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SOFTENERS SERIES: AC/A AS/A AS/A2

INSTRUCTIONS MANUAL

WARNING!

The equipment must be used only for the utilization for which they have been designed, as shown in the technical documentation.

Read carefully this leaflet until the end before starting any operation.Proceed strictly according to all directions included in this manual.

Automatic softeners series AC & AS are designed to treat raw water supplied from municipalities or from well.

ANY OTHER APPLICATIONS OF THE EQUIPMENT DIFFERENT THAN THE MENTIONED ONES IS MADE UNDER THE ONLY RESPONSIBILITY OF THE USER.

For any assistance concerning the installations, maintenance or utilization of the equipment apply the NOBEL Service Center closest to you or directly:

NOBEL S.r.l.e-mail: [email protected]

tel. +39 02 2827968 fax +39 02 2610839

AUTOMATIC SOFTENERS INSTRUCTIONS MANUAL AC/A AS/A

s.r.l. - ITALY of 13 asa_mi-r3.doc – r 3

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INDEX1. Safety .......................................................................................................................................3

1.1. CE mark, declaration of conformity.....................................................................................31.2. How to displace the unit......................................................................................................31.3. Hydraulics ...........................................................................................................................31.4. Electrical .............................................................................................................................31.5. How to store, delivery and install ........................................................................................3

2. Principles of working ................................................................................................................43. Technical characteristics ..........................................................................................................4

3.1. Assumed raw water characteristics ....................................................................................43.2. Technical characteristics (general) .....................................................................................43.3. Characteristics for each model ...........................................................................................53.4. Dimensions .........................................................................................................................53.5. Weight.................................................................................................................................5

4. Installation ................................................................................................................................64.1. Room conditions .................................................................................................................64.2. How to remove packaging ..................................................................................................64.3. How to move and lift the unit...............................................................................................64.4. Placing ................................................................................................................................64.5. Hydraulic connections.........................................................................................................74.6. Electrical wiring connections...............................................................................................7

5. End cycle and regeneration......................................................................................................85.1. End cycle ............................................................................................................................85.2. Regeneration ......................................................................................................................85.3. Programmer ........................................................................................................................95.3.1. Automatic regeneration ..............................................................................................95.3.2. Hand-driven regeneration.........................................................................................10

6. How to set the residual hardness ...........................................................................................107. Starting-up..............................................................................................................................118. Maintenance...........................................................................................................................12

8.1. Disposal ............................................................................................................................129. Components ...........................................................................................................................1210. Trouble shooting guide....................................................................................................13

Annex:

• DRAWING 1: components AC AS series • DRAWING 2: installation and dimensions AC series • DRAWING 3: installation and dimensions AS series • DRAWING 4: automatic valves A (A255) and A2 (A268) • declaration of conformity



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1. Safety

1.1. CE mark, declaration of conformity The equipment is designed to meet state-of-the-art safety requirements, has been

tested and left the factory in a condition in which it is safe to operate. The equipment complies with the applicable standards and regulations as listed in the

CE declaration of conformity and thus complies with the statutory requirements of the CE Directives.

NOBEL confirms the successful testing of the equipment by sticking to it the CE mark.

1.2. How to displace the unit Particular care and attention should be put in during moving and displacing of heavy

items, in order to avoid injuries to persons or damage properties. (see § 3.5 page 5).

1.3. Hydraulics All operations must be performed by and/or under direct supervision of skilled and

authorized operators, using proper tools and personal protection devices if required (CE marked).

Before any operation of taking out pipes or part of hydraulic system, it is required to release the pressure inside and empty the part of the system.

1.4. Electrical Before starting any operation on electrical devices, be sure that main power supply is

OFF. All operations must be performed by skilled and authorized operators. In case of liquid leakage, switch off the main power supply before operate. Before the

switching ON, be sure all the parts of the system are perfectly dry. Check that the available electrical power is correct, (see § 3.2 page 4) before connection. Do not make preliminary wiring connections.

1.5. How to store, delivery and install t = ºC t = ºF humidity rel. notes

• closed rooms 5÷45 41÷113 5÷95% without condensate

• open space 5÷45 41÷113 5÷95% without condensate protect from sun-light and rain. • transport 5÷45 41÷113 5÷95% without condensate protect from sun-light and rain. • installation 5÷45 41÷113 5÷95% without condensate protect from sun-light and rain



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2. Principles of working

Softening is the process that allows to remove calcium and magnesium from water. These two elements, together with bicarbonate, are the main cause of the scale inside thermal plant and domestic appliances (heating system, laundry machines, etc.). They also can cause big trouble in many industrial process.

The process of softening is featured by ion exchange. The resins contained in the column exchange the ions calcium and magnesium (Ca++ and Mg++) against sodium ions (Na+), of which they are charged. When the resins are exhausted, they are fully charged of calcium and magnesium (Ca++ e Mg++) while they do not have any more sodium ions (Na+) available for exchanging and they need to be regenerated.

Regeneration means re-built the charge of sodium ions (Na+) available from sodium chloride (NaCl), common salt used in kitchen. During regeneration an exchanging back is performed of sodium ions (Na+) against ions calcium and magnesium (Ca++ e Mg++) which are carried away to drain. The equipment prepares automatically the brine from the salt (NaCl) in grain or tablets.

AC and AS series softeners are used for water treatment for residential and industrial applications as well. All the materials, resins included, are food grade and approved for drinking water.

The range of models includes systems with capacity from 1 up to 4.5 m³/h and capacity from 60 up to 800 m³ x ºF. The working of the system is controlled by an automatic programmer, allowing to schedule the frequency and the hour for the regeneration. Then the system automatically starts the regeneration that proceed automatically. During regeneration, an internal by-pass allows the supplying of non softened water.

These system can be equipped with automatic sterilizing device (Nobel CL 90),according to the local laws of some countries for the treatment of drinking water.

3. Technical characteristics

3.1. Assumed raw water characteristics • organics NIL • water temperature (min÷max) ºC (ºF) 5÷40 (41÷104) • water pressure (min÷max) bar (kPa) 2÷8 (200÷800)

3.2. Technical characteristics (general) • hardness of treated water (with raw water up to 30°Fr) ºFr < 0.5 • power supply V ph/Hz W 230 1/50 10 • regeneration time min. 120



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3.3. Characteristics for each model MODEL connections flow max. cycle brine tank capacity consumption for

regenerationIN/OUT drain mm m³/h m³ x ºFr l tot ≅ kg salt salt kg water l

AC 60/A 1" 13.5 1.2 60 35 1.5 80 AC 90/A 1" 13.5 1.8 90 55 2.25 120 AC 150/A 1" 13.5 2.4 150 60 3.75 200 AS 60/A 1" 13.5 1.2 90 100 1.5 80 AS 90/A 1" 13.5 1.6 90 100 2.25 120 AS 150/A 1" 13.5 2.4 150 100 3.75 200 AS 210/A 1" 13.5 2.8 210 100 5.25 280 AS 300/A 1" 13.5 3.2 300 150 7.5 400 AS 450/A 1" 13.5 3.5 450 150 11.25 600 AS 600/A 1" 13.5 3.7 600 150 15.0 800 AS 450/A2 1" M ¾" M 4.1 450 150 11.25 600 AS 600/A2 1" M ¾" M 4.5 600 150 15.0 800 AS 800/A2 1" M ¾" M 4.5 800 200 19.5 1040

3.4. Dimensions

See DRAWING 2 or 3 installation & dimensions

3.5. Weight WEIGHT (approx)

MODEL vessel with resins

brine tank shipping weight

on service

kg kg kg vessel kg brine tank (fill) kg AC 60 / / 30 70 / AC 90 / / 35 110 / AC 150 / / 50 150 / AS 60 20 5 35 35 110 AS 90 25 5 35 45 110 AS 150 35 5 45 65 110 AS 210 45 5 55 85 110 AS 300 60 6 75 120 160 AS 450 85 6 105 170 160 AS 600 115 6 140 230 160 AS 800 145 7 170 290 210



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4. Installation

4.1. Room conditions In cold countries, whether the room temperature is below 15 °C (59°F), the salt

requires longer time to be dissolved, even up to 10 hours; this feature must be considered in designing and selecting the correct system. Apply Nobel Technical Dept. for further information.

4.2. How to remove packaging The packaging consist of one wooden crates that contain the vessel with resins, on

which the automatic valves have been already mounted; the brine tanks is shipped as separated, already assembled and protected by a plastic foil wrapped around.

Open the wooden crate removing, first, the side cover, then withdraw carefully the contents. Keep the cards and everything contained inside the packaging.

For models AC, which have the brine tank integrated in main structure, the packaging consist of one carton box.

4.3. How to move and lift the unit The vessel containing the resins can be easily moved until it is in original packaging;

after removed the packaging it can be moved for short stretches by rotating it around their base, very carefully, to avoid the breaking of the plastic end.

The empty vessel and the brine tank can be moved avoiding bump or crashing which can seriously damage them.

Always do not move the vessel handling them by the top-mounted control valve.

4.4. Placing (see DRAWING 2 or 3 installation & dimensions)

• Follow the directions of the dimensional drawing for the correct placing of the unit, according to the dimensions of the available room and the required room for service and maintenance.

• Place the column of resins and the brine tank on a perfectly flat surface. NOTE : AC models, have the brine tank integrated in main structure.



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4.5. Hydraulic connections (see DRAWING 2 or 3 installation & dimensions, DRAWING 4 automatic valves)

• connect the inlet and outlet fittings, placed on the back side of automatic valve, to the untreated water line. In order to avoid shut-off during maintenance operations, an emergency by-pass line should be provided.

CAUTION: It is recommended to hold the pipes with adequate brackets, to avoid breaking on the plastic structure.

• complete the line from the injector fitting placed on the air-check glass of the control valve to the fitting of the suction pipe mounted inside the regenerant tank, using the supplied plastic tube. For AC models such connection is already done.

Whether the units are pre-arranged to be completed with CL 90 device, the air-check glass is removed and an elbow fitting is screwed on; in this case the plastic tube from the brine tank must be connected to the elbow fitting .

• complete the line from the drain hose connection (placed between the inlet and outlet connections of automatic valve), to a floor drain, using a proper sized common flexible rubber or plastic tube (see § 3.3 page 5).

• connect the overflow fitting of the brine tank to a floor drain; this line must run separately from the above mentioned drain connection.

4.6. Electrical wiring connections

• Connect the power plug from the feeder in the proper socket placed in the rear of the programmer.

• Connect the power feeder to a power socket; check that the available power is correct as listed in technical characteristics (see § 3.2 page 4).



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5. End cycle and regeneration

5.1. End cycle The softeners are equipped with a programmer that allows to schedule the automatic

regeneration according to time. The programmer works at 12 V (10 VA) power and it is normally supplied complete of

built-in transformer in order to be connected directly to the main supply (230 V 50 Hz). The end-cycle has to be adjusted according to the quality of available water and the

consumption of water.

The max. quantity of available soft water the equipment can supply between two following regeneration is to be calculated as follows:

=

where 1°Fr = 10 ppm CaCO3 = 0.56° German

The cycle of all NOBEL softeners are expressed by the number identifying the model (i.e. AS600, the cycle is 600 m3 x °Fr).

5.2. Regeneration

The regeneration phases run one after one, as follows :

1. backwashing: during this phase, the water flush from the bottom to the top of the column, lifting the resins which are mixed together and release the solids trapped on surfaces of the resins bed during the service. The backwashing water flows to drain from the top of the column. This is the only phase, during which the water crosses through the column from the bottom to the top.

2. brine drawing: during this phase, a concentrated solution of water and sodium chloride (common kitchen salt, in grain or, better, tablet) is drawn from the brine tank to the resins column, by an injector. The brine crosses through the column from the top to the bottom.

3. slow rinse: it is the first step of the rinse, during which the ion exchanges between sodium chloride and resins is featured. This phase tarts when the brine tank is completely empty (all brine has been drawn); a special device built-in the air-check glass or in the air check valve avoids the air drawing.

4. fast rinse: it is the phase during which the residual of salt is flushed away through the resins; at the end of this phase the resins column is ready to start again a new service cycle.

NOTE : During the fast rinse phase the unit supplies the water to the brine tank, in order to prepare the brine for the following regeneration. The brine tank refill will be automatically completed by time.

NOTE : During regeneration the system supplies non softened water thanks to a by-pass inside the automatic valve.

m³ of available soft water per cycle cycle of the softener (m³ ∗ ºFr)total hardness of raw water (°Fr)



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5.3. Programmer The softener is equipped with a programmer allowing to run the regeneration

automatically, according to time schedule (24 hours- 7 days; max 1 regeneration per day).The electrical parts works at a low-tension by a transformer built-in the main feeder.To remove the programmer from the automatic control valve, rotate the locking flag of

90° and withdraw it completely; then, pull up the programmer from its seat.To re-assembly the programmer again, check that the cam shaft is perfectly fit to the

programmer and that the programmer is correctly fit to its seat. Then, fix it definitely inserting the locking flag.

5.3.1. Automatic regeneration The unit is programmed in order to run the regeneration during the night (approx. at

02.30 a.m.), during which it is assumed there is a lower consumption of water. Whether it is desired to run the regeneration at different time of day, just set the actual time of day faster or slower accordingly (naturally, the regeneration will run the same number of hours earlier or later).

Proceed as follows for the program:• Pull all pins B on the weekly disk A outward (away from programmer) • Turn the weekly disk A until the arrow G points to current day • Depress the pin(s) B at day(s) for which regeneration is desired • Grasp the clock dial C and pull it outward. Turn in either direction until actual time of

the day on clock dial is in line with the arrow E. Release the clock dial.



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5.3.2. Hand-driven regeneration Pull up all pins B on the weekly disk A.

To start regeneration, simply press and turn counter-clockwise the F knob until the arrow points "INIZIO" (START). The regeneration will be automatically completed.

Whether the hand-driven regeneration is run as additional at the automatic ones, it is not required to pull out all pins B form A disk, but it is just required to operate with the F button as above explained.

When the regeneration is completed the unit will go ahead to work according to the pre-set schedule.

It is required that the power supply is ON, and that there is enough brine inside the tank.

NOTE : Electricity is used only to run the timer and to rotate the cam shaft. All other functions are operated by water pressure. Therefore, in the event of a power failure, all the various regeneration positions may be dialled manually by depressed the pointer F knob and turning it counter-clockwise as explained at paragraph "Starting-up".

The sequence and the time of each phases of regeneration are the following :

PHASES TIME (minutes) MODELS C/W CAM SHAFT

NORMAL * MODELS C/W CAM SHAFT

XS * Backwash 13 13

Brine drawing and slow rinse

52 62

Rinse 5.5 12 Brine tank refill 9 18

* for cam shaft type see § "components" page 12.

6. How to set the residual hardness

The units AC/A and AS/A series are equipped with a special blending valve to set the residual hardness. The valve is placed between the inlet and outlet connections.

Using a 6 mm key, rotate the valve spindle until the desired residual hardness is reached. Test the hardness of outlet water using the supplied test kit.

Caution: The outlet water from the resin is completely softened; the blending valve just make a proper addiction of some untreated water to treated water.



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7. Starting-up

The starting-up of the unit consists of running a first regeneration cycle, during which the columns of resins and brine tank will be filled of water, all automatic features will be checked and the unit will be prepared to start the service.

During the starting-up is not required that salt is available inside the brine tank. At the end of the first regeneration, put the salt into the brine tank (it can also be

completely filled). Take care not to put salt inside the protection pipe. See § maintenance page 12 for recommended quality of salt to be used.

To start-up the unit, proceed as follows :

• DISCONNECT ELECTRIC POWER • Open the by-pass valve, keeping the inlet and outlet ones shut. • Press and turn counter-clockwise the F knob until the arrow points

"CONTROCORRENTE" (BACKWASH). • Open slowly and not completely the inlet valve. Water will enter from the bottom of

the column as air will be expelled from the top to the drain. • When only water will come out, open completely the inlet valve and allow the water

flush until the water looks clear. • Using a pail, add water in the brine tank, until the water mark is approx. 30 cm (12

inches) from the bottom (this is required for the initial regeneration only and is automatically filled thereafter).

• Press and turn counter-clockwise the F knob until the arrow points "RIEMPIMENTO VASCA DEL SALE E LAVAGGIO" (RINSE and BRINE TANK REFILL). Even if some water flows from the drain line, water flows to the brine tank. Allow to flow for 2 minutes, until the air contained in the pipe is expelled.

• Press and turn counter-clockwise the F knob until the arrow points "INIEZIONE SALE E RISCIACQUO" (BRINE DRAWING AND RINSE). Even if some water flows from the drain line, water flows from the brine tank to the unit.

Check the proper drawing of the brine through the transparent air check glass (if there is; otherwise through the plastic brine tubing).

• Press and turn counter-clockwise the F knob until the arrow points "RIEMPIMENTO VASCA DEL SALE E LAVAGGIO" (RINSE and BRINE TANK REFILL). Allow the water flush until the water looks clear.

• Press and turn counter-clockwise the F knob until the arrow points "ESERCIZIO" (SERVICE).

• Switch on electrical power. • Put the salt into the brine tank (it can also be completely filled). Take care not to put

salt inside the protection pipe. • open the outlet valve and close the by-pass valve

Starting now the unit is on service and feeds treated water.



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8. Maintenance

Softeners are equipment designed to treat raw water supplied from municipalities or from well.

ANY OTHER APPLICATIONS OF THE EQUIPMENT DIFFERENT THAN THE MENTIONED ONES IS MADE UNDER THE ONLY RESPONSIBILITY OF THE USER.

The correct handling of the equipment requires :

• take off the raw water suspended solids, if any, by an adequate filtration. • check that the water pressure is within the stated values. • check that the arrow E indicates the correct time of day on the wheel C. A power

black-out will cause a late on the correct time of the programmer, hence the regeneration will start on undesired time of the day.

• check the salt level in the brine tank. A salt lack will cause the incomplete regeneration of the resins, or not any regeneration at all.

• it is suggested to use clean salt, better in the shape of tablets, available almost everywhere, in order to avoid residuals of sand or dirties in the tank and along the brine lines.

Not any further special maintenance operations are required. The only consumption material is salt. The average life of the ion exchange resins is approx. 5÷8 years, according to the

quality of raw water and how often regeneration is featured.

8.1. Disposal In case of disposal of the unit or parts of it, it must be made according to local laws concerning

the waste of the materials. It should be taken in consideration that resins are usually listed as plastic materials and not as toxic or harmful material (the safety bulletin of resins are available upon request).

9. Components

MODEL automaticvalve cam shaft

resin vessel resins resin pipe brine tubing

brine suction pipe

type Ø x h (inches) l Ø (inches) Ø ext mm Ø (inches)

AC 60/A A255 normal 9x17 10 1.05 9.5 ³/8

AC 90/A A255 normal 8x30 15 1.05 9.5 ³/8

AC 150/A A255 normal 10x35 25 1.05 9.5 ³/8

AS 60/A A255 normal 7x30 10 1.05 9.5 ³/8

AS 90/A A255 normal 7x35 15 1.05 9.5 ³/8

AS 150/A A255 normal 8x44 25 1.05 9.5 ³/8

AS 210/A A255 normal 10x44 35 1.05 9.5 ³/8

AS 300/A A255 normal 10x54 50 1.05 9.5 ³/8

AS 450/A A255 XS 13x54 75 1.05 9.5 ³/8

AS 600/A A255 XS 14x65 100 1.05 9.5 ³/8

AS 450/A2 A268 XS 13x54 75 1.05 9.5 ³/8

AS 600/A2 A268 XS 14x65 100 1.05 9.5 ³/8

AS 800/A2 A268 XS 16x65 130 1.05 9.5 ³/8

All models are equipped with programmer type A440.

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s.r.l.TEL. +39 02 2827968 FAX +39 02 2610839 e-mail [email protected]

via G.Galilei, 5 20090 Segrate (MI) - ITALY

AZIENDA CON SISTEMA QUALITÁ CERTIFICATO DA DNV

UNI EN ISO 9001/2008 www.nobelitaly.it

società italiana per lo studio e la realizzazione di apparecchiature ed impianti per il trattamento acqua engineering and manufacturing of equipments and plants for water treatment

M

3.6-

r4 sede legale : via dell’Unione 3 20122 Milano

C.C.I.A.A. 1250687 - EXPORT MI 044905 - Reg. Trib. Milano nº 272528 vol.7032 fasc.28 società a responsabilità limitata - cap. soc. € 99.000 i.v. - C.F. e P.I. : IT 08829620155

rev. 1

DICHIARAZIONE DI CONFORMITÀ DECLARATION OF CONFORMITY

La Nobel srl dichiara che l’apparecchiatura (vedi etichetta in prima pagina) delle serie

Nobel srl hereby declares that the equipment (see label on first page) of seriesAC – AS

è conforme alle seguenti Direttive Europee:

2006/42/CE – 2006/95/CE – 2004/108/CE

Principali Norme armonizzate osservate durante la progettazione e costruzione:

UNI EN ISO 12100:2010 – UNI EN 60204-1 (CEI 44-5)

Il direttore tecnico è autorizzato alla costituzione del fascicolo tecnico.

complies to the requirement of the following European Directives :

2006/42/CE – 2006/95/CE – 2004/108/CE

Besides, the main regulations followed for the design and manufacturing are :

UNI EN ISO 12100:2010 – UNI EN 60204-1 (CEI 44-5)

The technical manager is authorized to manage the technical folder.

Direttore Tecnico Technical Manager Giorgio Da Dalt

Milano, 18 febbraio 2013

softeners series: ac/a as/a as/a2 - nobel.srl€¦ · softeners series: ac/a as/a as/a2 ... all...

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