Ofs Softcontrol Smart User manual

Softcontrol Smart
Instruction Manual
Version 2.2

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Index:
1. Manufacturer.................................................................................................................5
2. Correct Usage in Accordance with Regulations...........................................................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 the Device ..................................................................................8
8. Operational Mode.........................................................................................................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. External Signaling by 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-status and displays of functional status..............................................................14
11. Service ........................................................................................................................15
11.1. Delivery/Transport/Storage of hardness sensor..........................................................15
11.2. Operating conditions of the sensor.............................................................................16
11.3. Sensor mounting/Sensor replacement.........................................................................16
11.4. Malfunction/Breakdown of the sensor........................................................................17
12. Malfunctions and possible causes...............................................................................18
13. Decommissioning.......................................................................................................19
14. Dismounting ...............................................................................................................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
2. Correct Usage in Accordance with Regulations
Softcontrol Smart monitors increased concentrations of residual hardness in soft water of a
connected water softening plant on cation exchange base. It offers a continuous, safe thres-
hold value monitoring with alerting on exceeding. With a fixed hardness threshold value of
10% based on the input water hardness, the device triggers an alarm.
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. 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.
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 had 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 has to 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.
Softcontrol Smart must be operated continuously earthed with a 230 volt 50 Hz
power supply via an earthed electrical power point respectively with the wall
power supply 100 ... 240 volt provided by the manufacturer.
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 possi-
ble.
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
Softcontrol Smart is an online water hardness measuring system for continuously monitoring of in-
creased concentrations of residual hardness in soft water hardness of a connected water softening plant
on cation exchange base.
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 on detected
hardness breakthroughs. With a fixed hardness threshold value of 10% based on the input water hard-
ness, the device triggers an alarm. The determination of the water hardness is possible from 0.18
mmol/l 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 protected against pres-
sure. The measurement cycle can be controlled alternatively by impulses of a connected water meter.
By automatically opening and closing of the upstream stop valves the water samples will be replaced
and rejected free of pressure. With recognition of increased water hardness in soft water or of service
requirements of the hardness measuring system alarm will be signalized.
Measuring functions and their results are represented with colored LEDs.
The measuring system calibrates itself by automatically switching from soft water to raw water at
fixed time intervals.
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. Operational Mode
Time controlled or flow rate controlled measurement / active operation
If the device is not connected to a water meter it operates time controlled and measures con-
tinuously every 15 minutes.
Optional it is possible to connect an external water meter. If the device is recognizing water
meter impulses it changes automatically to a continuous flow rate controlled measurement.
Standby-mode / passive operation
The device is in ready-to-operate status out of operating time. A constant luminescent LED
shows passive operation.
Water hardness alarm/brine-inrush
When water hardness is recognized in the soft water, the optical alarm will be released imme-
diately and the external water hardness alarm will be triggered time-delayed. Furthermore the
device recognizes brine-inrush and signalizes this as brine alarm.
Valve alarm
Leak-tightness of the valves is constantly monitored. Alarm will be signalized with recogniz-
ing valve leakage caused for example of fouling at the valves.
Sensor alarm
The sensor quality is cyclically monitored. Therefore measurements in the samples are real-
ized during this process. The sensor quality will be calculated out off the measured voltage.
Sensor alarm will be signalized if these results do not comply with the defined quality param-
eters.

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9. Installation
9.1. Mechanical Installation
Softcontrol Smart is to install very close to the softening system to be monitored. Installation
is possible as wall or frame mounted device. 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 permanently with a water pressure of minimum 1 bar
up to 10 bars.
Once the area where the unit is to be installed has been selected and prepared the device can
be installed easily.
9.2. Hydraulic Installation
Only after fixing the unit at the wall resp. frame the hydraulic installation of inlets, outlet and
hardness sensor is to carry as following:
1. Install pre-filter according to the flow direction. Flow direction is marked by a pointing
arrow on the filter case. The filter should be installed preferably close to the sample
points to protect also the sample hoses against obstructions.
2. Push raw water hose Ø 4 mm as far as it will go into the plug-in connection „hard water“.
3. Push soft water hose Ø 4 mm as far as it will go into the plug-in connection „soft water”.
4. Push drain hose Ø 8 mm into the angel joint
5. Push sensor cable into the sensor socket
6. Insert sensor straight and pressure safe into the T- fitting
Do not touch or damage the electrodes!
7. Open up streamed raw and soft water stop valve and check leak-tightness of the installed
connections
The system is now subject to water pressure up to the closed valves RW
and WW.
8. If the pressure test is successful, the installation has been completed.
Note:
The pre-filters may not be necessary if existing filter systems (≤ 0.1 mm) are able to remove
dirt which would otherwise reach the sampling valves.

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9.2.1. Scheme hydraulic Installation
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
After realizing the above described installation and succesful hydraulic installation
Softcontrol Smart is ready for operation.
An optional connection of a water meter or an external signal output is possible by using the
provided 5-pin plug adapter.
1
2
3
4
N
ot
e:
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ac
h
te
r
m
in
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is
m
ar
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e
d
w
it
h
a
n
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t
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at
er
Note:
Each terminal is marked with a number!
The groove of the inverse-polarity protection
is to place in the direction of the back panel of
the device.

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9.3.1. External Signaling by potential free contact
The alarm signal will put out at the terminals 1 and 2 of the external 5-pin plug adapter. The
following external electrical requirements must be fulfilled absolutely:
External Requirements: Contact positions in alarm conditions:
Maximum connection voltage: 24 Volt
Maximum current: 0.5 Ampere
The logical behavior is shown in the following table:
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 a continuous monitoring during the soft water sampling and to avoid threshold value ex-
ceeding alarm caused of the so-called „hardness breakthrough“ it is recommend to monitor
the soft water sampling not within fixed time distances. Therefore it is possible to connect a
mechanical or electrical water meter to the device.
9.3.2.1. Connection mechanical water meter
The water meter to be connected must be equipped with potential free contacts. The electrical
connection is to realize at terminal 5/3 of the external 5-pin plug adapter.
9.3.2.2. Connection electronical water meter (turbine with Hall-contacts)
The electronical water meter is to connect at the terminal 3, 4 and 5 of the external 5-pin plug
adapter. Attention should be paid to the correct polarity and prevention of short-circuits at the
terminals of the water meter and the plug adapter.
1 2
Terminal 5 + 5 V
Terminal 4 GND
Terminal 3 Impulse

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10. LED-status and displays of functional status
The functional status and the measuring results are shown by luminescent or flashing LEDs:
All three LEDs are flashing synchronous if the sensor is absent or not correctly installed.
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 is clearly identifiable by its sensor number. Prior to delivery each sensor
has to pas an extensive quality check, where the sensor quality will be checked and docu-
mented.
The sensible part of the sensor is tightly closed with a protective cap to protect the sensor
membrane against interferences and to keep it in a sterile and humid climate. Hereby it is en-
sured that the sensor can be put in operation directly after removing the protective cap.
The sensor system will be supplied in a special folded box. If the protective cap is tightly
closed and with internal humidity a delivery without prejudice is realized. A comparison of
the number on the sensor with the numbers indicated at packaging and delivery note is rec-
ommended.
Further the sensor should be stored in the folded box between 10°C and 15 °C if possible.
Please note:
Up to the time of operation the protective cap has to be kept tightly closed. The humidity pre-
cipitates inside the protective cap and avoids a drying-out of the sensor membrane.
Sensors without tightly closed protective cap dries up fasten and may under certain circum-
stances not operate properly, or may operate with a time distance of 1 - 2 days only.
Basically, the protective cap should not be removed unless for immediate mounting to protect
the sterile and humid internal climate.
Storage in folded box at temperatures between 10°C and 15 °C

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11.2. Operating conditions of the sensor
The quality of the sensor is influenced by water quality, especially contents of precipitation of
iron, high chlorine or brine concentrations and growing bacteria cultures.
The sensor must be replaced not later than signaling „sensor alarm“ by the device.
Required water conditions:
-Natural raw water with a hardness value between 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 has to be free of acids, bases incl. brine and other basic liquids, tensides,
oils, solvents and heavy metals.
11.3. Sensor mounting/Sensor replacement
1. Separate plug-in power supply unit from the power line or interrupt power supply
2. Separate sensor cable from the used up sensor (at sensor replacement)
3. Press down the female adaptor ring at the t-fitting at the measuring chamber in which the
sensor is placed and unplug the used up sensor simultaneously (at sensor replacement)
4. Take the new sensor out of the box and pull it out of the protective cap straightly
Do not touch or damage the sensible sensor part!
5. Push the new sensor firmly in t-fitting of the measurement chamber. Push it straightly in,
to avoid any contact to the pipe wall. Verify that the sensor is firmly in place by pulling it
lightly.
6. Plug the sensor cable on the new sensor (keep inverse-polarity protection in mind)
The sensor cable must engage hearable and tightly!
7. Plug the power supply unit in resp. connect the power supply. The device checks the sen-
sor plug-in connection at decommissioning and signals sensor alarm if it not recognizes
the new sensor. In this case disconnect the device once again and check the plug-in con-
nection of the sensor.
8. Sensor mounting/replacement has been successfully completed if the device recognizes
the new sensor and starts with 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 an adequate monitoring.
Examples:
Rust- and iron deposits form a light red/brown coating in the flow chamber and the sensor
system
Up streamed filters should prevent from precipitations of iron, copper or aluminium.
Bio film growth in consequence of to high microbial count in the water
Bio films appear highly when the softening plant or the device has been out of operation for
some days or weeks and water was kept in the chamber.
In case of longer immobilization time the device should be electrically disconnected. The
sensor should be removed from the measuring chamber and stored according storage con-
ditions. The measuring chamber should be free of water.
2. Chlorine impact
Chlorine addition, as often seen in raw water supply, may destroy the sensor (depending on
concentration and duration. A strong deep black coloring of the metal electrodes indicates
high chlorine influence. The sensor may indicate threshold value exceeding, while no thresh-
old value exceeding exists.
The sensor is defect and has to be replaced.
3. Brine solution impact
Should the outlet valves of the softening plant be defective, it is possible that during the re-
generation process but even if there is low water throughput, brine from the brine container
may washed out into the soft water, which will be evaluated by the sensor as threshold value
exceeding.
With very high sodium concentration against the calcium-magnesium concentration, the sen-
sor signal will be influenced by the very high sodium content, which creates sensor error. A
high brine concentration can be measured by conductivity difference measurement between
raw and soft water. With an excessively high and concentrated brine impact, the sensor will
be destroyed, whereby it will indicate threshold value alarm even if the softening system op-
erates properly.
The sensor has to be replaced.

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12. Malfunctions and possible causes
Problem
To do
1. Signalization of threshold value exceeding without there being any excessive water
hardness
water through put through measuring
chamber to low
check, that by switched valve water must
flow out of the drain
raw water valve does not close correctly,
(usually due to deposits in valve seat)
leading to small amounts of raw water in
the measuring cell parallel to the soft wa-
ter entry
replace valve
low brine concentration in soft water
rinse active column of softening plant once
again
sensor is soiled or damaged by brine
replace sensor
2. Sensor not recognized
sensor cable is not properly plugged in or
electrical plug-in connection defective
examine the electrical connection between
sensor and device
3. Brine alarm
high brine concentration in the soft water;
conductivity of soft water is much higher
than conductivity of raw water
rinse active column of softening plant once
again
noncontinuous raw or soft water inlet, raw
or soft water does not flow around the
sensor
restore water supply
sensor is soiled or damaged by brine
replace sensor
4. Valves leaking
one of the valves does not close properly
remove the hoses from the measurement
chamber and check, if drop wise water
leaks from the valves, even if the valves are
closed replace affected valve
5. Raw or soft water does not flow
sample inlet closed
check stop valves
pre-filter blocked
clean pre-filter
sample hose blocked
check and clean sample hose
defective valve
replace valve

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13. Decommissioning
For decommissioning of the device the following steps are to realize:
1. Unplug the power supply unit / disconnect operating voltage
2. Close raw and soft water supply manually by the stop valves)
3. If the device should be decommissioned for more than 2 days, remove the sensor.
Protect the sensible sensor part by a protective cap filled with approx. 1 ml raw water.
Store the sensor in a cool (10 … 15°C) and dark place.
14. Dismounting
1. Take the device out of operating as described above
2. Remove the raw and soft water hoses (push the safety ring of the connector down and
pull the hoses out)
3. Disconnect cables for external signal output and/or water meter
4. Dismount the device from the wall/frame

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15. Sensor System
selective sensor for calcium and magnesium ions type 670
16. Accessories
1 supply unit for connection of water flow meter and external signalling
1 m drainage hose ø 6 mm o.d., ø 4 mm i.d.
4 m sampling hose ø 4 mm o.d., ø 2 mm i.d.
2 screw joints 1/4“ to 4 mm hose
2 prefilters 100 µm (optional)