Ofs Softening Control User manual

Softening Control
Instruction Manual
Version 1.13

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Index
1. Manufacturer................................................................................................................5
2. Correct usage in accordance with regulations..............................................................5
3. Warranty.......................................................................................................................5
4. Liability........................................................................................................................5
5. Terms of license...........................................................................................................6
6. General safety instructions...........................................................................................6
6.1 Symbols........................................................................................................................6
6.2 Operating personnel.....................................................................................................6
6.3 Safety requirements......................................................................................................7
7. General overview of the device ...................................................................................8
8. Characteristics..............................................................................................................9
9. Installation..................................................................................................................10
9.1 Mechanical installation ..............................................................................................10
9.2 Hydraulic installation.................................................................................................10
9.2.1 Scheme hydraulic installation....................................................................................11
9.3 Electrical installation..................................................................................................12
9.3.1 Connection of power supply ......................................................................................12
9.3.2 Output water hardness by active current loop............................................................12
9.3.3 Connection ON / OFF signal .....................................................................................12
9.3.4 External signalling by potential free contact..............................................................13
9.3.5 Connection external closer for activation of measurement........................................14
9.3.6 Connection of water meter.........................................................................................14
9.3.6.1 Connection mechanical water meter..........................................................................14
9.3.6.2 Connection electronic water meter (turbine with Hall-contacts)...............................14
9.3.7 Overview electrical connections................................................................................15
10. Commissioning ..........................................................................................................16
10.1 Setting of DIP-Switches.............................................................................................16
10.2 Explanation of LED-Display .....................................................................................18
10.2.1 Explanation of LED-status for displaying of water hardness evaluation...................18
10.2.2 Explanation of LED-status for displaying of functional status..................................19
10.3 Operating tests............................................................................................................20
10.3.1 Test of water quality ..................................................................................................20
10.3.2 Test of external signaling...........................................................................................20
10.3.3 Test sensor performance ............................................................................................20
11. Service........................................................................................................................21
11.1 Delivery/Transport/Storage of hardness sensor.........................................................21
11.2 Operating conditions of the sensor.............................................................................22
11.3 Sensor mounting/Sensor replacement........................................................................22
11.4 Malfunction/Breakdown of sensor.............................................................................23
12. Malfunctions and possible causes..............................................................................24
13. Decommissioning.......................................................................................................25
14. Dismounting...............................................................................................................25
15. Sensor system.............................................................................................................25
16. Accessories.................................................................................................................25
17. Technical data ............................................................................................................26
18. EU-Declaration of conformity ...................................................................................27

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1. Manufacturer
OFS Online Fluid Sensoric GmbH
Gesellschaft für analytische und meßtechnische Systeme
Heidelbergweg 9
07580 Ronneburg
Germany
Phone: [phone]
Fax: [phone]
[email protected]
www.water-monitoring.com
2. Correct usage in accordance with regulations
Softening Control monitors a parameterizable threshold value of residual water hardness in
soft water of softening plants based on cation exchange. It provides a gradual percentage
monitoring of the water hardness threshold values from 0.25% to 10% of the input water
hardness.
3. Warranty
The manufacturer provides a warranty for its products of 2 years from delivery date.
From this warranty the measuring sensor is excluded.
The warranty expires in the case of:
incorrect installation or operation, resp. maintenance
incorrect or unauthorized intervention of the device or its components
incorrect analytical, mechanical or electrical effects of any kind
damages or subsequent damages due to incorrect operating
damages or subsequent damages due to incorrect or unauthorized connection of systems to
the control circuit
damages or subsequent damages traced back to low sample liquid quality.
4. Liability
The manufacturer accepts no liability for up or down streamed facilities and processes caus-
ing malfunction, failures, damages or subsequent damages, which are directly or indirectly
connected to the control circuit of the device or having or could have an effect and which lead
back to malfunctions or failures of the device.
The liability disclaimer is based on the possibility that electrical impulses and currents, inor-
ganic and organic precipitations, sedimentation of corrosion or oxidation materials, microbio-
logical loads, flocculation or digestion may appear in the sample liquid, unnoticed by the user.

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5. Terms of license
On purchase, the user acquires an exclusive non-transferable right of use for the installed
software. The use is permitted for the operation of the purchased device only. Any other use,
transmission, copying or recompilation of the software is prohibited. Equal conditions apply
for software updates.
6. General safety instructions
6.1 Symbols
Important information in this manual are marked by the following symbols. This information
are of particular importance for a safe and hazard-free operation of the device.
Caution! With disregarding of so marked information the device or sensor
could be damaged.
Warning! The disregarding of so marked information may cause injuries or
property damages.
Danger of fatal injury or damages from electrical current! Information
marked with this sign must be observed absolutely. The disregarding of this in-
formation may cause damages at the device, fatal injuries or property damages.
6.2 Operating personnel
The unit is to install and operate only by personnel who have been trained and authorized pre-
viously. They must have read and understood this manual. The following safety instructions
must be observed strictly.

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6.3 Safety requirements
The measuring device is set up as wall mounted unit and must be installed ac-
cording to installation instruction.
It should be operated in rooms with a relative humidity between 20 % and 60
% and an ambient temperature between 5°C and 50°C. It must be ensured that
condensation can not form in the housing.
Operation in connection with ionization or electrolysis units is not permitted.
The device must be protected against liquids and unauthorized mechanical or
electrical intervention.
The device may be operated only with a safety extra-low voltage of 24 V DC
respectively with the wall power supply for 230 V AC provided by the manu-
facturer.
The mechanical installation and commissioning must be carried out with the
power disconnected.
The electrical connection to external control equipment and instrumentation
must not exceed the specified voltage.
The raw water and soft water of the monitored or controlled process must cor-
respond to the relevant drinking water specifications.
During operation a constant water pressure of minimum 1 up to maximum 10
bars on the samplers is to ensure. The difference between raw and soft water
pressure should be as low as possible.
The sample liquids should be free of any particles, otherwise flow filters of ≤
0.1 mm has to be installed up streamed to the sampling units.
The electric power must be disconnected from the unit prior to the removal of
the sensor from the measuring chamber.
The system is under water pressure up to the solenoid valves. The raw and soft
water inlet must be cut off prior to carrying out any maintenance work on the
solenoid valves or dismantling the measuring unit.
Any time the unit is taken out of service, the sensor needs to be removed from
the device and stored correctly.
The Manufacturer reserves the right to make any technical changes to reflect
further developments.

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7. General overview of the device
Softening Control is an online water hardness measuring system for continuous monitoring of
water hardness differences between process inlet and process outlet of a connected water sof-
tening system based on cation exchange.
By using of bypass technology the device extracts time controlled or flow rate depending
minimal amounts of raw or soft water from the process, evaluates the residual hardness and
alerts with exceeding of a preset threshold value. The threshold value can be parameterized by
DIP-Switches with individually defined steps of 0.25% up to 10% residual hardness in refer-
ence to 100% raw water hardness.
The measurements will be carried out cyclically every 15 minutes in a flow-through chamber
where a selective sensor for calcium and magnesium ions operates in an environment protect-
ed against pressure. In each measurement cycle the water sample stays a preset period in the
measurement chamber and will be evaluated after a preset resting time. The measurement
cycle can be controlled alternatively by impulses of a connected water meter or a potential
free closer.
By automatic opening and closing of the upstream stop valves the water samples will be re-
placed and rejected free of pressure. With exceeding of threshold value a potential free switch
will be activated with a delay of 1or 10 minutes. With recognizing of an interference or need
of sensor exchange a second potential free switch will be activated.
Measuring functions and their results are represented with colored LEDs. At the same time
the measurement value will put out through a current loop 4…20mA.
In intervals of five days the sensor quality will be checked. If the result does not comply with
the predefined minimum requirements, the need for sensor exchange will be signalized.
optional
connection water meter
optional
external signal output
power supply unit
100 … 240 V AC
50 … 60 Hz
reserve connection
raw water
measurement chamber
Ventil RW
Ventil WW
soft water
sensor
valve
raw water
filter
V
softener
raw water
soft water
pressure
free drain
valve
soft water
filter

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Once a day a sensor forming will take place in row water, which purposes of an increasement
of the sensors service quality. The sensor forming will take 17 minutes. During this time no
water hardness measurement will take place.
The measurement system can set in off-line-mode by a connected potential free closer. In this
mode no measurement will take place.
The measuring system is automatically calibrated by time controlled automatic change over
from soft water to raw water. There is no need for additional indicators or reagents.
8. Characteristics
Water hardness of raw water will be defined automatically with 100%.
Water hardness of soft water will be determined in percentages and rated to a fixed
threshold value, given by a DIP-switch.
The difference value shows the actual efficiency of the softening plant.
The threshold value can be defined individually in steps of 0.25% up to 10% in refer-
ence to the row water hardness.
Displaying of the measurement results by colored LEDs in traffic lights position.
Possibility for connection for monitoring of an external mechanical contact water meter
at outlet of softener system with an impulse sequence ~ 1 second/impulse
Time controlled cyclic measuring with measuring breaks of 15 minutes between two
measurements or process controlled continuous measuring when soft water is being re-
leased and the contact water meter is registering impulses
Parameterizing by DIP-Switches at the device
Detection of high brine concentration in soft water
Self monitoring of hardness sensor with signaling on need for replacement
Output of indicated value through 4 to 20 mA current loop

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9. Installation
9.1 Mechanical installation
Softening Control must be installed in close proximity to the softening system to be moni-
tored. Installation is possible as wall or base frame mounted device with an installation space
of 300 x 300 x 150 mm (wide x height x depth), preferably at eye level. For installation at the
mounting area the mounting hole at the device case are to be used. Fitting accessories are to
be provided on site.
For sampling of raw and soft water branch pipes with preferable ¼” internal thread and pre-
filter of ≤ 0.1mm should be installed at the process inlet and process outlet of the softening
system. Further it must be pointed out that during operation the device must be provided per-
manently with a water pressure of minimum 1 bar up to 10 bars.
After selection of mounting area and pre-installation of mounting screws and electrical con-
nections by removing the back panel, the device can be installed easily.
9.2 Hydraulic installation
The hydraulic installation of inlets, outlet and hardness sensor is only to be carried out after
the unit has been fixed at the wall resp. frame as following:
1. Push raw water hose Ø 4 mm (blue hose) as far as it will go into the pre-installed plug-in
connector “RW” outside of the casing
2. Push soft water hose Ø 4 mm (black hose) as far as it will go into the pre-installed plug-
in connector “SW” outside of the casing
Do not forget the prefilters!
3. Push the drainage tube Ø 6 mm tightly into the T-fitting at the outlet of the measurement
chamber
4. Plug the sensor socket of the sensor system into the electrical connection of the flow
measurement chamber at the device and fix it with the safety bolt
5. Push the analytical side of the sensor tightly into the T-fitting
Do not touch or damage the electrodes!
6. Open up streamed raw and soft water stop valve and check leak-tightness of the installed
raw and soft water hoses
The system is now subject to water pressure up to the closed valves RW and
WW.
7. If the pressure test is successful, the installation has been completed.