BAMOSOFT Control Water hardness monitor INSTRUCTIONS MANUAL Water hardness monitor BAMOSOFT Control 19-01-2011 376 M1 01 C DUR 376-01/1
Table of contents Page 1. Principle...3 2. Characteristics...4 3. Recommendations...4 3.1 Electric connections...4 3.2.1 Output alarm signal through a potential free contact...4 3.2.2 Analogue output 4-20 ma on water residual hardness...4 3.2.3 Connection of an external flow meter (pulse signal)...5 3.2.4 Connection of ON/OFF contact (stand-by / run)...5 3.2.5 Main power connection...5 3.2.6 Connections and wires description...5 3.3 Hydraulic Installation...6 4. Start up the system...7 4.1 Dip switches statement...7 4.2 LED-status and displays...8 4.3 Configuration tests...8 5. Maintenance...9 5.1 Advices...9 5.2 Delivery, transport, storage of sensor...9 5.3 Sensor mounting and replacement...9 5.4 Operating conditions, dysfunctions on sensor...10 6. Dysfunctions and causes...11 7. Setting down the system...11 8. Dismounting...11 9. Sensor identification...12 10. Accessories...12 11. Technical features...12 12. Correct use in accordance with standards...13 13. Safety Requirements...13 14. Warranty...13 376 M1 01 C 19-01-2011 Page 2
1 Principle BAMOSOFT Control provides a safe survey on water quality with a visual alarm and 4-20 ma output signal. The monitored softened water threshold value can be defined from 0.25% up to 10% in reference to raw water hardness (8 step values available). A pulse signal input allows running a monitoring cycle when necessary. Through a current loop the indicated water hardness value will put out and allows a record of the hardness progress. Example with tap water: - Raw water hardness inlet: 14 e (or = 20 f) - Threshold value set up at 10%: 1.4 e (or = 2.0 f) - 4-20 ma signal will cover the range 0 to 1.4 e (or 0 to 2 f) BAMOSOFT Control is an online water hardness measuring system for continuous monitoring of water hardness differences between process inlet and process outlet of a connected water softening system based on cations exchange. Using a bypass sampling, the instrument samples, time controlled or flow rate depending minimal amounts, raw and softened water from the process. It evaluates the residual hardness and alerts with exceeding of a preset threshold value. The threshold value can be configured with DIP switches by steps from 0.25% up to 10% (8 steps) of residual hardness in reference to 100% raw water hardness. The measurements will be carried out cyclically every 15 minutes in a flow-through chamber (measuring cell) where a selective sensor for calcium and magnesium ions operates in an environment protected against pressure. In each measurement cycle the water sample stays a preset period in the measuring cell and will be evaluated after a preset resting time. The measurement cycle can be controlled optionally by impulses from a flow meter. By automatically opening and closing of the upstream solenoid valves, the water samples will be replaced and rejected free of pressure. With exceeding of threshold value a potential free switch will be activated with a delay of 1 minute. With recognizing of an interference or need of sensor exchange a second potential free switch will be activated. Pressure free drain outlet For factory use Measurement chamber Optional output Optional input To power supply unit Softened water valve Filter Softened water Raw water Filter Raw water valve Raw water Softened water Water softener system Measuring functions and their results are represented with coloured LED. At the same time the measurement value will put out through a current loop 4 20mA (percentage varying from threshold value).each five days, the sensor performance will be automatically checked. If the result does not comply with the system requirements, the need for sensor exchange will be signalized. Once a day the valves will be tested for leaks. After this, a sensor test will take place in raw water, which purpose is an evaluation of performance. Valves and sensor tests will take 17 minutes. During this time no water hardness measurement will take place. The measurement system may be set in off-line-mode, by an external potential free contact. In this mode no measurement will take place. The daily automatically determination of sensor performance will be running on. The measuring system is automatically calibrated by time controlled automatic change over from softened water to raw water. There is no need for additional indicators or reagents. 376 M1 01 C 19-01-2011 Page 3
2 Characteristics < Water hardness of raw water will be defined automatically with 100% < Water hardness of softened water will be determined in percentage and rated to a fixed threshold value (by DIP switch) < The difference value shows the actual efficiency of the softening plant. < The threshold value can be defined by steps from 0.25% up to 10% (8 steps) in reference to the raw water hardness. < Display of the measurement analysis by coloured LED < Possibility to run the measuring cycle by an external contact, from a flow meter with pulse output (the pulse must be >0.5 s). The flow meter should be in the outlet line of the softening system. < Time controlled measuring cycle with measuring breaks of 15 minutes between two measurements, or process controlled continuous measuring when softened water is being released and the contact water meter is sending a pulse (<0.5 s) < Front access of DIP switches for the configuration < Detection of high brine concentration in softened water < Self diagnostic of hardness sensor with signal for replacement needed < Output of indicated value through 4 to 20 ma current loop 3 Recommendations! The BAMOSOFT Control should be mounted very close to the softening system. Installation is possible as wall or frame mounted with a free space around the unit of about 300 x 300 x 150 mm. For sampling of raw and softened water, 4 mm OD pipes are provided (with 1/4 internal thread connectors) and filters should be fitted as well as on the process inlet as on the process outlet of the softening system. During operation the water pressure must be 1 bar as a minimum and 7 bar as a maximum. Once the area where the unit is to be installed is ready the device can be fitted easily. After mounting the instrument and plugging the sensor into the measuring cell the BAMOSOFT Control is ready for operation. 3.1 Electric connections For the connection of the operating voltage and the external signal cables, the back panel has to be removed. The four M12 screws (joined at the sidewall of the unit) have to be used. The cable ends must be equipped with wire end ferrules with a maximum cross section of 0.5 mm 2 and fitted in the unit according to the following descriptions. 3.2.1 Output alarm signal through a potential free contact For alarm signal output on exceeding hardness or brine concentration, connect the cable to terminals 1, 2 and 3; the alarm for sensor replacement is to be connected to terminals 4, 5 and 6. Alarm signal loop requirements: Voltage 24 Volt as a maximum Current 0.5 Ampere as a maximum 1 3 2 Switching setting Threshold value exceeding or Brine solution alarm 4 5 6 Switching setting Threshold value exceeding or Sensor alarm Contact status: Signal status Terminals Contact Power failure or threshold value exceeding or brine solution alarm 1 and 3 closed Power failure or threshold value exceeding or brine solution alarm 1 and 2 open Power failure or sensor alarm required 4 and 6 closed Power failure or sensor alarm required 4 and 5 open 3.2.2 Analogue output 4-20 ma on water residual hardness The active signal of 4 20 ma represents a residual water hardness in the range of 0 2% or 0 10 %. The loop may be connected to the terminals 17 and 18. The terminal 17 represents the positive and terminal 18 the negative potential. Do not connect external voltage Use passive loop resistance of maximum 250 Ohm Requirements for electrical connections on the current loop: 376 M1 01 C 19-01-2011 Page 4
3.2.3 Connection of an external flow meter (pulse signal) For a continuous monitoring during the softened water sampling and to avoid threshold value exceeding alarm caused of the so-called "hardness breakthrough" it is recommended to monitor the softened water sampling not within fixed time distances. Therefore it is possible to connect a mechanical or electrical flow meter to the BAMOSOFT Control. Connection to a mechanical water meter: The water meter to be connected must be equipped with potential free contacts. The electrical connection is on the terminals 23 and 24 of the PCB. Connection to an electronic flow meter (Hall Effect sensors): The electronic flow meter is to connect at the terminals 24, 25 and 26 of the PCB. Open Collector (use of bipolar transistors): care must be taken not to destroy the circuits via incorrect polarity, over-voltage, transients or current overload. Pay attention to the good polarity of connections and to prevent short circuits. Open Collecteur collector Terminal Borne 25 25 + Vcc+ V DC Terminal Borne 24 24 terre Ground Terminal Borne 26 26 impulsions Pulse 3.2.4 Connection of ON/OFF contact (stand-by / run) BAMOSOFT Control is staying in ON-mode (running) as long as there is no short circuit between the terminals 20 and 21. It will stay on OFF-mode (stand-by) while both terminals are in contact. In this state no measurement will be done. Independently of the ON/OFF status, automatic calibration cycles stay active, therefore raw water and softened water pressures are permanently needed. CAUTION: The OFF-Line mode should be used for few minutes or some hours only, to avoid a non-monitoring of the softening plant and to protect the sensor system against germs. Requirements: Supply voltage 24 Volt as a maximum Current 0.5 Ampere as a maximum 20 21 OFF-Line-Mode 20 21 ON-Line-Mode 3.2.5 Main power connection The supply voltage of 24 V DC is to connect at the terminals 31 and 32. An electrical installed load of 5 Watt is necessary. The terminal 31 has the positive and the terminal 32 the negative potential. An operation with 230 V AC is allowed only with the power supply unit provided with the instrument. 3.2.6 Connections and wires description (*) = for supplied cabinet code number 376310 (H= high, M= middle, L= low) Terminal Configuration PG / wire (*) Description 1 Relay 1 COM H / brown Threshold value alarm 2 Relay 1 (closed) H / black at alarm:terminal1 and 2 opened; Terminal 1 and 3 closed 3 Relay 1 (opened) H / red 4 Relay 2 COM H / white Service alarm 5 Relay 2 (closed) H / grey at alarm: Terminal 4 and 5 opened; Terminal 4 and 6 closed 6 Relay 2 (opened) H / blue 17 4..20mA - M / black Loop resistor < 250 Ohm 18 4..20mA + M / red Loop resistor < 250 Ohm 20 Offline-contact M / brown Potential free contact 21 Offline-contact M / white Potential free contact 23 Mechanical water meter M / blue Potential free contact 24 Mechanical water meter M / grey Potential free contact or ground for Hall effect flow meter 25 Flow meter (Hall effect) voltage M / yellow Voltage 26 Flow meter (Hall effect) pulse M / orange Pulse 31 Operating voltage L / white +12... +18 V DC (power supply unit) 32 Operating voltage L / grey -12... -18 V DC (power supply unit) 376 M1 01 C 19-01-2011 Page 5
3.3 Hydraulic Installation The hydraulic fittings on for inlets, outlet and hardness sensor may be carried out after the unit has been fixed at the wall or frame as following: 1) Fit the filters respecting the direction of flow, as close as possible to the stop valves in order to protect the hoses. 2) Push raw water hose Ø 4 mm as far as it will go into the plug-in connector RW (solenoid valve) 3) Push softened water hose Ø 4 mm as far as it will go into the plug-in connector SW (solenoid valve) 4) Push the drain tube Ø 8 mm tightly into the T-fitting at the outlet of the measuring cell 5) Plug the sensor socket of the sensor system to the measuring system cable. 6) Install the electrode tightly into the measuring cell CAUTION: Do not touch or damage the electrodes 7) Open raw and softened water stop valves and check leak-tightness of all pipes. CAUTION: The system is now under pressure up to the closed valves RW and SW 8) If the pressure test is successful, the installation has been completed. Note: The pre-filters may not be necessary if already existing filter systems ( 0.1 mm) are able to remove dirt which would otherwise reach the sampling valves. Pressure free drain outlet 4) For factory use Measurement chamber 6) 5) Optional output Optional input To power supply unit 3) Softened water valve Filter Softened water 1) Raw water 1) Filter Raw water valve 2) Raw water Softened water Water softener system 376 M1 01 C 19-01-2011 Page 6
4 Start up the system 4.1 Dip switches statement Prior to commissioning of Softening Control the correct installation and connections to the softening system must be checked again. This includes the softener system should be operating and adequate softened water quality should be avail-able at the outlet. Then, basically, it is to decide if the device monitors time or process controlled. According this decision a connection of contact water meter and setting of DIP switch 4 is to realize. The threshold value to be monitored is to set up with the DIP-switches 1-3. The following process parameters are relevant and have to be set as parameters manually using the DIP-switches: Process parameter Value range DIP-switches Threshold value Threshold value for softened water hardness in % Measuring interval Time between 2 measurements or 0.25 % à 10 % 1, 2 and 3 Time controlled Process controlled 4 Current loop resolution 20 ma = 2 % or 10 % 5 Setting of threshold value (factory setting: 2%) DIP1 DIP2 DIP3 Threshold value ON ON ON 0.25 % OFF ON ON 0.50 % OFF ON OFF 1.00 % OFF OFF ON 2.00 % ON OFF ON 4.00 % ON ON OFF 6.00 % ON OFF OFF 8.00 % OFF OFF OFF 10.00 % Setting of measuring cycle (factory setting: 15 min) DIP4 ON OFF Measuring interval 15 minutes Water flow meter Setting of power circuit (factory setting: 10%) DIP5 Power circuit ON 20 ma = 2% OFF 20 ma = 10 % 376 M1 01 C 19-01-2011 Page 7
4.2 LED-status and displays The visual display will be shown by green, yellow and red LED: The visual display will be shown by green, yellow and red LED: - Hardness evaluation will be indicated through lighting LED, - Functional status through flashing LED. The optical display and evaluation are based on the pre-set threshold value. Hereby the raw water hardness is committed to 100% as absolute value. The progression of water hardness will be evaluated accordingly. 4.3 Configuration tests Test of water quality: By temporary interruption of power supply, BAMOSOFT Control restarts the measurement and proceeds to a new calibration independent of preset measuring cycle. Provided that the quality of softened water is really below the customized threshold value, upon completing the measurement result will be displayed by the luminescent green LED and the current loop comes into operation. In case of exceeding the threshold value recalibration will be done. If this results once again in an exceeding thresh-old value, an external threshold value alarm will be signalized and the measurement will be repeated until a lower deviation is cyclically confirmed. Test of external signalling: A threshold value can be initiated, if the softened water supply will be manually closed, whereby the raw water cannot be flushed out of the measuring chamber by the softened water. With repeated recognition of the exceeded threshold value the relevant threshold value relay will be switched until a lower deviation is confirmed back. A service alarm can be initiated by disconnection of the plug-in connection to the hardness sensor. Upon a short time the green and red LED will be flashing and the relay for service alarm will be switched until the sensor will be recognized. 376 M1 01 C 19-01-2011 Page 8
5 Maintenance 5.1 Advices The electric power must be disconnected prior to the removal of the sensor from the measuring cell. Otherwise water will be spurt out of the measuring chamber. The system is under pressure up to the solenoid valves. The raw and softened water inlets must be isolated prior to carrying out any maintenance work on the solenoid valves or dismantling the instrument. Otherwise water will be spurt out of the system. 5.2 Delivery, transport, storage of sensor Each hardness sensor is clearly identified by its serial number. Prior to delivery each sensor has to pass an extensive quality check, where the sensor quality will be checked and documented. The measuring part of the sensor is tightly closed with a protective cap to protect the sensor membrane against interferences and to keep it in a sterile and humid climate. Up to the time of operation the protective cap has to be kept tightly closed to the sensor. The humidity inside the protective cap avoids a drying-out of the sensor membrane. Install the sensor immediately after removing the protective cap. Sensors without tightly closed protective cap, dries up fasten and may not operate properly, or may operate after 1 to 2 days. The protective cap should not be removed unless for immediate mounting to protect the sterile and humid internal climate. Protection Cap! STORAGE: Ideally, the sensor should be stored in the folded box between 10 C and 15 C, or at least, in a cool place. Do not touch the electrode 5.3 5.3 Sensor mounting and replacement To replace the electrode, follow these steps: 1) Separate plug-in power supply unit from the power line or interrupt power supply 2) Separate sensor cable from sensor and unscrew the bolt to take of the sensor. 3) Press down the female adaptor ring at the t-fitting of measuring cell in which the sensor is fitted and unplug the used up sensor simultaneously 4) Take the new sensor out of the box and pull it out of the protective cap Do not touch or damage the sensible sensor part 5) Push the new sensor firmly in t-fitting of the measuring cell. Push it straight in, to avoid any contact to the pipe wall. Verify that the sensor is firmly in place by pulling it lightly. Plug the sensor cable on the new sensor (keep in mind the polarity protection) The sensor cable must engage audible and tightly (too strong effort could damage the connector) 6) Screw in the bolt to fix the electrode in place 7) Plug the power supply or switch on the power supply. The device checks the sensor plug-in connection and signals a sensor alarm if it not recognizes the new sensor. In this case disconnect the device once again and check the plug-in connection of the sensor. 8) Sensor mounting / replacement has been successfully completed if the device recognizes the new sensor and starts with measuring operation. 376 M1 01 C 19-01-2011 Page 9
5.4 Operating conditions, dysfunctions on sensor Operating conditions: The response quality of the sensor is influenced by water quality, especially contents of precipitation of iron, high chlorine or brine concentrations and growing bacteria cultures. The sensor must be replaced as soon as the alarm sensor signal is lighted Required water features Natural raw water with a hardness value between 2 f and 100 f (1.4 e to 70 e) [1 dh and 90 dh] Water temperature: +5 to 30 C ph-range: 5...9 ph Chlorine content: < 500 µg/l Germ content: < 5000 KBE/mL (< 5000 CFU/mL) The water has to be free of acids, bases incl. brine and other basic liquids, tensides (surfactants), oils, solvents and heavy metals. Malfunction / Breakdown: a) Deposits on the sensor Precipitations and deposits on the sensor prevent an adequate monitoring. Examples: Rust- and iron deposits form a light red-brown coating in the measuring cell and the sensor system Up streamed filters should prevent from precipitations of iron, copper or aluminium. Bio film growth in consequence of to high microbial count in the water Bio films appear highly when the softening plant or the device has been out of operation for some days or weeks and water was kept in the chamber. In case of long immobilization time the BAMOSOFT Control should be electrically disconnected. The sensor should be removed from the measuring cell and stored according to storage conditions. The measuring cell should be free of water (as well as the pipes, filters and accessories). b) Chlorine impact Chlorine addition, as often seen in raw water supply, may destroy the sensor (depending on concentration and duration). A strong deep black colouring of the metal electrodes indicates high chlorine influence. The sensor may indicate threshold value exceeding, while no threshold value exceeding exists. The sensor is defective and has to be replaced. c) Brine solution impact Should the outlet valves of the softening plant be defective, it is possible that during the regeneration process but even if there is low water throughput, brine from the brine container may washed out into the softened water, which will be evaluated by the sensor as threshold value exceeding. With very high sodium concentration against the calcium-magnesium concentration, the sensor signal will be influenced by the very high sodium content, which creates sensor error. A high brine concentration can be measured by conductivity difference measurement between raw and softened water. With an excessively high and concentrated brine impact, the sensor will be destroyed, whe reby it will indicate threshold value alarm even if the softening system operates properly. The sensor is defective and has to be replaced. 376 M1 01 C 19-01-2011 Page 10
6 Dysfunctions and causes a) Signalization of threshold value exceeding without there being any excessive water hardness Sampling water flow through measuring cell is too low Check the flow rate flowing out to the drain and adjust Existing low brine concentration in softened water Rinse again the active column of softening plant Sensor could be soiled or damaged by brine Replace the sensor b) Sensor not recognized Sensor cable is not properly plugged in or electrical plug-in connection is defective Check the electrical connection between sensor and the monitor c) Brine alarm High brine concentration in the softened water or, conductivity of softened water is higher than conductivity of raw water Rinse again the active column of softening plant Non continuous flow on raw or softened water inlet, raw or softened water does not flow around the sensor Restore the water supply Sensor could be soiled or damaged by brine Replace the sensor d) Valves leaking One of the valves does not close properly Remove the hoses from the measuring cell and check if drop wise water leaks from the valves even if the valves are closed. Replace affected valve One of the liquids (raw or softened water) does not flow Causes: - Sample inlet closed Check stop valves - Pre-filter clogged Check pre-filter - Sample hose clogged Check and clean sample hose - Defective valve Check and clean the valve 7 Setting down the system To set down the monitoring system, proceed as following: 1) Unplug the power supply unit or/and disconnect operating voltage 2) Close raw and softened water manually (stop valves) 3) If the device should be set down for more than 2 days, remove the sensor. Protect the sensible sensor part by a protective cap filled with approximately 1 ml of raw water. Store the sensor in a cool (10 to 15 C) and dark place. 8 Dismounting 1) Set down the monitoring system as described above 7 2) Remove the raw and softened water hoses (push the safety ring of the connector down and pull the hoses out) 3) Disconnect cables for external signal output and/or water meter 4) Dismount the device from the wall or frame 376 M1 01 C 19-01-2011 Page 11
9 Sensor identification 1 selective sensor for calcium and magnesium ions Type 650 10 Accessories Power supply unit 100... 240 V AC, 50/60 Hz Plug adaptor for connection of a flow meter and external alarm signal output 1 hose, 2 m long for drain outlet, Ø 6mm o.d. (DN 4 mm) 1 hose, 4 m long for 2 sampling inlets, Ø 4mm o.d. (DN 2 mm) 1 Instructions manual 2 filters with connection o.d. 4 mm / 1/4 Gas 11 Technical features Dimensions: Mass: Wall mounting housing: 95 x 145 x 35 mm (Overall system 120 x 220 x 120 mm) 800 g Ambient temperature: + 5... + 50 C % R. H.: 20... 80 % Power supply: Water connections: Drain sample: Water quality: External cycle switch 100 240 V 50/60 Hz 0.2 A, included separated unit Consumption approx. 6 Watt for PA tube o.d. 4 mm, i.d. 2 mm Pressure limits: 1 to 10 bar Recommended up stream dirt filters 0.1 mm Ø 6 mm as a minimum, pressure free Raw water, free of grease, oil and brine Germ content: < 5000 KBE/mL Pulse limit: > 0.5 s as a minimum OUTPUTS Alarm threshold / brine: Alarm system: (electrode / valves) Output signal: Electrode check up: Electrode time life: Contact, potential free; switching power 24 V DC / 1 A Contact, potential free; switching power 24 V DC / 1 A 4-20 ma (max. 250 Ohm) 0...16% (% of raw water 100%); resolution 1% (1% = 1 ma) Self diagnostic with alarm for low efficiency 6 to 12 months 376 M1 01 C 19-01-2011 Page 12
12 Correct use in accordance with standards The automatic measuring unit monitors a preset limit value of residual hardness in softened water of a connected water softening plant on cations exchange base. 13 Safety Requirements The automatic measuring unit is wall mounted in accordance with the installation instructions. Usage is permitted only in a room with relative humidity between 20% and 80% and a temperature between 5 C and 50 C. The equipment is to be protected from moisture and from damage due to mechanical or electrical disturbances. The measuring unit must be operated continuously earthed with a 230 V AC power supply via an earthed electrical power point respectively with the wall power supply 100... 240 Volt provided with the instrument. The mechanical installation and commissioning must be carried out with the power disconnected. The electrical connection to external control equipment and instrumentation must not exceed the specified voltage. The raw water and softened water specifications for the softening process are determined by the relevant drinking water specifications. During operation the pressure is to be maintained within a range from 1 bar to 7 bar at the sample points for raw water and softened water. The liquid to the sampler must be free of turbidity; otherwise a particle filter of 0.1 mm needs to be installed up-stream of the take off to the sampler. Operation in connection with ionization or electrolysis unit is not permitted.! The electric power must be disconnected from the unit prior to the removal of the sensor from the measuring cell. The system is under pressure up to the solenoid valves. The raw and softened water inlets must be cut off (stop valves) prior to carrying out any maintenance work on the solenoid valves or dismantling the measuring unit. Any time the unit is taken out of service, the sensor needs to be removed from the analyzer and correctly stored. 14 Guaranty BAMO Mesures SAS guaranties his product with the exception of the hardness selective sensor for 1 year date of invoice, accordingly to our General Conditions of Sales. The guarantee is rendered invalid by: Improper commissioning, improper operation or improper maintenance Improper or unauthorized tampering with the equipment or its components Improper analytical, mechanical or electrical activities of any kind Damage or consequential damage resulting from incorrect handling or operation Damage or consequential damage resulting from erroneous, improper or unauthorized systems connected into the control system or to the instrumentation Damage or consequential damage caused by inadequate quality of the liquid to the sampler. 376 M1 01 C 19-01-2011 Page 13