Thermo Scientific WAE 32-OSD User manual

Operating Instructions
Thermo Scientific Barnstead
Softening system WAE 32/60-OSD
Art. no.: 50140193 (WAE 32-OSD) Art. no.: 50140235 (WAE 60-OSD)
Serial number: ..........................
Be sure to read these instructions before you start to install and operate the system!
Rights to technical changes reserved

Thermo Scientific Barnstead
Softening system WAE 32/60-OSD
1
EC Declaration of Conformity
According to EC Machines Directive 2006/42/EC, Appendix II A
We hereby declare that the design and construction of the machine named below and the
versions of it that we have introduced into the market conform to the fundamental safety and
health requirements of EC Directive 2006/42/EC.
This declaration becomes invalid when changes that do not have our written approval are
made to the machine.
Manufacturer: Thermo Electron LED GmbH
Robert-Bosch-Straße 1
63505 Langenselbold, Germany
Description of the machine:
Function: Softening system for the production of soft water
Type: WAE 32/60-OSD
Article no.: 50140193, 50140235
We also declare that the machine additionally complies with the following
Guidelines/Directives which are valid for it:
EMC-Directive (2004/108/EC)
Harmonised standards applied:
DIN EN ISO 12100-1 Safety of machines, Part 1: Principles
DIN EN ISO 12100-2 Safety of machines, Part 2: Technical guidelines
DIN EN ISO 14121-1 Safety of machines, Part 3: Risk assessment
DIN EN 61326-1
Person responsible for documentation:
Detlef Opp
Stockland 3
56412 Niederelbert
Germany
Niederelbert, 1. April 2013
Detlef Opp, Head of Technical Documentation
Signature

Thermo Scientific Barnstead
Softening system WAE 32/60-OSD
2
Preface
Dear Sir or Madam
You have selected a high quality product with your decision to purchase a WAE 32/60-OSD
softening system.
Thank you for the confidence you have placed in us.
Please read through the information provided in these operating instructions before you begin to
carry out installation and follow it carefully during installation and the subsequent start-up.
This is particularly important as we, the manufacturer, cannot accept liability for any damage
that follows from incorrect installation and/or operation of the system, or from usage of it for
other than the specified intended purpose.
Niederelbert, 01.04.2013

Thermo Scientific Barnstead
Softening system WAE 32/60-OSD
3
Contents
2. Informative notes in these operating instructions......................................5
3. Transport and packaging...........................................................................6
3.1 Examination on receipt.....................................................................................................6
3.2 Complaints .......................................................................................................................6
3.3 Packaging and return shipment ........................................................................................6
4. Extent of delivery.......................................................................................7
5. Safety precautions.....................................................................................8
6. Intended purpose.......................................................................................9
7. Technical specifications...........................................................................10
8. The individual components in detail........................................................13
9. Physical properties of the ion exchange filter material............................14
10. How WAE 32/60-OSD functions............................................................15
11. The installation area..............................................................................16
12. Putting into operation.............................................................................17
13. Hose connections..................................................................................19
14. Filling the salt storage............................................................................20
15. Calculation of the capacity of WAE 32/60-OSD....................................21
16. Operating elements overview................................................................22
16.1 Displays shown –detailed description: .........................................................................22
16.2 Operator keys –detailed description:............................................................................23

Thermo Scientific Barnstead
Softening system WAE 32/60-OSD
4
17. Programming.........................................................................................24
17.1 First programme level....................................................................................................24
17.2 Second programme level...............................................................................................25
17.3 Third programme level ..................................................................................................27
18. Maintenance..........................................................................................29
18.1 Recommended maintenance intervals...........................................................................30
18.2 Disinfection ...................................................................................................................30
19. Waste disposal......................................................................................31
20. Consumable materials and accessories...............................................31
21. Maintenance record ..............................................................................32
20.1 Maintenance record (frequent or irregular work)............................................................33

Thermo Scientific Barnstead
Softening system WAE 32/60-OSD
5
2. Informative notes in these operating instructions
EC Mark of Conformity
Important operating and / or maintenance instructions! Read the
operating instructions with due care.
Risk of electric shock! Only appropriately qualified personnel are to
carry out electrical work on the system.
General information! Particularly important notes are marked with this
information sign.
Only plug the power supply in a socket that makes a protective
connection.
The information given in these operating instructions is only valid for your system with the serial
number that you are to enter on the front page.
Please enter the serial number* of your WAE 32/60-OSD system on
the front page.
* The serial number of your softening system is given on the type plate attached to it.
It is important that you correctly state following information whenever you have queries or order
replacement parts:
- Serial number of the system
- Article number of the system

Thermo Scientific Barnstead
Softening system WAE 32/60-OSD
6
3. Transport and packaging
Softening systems are carefully checked and packed prior to shipment, but damage could
nevertheless occur during shipment.
3.1 Examination on receipt
Check the completeness of the parts received against the delivery note.
Is the packaging damaged?
Examine the system and parts for damage.
3.2 Complaints
When system parts have been damaged during transport:
Contact the post, railway or forwarding agent immediately*.
Save the packaging and the outer cardboard carton (in case of a possible inspection
and/or for return shipment of the system)
3.3 Packaging and return shipment
Use the original packaging and materials if possible,
When these are no longer available:
Pack the system in a suitable plastic bag or sheet and a strong cardboard box so
that it is shock-proof.
* The time limit for claims is 6 days after receipt of the goods.
After this deadline, all rights to claims for damages are invalid.

Thermo Scientific Barnstead
Softening system WAE 32/60-OSD
7
4. Extent of delivery
The following items are included in the extent of delivery of softening system WAE 32/60-OSD:
1 piece WAE 32/60-OSD basic system Article-no. 50138577
or 50138579
- Incl. pre-assembled salt deficiency display Art.-no. 50140438
made up of the following parts:
oFloat switch
oSignal light
oRelay box
1 piece Connection kit for WAE 32/60-OSD Article-no. 50139639
Please compare the items that you have received against the above list.
If an item is missing, please contact the manufacturer.

Thermo Scientific Barnstead
Softening system WAE 32/60-OSD
8
5. Safety precautions
Observe these safety precautions for your own safety!
The exclusive purpose of your WAE 32/60-OSD softening system is to soften drinking
water.
Do not start to install or operate the system until you have taken notice of the
appropriate information given in these operating instructions.
Two people are required to lift and carry the softening system (to the installation
location, for example). Take hold of it at the corner points under the base plate.
Please note that the manufacturer is not liable for damages resulting from a use other
than the intended purpose or improper operation.
The CE-Mark is invalidated when constructional changes are made to the system or
products from other manufacturers are installed in it.
Protect the system from frost. The temperature in the area in which the system is
installed must be at least +2° C and is not to exceed +40° C.
Observe all applicable general regulations and requirements that apply at the
installation area, including accident prevention regulations.
The raw water pressure must be at least 2 bar and not more than 6 bar. If the raw
water pressure is higher, install an additional pressure reducing valve.
Water purification systems must be equipped with a safety device acc. to DIN EN
1717 to protect the tap water line from contamination.
A 230V, 50Hz socket with a protective contact must be made available.
The installation area must have a free running floor-level drain of at least DN 50 (38.5
internal diameter). When such a drain is not available, we recommend that you install
a water watcher (article no. 16.0129), otherwise the manufacturer will not accept any
liability for damage caused by water.
Gravity flow to the waste water system is to be ensured.
Position the system so that operation of the voltage network separation device is not
impaired.
Ensure that there will be sufficient working room around the system for unproblematic
operation of it when selecting the installation area.
The warranty is valid for a period of 12 months.

Thermo Scientific Barnstead
Softening system WAE 32/60-OSD
9
6. Intended purpose
The requirements made on the quality of ultra pure water are continuously increasing and
greater sophistication of technologies has reduced detection limits to extremely low values.
Together with the demand for user-convenient systems and complete solutions, these were the
decisive factors for the development of the novel softening system.
WAE 32/60-OSD is specifically designed for preparing soft water from drinking water and is
complete with an integrated salt deficiency display and disinfecting chlorine cell.

Thermo Scientific Barnstead
Softening system WAE 32/60-OSD
10
7. Technical specifications
Raw water quality required
Source
Drinking water acc. to DIN 2000.
Maximum raw water hardness
45 °dH*
Total content, iron and manganese
< 10 mg/L
Manganese content
< 2 mg/Litre
TOC content, max.
10,000 ppb
Total salt content, max.
4,000 mg/L **
Oil content
Oil-free
Chlorine content
< 0.2 mg/L
* 1°dH = 1.25°e (English) = 17.8 ppm
(American)
** = approx. 5970 µS/cm
Technical specifications
Operating pressure
min. 2 bar, max. 6 bar
Feed water pH
5 –9
Temperature range
min. 1°C, max. 40°C
Service life
approx. 250,000 regeneration cycles
Salt concentration during regeneration
approx. 8-15% (acc. to DIN EN973)
Salt type
Sodium chloride salt tablets or broken salt acc. to DIN
EN 973 (never use loose salt!)
Salt required for one regeneration
approx. 240 g. NaCl per litre of resin filling
Wastewater from one regeneration
approx. 10 x quantity of resin filling
Regeneration time
approx. 1 hour
Back rinsing space
20-40% of the resin bed height
Flow rate WAE 32/60-OSD
approx. 0.5 m³/hour
Harz content WAE 32 OSD
8 Litre
Harz content WAE 60-OSD
15 Litre
Dimensions
WAE 32 OSD
WAE 60-OSD
Height
670 mm
1115 mm
Width
320 mm
320 mm
Depth
500 mm
500 mm
Weight:
16.5 kg
27 kg
Water connections
Raw water inlet
R ¾“
Soft water outlet
R ¾“
Rinse water outlet
Hose connection nipple (1/2”)
Brine compartment overflow
Angled hose connection nipple (1/2”)

Thermo Scientific Barnstead
Softening system WAE 32/60-OSD
11
Electrical connections
Input voltage
AC 230V, 50Hz
Protection class
Class II
Ambient conditions (DIN EN 61010-1 (VDE 0411-1):2011-02)
Usage
Indoors
Altitude
up to 2000 m
Temperature range
5° C to 40° C
Relative humidity
Highest relative humidity 80 % at temperatures of up
to 31° C, linearly decreasing to 50 % relative humidity
at 40° C
Line voltage fluctuation
not more than ± 10 % of the nominal voltage
Transient overvoltages
as commonly occur in the supply network
(overvoltage category II acc. to IEC 60364-4-443)
Note: The nominal level of the transient overvoltage
is the withstanding impulse voltage acc. to
overvoltage category II acc. to IEC 60364-4-443
Ventilation requirements
No particular requirements.
Degree of pollution
2
WAE 32 OSD

Thermo Scientific Barnstead
Softening system WAE 32/60-OSD
12
WAE 60 OSD
Dimensions - Connections - Hose connections
WAE 32 OSD WAE 60 OSD

Thermo Scientific Barnstead
Softening system WAE 32/60-OSD
13
8. The individual components in detail
The suction lance in
detail:
A small ball in the intake strainer
blocks the suction hose, when
brine is no longer available. The
system then switches
automatically to a slow rinsing
mode.
During the re-filling of water into
the brine compartment, the
safety float switch effectively
prevents overflowing of the tank.
Alarm lamp of the salt
deficiency display:
The red alarm lamp lights up
when the stock of salt goes
below approx.40%.
More salt must soon be filled
into the salt storage tank.
Float switch of the salt
deficiency display (similar
to photo):
The float switch is installed in
the brine compartment. In
normal operation it is in an
inclined position with the
connecting cable down
between the salt tablets. It
sinks down when these
dissolve. At a certain position,
the switch sends a signal
which triggers the alarm
lamp.
Relay box of the salt
deficiency display:
The relay box is firmly attached to
the back of the softening system. It
serves, among other, as central
voltage supply of the unit.
Both the float switch and the control
head transformer are firmly
connected here. The alarm lamp is
connected via a reverse polarity
and water protected plug.
Digital control
head
(Details see p.22,
Chapter: 16. Operating
elements overview)
Brine suction pipe:
Protects both suction lance and
float switch from blockage by
lumps of salt.
GFRP pressure tank:
contains the resin filling
fillingHarzfüllung
Housing of
WAE 32/60-OSD:
Holds all
components and
serves as salt
storage tank
Suction lance with safety float switch and
check valve (Details below)
Alarm lamp of the
salt deficiency
display (Details below)
Cap of brine
suction pipe
Lid of brine
compartment
container
Dust cover

Thermo Scientific Barnstead
Softening system WAE 32/60-OSD
14
9. Physical properties of the ion exchange filter material
Strong acidic cation exchanger
Appearance:
Mixture of white, light brown and dark brown grains of
resin
Weight: 0.73 kg/dm³
Grain size: 0.3-1.2 mm
Capacity:
WAE 32 OSD 3.2 m³ at 10°dH
WAE 60 OSD 6.0 m³ at 10°dH
Iron (Fe) 1.0 g/litre resin
Manganese 0.5 g/litre resin
TOC 0.5 g O2/litre resin

Thermo Scientific Barnstead
Softening system WAE 32/60-OSD
15
10. How WAE 32/60-OSD functions
Softening systems of the WAE 32/60-OSD series convert drinking water to soft water. For this,
the drinking water must flow into the system at a pressure of between the minimum and
maximum values of 2 to 6 bar.
When the system duly functions, the typical remaining hardness at the system outlet is <1°dH;
<1,25e; <17,8ppm.
Drinking water enters the system at the inlet. It flows through the control head and down into the
GFRP cylinder which is filled with strong acid cation exchanger resin. This resin is pre-loaded
with Na+ions which exchange with Ca2+ and Mg2+ ions (so-called hardness formers) during the
flow of water flow through it.
The hardness formers are firmly held by the resin, so that the result of this process is water at
the softening system outlet that is free of them. It is accordingly called soft water.
The ion exchange resin in the flask is exhausted when it is completely loaded with Ca2+ and
Mg2+ ions and no further Na+ions are available for the production of soft water. It must now be
regenerated.
The control head that has been programmed with details of the condition of the local water
during installation subsequently, completely and automatically steers the regeneration cycle.
The user must only fill regeneration salt for the re-loading of the resin with Na+ in the system at
regular intervals.
A special feature of the WAE 32/60-OSD softening system series is the factory installed salt
deficiency display. This triggers an alarm via the signal lamp that is supplied when the salt
filling level is down to approx. 40% of the maximum volume.
The system is also equipped with an integrated “chlorine cell”. This electrochemically generates
chlorine from a part of the saline solution used in the regeneration process. The chlorine that is
produced disinfects the resin bed during regeneration and so minimizes bacterial growth.
This disinfecting function additionally acts together with a valve to provide a so-called holiday
setting. When the system determines that no water has been withdrawn for 4 successive days,
regeneration is automatically triggered. When no water is withdrawn during the following 4 days,
the process is repeated and now stops in the disinfection step of the regeneration programme.
Regeneration is automatically ended as soon as a water usage is registered.
CAUTION: Connected equipment could be briefly supplied with hard water
during automatic quantity controlled regeneration and/or in the course of
the holiday setting of the valve!

Thermo Scientific Barnstead
Softening system WAE 32/60-OSD
16
11. The installation area
The following criteria are to be considered in your selection of the installation area:
The temperature in the room where the system is used must be in the +2°C to +40°C
range.
A floor drain of size at least DN 50 is to be planned. A water watcher (article no.
16.0129) must be installed for flooding protection when no such drain is available!
A free gravity flow of rinse water to the drainage system must be available.
A socket for the voltage given on the type plate of the system must be situated
immediately alongside the system. The protection of it must be appropriate for the power
requirements given in the technical specifications.
There must be sufficient working room for installation and operation of the system.
A raw water connector (R ¾“) that can be shut off must be installed in the direct vicinity
of the system.
A waste water connector must be available in the immediate vicinity of the system.
Easy access must be ensured.

Thermo Scientific Barnstead
Softening system WAE 32/60-OSD
17
12. Putting into operation
1. Ensure that the position planned for your WAE 32/60-OSD softening system is level,
secure and stable.
2. All hose connections must fulfil current regulations. The internal diameter of the waste
water hose must be at least 13 mm (1/2"). When this hose is longer that 6 m, the
minimum diameter is 19 mm (3/4").
3. Soldering work on the piping and waste water connection must be carried out before
you install your WAE 32/60-OSD softening system, otherwise the system could suffer
irreparable harm.
4. Prior to connecting the WAE 32/60-OSD, open the water mains connection to rinse
soldering residues and foreign matter out of the piping.
5. After this rinsing, close the water supply, the rinsing duct and the overflow (see p.19,
Chapter: 13. Hose connections). As next step, close off the soft water outlet, whereby
the use of a separate shut-off valve is recommended for this.
6. Slowly open the water supply to the WAE 32/60-OSD and leave the outlet of it closed
until water stops flowing.
7. Now carefully open the softening system outlet so that air can completely escape out of
the glass fibre reinforced filter housing.
8. Before you connect the softening system to the power supply system, fix or position the
alarm lamp so that it is easily visible. Fixing material for this is supplied in the extent of
delivery. Subsequently connect the alarm lamp by plugging the reverse polarity and
water protected plug in the socket intended for it at the underside of the relay box that is
at the back of the system.
CAUTION: Normally, when connection is made between the power supply system
and the mains, the alarm lamp should light up, as the float switch is now hanging
in the compartment.
9. Connect the softening system to the power supply system and carry out the basic
programming (see p.24, Chapter: 17. Programming) of the control head. Following this,
enter the correct time of day (use the control head arrow keys for this).
10.Fill the brine compartment up to a height of approx. 6 to 7 cm with water, but do not yet
fill any salt in!
11.Press and hold the regeneration key ““for longer than 5 seconds to trigger manual
regeneration and allow the first step (salting) to run to completion. This first step is an
absolute must for your WAE 32/60-OSD softening system, as the water that was filled
into the brine compartment has now reached its minimum level. This allows a simple
control of the final water level after the ending of the last regeneration step, that should
be “>15cm”(without salt).
12.Allow the regeneration to carry on running until the third regeneration step (back rinsing)
has come to an end. The resin in the glass fibre reinforced filter housing must be rinsed
to remove small dirt particles.

Thermo Scientific Barnstead
Softening system WAE 32/60-OSD
18
13.When the third step has been completed, the 4th and 5th regeneration steps can be
skipped. In each case, do this by pressing the regeneration key ““when the
numbers in the display have stopped flashing.
14.In the 6th step that follows (re-filling the brine compartment with water), wait until the
control head returns to its stat position and then please check the water level in the brine
compartment. It should be “>15cm”. A higher water level is unproblematic. When the
level is lower, however, the programmed time for re-filling (regeneration step „6“) must
be increased a little, which means that the steps 9 to 13 must again be gone through.
This procedure must be repeated until the set filling time results in there being sufficient
water in the compartment.
15.Lift the float switch for the salt deficiency display up and out of the brine compartment
and fill in salt tablets or broken salt acc. to DIN EN 973.
CAUTION: Please never use fine grained salt! It damages the valves!
16.Position the float switch at an incline with the cable down between the salt tablets and
ensure that it is firmly seated. This guaranties optimal functioning of the salt deficiency
display (see also p.20, Chapter: 14. Filling the salt storage). The alarm lamp of the salt
deficiency display should no longer light up.
17.After you have checked the operating parameters, and have possibly re-programmed
them, your WAE 32/60-OSD is ready for use in automatic operation following connection
to an instrument that is to be supplied with soft water.

Thermo Scientific Barnstead
Softening system WAE 32/60-OSD
19
13. Hose connections
Soft water outlet of the
softening system with attached
brass adapter (article
no.:14.5058, contained in the
installation kit).
Feed water inlet of the
softening system with attached
brass adapter (article
no.:14.5058, contained in the
installation kit).
Softening system rinsing
connector connected to a
funnel siphon with free
gravity flow. The hose is
secured by means of a
worm thread clamp that is
supplied in the installation
kit.
Overflow connector of the brine compartment
connected to a funnel siphon with free gravity
flow. The hose is secured by means of a
worm thread clamp that is supplied in the
installation kit.