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

SERVICE MANUAL
NON HWS SOFTENERS
ORION II
ORION 500 –6000 Standard Softeners
Page 11 of 31
DOMAON0101 Issue A
June 08
cycle and if not removed may ultimately cause blockage of the bed. It will also assist in
removing any fines resulting from broken resin beads and reclassify the resin bed. The
backwash is controlled by a flow controller which ensures a consistent rate of flow, the
backwash water is then directed to drain via the rinse drain connection. On completion
of the backwashing the resin is allowed to settle.
In the Backwash stage of regeneration the feedwater port will be connected to the
softener outlet port and the softener inlet port will be connected to the drain port. In
addition the feedwater port will be also connected to the product outlet port to allow for
bypass during regeneration.
4.2.2 Brining
A tank TK16-01 or TK16-02 adjacent to the softener(s) contains both sufficient salt for a
number of regenerations and a fixed volume of brine required for each regeneration
cycle. When the MCV moves to the brining position, feed water flows through a venturi
type ejector which draws saturated brine from the brine tank and dilutes the brine to the
required concentration. The brine is then passed downwards through the resin bed. The
effluent contains the hardness ions removed by the resin during the service cycle and
excess brine. This flows up the riser tube through the MCV and out through the drain
connection. When all the brine has been drawn into the softener the float valve
contained in the salt tank will fall closing off the suction line to prevent air being drawn
into the vessel through the venturi ejector.
4.2.3 Slow or Displacement Rinse
After the brining stage the resin beads are rinsed. Water continues to pass through the
ejector and through the resin bed to displace most of the remaining brine in the resin
vessel.
4.2.4 Fast or Final Rinse
Following the pre-programmed brine and slow rinse stage there is a fast final rinse
stage. The MCV changes position to enable a higher flow rate of water to rinse the resin
in a downward direction in order to displace any remaining traces of brine solution which
also flows to drain.
In the Fast Rinse stage the feedwater port will be connected directly to the softener inlet
port. The softener outlet port will again be connected to the drain port to enable fast
rinsing of the softener.
Following completion of the regeneration cycle the softener, will either return to service.
4.2.5 Manual Initiation
Manual initiation of the softeners can be initiated with level 1 security access, which also
allows a step through of the regeneration sequence. There is no step through of salt re-
saturation stage.
Once initiated, the sequence of operations is identical for each softener: -

SERVICE MANUAL
NON HWS SOFTENERS
ORION II
ORION 500 –6000 Standard Softeners
Page 12 of 31
DOMAON0101 Issue A
June 08
4.2.6 Position of the SIATA 132 Valve during Service and Regeneration stages
Orion 500 - 2000
E = Inlet, U = Outlet, S/D = Drain, A.C = Top of Vessel, B.C = Bottom of Vessel

SERVICE MANUAL
NON HWS SOFTENERS
ORION II
ORION 500 –6000 Standard Softeners
Page 13 of 31
DOMAON0101 Issue A
June 08
4.2.7 Pneumatic connections to the SIATA 132 Multiport Valves
Orion 500 –2000
Each Softener (BES) or Carbosoft (CBES) unit contains one SIATA 132 type multiport
valve and one normally closed diaphragm valve. These valves are controlled by
pneumatic pressure via solenoid valves located in the control cabinet.
The Multiport valve can be viewed as two double acting valves located in the same
housing, each of which can be controlled independently. Each valve is supplied with
four pneumatic feed lines, which are colour coded for ease of identification. To ensure
that the valves function correctly It is most important that these connections are fitted to
the correct connection onto each of the valves.
Inlet Outlet
Yellow Blue
Black
Green
The solenoid valves are located in the controls section of the Orion control cabinet.
Each Valve contains a manual override facility. With Instrument air supplied to the Orion
the Softener valve positions can be manually adjusted using the controlling Solenoid
valves.
For further information see control panel pneumatic diagram DOECON1002.
Pneumatic
Tube
Colour
Softener 1
Line Number
Softener 1
Operated by
Solenoid Valve
Softener 2
Line Number
Softener 2
Operated by
Solenoid Valve
Black
0
SV-SOFT1 Port A
5
SV-SOFT4 Port A
Yellow
1
SV-SOFT1 Port B
6
SV-SOFT4 Port B
Green
2
SV-SOFT2 Port B
7
SV-SOFT5 Port B
Blue
3
SV-SOFT2 Port A
8
SV-SOFT5 Port A

SERVICE MANUAL
NON HWS SOFTENERS
ORION II
ORION 500 –6000 Standard Softeners
Page 14 of 31
DOMAON0101 Issue A
June 08
4.2.8 Position of the SIATA 250 Valve during Service and Regeneration stages
Orion 4000 - 6000
E = INLET, U = OUTLET, S/D = DRAIN, A.C = TOP OF VESSEL, B.C = BOTTOM OF VESSEL
NOTE: THE VALVE CONTAINS A BACKWASH VALVE, NOT A P VALVE

SERVICE MANUAL
NON HWS SOFTENERS
ORION II
ORION 500 –6000 Standard Softeners
Page 15 of 31
DOMAON0101 Issue A
June 08

SERVICE MANUAL
NON HWS SOFTENERS
ORION II
ORION 500 –6000 Standard Softeners
Page 16 of 31
DOMAON0101 Issue A
June 08

SERVICE MANUAL
NON HWS SOFTENERS
ORION II
ORION 500 –6000 Standard Softeners
Page 17 of 31
DOMAON0101 Issue A
June 08
4.2.9 Pneumatic connections to the SIATA 250 Multiport Valves.
Orion 4000 –6000
Each Softener (BES) or Carbosoft (CBES) unit contains one SIATA 250 type multiport
valve and one normally closed diaphragm valve. These valves are controlled by
pneumatic pressure via solenoid valves located in the control cabinet.
The Multiport valve can be viewed as two double acting valves located in the same
housing, each of which can be controlled independently. Each valve is supplied with
four pneumatic feed lines, which are colour coded for ease of identification (see below).
To ensure that the valves function correctly It is most important that these connections
are fitted to the correct connection onto each of the valves. For further information see
ORION control panel pneumatic diagram DOECON1002
Outlet Inlet
Yellow
Blue Yellow
Green Black
The solenoid valves are located in the controls section of the Orion control cabinet.
EACH VALVE CONTAINS A MANUAL OVERRIDE FACILITY. WITH INSTRUMENT AIR SUPPLIED TO
THE ORION THE SOFTENER VALVE POSITIONS CAN BE MANUALLY ADJUSTED USING THE
CONTROLLING SOLENOID VALVES.
FOR FURTHER INFORMATION SEE CONTROL PANEL PNEUMATIC DIAGRAM DOEC1002.
Pneumatic
Tube
Colour
Softener 1
Line Number
Softener 1
Operated by
Solenoid Valve
Softener 2
Line Number
Softener 2
Operated by
Solenoid Valve
Black
0
SV-SOFT1 Port A
5
SV-SOFT4 Port A
Yellow
1
SV-SOFT1 Port B
6
SV-SOFT4 Port B
Green
2
SV-SOFT2 Port B
7
SV-SOFT5 Port B
Blue
3
SV-SOFT2 Port A
8
SV-SOFT5 Port A

SERVICE MANUAL
NON HWS SOFTENERS
ORION II
ORION 500 –6000 Standard Softeners
Page 18 of 31
DOMAON0101 Issue A
June 08
5 INSTALLATION
The Softeners are normally supplied mounted on the Orion unit complete with pipe
work.
5.1 INITIAL CHECKS
It is essential that the following Checks and actions be carried out:
All components and media have been supplied and are in a serviceable condition.
Connections of Services. Once the Orion is positioned the following services will
need to be connected. The feed water connection will need to be made to the inlet
connection. Ensure that the feed water meets the minimum specifications required.
Check that pipework and associated tank and pump have been correctly installed,
flushed, sanitised and commissioned before any water is allowed to enter the Orion
unit. Check that the recycle pipe work adjacent to Valve V10-01 is fitted to allow a
minimum flow of softened water to be returned to the feed water tank.
If the Orion is connected directly to a pressurised feed without a break tank and
pump then a suitable anti-vacuum valve and non return valve should be fitted to the
feed water pipe.
Fit a set of Cartridge filters to the Filter housing(s).
Feed water flow, pressure and temperature is within the specified limits for the unit
and is continuously available.
A minimum height of 900 mm is available above the unit to allow access for
Servicing and maintenance.
Slacken the transit retaining straps fitted to each softener.
5.2 DRAIN CONNECTION
Locate the drain connection adjacent to the softeners on the base of the skid. Connect
this to a local gravity drain on the same level as the Orion. If the softener drain is not
immediately adjacent to the softener an air break or tundish should be installed local to
the softener to take away the regeneration and rinse water. The drain connection must
be via an air gap (50mm). It is essential that the softener and pipework are never
subjected to negative pressure (vacuum which could damage the softener vessel.
Check that the drain or gully is capable of taking the effluent flow to drain as stated in
the Technical Data section for the softener being installed.

SERVICE MANUAL
NON HWS SOFTENERS
ORION II
ORION 500 –6000 Standard Softeners
Page 19 of 31
DOMAON0101 Issue A
June 08
5.3 SALT STORAGE TANKS, SALT SATURATORS
Depending on the equipment chosen on of the following Brine Tank options will be
supplied with the unit –
TK15-01
TK16-01 & TK16-02
TK17-01 & TK17-02
Place the tank or tanks as close as possible to the Orion Softeners so that the two brine
draw-off and refill tubes (supplied with the salt tank), can be connected to the ejectors
using the push in type connectors on the brine valves and ejector bodies. Where two
tanks are supplied, one is connected to each softener.
5.4 LOW LEVEL SALT ALARM SWITCHES
Each Brine Tank has a Salt Level Switch –
LS15-01
LS16-01 & LS16-02
LS17-01 & LS17-02
Connect the signal cable to the Switch located in the lid of the salt tank using the cable
connector.

SERVICE MANUAL
NON HWS SOFTENERS
ORION II
ORION 500 –6000 Standard Softeners
Page 20 of 31
DOMAON0101 Issue A
June 08
6 COMMISSIONING AND OPERATING PROCEDURES
Commissioning should normally be carried out by a Veolia Water Commissioning or
Service Engineer.
The Multiport control valves (VA11-03 and VA 11-04) have a serial number label
attached to the inside of the backplate. Valve 1 fits on Vessel 1. Please note this
before removing the valves. The valves should always be refitted onto the correct
vessel.
Mark the position of the control valve relative to the vessel so that it can be refitted to
the same degree of tightness.
6.1 FILLING THE VESSELS
The vessels may be filled at the factory prior to despatch. If they are not, before
filling the vessels, check that the hardness sensor sampler is correctly positioned
in each vessel (see above)
The resin and carbon is supplied in 25 litre/kg polyethylene bags and sufficient is
provided to charge the units.
6.2 MEDIA REQUIRED FOR EACH SOFTENER
See Section 2.3
Always load the resin into a vessel which contains water
When loading a Carbosfoft (CBES option) load the activated carbon first followed
by the activated carbon
6.3 EQUIPMENT REQUIRED
Media loading funnels for 4” diameter vessel openings.
Scoops for loading media.
A white bucket
Personal Protection equipment.
Glycerol
Bungs for Down-tubes
6.4 FILLING THE VESSELS WITH GAC
This section only applies to Carbosoft (CBES) units. For Softeners (BES) see
charging the vessels with softening resin.
The Multiport control valves (VA10-01 and VA10-03) have a serial number label
attached to the inside of the backplate. Valve 1 fits on Vessel 1. Please note this
before removing the valves. The valves should always be refitted onto the correct
vessel.