Ofs Softcontrol Smart User manual

Softcontrol Smart
Instruction Manual
Version 2.3

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Index
1. MANUFACTURER .....................................................................................................5
2. INTENDED USE..........................................................................................................5
3. WARRANTY...............................................................................................................5
4. LIABILITY...................................................................................................................5
5. LICENSE CONDITIONS ............................................................................................6
6. GENERAL SAFETY INSTRUCTIONS......................................................................6
6.1. SYMBOLS ...................................................................................................................6
6.2. OPERATING PERSONNEL........................................................................................6
6.3. SAFETY REQUIREMENTS .......................................................................................7
7. GENERAL OVERVIEW OF FUNCTIONS................................................................8
8. OPERATING MODES.................................................................................................9
9. INSTALLATION .......................................................................................................10
9.1. MECHANICAL INSTALLATION............................................................................10
9.2. HYDRAULIC INSTALLATION...............................................................................10
9.2.1. HYDRAULIC INSTALLATION SCHEME .............................................................11
9.3. ELECTRICAL INSTALLATION..............................................................................12
9.3.1. EXTERNAL SIGNALING VIA POTENTIAL-FREE CONTACT ..........................13
9.3.2. CONNECTION - EXTERNAL WATER METER....................................................13
9.3.2.1. CONNECTION - MECHANICAL WATER METER...............................................13
9.3.2.2. CONNECTION - ELECTRONICAL WATER METER (TURBINE WITH HALL
CONTACTS)..............................................................................................................13
10. LED FUNCTIONS AND DISPLAYS .......................................................................14
11. SERVICE....................................................................................................................15
11.1. DELIVERY/TRANSPORT/STORAGE OF HARDNESS SENSOR........................15
11.2. OPERATING CONDITIONS OF THE SENSOR.....................................................16
11.3. SENSOR CONNECTION/SENSOR REPLACEMENT ...........................................16
11.4. MALFUNCTION/BREAKDOWN OF THE SENSOR.............................................17
12. MALFUNCTIONS AND POSSIBLE CAUSES........................................................18
13. DECOMMISSIONING ..............................................................................................19
14. DISMANTLING.........................................................................................................19
15. SENSOR SYSTEM....................................................................................................20
16. ACCESSORIES..........................................................................................................20
17. TECHNICAL DATA..................................................................................................21
18. EU-DECLARATION OF CONFORMITY................................................................23

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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/en/
2. Intended use
Softcontrol Smart is used to monitor increased hardness concentrations in the soft water of
water softening systems based on cation exchangers. It offers continuous, safe limit value
monitoring with an alarm when exceeded. At a fixed hardness limit of 10% based on the input
water hardness, the device triggers an alarm.
3. Warranty
The manufacturer guarantees the device for 2 years from delivery.
The ion-selective sensor is an exception to this.
The guarantee expires if:
improper commissioning or improper operation or maintenance
improper or unauthorized intervention in the device or its components
improper analytical, mechanical or electrical impact of any kind
damage or consequential damage caused by improper use or operation
damage or consequential damage caused by faulty or improper or unauthorized systems
connected in the control and regulating circuit
damage or consequential damage that can be traced back to poor quality sample liquids
4. Liability
The manufacturer assumes no liability for upstream or downstream equipment and process /
production processes of the user, their malfunctions, failures, damage or consequential dam-
age that are directly or indirectly connected to the monitoring or control circuit of the device
or that have or could have an impact on malfunctions or malfunctions in the manufacturer's
devices
The exclusion of liability is based on the fact that electrical impulses and currents, inorganic
or organic precipitates, sedimentation of corrosive or oxidizing substances, microbiological
contamination, flocculation or putrefaction in the sample liquids occur only briefly and can be
ignored by the user.

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5. License conditions
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.
Attention! Failure to comply with instructions marked in this way may result
in damage to the device or the sensors.
Warning! If notices marked in this way are ignored, this can lead to injuries or
material damage.
Electric current hazard! Notes marked in this way must be observed. Failure
to do so can result in damage to the device, injuries or property damage.
6.2. Operating personnel
The device installation and operation of the device may only be carried out by trained and
qualified persons. They must have read and understood the operating instructions. The follow-
ing safety instructions must be strictly observed.

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6.3. Safety requirements
Softcontrol Smart is to be installed as a wall device in accordance with the instal-
lation regulations. It may only be operated in rooms with a relative humidity of
20% to 60% and ambient temperatures between 5 ° C and 50 ° C. It must be en-
sured that no condensation can form in the housing.
Operation in connection with ionization or electrolysis systems is not permitted.
The device must be protected from direct moisture and unauthorized mechanical
or electrical interference.
Softcontrol Smart may only be operated with a protective low voltage of 15 volts
DC or with the plug-in power supply unit for 100… 240 volts AC supplied by the
manufacturer.
The mechanical commissioning must always be carried out in a voltage-free state.
The electrical connection to external signaling devices must not exceed the per-
missible safety extra-low voltage.
The raw and soft water of the softening process to be monitored must basically
meet the requirements of the applicable drinking water ordinance.
A constant sample pressure of a minimum of 1 to a maximum of 7 bar at the sam-
plers of raw and soft water must be ensured during operation.
The difference between raw and soft water pressure should be as small as possi-
ble.
The sample liquids must be free of particles, otherwise flow filters ≤ 0.1 mm must
be installed in front of the sample inputs.
Before removing the sensor from the measuring chamber, the power supply to the
device must be interrupted. Otherwise water may splash out of the measuring
chamber.
There is constant water pressure up to the solenoid valves. Before servicing the
solenoid valves or before dismantling the measuring device, the raw and soft wa-
ter lines must be shut off. Otherwise, water may splash.
When decommissioning, the sensor must be removed from the measuring cell and
stored accordingly.
The manufacturer reserves the right to make changes in line with technical progress.

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7. General overview of functions
Softcontrol Smart is an online water hardness measuring system for the continuous monitoring of soft
water on a connected water softening system based on cation exchangers for increased hardness con-
centrations.
For this purpose, the device in the bypass takes minimal amounts of raw or soft water from the process
in a time-controlled or flow-controlled manner, evaluates the residual water hardness and issues an
alarm if hardness breakthroughs are detected. At a fixed hardness limit of 10% based on the input wa-
ter hardness, the device triggers an alarm. The determination of the water hardness is possible from
0.18 mmol/l raw water hardness. The measurements are carried out cyclically every 15 minutes in a
flow measuring chamber, in which a selective sensor for calcium and magnesium ions is inserted pres-
sure-proof. Alternatively, the measuring cycle can be controlled by pulses from a connected water
meter.
The process water samples are exchanged by automatically opening or closing the upstream shut-off
valves and then discarded without pressure. If hardness breakthroughs are recognized or a service case
for the measuring system is required, an alarm is signaled. The measurement functions and their re-
sults are displayed with colored LEDs. The measuring system calibrates itself through automatic, cy-
clical switching from soft water to raw water.
raw water
drain
(pressure free)
raw water
optional
external
signal-output
optional
connection
water meter
valve
raw water
sensor
measurement chamber
power supply
240V / 50 Hz
V
softener
sensor cable
soft water
filter
filter
valve
soft water
5soft water

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8. Operating modes
Time- or flow-controlled measurement / active operation
If the device is operated without being connected to a water meter, it works time-controlled
and measures at 15-minute intervals.
An external water meter can optionally be connected. If the device detects water meter pulses,
it switches to continuous flow-controlled measurement.
Standby mode / passive operation
The device is ready for operation outside of the active operating times. A constantly lit LED
indicates passive operation.
Hard water alarm / brine intrusion
If the water hardness is detected in the soft water, the visual alarm is triggered immediately
and the external hard water alarm is triggered after a delay. The device also detects brine in-
gress and signals this as a brine alarm.
Valve alarm
The tightness of the valves is monitored by sensors. With detection of a leak, for example if
the valve seat is contaminated, an alarm is signaled.
Sensor alarm
The sensor quality is checked cyclically. For this purpose, measurements are carried out in
raw and soft water. The sensor quality is calculated from the measured values. If it does not
correspond to the specified quality parameters, a sensor alarm is signaled.

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9. Installation
9.1. Mechanical installation
Softcontrol Smart is to be installed in the immediate vicinity of the water softener to be moni-
tored as a wall or frame mounting. For the extraction of the raw and soft water, there must be
branches with preferably ¼ "internal threads at the inlet and outlet of the softening system as
well as upstream flow fine filters ≤ 0.1 mm. Furthermore, it must be ensured that a water
pressure of at least 1 bar to
a maximum of 7 bar is applied. After selecting the mounting surface, the device can be
mounted.
9.2. Hydraulic installation
The hydraulic installation of the inflows, the outflow and the hardness sensor must only be
carried out as follows after it has been firmly mounted on the wall:
1. Install the fine filter. The direction of flow must be observed. This is indicated by an
arrow on the filter housing. The fine filters are preferably installed directly at the sam-
pling points for raw and soft water in order to also protect the sample hoses from
clogging.
2. Insert the raw water hose Ø 4 mm as far as it will go into the “hard water” plug-in
connection so that it is pressure-proof.
3. Insert the soft water hose Ø 4 mm into the "soft water" plug-in connection as far as it
will go.
4. Plug the drain hose Ø 8 mm into the angle connector in a pressure-proof manner
5. Plug the sensor cable into the sensor socket
6. Insert the sensor straight and pressure-proof into the T-piece
Do not touch or damage the electrodes!
7. Open the upstream raw and soft water shut-off taps and check all connectors for leaks.
Water pressure is now applied up to the normally closed valves RW and
SW.
8. The installation is completed with a positive leak test.
Note: Upstream fine filters can be omitted if the existing filter systems (≤ 0.1 mm) prevent
the sampling valves from clogging with dirt particles!

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9.2.1. Hydraulic installation scheme
soft water
raw water
optional
connection
water meter
valve
raw water
measurement chamber
power supply
240V / 50 Hz
V
softener
filter
filter
raw water
sensor cable
drain
(pressure-free)
1
1
2
3
5
6
4
sensor
soft water
valve
soft water
optional
external
signal-output

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9.3. Electrical installation
Softcontrol Smart is immediately ready for operation after the assembly described above and
after successful hydraulic installation.
Optionally, a water meter or an external signal output can be connected using the supplied 5-
pin plug.
1
2
3
4
N
ot
e:
E
ac
h
te
r
m
in
al
is
m
ar
k
e
d
w
it
h
a
n
5
S
of
t
w
at
er
Note:
The individual contacts are identified by num-
bers!
The groove of the polarity reversal protection
always points downwards (towards the rear of
the housing).

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9.3.1. External signaling via potential-free contact
The alarm signal is output at terminals 1 and 2 of the external 5-pin screw connector.
The following external electrical requirements for wiring must be observed.
External requirements: Switch position in alarm state:
Maximum connection voltage: 24 volt
Maximum current: 0.5 ampere
The logical behavior is specified in the following table with signal status:
Signal status
Terminal
Contact status
power failure or threshold value exceeding or
brine alarm or valve alarm or sensor alarm
1/2
open
no alarm
1/2
closed
9.3.2. Connection - external water meter
For continuous monitoring during the soft water withdrawal and to hide excess hardness lev-
els due to so-called "hardness", it is recommended not to carry out the monitoring according
to fixed time cycles, but continuously during the entire soft water withdrawal. To this end, it
makes sense to connect a mechanical contact water meter or an electronic water meter.
9.3.2.1. Connection - mechanical water meter
The contact water meter used must have potential-free contacts. The electrical connection is
made at the external 5-pin screw connector (terminal 5/3).
9.3.2.2. Connection - electronical water meter (turbine with Hall contacts)
The electronic water meter must be connected to terminals 3, 4 and 5 on the external 5-pin
screw connector. Pay particular attention to the correct polarity as well as avoiding short cir-
cuits at the connections of the water meter or in the screw plug!
1 2
Terminal 5 + 5 V
Terminal 4 GND
Terminal 3 Impulses

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10. LED functions and displays
Device status and measurement results are shown by glowing and flashing LEDs:
If the sensor is missing or not installed correctly, all three LEDs light up at the same time.
LED „OK/measurement“ lights up:
passive operation mode
no increased water hardness recog-
nized = good soft water quality
LED „OK/measurement“ is flashing:
aktive operational mode
measurement or calibration is
activated
LED „hard water / brine“ lights up:
Threshold value alarm
LED „hardwater / brine“ is flashing:
Brine alarm
LED „sensor/valve“ lights up:
Sensor alarm
LED „sensor/valve“ is flashing:
Valve alarm

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11. Service
11.1. Delivery/transport/storage of hardness sensor
Each hardness sensor has a sensor number that uniquely identifies it.
Before delivery, the sensor quality was checked and verified by a final inspection.
To protect the sensor membrane, the sensitive sensor part is tightly closed with a protective
tube. This enables the sensor to be in a sterile, humid environment. This ensures that the sen-
sor can be put into operation immediately.
The sensors are packed in a special folding box for shipping. The delivery was undamaged
when the protective cap is firmly seated on the sensor and steamed up inside. A comparison
of the number on the sensor with the number given on the packaging and on the delivery note
is recommended.
The sensor should be stored in the folding box at 10 ° C to 15 ° C and used as soon as possi-
ble.
Please note:
The protective cap must remain tightly closed until the sensor is used. The moisture condens-
es inside and prevents the sensor from drying out.
Sensors without a tightly closed protective cap dry out quickly and may not work properly
again or only after 1 to 2 days.
In principle, the protective cap should not be removed without using the sensor immediately,
in order not to destroy the humid and sterile climate in the protective cap.
Storage in the folding box at temperatures of 10 ° C to 15 ° C.

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11.2. Operating conditions of the sensor
Sensor usage conditions:
The quality of the sensor is influenced by the water quality, in particular the precipitation of
iron, high chlorine or brine concentrations and growing bacterial cultures and must be re-
placed at the latest when the sensor alarm is signaled.
Required water conditions:
-natural raw water with a hardness value of 0.18 mmol/l to 10.8 mmol/l
-water temperature: 5..30 ° C
-pH range: 5 ... 9 pH
-chlorine content: <500 µg / l
-germ content: <5,000 CFU / ml
The water must be free from acids, alkalis, salt solutions (brine), tensides, fats, oils,
solvents and heavy metals.
11.3. Sensor connection/sensor replacement
1. Disconnect the plug-in power supply unit from the mains or interrupt the power supp-
ly
2. Disconnect the sensor cable from the used sensor (when changing the sensor)
3. Press down the pressure ring on the T-piece of the flow measuring chamber in which
the sensor is located and at the same time pull the used sensor straight out of the flow
measuring chamber. (when changing sensors)
4. Take the new sensor out of the folding box and pull it straight out of the protective tu-
be.
Do not touch or damage the sensor tip!
5. Press the new sensor firmly into the T-piece of the flow chamber. Sensor included
insert straight to prevent contact with the pipe wall.
By pulling on the sensor, the firm and pressure-proof seat in the T-piece can be
checked.
6. Plug the sensor cable onto the sensor (observe polarity reversal protection on the plug)
The sensor cable must click into place audibly and tangibly.
7. Reconnect the plug-in power supply to the mains or switch on the power supply. The
device checks the sensor plug connection when it is restarted and displays an alarm if
the sensor is not recognized. In this case, the device must be switched off again and
the plug connection to the sensor checked for contact security.
8. The sensor change is complete when the device detects the new sensor and resumes
measuring operation.

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11.4. Malfunction/breakdown of the sensor
1. Deposits on the sensor
Precipitations and deposits on the sensor prevent appropriate hardness monitoring.
Examples:
Rust and iron deposits form a slightly red-brown layer in the flow measuring chamber and
on the sensor system
Upstream filters should prevent iron, copper or aluminum precipitation
Biofilm formation due to excessive germ counts in the water
Biofilms occur very strongly when the water softening system or the device has been
switched off for several days or weeks and the water is in the flow chamber.
If the device is not used for a longer period of time, it must be shut down electrically, the
sensor must be removed from the measuring chamber and stored accordingly, and the wa-
ter must be removed from the measuring chamber.
2. Chlorine exposure
Impact chlorination, as is sometimes carried out in raw water pipes, can damage the sensor
depending on its intensity and duration. Strong, deep black discolorations on the metal elec-
trodes indicate a high level of chlorine exposure. The sensor can indicate that the limit value
has been exceeded, although none is present.
The sensor is destroyed and must be replaced.
3. Brine exposure
Defective outlet valves on the softening system can cause brine from the brine tank to be
flushed into the soft water during regeneration, but also constantly when the water throughput
is weak, which could then be assessed as an excess hardness by the sensor system.
If the sodium concentration is very high compared to the calcium-magnesium concentration,
the sensor signal is strongly influenced by the excessive sodium content, as this has a disrup-
tive effect on the sensor. An increased brine concentration can be recognized by measuring
the conductance difference between raw and soft water. If the brine exposure is too high or
too intense, the sensor is destroyed, which means that a limit value alarm is displayed even if
the softening system is working correctly.
The sensor must be replaced.

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12. Malfunctions and possible causes
Problem
To do
1. Signaling that the threshold value has been exceeded with normal soft water hardness
below the limit value
to low water flow through measurement
chamber
when the valve is switched on, water must
come from the drain
the raw water valve does not close com-
pletely (e.g. due to deposits in the valve
seat), which means that small amounts of
raw water flow into the measuring cell in
addition to the soft water
replace valve
low brine concentration in soft water
rinse active column of softening plant once
again
sensor possibly contaminated
or damaged by brine
replace sensor
2. Sensor not recognized
sensor not plugged in correctly
or electrical plug connection defective
Check plug connection or connection cable
for continuity
3. Brine alarm
high concentration of brine in the soft wa-
ter, conductivity compared to the raw wa-
ter is significantly higher
rinse the active column again
raw or soft water flow interrupted, sensor
no longer rinsed with soft or raw water
restore the water supply
sensor possibly contaminated or damaged
by brine
replace sensor
4. Valve leaking
one of the two valves no longer closes
properly
remove the hoses from the measurement
chamber and check whether drops of water
are escaping despite the closed valves
replace affected valve
5. Raw or soft water does not flow
sample inlet closed
check shut-off valves
pre-filter blocked
clean fine-filter
sample hose blocked
check sample hose for flow
defective valve
replace valve

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13. Decommissioning
The following steps must be carried out to shut down the device:
1. Switch off the operating voltage by pulling the plug-in power supply unit out of the
mains socket
2. Manually shut off the raw water and soft water pipes
3. If the measuring device is to be taken out of operation for a period longer than 2 days,
the hardness sensor must be removed and the sensor protection cap filled with approx. 1
ml of raw water carefully placed on the hardness sensor. The sensor should be stored in
a cool (10-15 ° C) and dark place.
14. Dismantling
For dismantling, the measuring device must be taken out of operation as described above. The
hoses for raw and soft water must then be removed. To do this, the connector's locking ring is
pushed back and the hose is pulled out of the connector.
The next step is to dismantle the device from the wall. If external cables are connected to the
device (water meter, external signal output), these must be disconnected.

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15. Sensor System
selective sensor for calcium and magnesium ions type 670
16. Accessories
1 piece plug in for connection of water meter and external signal output
4 m flexible pressure-proof PA line 4 mm OD / 2 mm ID (sampling hose)
1 m flexible pressure-proof PA line 8 mm OD / 6 mm ID (drainage hose)
2 pieces screw-in connection 4 mm x ¼ "
2 pieces of pre-filter 100 µm with plug connection for sampling hose 4 mm OD
(optional)