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A water softener reduces the calcium or magnesium ion concentration in hard water.

These "hardness ions" cause two major kinds of problems:

→ The metal ions react with soaps and calcium sensitive detergents, hindering their ability to lather properly and forming an unsightly precipitate - the familiar scum or "bathtub ring". Presence of "hardness ions" also inhibits the cleaning effect of detergent formulations.
→ More seriously, calcium and magnesium carbonates tend to precipitate out as adherent solids on the surfaces of pipes and especially on the hot heat exchanger surfaces of boilers. The resulting scale buildup can restrict water flow in pipes. In boilers, the deposits act as thermal insulation that impedes the flow of heat into the water; this not only reduces heating efficiency, but allows the metal to overheat which, in a pressurized system, can lead to catastrophic failure.

How Rechargeable Water Softeners Work.

The water to be treated passes through a bed of the resin (HCR/S/E/S DOW CHEMICAL type resin); the negatively-charged resins absorb and bind metal ions, which are always positively charged. The resins initially contain univalent sodium ions, which exchange with divalent calcium and magnesium ions in the water. This exchange eliminates the possibility of precipitation and soap scum formation. As the water passes through both kinds of resin, the hardness ions replace the sodium which is released into the water.

Fully Automatic Softener :- Automatic MPV and Fully Automatic Filter with Softener

Orange is range of Fully Automatic Softener and range of most advance yet very economical Fully Automatic water treatment systems.

Programming options:-

→ Manual or Auto or Start Up Rinse.
→ Brine Interlock- Start regeneration only if Brine present in tank.
→ Combined volume & conductivity Interlock.
→ Conductivity Interlock.
→ Series or working standby.

Output Option:-

→ Pump On/Off Relay
→ Two spare relays.
→ Alarm in case of fault
→ Output pulse signaling end of regeneration cycle

Input Option:-

→ Flow Sensor

→ Raw water tank level / Treated

→ water tank level

→ Conductivity (DM Plant)

→ Flow Sensor

→ Brine Level Switch

→ External Pulse

Possibilities and Scope of Automation

Fully Automatic:

Automatic regeneration takes place based on external signals.

A. Real Time clock (optional) Regeneration starts at the programmed time and day of the week and unit goes back into service on its own once the regeneration is over.
B. Pump ON timer coupled with level controller: Pump on timer decides when the plant capacity is over & it needs regeneration. Regeneration starts after receiving signal from Astero Panel which has multiple function like:

a. Inbuilt Starter
b. Pump ON timer: sends signal to Auto MPV whenever pump starts. The balance time left for regeneration is constantly displayed on Auto MPV. When balance time reaches zero, the unit goes into regeneration automatically.
c. Level controller:- raw water pump automatically starts and stops based on level in product water tank. Additionally if raw water tank is empty the RWP switches OFF automatically.

i. Current overload protection and single phase protection protects the raw water pump from burnouts & prevents shutdowns.

C. Flow sensor:- Auto valve counts down the reprogrammed output based on signal from flow sensor. When it reaches zero, the unit goes into regeneration automatically.

Brine Tank Automation :-

A brine level switch can be inserted in the brine tank which switches between brine and water.

A. When regeneration is initiated by any means, the Auto MPV first checks whether the Brine switch indicates presence of brine. If not it gives an alarm indicator.

B. When regeneration step is over, if the brine switch still detects brine it gives an alarm ‘Regeneration incomplete’.

Spare Relay (Standard) :-

spare relay output is available which can be programmed to start any time after start of cycle and for any duration up to 99 min. It’s possible uses are as follows;

A.. Remote (Panel) indication of regeneration in progress.

B.. Operation of ‘ fast rinse ’ solenoid valve for down flow softeners.

C.. Operation of ‘ raw water bypass ‘ solenoid valve during regeneration.

D.. Operation of ‘regeneration suction solenoid valve in Auto D.M. plant.

E.. To bypass high pressure cut off of Hydro-pneumatic system during regeneration.

Second Spare Relay ( Optional) :-

This relay can be used to operate a remote (panel) annunciator whenever any fault condition occurs.

Conditions under which annunciator (buzzer) will activate ;

1.. If unit does not go from one step to another within specified time limit (200 sec.)

2.. When brine switch is provided and if brine is not ready at the start of regeneration.

3.. If brine still remains in brine tank at end of regeneration.

4.. Internal malfunction. (Reed switch short)

Brine switch interlock : -

This has been reprogrammed to get a separate regeneration and slow rinse mode. If enabled and level switch / floaty is in regenerate tank connected to Auto MPV, then the regeneration time is counted down but reset when level in regenerate tank goes low. After this, the valve position remains unchanged but, a slow rinse time is counted down. In effect, the regeneration time becomes variable depending on the level switch & slow rinse time gets added.

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