Veolia Orion II 500 User manual

SERVICE MANUAL
NON HWS SOFTENERS
ORION II
ORION 500 –6000 Standard Softeners
Page 1 of 31
DOMAON0101 Issue A
June 08
Orion II 500 –6000
Non HWS Softener Service Manual

SERVICE MANUAL
NON HWS SOFTENERS
ORION II
ORION 500 –6000 Standard Softeners
Page 2 of 31
DOMAON0101 Issue A
June 08
TABLE OF CONTENTS
1HEALTH AND SAFETY RECOMMENDATIONS.................................................................4
1.1 CHEMICALS...................................................................................................................................... 4
1.2 ELECTRICITY ................................................................................................................................... 4
1.3 EMERGENCY SHUTDOWN ............................................................................................................. 4
1.4 AIR AND WATER PRESSURE ......................................................................................................... 4
1.5 ION EXCHANGE RESINS................................................................................................................. 4
2TECHNICAL SPECIFICATIONS .........................................................................................5
2.1 CAPACITY DATA –SOFTENER OPTION (BES).............................................................................. 5
2.2 CAPACITY DATA –CARBOSOFT OPTION (CBES) ........................................................................ 6
2.3 OPERATING PARAMETERS............................................................................................................ 7
2.4 FEEDWATER LIMITS........................................................................................................................ 8
2.5 SALT SPECIFICATIONS................................................................................................................... 8
3SOFTENER MAIN COMPONENTS.....................................................................................9
3.1 VESSELS .......................................................................................................................................... 9
3.2 SOFTENING RESIN.......................................................................................................................... 9
3.3 GRANULAR ACTIVATED CARBON................................................................................................. 9
3.4 CONTROL VALVES.......................................................................................................................... 9
3.5 CONTROLLER .................................................................................................................................. 9
3.6 SALT STORAGE / BRINE SYSTEM................................................................................................. 9
4PROCESS AND EQUIPMENT DESCRIPTION .................................................................10
4.1 THE SOFTENING PROCESS......................................................................................................... 10
4.2 RESIN REGENERATION................................................................................................................ 10
4.2.1 BACKWASHING........................................................................................................................ 10
4.2.2 BRINING.................................................................................................................................. 11
4.2.3 SLOW OR DISPLACEMENT RINSE.............................................................................................. 11
4.2.4 FAST OR FINAL RINSE ............................................................................................................. 11
4.2.5 MANUAL INITIATION ................................................................................................................. 11
4.2.6 POSITION OF THE SIATA 132 VALVE DURING SERVICE AND REGENERATION STAGES ................. 12
4.2.7 PNEUMATIC CONNECTIONS TO THE SIATA 132 MULTIPORT VALVES.......................................... 13
4.2.8 POSITION OF THE SIATA 250 VALVE DURING SERVICE AND REGENERATION STAGES ................. 14
4.2.9 PNEUMATIC CONNECTIONS TO THE SIATA 250 MULTIPORT VALVES.......................................... 17
5INSTALLATION.................................................................................................................18
5.1 INITIAL CHECKS............................................................................................................................. 18
5.2 DRAIN CONNECTION .................................................................................................................... 18
5.3 SALT STORAGE TANKS, SALT SATURATORS........................................................................... 19
5.4 LOW LEVEL SALT ALARM SWITCHES......................................................................................... 19
6COMMISSIONING AND OPERATING PROCEDURES.....................................................20
6.1 FILLING THE VESSELS ................................................................................................................. 20
6.2 MEDIA REQUIRED FOR EACH SOFTENER................................................................................. 20
6.3 EQUIPMENT REQUIRED ............................................................................................................... 20
6.4 FILLING THE VESSELS WITH GAC .............................................................................................. 20
6.4.1 INITIAL BACKWASHING THE GAC.............................................................................................. 21
6.4.2 GAC COMMISSIONING BACKWASH FLOW RATES....................................................................... 22
6.5 FILLING THE VESSELS WITH SOFTENING RESIN..................................................................... 22
6.5.1 CARBOSOFT UNITS.................................................................................................................. 22
6.5.2 STANDARD SOFTENER............................................................................................................. 23
6.5.3 REFIT VALVES......................................................................................................................... 23
6.6 RINSING THE MEDIA..................................................................................................................... 24

SERVICE MANUAL
NON HWS SOFTENERS
ORION II
ORION 500 –6000 Standard Softeners
Page 3 of 31
DOMAON0101 Issue A
June 08
6.7 CALCULATING THE INTER REGENERATION VOLUMES........................................................... 25
6.8 SETTING / CHECKING THE BRINE VALVE FLOAT LEVEL......................................................... 26
6.9INITIAL FILLING WITH SALT.......................................................................................................... 27
6.10 PRE-SERVICE REGENERATION............................................................................................... 27
7OPERATION AND MAINTENANCE..................................................................................28
7.1 INTRODUCTION............................................................................................................................. 28
7.2 REFILLING WITH SALT.................................................................................................................. 28
7.3 SOFTENED WATER TEST............................................................................................................. 28
7.4 CHANGING THE REGENERATION LEVEL................................................................................... 28
8GENERAL MAINTENANCE..............................................................................................29
8.1 DAILY .............................................................................................................................................. 29
8.2 CLEANING AND SANITISING SOFTENER RESINS..................................................................... 29
9FAULT FINDING PROCEDURE........................................................................................30

SERVICE MANUAL
NON HWS SOFTENERS
ORION II
ORION 500 –6000 Standard Softeners
Page 4 of 31
DOMAON0101 Issue A
June 08
1 HEALTH AND SAFETY RECOMMENDATIONS
Use caution when working on Veolia WaterWater equipment. The following items are
likely to present possible hazards - chemicals, ion exchange resins, electricity, air
pressure and water pressure. Please ensure personnel are familiar with these hazards
and that adequate precautions are maintained.
1.1 CHEMICALS
Salt is the only Chemical used on ORION Softeners systems during normal and it is
added to the Brine Tank(s) for regenerating the softeners
Refer to safety data sheets supplied with the above product and follow the safety
instructions during use.
1.2 ELECTRICITY
The unit must be properly earthed and the correct rated fuses should be fitted. Power
should be switched off at a remote isolator before commencing work on the equipment.
1.3 EMERGENCY SHUTDOWN
In an emergency the system can be shut down using the emergency shut down button
on the control panel to quickly stop the unit, since the Shutdown command on the HMI
touch panel requires a password and therefore time to activate.
1.4 AIR AND WATER PRESSURE
Veolia Water equipment operates at pressure and, where possible, this should be
reduced before commencing work. Normal protection from freezing should be taken, as
ice inside pressure vessels and pipework can cause rupture. Compressed air can be
dangerous and care should be taken with its use.
1.5 ION EXCHANGE RESINS
Proprietary Softening Ion Exchange resins are used in the ORION Softeners.
Refer to safety data sheets supplied with the above products and follow the safety
instructions during use.
IF IN DOUBT FURTHER INFORMATION ON SAFETY CAN BE OBTAINED FROM
THE VEOLIA WATERWATER SERVICE ORGANISATION

SERVICE MANUAL
NON HWS SOFTENERS
ORION II
ORION 500 –6000 Standard Softeners
Page 5 of 31
DOMAON0101 Issue A
June 08
2 TECHNICAL SPECIFICATIONS
2.1 CAPACITY DATA –SOFTENER OPTION (BES)
ORION II Model No.
500&1000
2000
4000
6000
Model Number
Units
80
135
250
350
Multiport Valve Type SIATA
132
132
250
250
Maximum Service Flow
Rate
m3/h
gal/h
3.5
770
5.0
1100
9.5
1717
12.5
3302
Capacity per regeneration
(approx)
kg
4.0
6.75
12.5
17.5
Capacity (at 200mg/l total
hardness as CaCO3)
m3
US gals
15
3300
22.5
4950
63
13,860
88
19,360
Regeneration time -default
(adjustable)
min
79
79
94
94
Maximum effluent flow rate
m3/h
US gpm
1.0
220
1.5
330
3.8
836
5.3
1166
Salt used per regeneration (
adjustable)
kg
9.6
16.2
30
42
Minimum operating pressure
at regen flow
bar (psi)
3 (45)
3 (45)
3 (45)
3 (45)
Maximum operating
pressure
bar (psi)
6 (90)
6 (90)
6(90)
6(90)
Maximum operating
temperature
ºC
35
35
35
35
Salt tank height
Salt tank diameter
mm
mm
1050
490
1050
630
1100
760
1100
760
Salt Tank capacity (approx)
kg
75
125
200
200
Minimum head room
mm
Allow 1000mm above overall height