3.1 Variants of the Pure Water System .......................................................................................................... 7
3.1.1 Water Softener and Clear Water System ................................................................................................. 7
3.1.3 Basic System with Dosing unit ................................................................................................................ 10
3.1.4 Basic System with Air Humidification ..................................................................................................... 11
3.2 System Description ................................................................................................................................. 11
3.2.2 Functional Description: Water Softener .................................................................................................. 12
3.2.3 Functional Description: Clear Water Systems (PerPur) ......................................................................... 15
3.2.3.1 Service Recommendation ....................................................................................................................... 15
3.2.3.2 Certificate of Hygiene ............................................................................................................................. 15
3.2.3.3 Explanation of PerPur Display ................................................................................................................ 16
3.2.4 Functional Description of Pressure Boost .............................................................................................. 19
3.2.5 Functional Description of the Dosing unit ............................................................................................... 21
4. Fundamentals of Planning ...................................................................................................................... 22
4.1 Planning a Pure Water System............................................................................................................... 22
4.1.1 Pure Water System with Water Softener of Type AC (Air Humidification) ............................................. 22
4.1.2 Pure Water System with Water Softener Type SoftCab (Air Humidification and Process Water) ......... 24
4.1.3 Pure Water System with Water Softener of Type WSD ......................................................................... 24
4.2 Water Supply .......................................................................................................................................... 26
5.3.2 Water Softener ........................................................................................................................................ 29
5.3.7 Dosing unit .............................................................................................................................................. 34
5.4.1 Water Softener ........................................................................................................................................ 36
5.4.1.1 Water Softener Type AC ......................................................................................................................... 36
5.4.1.2 Water Softener Type SoftCab 25 DR ..................................................................................................... 36
5.4.2 Clear Water System PerPur ................................................................................................................... 37
6.1 Shutdown During Daily Operation .......................................................................................................... 40
6.2 Startup during Daily Operation ............................................................................................................... 41
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6.3 Checks/regular service ........................................................................................................................... 41
6.4.1 Salt in Water Softener ............................................................................................................................. 43
6.4.2 Filter of the installation rail ...................................................................................................................... 43
7. Malfunctions and their Remedies ........................................................................................................... 44
7.1 What to do if ... . ...................................................................................................................................... 44
7.2 Exchange of Defective System Components ......................................................................................... 46
7.2.1 Water Softener ........................................................................................................................................ 46
7.2.2 Clear Water System PerPur ................................................................................................................... 48
7.2.4 Dosing unit .............................................................................................................................................. 50
8. Technical Data ........................................................................................................................................ 51
8.1 Water Softeners ...................................................................................................................................... 51
8.2 Water Tanks ............................................................................................................................................ 52
8.5 Dosing unit .............................................................................................................................................. 54
9.1 Replacement Parts ................................................................................................................................. 55
9.2 Pressure Tests at the Tanks (legal requirement) ................................................................................... 55
9.4 Fresenius Test Certificate ....................................................................................................................... 57
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1.Introduction
1.1 Greetings!
We thank you for deciding in favour of the DRAABE Pure Water System.
The Pure Water System is constructed in accordance with the state of the art and recog-
nized technical safety rules. However, incorrect use of the system can lead to certain hazards for the user or third parties and/or cause damage to material assets.
Therefore, to ensure safe, appropriate, economic operation please observe and follow all
the information and safety cautions in this technical documentation.
If you have any questions which are not answered at all or not answered sufficiently by this
documentation, be sure to put them to your local Nortec Systems area representative or to
our service hotline (262.884.4669). We would be glad to help you personally.
1.2 Remarks on Technical Documentation
Subject of this documentation
The subject of this technical documentation is the DRAABE Pure Water System. System
parts (e.g. water softener, pure water system, etc.) are only described to the extent required
for proper operation. Since there is a wide variety of ways in which the system can be extended, this documentation focuses on basic systems. Various system parts are available
for different applications and performance needs. Increases in required levels of water purity exert an influence on the various system parts. Some accessories are not necessarily
required, whereas others belong to any standard configuration. Further information about
accessory parts and individually tailored customer solutions is to be found in the customer
specific diagrams or it can obtained by contacting Nortec Systems.
The explanations in this technical documentation are restricted to the
- Planning,
- Installation,
- Start-up,
- Operation and
- Maintenance
of the Pure Water System.
The technical documentation is supplemented by other documentation such as brochures,
ordering forms and diagrams. Where necessary, you will find references to these publications in this technical documentation.
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Page 5
Meanings of Symbols
This symbol points to Safety and Hazards Comments. As the symbol suggests, disregard
of these comments can lead to damage to persons and/or material assets. Such comments are also clearly set apart by means of the word CAUTION.
This symbol, or the word IMPORTANT, points to other important remarks.
Your Documentation
Please keep this technical documentation in a safe place where it is always available when
you need it. If the documentation ever gets lost, please contact Nortec Systems.
Language Versions
This technical documentation is available in a number of languages. For further information
about this, please contact Nortec Systems.
2.Concerning Your Safety
Agreement on Intended Uses
The Pure Water System is intended exclusively for the production of pure water for in-
dustrial purposes. It must be operated within the specified conditions of operation in
rooms in which there is no danger of an explosion. All other uses of the Pure Water System
are not intended uses and can lead to situations in which the System is a source of danger.
Use as intended includes observation of all the information in these instructions (especially the comments on safety) and strict adherence to the specified operating conditions.
General Comments on Safety
- The Pure Water System may only be installed and operated by persons who are
familiar with the product and sufficiently qualified for the work at hand. It is up to
the customer to supplement the technical documentation with instructions internal
to the company in reference to supervisory and reporting obligations, work organisation, staff qualifications, etc.
- Before starting work at components of the Pure Water System, you must be sure
that the system has been correctly shut down as in chapter 7.2 and also secured
against being started up by mistake (prevent power from being turned on, turn off
the water supply and let all pressure out of the systems).
- Observe all local safety regulations in respect to:
- exposure to electric and electronic devices that draw on mains current
- design of water and low pressure air systems.
- Poorly maintained air humidifier systems represent a danger to human health.
Therefore, the prescribed maintenance periods must be observed and the main-tenance work carried out correctly.
- If there is ever reason to believe that completely safe operations are no longer
possible, then the Pure Water System must be shut down at once and secured
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Page 6
against being started up again by mistake, and Nortec Systems should be
informed. This can be the case under any of the following circumstances:
- when one or more components of the system have been damaged,
- when the system no longer works properly
- when connections or lines leak.
- The electrical system components (PerPur, DE 3-5) are IP00 protected. Take care
that they are protected against dripping and sprayed water at their locations.
CAUTION: If the System is installed in a room that has no water drain, then water
sensors with automatic cut-off valves must be installed to shut off the water supply
in case of damage to the system which conducts water.
- To avoid damage from water you should not store any water sensitive materials di-
rectly under system components.
- The Clear Water System may only be operated with softened water (0-1°dH, 17
ppm). Well water and rain water are not suitable. The water supply must be virtually
germ free.
- If the pure water (generated by water softener and pure water system) is used for
an air humidification system, a greater or lesser amount of mineral deposits can
accumulate in the vicinity of the aerosol mist. Sensitive materials and devices are to
be taken away from this area or protected accordingly.
- Except for the work described in these instructions, no invasive operation of any
kind may be carried out on the Pure Water System.
- Only use original accessories and spare parts from DRAABE.
- Except with the written permission of DRAABE, no changes may be made to the
Pure Water System.
- In the event of changes to the system, an acceptance procedure is to be carried out
by the Nortec Systems customer service or other person authorized by Nortec Systems before the first start-up of the changed system.
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3. Product Overview
3.1 Variants of the Pure Water System
The system is very flexible. Customer specific systems are oriented to the amount of pure
water needed. All systems have a water softener and a pure water system. This two stage
water treatment yields very soft water (0-1°dH, 17 ppm) which is also demineralised (9599%).
The system variants described below just illustrate the most frequent applications. It goes
without saying that each system can adapt to customer needs. Each customer receives a
diagram which is only applicable to the given customer system. The customer specific configuration is shown in the diagram.
3.1.1 Water Softener and Clear Water System
The minimum configuration (see p. 8, view of basic system) consists of a water softener, an
installation rail, a pure water system and a storage tank. These system parts form the basis
of all system variants. Water circulation is completely closed; this is of great importance
from the point of view of hygiene. The water produced by this basic system is primarily
used for DRAABE Air Humidification or as process water for printing presses.
The water fed into the system (drinking water) is softened by the water softener (0-1°dH, 17
ppm), filtered through the two stage filter combination and, in the last treatment stage, demineralised by the pure water system. The pure water system also retains organic substances.
The pure water system provides a remote fault indicator. The closer, in its closed state, signals that there is a fault. This contact can turn an optical or acoustic transmitter on or off or
can be used by the building services management system (BMS). The pure water system
also organises the optimum regeneration point of the water softener.
The pure water produced by the system is stored in the storage tank (mounted on wall or
standing).
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The working pressure of the basic system lies between 2 - 3 bar (29 – 44 psi). If the quan-
tity of pure water produced when the pressure lies in this range is insufficient, it is possible
to add a pressure boost. The pressure boost (DE 3-5) increases working pressure to 3 - 5
bar (44 – 72 psi). This is useful when the consumers are at a distance or require higher input pressure.
The boost in pressure yields system separation between process water and the output of
the pure water system. This is especially important when the pure water is used both for
printing presses and for a DRAABE air humidifier.
The pressure boost forces the pure water into a standing storage tank. There must always
be a non-return valve between the pressure boost and the standing tank so that the water
in the tank cannot be forced back.
This variant is used when the pure water is to be used as process water.
IMPORTANT: Further information on the performance of a pressure boost can be found in
Chapter 4, "Fundamentals of Planning".
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The pure water produced has a hardness of 0-1°dH (17 ppm) and a conductance value of
7-30 S (dependent on the conductance of the water being processed, e.g. drinking water).
Water with these values is not suitable for process water for printing presses. For an optimal printing result to be obtained with minimal consumption of operating materials, a hardness concentrate needs to be added. We recommend DRAABE hardness concentrate
Aqua-Plus.
This task of adding this concentrate (additive) is carried out by the dosing unit. The dosage
used is 0,5%. The result is a supply of optimally conditioned process water.
IMPORTANT: Further information can be found in chapters 4 "Fundamentals of Planning"
and in 3.2.4 "Functional Description".
System View
Figure 3: PerPur with Dosing unit
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bar
bar
activ charcoal filter
microfilter 5 µ
0
1
2
3
4
5
6
7
2
3.1.4 Basic System with Air Humidification
In addition to being used as process water, the pure water can also be used for humidification of the air. With humidification there is a distinction between unitary and binary nozzle
systems.
The DRAABE high pressure pulsation system (HighPur) increases the pressure to about 80
bar (1232 psi) and conducts the water to the atomizers via the high pressure ring.
Binary nozzle systems need compressed air and water. The pure water produced by the
basic system with a working pressure of 2-3 bar (29-44 psi) is mixed with compressed air
(working pressure around 6 bar (87 psi)) and atomized.
3.2 System Description
The DRAABE Pure Water System is a modern water treatment system which provides for a
maximum of comfort and economy.
The system is built in dependence on the application and performance required. For this
purpose there is a variety of system components which differ primarily in their operating
data (e.g. pure water output, desalination performance). Greater performance of individual
components has an influence on the selection of other system components (e.g. water softener) and their installation and operation. It is possible to construct simple systems, double
systems and systems with several pure water subsystems.
The following sections describe the function of the individual system components.
3.2.1 Functional Description: Installation Rail
The installation rail has several tasks. First of all, it serves as the interface between the
drinking water network (company network) and the downstream water treatment system. A
non-return valve makes it impossible for treated water to get back into the drinking water
network.
Secondly, the water softener is bound to the installation rail (3). Various shut-off control
units (2) make it possible to replace the water softener by hand (e.g. for maintenance).
A two stage filter (4, 5) protects the downstream systems. The decrease in pressure across
the filters can be read from the two manometers (1, 6). Here, too, the shut-off controls
make it easy to carry out a replacement if that becomes necessary (see chap. 7.2). The water pressure of the drinking water network (1) and of the filtered water (6) can be controlled
continuously.
After filtration comes a hand faucet (7) via which a water sample can be drawn at any time.
Figure 4: Installation Rail
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3.2.2 Functional Description: Water Softener
The following description refers to the water softener type AC as well as to the water softener type SoftCab 25 DR. For this description see also the drawings page 13 and 14. For
new installations, solely the water softener SoftCab will be used. But for the sake of completeness, the AC is described, too.
The water softener is the first stage of water treatment. It softens the water. That means
that the quantity of substances in the water which are decisive in the formation of lime is
very greatly reduced. A very soft water (0-1 °dH, 0-17 ppm) comes out of the exit of the water softener.
IMPORTANT: Softened water is of great importance for faultless operation of the downstream pure water system (see section 3.2.3).
The water softener carries out its task of removing liming agents by applying the principle of
ion exchange. In the water softener there are resin pellets which bind magnesium and calcium ions and release salt ions into the water. When a certain fixed quantity of water is
treated, the resins wear out and have to be regenerated. That means the bound ions are
rinsed away and exchanged for fresh salt ions. This regeneration process is fully automatic
and lasts about 2 hours.
IMPORTANT: During regeneration the water supply into the downstream system is shut off!
The time of regeneration is determined by the softener type. There are two types. By the
first type the pure water system controls the regeneration of the water softener (Type
AC2101). A microprocessor calculates the time for the next regeneration on the basis of
water consumption. When this time is reached, the microprocessor sends a signal to the
AC, which automatically controls the regeneration process. When regeneration is over, the
AC informs the pure water system and that system resumes its work.
The second type (SoftCab 25 DR) can be operated time- as well as quantity-controlled. For
using the time-controlled mode, day and time of the regeneration have to be pre-selected.
When using the quantity-controlled mode, the SoftCab calculates the time for the regeneration independently. When reaching the point in time for the regeneration, the water softener
gives a signal to the pure water system which hereupon interrupts its production. After the
process is finished, the water softener gives a release signal to the pure water system and
the system continues its operation.
Salt in tablet form is required for the softening process. The water softener has a supply of
salt. This supply may not fall below a certain fixed level. If it does, the water softener is no
longer able to work. Since this would also cause damage to the downstream pure water
system, the water softener's are equipped with a salt refill sensor. This sensor detects the
lack of salt and informs the pure water system. The pure water system indicates the need
for more salt on the display and then shuts itself off (further details in 3.2.3).
IMPORTANT: Only residue free tablet salt which conforms to DIN 19604 or EN 973 (no
broken salt, etc.) may be used!
CAUTION: If an water softener does not use up any salt, call up Nortec Systems
Customer Ser-vice at once!
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3
2
4
1
7
5
6
Meaning of Numbers in Following Illustration
1 salt refill sensor
2 go and return tubes
3 rinse water drain (for regeneration)
4 safety overflow
5 drain
6 salt container
7 control line (connection to the pure water system)
plug-in power supply
120VAC, 60Hz
with 12VAC
minimum salt level
normal water level
Figure 5: Water softener (AC)
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Meaning of Numbers in Following Illustration
3
2
4
1
7
5
6
1 salt refill sensor
2 go and return tubes
3 rinse water drain (for regeneration)
4 safety overflow
5 drain
6 salt container
7 control line (connection to the pure water system)
plug-in power supply
120VAC, 60Hz
with 12VAC
minimum salt level
normal water level
Figure 6: Water softener SoftCab 25DR
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3.2.3 Functional Description: Clear Water Systems (PerPur)
The Pure Water System PerPur is the heart of the water treatment system. The pure water
system works by the principle of reverse osmosis and desalinates the water which has just
been softened. Its output is the desalinated product (95-99% desalinated), the so called
pure water permeate. This pure water can be used as is for an air humidification system or
else mixed with an additive that renders it suitable for use by printing presses.
The systems are equipped with comprehensive hygiene functions. The DRAABE BioSafe
System ensures hygienically faultless operation. The demanding hygienic requirements
placed on a pure water system are of especially great importance when the water being purified is destined for an air humidification system.
3.2.3.1 Service Recommendation
Regular maintenance, in addition to the Pure Water System's good concept, is of great importance for undisrupted operation which adheres to a high standard of hygiene.
Many Professional Associations advocates regular maintenance and service. DRAABE
company agree that in view of the considerations given below, reverse osmosis systems
must be serviced regularly.
Reverse osmosis systems work with a separating membrane. The undesirable substances
in the water precipitate there and are conducted to the drain. The product (pure water)
reaches the exit from the separating membrane. A separating membrane's operating properties change through erosion and deposits (minerals, iron). Consequently, each separating
membrane must be cleansed thoroughly after several months of operation.
With the patented DRAABE Container System this servicing procedure is easy, low cost
and can be carried out without downtime in the customer's operations. Under the rental
contract the customer automatically receives an exchange container every 6 to 8 months.
The used container is sent back to the producer, where it is serviced. There the membrane
is cleansed as required and always disinfected. Its operating data are checked and optimised. This service operation including disinfection is confirmed in the BG Service Book.
3.2.3.2 Certificate of Hygiene
The DRAABE Pure Water Systems are examined microbiologically for their hygiene by
Fresenius Institute, which is an independent institute. The examinations are carried out at
regular intervals and take place under test conditions which correspond to reality. Our systems completely fulfil the requirements set by the Institute and the Professional Association
for Printing and Paper Processing, which is located in Germany, Wiesbaden. Our systems
work faultlessly in respect to hygiene. In an annex (section 9.3) you will find the Test Certificate issued by the Fresenius Institute.
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3.2.3.3 Explanation of PerPur Display
Two additional functions of the PerPur need to be explained.
The salt consumption optimisation mechanism controlled by a micro processor sees to it
that the water softener is regenerated when a certain customer dependent operating time
has passed. The 5 pole plug 1 (see illustration below) establishes a permanent connection
between the water softener and the pure water system (see section 3.2.2).
The system has a remote fault indicator which is triggered by all malfunctions. If there is a
malfunction, this can be passed via the 2 pole plug 2 to an optical and/or acoustic transmitter. This signal can also be sent to a building services management system.
The remote fault indicator is implemented by a voltage free closer.
plug 1plug 2
Figure 7: PerPur Display
Explanation of the LED Displays:
LED Inlet pressure: The water inlet to the Clear Water System is monitored continuously. If
the water supply is disrupted, the pressure switch notices that, the system shuts itself down and the red LED lights up.
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IMPORTANT: This indicator can also come if the upstream water softener is in regeneration mode, but then there is no malfunction, for after regeneration the system turns itself on
again. If the latter does not happen, then there is, in fact, a malfunction and the remote fault
indicator goes on (switch closes).
LED Operation: This green LED is always lit when pure water is being produced.
LED Tank full: The system generates pure water into a closed system. The pure wa-
ter tank (both wall and standing models) also follows this concept. A
pressure switch at the exit of the pure water system indicates that the
tank is full and the green LED lights up.
LED Conductance: The conductance of the pure water being produced says a lot about
the functioning of the pure water system. If the conductance leaves a
certain defined range, the system is no longer working properly. For
this reason, the conductance of the water being produced is monitored
continuously. If the boundary value is exceeded the red LED goes on
and the remote fault indicator switch closes.
LED Lack of salt: When this red LED lights up then there is no longer enough salt in the
water softener's supply container and the remote fault indicator switch
closes. When the container is refilled with salt it takes about 20 minutes for the sensor to notice that there is enough salt again.
LED Regeneration: This red LED is lit when the water softener is in regeneration mode,
and when this mode terminates the LED goes off.
LED Rinsing: With every restart, regardless of the reason for which the system
stopped, a magnetic valve ensures that the first freshly produced pure
water does not flow into the tank but is directed to the drain. During
this process this yellow LED is lit.
The system is equipped with a fresh water mechanism. There is a danger that stagnant
water will germinate if, after the tank has filled up (LED "Tank full" is lit), 10 hours elapse
without sufficient consumption of pure water (the system has not entered operating mode).
To counteract this danger, the system then goes into operating mode for a short period of
time and LED "Rinsing" lights up.
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3.2.3.4 Explanation PerPur 200 Display
Die pure water system PerPur 200 is equipped with an extended set of system controls.
This model has all the displays and functions of the models already described. In addition it
has the two additional displays and functions described below.
(1) (2)
(1) LED Maintenance: This yellow LED, when lit, demands that unplanned mainte-
nance be carried out in addition to the regular service cycle of
6 to 8 months. This can happen because the separating membrane has been overworked and internal regulation is no
longer able to set the required performance parameters.
Another possibility is that the pumping rate has fallen steeply
but this was not to be expected.
When this LED lights up, the DRAABE Customer Service must
definitely be informed. The system will produce for another 14
days before it shuts itself down. When the problem is solved,
the LED is turned off by a reset at the network switch.
(2) LED Pump fault: If pumping pressure reaches a fixed upper boundary value
(excessive pressure), the system shuts itself down and this
red LED lights up. Please inform the DRAABE Customer Service in such a case. The LED can be turned off through a reset
at the network switch.
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3.2.4 Functional Description of Pressure Boost
The pressure boost system (DE) increases the output pressure of the pure water system
from the range 2-3 (29-44 psi) to the range 3-5 bar (44-73 psi).
The DE can be divided into two parts. The lower part is fixed to a wall and serves as an interim storage tank. A float valve controls its inlet. If the interim tank is not completely full,
pure water can flow into it. When the maximum water level has been reached, the valve
turns the inlet off. The interim tank is equipped with a safety overflow and a drain plug.
inlet (pure water) float valve
interim
storage tank
safety overflow
drain plug
Figure 8: Pressure Boost (lower part)
The upper part contains all the technical components for the pressure boost such as the
pump and pressure switch. This part can be exchanged for maintenance or if there is a disruption of service. The operator cannot and may not service or repair anything in or on this
upper part. The upper part is serviced and repaired on the manufacturer's premises.
The upper part is correctly placed on the lower part (see section 8.4) and then it's just necessary for the plug for the voltage supply (120VAC) to be plugged into the network socket.
The DE is operational as soon as its network switch (1) has been turned on. The pump,
which is in the upper part, goes on when a sufficient quantity of water is present in the interim tank. The water level is monitored by two float valves (2). The pump forces the water
from the interim store into a standing storage tank. The pump stops when a system pressure of 5 bar (73 psi) has been reached. The system pressure can always be read on the
manometer (3). When the standing and interim tanks are full, the DE is in stand-by mode.
The system pressure goes down as water from the standing tank is used. When this pressure reaches 3 bar (44 psi) the DE starts boosting it again until it has risen to 5 bar (73 psi).
The switch on and switch off points are regulated by a pressure switch. In addition, the DE
is equipped with a safety pressure switch (4). This switch is triggered at 6 bar (87 psi) and
can only be reset mechanically (see section 7.1 for further details).
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EIN
AUS
Sicherung
1A
(5) electrical fuse for the motor of the pump
(1) main switch (ON/OFF), illuminated
(3) manometer
(4) safety switch operating pressure
120VAC, 60Hz
to the
standing storage tank
(2) float valves
Figure 9: Pressure boost (upper part)
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3.2.5 Functional Description of the Dosing unit
Aqua - Plus
Dosing unit
0,5%
Process water is supplied by a fully automatic, one stage dosage facility. The pure water
produced by the system is mixed with 0,5% (fixed setting) of the hardening concentrate
"Aqua-Plus" so as to ensure constant water hardness in the range 8°-10° dH (138-173
ppm).
CAUTION: Only use "Aqua-Plus"! Experience has shown that with other hardening concentrates, which may not contain enough fungicides, germination of the system can set in.
The quality of the process water ought to be checked once a week. When the DRAABE
hardening concentrate "Aqua-Plus" is used, this can be done with a conductance measurement (but not with a titration test or hardness test strip).
The following procedure should be followed when taking this measurement:
1. let the first 10 litres drain off
2. catch the next 10 litres in a clean container
3. stir thoroughly
4. measure the conductance with a calibrated device (500 – 700 µS = 8° - 10° dH (138173 ppm)).
IMPORTANT: If a different hardness concentrate is used, ask its manufacturer which
measuring method should be applied.
Figure 10: Dosing unit
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4. Fundamentals of Planning
The fundamentals of planning described below are theoretical. In practise, the required
humidification will also be influenced by parameters which cannot be identified in this
documentation. In many cases the theoretical values given here must be supplemented or
corrected by values from experience. Our advisors would be glad to assist you with this.
4.1 Planning a Pure Water System
Follow the procedure below when selecting or designing the system:
- determine the needs for pure water (water for humidification, process water)
- ascertain data of the water to be treated (drinking water, company network)
- decide on a pure water system (PerPur 60/120)
- determine the need for soft water
- decide which type of water softener to use (AC/SoftCab 25 DR, WSD)
- determine the need for further devices (e.g. a dosing unit)
4.1.1 Pure Water System with Water Softener of Type AC (Air Humidification)
The following sections contain all the information required for the individual planning steps.
Each step is illustrated with a computational example based on the following system data.
EXAMPLE 1
A DRAABE Pure Water System is to be installed in the paper warehouse of a printing plant
for use by an air humidification system. The following data are known:
IMPORTANT: The water data must be taken with calibrated measuring devices. Use of incorrect values during planning would have far reaching consequences.
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For a humidification rate of 57 kg/h (126 lbs/h) a 120 litre system is required, that is, the
PerPur 120. Here it does not matter how much of this total is to be used in which way. It
could all be used for humidification or some of it could be used as process water. That does
not affect the amount which passes through the water softener and wears its resins out.
To design a water softener one must understand that when pure water is produced by reverse osmosis (this applies to all manufacturers) waste water (concentrate) is also produced and this water was treated by the water softener too. To provide for this extra water,
the required output rates are doubled. Also, a safety term is included for water hardness.
In our example:
pure water output x 2 = 240 kg/h (530 lbs/h).
Here we are using an AC 2101. It has a capacity of 100,000 litres for 1°dH.
A safety term of 5°dH is added to the raw water hardness of 16°dH to yield:
total pure water output: 240 kg/h (530 lbs/h)
capacity of softener: 100000 litres / (16°dH + 5°dH) = 4760 litres
time before regeneration: 4760 litres / 240 litres/h = 19,8h
SOLUTION TO EXAMPLE 1
According to the foregoing example the resins must be regenerated after ~ 20 hours.
IMPORTANT: During the periods of regeneration (approx. 2 hours) no treated water is
available for air humidification.
For questions about computation of humidification rates please contact DRAABE Ottawa.
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4.1.2 Pure Water System with Water Softener Type SoftCab (Air Humidification and Process Water)
EXAMPLE 2
A DRAABE Pure Water System is to be installed in the paper warehouse of a printing plant
for air humidification and for process water. The following data are known:
humidification rate: 57 kg/h (126 lbs/h).
process water rate: 40 kg/h (89 lbs/h).
humidifier type: unitary nozzles, DRAABE TurboFog
raw water: hardness = 16°dH
conductance = 400µS
With a total rate of 97 kg/h (215 lbs/h) for humidification water and process water one
needs a 120 litre system. A PerPur 120 is selected.
In our Example 2 we use a SoftCab 25 DR. This has a capacity of 90,000 litres for 1°dH
The required output rates are doubled because of the waste water for reverse osmosis and
the raw water hardness of 16°dH is increased by a safety term of 5°dH.
total pure water rate: 240 litres/h (530 lbs/h) ((= 2 x 120 litres))
capacity of softener: 90000 litres / (16°dH + 5°dH) = 4200 litres
time before regeneration: 4200 litres / 240 litres/h = 17h
SOLUTION TO EXAMPLE 2
According to the foregoing example the resins must be regenerated after ~ 17 hours.
IMPORTANT: During the periods of regeneration (approx. 2 hours) no treated water is
available for air humidification.
For questions about computation of humidification rates please contact DRAABE Ottawa.
4.1.3 Pure Water System with Water Softener of Type WSD
Systems with double softener (WSD) use two resin cartridges. When one of them is being
regenerated the other is producing softened water. The result is a continuous, uninterrupted
supply of treated water.
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Figure 11: PerPur with double softener (WSD)
EXAMPLE 2
A DRAABE Pure Water System is to be installed in the paper warehouse of a printing plant
for air humidification and for process water. The following data are known:
humidification rate: 100 kg/h (220 lbs/h)
process water rate: 150 kg/h (330 lbs/h)
humidifier type: unitary nozzles, DRAABE TurboFog
raw water: hardness = 16°dH
conductance = 400µS
With a total rate of 250 kg/h (550 lbs/h) for humidification water and process water one
needs tree 120 litre system. Tree PerPur 120 are selected.
For uninterrupted water treatment, each resin cartridge must work for at least 8 hours before its resins wear out and have to be regenerated. This assumption is used for the following computation of the minimum capacity required of the resin cartridges. The formula is:
WW = W x (HK + 5°dH) x 8
WW: soft water
W: water requirement ( {humidification_rate + process_water_rate} x 2 )
HK: customer dependent water hardness
5°dH: safety term
8: minimum working hours for resin cartridges
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SOLUTION TO EXAMPLE 2
WW = 500 litres/h x (16°dH + 5°dH) x 8h = 84000 litres
To be selected: a WSD 120 with capacity of 120,000 litres per resin cartridge.
For questions about computation of humidification rates please contact DRAABE Ottawa.
4.2 Water Supply
The DRAABE Pure Water System may only be operated with soft water. This prerequisite
is fulfilled if the water is pre processed with a DRAABE Water Softener. On the other hand,
well water, rain water and fully desalinated water are not allowed. As a matter of principle,
the water may not contain any colloids or organic substances.
The DRAABE Air Humidification System is equipped with automatic rinsing intervals and a
subsystem for keeping the water fresh so that stagnant water does not become contaminated by germs. For these important hygienic functions to be carried out at all times, the
System may not be turned off and its water supply may not be interrupted.
Processing water from reverse osmosis systems still contains a residue of salts between 1
and 5% of the original water. This minimal residue is discharged by the air humidification
system into air in the room. Therefore, the air humidification system is not suitable for applications for which an especially high standard for lack of particles in the room's air is required (clean rooms, computing centres, etc.).
As a monopropellant jet system, the DRAABE air humidifier system places special demands on the water it is to atomise. It may only be operated with desalinated and virtually
bacteria-free pure water.
Only treated water may be used. That means a three-stage treatment process must always
be run before the water can be fed in to the HighPur.
All the following requirements in terms of water treatment are extremely important to ensure safe, hygienic functioning. The operator shall ensure that the following requirements
are met on a permanent basis. The requirements for a water treatment are met if a
DRAABE pure water system is used. Of course, such systems must also be subjected to
regular checking and maintenance.
A water flow pressure of 3 - 4 bar (44-58 psi) must be maintained continuously for reliable
functioning of the Pure Water System to be guaranteed. The flow pressure may not exceed
4 bar (58 psi).
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The following requirements are placed on the incoming raw water (drinking water):
- The water must be free of suspended particles which are larger than 5µ.
- The water must be free of colloids and organic substances.
- Well water, rain water and fully desalinated water are not acceptable
- It must meet standards for drinking water (e.g. number of organic materials)
- The maximum germ content of 1000 germs/ml may not be exceeded.
- It must have no chemical substances/additives (e.g. chlorine, ozone, disinfectants).
- No additional devices (e.g. dosing facilities) which change the properties of the in-
coming raw water may be used.
- Water temperature in the range 6 – 20 °C (43-68 °F).
- Flow pressure 3 – 4 bar (44-58 psi).
If an osmosis product of some third party is used (i.e. not a DRAABE product), then the following values must be provided continuously by the operator:
- Demineralisation via reverse osmosis (inorganic membrane)
- Water values at output of water preparation
Water hardness < 0.1 °dH (< 17 ppm)
Electric conductance 5-10 µS
Water temperature 6-25 °C (43-77 °F)
Flow pressure 2-3 bar (29-44 psi)
- No use may be made of water tanks with floating controls; rather, closed mem-
branes in stainless steel or plastic for interim storage of the product are to be used
(pressure control).
- Fittings and pipes must be made of materials which are allowed in the food industry
(plastic, stainless steel). Do not use copper pipes or brass.
- The pure water must be free of organic substances.
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5. Installation
5.1 Safety, General Comments
- Assembly and installation work may only be carried out by properly trained techni-
cians (sanitary fitters, electricians). The person who commissions the installation is re-
sponsible for ascertaining that these technicians are qualified.
- All local regulations and guidelines an carrying out electric and water installations are
to be observed and adhered to.
- It is imperative that the information and regulations in this chapter on position-
ing system components, on assembly and on the electric installations be observed and adhered to.
5.2 Positioning, General Comments
As a matter of principle, the positioning of a system is determined during planning and recorded in the system documents. In every case the following general comments on positioning are to be observed and adhered to.
- Take care that the construction (wall, column, ceiling construction, etc.) on which the
devices and system components are to be mounted has adequate carrying capacity
and is suitable for secure mounting.
- The system components should be mounted in such a way that sufficient room is avail-
able both for operations and for maintenance.
- No live wires may be laid or present in the area below the installation rail and consoles.
If you have questions about positioning, please contact DRAABE in Ottawa.
5.3 Assembly, General Comments
- The installation is to be carried out in accordance with the general rules of technology
and the connection regulations of the local supply companies.
- Before installation begins, use the shipping note to check that the delivery is complete
and intact.
- Pipe assembly may only be carried out by authorised master craftsmen who have had
experience working with PVC.
- No rebuilding or other changes may be carried out on the devices on one's own au-
thority.
- No additional fittings (e.g. valves, etc.) may be installed within the DRAABE system
except as is noted in the installation diagram.
- These installation instructions are only valid for the indicated systems. The systems
delivered to customers are accompanied by corresponding system diagrams with instructions for the given customer installation. The assembly instructions, diagrams and
other instructions are binding for execution the installation.
- It is imperative that you observe the specifications for materials.
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bar
bar
190 mm
(7.5 inches)
780 mm
(30.7 inches)
Pipe
5.3.1 Installation rail
- The installation location must be selected so that access to the installation rail is guar-
- Direct sunlight and heat radiation are to be avoided.
anteed at all times and so that the water softener can be connected to the installation
rail. The hose length is 500mm (19.7 inches).
Together with the installation
rail a fitting is delivered
which can be used to connect this unit by a PVC or
CPVC pipe (16mm outer diameter).
CAUTION:
Except as is explicitly stated in these instructions, parts which conduct electricity as well as
all other goods may not ever be mounted or stored in the space under the installation rail
because even slight leakage from the pure water system could result in damages.
5.3.2 Water Softener
- The water softener is to be positioned under the installation rail.
- If at all possible, this device should be installed in a room to which only a limited cate-
gory of persons is granted access.
- The surrounding temperature must lie between +10°C (50°F) und +30°C (86°F)
throughout the year.
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120 V~/ plug in
power supply
12 V~
Figure 13: Installing the Water Softener
IMPORTANT:
The water softener is delivered ready to plug in with a 12V network part.
When mounting the alternating current connection be sure that the wall socket is mounted
approximately 25cm to the left or right of the water softener.
5.3.3 PerPur Console
- The PerPur console (weight ~ 60 kg, ), must be mounted on a wall that can bear loads.
- If at all possible, it should be installed in a room to which only a limited category of
- The surrounding temperature must lie between +10°C (50°F) and +30°C (86°F)
- The location must be selected so that direct sunlight and heat radiation onto the con-
IMPORTANT:
The pure water system is delivered with a 120Vac plug and is ready for operation.
persons is granted access.
throughout the year.
sole and its equipment are impossible at all times.
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Pipe
When mounting the alternating current connection be sure the wall socket is mounted ap-
516 mm
(20 inches)
185 mm (7.3 inches)
258 mm
(11 inches)
proximately 25 cm (9.84 inches) to the left of the wall bracket and at the height of the pure
water system.
5.3.4 Pure Water Tank (wall model)
Threads: 3/8”, female
Figure 14: Mounting the PerPur Console
Together with the console
three fittings are delivered
which can be used to connect this unit by a PVC or
CPVC pipe (16mm outer diameter).
Upward clearance of 50cm (20 inches) across the entire width of the console should be
provided The clearance to the right should be 20cm (8 inches). The distance from the lower
edge to the floor should be 1.2m (47 inches).
CAUTION:
No parts which conduct electricity may be mounted under the console because leakage
could cause damages.
- Mounting on a wall that can bear loads is required (weight ~ 100kg).
- If at all possible, the device should be installed in a room to which only a limited cate-
gory of persons is granted access.
- The location must be selected so that direct sunlight and heat radiation onto the device
is impossible at all times.
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- The pure water tank DWD 80 is designed for a maximum pressure of 10 bar (145 psi).
Greater pressures are not permissible!
DWD 18, thread: 3/4”, male
DWD 80, thread: 1”, male
Figure 15: Mounting of storage tank to be mounted on a wall
IMPORTANT:
If a pure water tank is to be mounted downstream from the pressure boost, then it is absolutely necessary to use a DWD 18 or DWD 80.
5.3.5 Pure Water Tank (floor model)
- If at all possible, the device should be installed in a room to which only a limited cate-
gory of persons is granted access.
- The location must be selected so that direct sunlight and heat radiation onto the device
is impossible at all times.
- The pure water tank is designed for a maximum pressure of 3 bar (44 psi). Higher
pressures are not permissible!
5.3.6 Pressure Booster
- If at all possible, the device should be installed in a room to which only a limited cate-
gory of persons is granted access.
- The surrounding temperature must lie between +10°C (50°F) and +30°C (86°F)
throughout the year.
- The location must be selected so that direct sunlight and heat radiation onto the device
is impossible at all times.
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EIN
AUS
Sicherung
1A
Pipe
Pipe
Pipe
320 mm
(12.6 inches)
158 mm
(6.3 inches)
Figure 16: Mounting a Pressure Booster
CAUTION:
No parts which conduct electricity may be mounted under the pressure boost because
leakage could cause damages.
delivered by DRAABE
OUT pure water
(to pure water tank)
Connection to unit by
OUT overflow 16mm pipe
(to drain) (outer diameter)
Connection to unit by
16mm pipe
(outer diameter)
INLET
(from water treatment)
3/8”, male
Together with the pressure booster a fitting is
delivered which can be
used to do the connection by 16mm pipe
(outer diameter)
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Pipe
Pipe
70 mm
(2.76 inches)
5.3.7 Dosing unit
- The dosing unit must be mounted on a wall which can bear loads.
- If at all possible, the dosing unit should be installed in a room to which only a limited
- The surrounding temperature must lie between +10°C (50°F) and +25°C (77°F)
category of persons is granted access.
throughout the year.
Figure 17: Mounting a Dosing unit
Delivered by DRAABE Delivered by DRAABE
INLET OUTLET
(from pure water tank (to printing machine
or pressure holding valve) connection to dosing unit by
connection to dosing unit by 16mm pipe (outer diameter)
16mm pipe (outer diameter)
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Water softener
Discharge
Installation rail
Console
Drain
Rinsing pipe
Safty overflow
Hose bridge for
test of water thighness
5.3.8 Low Pressure Circulation (Pressure Test)
- Only PVC pressure pipe, PVC threaded joints and fittings in PVC pursuant to the ma-
terial specifications may be used.
- The pipes are to be laid so that they are free of stress. The clamp distance may be at
most 1m.
- The pipes may not be contaminated during installation.
- The mounting height of the water drain funnel must lie below the safety overflow of the
water softener (drop of at least 5%).
- When laying lines be sure direct sunlight and proximity to sources of heat are avoided.
- When assembly is complete the pipe system is to be subjected to a hydraulic pressure
test of 3 bar, 44 psi (with water as medium). The console has been provided with a
hose bridge and a blind plug for this purpose.
Figure 18: Low Pressure Test
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IMPORTANT:
When the system is placed in operation, it is checked out by the DRAABE customer service
technician for conformity to specifications. The technician is authorised to cancel initial operations if the installation is found to be erroneous.
5.4 Electrical Installation
The documentation does not cover the installation of the voltage supply. However, requirements placed on this supply are treated. The installation of the electric components of the
pure water system is shown together with the place where the voltage supply must be applied.
CAUTION:
The electrical installation, including the voltage supply, must conform to all local safety
regulations and standards.
IMPORTANT:
- Be sure to put the attachment cables through the cable run that is supplied.
- The cable ends are to be fitted with suitable cable end sleeves.
- Observe the values indicated for fuse protection.
- The installation may only be carried out in accordance with the diagrams gone into
here.
- During installation the voltage supply must be turned off and secured against acciden-
tal activation.
5.4.1 Water Softener
The water softener is delivered with a 12V network part and is ready to connect. For new
installations, solely the water softener SoftCab will be used. But for the sake of completeness, the AC is described, too.
5.4.1.1 Water Softener Type AC
The type AC2101 is consumption driven. This means, that the regeneration time depends
on the water consumption.
consumption driven
A consumption driven water softener (AC2101) is to be connected with the clean water system by means of the 5 pole plug delivered with it. A micro processor in the clean water system calculates the times of regeneration in dependence on water consumption and when
these times are reached it sends a signal to the AC.
5.4.1.2 Water Softener Type SoftCab 25 DR
The water softener has to be connected to the pure water system by using the 5-pin-lug (included in delivery). The water softener can run both time-controlled and quantity-controlled.
The time-controlled mode executes the regeneration at a fixed time. When running the
quantity-controlled mode, the microprocessor of the SoftCab 25 DR calculates the point in
time for the regeneration subject to the water consumption. When reaching the time for the
regeneration, the SoftCab gives a signal to the pure water system. The respective mode
(time- or quantity-controlled) is defined ahead of delivery. When starting up the water sof-
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Page 37
tener, only the time has to be adjusted. Therefore the grey cover has to be removed from
12
SET
CLOCK
NEXTREGEN
120 V ~
Remote fault indicator
ee
Water
softener
the water softener. Press the key “set clock” (1): now the hour display blinks. With the arrow
key (2) the time can be adjusted. After pressing the key “set clock” again, the minute display
blinks. Use the arrow keys to adjust the minutes. After that, press the key “set clock” again
in order to leave the adjustment mode. Put the cover onto the water softener again.
5.4.2 Clear Water System PerPur
Figure 19: Display SoftCab 25DR
The voltage supply is established via a wall socket and the connecting cable delivered with
the system, which has a 3 pole shockproof plug.
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Figure 20: Connecting the PerPur
Page 38
voltage supply PerPur: 120VAC, 10%, 1 Phase
fuse protection: 15A, surge proof
wires: L1, N, PE
cable cross section: 1.5 mm² (16 AWG)
The remote fault indicator can be connected by means of a 2 pole plug with an optical or
acoustic transmitter or with a building services management system.
5.4.3 Pressure Booster
The voltage supply is established via a wall socket and the connecting cable at the DE 3-5,
which has a 3 pole shockproof plug.
supply voltage DE 3-5: 120VAC, 10%, 1 Phase
fuse protection: 10A, surge proof
wires: L1, N, PE
cable cross section: 1.5 mm² (16 AWG)
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5.5 Specifications for Materials
CAUTION:
The following specifications of materials must absolutely be adhered to in every particular.
They are a part of the guarantee! Only installation materials delivered by the DRAABE
company are permissible!
5.5.1 Hoses, Pipes, Fittings
Material for pipes and fittings: PVC pipe (grey) or CPVC pipe (white), UV resistant
or opaque, must fulfil the ASTM Standards D-2846
, ANSI/NSF Standard 14
operating pressure: 10 bar (145 psi)
temperature when used: 6-37°C (43 – 100°F)
medium: tap water, softened water or pure water
If the outputs of two pure water systems are pooled (both work in the same tank) then the
pipes and fittings from the output should have inner diameter ≥ 16mm (0.63 inches).
5.5.2 Electrical Components
cables
use: from water softener to the pure water system
designation: LIYY 5 x 0,5 mm² (20 AWG)
party responsible: delivered with DRAABE SMB
use: network connection PerPur, pressure boost
designation: H05VV-F 3 x 0,75 mm² (18 AWG)
party responsible: installer or operator
wall sockets
use: pure water system, water softener, pressure boost
technical data: 120VAC
15A
water protected
poles: P, N, PE
party responsible: installer or operator
plug in power supply
use: water softener
technical data: 120Vac (primary), 12Vac (secondary)
party responsible: delivered with DRAABE water softener
inches)
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6. Operation
The system may not be used by the operator (customer) or some person authorised by the
operator (customer) until DRAABE customer service or a person authorised by DRAABE
has approved this. Also, the person operating the system must have been introduced by
DRAABE to proper operation. When placing the system in operation after being instructed
in its proper use, the operator (customer) is obliged to ensure that all persons who operate
the system have been properly instructed. This is a condition for the DRAABE warranty.
6.1 Shutdown During Daily Operation
For maintenance work, replacement of system components which are defective or are to be
serviced or in the case of malfunctioning of the system it can be necessary to turn off the
system. Precisely when the system must be turned off is gone into in Chapter 8.
Complete Shutdown. Here, selected system parts or even the entire system is made voltage free and the water supply is turned off.
PerPur: Network switch OFF (AUS).
If wall socket has a switch, turn this switch off too.
Shut off water inlet valves by hand.
Water Softener: Pull network part out of wall socket.
Shut off water inlet valves by hand.
DE 3-5: Network switch OFF (AUS).
CAUTION: For longer shutdowns (more than 24 hours) there is a danger of germ contamination (automatic fresh water automatic, FWA, is not active). Before any complete
shutdown (or directly afterwards) please be sure to inform DRAABE customer service.
Partial Shutdown. Here it is only necessary to prevent restart of the system while a component is being replaced.
PerPur: Shut off water inlet. The absence of pressure puts the PerPur
Water Softener: Shut off water inlet valves by hand.
DE 3-5: Turn off water inlet. This makes it impossible for the DE 3-5 to
CAUTION:
For longer shutdowns (more than 24 hours) there is a danger of germ contamination
(automatic fresh water automatic, FWA, is not active). Before any complete shutdown (or
directly thereafter) please be sure to inform DRAABE customer service.
If wall socket has a switch, turn this switch off too.
in an error status, preventing it from starting up.
start up again.
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6.2 Startup during Daily Operation
Depending on whether a partial or complete shutdown was carried out, the components
that were turned off must be turned on again in the reverse order. As a matter of principle:
PerPur: First turn on water inlet, then establish 120VAC supply, then
turn on network switch.
Water Softener: First turn on water inlet, then the voltage supply.
DE 3-5: First turn on water inlet, then establish 120VAC supply, then
turn on network switch.
6.3 Checks/regular service
Regular service
PerPur:Aside from the inspections described here, the container is subject to regular service. The
operational safety as well as the hygienically clean function depend on regular service.
The manufacturer recommends a service cycle of 6 to 8 months. Service must be performed by the manufacturer. Only the manufacturer has special test equipment at his disposal, has the required knowledge to perform the necessary work and enters into a commitment towards the user by performing the service.
Note to purchasers (byer) of PerPur: For the duration of the 24-month warranty period,
the user is obliged to comply with the above mentioned service cycle. Failure to comply
may render the warranty null and void. Should a functional defect of the PerPur occur during the 24-month warranty period, warranty claims will only be accepted by Draabe, if the
described service intervals for the PerPur have been complied with, i.e., if regular service
has not been performed on the PerPur at max. time intervals of 8 months, the warranty of
the PerPur will be rendered null and void.
Transport costs are the responsibility of the user. Service costs must be paid by the user
(the user receives a report of service work performed as well as a guarantee for exchanged
parts). For the time of service work (2-3 weeks) the user will receive a rental unit. The cost
of the rental unit is included in the service costs.
Regular service is also recommended after the expiry of the warranty period.
Note to lessees (rental) of PerPur: The manufacturer is responsible for the above men-
tioned service cycle. Transport costs for the return from the user to the manufacturer are
charged the responsibility of the user. Service costs are included in the lease.
Whenever inspections reveal something suspicious or any case of incorrect functioning, the
DRAABE customer service are to be notified at once! Inspection work may only be carried
out by properly instructed persons. The operator (customer) is responsible for checking that
the inspectors are suitable for the task and are instructed properly.
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bar
bar
activ charcoal filter
microfilter 5 µ
0
1
2
3
4
5
6
7
2
Checks
Water Softener: Check salt: Salt level should be checked regularly and the Wa-
ter Softener refilled as required (see page 13).
Cycle: every two days
Dosing unit: Check Aqua-Plus: The Aqua-Plus level should be checked
regularly and the container replaced as appropriate.
The water softener's input pressure and output pressure (i.e. PerPur input pressure) can be
read at the two manometers. The difference indicates the pressure lost in the water softener, the filter of the pressure reducer and the two cartridge filters. If, as is assumed here,
the water softener is working properly, then this pressure difference just indicates the condition of the filters. The more material that these filters have filtered out, the greater the loss
of water pressure.
When this difference, or pressure loss, exceeds 0.9 bar (13.5psi), the filter of the pressure
reducer must be cleaned (1) and/or the filters (4, 5) must be replaced. In this case please
get in touch with your Nortec Systems Customer Service.
Cycle: once a weeks
6.3.2 Storage Tank (initial pressure)
Valve where the pressure meatering device has to be connected.
The initial pressure of the storage tank can be checked with a pressure measuring device.
Then the tank must be completely empty. The pressure must be 0.7 bar (10 psi).
Cycle: every 6 months
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6.4 Consumables
6.4.1 Salt in Water Softener
The water softening process requires salt in tablet form. If the salt supply in a Water Softener has been consumed, then salt must be refilled. For this, take off the blue covering and
then the white cover underneath it. Refill with a new package of salt (25kg) and put the
cover and covering back on the water softener (see page 13).
IMPORTANT:
Only residue free tablet salt as in DIN 19604 or EN 973 (no broken salt, etc.) may be used!
IMPORTANT:
If no consumption of salt is established, inform Nortec Systems Customer Service at
once! This case could indicate a mal function.
6.4.2 Filter of the installation rail
For each regular servicing of the pure water system the filters of the installation rail must be
replaced. These are delivered with the exchange container. If there is a severe drop in
pressure or any discolouration during operation, contact Nortec Systems Customer Service.
6.4.3 Aqua-Plus
Aqua-Plus is not a hazardous substance as defined by chemicals legislation and EU Directive 67/548/EEC; however, when it is not properly handled it still constitutes a threat to human beings and the environment. In addition to the safety measures listed below the regionally applicable safety measures for handling chemicals should be observed:
- Avoid all contact with the eyes and any longer contact with the skin.
- Change any contaminated clothing immediately. Preventive skin protection is neces-
sary. When work is over wash hands and face.
- Do not allow Aqua-Plus to get into the sewage system or the ground.
- To remove Aqua-Plus, use material that binds water. Rinse away small amounts with
water.
- Aqua-Plus should be stored in an airtight, leak-proof container at 10 to 25°C (50 to
77°F).
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PerPur
Control lamp
(LED display)
Function
Possible reasons
Possible solutions
Inlet pressure
(red)
ON in case of a malfunction
The internal pressure switch
is indicating a malfunction if
the flow pressure is below 1.3
bar (19psi).
Note: Important is the flow
pressure during start and
operation of the pump (LED
operation ON).
1. Pre installed water softener is in the regeneration mode. If a connection
between water softener
and PerPur is installed
the LED regeneration
(green) is also ON.
2. Water supply is broken.
3. Pre filter blocked.
4. Internal pressure switch
has a malfunction.
1. Wait until the regeneration is finished (LED regeneration OF). Normally
a regeneration takes 120
minutes. If the system
doesn’t starts after 120
minutes it could be that
the water softener has a
mal function. In this case
please contact the service department.
2. Check the water supply.
Is a hand valve closed?
3. Check the two pressure
gauges on the installation
rail (see page 11).
4. Please contact the service department.
Inlet pressure
(red)
BLINKING in case of
a malfunction.
Internal pressure switch has
indicated a too high output
pressure (over 5 bar (72 psi).
Please contact the service
department.
operating
(green)
BLINKING in case of
a malfunction.
Internal motor protection
switch has indicated a too
high current.
Please contact the service
department.
Lack of salt
(red)
ON in case of a malfunction.
Check the salt level of the
pre installed water softener.
Please fill in salt (see page
13).
Water Softener
Function
Possible reasons
Possible solutions
No consumption of
salt.
1. Malfunction control unit of
the water softener
2. Power supply of the water
softener broken.
3. Connection between
PerPur and water softener broken.
1. Please contact the service department.
2. Check the power supply
and the plug in power
supply.
3. Check the cables.
If you get no positive results,
please contact the service
department.
7. Malfunctions and their Remedies
7.1 What to do if ... .
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Consumption of salt
is too high.
1. Malfunction control unit of
the water softener.
2. Power supply of the water
softener broken.
1. Please contact the service department.
2. Check the power supply
and the plug in power
supply.
If you get no positive results,
please contact the service
department.
The system can not
finish the regeneration mode.
1. Malfunction control
unit of the water softener.
2. Malfunction of the
PerPur
Please contact the service
department.
DE3-5
Function
Possible reasons
Possible solutions
No function.
Control lamp
of the main
switch OFF.
Power supply broken.
Check the power supply
(fuses, voltage etc.). If you
get no positive results,
please contact the service
department.
Unit doesen’t
increases the
inlet pressure.
1. Inlet broken/interrupted.
2. Malfunction of the
PerPur.
3. PerPur is in the regeneration mode.
4. Malfunction of the internal
booster pump.
5. Malfunction of a internal
pressure switch.
1. Check the pre installed
water treatment.
2. Check the PerPur
3. Wait until the regeneration is finished.
4. Please contact the service department.
5. Please contact the service department.
Dosing unit
Function
Possible reasons
Possible solutions
Printing results
of your printing
machine is not
satisfactorily.
1. Not enough Aqua Plus in
the reservoir.
2. Malfunction of the dosing
unit.
1. Nachfüllen.
2. Check the dosing unit
(see page 19).
If you get no positive results,
please contact the service
department.
Please inform Nortec Systems customer service if you ever find a malfunction in the
system (262.884.4669).
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7.2 Exchange of Defective System Components
Inlet
Water softener
Discharge
120 V~/ plug in
power supply
12 V~
120 V ~
Installation rail
Drain
Remote fault indicator
Pure water system (PerPur)
3
1
4
2
5
6
Components may only be replaced by properly instructed, trained persons. The operator
(customer) is responsible for checking that these persons are suitable and have been properly instructed and trained and is obliged to stick to the requirements from Nortec Systems,
espe-cially those in this documentation.
CAUTION:
- Indicate to the people around you that work is being carried out on the water treatment
or air humidification system (as applicable).
- Make sure that it is impossible for the system to be turned on again by mistake.
7.2.1 Water Softener
Figure 21: Replace Water Softener
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Page 47
- Turn off the pure water PerPur unit (1).
- Block the water supply (2) at the installation rail.
- Pull the plug-in network part (3) out of the socket.
- With 2041/2101: Disconnect 5 pole plug (4) at the PerPur unit.
- Take the hoses with steel jackets (5) away from the water softener (wrench 19).
- Take away the textile hoses (6) from the water softener and take the device away.
- Put the new water softener in place, attach hoses, be sure that all seals are present
and in order.
- Connect plug to the pure water system (PerPur unit).
- Fill salt container with tablet salt and add 10 litres of water, using a pail.
- Plug network part into the socket.
- Open water supply. The pressure indicated by the manometer should rise. Check that
all connections are watertight (visual inspection).
- Turn on the pure water system (PerPur unit).
The DRAABE Pure Water System (PerPur) turns on automatically in 15 minutes.
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7.2.2 Clear Water System PerPur
Inlet
Water softener
Expansion reservoir
Discharge
120 V~/ plug in
power supply
12 V~
120 V ~
Installation rail
Pure water outlet
Pure water
Drain
Remote fault indicator
Pure water system (PerPur)
ee
2
1
3
4
5
6
7
8
Figure 22: Replace PerPur Unit
- Turn off device at the network switch (1) and pull out the plug (2).
- Disconnect both plugs (3) from the device, detaching the knurled ring at each plug.
- Block the water supply (4) at the installation rail.
- Open the discharge faucet (5) to let the pressure out.
- Unscrew the filter housings (6) and put in new filter elements. (The old filters can be
thrown away with normal trash).
- Fully empty the pure water tank via the discharge faucet (7).
- Detach self retracting hoses (8) (wrench 14/17) and let them slide into the container.
- Take the PerPur unit away from the console and put the new device in place.
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- Connect by going through the above steps in reverse order.
6
5
4
217
3
7.2.3 Pressure Boost
Figure 23: Replace Pressure Boost
- Turn off unit via the network switch (1) and pull out the network plug.
- Block off the water supply (3).
- Take out the screws (4).
- Take off the upper part (5) of the DE 3-5.
- Put the new device in place and connect by following above steps in reverse order.
CAUTION:
If a shut-off valve is present in the place of a non-return valve (6), then this valve must definitely be opened before the device is turned on again because otherwise the excess pressure safety device will be triggered!
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7.2.4 Dosing unit
supply
printing mashine
Aqua - Plus
Dosing unit
0,5%
1
3
3
2
Figure 24: Replace Dosing unit
- Close faucet (1) at entrance (and at exit, if present).
- Take the dosing unit hose away from the dosing unit and detach the spigot (2).
- Unscrew the PVC screw fitting (3), having first placed a pail below to catch any water.
- Take the dosing unit from the bracket.
- Place new dosing unit in the bracket. Be sure to observe the direction of flow!
- Connect dosing unit hose and screw the spigot on tight.
- Open faucet slowly.
- Draw off water at the exit.
While drawing water off, observe whether the dosing unit emits a pumping noise and
whether Aqua-Plus is sucked up through the dosing unit hose (transparent hose).
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Page 51
desalination performance
100,000 litres
dimensions
1130 x 320 x 530mm
44.5 x 12.6 x 20.9 inches
weight (without filling)
38 kg
operating voltage
12VAC, 60Hz
power consumption
10W
operating water pressure
2 bar (30 psi), flow pressure max. 6 bar (87 psi)
pressure loss (with rated output)
1,2 bar (17.4 psi)
Installation category
II
pollution degree
2
application
only in rooms
altitude above sea level
6,670 ft
surrounding temperature
7-35°C (45-95°F)
surrounding humidity
max. 80%, prevent condensation
approval
GS, CE, CCSAUS
desalination performance
90,000 litres
dimensions
1220mm x 330mm x 410mm
weight (without filling)
38 kg
operating voltage
12VAC, 60Hz
power consumption
10W
operating water pressure
2 bar (30 psi), flow pressure max. 6 bar (87 psi)
pressure loss (with rated output)
1,2 bar (17.4 psi)
installation category
II
pollution degree
2
application
only in rooms
altitude above sea level
6,670 ft
surrounding temperature
7-35°C (45-95°F)
surrounding humidity
max. 80%, prevent condensation
approval
GS, CE
8. Technical Data
8.1 Water Softeners
AC2101:
SoftCab 25 DR:
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Page 52
volume
18 litres
dimensions
Ø 360 mm (14.2 inches)
permissible operating pressure
10 bar (145 psi)
connection
1“ (outer)
weight empty
approx. 6 kg
approval
GS, CE, CCSAUS
volume
80 litres
dimensions
Ø 605 mm (23.5 inches)
permissible operating pressure
10 bar (145 psi)
connection
1“ (outer)
weight empty
approx. 16 kg
approval
GS, CE, CCSAUS
volume
235 litres
dimensions
Ø: 610 mm (24 inches), h: 1088 mm (43 inches)
permissible operating pressure
8.6 bar (124 psi)
connection
1 1/4“ (inner)
weight empty
approx. 23kg
approval
GS, CE
Volume
450 litres
dimensions
Ø: 610 mm (24 inches), h: 2040 mm (80 inches)
permissible operating pressure
8.6 bar (124 psi)
connection
1 1/4“ (inner)
weight empty
approx. 43kg
approval
GS, CE
Volume
600 litres
dimensions
Ø: 770 mm (31 inches), h: 1758 mm (70 inches)
permissible operating pressure
8.6 bar (124 psi)
connection
2“ (inner)
weight empty
approx. 76kg
approval
GS, CE, CCSAUS
8.2 Water Tanks
8.2.1 Tanks (wall models)
DWD 18:
DWD 80:
8.2.2 Tanks (standing models)
WM-235:
WM-450:
WM-600:
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WM-1000:
volume
1000 litres
dimensions
Ø: 922 mm (36.3 inches), h: 2145 mm (85 inches)
permissible operating pressure
8.6 bar (124 psi)
connection
2“ (inner)
weight empty
approx. 117kg
approval
GS, CE, CCSAUS
flow rate
120 kg/h, ± 10%
dimensions
600 x 400 x 400 mm
23.6 x 15.7 x 15.7 inches
weight
approx. 35 kg
operating voltage
120VAC, 60Hz, ± 10%
power consumption
600W
installation category
II
pollution degree
2
application
only in rooms
altitude above sea level
6,670 ft
surrounding temperature
7-35°C (45-95°F)
surrounding humidity
max. 80%, prevent condensation
approval
GS, CE, CCSAUS
flow rate
200 kg/h, ± 10%
dimensions
600 x 400 x 400 mm
23.6 x 15.7 x 15.7 inches
weight
approx. 40 kg
operating voltage
120VAC, 50-60Hz, ± 10%
power consumption
600W
installation category
II
pollution degree
2
application
only in rooms
altitude above sea level
6,670 ft
surrounding temperature
7-35°C (45-95°F)
surrounding humidity
max. 80%, prevent condensation
approval
GS, CE
8.3 Clear Water System PerPur
PerPur 120 (types CSF2122 or CSF3122):
PerPur 200:
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8.4 Pressure Booster
flow rate
200 l/h
dimensions
410 x 600 x 315mm
16.1 x 23.6 x 12.4 inches
weight
approx. 20 kg
operating voltage
120VAC, 60Hz, ± 10%
power consumption
195W
installation category
II
pollution degree
2
application
only in rooms
altitude above sea level
6,670 ft
surrounding temperature
7-35°C (45-95°F)
surrounding humidity
max. 80%, prevent condensation
approval
GS, CE
operating water throughput
10 l/h – 1500 l/h
dimensions
130 x 130 x 280mm
5.1 x 5.1 x 11 inches
weight
approx. 2 kg
water temperature
5°C – 40°C (41°F – 104°F)
dosage value
0.5 %
operating water pressure
0,5 – 5 bar (7 – 70 psi)
differential pressure
0,3 – 1 bar (5.8 – 23.8 psi)
application
only in rooms
altitude above sea level
6,670 ft
surrounding temperature
10-25°C (50-77°F)
surrounding humidity
max. 80%, prevent condensation
approval
GS, CE, CCSAUS
8.5 Dosing unit
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9.Appendix
Position
Article No.
Article Name
1
001026
salt briquettes 25 kg
2
004039
microfilter
3
004040
activated carbon filter
Groups II and II
DWD 18, DWD 80
Group IV
WM-0235, WM-0450, WM-0600,
WM-1000
9.1 Replacement Parts
9.2 Pressure Tests at the Tanks (legal requirement)
According to paragraph 10 of the German Ordinance on Pressure Vessels (DruckBehV),
recurrent tests are to be carried out on pressure vessels (inner and pressure test). Type
and scope of test depend on which of various groups the vessel belongs to:
Groups II and III: Recurrent tests by an expert. The time intervals between tests are deter-
mined by the operator.
Group IV: Recurrent tests by an expert.
outer test: every 2 years
inner test: every 5 years
pressure test: every 10 years
Responsibility for ensuring that the recurrent tests are carried out lies with the operator.
The pressure vessels to be obtained from us are to be placed in the following groups:
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9.3 h,x-Diagram
12345678910 11 12 13 14 15
x(g/kg)
0
1
0
%
5
0
%
9
0
%
2
0
%
6
0
%
1
0
0
%
3
0
%
7
0
%
4
0
%
8
0
%
-10°
- 5°
0°
5°
10°
15°
20°
25°
30°
35°
t(°c)
1
,
2
0
1,25
1
,
1
5
p
(
k
g
/
m
)
3
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9.4 Fresenius Test Certificate
Test report
Order no 479652
Client no 5464400
Dr Ansgar Ferner/Th
Tel. +49 /-, Fax ansgar.ferner@institut-fresenius.de
Consumer Testing Services
Meat & Food-Management systems
SGS INSTITUT FRESENIUS GmbH
Im Maisel 14
Taunusstein
Test certificate
Test objects:
Product description: Air humidification system
Model: PUR
Appliances tested :
DRAABE pure water system PerPur, SynPur
DRAABE high pressure system HighPur
DRAABE air humidification system Turbo Fog (TF4, TF16, TF32
DI Flex (ED/HT), BS
Test period:
The DRAABE appliances that are listed as "tested appliances" were microbiologically tested by us in 2005 over a period of 6 months.
Microbiological check studies are carried out on the system at regular intervals to also confirm the results in the long term.
Test conditions and requirements:
The system must permanently prove that it permanently functions hygienically as part of this study. In this process the test conditions
assume the "worst case". This is the case if:
- the entire system is in standby mode
- no air humidification is demanded
- the room air does not require any conditioning in terms of the humidity (% air humidity)
The hygiene levels must ensure the maintenance of the following requirements during the entire test period (3% humidification EIN). Procedures were not employed which cause the additional discharge of chemicals /biocides in the room air.
The system was contaminated with a germ compound three times in the course of the test. The system configuration corresponded to the
maximum extension level of the DRAABE system (see above). The results shall be stated by means of a detailed analysis report.
Contents of the analysis report:
Materials tested, description of the test, test bacteria, contamination interval, germ pollution, individual results, composition and quantity of
the germ compound (for the contamination process).
Results:
The DRAABE system tested by us completely fulfils the aforementioned requirements. As a result the requirements for the
awarding of the INSTITUT FRESENIUS quality seal have been fulfilled. The DRAABE system that was tested works perfectly in
terms of the hygiene levels and fulfils the present demands (as at: December 2005) of BG Druck und Papierverarbeitung, Wiesbaden.
The following total germ levels were not exceeded:
Admission water air humidification KBE*/ml
Humidifier water KBE*/ml
The evaluation of the test result is based on the data of a system operating in accordance with the operating instructions drafted by
DRAABE and their service intervals.
Taunusstein, December 2005
SGS INSTITUT FRESENIUS GmbH
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germ forming units
Page 58
Dr. Ansgar Ferner Franz-Josef Schäfer
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