OptiSoft - OptiPure

OptiSoft
OS-10, OS-13,
OS-20 & OS-29
Softeners
Installation, Operation
& Maintenance Manual
Rev. 2
OptiSoft_iom_manual_v2.indd
©2018 OptiPure A Division of Aquion, Inc.
All Rights Reserved
Manufactured By:
OptiPure
A Division of Aquion, Inc.
2605 Technology Drive, Bldg. 300
Plano,TX 75074
P: 972.881.9797 F: 972.422.6262
2
OptiSoft System Installation, Operation & Maintenance
Service Contact
For local maintenance and service information
please contact your nearest Authorized Service
Representative. Service inquiries may be directed to
technical support at:
OptiPure a division of Aquion, Inc.
2605 Technology Dr. Bldg. 300
Plano, TX 75074 USA
Phone #: 972.881.9797
Fax #: 972.422.6262
E-mail correspondence to:
techsupport@optipure.net
Safety Instructions
1. Please read and follow these instructions when
connecting and using the system.
2. Plumbing and electrical connections should be
performed by qualified persons in accordance
with local codes.
3. Never use the system if the power cord or other
parts of the system have been damaged. Do not
allow anything to rest on the power cord, and
keep the cord away from any place where people
may trip over them.
4. Do not lay the softener on its side.
5. When disconnecting from the electric socket hold
the plug, not the cord.
6. Unplug the softener prior to any service.
7. Use approved Air-Gaps when connecting to drain
lines.
8. Do not exceed system pressure/temperature
rating and use water hammer arrestors when
water hammer is evident.
9. Use flexible hoses for connecting the softener.
Installation Requirements
This product must be installed and maintained in
accordance with manufacturer’s guidelines and local
regulatory plumbing and electrical codes.
Location
The system should be installed indoors, in the proximity
(within 25 feet) of the equipment to be fed by the softener,
and protected from the elements. Do not let the softener
freeze or be exposed to rain, direct sunlight, or high
ambient temperatures. Ensure the floor under the softener
is clean and level.
Feed water operating parameters
Minimum Temperature:
Minimum Pressure:
Maximum Temp/Pressure:
35° F (2° C)
20 psi (1.4 bar)
120° F (48° C) at 120 psi (8.3 bar)
----OR---149° F (65° C) at 73 psi (5.0 bar)
Feed water supply
An adequate flow and pressure of water to the unit is
essential for successful operation. Provide a dedicated 3/4”
water line (1/2” minimum) to the immediate location of the
installation. Less than 2 feet from the rear side of where the
softener is to be installed, install a water supply ball valve
(user supplied, 3/4” recommended, 1/2” minimum). Come
out of the water supply valve with a 3/4” male pipe thread
fitting for connection to the 24” long flex hoses provided
with the softener. Use the supplied metal flex hoses or
other flexible hose for both inlet and outlet connections to
the softener.
Drain requirements
A drain near the floor level should be located within 5 feet
of the location of the unit. Plastic pipe of either 1-1/4” or
1-1/2” is recommended for the drain connection. The drain
connection should be accessible for system set-up and
service. Drain must allow a minimum flow of 12 gallons
per minute. Use the supplied air gap or other approved air
gap that allows for two 1/2” drain connections. (Use two
separate hoses for the two drains.) The supplied air gap fits
either 1-1/4” or 1-1/2” plastic pipe.
Electrical requirements
A power source (110V, 60Hz, 17 watt) should be located
within 5 feet of the location of the unit.
OptiSoft System Installation, Operation & Maintenance
3
Specifications
Softener inlet/outlet connections
The connectors on the softener unit are 3/4” male pipe
thread. Two corrugated metal flex hoses, 24” long, with female
3/4” pipe thread ends, are supplied for connecting to 3/4”
male fittings for the feed water and downstream plumbing.
Use these or similar flex hoses for making connections to
the softener rather than hard-plumbing to the softener with
metal or plastic pipe. Each of the swivel connectors at the
ends of the flex hose has a rubber seal to make a seal to the
end of the pipe fitting to which it is connected. They require
no thread tape and should only be tightened snugly, without
over-tightening.
Hardness blending capacity
The softener is supplied with a blending valve to introduce
some hardness from the feed water into the treated water
outlet. The valve can be used to control how much hardness
is in the treated water, with a maximum of approximately 2530% of the feed hardness.
Model specifications
OS-10 OS-13 OS-20 OS-29
Model
Size (resin capacity,
cuft)
Nominal exchange
capacity (kilograins)*
Salt usage per regen.
(lb)
Recommended
maximum flow (gpm)
Weight (lb)
Salt storage capacity
(lb)
0.3
0.4
0.6
0.9
5.0
7.5
12.6
18.3
2.4
3.3
5.1
7.3
4.0
5.3
7.9
11.4
34
30
44
37
58
51
79
77
*Softened water capacity (gallons) between resin regeneration
cycles depends on feed water hardness.
Equipment Dimensions
OS-10 Micro
OS-13 Mini
OS-20 Midi
OS-29 Maxi
4
OptiSoft System Installation, Operation & Maintenance
Getting To Know Your System – Important Components
The OptiSoft softener works to condition water for use by downstream
equipment, by removing minerals and exchanging them for sodium ions
(from the salt in the brine tank). It automatically tracks the softening capacity remaining in the resin and performs a resin regeneration cycle as needed
to replenish the resin’s softening capacity. It incorporates a Blending
Valve to enable blending some hardness back into the treated water (up
to 25–30% of the feed hardness), to supply water to your equipment with
the characteristics that you desire.
Main cover
- remove to
access
controller
Brine tank
overflow
drain hose
barb
Salt lid
- remove for
filling with salt
Flex hoses (2)
Brine tank
Pipe thread
adapters (2)
- fit onto bypass
assy inlet/outlet
Outlet
valve
OUT
Softener cabinet
(OS-20 shown)
Control
valve
IN
Inlet
valve
Blending valve
- screw in center of
outlet valve handle
Bypass Assembly
OUT
Control valve
- on top of
mineral tank
Mineral tank
IN
- located inside softener cabinet
Brine suction
tube
Control valve
drain hose
barb
Electrical
power socket
OptiSoft System Installation, Operation & Maintenance
5
Control valve display
Power
transformer
Drain air
gap
Buttons: Scroll
Up Arrow
Down Arrow
System Installation
1. Unpack the softener and inspect for damage. Locate
the softener so as to allow full access to all sides of the
tank. Remove the salt lid and main cover.
2. Lift up the mineral tank and remove bagged parts from
inside the bottom of the brine tank.
NOTE: Do not remove the protective filter
bag from the bottom of the suction tube
(photo B).
3. (OS-10 & OS-13 Only) Place the softener on its
side. Holding the metal reinforcement plate in place on
B. Filter bag
around
suction tube
in brine tank
the bottom of the softener cabinet, screw and tighten
the casters into the threads at the four corners, using
the supplied washers. Place the two casters with brakes
at the front (or wherever they will be most accessible).
Place the cabinet in an upright position.
4. Identify the control valve drain hose connection, which
is a white hose barb on the left side of the control
valve, pointing toward the rear of the unit (see photo
D). Using a piece of 1/2” reinforced hose long enough
to reach from the softener to the drain, install a drain
hose on the control valve drain hose barb. Secure it
with a supplied plastic clamp, and tighten the clamp
with pliers. Flow from this drain will be under pressure.
5. Identify the non-return valve fitting (see photo E), and
see the arrows which appear on the side of each one.
D. Control valve
drain hose
connection
A. Softener with covers removed
C. OS-10 with casters
6
OptiSoft System Installation, Operation & Maintenance
G. Install bypass on
back of control valve
E. Non-Return Valve Fitting
F. Ensure gaskets are installed in
both connections of bypass assy
(Ensure the gasket is in place inside the black plastic
nut, on both adapters.) Install the one with the arrow
pointing toward the black plastic end onto the inlet
of the bypass assembly. Install the one with the arrow
pointing toward the brass end onto the outlet of the
bypass assembly.
6. Install the bypass assembly onto the inlet/outlet
connections on the rear of the control valve, being sure
to use the gaskets in the connectors. Hold the bypass
assembly in place with inlet/outlet horizontal, and
tighten the nuts firmly by hand (photos F, G).
7. Tighten all the connections (photo H) on the softener
using slip-joint pliers, but do not overtighten the
fittings. (Overtightening will cause leaking by distorting
the seals or cracking the plastic.)
8. Using one of the supplied 24” long metal flex hoses,
make the connection from the feed water supply valve
to the inlet of the bypass assembly (photo H). Each of
the connectors at the ends of the flex hose is 3/4” FPT,
with a rubber seal in it to make a seal to the end of
the 3/4” MPT fitting to which it is connected (photo I).
The metal flex hose swivel connectors do not
require thread tape, and they should not be
tightened as tight as ordinary pipe fittings.
INLET
OUTLET
Drain hose routed
under bypass
Pipe thread
adapters on back
of bypass assy
Tighten the nuts snugly
with a wrench; overtightening will distort the
rubber seals and cause
leaking.
Bend the flex hose as
needed to make the
connection so the fittings
are not under stress.
I. Flex hose swivel connectors with rubber seals
NOTE: Do not hardplumb all the way to the softener using metal
or plastic pipe.
9. Attach the other 24” metal flex hose to the outlet of
the bypass assembly and tighten the nut.
10. At the drain, plan the drain connections, but do not
make permanent connections of the drain
hoses or air gap at this time.
The drain connections will later be made using the
OUTLET
H. Connections
Metal flex hoses connected to inlet & outlet
Firmly tighten all
connections
INLET
OptiSoft System Installation, Operation & Maintenance
J. Supplied air gap fits
inside 1-1/2” plastic pipe
if needed
supplied air gap fitting or another approved air gap
connection that allows for two 1/2” hose connections
if needed. The supplied air gap fitting may be
fitted (using PVC cement) over the outside
of a 1-1/4” plastic pipe, or inside a 1-1/2”
pipe (photo J). If the drain pipe is neither of
these sizes, then accommodation will need
to be made at this time in preparation for
installation of an air gap. Ensure also that
the drain is as close to the floor as possible,
to ensure down-hill flow from the softener
cabinet overflow hose connection to the
drain.
11. Plug the power transformer output connector to the
socket on the wire coming out the back of the control
valve. Secure the wires together with the twist clamp
(photo K) to prevent it from inadvertently coming
unplugged.
12. Plug the transformer into the electrical outlet.
Control Panel Setup
When making the following settings, note that if no
buttons are pressed on the control panel for 5 minutes, the
controller will automatically return to service mode and
no changes will be saved.The up or down arrow
button must be pressed after stepping through
all the settings for any setting changes to be
saved. (See step 6.)
1. Perform a test to determine the total hardness of your
feed water, preferably in grains per gallon (written
as “grains” or “gpg”). Note the units used by your
testing method. (If you have the hardness expressed in
“mg/L” or “ppm”, you can divide this number by 17.2
to convert to grains.) Record the results of this
test.
Note: if you have additional Iron in your water, 1 ppm
7
K. Twist clamp securing
connected wires
of Iron counts as 4 gpg of hardness. (e.g., if you have 10
grains of ordinary hardness + 2ppm of Iron, this counts
as 10 + 2x4 = 18 grains)
2. To enter programming mode on the control panel,
press the scroll button
and hold it until the display
shows
Language:English
Press up or down arrow buttons to change the
language.
3. Press and release the scroll button
will show the time, similar to
Set time: 8:01AM
Press up or down arrow buttons to increment the time
forward or backward to the current time.
4. Press and release the scroll button
will show
Press up or down arrow buttons to change to the
desired units for hardness (usually grains = gpg).
, and the display
Set Hardn:10 gpg
Press up or down arrow buttons to set the hardness
to that of of your feed water (determined in step 1).
6. Press and release the scroll button
will show
, and the display
HardUnit: Grns
5. Press and release the scroll button
will show
, and the display
Exit
, and the display
8
OptiSoft System Installation, Operation & Maintenance
IMPORTANT: Press either the up or down
arrow button to save the settings you
entered and exit programming mode.
Startup
1. Ensure both valves on the bypass assembly are in
“bypass” position (photo M).
P. Water & salt
added to brine
tank
2. Use a flathead screwdriver to close the hardness blend
adjustment valve (photo M) on the outlet of the bypass
assembly, by turning it all the way clockwise.
3. Slowly open the valve at the water supply.
4. Allow water to run to drain briefly to flush the line.
5. On the softener bypass, open the outlet valve (photo
N).
6. Slowly open the inlet valve (photo O). Water will fill
the mineral tank, then begin to flow from the outlet.
7. Add salt to the brine tank (photo P), until the cabinet is
1/3 to 2/3 full. Do not fill higher than 2/3.
OUT
Hardness Adjustment
IN
Blending valve
(screw head)
M. Bypass position
OUT
IN
If some hardness in the treated water is desired, use the
blend adjustment valve, located on the outlet valve of the
bypass assembly (photos Q), to adjust the hardness to the
desired setting. The blend valve will increase the hardness
of the treated water by approximately 6% of the feed
hardness, for each complete turn counter-clockwise, up to
4 turns. (Beyond 4 turns, only a slight additional hardness
increase is likely.) The maximum hardness possible with
blending is 25–30% of feed hardness, with the valve open
to approximately 7 turns. Complete the following steps,
recording the results of hardness tests (and corresponding
blend valve settings) each time a test is performed:
1. If closed, open the water supply valve, in order to allow
flow from the softener outlet.
N. Outlet open,
Inlet in bypass
IN
OUT
O. Both valves
fully open
2. With the blend valve still completely closed, collect a
sample of the treated water coming from the softener
outlet.Verify softening effectiveness by performing a
hardness test on the treated water. (This is a blend
setting of “0 turns”.)
NOTE: If your desired hardness is less than 25%
of the feed water hardness measured previously
during “Control Panel Setup,” then follow the
steps below to set the blend to achieve the
desired hardness. Otherwise, open the blend
valve all the way to achieve the maximum
possible hardness, and skip to step #9 below.
OptiSoft System Installation, Operation & Maintenance
3. (See photo.) Using a felt tip pen, put a mark - aligned
with the screw slot - on the brass housing of the blend
valve adjustment screw, at one end of the screw slot.
This mark will be your reference point when counting
turns of the adjustment screw. Also mark the end of
the screw slot adjacent to the mark you placed on the
housing.
4. Based on your desired treated water hardness,
estimate the required blend setting, using the feed
hardness measurement you determined previously
during “Control Panel Setup”:
a. First, calculate the Hardness Increase Per Turn:
Hardness Increase Per Turn = 0.06 x Feed Hardness
b. Then calculate the Estimated Blend Setting:
Estimated Blend Setting = Desired Hardness
÷ Hardness Increase Per Turn
Round this number off to a single decimal place. This
is the approximate number of turns counter-clockwise
that the blend valve should be turned to achieve the
desired hardness.
Note that the highest available hardness is at a
blend setting of approximately 4 turns. A higher
hardness than this may not be possible with
adjustment of the blend valve. However, to achieve
the maximum possible hardness, open the blend
valve all the way (approximately 7 turns).
adjustment screw, plus any fraction of a turn after the
decimal place.
6. Perform a hardness test on a sample of the treated
water coming from the softener.
7. If the measured hardness is less than the desired
hardness, make small correcting adjustments by turning
the screw counter-clockwise (noting the fractional
amount of a turn), performing a hardness test after
each adjustment, until the desired hardness is achieved.
The final blend setting is equal to: Estimated Blend
Setting + total sum of fractional turns made counterclockwise to correct.
8. If the measured hardness is more than the desired
hardness, make small correcting adjustments by turning
the screw clockwise (carefully noting the fractional
amount of a turn), performing a hardness test after
each adjustment, until the desired hardness is achieved.
The final blend setting is equal to: Estimated Blend
Setting - total sum of fractional turns made clockwise
to correct.
9. Make a record of the final treated water
hardness measurement and the final blend
setting. You may wish to place a piece of tape
over the blend adjustment screw to avoid having the
adjustment inadvertently changed.
10. Close the water supply valve.
5. Using a flathead screwdriver, open the blend valve
to the Estimated Blend Setting, carefully counting
complete turns of the mark on the slot in the
Make a mark on brass
housing & in one end
of screw slot.
Blend valve in outlet valve of
bypass assembly. Blend valve
screw fully closed (appears the
same as 1 full turn, 2 full turns,
etc.)
Photos Q. Blend
valve setting
Valve opened
1/4 turn counterclockwise (appears the same as
1-1/4 turn, 2-1/4
turns, etc)
Valve opened
1/2 turn counterclockwise
9
10
OptiSoft System Installation, Operation & Maintenance
Completing the Installation
Once the blend valve has been set to the desired hardness,
the installation can be completed and the unit placed in
service.
Install the air gap at the drain (photo R). Ensure the air gap
is secured permanently in place. Connect each of the drain
hoses to the air gap, securing each with a clamp.
Complete the connection of the 3/4” outlet flex hose to
the plumbing feeding the downstream equipment. Open
the water supply valve, and ensure both inlet and outlet
valves of the bypass assembly are fully open. Check all fitting
connections on the softener for any leaks. (Close the water
supply valve if necessary to correct any leaks, then re-open
valve.) Verify availability of treated water to the downstream
equipment, and check for plumbing leaks downstream of
the softener.
Bypassing the Softener
OUT
IN
S. Bypass position
If it ever becomes necessary
R. Drain
to bypass the softener
hoses confor service while allowing
nected to
feed water to flow to
air gap at
downstream equipment,
drain pipe
the bypass assembly on the
softener can be used. To
simply place the softener
in bypass mode, turn
both valves on the bypass
assembly on back of the softener to the bypass position
(photo S).
Note:The mineral tank of the softener will still
contain pressurized water when the valves on
the bypass assembly are closed. Perform the
following steps to release pressure.
If the softener is to be disconnected or opened up, then
1. Close the feed water supply valve and temporarily
open a valve downstream of the softener to release the
water pressure inside the softener.
2. Then turn the valves on the softener bypass to the
bypass position to isolate the softener from feed
pressure.
3. The water supply valve can then be re-opened if water
is needed downstream.
Understanding the Controller
The controller determines the softening capacity of the
resin based on the feed water hardness which the user
inputs into the controller (during “Control Panel Setup”
above). As softened water is being used, the controller
measures the water volume used and tracks when the
softening capacity is consumed.
When the capacity has been used, the controller performs
an automatic regeneration of the softener resin (by
backwashing with the salt brine stored in the brine tank)
to restore the resin to the original softening capacity. This
depletes salt from the mineral tank. Salt must therefore
be manually added to the mineral tank to supply brine for
subsequent resin regeneration cycles.
Buttons: The control panel has three buttons for the
user to do the controller setup and to initiate or stop a
regeneration cycle. There is a “scroll” button
which
is generally used for advancing the display to the next
parameter. There are also buttons with an “Up” arrow and a
“Down” arrow, generally used for increasing or decreasing
the value of the parameter being set.
Service Mode: The normal operating mode of the
control panel when the power transformer is plugged into
an outlet is “service mode,” which is indicated on the panel
by a display of the time of day and the remaining softening
capacity, such as
8:01AM 1000GL-
Startup or Power Failure: In the event of a
temporary power failure, the controller settings will be
maintained for several hours. However, after a prolonged
period without power, upon power restoration the display
will return to 8:00AM, and the display will flash to indicate
that the control panel setup needs to be performed. (See
“Control Panel Setup.”)
If a temporary power failure occurs during a regeneration
cycle, then a minute after power restoration, the controller
will restart a regeneration cycle.
Regeneration Mode: A regeneration cycle can occur
automatically (normally at 2:00 AM) after the softening
capacity has been consumed, or it can be initiated manually
by the user.
1. To initiate a manual regeneration, press and
release the scroll button
. The display will show a
countdown:
OptiSoft System Installation, Operation & Maintenance
Regen in 10 sec
Monitoring & Maintenance
If no other buttons are pressed, then after 10
seconds the regeneration cycle will begin.
2. It is also possible to delay the manual regeneration to
night-time (2:00 AM). To do this, while the display is
counting down, showing
Regen in 10 sec
press and release the scroll button
display will show:
again. The
Regen @ 2:00AM
The regeneration cycle will begin at that time.
3. To cancel the initiation of a regeneration cycle (before
the regeneration has begun), press the scroll button
again to return to service mode.
Once a regeneration cycle has begun, the display will
show the current phase of the regeneration cycle.
1. First, water will be added to the brine tank if necessary:
BRINE FILL
2. Then before the regeneration backwash begins, the
display will show
REGEN PENDING
3. And during the regeneration process, it will show
the remaining regeneration time and the number of
minutes remaining in the current cycle, such as:
11
Rgn: 75 Cyc3:75
During this process (which takes and hour and fifteen
minutes), if there is downstream demand for water,
feed water (unsoftened) will automatically be passed
through the control valve to meet the demand.
4. During either an automatic or a manual regeneration,
the controller can be advanced to the next phase
of the regeneration by pressing the scroll button
. To cancel the regeneration cycle and return to
service mode, press the scroll button
repeatedly
to step through the regeneration phases and exit the
regeneration mode.
Programming Mode: Functions of programming mode
are described under “Control Panel Setup.”
The Softener should be monitored and all pertinent data
recorded periodically. Data is needed to determine the
operating efficiency and for performing system maintenance.
NOTE :Warranty claims can not be processed without
adequate operating data and history of the softener.
Periodically test the hardness of the feed and treated
water to ensure that the system is removing hardness and
protecting downstream equipment.
Salt Replenishing
CAUTION: DO NOT RUN OUT OF SALT!
FAILURE TO REPLENISH SALT WILL PREVENT
THE SOFTENER FROM REMOVING HARDNESS
AND PROTECTING DOWNSTREAM
EQUIPMENT. MONITOR SALT LEVEL DAILY.
Remove the Salt Lid and check the level of salt in the brine
tank regularly, adding more salt when necessary. The cabinet
should be kept between 1/3 and 2/3 full of salt. (Salt level
should always be above the water level.) A lower level of
salt can cause a failure to soften the treated water. A higher
level can cause “salt bridging”, a hard crust between walls
of the cabinet that prevents free movement of the salt. If
salt appears to be caked with a crust, bump the side of the
cabinet to knock it loose.
Operating Do’s & Don’ts
DO
 Maintain operating conditions as specified at the
beginning of this manual.
 Monitor the system and keep daily logs.
 Maintain the proper water pressure for back washing.
 Position softeners or align plumbing by moving the
entire unit
 Set the control panel for the local water hardness (see
“Control Panel Setup”)
DON’T
 Permit oils or fats in the feed water.
 Shut down the system for extended periods.
 Exceed the required operating pressures or
temperatures.
 Allow the softener to perform a regeneration cycle
with insufficient water flow.
 Position softeners or align plumbing by holding just the
control valve or tank fittings.
 Connect the brine tank safety overflow drain fitting
directly to the control valve drain line.
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