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OPERATORS MANUAL ORION II ORION II Operators Manual Models 500 – 10000 Orion II 500-10000 Operators Page 1 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
......................20 OFTENERS MM FEEDWATER REQUIREMENTS......................20 MAXIMUM FLOWS L/H ........................20 SERVICES ............................21 4.7.1 ............................. 21 LECTRICAL 4.7.2 ..........................21 OMPRESSED AIR Orion II 500-10000 Operators Page 2 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
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NUMERIC DATA COLOURS ......................37 6.1.4 ACCESS ............................37 SCREENS ............................. 38 6.2.1 OVERVIEW ............................ 39 6.2.2 SOFTENERS ..........................42 6.2.3 PUMP ............................. 43 Orion II 500-10000 Operators Page 3 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
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EJECTION CEDI ..............................90 9.2.1 .................. 90 HAT IS ONTINUOUS LECTRODEIONISATION 9.2.2 ......................90 ECHNOLOGY ESCRIPTION 9.2.3 CEDI ....................... 91 OW THE SYSTEM WORKS Orion II 500-10000 Operators Page 4 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
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9.3.1 ........................92 URRENT CALCULATION OPERATING LOG SHEETS ......................... 93 9.4.1 ..........................93 AILY HEET 9.4.2 ........................95 EEKLY HEET 9.4.3 ..........................95 ICROBIOLOGY Orion II 500-10000 Operators Page 5 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
The Low voltage Directive (Electrical Safety) 2006/95/EC (including any additions or amendments thereafter) The Machinery Directive 98/37/EC (including any additions or amendments thereafter) P T Jordain. Technical Manager April 2008 Orion II 500-10000 Operators Page 6 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
ORION II 2 HEALTH AND SAFETY RECOMMENDATIONS Use caution when working on Veolia Water equipment. The following items are likely to present possible hazards - chemicals, ion exchange resins, electricity, air pressure, water pressure, hot water and hot surfaces. Please ensure personnel are familiar with these hazards and that adequate precautions are maintained.
IF IN DOUBT FURTHER INFORMATION ON SAFETY CAN BE OBTAINED FROM YOUR LOCAL VEOLIA WATER SERVICE DEPARTMENT Orion II 500-10000 Operators Page 8 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
500 to 10000 litres per hour. Ensure that the unit is installed by a Veolia Water engineer and operated in accordance with the instructions in this manual. If there are any enquiries regarding the installation, operation or servicing of the ORION unit contact Veolia Water, Service Department.
Used where the feed water contains high levels of carbon DG50 dioxide to enhance the operation of CEDI Module. CEDI Module Continuous Electrical Deionisation unit removes remainder CD60 of the dissolved ionic impurities. Orion II 500-10000 Operators Page 11 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
Unit starts and stops when tank empties and fills. There is, Start / Stop however, an intermittent recycle of water to prevent long periods of stagnation. Orion II 500-10000 Operators Page 12 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
An integrated control panel containing a combined LED Touch Control Panel Panel and Display (also called a Human Machine Interface or HMI), Programmable Logic Controller (PLC) Orion II 500-10000 Operators Page 13 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
In addition, water analyses of the feed water should be routinely checked (for example, hardness, silt density index, iron, etc.) so that wide fluctuations of composition and temperature can be quickly identified. If such fluctuations occur contact your local Veolia Water Service Department for advice. Orion II 500-10000 Operators...
Height 2100 2190 2400 2450 Shipping 2100 Height *NB On 8000 & 10000 Models the softeners are supplied as a separate assembly, see below. Orion II 500-10000 Operators Page 19 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
6000 8000 10000 Feed without Softeners 13.9 18.5 23.2 Drain without Softeners 13.9 Feed with Softeners 13.3 18.8 25.1 32.6 Drain with Softeners 15.0 Orion II 500-10000 Operators Page 20 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
Oil free Compressed Air, 0.2micron filtered, instrument grade. 2 – 9 bar <40 4.7.4 Ventilation Four Room Changes per hour. 4.7.5 Electrode Gasses Discharge to atmosphere recommended. Orion II 500-10000 Operators Page 21 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
Cadmium <0.2ppm Arsenic <0.5ppm Copper <0.5ppm Lead <0.2ppm Mercury <0.05ppm Iron <5ppm USE High Quality Tablet Salt. DO NOT USE Granular or Vacuum Salt. Orion II 500-10000 Operators Page 22 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
The hardness of the feed water should be measured on site, and loaded into the PLC via the Touch Panel or Human Machine Interface (HMI). The PLC will then Orion II 500-10000 Operators Page 23 of 95...
TK1. VA10-05 is open during Cooling Stage 1 following hot water sanitisation (HWS) to cool the hot water as it flows to drain. This prevents drain water maximum Orion II 500-10000 Operators Page 24 of 95...
Each Softener is fitted with a hardness detector (AS11-01 & AS 11-02) which senses when the softener requires regeneration. Orion II 500-10000 Operators Page 25 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
An automatic valve (VA11-07), fitted with a limit to open device (set up on commissioning) is located on a branch on the outlet of FT11-02 and is opened during Cooling Stages 1&2 following hot water sanitisation (HWS) to cool system. Orion II 500-10000 Operators Page 26 of 95 Manual Part no: DOMAON0100 Issue A...
The pH Controller (AE26-01) measures the pH of the feed water and supplies a control signal to the Sodium Hydroxide dosing set (Option 21). This reduces the amount of Carbon Dioxide and thereby ionic load in the feed to downstream deionisation equipment. Orion II 500-10000 Operators Page 27 of 95 Manual Part no: DOMAON0100 Issue A...
A CIP connection (CIP2) and isolation valve (V30-03) allow for bypass of the RO modules in the event that other sections of the system are to be cleaned with chemicals that are not compatible with the RO elements. Orion II 500-10000 Operators Page 28 of 95 Manual Part no: DOMAON0100 Issue A...
2. V40-02 is readjusted to the set points required for HWS. 3. RO feed pressure is adjusted by increasing or decreasing the pump speed, 7bar <45 C, 2.2bar >45 Orion II 500-10000 Operators Page 29 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
Feed to the CEDI unit(s) is split in two, providing a main stream (or dilute, which is normally approximately 90% of the feed flow) for purification and a second smaller stream (approximately Orion II 500-10000 Operators Page 30 of 95...
Important If the required product water quality is not being achieved and at the same time the current set point is not being achieved then the DC voltage setting may need to be changed on the CEDI Transformer, consult Veolia Water for assistance. 5.5.3 Option 61 Gas Separator An optional gas separator (GS61-01) can be fitted in the CEDI concentrate stream to separate the gases produced at the CEDI electrodes from the concentrate stream.
TOC monitor. The TOC monitor is disabled and isolated from the product line (via V81-01) during HWS and CIP operations and when the Orion is shutdown. Orion II 500-10000 Operators Page 32 of 95...
Manual CIP requires a written procedure to followed and equipment operated by the Force I/O screen on the HMI. Semi automatic CIP is prompted and run from the HMI, and requires less operator input. Orion II 500-10000 Operators Page 33 of 95 Manual Part no: DOMAON0100 Issue A...
ORION II The RO section can be cleaned by system operators, however, CEDI cleaning is more complicated and should be carried out by a Veolia Water service engineer. 5.10 HOT WATER SANITISATION (HWS) Hot water sanitisation of the RO feed tank (TK30-01), RO, Degasser (where fitted), CEDI, UV, UF or MF (where fitted) system is a fully automatic process set via the HMI.
The digital inputs / outputs are animated according to the following rules:- Rule One Items which only have digital outputs are animated grey while de-energised, and green while energised. Orion II 500-10000 Operators Page 35 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
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Blue ( output is off but limit switch inputs are not correct ) Blue ( output is off but limit switch inputs are not correct ) Orion II 500-10000 Operators Page 36 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
Access back to None prior to walking away from the HMI. For a complete list of what access level is required to perform certain function see appendix 3 – “Access Levels”. Orion II 500-10000 Operators Page 37 of 95 Manual Part no: DOMAON0100 Issue A...
Command Buttons and Status Information across the bottom of the screen See section 6.7 - “Process Status Text” for a full list of process status text Orion II 500-10000 Operators Page 38 of 95 Manual Part no: DOMAON0100 Issue A...
This can be set to 500, 1000, 2000, 4000, 6000, 8000 or 10,000. If the size of unit has not been setup the numeric value will be replaced by the text “not set”. Orion II 500-10000 Operators Page 39 of 95...
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The RO stage button has been replaced by stage 1 and stage 2 buttons and the additional modulating valve and flow transmitter associated with stage 2 are shown. Orion II 500-10000 Operators Page 40 of 95 Manual Part no: DOMAON0100 Issue A...
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ORION II Depending on the system configuration the Softeners and CDI stage may be disabled and hence the overview screen takes the following form:- Orion II 500-10000 Operators Page 41 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
The status of each softener is clearly shown above each softener. See section 6.7 Process Status Text for a complete list of status text. Orion II 500-10000 Operators Page 42 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
“M” (manual). Also the words “Manual Override Selected” is displayed on all screens so the operator knows something has been left in manual as seen below:- Orion II 500-10000 Operators Page 43 of 95 Manual Part no: DOMAON0100 Issue A...
RO element my need cleaning. Upon completion of a successful clean 1 hour after being put into service the new flex value is record. Orion II 500-10000 Operators Page 44 of 95 Manual Part no: DOMAON0100 Issue A...
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OPERATORS MANUAL ORION II If the system has been setup as a Twin Pass the RO screen will take the following form Orion II 500-10000 Operators Page 45 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
2000 unit without a UF the permeate will be setup 2222 and the concentrate inlet flow to 222. The resulting flow from the CDI will be 2000 l/h. Orion II 500-10000 Operators Page 46 of 95 Manual Part no: DOMAON0100 Issue A...
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2000 unit the Permeate will be set to ( 2000 + UF Recycle ) / 0.9 (2000 + 104 ) / 0.9 = 2338 and a CDI concentrate inlet flow of 233. Orion II 500-10000 Operators Page 47 of 95...
A trend of the system temperatures may be accessed by means of the graph symbol just below the product return temperature value. Orion II 500-10000 Operators Page 48 of 95 Manual Part no: DOMAON0100 Issue A...
The screen below is an example of when the system is configured for 1 x 3 way valve. The final water conductivity, final water temperature and final water TOC (if fitted ) are trended. The water demand signal is also animated. Orion II 500-10000 Operators Page 49 of 95 Manual Part no: DOMAON0100 Issue A...
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OPERATORS MANUAL ORION II If 2 x 2 ways vales are fitted the outlet screen will take the following form:- Orion II 500-10000 Operators Page 50 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
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OPERATORS MANUAL ORION II If 3 x 2 ways vales are fitted the outlet screen will take the following form:- Orion II 500-10000 Operators Page 51 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
From this screen the RO Clean sequence can be started providing the system status is “not in service”. Follow the “Operator Instructions” which appear in the big white box. Orion II 500-10000 Operators Page 52 of 95 Manual Part no: DOMAON0100 Issue A...
From this screen the RO Sanitise sequence can be started providing the system status is “not in service”. Follow the “Operator Instructions” which appear in the big white box. Orion II 500-10000 Operators Page 53 of 95 Manual Part no: DOMAON0100 Issue A...
From this screen the CDI Clean sequence can be started providing the system status is “not in service”. Follow the “Operator Instructions” which appear in the big white box. Orion II 500-10000 Operators Page 54 of 95 Manual Part no: DOMAON0100 Issue A...
ORION II PID VA40 Settings 6.4.2 HWS The HWS screen is where all settings associated with the HWS sequence are maintained as seen below:- Orion II 500-10000 Operators Page 56 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
OPERATORS MANUAL ORION II 6.4.3 CIP The CIP screen is where all settings associated with the CIP sequences are maintained as seen below:- Orion II 500-10000 Operators Page 57 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
The time / data can only be adjusted with Administrator access level. However, the hour digit can be adjusted up/down only once per 24 hour period. Orion II 500-10000 Operators Page 58 of 95 Manual Part no: DOMAON0100 Issue A...
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If the printer is set to “Connected” then an additional printer icon is seen at the top of every screen next to the model size as seen below. This allows each screen to be captured and dump to the connected printer. Orion II 500-10000 Operators Page 59 of 95 Manual Part no: DOMAON0100 Issue A...
These are set setup as parts of the modes size and should not every need to be adjusted. The analogue Raw value is also shown together with the associated Actual for each channel based on the 20 mA Full Scale Deflection setting. Orion II 500-10000 Operators Page 60 of 95 Manual Part no: DOMAON0100 Issue A...
The Options screen is where the main system configuration is performed as seen below:- These setting can only be modified with Engineer access level and providing the system status is “not in service”. Orion II 500-10000 Operators Page 61 of 95 Manual Part no: DOMAON0100 Issue A...
The Users screen is where users and their associated passwords are maintained as seen below:- This screen is only provided with the CFR-Part11 compliant HMI software. Orion II 500-10000 Operators Page 62 of 95 Manual Part no: DOMAON0100 Issue A...
Anyone can access this screen to monitor the state of the I/O. However, to toggle the state of a digital output engineering access level is required. Orion II 500-10000 Operators Page 63 of 95 Manual Part no: DOMAON0100 Issue A...
When in training mode the unit may be put into service without the plant starting up. All system I/O is simulated so the operator gets the appearance the plant is running without it actually running. Orion II 500-10000 Operators Page 64 of 95...
This event log is stored in volatile memory so is lost when the power is removed. The event log is non-volatile on the CFR-Part11 version of the HMI. Orion II 500-10000 Operators Page 65 of 95 Manual Part no: DOMAON0100 Issue A...
The Alarm button will animate red if any alarms are present in the system as seen below. Press the alarm button to access the alarm screen. Orion II 500-10000 Operators Page 66 of 95 Manual Part no: DOMAON0100 Issue A...
De activated alarms can be removed from the alarm view window by pressed the button with the tick. If an alarm is accepted with the tick button first the status will change to “A” for accepted. Orion II 500-10000 Operators Page 67 of 95...
Brine Draw In Service Fast Rinse In Service In Service Open Bypass Valve In Service Back Wash In Service Brine Draw In Service Fast Rinse Orion II 500-10000 Operators Page 69 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
Move to Fast Rinse In Service Fast Rinse In Service Move to Tank Refill In Service Brine Tank Refill In Service Move to Service Orion II 500-10000 Operators Page 70 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
The operator has attempted to start the service / Fatal – Operation attempted while hws or cip while the model size is in the “not set” model is “not set” state. Orion II 500-10000 Operators Page 71 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
Warning - Over Temp Feed Water from the Thornton meter when the feed temperature is above a set point. If in service and feeding the Orion II 500-10000 Operators Page 72 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
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Current Out of Range seconds. It is either less than 3.75 mA or greater than 20.25 mA Warning - Analogue Input CDI1 See above Orion II 500-10000 Operators Page 73 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
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See above Out of Range Warning - Analogue Input TT3001 See above Out of Range Warning - Analogue Input TT3002 See above Out of Range Orion II 500-10000 Operators Page 74 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
30 seconds. It is either less than 3.75 mA or greater than 20.25 mA Warning - Analogue Input FT1102 See above Out of Range Orion II 500-10000 Operators Page 75 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
Engineer (Blue Key) Terminate Application Engineer (Blue Key) Delete Event Log Engineer (Blue Key) Training Mode Engineer (Blue Key) Display RO Recovery values Engineer (Blue Key) Orion II 500-10000 Operators Page 76 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
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If an engineer key is used which has expired the following message will be seen:- I-Buttons can be checked for their type and expired date by means of the “I-Button Data” panel located on the “System Configuration - Other” screen. Orion II 500-10000 Operators Page 77 of 95 Manual Part no: DOMAON0100 Issue A...
Switch on the power to the system. The HMI screen will boot up after about 30 seconds and automatically load the relevant operating programme, (factory set) and then the graphical Orion II 500-10000 Operators Page 78 of 95 Manual Part no: DOMAON0100 Issue A...
PREVENT BACTERIAL CONTAMINATION. IF IT IS TO BE SHUT DOWN FOR LONGER THAN ONE MONTH THEN IT SHOULD BE PRESERVED WITH CHEMICALS FOR THE SAME REASON. A VEOLIA WATER ENGINEER WILL BE REQUIRED TO PRESERVE THE UNIT. 7.3 PLANT MONITORING The plant should be monitored on a daily basis and operating parameters recorded on log sheets.
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This is therefore at the discretion of the user. Examples of log sheets are provided in the Appendix and are available electronically from Veolia Water and should be tailored to specific customer requirements. The content of the log sheets also depends on what optional equipment (if any) is included.
1. Fit needle to syringe and insert fully into sample valve. 2. Express 20ml of fluid into port. 3. As needle is removed, squirt a few ml of fluid over outside of Luer connection. Orion II 500-10000 Operators Page 81 of 95 Manual Part no: DOMAON0100 Issue A...
7. If the valve is stored in sanitant but not used for a period of time greater than two weeks then it should be re-sanitised before use. Orion II 500-10000 Operators Page 82 of 95 Manual Part no: DOMAON0100 Issue A...
CHEGRO0083) and is used at the rate of 1.5kg, ORION 500 – 2000 and 3kg, ORION 4000 - 6000. It is also available in 8kg drums Veolia part number CHEGRO0084 and is used at the rate of 8kg for Orion 8000 - 10000 ...
The Failure percentage (normally 10%) is configurable from the HMI (with engineering access). A user with engineering level access can overwrite the initial flux value if required. Orion II 500-10000 Operators Page 84 of 95 Manual Part no: DOMAON0100 Issue A...
/ precautions to those detailed on the HMI screen and in the instructions below, in order to ensure safe operation of the CIP procedures. Veolia Water engineers are available to provide assistance in this process if required. 8.3.2 Cleaning Instructions...
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As a minimum requirement the Rinse stage is not complete until the minimum pre-set salt rejection is achieved and AIC30-01 conductivity is below the high conductivity alarm point. This Orion II 500-10000 Operators Page 86 of 95 Manual Part no: DOMAON0100 Issue A...
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A fatal alarm raised during CIP will shut the system down. Once this has been cleared the user will be able to restart the CIP from the HMI. Orion II 500-10000 Operators Page 87 of 95 Manual Part no: DOMAON0100 Issue A...
Orion II 500-10000 Operators Page 88 of 95 Manual Part no: DOMAON0100 Issue A...
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This in turn results in higher product water conductivities of 10 - 20μS/cm and an overall system rejection of 96 – 98%. Orion II 500-10000 Operators Page 89 of 95 Manual Part no: DOMAON0100 Issue A...
When the electric field is applied, ions in the liquid are attracted to their respective counter-electrodes. The result is that the dilute compartments are depleted of ions and the concentrate compartments are concentrated with ions. Orion II 500-10000 Operators Page 90 of 95 Manual Part no: DOMAON0100 Issue A...
6. Waste stream removes concentrated ions from system. Feed Water NaCl Waste Product Water Stream (NaCl) conc Orion II 500-10000 Operators Page 91 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
Important If the required product water quality is not being achieved and at the same time the current set point is not being achieved then the DC voltage setting may need to be changed on the CEDI Transformer, consult Veolia Water for assistance. Orion II 500-10000 Operators...
Examples of a log sheets are shown overleaf, however, these will vary according to the options chosen. The log sheets are available from Veolia Water in soft copy and can be tailored to the installation including action limits. 9.4.1 Daily Log Sheet See overleaf.
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Product Recycle Temperature μS/cm AE30-01 Feed Water Conductivity μS/cm AE45-01 RO Permeate Conductivity μS/cm AE80-01 Product Conductivity RO Rejection RO Recovery RO Corrected Flux CEDI Recovery Orion II 500-10000 Operators Page 94 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
RO Permeate Endotoxin EU/ml UV Feed Water Bacteria CFU/ml V70-01 UV Feed Water Endotoxin EU/ml Product Water Bacteria CFU/ml V80-01 Product Water Endotoxin EU/ml Orion II 500-10000 Operators Page 95 of 95 Manual Part no: DOMAON0100 Issue A April 2008...
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