Hydrotec HYDROION VAS 75-CS 1-A, HYDROION VAS 25-CS 1-B, HYDROION VAS 75-CS 1-B, HYDROION VAS 125-CS 1.5-A, HYDROION VAS 125-CS 1.5-B Operating And Maintenance Manual

Last change 10/2018 E-P | Subject to technical modifications

Operating and Maintenance Manual

®

HYDROION

Type: VAS – CS

Serial number: ____________________

HYDROTEC UK Ltd. Telephone [phone]
Hydrotec House
5 Manor Courtyard, Hughenden Avenue
High Wycombe, Bucks. HP13 5RE Fax [phone]

Web: www.hydrotec.co.uk

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Index

The individual chapters are listed in the survey below. More detailed information is shown in
the respective overlays.

Preface

Chapter I General information
Chapter II Transport and storage
Chapter III System description / Technical data
Chapter IV Assembly and installation
Chapter V Micro processor control
Chapter VI Start up / Taking out of service
Chapter VII Troubleshooting
Chapter VIII Monitoring and maintenance

Appendices 1 Installation schematic softener
Appendices 2 Calculation soft water capacity
Appendices 3 Calculation sodium content
Appendices 4 Start up and training record - Softener HYDRO ION®
Appendices 5 Log book
Appendices 6 Commissioning request
Appendices 7 PUROLITE - ION EXCHANGE RESIN - Safety data sheet

Imprint

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Preface

The HYDROION® Softener are constructed and manufactured with respect to and in consideration
of all current standards as well as further technical specifications, and corresponds to the latest
state-of-the-art technology, allowing for maximum safety under all operating conditions.

System safety in operation can only be assured if all necessary measures are taken beforehand. It
is part of the operator’s diligence to plan and monitor such measures and implement them with due
care.

The operating and maintenance manual includes important information for a save installation,
operation and commissioning. Please make yourself familiar with all details prior to start operation.

For any additional information or problems encountered in conjunction with operation, please
contact our Customer Service Department at the following address:

Hydrotec (UK) Ltd

Hydrotec House

5 Manor Courtyard, Hughenden Avenue

High Wycombe, Bucks HP13 5RE

Tel: [phone]

Email: [e-mail]

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Index Chapter I – General information

Page

1. Documentation 5

2. Safety information 5

2.1 Operator’s duty of care 5

2.2 Appropriate use 6

2.3 Basic safety measures 6
Maintenance, repair and electric work 7
Start up after maintenance and repair work 7
Environmental regulations 7

2.4 Risk in the event of safety instructions being disregarded 8

2.5 Operational and ancillary materials 8

2.6 Used safety signs and instruction symbols 8

3. Warranty 9

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1. Documentation

The following information is included for the operator in the operation and maintenance manual:

• Safety information

• Information and instructions for assembly

start-up
operation
maintenance
troubleshooting

• Technical Data

The operation and maintenance manual together with all other technical information and documents
must always be kept readily accessible.

The O&M includes several chapters marked with roman numerals (see global index). The page
reference is shown right below on each page.
Information about the chapter contents see index on page 1 of each chapter.

For any additional information or problems encountered in conjunction with operation, please
contact our Customer Service Department at the following address:

Hydrotec (UK) Ltd.

Hydrotec House

5 Manor Courtyard, Hughenden Avenue

High Wycombe, Bucks HP13 5RE

Tel: [phone]

Email: [e-mail]

2. Safety information

2.1 Operator’s duty of care

The system is constructed and manufactured with respect to and in consideration of all current
standards as well as further technical specifications, and corresponds to the latest state-of-the-art
technology, allowing for maximum safety under all operating conditions.

System safety in operation can only be assured if all necessary measures are taken beforehand. It
is part of the operator’s diligence to plan and monitor such measures and implement them with due
care.

The operator must ensure that:

- The system is used in accordance with the specified purpose

- The system is maintained in a serviceable condition, with the safety facilities being monitored

for correct function in regular intervals

- The operation and maintenance manual is always in a legible condition and available next
to the unit

- The operation, maintenance and repair work is carried out by qualified and authorised
personnel only

- All safety and warning information attached to the system must not be removed and must be
kept in a legible condition

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2.2 Appropriate use

The system is manufactured to the latest German technical safety standards employing the latest
state-of-the-art technology.

If incorrectly treated, not maintained properly at regular intervals or not used for the correct purpose
according to the specifications, the softener may incur risks and/or damage.

Operation of system shall be within the technical parameters and limit values in chapter III.
The softener unit is to be operated and maintained in good working order and according to the
specification it was designed for only.

Important! Any other use of the system, other than described, is deemed to be not in

accordance with the specification.
The manufacturer / supplier does not accept any liability resulting from the

improper use of the system. Such risks are borne by the operator alone.
All regulations and instructions in the operating and maintenance manual and

such regulations as are applicable locally must be strictly adhered to.
Any malfunctions must be corrected immediately.

2.3 Basic safety measures

Prior to starting the system it must be guaranteed that:

- No-one can suffer injury due to the system operation

- All safety facilities are in a perfectly serviceable condition

The system must be operated in perfect condition only. All faults must be notified to the person
responsible immediately after being noticed.

In order to avoid flooding of installation site, there is a drainage and / or leak control with alarm to be
provided locally.

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Maintenance and repair work

- All inspection and maintenance intervals specified in the operation and maintenance manual
must be adhered to

- Prior to any repair work, the system must be disconnected from mains

- Prior any repair and electrical work the system is to be disconnected from the piping system

(the system must be de-pressurised) and shall be protected from accidental restart

- Only suitable and correctly functioning load-supporting devices shall be used when replacing
heavy components or system elements

- Hose lines shall be replaced regularly (preventive maintenance) even if no damage is visible

- During work at the plant suitable and corresponding protective clothing shall be worn (e.g.

when handling with liquids such as acids and bases/alkalis)

Electrical work

- Prior to any work on electric components the system must be disconnected from the mains

- Electric equipment must be checked in regular intervals

- Any possible loose connections must be re-secured and damaged electric cabling replaced

immediately

- Casings of electric equipment and system components must never be cleaned with a water
hose (spray)

- Electric components must never be touched with wet hands

- Valid VDE regulations must be adhered to, especially the regulations for the required

potential equalisation

- EMC interferences must be avoided and if necessary a mains filter protection shall be
applied

- Cable connections shall always be kept as short as possible

- Sensor and low voltage cables shall never be laid parallel to current-carrying wires (230 V or

400 V).

Start-up after maintenance and repair work

- Check screw connections for tight fit

- Ensure that any components removed beforehand (e.g. tank lid, screen or filter) are installed

and restored to their correct operational position

- It is to be ensured that all material, tools and other appliances which were necessary for
maintenance and repair work are removed from the working area of the system

- Any liquid that has leaked is to be removed

- Ensure that all safety equipment is in a perfectly serviceable condition

Regulations in respect of environmental protection

When working on and with the system, all legal regulations in respect of waste minimisation and
proper disposal (if appropriate) must be observed and respected.

The water-endangering substances listed below in particular must not be allowed to contaminate the
soil or enter the drainage system during installation, maintenance and repair work:

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This icon indicates general information which must be observed during the
operation of water treatment systems.

This warning symbol indicates information which shall be observed for the
purpose of your own personal safety and to prevent any cause of damage to the
systems.

This warning symbol indicates work which shall only be carried out by qualified
electricians according to VDE regulations or by responsible institutions or
specialized companies.

This symbol indicates information which must be observed for handling of
environmentally hazardous and water-endangering substances.

This icon indicates information to be observed during any maintenance and repair
work and for maintenance intervals.

- Grease and lubrication oils

- Hydraulic oils

- Cooling agents

- Acids and alkalis (bases)

- Disinfection agents

- Cleaning materials containing solvents

Such substances must be stored, transported and collected in suitable tanks and disposed
of in accordance with the applicable regulations.

2.4 Risk in the event of safety instructions being disregarded

The consequences of disregarding safety instructions can be dangerous to the system, material and
personnel, and the loss of any warranty claims.

We shall accept no liability for possible water damage caused due to disregard of the safety
instructions.

2.5 Operational and ancillary materials

All materials shall be handled in accordance with the COSHH regulation (the Control of Substances
Hazardous to Health 2002). Material Safety Data Sheets are provided in the Appendices.

Safety datasheets

The operating media used:

- Highly acidic cation exchange resin

- Regeneration salt

are not considered to be hazardous substances in the meaning of the legal provisions.

2.6 Safety and warning symbols

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3. Warranty

The warranty period for the system is 12 months, calculated from either the date of commissioning
by Hydrotec (UK) Ltd. or 15 months from the date of supply in the event that commissioning is not
included with the supply agreement, whichever is the shorter. The plant must be operated and
maintained in accordance with Hydrotec (UK) Ltd’s requirements. It is recommended that a service
contract is taken out for the unit.

Claims under warranty will only be accepted in the meaning of our General Conditions of Sale and
Supply subject to the following conditions:

- The system is used and operated in accordance with information and instructions in the
operation and maintenance manual

- The system is treated properly

- Repair work is to be carried out exclusively by authorised specialists

- Original spare parts or parts recommended by Hydrotec (UK) Ltd. shall be used

exclusively

- No modifications are carried out on the system by users themselves

- The stipulated operation parameters (pressures, flow volume) are maintained and a

water temperature of 30°C is not exceeded

- Start-up of the system has been carried out by our service personnel

- That after installation and longer standstill periods a chemical disinfection has been

effected

- A yearly maintenance is carried out by our service personnel

Excluded from warranty claim are all parts subject to wear and tear such as:

- All moving parts, motors, seals, membranes, filter etc.

Warranty claims cannot be accepted in cases of:

- Operation and installation errors

- Faulty maintenance

- Deliberate damage or negligent handling

Any unauthorised modifications are not permitted for safety reasons. Original spare parts and
accessories are especially designed for the softener series HYDROION®.

Original spare parts shall be used exclusively!
Important information for any queries and spare parts orders:

- Softener type (model number)

- Serial number

- Date of manufacture

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Chapter II – Transport and storage

All system parts of the HYDROION® softener unit should be secured against jolting and
falling during transport and storage.

Appropriate means must be used in order to avoid and exclude any damage during transport.
The entire delivery must be checked for completeness and possible transport damage immediately

upon receipt at the warehouse / site.
Any transport damage must be notified to the supplier immediately.

Important!
Pressure tanks get damaged by shock load!

In order to protect the feet, the tanks shall be lifted for transport (not tilted!).

The system and resin must be protected from frost during transport and storage
(recommended temperature 5-40°C). Storage outside these conditions can damage and
destroy the resin and resin vessel.

Components, fittings and pipes shall never be used for fixing of conveyor belts or other
supporting means of transport!

Do not lift the system via the components, fittings or pipes!
If disregarded, system components can easily get damaged and break/crack!

Regeneration material

Common salt (sodium chloride) supplied in tablet form according to EN 973 (DIN19604) is to be
used as the regenerant. Typically the salt is supplied in 25 kg plastic sacks which must be stored in
clean and dry areas only.

Hydrotec (UK) Ltd. is not a salt supplier. Supply of salt is the responsibility of the operator.

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Index Chapter III – System description / Technical Data

Page

1. System description 12

1.1 General 12

1.2 Function 13

1.3 Water pressure 14

2. Technical Data 15

2.1 HYDRO ION® VAS – CS – A 15

2.2 HYDRO ION® VAS – CS – B 16

2.3 Installation schematic 17

2.4 Pressure loss 18

3. Scope of supply 19

3.1 Components 19

- Resin vessel 19

- Resin 20

- Control valve 20

- Micro processor control 21

- Water volume counter 21

- Brine tank 22

- Brine exhaust 22

- Brine lack sensor 22

- Chlorinator 23

- Measuring kit total (permanent) hardness 23

3.2 Accessories 24

- System separator 24

- Assembly mounting 24

- External blending 25

- Flexible hoses 25

- Regenerant 25

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fig.1

1. System description

1.1 General

Simplex softener HYDRO ION® VAS – CS

HYDROION® VAS softeners are designed and used to chemically transform hard water into soft
water. The treatment process is via the ‘ion-exchange’ method, whereby the hard water flows over
the resin media in the pressure vessel. The elements responsible for hardness, calcium and
magnesium ions present in the water are bound reversibly to the ion exchange resin and in return,
sodium ions are released into the water. The accumulation of calcium and magnesium ions
(hardness) on the resin is periodically removed by a regeneration process using sodium chloride
(common salt) solution or brine.

Plant type: HYDRO ION® VAS - CS – A / B (Salt saving mode)
Treatment normally for

- Drinking water application according to DIN 19636

- Preparation of cooling water according to VDI 3803

Softener designed as Simplex system.

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1.2 Function

System HYDRO ION® VAS exclusively suited to soften hard water having drinking water
characteristics.

That means the water must be clear, colourless, free from chlorine, iron, manganese and oil in order
to avoid a damage of the exchange material by blocking.

The feature of hard water is substantial for the efficiency of the ion exchange material and the
operation of the system.

The ambient temperature for the system must be free from frost and not exceed 40°C since
otherwise the ion exchange resin will be irreversibly damaged and/or the pressure resistance of
used materials is reduced.

The HYDRO ION® VAS water softener is controlled by a water meter.
The softening of the water is by means of the ion exchange resin in the pressure vessel. The

process of ion exchange is the exchange of the hard minerals (calcium and magnesium ions) with
sodium ions. Water treated in this manner is called softened water.

The ion-exchange resin becomes exhausted after a certain water volume has passed and at this
point it must be regeneration with sodium chloride (common salt).

Operation / regeneration of the softener in the different stages in accordance with the following
processes:

Operation = soft water production

The water to be treated passes through the iron exchange resin bed from top to bottom and goes to
service as soft water via a riser tube.

Backwash

Water passes through the ion exchange resin bed from bottom to top, to fluidise and aerate the bed.
The back wash is sent to drain.

Brining / slow rinse

Brine is drawn by means of an injector, diluted, and fed through the ion exchange resin from top to
bottom. Whilst the process is taking place, the calcium and magnesium ions attached to the resin
are exchanged for sodium ions, thus regenerating it. Effluent goes to drain.

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water

incoming

to the consumer

reservoir

pressure
booster
system

softener

fig.2

Fast rinse

Hard water flows from top to bottom through the ion exchange resin, driving out the excess residues
of brining process. Effluent goes to drain.

Brine tank fill

After brining and rinsing, water is fed to the brine tank, via the brine draw line, filling it again up to
the normal water working level, this is to ensure that concentrated brine available for the next
regeneration process.

The softener is returned to service!

1.3 Water pressure

In order to guarantee optimum and economic operation of the system, the water pressure should be
adjusted to between 2.0 bar and 8.0 bar.

The water pressure should not fall below 2.0 bar, in order not to impair the functional performance of
the softener.

Regular maintenance avoids the increase of pressure loss and guarantees correct system
operation.

The water pressure must not exceed 8 bar, doing so may pose a safety risk and cause operational
problems, it is recommended that a pressure reducing valve be fitted upstream of the water
softener.

Caution!

Pressure booster systems must not be installed in flow direction directly after a water treatment
system into the piping.

In case a pressure booster system is required for the transport to the consumer the system shall
only transport soft water into a pressure-less vessel which is used for the subsequent pressure
booster system.

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2.1 Technical data

HYDROION® VAS – CS – A

Systems with full salting
(Type A)

25-CS

1 - A

50-CS

1 - A

75-CS

1 - A

125-CS

1,5 - A

150-CS

1,5 - A

200-CS

1,5 - A

250-CS

2 - A

375-CS

2 - A

600-CS

2 - A

Connection mains / soft water line

DN 25 (1")

DN 40 (1 1/2")

DN 50 (2")

DN 80

Drain line (mind.)

DN 50

DN 50

DN 70

Mains electrical connection

230 V / 50 Hz AC

230 V / 50 Hz AC

230 V / 50 Hz AC

Electrical connection (secondary)

12 V AC

12 V AC

12 V AC

Water temperature (min./max.)

5 °C / 30 °C

5 °C / 30 °C

5 °C / 30 °C

Ambient temperature (min./max.)

5 °C / 40 °C

5 °C / 40 °C

5 °C / 40 °C

Operational pressure
(min./max.) 2)

2 bar / 8 bar

2 bar / 8 bar

2 bar / 8 bar

Performance data

Nominal flow

1)

m³/h

2.5

3.5

4.5

6.5

8.0

10.5

13.5

17.0

24.0

Flow rate at blending
(300 ppm to 60 ppm)

m³/h

3.1

4.4

5.6

8.1

10.0

13.1

16.9

21.3

30.0

Pressure loss at rated flow 1)

bar

0.43

0.66

0.88

0.78

0.65

1.14

1.05

1.34

1.94

Capacity at 300 ppm CaCO3 1)

m³

5.3

10.8

16.2

27.3

32.2

43.5

54.9

82.8

132.3

Salt consumption

kg 5 10

15

25

30

40

50

75

120

Waste water volume per
regeneration

m³

0.17

0.36

0.55

0.88

1.06

1.40

1.73

2.62

4.20

Volume and weights

Resin vessel volume

Ltr.

38.4

79.5

115

153

277

277

344

473

704

Quantity of resin

Ltr.

25

50

75

125

150

200

250

375

600

Quantity of gravel

kg 4 7

10

17

40

40

40

58

40

Brine tank volume

Ltr.

140

190

340

460

460

670

920

1000

1500

Regeneration salt supply

kg

50

75

125

175

162

250

325

375

525

Operational weight
(complete unit) max.

kg

125

210

325

465

620

740

925

1210

1750

Dimensions

Height (max.)

mm

1235

1530

1600

1600

1700

1700

2000

2200

2220

Ceiling height (min.)

H

mm

1800

1800

1900

1900

2000

2000

2200

2400

2500

Width (max.)

B

mm

910

960

1160

1360

1550

1730

1980

2050

2480

Depth (max.)

T

mm

600

600

725

850

850

1000

1150

1150

1500

Clearance tank/tank (ca.)

A1

mm

510

530

630

760

820

900

1020

1070

1340

Diameter pressure tank

D1

mm

258

310

363

413

555

555

555

635

779

Diameter brine tank
(min. / max.)

D2

mm

460 /

565

460 /

565

594 /

723

703 /

833

703 /

833

847 /

973

997 /
1123

1015 /

1120

1050 /

1150

Height pressure tank
(incl. foot)

H1

mm

897

± 6

1232

± 6

1344

± 6

1341

± 15

1434

± 15

1434

± 15

1721

± 15

1918

± 15

1892

± 15

Height top control valve

H2

mm

1080

1420

1530

1570

1665

1665

1930

2130

2160

Height brine tank

H3

mm

843

1123

1200

1196

1196

1196

1206

1340

1500

Height feed (mains
water) / discharge
(softwater)

H4

mm

960

1295

1400

1430

1520

1520

1810

2010

2040

Control box (W x H x D)

mm

240 x 170 x 110

Mounting board (W x H x D)

mm

330 x 200 x 10

2. Technical Data

1)

Parameters are dependent on operation mode and water input quality.

2)

At operating pressure min. the flow pressure is decisive, at operating pressure max. the static

pressure is decisive

For the use in the field of boiler feed water, preliminary treatment and reverse osmosis a project
planning is always required performed by our Applications engineering department!

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2.2 Technical data

HYDROION® VAS – CS – B

Systems with economise
salting (Type B)

25-CS 1

- B

50-CS 1

- B

75-CS 1

- B

125-CS

1,5 - B

150-CS

1,5 - B

200-CS

1,5 - B

250-CS

2 - B

375-CS

2 - B

600-CS

2 - B

Connection mains / soft water line

DN 25 (1")

DN 40 (1 1/2")

DN 50 (2")

DN 80

Drain line (mind.)

DN 50

DN 50

DN 70

Mains electrical connection

230 V / 50 Hz AC

230 V / 50 Hz AC

230 V / 50 Hz AC

Electrical connection (secondary)

12 V AC

12 V AC

12 V AC

Water temperature (min./max.)

5 °C / 30 °C

5 °C / 30 °C

5 °C / 30 °C

Ambient temperature (min./max.)

5 °C / 40 °C

5 °C / 40 °C

5 °C / 40 °C

Operational pressure (min./max.) 2)

2 bar / 8 bar

2 bar / 8 bar

2 bar / 8 bar

Performance data

Nominal flow

1)

m³/h

2.5

3.5

4.5

6.5

8.0

10.5

13.5

17.0

24.0

Flow rate at blending
(300 ppm to 60 ppm)

m³/h

3.1

4.4

5.6

8.1

10.0

13.1

16.9

21.3

30.0

Pressure loss at rated flow 1)

bar

0.43

0.66

0.88

0.78

0.65

1.14

1.05

1.34

1.94

Capacity at 300 ppm CaCO3 1)

m³

3.9

7.8

11.8

19.9

23.4

31.6

39.9

60.2

96.2

Salt consumption

kg 2 4 6 10

12

16

20

30

48

Waste water volume per
regeneration

m³

0.15

0.31

0.46

0.76

0.92

1.22

1.52

2.28

3.66

Volume and weights

Resin vessel volume

Ltr.

38,4

79,5

115

153

277

277

344

473

704

Quantity of resin

Ltr.

25

50

75

125

150

200

250

375

600

Quantity of gravel

kg 4 7

10

17

40

40

40

58

40

Brine tank volume

Ltr.

140

190

190

340

340

460

460

670

920

Regeneration salt supply

kg

50

75

75

125

125

175

175

250

337

Operational weight
(complete unit) max.

kg

125

210

270

410

580

660

765

1080

1550

Dimensions

Height (max.)

mm

1235

1530

1600

1600

1700

1680

2000

2200

2220

Ceiling height (mind.)

H

mm

1800

1800

1900

1900

2000

2000

2200

2400

2500

Width (max.)

B

mm

910

960

1020

1250

1400

1500

1540

1760

2060

Depth (max.)

T

mm

600

600

600

750

750

850

850

1000

1150

Clearance tank/tank (ca.)

A1

mm

510

530

560

700

770

830

870

980

1130

Diameter pressure tank

D1

mm

258

310

363

413

555

555

555

635

779

Diameter brine tank
(min. / max.)

D2

mm

460 /

565

460 /

565

460 /

565

594 /

723

594 /

723

703 /

833

703 /

833

847 /

973

997 /
1123

Height pressure tank (max.)

H1

mm

897

± 6

1232

± 6

1344

± 6

1341

± 15

1434

± 15

1434

± 15

1721

± 15

1918

± 15

1892

± 15

Height top control valve

H2

mm

1080

1420

1530

1570

1665

1665

1930

2130

2160

Height brine tank

H3

mm

843

1123

1123

1200

1200

1196

1196

1196

1206

Height feed (mains water) /
discharge (softwater)

H4

mm

960

1295

1400

1430

1520

1520

1810

2010

2040

Control box (W x H x D)

mm

240 x 170 x 110

Mounting board (W x H x D)

mm

330 x 200 x 10

1)

Parameters are dependent on operation mode and water input quality.

2)

At operating pressure min. the flow pressure is decisive, at operating pressure max. the static

pressure is decisive

For the use in the field of boiler feed water, preliminary treatment and reverse osmosis is this model
series not suitable!

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2.3 Installation schematic

Height feed (mains water) / discharge (softwater)

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2.4 Pressure loss curve

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Equipment

Description

HYDRO ION® VAS – CS 1,5
(example)

1 = Resin vessel 1 (pressure tub)
2 = Control valve
3 = Brine tank
4 = Electronic control
5 = Input
6 = Output (softened water)
7 = Wash water drain

Resin vessel

Pressure tank of corrosion-resistant glass-fibre
reinforced plastics with PE-inliner (approved
for foodstuffs) with nozzle (jet) system.

Number: 1
Top threaded connection:

2 1/2“ HYDRO ION® VAS – CS 1
4” HYDRO ION® VAS – CS 1.5
4“ HYDRO ION® VAS – CS 2
6“ flanged HYDRO ION® VAS 600 – CS 2

1 2 3 4 5

6

7

fig.3

3. Scope of supply

3.1 Components

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Resin media

Strong acid cat-ion exchange resin to be suited
for drinking water application PFC100E grade.

Control valve

Microprocessor controlled, menu driven
system for control of operating modes,
functions and display.

Number: 1
Operating pressure: 2,5 to 8 bar
Operating temperature: 5 to 40 °C

HYDRO ION® VAS – CS 1
Material: Plastics (Noryl)
With top nozzle and
system pcb CB 204
Connections:
Incoming/soft water: 1“ (male)
Brine intake: 3/8“
Waste water: DN 20
Tank connection: 2 1/2“ – 8 NPSM

HYDRO ION

®

VAS – CS 1.5
Material: Brass with epoxy resin
coating and
system pcb CB 204

Connections:
Incoming/soft water: 1 1/2“ (female)
Brine intake: 1/2“
Waste water: DN 20 / DN 25
Tank connection: 4“ – 8 NPSM

HYDRO ION

®

VAS – CS 2

Material: Brass with epoxy resin
coating and
system pcb CB 204

Connections:
Incoming/soft water: 2“ (female)
Brine intake: 3/4“
Waste water: DN 25
Tank connection: 4“ – 8 UN

fig.4

fig.5

fig.6

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Micro processor control

Micro processor control in wall-mounted
casing, menu driven for different operation
modes such as:

- volume control with temporally priority circuit

- time control

- quality control in combination with
hardness control

- forced regeneration

- water refresh

- automatic disinfection

- external release

- external regeneration

- “brine alarm” - sensor in brine tank
(Function even at 2 brine tanks)

- “pressure alarm” - sensor

Hygienic operation of softener in two steps:
Phase 1: Refresh

(Interval rinsing / water-refresh)

For prevention of stagnation phases a switch
between both vessels takes place in short
intervals. Stagnated water is minimized in
stand-by.

Interval rinsing: At this setting the stagnated
water (defined volume) is led directly into the
drain line.

Water-refresh: In contrast to interval rinsing
the stagnated water (defined volume) is led
into the soft water system instead.

Phase 2: Disinfection
Is possible during regeneration.

Functions and messages:

- Diagnostic mode

- Error list (emBrick list) for errors

occurring during operation of the
controller

- Information mode with display on
monitor

- LED signal malfunction / operation

- universal output (maintenance /

regeneration / brine lack)

The electronic controller is pre-installed and
pre-assembled on a mounting plate and ready
for wall mounting.

Water meter

HYDRO ION® VAS – CS 1

The water meter 1” is integrated in the casing

of the control valve.

fig.7

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HYDRO ION® VAS – CS 1,5
Water meter as external installation unit,
mounted direct to the soft water output.

Connection: input 1 ½“ external thread
output 1 ½“ internal thread
Voltage: 12 V AC

Cable suited to connect the control to the central
control valve 1.

HYDRO ION® VAS – CS 2
Water volume meter as external installation unit,
mounted direct to the soft water output.

Connection: input 2“ external thread
output 2“ internal thread
Voltage : 12 V AC

Cable suited to connect the control to the central
control valves 1.

Brine tank

Storage tank for regeneration salt, designed as
tank with sieve base, brine tube and overflow.

Number: 1 off
Material: Polyethylene

Brine exhaust

Installed in the brine tube of the brine tank,
consisting of:

Brine safety valve
Float switch
Brine hose

Brine alarm sensor

Brine alarm sensor to control the brine level in
the tank, installed in the brine tube and consisting
of:

- float switch

- protective tube

- electric connection cable to micro processor
control

Switching capacity: max. 10 W/VA
Voltage: max. 12 V
Currency: max. 0.5 A

Connection cable

Connection cable

fig.8

fig.9

fig.10

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Chlorinator (Option)

Chlorinator used for the automatic disinfection
during regeneration phase of softener, consisting of:

- electrodes installed in PVC assembly element

- control cable for the connection to the micro
processor control

Control voltage: max. 15 V
Connection: 3/8“ (VAS – CS 1)

1/2“ (VAS – CS 1,5/ 2)
The electrodes are activated automatically once the

brine intake cycle of the regeneration phase starts.
Chlorine is produced that starts the disinfection of
the resin bed.

The process is finished automatically once the
programmed time period for disinfection is elapsed.
The electrodes are de-activated again.

Measuring kit permanent hardness

The below measuring kits shall be available for
setting and control of the system:

Determination of permanent hardness:
Measuring range up to 760 ppm

Control cable

T-fitting

Chlorinator

fig.11

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Back flow prevention device

Connection size dependent on
customer’s request
(Nom. flow to be considered!)

To separate drinking water from non drinking water up to
and including liquid category 4 (DIN 1988, part 4) for
systems according to DIN 1717 with controlled
separation (installation type 2 according to DIN 1988)
with integrated differential pressure controlled and
maintenance friendly safety cartridge, non-return system,
three test valves and drain connection.

Material: red brass
without dead space, noise
tested as per ISO 38222, with
SVGW/DVGW-certificate
Temperature: max. 60 ° C
Nom. pressure: PN 10 (connection screwing
with external thread)
Pressure loss: 1.0 bar

Back flow prevention to be in accordance with local
regulations.

Connection local incoming/
soft water pipe

Assembly mount

HYDRO ION® VAS – CS 1
With blending

Art.-No.
Excluding blending

Art.-No.

The mount replaces the by-pass line to be provided
locally. Two valves stop the supply and discharge and
allow service work. The fitting can be used including or
excluding blending.

Material: corrosion resistant
red brass as per DIN 1705
Water temperature: max. 90 ° C
Pressure step: PN 10
Connections : R 1“
Installation length: 166 mm

HYDRO ION® VAS – CS 1,5

With blending
Art.-No

Excluding blending
Art.-No.

Material: corrosion resistant
red brass as per DIN 1705
Water temperature: max. 90 ° C
Pressure step: PN 10
connections: R 1 1/2“
installation length: 200 mm

HYDRO ION® VAS – CS 2

There is no mount available for such sizes. Installation of
softener has to be realized in rigid pipe work.

3.2 Accessories

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External blending

Blending unit DN 32
Art.-No.

Blending unit DN 50
Art.-No.

Fully automatic operating blending valve for installation
in bypass.

Material: corrosion resistant
red brass as per DIN 1705
Water temperature: max. 90 °C
Pressure step: PN 10

Connections : R 1 1/4“ (DN 32)
Installation length: 130 mm

Installation length: R 2“ (DN 50)
Installation length: 139 mm

Flexible hose
HYDRO ION® VAS – CS 1

Flexible hose - Art.-No.

HYDRO ION® VAS – CS 1,5
Flexible hose - Art.-No.

2 flexible hoses for system connection
Dimensions: 2 x 1“ (ÜM)

Length: 800 mm

2 flexible hoses for system connection
Dimensions : 1 1/2“ (AG) x 1 1/2“ (ÜM)

Length: 1000 mm

Regenerant
Art.-No.

In form of tablets (not granular!)
25 kg PE bag (Not available from Hydrotec UK Ltd.)

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Index chapter IV – Installation and assembly

Page

1. General information 27

2. Installation location 28

3. Work prior to assembly 28

Control of shipment 28
Drain connection 28
Incoming and soft water pipe 28

3.1 Filling of filter vessel with quartz gravel and exchange resin 29

4. Hydraulic connections at control valve 31
Control valve 1“ HYDRO ION® VAS – CS 1 31
Control valve 1 1/2“ HYDRO ION® VAS – CS 1.5 31
Control valve 2“ HYDRO ION® VAS – CS 2 31
Brine line 32
Brine lack sensor 32
Chlorinator 32
Wash water connection (drain) 32

5. Electric connections 33
Mains connection 33
Connection pcb control valve 33
Connection water volume meter 34

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Fine filter

System sep.

Water meter
Incoming

water

Softener

fig.12

1. General information

The HYDRO ION ® VAS – CS softener is designed as Simplex system consisting of one resin vessel
(pressure vessel) with ion exchange resin and support quartz gravel as well as one control valve on
top of the filter vessel each. All operation modes are realized by means of a micro processor control.

 The softener system HYDROION® VAS 25 is filled with exchange resin ex works. The system

up to “VAS 600” has to be filled with exchange resin in situ (chapter IV section 3.1).

The resin vessel for the HYDROION® VAS range is dispatched empty for handling purposes

and must be filled with the gravel and ion exchange resin on site (see Chapter 6.5.1.). The resin
will be supplied separately in 25l bags.

It is the responsibility of the commissioning engineer to fill the resin vessel with the gravel and

resin. Hydrotec (UK) Ltd. will perform this service during commissioning visit.

 Necessary pipe connections to the central control valve must be performed on site.
 Softener is controlled via water flow meter installed in the soft water pipe.
 The control settings are programmed in the microprocessor control unit.
 Information and parameters such as time, regeneration status, residual capacity, water

consumption, operation days, functions and actual state for inputs and outputs are shown in the
display of the microprocessor control unit.

 The brine container / salt bin which holds the tablet salt regenerant must be located immediately

adjacent to the resin vessel.
The supply of the regenerant to the control valve of the respective vessel is by float valve and

hose line into the vessel.
 Wash water (waste water) is discharged to drain.
Incoming water is drinking water

According to standard EN1717 (DIN 1988), water softeners have to be provided with the

following safety fittings:

- Black flow prevention device
Due to the installation of a back flow prevention device, the pipe work is protected against
the return of treated drinking water into the drinking water system.

Please consult local regulation.

- Protective filter
Suited for the protection of the pipe installation and the softener against malfunction and
corrosion damage that can arise by foreign particles such as rust, sand etc.

According to standard DIN 13443-1, a filter has to be installed in the pipe before the system
separator and just after the water meter in case of metal pipe work.
The installation of a protective filter is recommended for plastic pipe work as well.

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Delivery check

Prior to starting assembly, the equipment must be
checked for completeness and possible transport
damage.

Any deviation must be notified immediately.

Waste water connection

The local waste water connection must be provided as
free discharge as per EN1717 (DIN 1988).
The cross section of the drain must be sufficiently
dimensioned (DN 50 at least).

Mains / incoming and soft
water pipes

The mains water and soft water pipes must be designed
locally in the required cross section and in the necessary
position in relation to the system.
Materials for soft water pipes should be plastic or
stainless steel.

Furthermore DIN 19636 (section: “protection against bacterial contamination”) must be observed:
“As water softening systems, especially at discontinuous operation, are vulnerable to bacterial

contamination, this must be prevented by means of suitable constructive or chemical-physical
measures.”

In order to keep that DIN 19636, a forced regeneration after 4 days (96 hours) has to be
programmed in the controller of the HYDRO ION ® VAS – CS softener system.

Installation of a chlorine producer into the brine hose is provided ex works for the system designs
VAS CS – A (systems with full salting) and B (systems with economic salting).

The chlorinator is actuated via the micro processor control unit.

The installation of the system must be carried out by trained and qualified personnel.
DIN 1988, DIN EN 12506 and DIN EN 806 are to be observed during installation.

2. Installation location

The below has to be guaranteed in respect of the installation and operation of a softener:

 The HYDRO ION® VAS - CS softener is to be installed in a frost-protected area.
 The ambient temperature must not drop below 5°C and not exceed 40°C.
 A free discharge to the drainage system as per EN 1717 (DIN 1988) for waste water and

overflow of brine tank in accordance with the discharge volume is to be provided locally.

 Installation should be located on even floor with level tolerances as per DIN 18202.
 The minimum installation dimensions are shown in the dimensional drawings and table (see

chapter III).

 An electrical connection of 230 V, 50 Hz, 3 A fused spur is to be provided locally for the

operation of the micro processor control.

 In order to avoid flooding by leakage, the installation location must be provided with ground

drainage discharge or leakage monitor with corresponding alarm.

3. Work prior to assembly

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Seal the upper pipe opening of the riser with
insulating tape in order to prevent resin or
quartz gravel entering the riser tube during
filling of the resin tank.

Lower distributor (1“ systems)
1 = filter on end of riser tube

2 = resin vessel base
Position the riser tube in the resin vessel in

such a way, that the riser tube stands in the
middle of the container base.

Star-type distributor (1 ½“ and 2“­systems)

1 = nozzle rod
2 = star-type distributor

The star-type distributor shall be put together
and placed in the vessel in a way that it
stands on the vessel base.
The pipe cover must not be forgotten!

nozzle rod

protection cap

2 1 1

2

fig.13

fig.14

fig.15

3.1 Filling of resin vessel with quartz gravel and exchange resin

Assembly of resin vessel (pressure vessel) and brine tank, whereby a sufficient area must be
available for operation and maintenance as well as supply and discharge lines.
(Installation schematics see appendices 1)

Note:

The quartz gravel volume is sufficient for both filter vessels and packed in the respective required
quantity.

It is recommended to wash the quartz gravel prior to being filled into the vessel in order to eliminate
any possible contamination.

(Best in a bucket under flowing water and constant stirring)

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Upper distributor
HYDRO ION® VAS – CS 1

Upper distributor
HYDRO ION®

VAS – CS 1,5
(Di 50 mm)
VAS – CS 2
(Di 63 mm)

Filling of filter vessel as below:
Step 1:

Fill the resin vessel to approximately one quarter
of its volume with clean water.

Step 2:

Fill the quartz gravel in the resin vessel.
A good distribution must be guaranteed!

Step 3:

Separate the resin and fill it in the vessels.
A good distribution must be guaranteed!

The respective quantity to be filled into the
vessels are shown in chapter III / point 2.1 and

2.2 (table with technical data).

Step 4:

Clear any contamination, such as resin off the
threaded opening to the vessel, with clean water.

Step 5:

The closure of the nozzle rod must be removed
again.

Step 6:

The control together with top distributor must be
mounted on the vessels and the unit be aligned.
It has to be guaranteed that the nozzle rod can
be inserted into the opening of the control valves
without problem.

Step 7:

The prepared connections for incoming and soft
water must be connected.

Note:
All sealings (O-Ringe) at the vessel

connection of the control valves must not be
damaged and fit straightly.

to control valve

to control valve

nozzle rod

nozzle rod

fig.16

fig.18

fig.17

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Control valve 1“ - HYDRO ION® VAS CS 1

1 = Mains water connection (inlet)
2 = Soft water connection (outlet)
3 = Connection for brine line
4 = Waste water connection

Control valve 1 1/2“ - HYDRO ION® VAS CS 1.5

Control valve 2“ - HYDRO ION® VAS CS 2

3

1 2 4 3 2 1 4 2 1

4

fig.18

fig.19

fig.20

Water meter

4. Hydraulic connections at control valve

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Brine line

The brine is taken from the brine tank by means of a hose.
Brine is drawn in by the control valve and flows through the
intake pipe to the injector, passing the injector, before
reaching the filter media. The injector is used to limit the
brine quantity that is dependent on the quantity of filter
media.

The brine intake hose has to be fixed to the hose connection
of the brine valve (in brine tank). The hose must be fixed to
the connections of the control valve.

HYDRO ION® VAS - CS 1
Control valve 1“: connection 3/8“

HYDRO ION® VAS - CS 1.5
Control valve 1.5”: connection 1/2“

HYDRO ION® VAS - CS 2
Control valve 2“: connection 3/4“

The waste water hose that is included in the delivery scope
must be connected in an appropriate length and size to the
local drain.

Brine lack sensor

The brine lack sensor is mounted already in the brine tube of
the brine tank and has to be connected electrically to the
micro processor control.

Chlorinator

If necessary and ordered, the
chlorinator is already
mounted in the brine intake
pipe.

Waste water connection

Waste water connection of control valve 1“: 3/4“
Waste water connection of control valve 1 1/2“: 3/4“ or 1“
Waste water connection of control valve 2“: 1“

The waste water hose must be fixed in an appropriate length
to the connection leading into drain.

It must be guaranteed that discharge of waste water into the
local drain (channel) is without any pressure applied.
Otherwise, regeneration takes place whereby no brine is
drawn in.

To control valve

From brine tank

fig.21

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Mains connection
The control in wall mount casing must

be installed at eye level and easily
accessible!

A safety socket must be provided locally next to
the mains cable of the micro processor control.

Permanent voltage must be provided
(230 V / 50 Hz).

Do not use the lighting circuit!

Figure 23 shows all electrical supplies and
control lines to the micro processor control unit.

1 = Power supply
2 = Connection cable chlorinator
3 = Connection cable brine level sensor
4 = Connection cable control valve 1 (A)
5 = Connection cable control valve 2 (B)

Connection pcb control valve

Connections to terminal of pcb of control valve
(from top to below)

Terminal

Magenta 29 / 38

Grey 28 / 37
Black 27 / 36
Red 26 / 35
Blue 25 / 34
Brown 24 / 33
White 23 / 32
Yellow 22 / 31
Green 21 / 30

1 = Connection motor control valve
2 = Connection water flow meter

1

1

2

fig.23
3

2

4

5

fig.22

Important!

 All pipe connections must be done without any tension applied on. If necessary, the

subsequent pipes must be provided with corresponding mounts or supports.

 Hoses must not be bent and hose connections must be screwed tight.
 Waste water, overflow and discharge lines must be provided from the connections at the

control valve until waste water drain with an appropriate inclination.

The waste water must be allowed to drain without backflow.

Backflow is not allowed for hygienic reasons!

5. Electrical connections

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Connection water flow meter

HYDRO ION® VAS – CS 1
The water meter is firmly installed in the soft water

output of the valve in case of control valves 1” and

is electrically connected to the pcb by means of
plug cable (see figure 18).

HYDRO ION® VAS – CS 1,5
HYDRO ION® VAS – CS 2

The water meter is installed in the output of the soft
water line in case of control valves 1.5“ and 2“.

Electrical connection is realized by means of plug
cable at the control valve.

Water meter

Control valve

fig.24

All work at electrical equipment of the softener shall be
carried out by an authorized expert only!

Note!
Since there is the risk of germ formation, it is recommended to disinfect the softener after

vessel filling and short before commissioning.

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Index Chapter V – Micro processor control

Page

1. HC - SOFTENER 36

1.1 Display / LED’s / Operating keys 37

1.2 Display content whilst the controller is run up 37

1.3 Main display – view 38

1.4 Access levels 40

2. Menu survey 41

3. Alarm 42

3.1 Acknowledge alarm 42

3.2 Alarm records 44

4. Total hardness 45

5. Operation mode 45

6. Protocol settings 46

7. SD-Card (messaging) 46

8. Language 47

9. System time 46

10. System date 47

11. Information 47

12. Menu structure 48

13. Electrical installation / wiring / terminal posts 51

13.1 Installation and commissioning 52

13.2 Technical data HC – softener controller 53

13.3 PCP equipment and terminal charge 54

13.4 Fine fuses 60

14. Parameter settings HYDROION® VAS – CS 61

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1. HC – SOFTENER

Our HC SOFTENER controllers ensure a regulation and control of operating process and
regeneration of single unit.

Regeneration can be released by different modes. Volume controlled with time priority (e.g. forced
regeneration after 4 days). A hundred percent time controlled with a pre-set regeneration interval.
Quality controlled regeneration, for example in conjunction with a hardness control device that
supplies an external contact input in case of hardness break, is possible as well.

Different VFC outputs are given to control the operation of the softener:

 External regeneration release
 Salt lack in brine tank
 Pressure shortage

The universal VFC output can be programmed for the below functions:

 Warn signal
 Regeneration active
 Brine lack

An additional VFC relay output confirms possible failure records.
Both relay outputs are designed as VFC alternator.
Several VFC-affected outputs are available for power supply and for the approach of possible

additional plant components:

 Brine pump
 Circulation pump

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HC – Applikation
SOFTENER = softener controller

Software-Version

Arrow keys

Input key/
Enter/CR

Function keys(charge
acc. below display)

Escape

LED operation

LED error

1.1 Display/LED’s/ Operating keys

1.2 Display content whilst the controller is run up

The controller is switched-on with the ON/OFF button (left side at casing) and supplied with mains
voltage. The below display is shown when the controller is run up:

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LED green – ON – Vessel in operation

Vessel number –
Vessel 1 in front view

1.3 Main display / view

Two or three different main displays / views exist dependent on plant construction, in between the
controller is switching automatically.

Main display with date, time and software version

Display for filter in operation – identical for all plant constructions

- total capacity that can be treated

- available residual capacity

- actual flow

- time remaining until release of forced regeneration (option)

Ready for operation display – in case of Duplex system only

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LED green – OFF – Vessel in regeneration

Regeneration display

- actual regeneration phase

- time remaining of regeneration phase

At the beginning of regeneration the following messages are shown on display.

- Pre-regeneration filter 1

- Pre-operation filter 1

These messages are displayed on the screen until the control valve is in their correct end position.

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Regeneration display – release of regeneration locked

- brine formation time not yet finished/elapsed

- lock time active

1.4 Access levels

The controller has four access levels to avoid access by unauthorized persons.

Example for input of password:

Passwords

There are 4 access levels with the below passwords:
Level 1 [user password]: 1111  plumber

Level 2 [admin password]: 2222  supplier
Level 3 [engineer password]:  plant engineer
Level 4 [super password]:  plant engineer

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2. Menu survey

The main menu is called via the keys F3 or Enter. Different functions and settings can be called
from the main menu as below:

Main menu

Alarms
Settings
Total hardness

Service

Operation mode
Protocol Setting

SD-Card
Language
System Time
System Date
Information

The desired menu point can be achieved and selected via the keys F3 or Enter.
The controller returns to any higher menu via the keys F1 or Escape. If any setting was modified,

confirmation is required prior returning to main view that the new setting must be stored.
The respective necessary release must be confirmed to select the different menu points

(see topic 1.4).
These are:

 Alarm no password required
 Settings Level 1 > plumber
 Total hardness no password required
 Service Level 3 > plant engineer
 Operation mode no password required
 Protocol Setting no password required
 SD-Card nor password required
 Language no password required
 System time no password required
 System date no password required
 Information no password required

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LED red - ON

3. Alarm

3.1 Acknowledge alarm

Immediately upon release of an alarm, the below display is shown with the number of actual alarms
and the reason for the record.

The controller returns to main menu view via the keys F1 or Escape.
The alarm record is maintained and can be called anew via the main menu.
The failure LED lights red for the duration of an alarm record.

The alarm is acknowledged via the keys F3 or Enter.

NOTE: Any failure must be eliminated prior being acknowledged.

Example 1:

 Alarm „brine lack“
 That is caused if regeneration is released but no saturated brine is available or

if salt must be added to the brine tank

 Salt must be refilled into brine tank
 A brine formation time (ca. 2 to 3 hours) must be allowed to pass
 The alarm is automatically acknowledged by the controller once saturated brine is available

as the float in the brine tank rises and thus, closes the input contact

 The number of alarms is reduced to zero / the red LED extinguishes

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Example 2:

 Pre-warn „power failure“
 “power failure“ warning is shown in the controller
 The warning record is shown even after the controller has been switched off and on again
 If power supply was interrupted for a longer time period, no flow was determined during such

period and the capacity was not reduced

 Manual regeneration is worthwhile then to avoid overriding the plant capacity
 The warning record is acknowledged via the keys F3 or Enter

NOTE:

If several failures and alarms are evident, these must be eliminated and acknowledged all
one after the other.

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Record

Failure

Reason / background

Action

Pre-warn

Maintenance
necessary

Maintenance interval
soon running out

Arrange for maintenance soon and
confirm in menu

Alarm

Maintenance
necessary

Maintenance interval ran
out

Arrange for immediate maintenance
and confirm in menu

Pre-warn

Power failure

Separated for mains of
power failure

Acknowledge failure

Pre-warn

Brine lack

No saturated brine in
brine tank

Add salt into brine tank

Alarm

Brine lack

No saturated brine in
brine tank and a
regeneration is due to be
released

Add salt into brine tank
Pre-warn

Chlorinator
 Blockage

The actual current is
outside the tolerance for
nominal current

Deposit on chlorine electrode
 clean or replace

Pre-warn

Chlorinator
 Blockage

The duration of the
chlorine production is
higher than the brine
intake period

Check brine intake period and
chlorine production duration and
adjust if necessary. Alarm delay set
too low

Alarm

Chlorinator
 Saturation

The required current
cannot be achieved
even with quite high
voltage

Too low brine saturation

 add salt tablets
 possibly check hydraulics of brine

intake

Alarm

Chlorinator
 Short circuit

Hardware error or false
terminal charge

Check installation

Alarm

head 1/2 time
exceeded

Move time of valve
motor too long

Check plug connections at valve and
terminals in the controller

Alarm

head ½ time
increments

Piston position not
reached

Check plug connections at valve and
terminals in the controller

Alarm

head 1/2 stdby current

Hardware error

Check pcb’s and terminals

Alarm

head 1/2 tract. current

Hardware error

Check pcb’s and terminals

Alarm

head 1/2 high current

Hardware error

Check pcb’s and terminals

Alarm

head 1/2 low voltage

Hardware error

Check pcb’s and terminals

Alarm

head 1/2 high voltage

Hardware error

Check pcb’s and terminals

Alam

Alternator low current

Hardware error

Check pcb’s and terminals

Alarm

Alternator high current

Hardware error

Check pcb’s and terminals

Alarm

Alternator time
exceeded

Move time of valve
motor too long

Check plug and socket contacts on
valve and terminal clamps on the
control unit

Alarm

Alternator low voltage

Hardware error

Check pcb’s and terminals

Alarm

flow fallen below

Too less flow

Increase removal

Alarm

flow exceeded

Too high flow

Reduce removal

Alarm

lack of pressure

Too low input pressure

Check input pressure

3.2 Alarm records

Below is a survey of possible alarm or warning records:

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LED red - OFF

The below display is shown when calling the menu point „alarm“ in case of troublefree operation:

No record, warning and no alarm actually evident.

4. Total hardness

The local mains water hardness is programmed in the menu point total hardness.

Setting range 5°dH to 80°dH (89 ppm to 1430 ppm)

5. Operation mode

The main menu item „Operation mode“ is used for release of regeneration. Furthermore
regeneration steps can be skipped under this menu item. It is displayed by a message if a menu
item should not be selectable due to technical reasons.

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Datentransfer

All Data > SD-Card
PAR Data > SD-Card
SYS Data > SD-Card
PROC-Data > SD-Card
SD- Card > All Data
SD- Card > PAR Data
SD- Card > SYS Data
SD- Card > PROC Data
Calib. > SD- Card
SD- Card > Kalib.
Delimiter

6. Operation settings

In the main menu item „Protocol settings“ the currently
programmed protocol settings can be accessed via “Info

Protocol”. For this purpose, no password is required.

In the second menu item you can change the protocol
settings. Access-Level 3 is required.

Under the menu item „Single recording“, the following
information will be stored on the SD card at the execution
time.

- Logging - Protocol (Systemtime, Date, … )

7. SD-Card (messaging)

The menu item „SD-Card“ is used for
transfer of data of the SD-Card to the
controller, and vice versa.

Description:
All data - PAR, SYS, PROC
PAR - Parameter Data
SYS - System Data
PROC - Process Data
Calib. - Calibration Data

An access level is not required for this
menu item in the Main menu!

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8. Language

The unit for mains (permanent) hardness as well as the unit for resin capacity is altered in
conjunction with the language setting.

Unit total hardness in German: °dH
Unit total hardness in English: ppm

Unit resin capacity in German: m³x°dH
Unit resin capacity in English: m³

The actual values and figures are converted and shown in the respective unit after the language has
been selected.

Example:

German display:
Total hardness - 20°dH Kapazität - 65 m³x°dH

English display:
Total hardness - 356 ppm Capacity - 1157 m³

9. System time

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Menu point

Display

Regeneration

Total number of regenerations
In case of Duplex or parallel system the sum of both vessels

Regen. F1

Number of regenerations Vessel 1

Regen. F2

Number of regenerations Vessel 2

Total volume

Total water volume treated in m³

Volume F1

Water volume treated in Vessel 1

Volume F2

Water volume treated in Vessel 2

Last regeneratioin

Date and time of last regeneration

Last regeneration F1

Date and time of last regeneration Vessel 1

Last regeneration F2

Date and time of last regeneration Vessel 2

Flow

Maximum determined flow since last regeneration of the Vessel in
operation

Save Information

The above mentioned informations – technical data will be stored on
the SD-Card (.csv file). For this action, access level 3 is required.

10. System update

11. Information

All operation and regeneration parameters can be called in the information menu.

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Alarms

Settings

Design

Single / Double / Parallel Unit

Rinsing

Refresh mode

Interval rinsing

Interval

Volume

Flow

Inputs

Brine cure

Ext. regeneration

Brine alarm

Pressure lack

Brine tank

1 brine tank

Regeneration mode
Amount

Time

Chlor. gen.

Chlor. gen. active

Selection Chlorine gen. A

Start delay

Target current

Tolerance

Period

Alarm delay

Blockage limit

Saturation lim.

Circulation
Minimum flow

delay

Capacity

Clack valve

Clack type

t-backwash

t-brine dr:/sl.

t-fast rinse

t-fill

t-brine format.

Forced regenerat.

Lock times

Operation valve

1st lock time

2nd lock time

3rd lock time

4th lock time

Universal out
Brine alarm, Regeneration, Warning

Cont. Type

Alarm sound

Total hardness

Service

System info

SW Version

Syspar-Vers.

Par-Vers

Cali.-Vers

Com. Module

Auto DLS time

Firmware Update

Op. time

Maintenance type

Maint. bef.

Maint. (Warn)

Maint. (Alarm)

Maintenance done

Reset

Reset brine timer

Diagnosis

Calibration

emBrick List

Operation mode

operation1

regeneration 1

regeneration step

12. Menu structure

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Protocol settings

Info Protocol

SD Card

Recording

Delimiter

Number. Of Elem.

Rec. Intervall

New.File Intervall

Settings Protocol

Recording

Delimiter

Rec. Intervall

New.File-Interval

Single recording

SD card

All Data > SD-Card

PAR Data > SD-Card

SYS Data > SD-Card

PROC-Data > SD-Card

SD- Card > All Data

SD- Card > PAR Data

SD- Card > SYS Data

SD- Card > PROC Data

Calib. > SD- Card

SD- Card > Kalib.

Delimiter

Language

German / English

System Time

System Date

Information

Regenerations

Regen. F1

Total capac.

Amount F1

Last Reg. (Date)

Last Reg. (Time)

Last Reg. F1 (Date)

Last Reg. F1 (Time)

max. flow

Save information

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13. Electrical installation / wiring / terminal posts

Work at electric equipment

- Prior any work at electric equipment, the system/machine must be set de-energized.

- All respective regulations (DIN, VDE, UVV) must be observed for installation and operation

of the controller.

- Repair work at electrical equipment must be carried out by skilled experts only!

- Electric equipment must be controlled in regular intervals!

- Any loose connections must be fixed!

- Damaged cable/wiring must be replaced immediately!

- Switchboard / controller casing must always be kept closed and locked! Access is reserved

to authorized staff!

- Switchboard / controller casing of electric equipment must never be cleaned by using a water
hose!

Any negligence of the information can result in damage of the controller as well as the total
system and, as a consequence loss of warranty claim!

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13.1 Electrical installation / wiring / terminal posts

Installation requirement

- The maximum admissible load of switching outputs as well as the total system capacity must
not be exceeded by the connected consumer.

- All inductive consumers (valves, motors, contactors, transformers) must be equipped with
suitable suppressors (RC-unit, varistor (VDR), diode etc.).

- High line disturbance levels of any external units (frequency converter, motors, inductive
furnaces etc.) existing next to the controller must be reduced by suitable measurement or
otherwise, respective external suppressors (mains filter) provided at the supply voltage input
of the controller.

- Transmitting (data) systems of any type, including mobile transmitting units must not be
operated next to the controller to avoid possible EMC influences.

Assembly direction

The below direction must be observed in view of PCB wiring:

- The clamps must be handled carefully and the wires clamped/inserted with minimum power
only.

- The connection clamps (without screws) are suited to take flexible wiring (without wire end
sleeve) up to 0.5 mm² (at sensor inputs) or flexible wiring (without wire end sleeve) 1.00 mm²
or 1.5 mm² rigid wire. Using wire end sleeves is not admissible in accordance with

supplier information.

- The screw connection terminals (PE 1 – PE 6) can take the following wires:
> rigid wires 0.14 – 2.5 mm²
> flexible wires 0.14 – 1.5 mm² or 0.25 – 1.5 mm² (with wire end sleeves)

- Prior putting into the clamp, the wire must be insulated over a length of min. 5 mm. It is
recommended to turn the wire end somewhat or to apply tin coat.

- The respective VDE regulations must be observed in view of all assembly work.

- Work at electric equipment must be carried out by skilled experts only.

Installation of controller

Installation shall be in the below sequence:

- Fixing of controller: the controller must be wall mounted in a dry, well accessible and well
visible area.

- The sensors / initiators must be connected (flow record).

- The actors must be connected (e.g. pumps, valves).

- Subsequently, the controller must be connected to mains.

The correct connected voltage must be observed!

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minimum

typical

maximum

Unit

Nom. operating voltage (AC)

205

230 250

V

Mains frequency

47

50 63

HZ

Nom. apparent power (excluding consumer)

6 8

15

VA

Ambient temperature (operation)

0

40

°C

Ambient temperature (storage)

- 10

60

°C

Rel. humidity (not condensing)

15

80

%

Inputs

Switching current

15

mA

Switching voltage

25

V

Outputs

Disruptive strength

250

V

Load AC

4

A

Load DC

1

A

Dimensions

Length 230

mm

Width

205

mm

Height

83

mm

13.2 Technical Data HC – softener controller

The controller must be operated in accordance with the below conditions:

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Input 24 VDC
clack board

Inputs and Outputs for
the control valves

Output 24 VDC for
the clack board

Output 24 VDC for
the chlorine board

Power supply
230 V / 50 Hz

Output
230 V / 50 Hz

Outputs with potential
230 V / 50 Hz

Relay outputs
potential free

Digital Inputs
potential-free

Output for
chlorinator

Input 24 VDC
chlorine board

PE-terminal 1-6

13.3 PCP equipment and terminal charge

Main board and wiring

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No.

Name

Function

Colour

1

230 V-PE

Power Supply 230 V / 50 Hz
Ground

2

230 V-N

blue

3

230 V-L

brown

4

230 V-PE

Output 230 V / 50 Hz

5

230 V-N

6 230 V-L

7

230 V-PE

PE-Connections 1-6. The grounding cable is already clamped!

No.

Name

Function

Colour

1

PE 1

PE-Connection “L-board” (PCB)

Ground

2

PE 2

- housing

- pipelines
3

PE 3

4

PE 4

5

PE 5

6

PE 6

No.

Name

Function

Annotations

Colour

7

230 V-N

Relay 1

Brine pump

8

230 V-Lno

9

230 V-N

Relay 2

Circulation pump

10

230 V-Lno

11

230 V-N

Relay 3

Not used

12

230 V-Lnc

13

230 V-Lno

14

230 V-N

Relay 4

Not used

15

230 V-Lnc

16

230 V-Lno

1

2 3 4 5 6

7 1 2 3 4

5

6

Wiring on the main board:
Power supply

230 V – Outputs – potential-free

Relays only operate 230 Volts!

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No.

Name

Function

23

Input [Di1]

24

GND

25

Input [Di2]

external regeneration release

26

GND

27

Input [Di3]

brine sensor

28

GND

29

Input [Di4]

30

GND

31

Input [Di5]

pressure switch

32

GND

No.

Name

Function

Colour

17

NC

selectable:
warning, regeneration or brine error

Relay 5

18

C

19

NO 20

NC

error

Relay 6

21

C

22

NO

Output Error – Warning – potential-free

The relays can be operated with the same voltage levels. Either 230 VAC, or 24 VAC or 24
VDC. Mixing of voltage levels is not allowed.

Digital Inputs – potential-free

Only sensors with potential-free contacts!

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No.

Name

Function

Colour

1

10

Motor Enable

Enabling piston motor

green

2

11

Motor Direction

Direction piston motor

yellow

3

12

+ 5 V

Power supply

white

4

13

GND

brown

5

14

Increments

Analogue output – optical detection of
piston position

blue

6

15

Increments Enable

Enabling piston control

red

7

16

water meter pulses

Water meter pulses

black

8

17

LED Production

Operation LED

grey

9

18

LED Regeneration

Regeneration-LED

purple

19

Motor Endable

20

Motor Direction

21

+ 24 V

Power supply Clack board

red (thick)

22

GND

blue (thick)

23

+ 24 V

Power output

red (thick)

24

GND

For the chlorine board

blue (thick)

Wiring clack board:

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No.

Name

Function

Colour

29

38

Motor Enable

Enabling piston motor

purple

28

37

Motor Direction

Direction piston motor

grey

27

36

+ 5 V

Power supply

black

26

35

GND

red

25

34

Increments

Analogue output – optical
detection of piston position

blue
24

33

Increments Enable

Enabling piston control

brown

23

32

Impulse input

Water meter pulses

white

22

31

LED production

Operation LED

yellow

21

30

LED regeneration

Regeneration-LED

green

Detection piston position

Board at the control valve

Backside with optical detection of piston position:

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No.

Name

Function

Colour

1

01/ 0 V

power supply chlorinator

brown

2

blue

3

02 / 0 V

4

5

24 V

power supply chlorinator board

red

6

GND

power supply chlorinator board

blue

7

24 V

power supply chlorinator board

(red)

8

GND

power supply chlorinator board

(blue)

Wiring chlorinator board:

The power supply of the chlorinator(s) is provided in opposite polarity after each treatment.

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Name

Type

F 1

5 x 20 mm fuse T 200mA L 250V

F 2

5 x 20 mm fuse T 5A L 250V

F 1

F 2

Connection for

SD memory card

USB for PC

connection

Board in the housing cap

13.4 Fine fuses

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Type HYDROION® VAS

25 -

CS

50 -

CS

75 -

CS

125 -

CS

150 -

CS

200 -

CS

250 -

CS

375 -

CS

600 -

CS

Connections

1"

1"

1"

1 1/2"

1 1/2"

1 1/2"

2"

(DN50)

2"

(DN50)

2"

(DN80)

Resin volume

litres

25

50

75

125

150

200

250

375

600

Injector

blue

orange

orange

yellow

yellow

green

2C

2D

2F

DLFC

Type

3/4"

3/4"

3/4"

3/4"

1"

1"

1"

1"

1"

ltr./min

8.3

12.1

15.9

20.0

34.0

37.8

37.8

49.2

75.5

BLFC

ltr./min.

1.9

1.9

1.9

1.9

1.9

1.9

10.2

15.9

20.0

Full salting – Type A

Salt consumption

kg 5 10

15

25

30

40

50

75

120

Brine volume

litres

16

32

48

81

97

129

161

242

387

Float assembly height

mm

190

300

275

315

360

340

380

455

530

Sieve bottom height

mm

130

220

200

240

285

260

290

385

460

Cycle options – Type A

Backwash

min. 5 6 7 9 7 8

10

11

12

Brine und Slow Rinse

min.

37

40

61

49

59

61

70

65

66

Fast Rinse

min. 6 8 9 13 9 11

13

15

16

Fill

min. 9 18

27

45

53

71

17

20

31

Chlorinator (Type A) – Alarm delay 300 seconds

Salting

min.

12

15

23

16

19

18

20

19

20

On delay

sec.

25

25

25

25

25

25

25

25

25

Period

min.

11

14

22

15

18

17

19

18

19

Chlorinator current rating

mA

100

100

100

150

150

150

200

200

200

Economic salting– Type B

Salt consumption

kg 2 4 6 10

12

16

20

30

48

Brine volume

litre 6 13

19

32

39

52

65

97

155

Float assembly height

mm

120

170

215

220

245

235

335

345

370

Sieve bottom height

mm

70

100

130

150

175

165

250

255

280

Cycle options – Type B

Backwash

min. 5 6 7 9 7 8

10

11

12

Brine und Slow Rinse

min.

30

31

47

40

48

49

58

53

54

Fast Rinse

min. 6 8 9 13 9 11

13

15

16

Fill

min. 4 7

11

18

21

29 7 8

13

Chlorinator (Type B) – Alarm delay 120 seconds

Salting

min. 5 6 9 6 8 7 8 8

8

On delay

sec.

25

25

25

25

25

25

25

25

25

Period

min. 4 5 8 5 7 6 7 7

7

Chlorinator current rating

mA

150

150

150

200

200

200

250

250

250

Water-refresh applies to Type A and Type B

Water volume (in Stand-by)

litres

40

80

120

160

260

260

330

480

680

Interval rinsing flow

l/min

8.3

12.1

15.9

20

34

37.8

37.8

49-2

75.7

14. Parameter settings HYDROION® VAS – CS

Regeneration cycles and times

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Index chapter VI – Commissioning / Taking out of Service

Page

1. Check prior to commissioning 63

2. Start up of softener 64

Preparation 64
Programming of control unit 64
Backwash of softener / manual regeneration 65
Brine tank filling 65
Adjusting of soft water hardness 66
Blending at control valve HYDRO ION® VAS - CS 1 66
Control of soft water hardness 66

3. Taking out of operation 67
Extended out of operation period 67
Re-start 67

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Filling of quartz gravel / resin

Have the resin vessels (pressure vessel) been filled as
described in chapter IV?

Quantity see table chapter III / point 2

Hydraulic connections

Is the below pipeline connected and tight?

- mains water pipe

- soft water pipe

- wash water pipe (waste water)

- brine line

- overflow brine tank
Are the connecting pipes connected properly and tight?

Electrical connection

Is a safety socket installed next to the mains cable and is
permanent voltage available?

Is the water meter connected to the plug connections of
the central control valve?

Is the below equipment connected to the micro processor
control unit?

- control valve

- brine level sensor

- chlorinator
Is the micro processor control unit connected to mains?

Mains water pressure

The mains water pressure may not drop below or
exceeding the following parameters:

Min. pressure: 2.0 bar (flow pressure)
Max. pressure: 8.0 bar (static pressure)

Regenerant

Is sufficient regenerant available for the first and initial
brine tank filling at least?

Salt quantity see tables in chapter III / point 2

Important!

Do not fill in the salt yet!
Brine valve

The float is adjusted ex works to the necessary brine
volume.

1. Check prior to commissioning

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Preparation

Close stop valves before and after softener.
Control of permanent hardness mains water by using the

measuring kit.
Switch on micro processor control (ON/OFF - switcher on

control case - left side)

Programming of control unit

The control unit is programmed ex works.
The mains water hardness is set to 300 ppm.
Adjustment to local water hardness and water pressure
may be necessary.

Brine filling time of brine tank is to be adjusted to the actual
parameters in situ.

Programming of operation parameters see chapter V /
point 4.

System rinsing / manual
regeneration

Backwash (manual regeneration):

- Open the stop valve in the mains water line

- Available air in vessel and arrears in resin
will removed out of plant

Condition:

The motor of the control valve must be in standard start
position!

- The display monitoring informs about:

 operating vessel
 cycle
 residual cycle time

- Regeneration will be start with backwash – cycle

- Open the stop valve in mains water line for manual
regeneration

- Open point of use

2. Start- up of softener

Commissioning and start-up may be carried out by skilled experts only. We recommend that
such work is done by our service personnel.

This will be performed by the Hydrotec engineer upon the completion of a Commissioning Request
Form.

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Backwash
(manual regeneration)

The display is shown
when the controller is
run up:

Operating keys:

Starting manual regeneration “softener 1” as follows:

- Press Function key Main menu

- Press arrow key on menu item Operation mode

- Press input key

- Press arrow key on menu item Regeneration 1

- Press input key

- Run? Yes

- 10 minutes backwash

- Press arrow key on menu item Regeneration

step

- Press input key

Manual regeneration “softener 2“ (only VAD - duplex system)

- Press arrow key on menu item Regeneration 2

- Press input key

- Run? Yes

- 10 minutes backwash

Return to “Superior menu” on controller:

- Function key or press Escape
The backwashed vessel will switch in “Operation mode“.

Start up of softener

The last pressure vessel having passed the backwash cycle goes
automatically in standby whilst the first pressure vessel is in
operation. (Only duplex-softener - VAD)

Filling of brine tank

Fill water in brine tank to approx. 15 mm high above sieve base.
Fill the salt tank and distribute even on the sieve base (common

salt tablets are required for regeneration; that is not supplied by
Hydrotec (UK) Ltd.
The brine tank can be filled to approx. 150 to 200 mm to lid.

Since contamination in the salt may result in failure to the brine
valve and injector of the control valve, we generally recommend
to use regenerant as per DIN 19604.

break-off

(ESC)

Function keys

Input key/

Enter

Arrow keys

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Stop valves

The valves must be opened in mains water pipe and in soft
water pipe so that water can be removed.

Setting of soft water
hardness

The blending water hardness is set to 60 ppm at the
blending unit of the control valve 1“and at an installed
mounting unit (for 1“ and 1 ½“ units).
In case of larger sized softeners, the mixed water hardness
can be set at a blending fitting that is installed in the by­pass.
For setting see separate documentation!

If the softener is installed before an RO system and if the
water is used to feed boilers, no blending is allowed to be
installed in the RO feed or to boiler water tank.

Blending at control valve
HYDRO ION® VAS - CS 1

Adjustment of soft water hardness at
blending unit of control valve:

- close the adjusting screw anti clockwise until
the unit is closed

- open the stop fittings in mains and soft water
pipe until the desired flow is reached

- open the adjusting screw in clockwise direction
until the desired blending hardness is achieved

The set hardness is controlled by means of the
hardness test kit.

Programming of mains water hardness is carried
out when the control unit is programmed.

Programming of operation parameter see
chapter V / point 4.

Control of soft water hardness

The set hardness is controlled by means of the
hardness test kit.

Calculation of soft water volume and sodium
contents sees appendices 2 and 3!

An adjustment is necessary in case of any
deviation.

Programming of operation parameters see
chapter V / point 4.

Visual inspection

A final visual inspection shall be carried out.
No leakage shall be evident whatsoever.

Note:

No water may penetrate from the waste water
hose in regeneration cycle 4 (Fill) when filling the
brine tank!

Adjusting

screw blending

fig.23

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Volume reduction

Dependent on application, a volume reduction
of the system may be necessary in order to
avoid excess operation (the residual hardness
can increase when the maximum flow is
exceeded).

Such volume reduction must be carried out at
soft water side or by the installation of a
volume limit unit.

Extended taking out
of service

Prior to any extended period out of operation, the softener must be
regenerated completely.

After regeneration has been concluded, the stop valves in the raw
and soft water lines must be closed.

Mains power should be shut off at the spur.
Even when taking out of operation, the softener may be protected

against frost.
If a bypass is available for the softener, that must be opened if the

following consumers shall not be supplied with not softened water.

Restoring operation

Turn on mains power at spur.
The valve in the raw water line must be opened slowly.
Manual regeneration to be carried out.
Once regeneration has been carried out, allow a brine formation

time of 5 hours to elapse (under normal ambient conditions).
The stop fitting at soft water side shall then be opened slowly.

An extended standstill of the softener may bear a risk of
germination and a disinfection of the system is required.

Such disinfection shall be carried out by skilled persons only.
Please call our service for further information.

Commissioning record

An acceptance certificate is attached to the operating manual (see appendices 4), which must be
duly filled in by the service technician at commissioning.

It is necessary to complete the Commissioning Settings in the manual as well as the Log
Book so that warranty claims can be accepted.

3. Taking out of operation

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Index chapter VII – Troubleshooting / fault finding

Page

1. Malfunction control unit 69

2. No water supplied by softener 69

3. Residual hardness at consumer too high 70

4. Overflow of brine tank 71

5. Other faults 72

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No.

Inspection

Result

Action

1.

Open sample cock before
softener

No water

Open stop valves before
softener

Water flows

Proceed with 2

2.

Open sample cock in soft water
line
Water flows

Open service valve
leading to consumer

No water

Proceed with 3

3.

Check power supply as far as
control system
Interrupted power supply

Provide power supply

Power supply available

Proceed with 4

4.

Force regeneration and check
whether or not drive motor is
running (possibly with 2 – 6
minutes delay)

Drive motor starts

Regeneration interrupted
before switch-over was
finished

Drive motor does not
start

Faulty control;

Call service!

6.

Force regeneration in order to
change to second vessel

Water flows

Nozzles in exchanger are
possibly blocked.
Proceed with 7.

No water flows despite

Faulty control head;

Call service!

7.

After regeneration sequence has
been finished, switch-over to
regenerated vessel
No water does flow

Call service!

Water flows

Carry out maintenance
and arrange for system
to be inspected.

1. Malfunction of micro processor control

Different modes are monitored during operation and regeneration of the softener. If during operation
of the central control valve faults should become evident, the failure records are shown in the LCD
display and the failure contact and failure signal light switched.

Information regarding possible failure records see chapter V / point 6.

2. No water supply

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No.

Inspection

Result

Action

1.

Open soft water sample valve and
control residual hardness

Residual hardness < 5.0
ppm
(CaCO3)

Proceed with 6

Residual hardness > 5.0
ppm
(CaCO3)

Proceed with 2

2.

Check salt storage; the water
level must at least be covered
with salt

Too low salt storage

Refill salt

Salt storage sufficient

Proceed with 3

3.

Activate regeneration and check
whether or not brine is drawn in
Brine is drawn in

Proceed with 4

Brine is not drawn in

Proceed with 5

4.

Measure mains water hardness
and calculate attainable soft water
quantity and check with setting

Incorrect setting

Correct the setting

Correct setting but no
activation of regeneration

Call service!

5.

Check control valve: activate
manual regeneration and ensure
that all that control valve switches
to second vessel and that all
regeneration sequences are being
carried out
Control valve does not
carry out regeneration
sequences

Call service!

Control valve carries out
regeneration sequences

Stop water feed to
system; decrease
pressure and remove
and clean filling stop and
injector

6.

Check whether or not the by-pass
valve is closed

By-pass valve open
By-pass valve closed

Closes valve
Proceed with 7

7.

Check tightness of by-pass valve
(close mains water valves; no
water should flow to consumer at
all)

Water flow to consumer
(checked after by-pass
valve)

Replace by-pass valve;
proceed with 8

No water flows to
consumer (checked after
by-pass valve)

Proceed with 8

8.

Check whether or not additional
feed lines exist to consumer

Additional feeds

Close feeds
No additional feeds

Call service!

3. Excess residual hardness

If an assembly mount including blending valve is installed, that must initially be controlled and
adjusted.

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No.

Inspection

Result

Action

1.

Is the power supply as far as the
control system ensured without
interruption?

Power supply is
guaranteed

Proceed with 2

Power supply is
interrupted

Provide power supply
and initiate regeneration

2.

Check whether or not the control
valve is ready for operation

Operational readiness
correct

Proceed with 3

Operational readiness
incorrect

Possibly technical fault;

Call service!

3.

Calculate filling time of brine tank
and compare with technical
parameters

Filling time correct

Proceed with 4

Filling time too long

Correct filling time

4.

Is the brine being drawn
correctly? (The brine from the
tank must initially be drawn to
resin vessel and sufficient water
for one regeneration be filled back
to the salt tank). Initiate
regeneration

Sufficient brine quantity
drawn

Call service!

Brine not sufficiently
drawn

Check injector

5.

Dismantle injector and check for
contamination and damage

Contaminated or faulty
injector

Clean / replace injector
and active regeneration
after brine formation

Injector clean

Probably faulty brine
valve

Call service!

4. Brine tank overflows

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No.

Failure

Possible reason

Action

1.

Resin in channel

a) missing or broken top
nozzle
b) air included in softener

c) not adjusted backwash
stop
(DLFC)

a) dismantle or replace top
nozzle
b) guarantee that an air stop
is available in brine tank

c) check backwash flow

2.

Salt in water

a) filter / injector blocked
b) faulty control
c) contaminated or damaged

brine valve
d) brine fill stop (BLFC)

contaminated
e) water pressure too low

f) false programming

a) clean injector and replace
filter
b) check control and replace
on request
c) replace brine valve seat
and clean brine valve

d) clean BLFC
e) the min. water pressure is

2.0 bar (flow pressure)
f) check programming and
correct on request

3.

Constant regeneration

a) faulty control
b) faulty cables

a) check control and replace
on request
b) replace cables

Call service!

4.

Constant discharge to
drain

a) foreign particles in valve

b) internal valve leakage
c) valve remains in backwash

or salt-fill position
d) faulty or not starting motor

of programme switch unit
e) faulty control

a) dismount valve casing,
check, clean and
assemble again
b) replace sealing, spacer
rings and/or piston
c) replace sealing, spacer
rings or piston

d) replace motor

e) replace control

Call service!

5.

Decrease of water
pressure

a) mains water feed pipe
scaled up
b) iron deposit in valve
c) valve entry blocked

a) replace or clean pipe
b) clean resin and valve

c) dismount piston and clean
valve

Call service!

6.

Pressure loss too high

Contaminated resin

Call service!

5. Additional failures

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Index chapter VIII – Monitoring and Maintenance

Page

1. General information 74

2. Control to be carried out by operator (inspection) 74

Check permanent hardness mains water 75
Check soft water hardness 75
Check setting of control 75
Check salt level in brine tank 75
Check brine level 76
Check contamination in brine tank 76
Check tightness / visual inspection 76

3. Maintenance 76

3.1 Cleaning 77
Contact address service 78

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Inspection

Domestic / trade

Industry / boiler /
climatic

Pre-treatment
membrane process

Permanent hardness
mains water

1 x per month

1 x per week

1 x per week

Total hardness
softened water
(blended)

1 x per month

In industry on demand
(in case of soft water
1 x per day)

-----------------------------

boiler / climatic system
1 x per day

1 x per day

Inspection

daily

weekly

Operational pressure mains water (flow
pressure)

X

Temperature mains water

X

Value shown on water meter

X

Salt storage in brine tank

X

1. General information

In order to guarantee a perfect softener operation, it is necessary to take care for regular control
measures and to keep all local regulations.

The DIN EN 806-5:2012 and EN 14743 include regulations in view of inspection and maintenance of
softeners.

 A plant inspection shall be carried out after 2 months at the latest.

Such inspection is possible by the operator or an authorized service company.

 A semi-annual maintenance of the system shall be carried out by Hydrotec UK Ltd.

(service) or an authorized expert.

2. Routine inspection by the operator

A regular visual check of all system components (damage, leakage etc.) is necessary for the safe
operation of the softener.

The following parameters must be checked and recorded in an operation diary at the stated
intervals as a minimum in order to be in a position to deal with a problem immediately.

Additional control

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Check permanent hardness mains
water

Hardness control is carried out by means of test kits.
If the mains water total hardness changes, calculate and

adjust the soft water quantity again according to
appendices 2 and 3.

Setting of mains water hardness is according to chapter V
/ point 4.

Check soft water hardness

The soft water total hardness is:

- in case of reduced brining rate > 17,9 ppm CaCO3

- in case of softeners with blending, the total

hardness is normally adjusted to ca. 60 ppm for
domestic application.

Setting is done at the blending unit of the assembly
mount or an external blending.

Check settings of control

Interval: after 2 months

- Time

- Mains water hardness

(adjustment as per chapter V)

Check salt level in brine tank

Re-fill:
After visual inspection!

In order to guarantee regeneration of the system, the
brine tank must always be filled with sufficient regenerant
(as per DIN 19604) in the form of salt tablets.

The regeneration salt should be of high purity in order to
avoid foreign particles impairing the system operation due
to residues and deposits.

For hygiene reasons the below shall be considered:

- Salt tablets shall be cleaned prior to use so that no

contamination can penetrate the brine tank

- The regeneration salt shall be filled direct from the

open package into the brine tank

- It must be guaranteed that the brine tank is not

overfilled with salt

- A free space to rim of 100 to 200 mm at least shall

be maintained (dependent on size of brine tank)

- The brine tank must be closed again carefully

afterwards

- Once opened packages shall not be used

- The regeneration salt shall be stored in clean

and dry areas

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Check brine level

The filling height of the regeneration salt should always
be above the liquid level of the brine.
Otherwise correct operation of the regeneration cycle is
impossible with the result of hardness break.

Check contamination of brine tank

Interval: after 2 months

Tightness check; visual control

Interval: after 2 months

The control valves must be checked for tightness to
channel during operation.

Regular information about:

- Water quality

- Pressure conditions
of the mains water is condition for a perfect softener operation.

Extensive re-programming of the control may possibly be necessary in case of serious modification
regarding mains water quality that can be carried out our service personnel only. Call service
contact (see page 4).

3. Maintenance

A yearly maintenance is necessary as per DIN EN 806-5:2012 (EN 14743).
That includes a visual system inspection as well as a check of technical function of individual plant

components.

Inspection work carried out during maintenance:

- Check of regeneration activation

- Cleaning of injector and injector sieve

- Check of control valves for tightness (the wear seals are replaced on request)

- Functional check of drive motors and control valves

- Check of brine regulation and programme setting; adjustment of control to modified water quality

- Check of regeneration salt (quantity, quality)

- Check the hose connections and seals

- Check of mains and soft water hardness; adjustment to modified mains water quality; new
adjustment of blending water hardness

- Check of disinfection system (chlorinator)

- Check of non-return device

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Components (mains water)

Inspection work

Maintenance

System separator

6 months

12 months

Pressure regulator

12 month

Filter, backwash (80 – 150 µm)

6 months

Filter, non backwash (80 – 150 µm)

2 months

6 months

Filter (< 80 µm)

6 months

Water flow meter (cold)

12 months

6 years

Dosing system

2 months

6 months

Brine draw in

Flow direction

Flow control

(BLFC)

Injector filter

Injector

fig.24

Inspection- and maintenance interval

The below components in the mains water pipe shall be checked and maintained in the shown
intervals:

3.1 Cleaning

Important!

Please bear in mind that the cleaning should either be carried out by Hydrotec (UK) Ltd or by
an authorized specialist company.

Injector and injector sieve must be dismounted and cleaned in regular intervals dependent on purity
of mains water (during plant maintenance at the latest).

Control valve HYDRO ION

®

– CS 1

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Brine draw in

Flow control
(BLFC)

Injector

Flow

direction

fig.25

Control valve HYDRO ION
Control valve HYDRO ION

In order to carry out cleaning and maintenance work at the softener, it must be disconnected from
the mains water and depressurised.

Once this has been done, the parts can be dismantled and cleaned with an appropriate cleaner in
order to remove limescale deposits.

®

- CS 1.5

®

- CS 2

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Important:

Only use components which are approved for this valve type.
All inspection, cleaning and maintenance work shall be carried out with corresponding care

and disinfection measures be taken on request.

Please bear in mind that the annual maintenance should either be carried out by Hydrotec
(UK) Ltd or by an authorised specialist company since otherwise we cannot accept any
warranty claim.

For queries regarding operation and handling of softener, please contact our service
department

5 Manor Courtyard, Hughenden Avenue

High Wycombe, Bucks HP13 5RE

Email: [e-mail]



Hydrotec (UK) Ltd.

Hydrotec House

Tel: [phone]

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Appendices 1:

Installation schematic softener

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Type of plant

VAS – CS

25-CS

1”

50-CS

1“

75-CS

1“

125-CS

1 ½”

150-CS 1

½”

200-CS 1

½”

250-CS

2”

375-CS

2”

600-CS

2”

Capacity

(m³ @ 300 ppm)

VAS – CS - A

5.3

10.8

16.2

27.3

32.2

43.5

54.9

82.8

132.3

Economic salt use

VAS – CS - B

3.9

7.8

11.8

19.9

23.4

31.6

39.9

60.2

96.2

Appendices 2:

Calculation soft water capacity

Capacity of softener x S
L= in m³ soft water

Local permanent hardness

L = soft water volume between two regenerations
S = Safety factor 0.9 for boiler water and RO

0.8 for strong fluctuating supply water hardness

The local permanent water hardness shall be determined and controlled by means of a test kit.

Example:

A softener type VAS 50 - CS - B is installed. The supply water hardness is measured with 280 ppm.

7.8 m³ x 300 ppm x 0.9
L= = ca. 7.5 m³ soft water (economic salt use)

280 ppm

The softener can produce ca. 7.5 m³ soft water when using the full salt volume.
Regeneration of softener has to be after three days if the daily consumption is ca. 2.5 m³.

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Appendices 3:

Calculation sodium contents:

The sodium concentration in mixed water is increased due to softening dependent on the incoming
water hardness and the set mixed water hardness.
According to drinking water regulation 2001, the limit value for sodium is 200 mg/L.

If the mixed water or the sodium contents is still in accordance with the regulation can be calculated
as below:

ppm (CaCO3) Incoming water hardness (to be obtained from the water
work or to be measured by means of a test kit)

- ppm (CaCO3) Mixed water hardness (measured value)
= ppm x 0,46 (Na-Ion (sodium ion) exchange value)

= ppm (Na+) Increase of sodium contents by softening
+ ppm (Na+) Sodium contents in incoming water (to be obtained from

water work)
= mg/L (Na+) Total sodium contents in mixed water

Example: 300 ppm

- 60 ppm

------------------------------­ = 240 ppm x 0.46
= 110 ppm fed by softening
+ 10 ppm (assumed) in incoming water

-------------------------------­ = 120 ppm total sodium contents
==================

If the calculated total sodium contents exceed the limit value 200 ppm as per drinking water
regulation, the sodium feed has to be reduced by increasing the mixed water hardness.
A total hardness of 1 ppm (CaCO3) corresponds to 0.46 mg/l sodium contents. The calculation shall
be done anew with the corrected value.

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Start up and training record

Softener HYDRO ION®

Plant size / Serial number: ________________________________________________
Customer: ________________________________________________

 Temperature incoming water:____________________ °C
 Filter supply pressure: ____________________ bar (flow conditions)
 Filter initial pressure: ____________________ bar (flow conditions)
 Hardness incoming water: ____________________ ppm (CaCO3)
 Hardness soft water: ____________________ ppm (CaCO3)
 Iron contents incoming water: ____________________ mg/l
 Pressure incoming water: ____________________ bar (flow pressure)
 Pressure soft water : ____________________ bar (static pressure)
 Volume flow: ____________________ l/min
 Regeneration sequence checked: yes  no 
 Float valve function checked: yes  no 

 Note: ____________________________________________________________

____________________________________________________________
____________________________________________________________
____________________________________________________________

An instruction for the operation of the softener was given. The respective operation and maintenance manual was handed over. It was
confirmed that despite a careful planning and design of the installation drinking water of perfect quality is available at all removal taps only
if a regular total water replacement in all installation areas is guaranteed.

Place/Date: ______________________________________________________________

Supplier: _________________________________Customer:_____________________

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Component

Actual value

Type of softener

Injector number (or colour)

Size of DLFC

Size of BLFC

Sieve base (yes – no)

Height of brine tank (mm)

(to be measured)

Diameter of brine tank (mm)
(to be measured)

Height of brine tank (mm)
(to be measured)

No.

Designation

Actual value

1
Display format

2
Regeneration type

3
Soft water volume (to be calculated)

4
Start of regeneration

5
Forced regeneration

6
Backwash (min)

7
Besalzen / Langsamspülen (min)

8
Quick rinse (min)

9
Filling brine tank (min)

10

Water metre type

11

Valve-/softener type

12

Operation position

13

Frequency for electric connection

Parameters

Setting of control

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Date

Total
hardness
incoming

water

(ppm CaCO3)

Total

hardness

soft water

(ppm CaCO3)

Operating

pressure

(input)

(bar)

Temperature

(input)

(°C)

Water
metre

count (m³)

Salt

storage

(kg)

Signed

Log Book Softener HYDRO ION®

Installation site: _____________________________________________________
Time period: ________________________________________________________

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Date

Total
hardness
incoming

water

(ppm CaCO3)

Total

hardness

soft water

(ppm CaCO3)

Operating

pressure

(input)

(bar)

Temperature

(input)

(°C)

Water
metre

count (m³)

Salt

storage

(kg)

Signed

Log Book Softener HYDRO ION®

Installation site: _____________________________________________________
Time period: ________________________________________________________

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Operating & Maintenance Manual

®

System: HYDROION
Type: VAS - CS

VAS 25 – CS 1 - A/B
VAS 50 – CS 1 - A/B
VAS 75 – CS 1 - A/B

VAS 125 – CS 1.5 - A/B
VAS 150 – CS 1.5 - A/B
VAS 200 – CS 1.5 - A/B

VAS 250 – CS 2 - A/B
VAS 375 – CS 2 - A/B
VAS 600 – CS 2 - A/B

_________________________________________________________________________

Herausgeber/Publisher: HYDROTEC®
prepared by: AL / AC

All rights reserved!

© 10/2018 by HYDROTEC

17.10.2018 – modification: Chapter V – point 14
Float height adjustment due to a new brine valve 3/4"
Water softeners: VAS 250/375/600-CS A / B

Subject to technical modification!

All design parameters and dimensions as well as pictures correspond to the actual state at the date the
documentation was prepared.

We reserve the right to modification that suit the technical progress and improvement of the product.