodrain, open inlet
valvefullyand backwashuntil waterlooksclean
when caught inacontainer.
7.PushinREDKNOBand indextimercounter-
clockwisetoBRINE/RINSE position (arrowon
camshaft/timersupport pointing toBRINE/
RINSE on #1 cam). Observeaslowflowof
watertothe drain.
8.PushinREDKNOBand indextimerto
PRESSUR. (pressurise)position indicated on #1
cam(see Figure6). Keep inthisposition for5
minutes. Thisallowsthe tanktoreturntoline
pressureand permitseasiermovement ofthe
valvediscs.
9.Fill the brine tankwiththe properamount and
type ofsalt recommended forthe usewiththe
system.
10.PushinREDKNOBand indexpilot valveto
PURGE. Allowwatertoflowtodrainuntil clear.
During thistimethe brine tankwill fill until the
float closesthe brine tankvalve. Check that all
the brine fittingsaretight and that waterlevelin
brine tankosaccording tosoftener
specifications.
11.Indexthe valvetoSERVICE.
12.Closemanualby-pass valveand open outlet
valvefully.
SetTimer
Determine aregeneration scheduleforthe softener
and adjust the automatictimer(see Figure9)as
follows:
1.Put all SKIPPERPINSup (awayfromcontrol).
2.RotateSKIPPERWHEELuntil DAY ARROW
pointstodayofweek.
3.Depress SKIPPERPIN(S) forday(S)
regeneration isrequired.
4.Pull TIMERKNOBout (awayfromtimerface)
and rotateuntil BLACKARROWon tripperarm
pointstocorrect timeofdayon FacePlate.
5.Timerwill automaticallyinitiatebackwashon
preset daysat 2:30 A.M. Toaltertime, simply
reset TIMERKNOBtoan earlierorlatertime
whichwill change the timeofregeneration by
the samenumberofhours. (Timeindicated at
BLACKARROWwill no longerbe correct).
SetBACKWASHtiming (Figure 7)
Makesuretimeisinthe SERVICEposition. Loosen
the screw(A) on the whitegear(B) and rotatethe
greygear(C)withthe numbered decaluntil desired
START-UP PROCEDURE
Figure5
Figure6

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time(3, 6, 9, 12, 15, 27 minutes)alignswithpointer
on box(D). Tighten the screwon the whitegear.
SetPURGEtiming (Figure 8)
Makesuretimerisinthe SERVICEposition. Loosen
the screw(E) on the greygear(F)withthe pointer
until the pointeralignswiththe desired time(5-35
minutes). Tighten the screw.
A.Start-Up orinspection regeneration.
1.Disconnect electricalpower.
2.Pushthe REDKNOBand turncounter-
clockwisepast START toBACKWASH.
Leaveinposition fordesired time.
3.PushinREDKNOBand repeat forall
desired cycles. NOTE: At PRESSUR.
(pressurise)position pause foratleast5
minutes oruntil tankispressurised.
Final check-out
1.Test forsoft waterfromaconvenient soft water
tap.
2.Manualby-pass valvemust be closed (see
Figure2).
3.Manualinlet and outlet valvesopen (see Figure
2).
4.Brine line shut-off valveopen (see Figure4)
5.Drainline clearand unobstructed.
6.Electricalpowertotimer(not controlled by
switch).
7.Timeofday, frequency ofregeneration,
backwashtimerand brine/rinsetimeset
properly.
8.Properliquidlevelinthe brine tankand supply
ofsalt.
B.Manualinitiation ofregeneration.
1.Reconnect electricalpower.
2.PushinREDKNOBand turncounter-
clockwisetothe START position. Release.
Unit will then go through acomplete
regeneration asprogrammed.
MANUALOPERATION
Figure7
Figure9
Figure8

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1INLET 2BRINE
3BACKWASH
3BACKWASH
6OUTLET
5BY-PASS
4DRAIN
VALVE CLOSED VALVE OPEN
VALVE DISC
PUSH/PULL ROD
FlowDiagrams

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