Multi-functional Flow Control Valve for Water Treatment Systems Hankscraft Runxin RevV22

Transcription

1 Multi-functional Flow Control Valve for Water Treatment Systems Hankscraft Runxin RevV22 Instruction Manual Please read this manual in detail before using the valve and keep it in a safe place for future reference. I

2 Before the valve is put into use, please fill in the below content. Softener System Configuration Tank Size: Dia. in/mm, Height in/mm; Resin Volume ft 3 /L; Brine Tank Capacity L; Hardness of Raw Water grains/mmol/l; Pressure of Inlet Water psi/mpa; Control Valve Model ; Serial Number ; (13 digit number found on valve body) Specification of Drain Line Flow Control ; Injector No. ; Injector Color ; Water Source: Ground-water Filtered Ground-water Tap Water other. Quick conversion table 1 inch 25.4 mm 1 ft 3 (of resin) L 1 kg 2.2 lbs. 1 gal 3.79 L 1 m 3 /h (per hour) 4.4 gal/m (per minute) 1 gpg 17.1 mg/l or (ppm) Parameter Set Parameter Unit Factory Default Actual Value Control Mode A-01 (02,03,04) A-01 Water Treatment Capacity (Meter type) m 3 80 Service Days (Time clock type, by days) D. 03 Service Hours (Time clock type, by hours) H. 20 Regeneration Time Hr:Min Backwash Time Min. 10 Brine & Slow Rinse Time Min. 60 Fast Rinse Time Min. 10 Brine Refill Time Min. 05 Interval Regeneration Days D. 30 Output Mode b-01 (02) b-01 If there is no special requirement when the product is purchased, the #3 drain line flow control and #3 injector (yellow), is used for standard configuration. II

3 Notice Product Overview Main Application & Applicability Product Characteristics Service Condition Product Structure and Technical Parameters Installation Basic Setting & Usage The Function of PC Board Basic Setting & Usage Applications Flow Chart The Function and Connection of PC Board A. Signal Output Connector B. Interlock C. Pressure Relief Output D. Remote Handling Connector E. Interlock System F. Series System System Configuration and Flow Rate Curve Parameter settlement Parameter Enquiry and Setting Trial Running Trouble-shooting Assembly & Parts III

4 Preface Thank you for choosing this Hankscraft Runxin water softening system for your water treatment needs. Please read this manual carefully before attempting to use the system for the first time, and ALWAYS adhere to all safety and operating instructions. Doing so will protect your warranty and help keep your system running and operating safely and effectively. ***Before installing, read through this manual thoroughly. Failure to use this product within the described conditions may void the warranty*** All plumbing and electrical work should be performed by an accredited professional to ensure all local, municipal, state, and federal guidelines are met. Do not use the control valve with water that is unsafe or of unknown quality. This system does not sanitize or disinfect. Do not use the brine tube, injector body, or other connectors on the RevV valve as a handle to carry the system. Ensure there is salt in the brine tank at all times when this valve is used for softening. The brine tank should contain clean water and pellet softening salt only, at least 99.5% pure. The use of small grain or solar salt is not recommended. When there is moderate to high turbidity, a filter should be installed before the water softening system on the inlet side. If the water pressure exceeds 120psi, a pressure reducing valve must be installed before the water inlet. If the water pressure exceeds 80 psi, installing a pressure reducing valve before the water inlet is highly recommended. If the water pressure is under 21psi, a booster pump must be installed before the water inlet. Replacement parts for the RevV valve should only be purchased through Hankscraft resellers. Electrical components such as transformers are specific to the RevV valve from Hankscraft. Regular interval monitoring of the water quality and work environment is recommended to insure proper operation of the valve and system. 1. Product Overview 1.1. Main Application & Applicability Used for softening, demineralization or filtration water treatment systems RevV 22 (Down-flow regeneration) suitable for Ion exchange equipment, the raw water hardness 6.5mmol/L. Boiler softening water system RO pretreatment softening system, etc. (Filtration), suitable for swimming pool filter system. Filtration system Activated carbon filter or sand filter of RO pretreatment system. 1

5 1.2. Product Characteristics Hankscraft RevV22 Rotary Valve Manual Overview The advanced design incorporates a microcomputer control that analyzes real-world operating conditions and performs regeneration automatically. This unique control valve features highly polished, patented ceramic discs. The design incorporates one fixed and one moving disc, which rotates through positions to align channels creating five different fluid pathways. These five pathways, or stages, are: Service, Backwash, Brine & Slow Rinse, Brine Refill, and Fast Rinse. Two Installation Options Use side-mounted connector to change the valve from a top-mounted to side-mounted system. Screen is moveable. Brine refill controlled by electronic ball valve. During service, electronic ball valve will trigger the brine refill. For filtration system Drain outlet will be the same size as the (product water) outlet. Block the brine line connector to change the valve to a filter. Manual function Regeneration can be prompted by pressing at any time. Extended power outage If there is a power outage of more than 72 hours (3 days), the time of day indicator will flash to remind the end user to reset the current time of day. The other set parameters will not need to be reset. The system will resume working after power is restored. LED dynamic screen display Moving (green) display bar indicates the control valve is in service, otherwise, it is in the regeneration cycle. Buttons lock If the display board is not in use for more than 1 minute the buttons will lock. A light indicating this will appear. Before operating again press and hold the and buttons for 5 seconds to unlock. This function can deter unintended valve operation. Program model selection Press and hold and buttons for 2 seconds, after reconnecting the power, the model will be visible on the display board, all the icons will light up, indicating access to the model setting interface. Press to navigate to specific model, then press to save the chosen settings. or 2

6 Interlock function The interlock function is designed to have only one valve in regeneration, at a time, while multiple other valves are in service in a parallel valve system. In multi-step treatment systems such as RO pre-treatment, when several valves are in series, there is only one valve in regeneration or washing to ensure soft product water at all times (Application refer to Figure 3-9). Signal output There is a signal output connector on the main control board. This connector is designed to control external devices (Refer to Figure from Figure3-1 to Figure 3-8). b-01 and b-02 output modes: b-01: a signal that is sent through the entire duration of cycles during regeneration. In this mode, the signal can be sent once per cycle; b-02 Mode: the signal is sent at the end of one cycle and at the beginning of another. In this mode, the signal is sent five times per one complete cycle. Remote handling connector This valve has a remote handling connector. An external device which can determine when water quality is below desirable levels. When this occurs, the valve has the capability to respond to a remote signal and regenerate (Application refer to Figure3-11). Pressure relief output The valve will cut off feed water to the drain line when it switches in regeneration cycles (Same as signal output b-02). Some water treatment system, e.g. Deep Well, have a booster pump installed on the inlet to increase the system feed water pressure; this cut-off will prevent pressure on inlet from rising too quickly, potentially preventing damage to the valve. Pressure Relief Output can be used to avoid this problem. (For application refer to Figure3-10) All parameters can be modified Depending on the water quality and usage, the parameters in the system can be adjusted. Softener type(s) that can be selected (RevV 22) Model Name Meter A-01 Delayed Meter A-02 Immediate Intelligent A-03 Meter Delayed Intelligent A-04 Meter Immediate Instruction Regeneration happens when the capacity reaches zero and the preset time of regeneration is reached. Regeneration happens when the capacity reaches zero. Meter Delayed Regeneration type, but by setting Resin Volume, Feed Water Hardness, Regeneration Factor, the controller will calculate the System Capacity. Regeneration mode is the same as A-01. Meter Immediately Regeneration Type, but by setting Resin Volume, Feed Water Hardness, Regeneration Factor, the controller will calculate the System Capacity. 3

7 Maximum interval regeneration days System will automatically regenerate even if the water capacity was not reached in the time allotted. (Set on site) 1.3. Service Condition Hankscraft valve(s) should be used under the below conditions: Items Requirement Working conditions Working environment Inlet water quality Water pressure Water temperature Environment temperature Relative humidity Electrical facility Water turbidity Water hardness Free chlorine Iron MPa~0.6MPa (29-87psi) 5 ~50 (41⁰F-122⁰F) 5 ~50 (41⁰-122⁰F) 95% (25 ) (77⁰F) AC100~240V/50~60Hz Softener < 5FTU; Filter < 20FTU First Grade Na + < 6.5mmol/L; Second Grade Na + < 10mmol/L < 0.1mg/L or ppm < 0.3mg/L or ppm CODMn < 2mg/L (O 2) In the above table, First Grade Na+ represents First Grade Na+ Exchanger. Second Grade Na+ represents Second Grade Na+ Exchanger. When the water turbidity exceeds the conditions, a filter should be installed on the inlet of control valve. When the water hardness exceeds the conditions, the outlet water hardness will hardly reach the requirement of boiler feed water (0.03 mmol/l or 0.18 gpg). It is suggested to use a second grade softener Product Structure and Technical Parameters A. Product dimension (The below images are used for reference and are subject to the real product). 4

8 B. Technical parameter Transformer Output: DC24V/1.5A Model RevV 22 Inlet/ Outlet Drain Outlet Brine Line Connector Connector Size Base 2 M 1.5 M 3/4 M 4-8UN NOTE: M Male F Female OD Outer Diameters Riser Pipe 1-1/2"D-GB (Outer diameter 50mm) Flow Rate m 3 (29 psi) 18 (79 gal/m) Remark DF softener, meter type, and time clock type / DF Filter (side mount) 1.5. Installation A. Installation notice Before installation, read all instructions completely. Then obtain all materials and tools needed for installation. The installation of the softening system, pipes, and circuits should be completed by a certified water professional to ensure the valve will function and operate correctly. Perform installation according to the regional pipeline regulations and the specifications of the Water Inlet, Water Outlet, Drain Outlet, and Brine Line Connector. B. Device location 1 The filter or softener should be located close to the drain. 2 Ensure that the unit is installed with enough space for operating and maintenance. 3 Brine tank needs to be close to the softener. 4 The unit should be kept away from heat, and should not be exposed to the elements. Sunshine or rain will cause the system to be damaged. 5 Avoid introducing the system to Acid/Alkaline feed water or Magnetism/vibration, as they may cause the system to malfunction. 6 Do not install the filter, softener, or drain pipeline in areas where temperature may drop below 5, or rise above 50. (41⁰F~122⁰F) 7 Install the system in a location where the risk of loss is minimal, in case of water leaking. 5

9 C. Pipeline installation (RevV 22 top-mounted as an example) 1 Install control valve 2 a. As the Figure 1-1 shows, select a riser pipe that is 50mm OD, glue the riser pipe to the bottom strainer and put it into the mineral tank, cut the excessive tube off that is coming out the top opening of the pressure tank. Plug the riser tube to prevent unwanted minerals. b. Fill the mineral tank with resin, height is according to the design code. c. Attach the top distributor basket to the valve. d. Insert and fasten the riser tube into the control valve. Note: The length of riser tube should not be higher than 2 mm nor lower than 5 mm from the tank s top opening height, and its top end should be rounded to avoid damage of the O-ring inside the valve. Avoid dropping the O-ring from inside the control valve while rotating it on the tank. 3 Install flow meter As Figure1-2 shows, put the sealing ring into the nut of the flow meter, attach it to the water outlet; insert sensor into the flow meter. 4 Pipeline connection a. As Figure1-3 shows, installation of a pressure gauge on water inlet. b. Install sampling valves to inlet, outlet, and pipeline A.B.C.D. c. Inlet pipeline should be parallel to outlet pipeline. Fasten the inlet and outlet pipeline(s) with a fixed holder. 6

10 Note: If making a soldered copper installation, do all sweat soldering before connecting pipes to the valve. Torch heat will damage plastic parts. When turning threaded pipe fittings onto plastic fitting, be sure not to cross thread. If the valve is a time clock type (RevV 22), skip step 2. 5 Install drain pipeline (If no specified requirement, the standard DLFC is No.7703) a. Based on the table on P21, for RevV 22, if tank diameter is 900 mm (35.4 in), install step d. and use the matching DLFC. If the tank size bigger than 900 mm (35.4 in), you need to ask the supplier for another DLFC which doesn t have drill holes. Install it as below indicates. b. According to matched tank diameter size, manufacturer will determine the quantity of the 6 drill holes to use on the corresponding DLFC. c. Insert drain line flow control to drain hose connector, then screw it into drain outlet, and lock it. d. Glue the drain outlet with UPVC (DN40). Put drain outlet pipe to sewer as shown in the Figure 1-4. Note: Control valve should be higher than the drain outlet, and should be separated from the drain hose by at least 2 inches. Be sure not to connect the drain line directly to the sewer to avoid wastewater contamination. 6 Connect brine tube a. As Figure1-5 shows, use UPVC (DN20) to connect brine valve with brine line connector of control valve. Note: Keep brine line short and smooth. Line should not be bent or plugged. Brine valve must be installed. 7

11 2. Basic Setting & Usage 2.1. The Function of PC Board Hankscraft RevV22 Rotary Valve Manual A. Time of day indicator Light on,displays the time of day. Light flashes, reminds you to reset the time of day if electrical service was interrupted for 3 days or more (72 hours). B. Button lock indicator Light on, indicates the buttons are locked. At this time, pressing any button will not work (If the display is not used for 1 minute, will light and lock the buttons.) Solution:to unlock, press and hold both and for 5 seconds until the light turns off. C. Program mode indicator Light on,enter program display mode. Use or to view all values. When flashes, enter program set mode. Press or to adjust values. D. Menu/Confirm button Press, light turns on, enter program display mode and use or to view all values. In program display mode, press, will flash, enter program set mode, press or and adjust values. Press after all programs are set, a confirmation beep will sound meaning all settings are complete; returning to program display mode. E. Manual/Return button 8

12 Press in any status, it will proceed to next cycle. (Example: Press In Service status, it will start regeneration cycles instantly; Press Slow Rinse). while in Backwash status, it will end backwash and go to Brine & Press Press Press in program display mode, and it will return to in Service; in program set mode, and it will return program display mode. while adjusting the value, it will return to program display mode directly without saving value(s). F. Down and Up In program display mode, press or to view all values. In program set mode, press or to adjust values Basic Setting & Usage A. Parameter specification Factory Function Indicator Default Time of Day Random Control Mode A-01 A-01 Parameter set range 00:00 ~ 23:59 A-01 A-02 A-03 A-04 Service Days 1-03D. 0~99 Days Service Hours Regeneration Time 1-20H. 02:00 02:00 Resin Volume 50L. 5000L. Feed Water Hardness 0~99 Hours 00:00 ~ 23: L. Instruction Set the time of day; : flash. Regeneration happens when the capacity reaches zero and the preset time of regeneration is reached. Regeneration happens when the capacity reaches zero. Meter Delayed Regeneration type, but by setting Resin Volume, Feed Water Hardness, Regeneration Factor, the controller will calculate the System Capacity. Regeneration mode same as A- 01. Meter Immediately Regeneration Type, but by setting Resin Volume, Feed Water Hardness, Regeneration Factor, the controller will calculate the System Capacity. Regeneration mode same as A- 02. Only for Time Clock Type, regeneration by days. Only for Time Clock Type, regeneration by hours Regeneration time; : light on Resin volume in brine tank (L) Yd Feed water hardness (mmol/l) 9

13 Exchange Factor AL Water Treatment Capacity 80 m 3 0~ m 3 Backwash Time 10 min. 0~99 Brine & Slow Rinse Time 60 min. 0~99 Brine Refill Time 5 min. 0~99 Fast Rinse Time 10 min. 0~99 Maximum Interval Regeneration Days Output Control Mode H ~40 b or 02 Related to the raw water hardness. When hardness is higher, the factor is smaller. Water treatment capacity per cycle (m 3 ) Backwash time (Minute) Brine &Slow rinse time (Minute) Brine refill time (Minute) Fast rinse time (Minute) Regenerate on the day even though the available volume of treated water did not reach to zero (0). Mode b-01: Signal is sent at the start of regeneration and shuts off at the end of regeneration. (Connection refer to the Figure on P3) Mode b-02: Signal is available only during intervals of the regeneration cycles and in service. (Connection refer to the Figure on P3) B. Process Display Illustration In Service status, shown in figure A/B/C/D; Backwash status, shown in figure E/C; In Brine & slow rinse status, shown in F/C; In Fast Rinse status, shown in figure G/C; In Brine Refill status, shown in figure H/C. In each status, figures are shown for 15 seconds. Above displays are using the Meter Type as an example. For the Time Clock Type, it shows the rest days or hours, such as 1-03D or 1-10H. The display screen will only show -00- when the electrical motor is running. The time of day figure flashes continuously, such as 12:12 flashing, indicates a long outage of power. This is a reminder to reset the time of day. The display will show the error code, -E1- when the system is in error. Working process: Service Backwash Brine & Slow Rinse Fast Rinse Brine Refill Service. 10

14 C. Usage After installation is completed, parameters are set, and a test run is completed, the valve is ready to be put into use. In order to ensure the quality of outlet water, the user should complete the steps below: 1 Ensure that there is solid salt at all times in the brine tank when the valve is used for softening. The brine tank should use softening salts only, 99.5% pure. 2 Test the product water and raw water hardness on a regular basis. When the outlet water hardness is at an undesired level, press the button; the valve will temporary regenerate (It will not affect the original set operation cycle.) 3 When the feed water hardness changes, you can adjust the water treatment capacity as follows: Press and hold both and for 5 seconds to lift the lock status. Press, and the light turns on, then press, the display shows the control mode. If it shows A-01 or A-02, press three times, and the display will show the given water treatment capacity (If the control mode shows A-03 or A-04, then press four times, the display will show the feed water hardness); Press again, light will flash. Press or to change the capacity value (Or water hardness). Press a confirmation beep will sound, finishing the adjustment. Press to exit and return to service status. To estimate water treatment capacity, refer to the manufacturer s specifications. Selecting A-03 or A-04 intelligent control mode, the control will automatically calculate the water treatment capacity by setting resin volume, feed water hardness, and regeneration factors. 4 For A-01 or A-03 control mode (Delayed regeneration type), ensure the time is set correctly. If the time is not correct, you can adjust as follow: After lifting the lock status, press, the and lights turn on. Then press, the light and hour value will flash. Press or to change the hour value; Press again, light and minute value will flash. Press or to change the minute value; Press a confirmation beep will sound, finishing the adjustment. Press to exit and return to service status. The regeneration parameters have been set when the control valve left the factory to default settings or set up on initial installation. Generally, there is no need for it to be reset. 11

15 3. Applications 3.1. Flow Chart For filter valve only has service, backwash and fast rinse The Function and Connection of PC Board Open the front cover of the control valve, you will see the main control board and connection port as seen below: 12

16 Functions on PC board: Hankscraft RevV22 Rotary Valve Manual Function Application Explanation Outlet If the system requires no hard water to flow from solenoid valve outlet or if controlling the liquid level in water tank. Signal output connector b-01 Increase pressure for regeneration or washing. Use Inlet pump the liquid level controller to control inlet pump, ensuring there is water in tank. Signal output connector b-02 Pressure relief connector Interlock connector Remote handling connector Inlet solenoid valve or inlet pump Control the inlet bypass to release pressure To ensure only one control valve is in regeneration at a time in a system. Signal triggers the control to rotate to the next cycle. Used when inlet pressure is high, closes water inlet when valve is rotating to protect motor. When valve is changing cycles, pressure relief connector opens to prevent pressure from increasing too rapidly. Used in RO Pre-treatment, water is supplied simultaneously but regenerate in turn. Also, used in second grade ion exchange equipment, etc. It is used for on-line inspection systems, PC connections, and automatic or remote controlling valve. A. Signal Output Connector 1) Control Solenoid Valve (Set b-01) 1 Solenoid valve on the outlet controls the water level in brine tank. Instruction: If the system requires there to be no hard water flow from the outlet in regeneration cycle (Mainly for no hard water flow out when valve is switching or valve is in backwash or brine drawing positions), a solenoid valve should be installed on outlet, for wiring refer to Figure 3-1. Function: When valve is in service status, if soft water tank is short of water, solenoid valve is open to supply soft water, but if the tank has enough water, solenoid valve is closed, so no soft water is supplied. When the valve is in backwash status, there is no signal output. So, solenoid valve is closed, and no water flows into soft water tank. 2 Solenoid valve on inlet (Set b-02) Instruction: When inlet pressure exceeds (0.6MPa~87psi), install a solenoid valve on inlet. Control mode is b-02. Pressure is relieved when valve is switching to prevent damage, for wiring refer to Figure 3-2. As Figure 3-3 shows, it can also use the pressure relief port to work. 13

17 Instruction: When inlet pressure is high, install a solenoid valve on inlet to ensure the valve can switch properly. When valve is in position for Service, Backwash, Brine & Slow Rinse, Brine Refill and Fast Rinse, solenoid valve is open. When valve is switching between cycles, the solenoid valve is closed, ensuring no water can flow to the valve protecting it from damage during transition. This can prevent water bleed through or water hammering. Use interlock cables to daisy chain valves in parallel, or series, in the same system which is suited for RO pretreatment system or second grade Na + system. For wiring refer to Figure 3-4: 2) Liquid Level Controller controls Inlet Pump (Two-phase motor) (Set b-01) Instruction: For a system using well or middle-tank supplying water, liquid level controller and valve, together, controls pump opening or closing. For wiring refer to Figure 3-5: 14

18 Function: When the valve is in service, if the water tank is short of water, it starts the pump; if the tank has enough water, the switch of liquid level controller is closed, so the pump will not be in operation. When valve is in regeneration, inlet always has water no matter the condition(s) in the water tank. Valve does not pass water through the outlet in regeneration cycle, ensuring no water drains into the brine tank. 3) Liquid Level Switch in Water Tank Controls Inlet pump (Three-phase) (Set b-01) 4) Control Inlet Booster Pump (Set b-01 or b-02) Instruction: If inlet water pressure is less than (0.2MPa~29psi), which makes drawing difficult, a booster pump is suggested to be installed on inlet. Control mode b-01. When the system is in regeneration, booster pump is open, for wiring refer to Figure 3-7. If the booster pump current is higher than 5A, system needs to have a contactor installed. For wiring refer to Figure 3-8 below. 15

19 B. Interlock Instruction: In a parallel water treatment system, to ensure only one valve is in regeneration or washing cycle and (n- 1) valves in service, that is, that the function of supplying water simultaneously and regenerating individually, for wiring refer to Figure 3-9. Note: Use Interlock Cable to connect CN8 to CN7 on next valve in the loop. In a system with several valves, if the interlock cable is disconnected, the system will be divided into two individual systems. C. Pressure Relief Output Valve will cut off feed water to the drain line when it switches in regeneration cycles. In some water treatment system, e.g. Deep Well, one booster pump was installed on the inlet to increase the system water feed pressure. This cut-off will prevent pressure on the inlet from rising too fast, protecting the valve. Pressure Relief Output can be used to avoid this problem. For wiring refer to Figure D. Remote Handling Connector Online TDS meter monitors treated water rather than a flow meter, or PLC controlling the regeneration time. When the controller receives a contact closure from above instruments, regeneration begins. For wiring refers to Figure 3-11: E. Interlock System For 2 or more valves that are interlocked, connected in one system, and when all valves are in service but regenerate individually. For wiring refer to Figure

20 F. Series System This is a 2 or more valve system, all in service, with one flow meter for the entire system. For the time type valve, the regeneration time should be set and adjusted to the Max; for the volume type valve, connect its signal output connector with the remote handle connector of the time-type valve. This provides the function of supplying water simultaneously and regenerating in order. For wiring refer to Figure 3-13: 17

21 3.3. System Configuration and Flow Rate Curve A. Product Configuration Fixed bed softener valve configuration with: tank, resin volume, brine tank, and injector. Tank Size (in & mm) 30 / / / / / /2400 Resin Volume (ft 3 & L) Hankscraft RevV22 Rotary Valve Manual Flow Rate (m 3 /h) 15.90/ / / Brine Tank Size (in & mm) 33 /800 x 52 / /1050 x 57 / /1200 x 62 /1575 The Minimum Salt Consumption for Regeneration (kg & lbs.) Injector Model 67.5kg (149 lbs.) kg (297 lbs.) kg (364 lbs.) 7704 Attention: The flow rate calculation is based on linear velocity 25m / h; the minimum salt consumption for regeneration calculation is based on salt consumption 150g / L (Resin). B. Flow Rate Characteristic 1) Pressure-flow Rate Curve 18

22 2) Injector Parameter Table Inlet Pressure MPa/psi Hankscraft RevV22 Rotary Valve Manual 7701 Coffee 7702 Pink Draw Rate(gal/m & L/m) 7703 Yellow 7704 Blue 7705 White 0.20 (29psi) 4.95/ / / / / (36psi) 7.09/ / / / / (43psi) 8.47/ / / / / (50psi) 9.92/ / / / / (58psi) 11.13/ / / / / ) Configuration for Standard Injector and Drain Line Flow Control Tank Dia. In & mm Injector Model Injector Color Backwash / Fast Draw Rate Slow Rinse DLFC& Holes Rinse Quantity Gal/m & L/m Gal/m & L/m Gal/h & L/h / Coffee 8.45/ / / / Pink 10.44/ / / / Pink 10.44/ / / / Yellow 13.53/ / / / Yellow 13.53/ / / / Blue 17.15/ / / / White 19.13/ / /13 Remark: The above data for the product configuration and relevant characteristics are only for reference. When put into practice, results are subject to the different requirements of raw water hardness and application. Above parameter is tested under 0.3MPa (43.51 psi) inlet pressure. Holes quantity is the number of holes on DLFC. For numbers refer to above table Parameter settlement 1 Service time T1 Water treatment capacity: Q=V R K Y D (m 3 ) Hardness of inlet water (mmol/l) Exchange factor (mmol/l) 400~1000. Down-flow regeneration, take 400~750. Up-flow regeneration, take 450~1000. If the inlet water hardness is higher, the factor is smaller. By hours: T1=Q Q h (Hour) By days:t1=q Q d (Day) Resin volume (m 3 ) Water treatment capacity per hour (m 3 /h) Water treatment capacity (m 3 ) Water treatment capacity per day (m 3 /d) Water treatment capacity (m 3 ) 19

23 2 Backwash time T2 It is subject to the turbidity of inlet water. Generally, It is suggested to be set to 10~15 minutes. The higher the turbidity is, the longer backwash time can be set. However, if the turbidity is more than 5 FTU, it would be better to install a filter before the ion exchanger. 3 Brine& slow rinse time T3 T3= (40~50) H R (min.) Generally, T3=45H R (min.) In this formula, H R the height of resin in exchange tank (m.) 4 Brine refill timet4 Down-flow regeneration:t4=0.45 V R Brine refill speed (min.) Up-flow regeneration:t4=0.34 V R Brine refill speed (min.) In this formula, V R Resin volume (m 3 ) The Brine refill speed is related to inlet water pressure. It is suggested to increase by 1~2 minutes of calculated brine refilling time to make sure there is enough water in tank. (The condition is that there is a level controller installed in the brine tank) 5 Fast rinse time T5 T5=12 H R (min.) Generally, the water for fast rinse is 3~6 times of resin volume. It is suggested to be set 10~16 minutes, but subject to the outlet water reaching the requirement. 6 Exchange factor Exchange factor =E/ (k 1000) In this formula, E Resin working exchange capability (mmol/m 3 ), it is related to the quality of resin. Down-flow regeneration, take 800~900. Up-flow regeneration, take 900~1200. K Security factor, always take 1.2~2 it is related to the hardness of inlet water: the higher the hardness is, the bigger the K is. 7 Regeneration time The whole cycle for regeneration is approximately two hours. Please try to set up the regeneration time when you don t need water according to the actual situation. The calculation of parameters for each step is only for reference, the actual proper time will be determined/adjusted by water exchanger supplier. This calculation procedure of softener is only for industrial application; it is not suitable for small softeners in residential applications Parameter Enquiry and Setting Parameter Enquiry When light is on, press and hold both and for 5 seconds to lift the button lock status; then press and lights up, enter to program display mode; press or to view each value according to below process. (Press to exit and return to service status) 20

24 Parameter Setting In program display mode, press and enter into program set mode. Press or to adjust the value The Steps of Parameter Setting Items Process steps Symbol When time of day 12:12 continuously flashes; it is a reminder to reset the time; Time of Day 1. Press to enter into program display mode; both and symbol light will turn on, : flashes: Press, both and the hour value will flash, use or to adjust the hour value; 2. Press again, both and the minute value will flash, use or to adjust the minute value; 3. Press a confirmation beep will sound, confirming the adjustment, press to return. Control Mode 1. In control mode display status, press and enter into program set mode, and 01 values will flash; 2. Press or,to set the value to A-01, A-02, A-03 or A-04 control mode 3. Press a confirmation beep will sound, confirming the adjustment, press to return. Regeneration Time 1. In regeneration time display status, press and enter into program set mode. and 02 will flash; Press or to adjust the hour value; 2. Press again, and 00 will flashes, press or to adjust the minute value; 3. Press a confirmation beep will sound, confirming the adjustment, press to return. 21

25 Water Treatment Capacity 1. In water treatment capacity display status, it shows and Press and enter into program set mode. and will flash; 2. Press or to adjust the water treatment capacity value (m 3 ); 3. Press a confirmation beep will sound, confirming the adjustment, press to return. 1. In resin volume display status, it shows 100 L. Press and enter into program set mode. Resin Volume and 50 value will flash; 2. Press or to adjust the volume value (L); 3. Press a confirmation beep will sound, confirming the adjustment, press to return. 1. In feed water hardness display status, it shows yd1.2. Press and enter into program set Feed Water mode. and 1.2 value will flash; Hardness 2. Press or to adjust the volume value (mmol/l); 3. Press a confirmation beep will sound, confirming the adjustment, press to return. 1. In exchange factor display status, it shows AL.55. Press and enter into program set mode. Exchange Factor and 55 will flash; 2. Press or to adjust the exchange factor value; 3. Press a confirmation beep will sound, confirming the adjustment, press to return. 1. In backwash time display status, it shows and Press and enter into program set Backwash Time mode. and 10 will flash; 2. Press or to adjust the backwash time; 3. Press a confirmation beep will sound, confirming the adjustment, press to return. Brine& Slow Rinse Time 1. In Brine& slow rinse time display status, it shows and 3-60:00. Press and enter into program set mode. and 60 will flash; Press and to modify the Brine & slow rinse minute time; modify the Brine & slow rinse second time; 3. Press a confirmation beep will sound, confirming the adjustment, press to return. 1. In Fast rinse time display status, it shows and 4-10:00. Press and enter into program set Fast Rinse Time mode. and 10 will flash;press and to modify the Fast rinse minute time; 2. Press a confirmation beep will sound, then finish adjustment, press to return. Brine Refill Time 1. In Brine refill time display status, it shows and 5-05:00. Press and enter into program set mode. and 05 will flash; Press and to modify the Brine refill minute time; modify the Brine refill second time; 2. Press a confirmation beep will sound, confirming the adjustment, press to return. Maximum Interval Regeneration Days 1. In maximum Interval regeneration days display status, it shows H-30. Press and enter into program set mode. and 30 will flash; 2. Press or to adjust the Interval regeneration days; 3. Press a confirmation beep will sound, confirming the adjustment, press to return. 1. In signal output mode display status, it shows b-01. Press and enter into program set mode. Signal Output Mode and 01 will flash 2. Press or to adjust the b-02; 3. Press a confirmation beep will sound, confirming the adjustment, press to return. 22

26 For example, the fast rinse time of a softener is 12 minutes. After regenerating, the chlorides in the outlet water are always higher than normal, indicating that there is not enough time for fast rinse. If you want to increase the fast rinse time, the modification steps as follows: 1 Press and hold both and to lift the button lock status ( light off); 2 Press, and lights up; 3 Press or continuously until lights up. Then the digital area shows: 4-12M; 4 Press, and 12 will flash; 5 Press continuously until 12 changes to 15; 6 Press mode., there will be a confirmation beep and the figure will stop flashing; returning to program set 7 If you want to adjust other parameters, you can repeat the steps from 2 to 5; if not, press and quit program set mode, the display will show the current service status. 23

27 3.6. Trial Running After installing the multi-functional flow control valve on the resin tank with the connected pipes, and setting up the relevant parameters for the system, please conduct a trail run as follows: A. Close the inlet valve B & C, and open the bypass valve A. After cleaning the foreign materials in the pipe, close the bypass valve A. (as Figure 1-4 shows) B. Fill the brine tank with the planned amount of water and adjust the air check valve. Then add solid salt to the tank dissolving the salt as much as possible. C. Turn on power. Press and go in the Backwash position; when light is on (For floating bed, switch valve to Fast Rinse), slowly open the inlet valve B to 1/4 position, making the water flow into the resin tank; you should hear the sound of air-out from the drain pipeline. After all of the air is out of the pipeline, open inlet valve B completely to clean the foreign material out of the resin tank until the outlet water is clean. It will take 8~10 minutes to finish the whole process depending on media. D. Press, advancing the position from Backwash to Brine & Slow Rinse; when light is on it indicates the valve is entering Brine & Slow Rinse. The air check valve closes when control valve finishes drawing brine; slow rinse starts. About 60~65 minute process. E. Press to get to Fast rinse position. light will turn on. It takes about 10~15 minutes. Remove some outlet water for testing: if the water hardness reaches the desired requirement, and the chlorides in the water are almost the same level compared with the inlet water, then proceed to the next step. F. Press to Brine refill position. When the light is on it indicates the brine tank is being refilled with water to the required level. It takes about 5~6 minutes, then add solid salt to the brine tank. G. Press, this forces the control valve to advance to In Service status; light turns on and valve will start running. Note: When the control valve enters into the regeneration status, all programs will be completed automatically according to the setting times; if you want one of the steps to complete early, press. If the inlet pressure is too high, the media in tank can be damaged. When inlet pressure is too low, there is a sound of air emptying from the drain pipeline. After changing resin, empty air that is in the resin according to the above Step C. In the process of trial running, ensure there are no leakages in any cycle. The time for Backwash, Brine & Slow Rinse, Brine Refill and Fast Rinse position can be set and completed according to the calculation in the formula or suggestions from the control valve suppliers. 24

28 3.7. Trouble-Shooting A. Control Issues Problem Cause Correction 1. Softener fails to regenerate. 2. Regeneration time is not correct. 3. Softener yielding hard water. 4. Softener fails to draw brine. 5. Unit uses too much salt. 6. Excessive water in brine tank. 7. Pressure lost or iron in outlet water. A. Electrical service to unit has been interrupted. B. Regeneration cycles set incorrectly. C. Controller is defective. D. Motor fails to work. A. Time of Day is not set correctly. B. Power failure for more than 3 days. A. Bypass valve is open or leaking. B. No salt in brine tank. C. Injector plugged. D. Insufficient water flowing into brine tank. E. Leak at O-ring on riser pipe. F. Internal valve leak. G. Regeneration cycles not correct. H. Shortage of resin. I. Bad quality of feed water or turbine blocked. A. Line pressure is too low. B. Brine line is plugged. C. Brine line is leaking. D. Injector is plugged. E. Internal control leak. F. Drain line is plugged. G. Sizes of injector and DLFC don t match system size. H. Ball valve or cable failure A. Improper salt setting. B. Excessive water in brine tank. A. Brine refill time set too long. B. Foreign material in brine line. C. Foreign material in brine valve / plugs drain line flow control. D. No overflow safety in brine tank / float assembly. E. Ball valve doesn t close. A. Iron in the inlet pipe. B. Iron mass in the softener. C. Fouled resin bed. D. Too much iron in the raw water. 25 A. Verify permanent electricity (Check fuse, plug, pull chain or switch). B. Reset regeneration cycles. C. Replace controller. D. Replace motor. Check program and reset time of day. A. Close or repair bypass valve. B. Add salt to brine tank and maintain salt level above water level. C. Change or clean injector. D. Check brine tank refill time. E. Make sure riser pipe is not cracked. Check O-ring and ensure riser pipe is not extended past the top of pressure tank. F. Change valve body. G. Set correct regeneration cycles in programming. H. Add resin to mineral tank and check whether resin leaks. I. Reduce the inlet turbidity, clean or replace turbine. A. Increase line pressure. B. Clean brine line. C. Replace brine line. D. Clean or replace injector. E. Replace valve body. F. Clean drain line flow control. G. Select correct injector size and DLFC according to the P20 requirements. H. Replace ball valve or cable A. Check salt usage and salt setting. B. See problem no.6. A. Reset correct brine refill time. B. Clean brine line. C. Clean brine valve and brine line. D. Stop water supply and reinstall float assembly in brine tank. E. Close or replace ball valve or cable. A. Clean the inlet pipe. B. Clean valve and add resin cleaning chemical, increase frequency of regeneration. C. Check backwash, brine draw and brine tank refill. Increase frequency of regeneration and backwash time. D. Iron removal equipment is required to install before softening system.

29 8. Loss of mineral through drain line. 9. Control cycles continuously. 10. Drain flows continuously. 11. Interrupted or irregular brine. 12. Water flows from drain or brine line after regeneration. 13. Salt water in softened water. 14. Unit capacity decreases. A. Air in water system. B. Bottom distributor basket damaged. C. Improperly sized drain line flow control. A. Locating signal writing breakdown. B. Controller is faulty. C. Foreign material stuck the driving gear. D. Time of regeneration steps were set to zero. A. Internal valve leak. B. If there was a power outage during the backwash cycle. A. Water pressure too low or not stable. B. Injector is plugged or faulty. C. Air in resin tank. D. Material in resin tank during backwash. A. Foreign material in the valve; valve cannot close completely. B. Hard water mixed in valve body. C. Water pressure is too high which results in the valve not being in the right position. D. Ball valve or cable failure. A. Foreign material in injector or injector fails to work. B. Brine valve cannot be shut-off. C. Time of rapid rinse too short. A. Unit fails to regenerate or does not regenerate properly. B. Fouled resin bed. C. Salt setting incorrect. D. Softener setting incorrect. E. Reduced quality of raw water. F. Turbine of flow meter is stuck. A. Check that drain has proper air gap. B. Replace bottom distributor basket. C. Check for proper drain rate. A. Check and connect locating signal wiring. B. Replace controller. C. Remove foreign material. D. Check program setting and reset. A. Check and repair valve body or replace it. B. Adjust valve to service position or turn off bypass valve and restart. A. Increase water pressure. B. Clean or replace injector. C. Check and find the reason. D. Remove the material in resin tank. A. Clean foreign material in valve body. B. Change valve core or sealing ring. C. Reduce water pressure or use pressure release device. D. Replace ball valve or cable. A. Clean and repair injector. B. Repair brine valve or clean it. C. Extend rapid rinse time. A. Regenerate according to the correct operation requirement. B. Increase backwash flow rate and time, clean or change resin. C. Readjust brine drawing time. D. Test outlet water, recount, and reset parameters. E. Manual regenerate the system temporarily, then reset regeneration cycle. F. Disassemble flow meter and clean it or replace turbine. B. Controller Issues Problem Cause Correction 1. All indicators displayed on front panel. 2. No display on front panel. A. Wiring of front panel failure. B. Control board is faulty. C. Transformer damaged. D. Electrical service not stable. A. Wiring of front panel failure. B. Front panel damaged. C. Control board damaged. D. Electricity is interrupted. A. Check and replace the wiring. B. Replace control board. C. Check and replace transformer. D. Check and adjust electrical service. A. Check and replace wiring. B. Replace front panel. C. Replace control board. D. Check electricity. 26

30 3. E1 Flash 4. E2 Flash 5. E3 or E4 Flashes 3.8. Assembly & Parts (RevV-22) A. Wiring of locating board failure. B. Locating board damaged. C. Mechanical driven failure. D. Faulty control board. E. Wiring of motor failure. F. Motor 1 damaged. A. Wiring of locating board failure. B. Locating board damaged. C. Mechanical driven failure. D. Faulty control board. E. Wiring of motor failure. F. Motor 2 damaged. A. Replace wiring. B. Replace locating board. C. Check and repair mechanical part. D. Replace control board. E. Replace wiring. F. Replace motor 1. A. Replace wiring. B. Replace locating board. C. Check and repair mechanical part. D. Replace control board. E. Replace wiring. F. Replace motor 2. A. Control board is faulty. A. Replace control board. 27

31 Item No. Description Part No. Quantity Item No. Description Part No. Quantity 1 Side-mounted Connector Three-core Spring Screw, Cross ST3.9X Control Board Connector O-ring X Wire for Locating Board O-ring 48.9 X Front Cover Seal Ring Toggle Drain Line Flow Control Probe wire Animated Connector Wire for power Flow meter Locking Ring Screw, Cross ST2.9X Small Gear Screw, Cross ST3.9X Button C4X Wire for power Motor Fixed Disk Shaft Moving Disk Fixed Disk Shaft Moving Disk Anti-friction Washer Wire for power O-ring X Hexagonal Nut O-ring X Cable clip Pressure Nut Junction Plate Locating board Pin 2.5X Gear Injector Screw, Cross ST4.8X O-ring 52X Dust Cover Injector Cover Board Back Cover Screw, Cross ST4.8X Screw, Cross ST2.2X Screw, Cross M4X Display Board /4 Ball Valve Cable clip Display Shelf Board Front Cover Valve Body(ABS+GF10) Sticker Valve Body(PPO+GF10) Bushings Screw, Cross M4X Screw, Cross M4X

32 Flow meter structure: Flow Meter Components: Item No. Description Part No. Qty. Item No. Description Part No. Qty. 1 Animated Connector O-ring 60X Seal Ring Turbine Connector Rotator Fixed Connector Flow Meter Shell Side-mounted Connector Components: Item No. Description Part No. Qty. Item No. Description Part No. Qty. 1 Connector Joint O-ring 110X Steel Yoke End