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

SERVICE MANUAL
NON HWS SOFTENERS
ORION II
ORION 500 –6000 Standard Softeners
Page 6 of 31
DOMAON0101 Issue A
June 08
2.2 CAPACITY DATA –CARBOSOFT OPTION (CBES)
ORION II Model No.
500&1000
2000
4000
6000
Model Number
Units
80
135
250
350
Multiport Valve Type
132
132
250
250
Maximum Service Flow
Rate
m3/h
US gal/h
3.5
925
5.0
1321
9.5
1717
12.5
3302
Capacity per regeneration
(approx) as CaCO3
kg
3.0
4.5
8.1
12.9
Capacity (at 200mg/l total
hardness as CaCO3)
m3
USgals
15
3960
23
6075
48
12680
64.5
17040
Regeneration time -default
(adjustable)
min
79
79
94
94
Maximum effluent flow rate
m3/h
gpm
0.9
4
1.1
5
2.3
10
3.4
15
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
90
90
90
90
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

SERVICE MANUAL
NON HWS SOFTENERS
ORION II
ORION 500 –6000 Standard Softeners
Page 7 of 31
DOMAON0101 Issue A
June 08
2.3 OPERATING PARAMETERS
ORION II MODEL
500 &1000
2000
4000
6000
Model Number
Units
80
135
250
350
Max service flow rate (each unit)
m3/h
3.5
5.0
9.5
12.5
Resin volume ( BES)
litres
80
135
250
350
Resin volume (CBES)
litres
50
75
135
215
Activated Carbon Volume (CBES)
litres
30
55
45
56
Activated Carbon Weight, dry
kg
14
25
100
125
Backwash flowrate, nominal
l/min
16
24
32
44
Backwash time, default *
min
5
5
5
5
Backwash volume
litres
80
120
160
220
Motive/slow rinse flow rate - at 3 bar g ( approx)
l/m
4
7.5
17.0
17.0
Brine suction flow rate at 3 bar g (approx)
l/m
2
4.5
8.0
8.0
Salt used/regeneration
kg
9.6
13.5
30
42
Brine volume/regen - saturated
litres
34
58
107
150
Brine volume/regen - diluted
litres
103
155
321
450
Brine Draw + Slow Rinse time, default*
min
57
57
72
72
Slow rinse volume (approx.)
litres
160
270
1224
1224
Fast rinse flowrate- at 3 bar g (approx.)
l/min
16
24
63
88
Fast rinse time (approx) Default*
min
17
17
17
17
Fast rinse volume (approx.)
litres
272
405
1071
1496
Total regeneration effluent volume to drain (approx.)
litres
615
950
2776
3190
Total regeneration time *(approx.)
min
79
79
94
94
*Note: Regeneration Stage times are fully adjustable can be reconfigured from the
default stage times on the HMI softener screen if required.

SERVICE MANUAL
NON HWS SOFTENERS
ORION II
ORION 500 –6000 Standard Softeners
Page 8 of 31
DOMAON0101 Issue A
June 08
2.4 FEEDWATER LIMITS
Potable or drinking water
Free from organics, colloids and suspended matter
Pressure (bar)
4 to 6
Temperature 0C
5 to 30
Total Dissolved Solids mg/l
<1500
Total Hardness mg/l as CaCO3
<500
Free Chlorine mg/l
<0.02 (BES option) <0.2 (CBES option)
Iron mg/l
<0.2
Manganese mg/l
<0.1
Where the feed water total hardness exceeds this limit please contact Veolia Water for
advice.
2.5 SALT SPECIFICATIONS
In order to ensure optimum performance from the water softener it is important to
always use a high quality salt (Sodium Chloride, [NaCl]) for regeneration. Only
compacted (tablet) salt for use in water softeners should be used in the saturator.
Property
Specification
NaCl
>99.75%
Insoluble matter
<100mg/l
Alkalinity as Na2CO3
<150mg/l
Sulphate as Na2SO4
<600mg/l
Calcium
<100mg/l
Magnesium
<1mg/l
Cadmium
<0.2mg/l
Arsenic
<0.5mg/l
Copper
<0.5mg/l
Lead
<0.2mg/l
Mercury
<0.05mg/l
Iron
<5mg/l
USE High Quality Tablet Salt such as Elga part number CHGURG0111 –25kg bag.
Granular Salt can be used if a Salt bag is fitted into the Brine Tank.
DO NOT USE Vacuum Salt.

SERVICE MANUAL
NON HWS SOFTENERS
ORION II
ORION 500 –6000 Standard Softeners
Page 9 of 31
DOMAON0101 Issue A
June 08
3 SOFTENER MAIN COMPONENTS
3.1 VESSELS
Free standing glass reinforced plastic (GRP), high density polyethylene lined
composite vessel. The vessel holds the Softening Ion exchange resin in BES Models
and both Softening Ion exchange resin and Granular Activated Carbon in CBES models
3.2 SOFTENING RESIN
A charge of premium grade uniform bead size, strong acid cation resin. This will either
be loaded into the vessels or supplied in 25 litre bags, packed on a pallet.
3.3 GRANULAR ACTIVATED CARBON
A charge of premium grade Coconut shell GAC for removal of Free Chlorine. CarboSoft
units have some of the softening resin replaced with GAC, which is loaded into the
vessel below the resin.
This will be supplied in 25kg bags, packed on a pallet
3.4 CONTROL VALVES
All models use a top mounted glass filled ABS multiport control valve (MCV) a SIATA
type 132 valve on Orion Models 500-2000 and SIATA type 250 valve on Orion Models
4000 –6000. The valve is mounted directly onto the top of the resin vessel and is used
to control the regeneration processes.
A normally closed diaphragm valve is used on each unit to by pass the softener that is
being regenerated.
3.5 CONTROLLER
The softeners /CarboSofts are controlled from the central PLC. The valves are
controlled pneumatically by 24V solenoid valves located in the control cabinet
3.6 SALT STORAGE / BRINE SYSTEM
Polyethylene tanks complete with brine level control valves, grids and overflow
connections and protective lids serves as both a salt storage compartment and salt
saturator. Each Softener is supplied with one complete system, which includes low salt
level switches, which produces an alarm on the HMI when the Salt level is low.

SERVICE MANUAL
NON HWS SOFTENERS
ORION II
ORION 500 –6000 Standard Softeners
Page 10 of 31
DOMAON0101 Issue A
June 08
4 PROCESS AND EQUIPMENT DESCRIPTION
Each Orion is fitted with two softeners. These are designed to be fed with a pressurised
supply of Potable water. Under normal operation the two units operate in series. When
a unit is regenerated it is taken out of service during the regeneration process an
internal by- pass in the Multiport valves (MCV), (VA10-01 and VA 10-03) allows both the
regeneration of one unit and a continuous supply of softened water to be supplied
simultaneously. The softened water is filtered by being passed through a 5 micron
cartridge filter F11-01 and is then fed into the tank TK30-01 via the control valve V30-
10. .
4.1 THE SOFTENING PROCESS
Feed water is supplied to the unit at a pressure of 3-6barg.During the service cycle of
each softener hard water is fed under pressure into the inlet connection of the multiport
control valve (MCV), VA10-01 which is part of SOF10-01. The water flows through this
valve and its associated filter into the vessel containing the softening ion exchange
resin. As the water flows down through the resin bed the hardness ions of calcium and
magnesium are exchanged onto the resin and sodium ions are released into the water.
The softened water is collected through a resin-retaining filter, located at the bottom of
the vessel, connected to a riser pipe, which is connected to the valve. The softened
water flows up the riser pipe through the MCV and leaves the unit by passing through
the service outlet connection. When both softeners are in normal service the water then
passes into SOF10-02 in a similar way to the above process.
A preset capacity is programmed into the PLC as determined by the total hardness
concentration in the feed water. This is converted to volumetric capacity. The lead unit‟s
cycle is primarily controlled by volume throughput as measured by the flow meter FT10-
02 and transmitted to the PLC. If after a preset time period the unit has not regenerated,
then a regeneration cycle will be initiated.
The second, trail unit will be regenerated based on the frequency of regeneration of the
lead unit. This will normally be every 2nd or 3rd regeneration depending on the hardness
loading.
4.2 RESIN REGENERATION
The ion exchange resin regeneration cycle consists of a number of timed stages, all of
which are controlled by the PLC via solenoid valves and the MCV.
During the regeneration of, Softener No 1, bypass valve VA10-02 is open and for
softener No2 pass valve VA10-04 is open.
4.2.1 Backwashing
Feed water is passed in the opposite direction through the resin or resin and GAC bed
to that of the service cycle. Water is fed down the riser tube through the bottom filter
and up through the media. The media is fluidised and expands. The backwashing
process removes any dirt which may have collected on the resin bed during the service