KineticoPRO Hydrus HS 116s User manual

Owner’s Manual
Hydrus® Commercial Softening Systems
Models:
____________________________________________________________________________
HS 116S
HS 118S
HS 121S
HS 124S
HS 130S
HS 136S
HS 142S
HS 116SOD
HS 118SOD
HS 121SOD
HS 124SOD
HS 130SOD
HS 136SOD
HS 142SOD
HS 216SOD
HS 218SOD
HS 221SOD
HS 224SOD
HS 230SOD
HS 236SOD
HS 242SOD
HS 316SOD
HS 318SOD
HS 321SOD
HS 324SOD
HS 330SOD
HS 336SOD
HS 342SOD
HS 416SOD
HS 418SOD
HS 421SOD
HS 424SOD
HS 430SOD
HS 436SOD
HS 442SOD

Table of ConTenTs
The hydrus series CommerCial sofTeners
How a Water Softener Works ................................................................................................................................................................................................... 4
hydrus sofTener design feaTures.......................................................................................................................................................................................... 4
Automatic Operation ...................................................................................................................................................................................................................5
Countercurrent Regeneration ...................................................................................................................................................................................................5
Low Leakage.....................................................................................................................................................................................................................................6
High Flow Rates ..............................................................................................................................................................................................................................6
High Capacity...................................................................................................................................................................................................................................6
Low Maintenance Requirements...............................................................................................................................................................................................6
System Sizing ...................................................................................................................................................................................................................................7
operaTion
Concepts ........................................................................................................................................................................................................................................... 8
Level 1-2 Assembly.....................................................................................................................................................................................................................................8
Starting Regeneration...............................................................................................................................................................................................................................8
Regeneration Gear Stack.........................................................................................................................................................................................................................8
Control Disc ..................................................................................................................................................................................................................................................8
Level 3-6 Assembly....................................................................................................................................................................................................................................9
Simplex Systems ............................................................................................................................................................................................................................9
Multiplex Systems’ Regeneration Sequence........................................................................................................................................................................9
Plumbing ......................................................................................................................................................................................................................................... 10
Media Tanks......................................................................................................................................................................................................................................11
Upper Distributor...........................................................................................................................................................................................................................11
Media ..................................................................................................................................................................................................................................................11
Underbedding .................................................................................................................................................................................................................................11
Lower Distributor...........................................................................................................................................................................................................................11
Riser Tube .........................................................................................................................................................................................................................................11
Brining System................................................................................................................................................................................................................................11
Central Brining ...............................................................................................................................................................................................................................12
The Hydrus Valve ..........................................................................................................................................................................................................................12
sysTem ConfiguraTion
Sizing .................................................................................................................................................................................................................................................13
General guidelines for a multi-tank system: ............................................................................................................................................................................... 13
General guidelines for a single tank softener:............................................................................................................................................................................ 13
Compensated Hardness Equation:.................................................................................................................................................................................................14
Simplex Systems (maximum capacity in thousands of gallons) ............................................................................................................................................14
Two Tank Systems (maximum capacity in thousands of gallons) ......................................................................................................................................... 15
Three Tank Systems (maximum capacity in thousands of gallons) ......................................................................................................................................16
Four Tank Systems (maximum capacity in thousands of gallons) ........................................................................................................................................ 17
Gallons Set Point ................................................................................................................................................................................................................................... 17
Brining System...............................................................................................................................................................................................................................18
Venturi Installation ................................................................................................................................................................................................................................... 18
Central Brining ........................................................................................................................................................................................................................................... 19
454 High Flow Brine Valve....................................................................................................................................................................................................................19
484 3/4” Commercial Brine Valve......................................................................................................................................................................................................19
Backwash Flow Control............................................................................................................................................................................................................ 20
Remote Meter............................................................................................................................................................................................................................... 20
sysTem mainTenanCe
Adding Regenerant.................................................................................................................................................................................................................... 20
Brine Drums ....................................................................................................................................................................................................................................21
Remote Meter................................................................................................................................................................................................................................22
Manual Regeneration.............................................................................................................................................................................................................................. 22
Battery Replacement..................................................................................................................................................................................................................23
Battery Pack .............................................................................................................................................................................................................................................. 23
Battery Connection Terminal............................................................................................................................................................................................................... 23
Softener Sanitation Procedure ...............................................................................................................................................................................................23

TroubleshooTing
Frequent Regeneration..............................................................................................................................................................................................................25
Hard Water .....................................................................................................................................................................................................................................25
Hard Water Continued...............................................................................................................................................................................................................26
High Salt Consumption ............................................................................................................................................................................................................26
Iron Bleed Through ....................................................................................................................................................................................................................27
Leaks.................................................................................................................................................................................................................................................27
No Water to Service....................................................................................................................................................................................................................27
Pressure Loss ................................................................................................................................................................................................................................28
Salty Treated Water ....................................................................................................................................................................................................................28
Taste, Color and/or Odor .........................................................................................................................................................................................................28
Unit Sticks in Cycle......................................................................................................................................................................................................................29
Water Running to Drain.............................................................................................................................................................................................................29
parTs
Complete Systems, Tanks, Risers and Distribution........................................................................................................................................................ 30
Complete Softener Tank Assemblies ...............................................................................................................................................................................................30
Tanks.............................................................................................................................................................................................................................................................30
Distribution.................................................................................................................................................................................................................................................30
Complete Valves........................................................................................................................................................................................................................................ 31
Level 1 / 2 ................................................................................................................................................................................................................................................. 31
Level 3 - 5A............................................................................................................................................................................................................................................. 32
Level 5B - Base...................................................................................................................................................................................................................................... 33
Venturi Accessories ......................................................................................................................................................................................................................... 33
Gearing ................................................................................................................................................................................................................................................. 33
Inlet / Outlet Adapters ................................................................................................................................................................................................................... 33
Gears ..................................................................................................................................................................................................................................................... 33
Miscellaneous .....................................................................................................................................................................................................................................34
Drain Flow Control ...........................................................................................................................................................................................................................34
Internal Valves....................................................................................................................................................................................................................................34
Base Smart Start Controller.....................................................................................................................................................................................................35
Meters - Remote Reset...............................................................................................................................................................................................................................36
Brining System..............................................................................................................................................................................................................................36
Complete Brine Systems.......................................................................................................................................................................................................................36
Tanks.............................................................................................................................................................................................................................................................36
Wells1.............................................................................................................................................................................................................................................................36
Valves2..........................................................................................................................................................................................................................................................36
For Central Brine......................................................................................................................................................................................................................................36
Miscellaneous Components ................................................................................................................................................................................................................. 37
Installation Kits ......................................................................................................................................................................................................................................... 37
Master Installation Kit......................................................................................................................................................................................................................... 37
Hydrus Softener Installation Kit...................................................................................................................................................................................................... 37
Simplex..................................................................................................................................................................................................................................................... 37
Multiplex .................................................................................................................................................................................................................................................. 37
Venturi Kits ............................................................................................................................................................................................................................................. 37

HS Series Owner’s Manual
4
The hydrus series CommerCial sofTeners
The benefits of softened water are many:
• Savings in soap products and cleaners
• Reduction or elimination of fabric softeners in laundering facilities
• Reduction of boiler chemical costs
• Reduction in rinse aids that prevent water spotting
• Elimination of scale, which inhibits heat transfer
However, the benefits gained by softening in a commercial environment far exceed chemical savings. Commercial
facilities invest in high-quality equipment to carry out the daily tasks of operating that business, which is often
very expensive. Dishwashers, boilers, laundering equipment and the entire plumbing system is at risk of hardness
fouling that can severely limit the equipment’s useful life and can be the cause of costly repairs.
how awaTer sofTener works
Hard water contains calcium and magnesium ions. KineticoPRO®
softeners contain resin beads, which hold sodium ions. When
hard water passes through the resin beads, the calcium and
magnesium ions are exchanged for the sodium ions held by the
resin. Following this ion exchange process, the water leaving is
soft.
Once the resin bed is loaded with calcium and magnesium ions,
it must be cleansed, or regenerated, so that it can continue
to soften water. The salt in the brine tank mixes with water to
provide a source of saturated brine solution for regeneration
of the resin beads. The brine solution loosens the hardness
minerals from the resin, which have built up. Lastly, the system
fast rinses to drain, flushing the hardness minerals away. The
regenerated resin beads hold sodium ions, making them ready
for a new cycle of exchanging sodium ions for more calcium and
magnesium ions.
Unlike other softeners, the KineticoPRO multiplex Hydrus systems regenerate with soft water. The multiplex
systems also regenerate countercurrent to the service flow. Just as there are dierences in cleaning with soft
water, there are dierences in regenerating with soft water. The system uses only clean, soft water to carry out
the regeneration and to make the saturated brine solution in the salt storage tank. This decreases the loading on
the resin in general and preserves the virtually unloaded resin portion of the bed at the bottom of the tank. This
is one of the ways countercurrent regenerating softening systems provide the softest water in the industry.
hydrus sofTener design feaTures
There are two Hydrus softener series:
The HS 1xxs are simplex softeners. The xx indicates the tank diameter in inches. The simplex softeners
regenerate cocurrently using hard water, and by-pass hard water during regeneration.
The HS 1xxs OD, HS 2xxs OD, HS 3xxs OD and the HS 4xxs OD are all multiplex softeners. The multiplex
softeners regenerate countercurrent to the service flow, using soft water. Soft water for regeneration comes
from the softener tanks still in service. Multiplex systems do not by-pass hard water.
++
++
+
-
HARD WATER
SOFT WATER
Softener
Resin Tank
Depleted
Resin Beads
Charged
Resin Beads
Partially Depleted
Resin Beads
Ion Exchange
Resin
Magnesium Ions
Calcium Ions
Sodium Ions

HS Series Owner’s Manual
5
auTomaTiC operaTion
Once the Hydrus Softening System has been installed and set up, operation is completely automatic. The
standard, most ecient configuration is to have a flow meter in line that monitors the total amount of water that
is softened. Once the set volume of water has been softened, it signals a control device called the Smart Start™
Controller. The controller in turn signals the Hydrus Valve to regenerate. The Hydrus Valve automatically carries
out all of the regeneration operations.
CounTerCurrenT regeneraTion
Understanding the value of countercurrent regeneration starts with an understanding of the process by which an
ion exchange media is exhausted. Following the service flow through the media bed, the greatest concentration
of exchanged ions is at the entry point of the media bed. As the flow path is followed through the depth of the
media bed, a concentration gradient is formed.
The concentration gradient works in favor of countercurrent regeneration. By reversing the flow through
the exhausted bed, regenerating from lowest to highest concentration, it allows regenerant chemicals to be
introduced first to the media that is least exhausted and then, gradually, to the completely exhausted media at
the service entry to the tank.
The benefits of this type of regeneration include enhanced eciencies as well as improved product quality. The
overall salt consumption of a countercurrent system can be 40-50% less than a similar cocurrent system.
Service
Cocurrent Regeneration
30-kgr
Exhuasted
15-kgr
Exhuasted
Brining Service
Countercurrent Regeneration
30-kgr
Exhuasted
Brining
15-kgr
Exhuasted
During cocurrent regeneration, hardness ions are pushed from the
area of highest concentration through the area of least concentration,
like sweeping a pile of dirt over a swept part of the floor. To achieve
complete regeneration, a high dosage of salt is required, increasing
costs.
Regeneration is most ecient when carried out in the countercurrent
direction. First, the least contaminated part of the bed, followed by the
most. In this way, the bottom part of the bed maintains a high quality
standard, providing a polishing step just prior to the water leaving the
bed. Salt is conserved, and higher quality water is the result.

HS Series Owner’s Manual
6
low leakage
Leakage is a term used to describe the amount of hardness that passes through the softener and leaves as
hardness in the euent to the system. The use of countercurrent regeneration drastically reduces leakage. If
required, Hydrus softeners can be configured to provide hardness less than 1.0 mg/L, as calcium carbonate.
high flow raTes
KineticoPRO’s Hydrus Softening Systems are designed to accommodate the high flows demanded by today’s
growing businesses. Despite its compact size, the system provides softened water when needed, on demand.
Flow rates through a system and pressure drops are closely related. As the flow rate increases through a
softening system, the pressure drop increases. KineticoPRO Hydrus Softening Systems are designed specifically
to minimize pressure drop while maximizing flow rate.
The following features are built into every Hydrus Softening System:
• High flow distributors - provide minimal pressure loss through system.
• Dual layer underbedding, where beneficial - improves water distribution through system, increases salt
and water eciency and reduces pressure loss.
high CapaCiTy
Some manufactures rely upon high salt dosing to maximize capacity, but this practice leads to higher salt usage
and diminished eciency. KineticoPRO combines the latest technologies with solid engineering practices to
provide the most ecient softening system possible. With KineticoPRO softening systems, most applications
require salt dosing of only 5 lb/ft3of resin, compared to 15 lb/ft3and even 25 lb/ft3in competing systems.
In addition to the use of countercurrent regeneration to extend times between regenerations, high-capacity
media is used. This media is a premium grade gel cation exchange resin, which meets the performance
requirements of commercial water treatment.
Flow dynamics have an eect on capacity as well. The distribution system, the width versus the height of the
media tank, flow rate and retention time all play a factor in the capacity of the resin. A balance is struck between
all of these factors to provide the leading softening system in the industry.
Alternative brining configurations, electing capacity over eciency, are easily set on Hydrus systems.
KineticoPRO professionals are trained to know which is best for each installation.
low mainTenanCe requiremenTs
There are relatively few periodic maintenance requirements of a Hydrus Softening System. The brine tanks
require periodic filling. The state, local or building code may require daily inspection to check for leaks and verify
system operation.
On a less frequent basis, the performance of the system can be verified for hardness removal. Initially, this test
should be run more often in order to optimize brine settings.
Over the system’s lifetime, the resin may begin to lose capacity, and the regeneration frequency may have to be
stepped up. Indication of aging resin will show up in periodic hardness testing. Under general usage, the media is
expected to last 5 to 10 years. Deterioration is due primarily to attack by chlorine. If chlorine levels are regularly
above 0.2 mg/L, thought should be given to the addition of carbon pretreatment to the Hydrus Softening
System. Generally any amount of strong oxidant in the water will reduce the life of the resin.

HS Series Owner’s Manual
7
sysTem sizing
The system has been sized around the specific demands to be placed upon it in terms of peak flow rate, average
flow rate and hardness. If the softener is intended for a more seasonal application, consideration is given to
ensure the most ecient flow of soft water.
The peak flow rate, expressed in gallons per minute (gpm), is the maximum flow rate that is required for the
operation of a facility running at a substantial percentage of its maximum eective water demand. Equipment
selection, carried out by factory-trained KineticoPRO professionals, is made by fixture counts, data obtained
from equipment manuals and incoming pipe sizes.
The average flow rate, expressed in gallons per day (gpd) or per month, can be used to measure the normalized
flow demand. A monthly flow rate represents a 30-day cycle of daily flow, which tends to be a more accurate
estimation of average flow. These values are obtained from water meter readings and water bills.
The remaining factor used in properly sizing a KineticoPRO Hydrus system is the hardness of the water to
be treated. Hardness is a measure of the calcium and magnesium salts dissolved in the water. The positively-
charged portions of these salts, or cations, constitute the loading on the system used to soften the water. Some
contaminants, such as iron and manganese, also exchange and contribute to the “compensated” hardness of the
water.
HS 116s HS 118s HS 121s HS 124s HS 130s HS 136s HS 142s
Tanks (1) 16” x 65” (1) 18” x 65” (1) 21” x 65” (1) 24” x 65” (1) 30” x 72” (1) 36” x 72” (1) 42” x 72”
Resin Volume Per Tank 4 ft35 ft36 ft38 ft312 ft318 ft326 ft3
Service Flow 35 gpm 45 gpm 55 gpm 65 gpm 72 gpm 78 gpm 81 gpm
Service Flow in Regeneration By-pass By-pass By-pass By-pass By-pass By-pass By-pass
Regeneration Cocurrent Cocurrent Cocurrent Cocurrent Cocurrent Cocurrent Cocurrent
HS 216s OD HS 218s OD HS 221s OD HS 224s OD HS 230s OD HS 236s OD HS 242s OD
Tanks (2) 16” x 65” (2) 18” x 65” (2) 21” x 65” (2) 24” x 65” (2) 30” x 72” (2) 36” x 72” (2) 42” x 72”
Resin Volume Per Tank 4 ft35 ft36 ft38 ft312 ft318 ft326 ft3
Service Flow 70 gpm 90 gpm 110 gpm 130 gpm 144 gpm 156 gpm 162 gpm
Service Flow in Regeneration 27 gpm 37 gpm 45 gpm 50 gpm 52 gpm 48 gpm 41 gpm
Regeneration Countercurrent Countercurrent Countercurrent Countercurrent Countercurrent Countercurrent Countercurrent
HS 316s OD HS 318s OD HS 321s OD HS 324s OD HS 330s OD HS 336s OD HS 342s OD
Tanks (3) 16” x 65” (3) 18” x 65” (3) 21” x 65” (3) 24” x 65” (3) 30” x 72” (3) 36” x 72” (3) 42” x 72”
Resin Volume Per Tank 4 ft35 ft36 ft38 ft312 ft318 ft326 ft3
Service Flow 105 gpm 135 gpm 165 gpm 195 gpm 216 gpm 234 gpm 243 gpm
Service Flow in Regeneration 62 gpm 82 gpm 100 gpm 115 gpm 124 gpm 126 gpm 122 gpm
Regeneration Countercurrent Countercurrent Countercurrent Countercurrent Countercurrent Countercurrent Countercurrent
HS 416s OD HS 418s OD HS 421s OD HS 424s OD HS 430s OD HS 436s OD HS 442s OD
Tanks (4) 16” x 65” (4) 18” x 65” (4) 21” x 65” (4) 24” x 65” (4) 30” x 72” (4) 36” x 72” (4) 42” x 72”
Resin Volume Per Tank 4 ft35 ft36 ft38 ft312 ft318 ft326 ft3
Service Flow 140 gpm 180 gpm 220 gpm 260 gpm 288 gpm 312 gpm 324 gpm
Service Flow in Regeneration 97 gpm 127 gpm 155 gpm 180 gpm 196 gpm 204 gpm 203 gpm
Regeneration Countercurrent Countercurrent Countercurrent Countercurrent Countercurrent Countercurrent Countercurrent

HS Series Owner’s Manual
8
operaTion
This section is provided to instruct on the operation of tanks, controls and bringing systems. KineticoPRO’s
Hydrus Softening Systems are an assembly of five major sub-assemblies: media tank, remote meter, Smart Start
Controller, the brining system and the Hydrus Valve itself. Together, they provide softened water eciently,
reliably and continuously. The KineticoPRO professional, when enlisted, has inspected the installation and has
made all of the proper adjustments to the system to ensure proper installation, startup and operation.
ConCepTs
KineticoPRO’s Hydrus Valve is designed to control commercial, industrial and municipal water treatment
equipment. The valve controls all service and regeneration functions for a single tank. A separate valve is
required for each tank.
Level 1-2 Assembly
The level 1-2 assembly controls the service and regeneration cycles for the entire valve.
Starting Regeneration
External water flow to the “Start Port,” as
shown on page 27, starts the regeneration.
This water can come from opening a hand
valve, a solenoid valve or some similar
device. The regeneration start requires a
flow of about 0.5 gpm. This flow is regulated
internal to the valve, so the supply must be
able to meet or exceed this flow rate. The
length of time to start the cycle is dependent
on the length of the overall cycle. Times can
range from 5 to 20 minutes.
The regeneration start water enters the
level 1-2 assembly by means of a ¼” tubing
connection. It spins a turbine, which
advances the control disc. As this disc
advances, the regeneration control valve
opens. This allows flow back up to the level
1-2 assembly, passing the regeneration flow
control and the regeneration nozzle. Once
the regeneration control valve opens, the
external water flow through the ¼” tubing
can stop. The nozzle directs the flow past
the regeneration turbine, keeping the control
disc advancing through the regeneration
cycle and driving the regeneration gear
stack.
Regeneration Gear Stack
The regeneration gear stack controls the length of regeneration. Depending on the gearing used, a regeneration
can take between 20 minutes and 210 minutes. The regeneration gear stack drives the regeneration drive pawl,
which drives the control disc.
Control Disc
The control disc pressurizes or vents signal holes in the ceramic disc. These ceramic disc holes are connected to
servo valves located in the level 3-6 assembly. Level 2 assists in routing the pressure signals from the ceramic disc
holes to the proper location on the level 3-6 assembly. The control disc determines what function the module
takes. There is a dierent control disc for each valve configuration: simplex, multiplex, softener and filter. The
control disc is selected based on the tank’s function.
}Level 3-6
Assembly
}Level 1-2
Assembly

HS Series Owner’s Manual
9
Level 3-6 Assembly
The level 3-6 assembly holds the servo valve, valve seats, venturi and backwash flow control. Also included within
this assembly is the capability of a raw water by-pass. This is located on level 5A. The raw water by-pass is used
in simplex systems, allowing untreated water to be diverted to service during a regeneration. There are six valves:
inlet valve, outlet valve, drain valve, purge valve, regeneration control valve and start next valve. The following
graphic shows the general scheme and operation of the remarkable valve.
simplex sysTems
The KineticoPRO Hydrus System has two basic configurations: simplex and multiplex. The simplex configuration
is straightforward in its operation. As a single tank, the regeneration occurs without aecting any other tanks or
sub-systems that may be present. Raw water is by-passed around the treatment system during a regeneration.
Raw, untreated water is also used for the regeneration process and to refill the brine drum.
mulTiplex sysTems’ regeneraTion sequenCe
The multiplex systems’ configuration diers from simplex systems primarily during regeneration. When sizing the
multiplex systems, KineticoPRO professionals consider these dierences in order to meet the treatment goals.
In general, multiplex systems are used for applications that are more critical, where a continuous supply of soft
water is required, where high flow is required or where softened water specifications require countercurrent
regeneration with soft water.
During service, all of the tanks are operating at equal flow rates in parallel. The softening media removes
hardness and eventually approaches exhaustion. Taking several factors into account, a regeneration is initiated
based upon time and service, day and time, or volume of processed water, depending on whether or not the unit
is equipped with a flow meter.
Regeneration
Turbine
Raw Water By-pass
Next
Port
Start
Port
Next
Valve
Control
Valve
Countercurrent
Port
Purge
Valve
Venturi
Plug
4” Tank Thread
Flow Restrictor Cocurrent Port
Venturi
To Lower
Distributor
To Upper
Distributor
Drain Valve Inlet Valve
Level 1
Drain Port
Outlet Valve
Outlet Port Drain Port Inlet Port

HS Series Owner’s Manual
10
To provide the most ecient, productive regeneration, Hydrus multiplex systems use softened water for all four
stages of the regeneration and to refill the brine tank. For a better understanding, a triplex Hydrus system is used
in the following example.
The following steps describe the regeneration sequence of this three-tank system: T1, T2 and T3.
1. The remote meter measures the volume of water processed and closes a dry contact to activate the
Smart Start controller, which produces a hydraulic signal.
2. The lead tank receives the hydraulic signal from the Smart Start Controller at the Start Port, which spins
a turbine and advances the control disc to start the regeneration.
3. T1 shuts down, and a regeneration on this tank begins. The two remaining tanks continue to soften water
for distribution and also supply the softened water required for the regeneration of T1. The tanks are
sized so that the water system demand and the water used for regeneration can be met by the two tanks
in service. The inlet valve closes, but the outlet valve remains open. This allows soft water from T2 and T3
to be used for regeneration in a countercurrent fashion.
4. After T1 is regenerated, the Start-Next valve opens and sends a hydraulic signal to T2. At that point, T2
shuts down and a regeneration on it begins. T1 and T3 supply water for distribution and also supply the
softened water required for the regeneration of T2.
5. The process continues until all tanks in the train have regenerated. The Start-Next port in T3 is plugged
and not used.
plumbing1
It’s important that the Hydrus system be plumbed with isolation and by-pass valves and approved materials using
approved methods. It’s implicit that the system is installed with proper fittings and is provided with isolation and
expansion capabilities. Plumbing specification is outside the scope of this manual and subject to local code.
1 See installation manual for Hydrus - specific plumbing requirements, p/n 12190K
Remote Meter
Drain Air Gap
Inlet
Hydraulic Signal
Outlet
T2 T1 T3