USER MANUAL - EnwaEnwaMatic® USER MANUAL EM 825 - EM 1252 EM 1260 - EM 1665 - EM 1672 Manual and...

EnwaMatic®

USER MANUALEM 825 - EM 1252

EM 1260 - EM 1665 - EM 1672

Manual and Automatic Backwash

English

enwa.com

ORIGINAL INSTRUCTION

EnwaMatic Manual UK_V.1.15 sep 2015

Contact information

Internet: www.enwa.com

Norway: Enwa Water Technology ASNordre Kullerød 9PO Box 12413205 SandefjordNorwayPhone: +47 3348 8050E-mail: [email protected]

England:Enwa UKUnit AScotlands Industrial EstateCoalville, LeicestershireLE67 3JJUKPhone: +44 01530 830 354Fax: +44 01530 835 725E-mail: [email protected]

Sweden:Enwa Water Technology ABImportgatan 21SE-422 46 Hisings BackaSwedenPhone: +46 (0) 31 742 9250Fax: +46 (0) 31 742 9260E-mail: [email protected]

Germany:Enwa DeutschlandIn der Brückenwiese 453639 KönigswinterDeutschlandTelefon: +49 2244 9000256Fax: +49 2244 9000257E-Mail: [email protected]

To contact a local distributor or agent please look at www.enwa.com

Copyright

This document is the property of ENWA and is not to be reproduced, copied or disclosed to any party without the prior written consent of ENWA.

ELECTRONIC ORIGINAL.

The user is responsible for verification of released revision status on document copy.

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DECLARATION

ENWA WATER TECHNOLOGY ABImportgatan 21, SE-422 46 Hisings Backa,

Sweden

Declare that we are responsible for the product

EnwaMatic® Model No EM 825/EM1252/EM1260/EM1665/EM1672

This statement is in accordance with the following documents and directives:

Low Voltage Directive (2006/95/EG)EMC Directive (2004/108/EU)

PED Directive (97/23/EU) ROHS Directive (2011/65/EU)

Applicable standards:EN ISO 12100:2010

EN 61010-1:2011EN 61000-6-3,EN 61000-6-4, EN 61000-6-1, EN 61000-6-2

EN 13 445

We declare that the equipment complies with the above requirements and that factory approval has been fulfilled by Enwa Water Technology AB.

August 2015

Managing Director

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Table of contents

1. INTRODUCTION .............................................................................................................. 81.1 General...................................................................................................................................8 1.2 Purpose of this manual...........................................................................................................9 1.3 Product marking .....................................................................................................................9 1.4 Symbols and conventions ....................................................................................................10 1.5 Safety notes .........................................................................................................................10

2. TECHNICAL DATA ......................................................................................................... 112.1 EnwaMatic® unit componentst ............................................................................................. 11 2.2 Overall dimensions ...............................................................................................................12 2.3 Technical and operating conditions ......................................................................................14 2.4 Interface connections ...........................................................................................................16 2.5 Delivered and installed components ...................................................................................18

3. TECHNICAL DESCRIPTION ........................................................................................... 203.1 Purpose of equipment and limitations in use........................................................................20 3.2 Location of equipment ..........................................................................................................21 3.3 Functional description ..........................................................................................................21

4. PREPARATIONS FOR INSTALLATION............................................................................ 264.1 Installation location ...............................................................................................................26 4.2The side stream loop .............................................................................................................28 4.3 Pre- treatment water analysis...............................................................................................29

5. INSTALLATION .............................................................................................................. 305.1 General installation instructions ...........................................................................................30 5.2 Checklist before starting the installation ...............................................................................30 5.3 Installing EnwaMatic® ..........................................................................................................32

6. COMMISSIONING AND START-UP ................................................................................. 376.1 Filling up the unit and establish flow through EnwaMatic® ..................................................37 6.2 To enable the control unit and the automatic back wash sequence (EnwaMatic® autoMatic only) ......................................................................................................39

7. OPERATING INSTRUCTIONS ......................................................................................... 417.1 Backwash schedule..............................................................................................................41 7.2 EnwaMatic® back wash procedure ......................................................................................41 7.3 EnwaMatic® Automatic ........................................................................................................42

8. SERVICE AND MAINTENANCE ...................................................................................... 478.1 Routine maintenance ...........................................................................................................47 8.2 Yearly maintenance program and Maintenance Agreement ................................................50 8.3 Periodic Maintenance ...........................................................................................................50

APPENDIX A: ENWAMATIC® OPTIONS ....................................................................... 51

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9. BAF- BACKWASH ANTIFREEZE .................................................................................... 52 9.1 Introduction...........................................................................................................................52 9.2 Technical- and operating data and conditions ......................................................................52 9.3 Delivered and installed components EnwaMatic® BAF .......................................................57 9.4 Technical and functional description .....................................................................................58 9.5 Preparations for installation ..................................................................................................59 9.6 Installation ............................................................................................................................60 9.7 Commissioning and start-up.................................................................................................65 9.8 Operating instructions ..........................................................................................................68

10. ICP – OPTION WITH CIRCULATION PUMP ..................................................................... 75 10.1 Introduction.........................................................................................................................75 10.2 Technical and operating data .............................................................................................75 10.3 Delivered and installed components ..................................................................................75 10.4 Technical and functional description ...................................................................................75 10.5 Preparations for installations ..............................................................................................75 10.6 Installation ..........................................................................................................................77 10.7 Commissioning and start- up..............................................................................................77

11. BMS – OPTION FOR MONITORING AND LOGGING ........................................................ 78 11.1 Introduction .........................................................................................................................78 11.2 Delivered and installed components ...................................................................................78 11.3 Technical and functional description ...................................................................................78 11.4 Installation ..........................................................................................................................79 11.5 Commissioning and start- up ..............................................................................................80

APPENDIX B: SPARE PART LISTS ............................................................................... 81

APPENDIX C: ELECTRICAL CONNECTION DIAGRAMS ................................................ 87

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1. INTRODUCTION

1.1 GeneralThe EnwaMatic® is non- chemical water treatment for closed heating and cooling systems. It uses a side stream of a closed loop system, and filters the water through a granulated bed to inhibit corrosion, prevent scaling and restrict bacterial growth.

The EnwaMatic® needs to be backwashed regularly to dispose of any solids and dirt in the granulated bed. This is done by flushing clean water from the main cold water service in the reverse direction through the system.

For the EnwaMatic® manual model, repositioning of valves for backwash is done manually (by hand). The EnwaMatic® automatic model is controlled by a PLC, and will automatically operate the valves and backwash schedule.

In this manual EnwaMatic® is referred to as “EnwaMatic®” whilst EnwaMatic® with automatically operated backwash schedule is referred to as “EnwaMatic® Automatic”.

Fig 1: The EnwaMatic® Automatic system

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1.2 Purpose of this manualThis manual describes the functions, installation, operation and maintenance of the EnwaMatic® and EnwaMatic® Automatic models: EM 825, EM 1252, EM 1260, EM 1665 and EM 1672.If nothing else stated, information given for EnwaMatic® apply to both EnwaMatic® and EnwaMatic® Automatic.

This manual provides the user with the necessary information to understand how the equipment and associated equipment functions, together with sufficient information to operate and maintain the equipment in a safe and efficient manner.

The manual is intended used by competent, trained personnel.

1.3 Product markingWhen delivered, the EnwaMatic® unit is marked with an ENWA label (Fig 2) giving vital information about the specific unit, eg. model number, year of production and serial number. The serial number is an unique ID number given for each manufactured EnwaMatic® unit.

Fig 2: Product marking: EnwaMatic® unit with ENWA label.

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1.4 Symbols and conventionsThe following words and symbols found throughout this manual mark special messages to alert the operator of specific information concerning of the personnel, the equipment or the process.

See also section 1.5 “Safety Notes”.

Text set off in this manner provides warning notice that failure to follow these directions in this warning can result in personal injury or loss of life and/or extensive damage to equipment.

Text set off in this manner provides warning notice that failure to follow these instructions in this CAUTION can result in damage to the equipment.

Text set off in this manner present clarifying information or specific instructions relevant to the immediate instruction.

1.5 Safety notes

Never use an item of equipment that is damaged/modified or has defective parts,uch

Always ensure input power is disconnected before any service or repairs.

If the equipment is used in a manner not specified by manufacturer, the protection provided by the equipment can be impaired.

At water temperatures above 95 °C maximum, Bespoke (HT) EnwaMatic® must be installed.

Open and close valves carefully to prevent ‘pressure shock’ and damage to pipe work and fittings.

Installations with pumps that have integrated variable speed drives need special consideration. This will have implications for commissioning - contact ENWA.

The Automatic models are designed for 220-230 V 50/60 Hz.

Any unauthorised modification or operation may cause equipment damage and may void the warranty.

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2. TECHNICAL DATA

2.1 EnwaMatic® unit components

Fig 3: EnwaMatic® unit components

Pos. Description

a Insulated tank

b Water sample valve

c Check valve

d Valve C

e Manometer, inlet

f Valve B

g Air separator vent

h Filling plug

i Manometer, outlet

j Check valve

k Valve A

l Flow regulator

m Pressure independent constant flow valve (PICCV)n Bypass valve

o Check valve

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2.1.1 EnwaMatic® Automatic unit componentsUnit components for EnwaMatic® Automatic is similar to the manual model given in Fig 3, with exception of valve A-, B- and C which have electric actuator motors installed (Fig 4).

Fig 4: EnwaMatic® Automatic unit with electric actuator motors.

2.2 Overall dimensions

2.2.1 The EnwaMatic® unitThe outer dimensions of the EnwaMatic® unit are given in Fig 5. Specific weights and volumes are given in Tab 1.

Tab 1: EnwaMatic® weights and volumes

ModelWeight

empty 1) (kg)Weight

full 1) (kg)Volume steel tank,

empty (dm³)Capacity 2)

(m3)

EM 825 47 89 30 0-3

EM 1252 56 170 82 3-15

EM 1260 62 202 102 15-40

EM 1665 79 339 190 40-80

EM 1672 90 392 215 80-1301) Weight empty is the dead weight without filter media.

Weight full is the calculated weight inclusive filter media and water.

2) Capacity is the total volume of water within the closed loop of heating/ cooling water

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Fig 5: EnwaMatic® unit dimensions

ModelA

mmB

mmC

mmD

mmE

mmF

mmG

mmEM 825 1164 597 477 1440 227 213 575

EM 1252 1364 597 477 1640 227 213 575

EM 1260 1664 597 477 1940 227 213 575

EM 1665 1769 697 577 2054 323 276 731

EM 1672 1969 697 577 2254 286 295 756

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2.2.2 The control unit (EnwaMatic® Automatic only)Fig 6 gives the outer dimensions of the control unit.

Pos. Description Dimension (mm)

h Cabinet height 400

w Cabinet width 300

d Cabinet depth 210

Width cabinet + wall brackets mounted 360

Fig 6: Outer dimensions of the control unit for standard EnwaMatic® Automatic

2.3 Technical and operating conditions

2.3.1 The EnwaMatic®General technical and operating conditions for EnwaMatic® are given in Tab 2 and model specific operating- and backwash flows are given in Tab 3.

Tab 2: Technical and operational conditions for EnwaMatic®

Function Data

pH range 5-12

Minimum system water temperature -3 ºC

Maximum system water temperature 95 ºC10 bar

Minimum make-up water (Mains Cold Water Services, MCWS) pressure 2 bar dynamic

Table 3: Operation- and backwash flow for EnwaMatic®

EM 825 EM 1252 EM 1260 EM 1665 EM 1672

Operating flow (l/min) 3 - 6 8 - 12 20 - 25 55 - 70 75 - 90Backwash flow (l/min) ~ 20 ~ 40 ~ 40 ~ 60 ~ 60

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For systems that operate greater than 10 bar, 95 ºC & 130 , refer to BESPOKE

Maximum system operating pressure temperature

(m3)

2.3.2 The control unit (EnwaMatic® Automatic only)

Tab 4: Technical and operational conditions for the control unit

FunctionControl unit type

Standard Maritime/BAF

IP class 44

Air humidity 93% rel

Usage Indoor usage

Ambient temperature 0 - 50 ºC

Power requirements 230V / Single Phase, 50/60 Hz, 6A

External fuse 230V – 10A

Weight 12 kg

Power to valve motor 24V DC 1A

Insulation of external pumps F

Terminal rating X01 240V - 10A

Terminal rating X02 24V - 3A

External circuitRated switching voltage: 240V AC Max switching voltage: 400V AC

Continuous current: 8A

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2.4 Interface connections

2.4.1 Water interface connectionsThe water interface connections are presented in Fig 7. Corresponding connection type and sizes are given in Tab 5.

Pos. Description

1 Inlet (system water for filtration)2 Outlet (clean water)

3 Water source / Mains Cold Water Services (MCWS)

4 Drain

5 Sample valve

Fig 7: EnwaMatic® water interface connections

1) DN = Diameter Nominal: conform to International Standard Organisation (ISO) usage. Numbers in () refers toNPS, Nominal Pipe Size (inches).

2) Int = Internal threads

3) Ext = External threads

Water interface connection

Connection type

EM 825 EM 1252 EM 1260 EM 1665 EM 1672

Inlet (1) Union DN20 (¾”) Int DN20 (¾”) Int DN20 (¾”) Int DN25 (1”) Int DN40 (1 ½”) Int

Outlet (2) Union DN20 (¾”) Int DN20 (¾”) Int DN20 (¾”) Int DN25 (1”) Int DN40 (1 ½”) Int

MCWS (3) Union DN20 (¾”) Int DN20 (¾”) Int DN20 (¾”) Int DN25 (1”) Int DN25 (1”) Int

Drain (4) Union DN20 (¾”) Int DN20 (¾”) Int DN20 (¾”) Int DN25 (1”) Int DN40 (1 ½”) Int

Sample valve (5) Threads DN15 (1/2”)Ext DN15 (1/2”)Ext DN15 (1/2”)Ext DN10 (3/8”) Int DN10 (3/8”) Int

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5

4

3

1

2

2.4.2 Electrical interface connections (EnwaMatic® Automatic only)The electrical interface connections are presented in Fig 8. These only apply for EnwaMatic® Automatic.

Pos. Description

1 Control unit

2 Valves with electric actuator motor

3 230 V power supply

Fig 8: EnwaMatic® Automatic electrical interface connections

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1

3 2

2.5 Delivered and installed components

2.5.1 EnwaMatic® system componentsEnwaMatic® system components are presented in Fig 9.

Pos. Description1 Piping: Inlet (untreated water)

2 Piping: outlet (treated water)

3 Piping: Mains Cold Water Service (MCWS)

4 Piping: Drain

5 Sample valve

6 EnwaMatic® unit with pipework and valves (see Fig 3 or Fig 4)

7 Shut-off valve, outlet

8 Shut-off valve, inlet

9 Shut-off valve, MCWS

10 Control unit (EnwaMatic® Automatic only)

11 Standard cables with connectors (EnwaMatic® Automatic only)

Fig 9: EnwaMatic® system components

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1

8 7

2

9

3

4

5

11

10

6

2.5.2 EnwaMatic® standard delivery Standard delivery from ENWA includes the components listed in Tab 6.

Tab 6: EnwaMatic® standard delivery from ENWA (ref. Fig 9)

Pos. Description

6 EnwaMatic® unit with pipework and valves (ref. Fig 3, Fig 4)

10 Control unit (EnwaMatic® Automatic only)

11 Standard cables with connectors (EnwaMatic® Automatic only)

Filter- and reaction media, buckets labelled 1,2, 3+4 and 5

2.5.3 Installed system components Components listed in Tab 7 are needed to complete the installation of EnwaMatic® to a closed loop system. These components are not included in the standard delivery from ENWA.

Tab 7: EnwaMatic® system components not supplied by ENWA (ref. Fig 9)

Pos. Description

1 Piping: Inlet (untreated water)

2 Piping: outlet (treated water)

3 Piping: Mains Cold Water Service (MCWS)

4 Piping: Drain

7 Shut-off valve, outlet

8 Shut-off valve, inlet

9 Shut-off valve, MCWS

Optional: Backflow prevention with air gap on the Mains Cold Water Service.

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3. TECHNICAL DESCRIPTION

3.1 Purpose of equipment and limitations in useTo preserve the high efficiency of water based closed loop system for heating or cooling, it is important to maintain a high water quality. Poor water quality will degenerate the system by corrosion, scaling and bacterial growth. EnwaMatic® uses a side stream of the closed loop, and treats the water through a special granulate bed

The EnwaMatic® system is designed to operate with pure freshwater or a mixture of water and glycol/antifreeze liquid. The glycol/ antifreeze content in a system treated by EnwaMatic® should not exceed 35% (vol%). If the glycol content exceeds 35%, please contact ENWA for further assistance.

If the system water has been added, or will be added chemical containing corrosion and/ or scale inhibitors, ENWA should be consulted before installation of EnwaMatic®.

If your heating or cooling system contains aluminium components, please contact ENWA for further assistance

Due to EnwaMatic®’s operational pH (9-10,5) standard EnwaMatic® water treatment system is not compatible with heating or cooling systems with aluminium components. At pH 9-10,5 heavy corrosion of aluminium can occur

In general there are two ways to establish flow through the EnwaMatic® unit, 1); by the differential pressure across the main system pump (manual model), or 2); by installing a dedicated circulation pump. If the EnwaMatic® unit is installed across a main system pump set, a minimum of ΔP of 1,5 bar is required between the inlet and outlet connections of the EnwaMatic® unit to generate the side stream flow.

If ΔP < 1.5 bar between the inlet and return connection, a circulation pump has to be installed.

The make- up water (MCWS) pressure should be a minimum of 2 bar dynamic pressure to achieve sufficient backwash of the filter bed, refer to Technical Submissions for each model in the standard range 0-130,000 litres. The delivery pressure and flow rate for each model needs to be checked downstream of the FC4 / FC5 air break device i.e. At the units MCWS connection.

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For systems that operate greater than 10 bar, 95 deg C and 130,000 litre volumes, refer to bespoke units O&M

3.2 Location of equipmentThe unit can endure an external temperature of 0 ºC to 50 ºC. For external locations, a suitable enclosure should be constructed that allows access for maintenance, and sufficient insulation to protect against freezing. The inlet of EnwaMatic® has to be connected to the warmest part of the closed loop system.

The unit has to be installed on an even foundation. Where necessary a platform should be constructed.

For access to operate the valves, the minimum height above the unit has to be 50 cm from the top of the air separator.

EnwaMatic® requires a connection to drain. The plant room drain should be checked, and where necessary cleaned and tested to receive the backwash flows. The model specific backwash flows are listed in Tab 3.

If it is not possible to observe the backwash water in the drain, install a tundish close to the unit on the drain pipe, to observe the backwash water. Ensure the pipe work is suitably sized to prevent overflowing or flooding.

In dry plant areas it is necessary to connect the air separator vent to a drain. Use a reducer and compression fitting to adapt the vent outlet to accommodate a 6 mm hose / copper pipe (CHW / LTHW) .

3.3 Functional description

The EnwaMatic® system uses a side stream of the closed loop system and by filtration and adjusting the water parameters pH, alkalinity and hardness; it provides a complete self-adjusting corrosion- and mineral scale prevention, effective particle separation and restricts bacterial growths (Fig 10).

The EnwaMatic® needs to be backwashed regularly to dispose of any solids and dirt in the granulated bed/ filter media. During the backwash procedure, the EnwaMatic® unit is isolated from the system and flow is reversed. Clean water from the Mains Cold Water Service (MCWS) lifts the debris held in the unit and purges it to drain. For the manual model the backwash is done by repositioning the valves manually (by hand). The EnwaMatic® Automatic models are fully controlled by a PLC, and will automatically operate the valves and the backwash schedule (Fig 11).

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Fig 10: The EnwaMatic® system during normal operation

Fig 11: EnwaMatic® system during backwash operation

In Fig 12 a flow diagram for EnwaMatic® is presented.

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Pos. Description

A 3- way ball valve L-bore

B 3- way ball valve L-bore

C 2- way ball valve

D Flow regulator

E PICCV- Pressure independent flow valve

F Airvent

G 2- way ball valve bypass

H manometer

I check valve

J Backflow protection with air gap (optional)

Fig 12: Flow diagram for the EnwaMatic® system

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3.3.1 EnwaMatic® tank and granulate bedsThe EnwaMatic® contains five filter- and water treatment media (Fig 13). These filter the water to remove solids and unwanted particles and adjust the water chemistry in the system (pH, alkalinity and hardness).

Fig 13: The five filter- and treatment media layers in the EnwaMatic® unit

3.3.2 The control unit (Fig 14)The EnwaMatic® Automatic is controlled by a Programmable Logic Controller (PLC). The PLC controls the valves on the EnwaMatic® unit to run the backwash cycle automatically.

The PLC also generates an alarm, if for some reason, there is an incomplete program sequence or the valves are not positioning as intended during the program sequence.

The control unit can be connected to a Building Management System (BMS/SD) as an option (Appendix A).

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Fig 14: The control unit interface

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Pos. Description

A

Status lamps:• Green: run• Orange: backwash• Red: alarm

B The control panel

C Display

D Menu keys

E Navigation keys

F “ENTER”- key

4. PREPARATIONS FOR INSTALLATION

Make sure all preparations are completed before starting the installation of the EnwaMatic®

4.1 Installation location

The unit can endure an external temperature of 0 ºC to 50 ºC. For external locations, a suitable enclosure should be constructed that allows access for maintenance, and sufficient insulation to protect against freezing.

The unit has to be installed on an even foundation. Where necessary a platform should be constructed.

EnwaMatic® requires a connection to drain. The plant room drain should be checked, and where necessary cleaned and tested to receive the backwash flows. The model specific backwash flows are listed in Tab 3.

If it is not possible to observe the backwash water in the drain, install a tundish close to the unit on the drain pipe, to observe the backwash water. Ensure the pipe work is suitably sized to prevent overflowing or flooding.

In dry plant areas it is necessary to connect the air separator vent to a drain. Refer to page 21.

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4.1.1 Space requirements at the installation locationSpace requirements for EnwaMatic® at the installation location are given in Fig 15.

Fig 15: Space requirements for EnwaMatic® at the installation location

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D1 ≥ 600 mm D2 ≥ 600 mm

D3 ≥ 500 mm

D4 ≤ 2000 mm mm

D5~ 1500 mm

Pos. Description

D1 Minimum distance between the side stream inlet and the main system pump.

D2 Minimum distance between the side stream outlet and the main system pump.

D3 Minimum space required above the air separator vent:

D4 Distance between the control unit and the EnwaMatic® unit (EnwaMatic® Automatic only).

D5 Recommended height from the floor to the installed control unit (EnwaMatic® Automatic only).

4.2 The side stream loopThe EnwaMatic® unit is installed across a main system pump set. A minimum of ΔP of 1,5 bar is required between the inlet and outlet connections of the EnwaMatic® unit to generate the side stream flow. If there is insufficient ΔP, a small booster pump has to be installed on the inlet side of the unit to ensure adequate flow

If ΔP < 1.5 bar between the inlet and outlet connection of the EnwaMatic® unit, a circulation pump has to be installed.

The inlet of the side stream loop/ EnwaMatic® unit has to be connected to the area with the highest temperature of the main flow.

4.2.1 Installing the side stream loop

Ensure the side stream pipe dimensions are sized to create the correct flow through the EnwaMatic® unit.

The side stream inlet- and outlet pipe should be connected to the bottom side of the main system pipe.

Procedure

Step Description

1

Install the side stream inlet- and outlet pipe to the closed loop system. Minimum distance between the main system pump and the inlet and the outlet connection is given in Fig 15.

The side stream inlet pipe is connected to the delivery side (P+) of the main system pump.

The side stream outlet pipe is connected to the suction side (P-) of the main system pump.

2 Install shut-off valves on; Inlet, outlet and Main Cold Water Service (WCWS)

Make sure that the shut-off valves are closed during the entire installation process of EnwaMatic®.

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4.3 Pre- treatment water analysis

A water sample of the system water should always be collected before the EnwaMatic® is set into operation.

To get a good understanding of the system water quality and the treatment efficiency, it is of great importance to collect water samples before and after EnwaMatic® is set into operation.

If the system water has been added chemicals or currently is added chemicals, provide details of their composition and product data sheets where possible.

Procedure

Step Description

1 Locate an outlet for water sampling in the heating/ cooling system.

2Let the water run for minimum 10 seconds to ensure that any loose debris/ sludge in the tap is removed before sampling. Do not adjust the tap during sampling, this may dislodge possible debris/ sludge in the tap and cause contaminated water samples

3Flush the sample bottle with system water to avoid any potential contamination from the bottle.

4Fill up the sample bottle with system water from cooling or heating system. To prevent trapped air, top up the bottle and seal it.

Prevent any trapped air in the sample bottle. Trapped air may influence the character/ composition of the water sampled.

5Label the sample bottle and mark clearly following information: sampling date, name/ signature of the person collecting the sample, clients name, address, unit serial number, system type- and location

The system water sample should be sent to an accredited contract laboratory the same day or maximum 48 hours after sampling. If not, a new sample will need to be collected. The analytical results may be affected if the sample is stored too long.

6 Send the water sample to an accredited contract laboratory for analysis.

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Description

1A sample of the system water is collected and sent for analysis

Available information (MSDS, product information, etc.) about chemicals that have beenused, or to be used, is collected and evaluated.

2

The installation location is in accordance to recommendations:

Highest temperature in the closed loop system

ΔP > 1.5 bar

Ambient temperature 0-50oC

System pressure

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5.2.1 Lifting instruction:

EnwaMatic® has high center of gravity! Drain EnwaMatic® completely from water and filter media. Secure the tank from falling or that the equipment gets damaged during the lift!

Before lift, drain EnwaMatic® tank completely from water and filter media, disconnect water and electrical connections, unbolt unit from ground. Use both handles on sides or fork grip in bottom of tank (see arrows).

Using side handles: three persons needed, two for lifting and third to secure the EnwaMatic® from falling.

Using fork grip: secure EnwaMatic® from falling during lift, use some kind of straps or similar.

Details about weight are listed by type in chapter 2.2.1 .

Fig 16: Lifting points

5.3 Installing EnwaMatic®

5.3.1 Installing EnwaMatic® in the side stream loop:

Fig 17: Piping from the closed loop system to EnwaMatic® water interface connections

Procedure

Step Description (Fig 17)

1Install and connect the Mains Cold Water Supply pipe to the water supply inlet on the EnwaMatic® unit (3).

2 Install and connect the drain pipe to the EnwaMatic® unit (4).

3 Install and connect the side stream inlet pipe to the EnwaMatic® unit inlet (1).

4 Install and connect the side stream outlet pipe to the EnwaMatic® unit outlet (2).

Do not fill the EnwaMatic® tank with water. The tank will be filled up when the unit is started up the first time.

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1

2

3

4

5.3.2 Filling the EnwaMatic® unit with filter media:

Filling of filter should only be performed by Enwa’s commissioning engineer. Do not fill the filter with media.

The EnwaMatic® is delivered with filter media separately packed in four buckets labelled 1, 2, 3+4 and 5. Filter media 3 and 4 is delivered premixed in one bucket ready to use from ENWA.

Fig 18: Filling filter media into the EnwaMatic® unit

Dust masks in addition to standard Personal Protection Equipment are required during commissioning.

Make sure that the EnwaMatic® tank is empty before filling the media.

Procedure for ENWA commisisoning engineers

Step Description

1 Remove the filling plug and place a funnel in the filling hole (Fig 18, 1).

2 Verify that the tank is empty

3 Fill the EnwaMatic® unit in sequence with filter media labelled 1 through 5 (Fig 13).

4When filling is completed, measure the media level depth, D (Fig 19). The approximately depth levels should be in accordance to the listed levels in Tab 9. Record the media level depth on the accompanying registration form.

5 Mount the filling plug.

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Fig 19: Measuring media depth, D

Tab 9: Approx. media depth, D, after filling EnwaMatic® with filter media

5.3.3 Installing the control unit (EnwaMatic® Automatic only)The panel weighs 12kg, and the minimum space required underneath the panel to connect the cables is 200 mm. Minimum space required in front is 70 cm. The door requires at least 90 degree opening angle.

5.3.3.1 Wall mounting brackets

Before installation, the wall mounting brackets need to be fastened on the control cabinet (Fig 20). Four (4) mounting brackets pre- fitted with seal and expandable dowel (Fig 21) is included in the supply from ENWA (stored inside the cabinet itself).

Fig 20: Supplied wall mounting bracketsFig 21: The expandable dowel on the mounting bracket

Model Depth, D

EM 825 ~34 cm

EM 1252 ~33 cm

EM 1260 ~46 cm

EM 1665 ~44 cm

EM 1672 ~47 cm

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Procedure

Step Description

1Remove the caps from the enclosure holes on the backside of the control cabinet.

2Mount the bracket by inserting the expandable dowel into the enclosure hole from the outside.

3 Fasten the wall bracket from outside.

5.3.3.2 Installing the control unit

Make sure that the mounting wall can hold the weight of the control unit

Do not connect the control unit to the main power (220V). This is to be done during commissioning/ first time start-up.

Electrical connection diagrams are enclosed in Appendix C

Fig 22: Automatic valve with actuator sockets. The socket design may deviate from the picture.

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Procedure


1Mount the control unit to the wall, no more than 2 meters from the EnwaMatic® Automatic unit due to length of the signal- and power cables from the automatic valves/ motors, and about 1,5 meters above floor level (Fig 15).

2Connect the signal- and power cable from valve A to socket (4,5) on the bottom side of the control cabinet

3Connect the signal- and power cable from valve B to socket (6,7) on the bottom side of the control cabinet

4Connect the signal- and power cable from valve C to socket (8,9) on the bottom side of the control cabinet

5For connection of the ICP (Circulation Pump) and BMS option (2,3), please follow instruction given in Appendix A: EnwaMatic® Options

Fig 23: The connection interface on the bottom side of the control cabinet. Upon delivery the connection points are marked respectively.

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Pos. Description

1 Power Supply

2 Option: Circulation pump (ICP)

3 Option: BMS signals

4 Valve A motor

5 Valve A limit switch

6 Valve B motor

7 Valve B limit switch

8 Valve C motor

9 Valve C limit switch

10 Blanking plug

6. COMMISSIONING AND START-UP

To satisfy ENWA’s installation requirements, an authorised ENWA employee or representative should start the system for the first time.

Fig 24: EnwaMatic® valves. Left: Manual valve with handle. Right: Automatic valve with handle and manual override button

The automatic valves have a black button (Fig 24, 2) on the lower left side. Push this button down to rotate the valve handle (Fig 24, 1) manually during first- time start up.

6.1 Filling up the unit and establish flow through EnwaMatic®

Fig 25: The EnwaMatic® unit’s valves, bypass valve and flow regulator. Left: manual model, right: automatic model

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f

d

k

l

n

k

l

n d

f

Procedure


1Close the shut-off valves (inlet and outlet, Fig 9) connecting the EnwaMatic® to the heating/cooling system.

2 Verify that the EnwaMatic® is filled with filter media

3 Set valve C (d) in closed position by rotating the handle to point right.

4 Set valve A (k) in operate position by rotating the handle to point right.

5 Set valve B (f) in operate position by rotating the handle to point right.

6Slowly open the bypass valve (n) and let water from the main water supply (MCWS) fill the EnwaMatic®.

7 When the EnwaMatic® tank is filled up, close the bypass valve (n)

8Slowly open the shut-off valves (inlet and outlet, Fig 9) connecting the EnwaMatic® to the heating/cooling system.

9

Slowly open valve C (d):

EnwaMatic®; by rotating the valve to point down

EnwaMatic® Automatic: by rotating the valve to point up

This will equalize the pressure difference between the EnwaMatic® unit and the system.

10 If an additional circulation pump has been installed, switch it on.

11Press the red handle on the flow regulator (l), and adjust the red dial on the side to set flow rate in accordance with Table 10 below.

12

EnwaMatic® is now in operation.

For EnwaMatic® Automatic please follow instructions in section 6.2 to enable the control unit and the automatic backwash sequence.

If you are not able to acquire the right flow, please contact ENWA for further assistance.

Tab 10: Operational flow for the EnwaMatic® models

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ModelOptimal flow

Litre/minute

EM 825 2 – 4

EM 1252 8 – 12

EM 1260 20 – 25

EM 1665 55 – 70

EM 1672 75 – 95

6.2 To enable the control unit and the automatic back wash sequence

(EnwaMatic® Automatic only)

Fig 26: The control panel interface

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G

E

FD

C

Pos. Description

C Display

D

Menu keys:

# 1 = ON

# 2 = OFF

# 3 = BACKWASH

# 4 = RESET

ENavigation keys:

“▲”: navigate one step/ screen back“▼”: navigate one step/ screen forth

F

“ENTER” key:

Press “ENTER” after changing a value or just to exit and move on to next step

G“Information” key:

The menu keys #1-4 and their function is displayed

Procedure


1Connect the control unit to the main power (220V).

Valve C closes. The display shows: “EnwaMatic OFF, Status: Stop”.

2

Press menu key #1 “ON”. Valve C opens.

When valve C is opened, the display shows: “EnwaMatic ON, Status: Run”. The control unit is now enabled and EnwaMatic® is in automatic operation. The green status lamp (Fig 14) is lit.

A test sequence should always be run immediately after start-up to ensure the backwash- sequence (valves) is functioning as intended.

3Close the shut- off valve on the mains water supply (Fig 9, 9). Run a test sequence (ref. section 7.3.2).

4

When the test sequence is completed, open the shut- off valve on the mains water supply (Fig 9, 9). The EnwaMatic® is now in operation, and the automatic backwash program is activated, running a backwash once evry 14th day (twice a month)

Recommended backwash schedule after first- time start up is once every 2nd day the first 90 days thereafter once every 14th days.

5

Activate the “2-day” backwash sequence (ref. section 7.3.3).

EnwaMatic® Maritime will be running a backwash every 2nd day for 90 days. After this period the unit will automatically be set to standard backwash schedule: once every 14th days.

If needed, the standard backwash schedule can be adjusted. Please contact ENWA for further assistance.

The PLC’s date and time is preset to time zone GMT +1. The date and time can be adjusted if the unit is to be run in a different time zone. Please contact ENWA for further assistance.

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7. OPERATING INSTRUCTIONS

7.1 Backwash scheduleA backwash of the EnwaMatic® filter media bed is needed to dispose solids and to regenerate the filter media. Every backwash should last until drain water runs clear.

After first time start up, a frequent backwash schedule should be implemented. ENWA recommends a backwash of the EnwaMatic® unit every second day for 90 days (3 months). After 90 days, ENWA recommend, as a minimum, once a month.

The backwash schedule will be greatly dependant upon the quality of the specific site’s system water. ENWA’s recommendations are general, and based on site specific water quality; the backwash schedule could be adjusted accordingly.

For EnwaMatic® Automatic, the standard backwash schedule is set to once every 14th day (twice a month). Every backwash is set to last for 10 minutes. The backwash frequency can be reprogrammed upon request, please contact ENWA for further assistance.

7.2 EnwaMatic® back wash procedureOpen and close the manual valves carefully to prevent damage and ‘pressure shock’.

7.2.1 Change from normal operation to back wash:

Procedure


1 Close valve C (d), by rotating counter-clockwise, to point right.

2Set valve B (f) to ‘Back wash’ position by rotating counter-clockwise 90º, to point upwards.

3Set valve A (k) to ‘Backwash’ position by rotating counter-clockwise 90º, to point upwards.

4 Backwash for minimum 15 minutes or until the drain water runs clear.

5 Backwash completed.

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Positions of valves during operation Position of valves during back wash

Fig 27: Position of valves during operation and backwash

7.2.2 Change from backwash to operation

Procedure

Step Description (Refer to Fig 27)

1Set valve A (k) to ‘Operation’ position by rotating clockwise 90º, to point right.

2Set valve B (f) to ‘Operation’ position by rotating clockwise 90º, to point right.

3 Open valve C (d) by rotating clockwise, to point down.

4 The EnwaMatic® is set to normal operation.

7.3 EnwaMatic® AutomaticFig 28 present a diagram showing how to navigate between the different menus/ screens using the keys on the control panel (Fig 26).

The main screen (Fig 28, 1) displays the EnwaMatic® status. When EnwaMatic® is in operation (“ON”), there are a total of 8 different status and alarm lines that can be displayed. These are presented in Tab 11.

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d

f

k

d

f

k

Tab 11: Status and alarm list for EnwaMatic® Automatic

Status / alarm Description

Status: Run EnwaMatic® is in operation. The green status lamp is lit.

Status: Backwash A backwash sequence is ongoing. The orange status lamp is lit

Status: Test sequence A test- sequence is running.

Alarm: CircuitBreakFuse is blown (overloading/ short circuit). The red status lamp is lit. Automatic fuses are located inside the cabinet.

Alarm: Valve A Valve A failure; end switch not activated The red status lamp is litAlarm: Valve B Valve B failure; end switch not activated The red status lamp is lit.Alarm: Valve C Valve C failure; end switch not activated The red status lamp is lit

Alarm: Pump UPS1) Circulation pump failure; fuse is blown/ circuit break. The red status lamp is lit.

1) This alarm only applies for EnwaMatic® Automatic with an additional circulation pump installed. Please see Appendix A: “EnwaMatic® Options” for further details

7.3.1 To enable and disable EnwaMatic® water treatmentWhen there is no flow through the EnwaMatic® unit (valve C is closed) the main screen (Fig 28, 1) displays “EnwaMatic: OFF. Status: Stop”. When there is no flow, the EnwaMatic® water treatment is disabled.

1. To enable the water treatment and the automatic backwash sequence:

Push the key #1 “ON” (Fig 26, D). Valve C opens.

When valve C is opened, the main screen (Fig 28, 1) displays: “EnwaMatic: ON Status: Run”. EnwaMatic® Automatic is now in operation and the automatic backwash sequence is enabled.

2. To disable the water treatment and the automatic backwash sequence:

Push the key #2 “OFF” (Fig 26, D). Valve C closes.

When valve C is closed, the main screen (Fig 28, 1) displays: “EnwaMatic: OFF. Status: Stop”. EnwaMatic® Automatic and the automatic backwash sequence is now disabled.

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Fig 28: Diagram showing how to navigate between the available menus/ screen

Press the “ENTER” key (Figure 25) on the control panel after changing values or just to exit and move on to next step

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5: Menu key display2 sec delay

i

1: Main screen: EnwaMatic® status▼ ▲

2: Back wash count▼ ▲

3: Test sequence▼ ▲

4: 2-days back wash program”

7.3.2 To activate the test sequenceThe test sequence will test all valves in sequence to check if they are functioning correctly. The test last for approx. 10–15 minutes.

Procedure

Step Description

1Push the key “▼” twice. The menu “Start Test Seq.” will appear on the display (Fig 28, 3).

2 Push key #9. The test sequence starts.

3Push “▲” twice to return to the main screen (Fig 28, 1). The main screen will display “EnwaMatic: ON Status: Test Seq” as long as the test sequence is running.

4When the test is completed, the unit is automatically set to “run”, the green status lamp is lit and EnwaMatic® is in operation.

5If one or more of the valves is not functioning, an alarm will be generated. The red status lamp will be lit, and one of the alarms listed in Table 11 will appear on the display.

6 Check and clear out the corresponding valve(s)

7 Reset the alarm; push key #4 “RESET” (Fig 26, D)

8 Run a new test sequence.

7.3.3 To activate “2 day” backwash sequence

Procedure

Step Description

1Push the key “▼” three (3) times. The menu “StartupBackwash.” will appear on the display (Fig 28, 4).

2

Push key #5. The “2 day” backwash sequence is activated. EnwaMatic will be running a backwash every 2nd day for 90 days. After this period the unit will automatically be set to standard backwash schedule: once every 14th days.

3 Push “▲” three (3) times to return to the main screen.

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7.3.4 To deactivate “2 day” backwash sequence

Procedure

Step Description

1Push the key “▼” three (3) times. The menu “StartupBackwash.” will appear on the display (Fig 28, 4).

2Push key #6. The “2 day” backwash sequence is deactivated. EnwaMatic will be running standard backwash schedule: once every 14th days.

3 Push “▲” three (3) times to return to the main screen.

7.3.5 “Manual” BackwashFor inspection purpose, a manual backwash can be run from the panel whenever the EnwaMatic is in “ON” and “RUN” status.

Do not override the automatic valves manually (by hand) during this process.

Procedure

Step Description

1

Push key #3 “BW” (Fig 26, D). During approximately 90 seconds the valves will reposition for backwash.The main screen will display “EnwaMatic: ON Status: Backwash” and the orange status lamp will be lit as long as the sequence is running.

2When the backwash sequence is completed, the unit will automatically return to operation. The main screen will display “EnwaMatic: ON Status: Run” and the green status lamp is lit.

7.3.6 To reset an alarmIf an alarm is generated, the red status lamp will be lit, and one of the alarms listed in Table 11 will appear on the display.

To reset the alarm: Push key #4 “RESET”.

If OK, “EnwaMatic: ON Status: RUN” will appear on the display, and the green status lamp will be lit.

If not OK, a new alarm will be generated.

7.3.7 Backwash countPush the key “▼” once. The backwash menu will appear on the display (Fig 28, 2).

The backwash count (“counter”) inform how many times the EnwaMatic® unit has been backwashed since first time start up.

Push “▲” once to return to the main screen (Fig 28, 1).

The backwash count can be reset. Instructions how to do this is given upon specific request.

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8. SERVICE AND MAINTENANCETo ensure water quality in systems treated with EnwaMatic® is in accordance to specifications, inspection (and refilling if needed) of the granulated bed should be conducted at least once a year in addition to collecting and analyzing a system water sample. Water sampling – and refilling of filter media frequency and results should be recorded and filed for later use if needed.

Inspections of EnwaMatic®’s functionality and operational conditions should be incorporated on a regular basis to ensure that vital parts are functioning as intended, and if needed, replaced to maintain efficient water treatment and quality. Inspections are to be carried out by trained personnel. By trained personnel we define somebody who through his professional education and/ or experience is familiar with relevant systems, equipment and components.

8.1 Routine maintenance

8.1.1 Water sampling procedure

If the system contains chemicals, please state what chemicals are currently in use. Provide details of their composition and product data sheets where possible.

Step Description

1 Locate the water sampling valve on the EnwaMatic® unit.

2

Let the water run for minimum 10 seconds to ensure that any loose debris/ sludge in the tap is removed before sampling. Do not adjust the tap during sampling, this may dislodge possible stucked debris/ sludge in the tap and cause contaminated water samples

3Flush the sample bottle with system water to avoid any potential contamination from the bottle.

4Fill up the sample bottle with system water. To prevent trapped air, top up the bottle and seal it.

Prevent any trapped air in the sample bottle. Trapped air may influence the character/ composition of the water sampled.

5Label the sample bottle and mark clearly following information: sampling date, name/ signature of the person collecting the sample, clients name, address, system type- and location

The system water sample should be sent to an accredited contract laboratory the same day or maximum 48 hours after sampling. If not, a new sample will need to be collected. The analytical results may be affected if the sample is stored too long.

6 Send the water sample to an accredited contract laboratory for analysis.

7 Results should be recorded and kept available for later reference, if needed.

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8.1.2 Water analysis plan and result evaluationsThe first year EnwaMatic® is in operation it is recommended to perform water sampling after 3- and 12 months. After one year in operation, it is recommended to collect and analyze a system water sample at least once a year.

The water samples should be analyzed for a minimum number of parameters to ensure that the system water quality is in according to specifications. These parameters are:

• Appearance• pH• dissolved iron (Fe)• dissolved copper (Cu)• Suspended solids

Depending on the specific sites’ make- up water quality, hardness might also be included in the standard package of parameters.

Single water samples should be treated as snapshots, and it is important to see the results in context. As guidance, recommended specifications for good water quality in systems treated with EnwaMatic® are listed in Tab 12.

Tab 12: Recommended specifications for good water quality in systems treated by EnwaMatic®

Parameter Specificationsappearance Clear

pH 9 – 10,5

Dissolved iron (Fe) < 0,1 mg / liter

Dissolved copper (Cu) < 0,05 mg / liter

Suspended solids < 10 mg / liter

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8.1.3 Refilling of filter mediaFilter media layer 3 and 4 are consumed during operation. During the first year of operation, it is recommended to measure and refill consumed filter media 3- and 12 months after start up. After the first year, ENWA recommends that the filter media level is measured at least once a year and that consumed media is refilled. Premixed filter media 3 and 4 for refilling can be ordered from ENWA.

A manual backwash should be completed prior to refilling of filter media

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Procedure

Step Description

1

For EnwaMatic® Automatic only:

Disconnect the units power supply!

2Close the shut-off valves (inlet and outlet,) connecting EnwaMatic® to the heating or cooling system and close the MCWS shut-off valve (Fig 9)

3 Set the A-, B- and C valves in backwash position (Fig 27) to remove pressure in tank.

4 Remove the filling plug (Fig 18). Some water spill will occur.

5Measure and record the filter media depth. The approximately depth levels should be in accordance to the listed levels in Table 9 or the levels recorded at commissioning, if not, refilling of filter media is needed.

6 Place a funnel in the filling hole, and refill the EnwaMatic® unit with filter media 3+4.

7When filling is completed, measure and record the media level depth, D . The approximately depth levels should be in accordance to the listed levels in Table 9 or the levels recorded at commissioning.

8 Mount the filling plug. Set the valves back into operation position (Fig 27).

9Open the MCWS shut-off valve, and top up the unit with water from the Mains Cold Water Services

10 For EnwaMatic® Automatic only: Connect EnwaMatic® power supply

11Open the shut-off valves (inlet and outlet, Fig 9) connecting EnwaMatic® to the closed loop system.

12 Set EnwaMatic® into operation.

8.2 Yearly maintenance program and Maintenance AgreementENWA recommend a yearly maintenance program including the following:

• Sampling and analysis of the system water • A Manual Backwash• Function check of the EnwaMatic® system including inspection of vital parts of the unit.• Inspection of the granulated bed/ refilling of filter media

It is strongly recommended that the yearly maintenance is carried out by an ENWA representative. ENWA offer a “Maintenance Agreement”. The Maintenance Agreement is specific to ENWA and the cost is kept to a minimum. If there are several units at one site the cost per unit reduces accordingly. The cost is all inclusive, analysis, engineer’s time on site and consumable reaction media, consultancy on water chemistry and the overall warranty for effective treatment.

Please contact ENWA for further details and to arrange your Maintenance Agreement.

8.3 Periodic MaintenanceThe periodic service and maintenance is limited to the need of changing vital parts due to natural wearing from operation. There is no set scheme for the periodic maintenance, as vital parts should be changed/ cleaned only when needed. The periodic maintenance will be covered in the Maintenance Agreement.

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APPENDIX A: ENWAMATIC® OPTIONS

To make the EnwaMatic® water treatment system as flexible as possible, ENWA has developed a number of options that can be added to the EnwaMatic® Automatic models:

BAF (Backwash Antifreeze) - For systems containing glycol/ antifreeze chemicals

ICP (Integrated Circulation pump) - For systems with frequency controlled system pumps with low or variable differential pressure and therefore needs stabile flow through the EnwaMatic® unit.

BMS (Building Management Systems) - For the purpose of monitoring and logging alarms from the EnwaMatic®.

Fig 29: EnwaMatic® Automatic with all options included

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9. BAF- BACKWASH ANTIFREEZE

9.1 IntroductionStandard EnwaMatic® will during the backwash sequence, empty the unit tank by charging the content to the drain and refill the EnwaMatic® unit with untreated water from the main cold water source. For closed loop systems containing water added glycol/ antifreeze, this functionality will result in discharging glycol/ antifreeze to the drain and also increase the dilution of the glycol/ antifreeze content in the closed loop system. To comply with our customer’s environmental requirements, ENWA has developed the BAF- Backwash AntiFreeze - solution.

The EnwaMatic® BAF option is designed to prevent glycol/ antifreeze being discharged to drain during the backwash sequence. The BAF solution will also reduce the dilution effect caused by EnwaMatic®’s backwash sequence to a minimum.

If nothing else stated, information/ specifications given for EnwaMatic®/ EnwaMatic® Automatic applies to EnwaMatic® BAF.

9.2 Technical- and operating data and conditions

Fig 30: EnwaMatic® BAF system components and interface connections

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9.2.1 EnwaMatic® BAF system components and interface connectionsThe EnwaMatic® BAF unit is an EnwaMatic® Automatic unit (Fig 4, section 2.1.1) with extended pipe work mounted to connect the BAF pump to the EnwaMatic® unit. The EnwaMatic® BAF unit also include an additional air ventilator and flow switch mounted.

Fig 30 and Tab 13 shows the standard EnwaMatic® BAF system components and interface connections. Table 14 list the interface connection types- and sizes.

Tab 13: EnwaMatic® BAF system components and interface connections

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Pos. Description (Fig 30)

1 Inlet (untreated water)

2 Outlet (treated water)

3 Water source/ mains cold water services

4 Drain from EnwaMatic®, drain BAF pump

5 Sample valve

6 In BAF, interface connection EnwaMatic® BAF unit

7 Out BAF, interface connection EnwaMatic® BAF unit

8 In BAF, interface connection BAF pump

9 Out BAF, interface connection BAF pump

10 EnwaMatic® Automatic unit (Fig 4)

11 Control unit

12 BAF pump

13 Valve D with electrical actuators

14 Valve E with electrical actuators

15 Cables with connectors

16 Air ventilator

17 Air ventilator (BAF)

18 Flow switch

Piping:

• Inlet (1)

• Outlet (2)

• Water source/ main cold water services (3)

• Drain (EnwaMatic) (4)

• Drain (BAF pump) (4)

• In BAF (6, 8)

• Out BAF (7, 9)

Relay box (applies for 5-10 bar systems only)

Tab 14: EnwaMatic® BAF interface connection type and sizes (Fig 30,Tab 13)

1) DN = Diameter Nominal: conform to International Standard Organisation (ISO) usage. Numbers in () refers to NPS, Nominal Pipe Size (inches).

2) Int = Internal threads

3) Ext = External threads

9.2.2 General technical and operational conditionsGeneral technical and operational conditions and also operation- and backwash flows for EnwaMatic® BAF, is in compliance with conditions given for EnwaMatic® in Tab 2 and Tab 3 (section 2.3).

Glycol/ antifreeze content in a system treated with EnwaMatic® BAF should not exceed 35% (vol%). For systems with higher glycol/ antifreeze concentrations, please contact ENWA for project specific evaluations.

9.2.3 The control unitEnwaMatic® BAF is controlled by a Programmable Logic Controller (PLC). The PLC controls valves on EnwaMatic® unit to run backwash cycle automatically.

PLC also generates an alarm, if for some reason, there is an incomplete program sequence or the valves are not positioning as intended during the program sequence.

The control unit can be connected to a Building Management System (BMS/SD) as an option (Appendix A).

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Water interface connection

Connection type

EM 825 EM 1252 EM 1260 EM 1665 EM 1672

Inlet (1) Union DN20 (¾”) Int DN20 (¾”) Int DN20 (¾”) Int DN25 (1”) Int DN40 (1 ½”) Int

Outlet (2) Union DN20 (¾”) Int DN20 (¾”) Int DN20 (¾”) Int DN25 (1”) Int DN40 (1 ½”) Int

MCWS (3) Union DN20 (¾”) Int DN20 (¾”) Int DN20 (¾”) Int DN25 (1”) Int DN25 (1”) Int

Drain (4) Union DN20 (¾”) Int DN20 (¾”) Int DN20 (¾”) Int DN25 (1”) Int DN40 (1 ½”) Int

Drain BAF pump (4) Threads DN20 (¾”) Ext DN20 (¾”) Ext DN20 (¾”) Ext DN20 (¾”) Ext DN20 (¾”) Ext

Sample valve (5) Threads DN15 (1/2”) Ext DN15 (1/2”) Ext DN15 (1/2”) Ext DN10 (3/8”)Int DN10 (3/8”) Int

In BAF (6) Union DN20 (¾”) Int DN20 (¾”) Int DN20 (¾”) Int DN20 (¾”) Int DN20 (¾”) Int

Out BAF (7) Union DN20 (¾”) Int DN20 (¾”) Int DN20 (¾”) Int DN20 (¾”) Int DN20 (¾”) Int

In BAF pump (8) Union DN20 (¾”) Int DN20 (¾”) Int DN20 (¾”) Int DN20 (¾”) Int DN20 (¾”) Int

Out BAF pump (9) Union DN20 (¾”) Int DN20 (¾”) Int DN20 (¾”) Int DN20 (¾”) Int DN20 (¾”) Int

Pos. Description Dimension (mm)

h Cabinet height 400

w Cabinet width 300

d Cabinet depth 210

Width cabinet + wall brackets mounted 360

Fig 31: The EnwaMatic® BAF control unit dimensions

Tab 15: Technical and operating conditions for the EnwaMatic® BAF control unit

Function Data

IP class 44

Air humidity 93% rel

Usage Indoor usage

Ambient temperature 0 - 50 ºC

Power requirements 230V / Single Phase, 50/60 Hz

External fuse 230V – 10A

Weight 12 kg

Power to motor 24V DC 1A

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d: 210 mmh: 400 mm

w: 300 mm

Pos. DescriptionA Status lamps:

• Green: run• Orange: backwash• Red: alarm

B The control panel

C Display/ Touch screen

D Menu keys

Fig 32: The EnwaMatic® BAF control unit interface

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9.3 Delivered and installed components EnwaMatic® BAF

9.3.1 EnwaMatic® BAF standard deliveryEnwaMatic® BAF standard delivery from ENWA includes the components listed in Tab 16.

Tab 16: The EnwaMatic® BAF standard delivery from ENWA (Fig 30)

Pos. Description

10 EnwaMatic® Automatic unit (Fig 4)

11 Control unit

12 BAF pump



15 Cables with connectors

16 Air ventilator

17 Air ventilator (BAF)

18 Flow switch

BAF relay box (applies only for 5-10 bar systems)

Filter- and reaction media, buckets labelled 1, 2, 3+4 and 5

9.3.2 Installed system components not supplied by ENWAComponents listed below are needed to complete the installation of EnwaMatic® BAF. These components are not included in the standard delivery from ENWA.

1)

Piping from the EnwaMatic BAF interface connections:

• Inlet (1)• Outlet (2)• Water source/ main cold water services (3)• Drain (EnwaMatic) (4)• Drain (BAF pump) (4)• In BAF (6, 8)• Out BAF (7, 9)

2) Piping and shut- off valves for inlet and outlet of the side stream (Fig 9)

3) Piping and shut- off valves from the water source/ main cold water services

4) Optional: Backflow protection with air gap on Mains (MCWS)

Ensure that the pipe dimensions are sized to create the correct flow through the EnwaMatic® unit.

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9.4 Technical and functional descriptionDuring the backwash sequence, the standard EnwaMatic® will be isolated from the main system and the water held in the tank is flushed to drain. The unit is then refilled with untreated water from the mains cold water source.

The EnwaMatic® BAF option is designed to prevent glycol/ antifreeze being discharged to drain during the backwash sequence, thus keeping the dilution effect caused by EnwaMatic®’s backwash sequence at a minimum. This is achieved by pumping the content in the EnwaMatic® tank into the main system before the backwash and when the backwash is completed, the stored water is released back into the EnwaMatic® again. The EnwaMatic® BAF backwash sequence is described in Tab 17.

Tab 17: Technical description of the EnwaMatic® BAF backwash sequence

Step Description

1The BAF pump starts and the EnwaMatic® tank is exhausted. The main system’s “expansion tank” temporarily store the water/antifreeze held inside the EnwaMatic tank.

2When the EnwaMatic® has been pumped empty, the PLC runs through a standard backwash program for 10 minutes.

3

The backwash water inside the EnwaMatic tank is pumped to drain until the tank registers empty. This signals the PLC to return to normal service. Valve C opens and the EnwaMatic® is refilled with system water and the unit is brought back on line.

The BAF process requires that the main closed loop system has an expansion tank installed with the capacity of storing the extra volume of the water/ antifreeze pumped from the EnwaMatic® tank. Approximate model specific volumes are listed in Table 18.

Tab 18: Water volumes pumped into the main closed loop system during the BAF sequence (approx. volumes)

Model Volume (dm³)

EM 825 13

EM 1252 26

EM 1260 35

EM 1665 57

EM 1672 62

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9.5 Preparations for installationMake sure all preparations are completed before starting the installation of the EnwaMatic® BAF

9.5.1 Installation locationAs given in section 4.1, with this addition:

• Space requirements: Ensure there is enough space at the location to have the BAF pump and the corresponding piping installed nearby the EnwaMatic® unit. BAF pump dimensions are given in Fig 33.

Fig 33: BAF pump (0-5 bar) dimensions. All measures in mm. 5-10 bar pump, please contact ENWA.

9.5.2 The main closed loop system and the side stream loop.The expansion tank in the main closed loop system need to have the capacity to store the volume of the water/antifreeze pumped from the EnwaMatic® tank during the backwash sequence.

Further preparations as described in section 4.2, including the installation of the side stream loop (section 4.2.1).

9.5.3 Pre- treatment water sampleAs described in section 4.3.

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9.6 Installation

9.6.1 General installation instructionsIn general, the installation of EnwaMatic® BAF includes following steps:

1) Installing the EnwaMatic® unit in the side stream loop (section 5.3.1)

2) Filling the EnwaMatic® unit with filter media (section 5.3.2)

3) Installing the BAF pump and the corresponding piping

4) Installing the control unit

Only procedures related to BAF specific installations (step 3 and 4 above) are given in the sections below.

Before installation, check out the points given in Tab 19.

Tab 19: Checkpoints to clear out before installation of EnwaMatic® BAF

Description

1 The expansion tank in the main closed loop system is checked OK for BAF

2 A sample of the system water is collected and sent for analysis 3 The installation location is in accordance to recommendations in section

3.2 and section 9.5.1.

4 Installation of the side stream (section 4.2.1) OK

5 Installation of the EnwaMatic unit in the side stream (section 5.3.1) OK

6 Filling the EnwaMatic unit with filter media (section 5.3.2) OK

8 All system components ready and easy available

The control unit

Cables

BAF pump

Piping

Power supply:

o 0-5 bar systems: 220V / 50-60Hz

o 5-10 bar systems: 400V/ 50Hz

4 Appropriate mounting tools available

5 Installation manuals available

6 Personal Protection Equipment available

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9.6.2 Installation of EnwaMatic® BAF

Pos. Description

4 Drain,

6 In BAF, interface connection EnwaMatic® BAF unit

7 Out BAF, interface connection EnwaMatic® BAF unit

8 In BAF, interface connection BAF pump

9 Out BAF, interface connection BAF pump

11 Control unit

12 BAF pump



18 Flow switch

Fig 34: BAF option, installation.

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4

6

8

9

7

12

18

13

14

11

Ensure the side stream pipe dimensions are sized to create the correct flow through the EnwaMatic® unit.

Procedure


1If not already done so, install the EnwaMatic® unit in the side stream loop as described in section 5.3.1.

2 Place the BAF pump (12) nearby the EnwaMatic® unit.

3Install “In BAF” piping from the BAF pump interface connection (8) to “the EnwaMatic® interface connection (6)

4Install “Out BAF” piping from the BAF pump interface connection (9) to “the EnwaMatic® interface connection (7)

5 Install piping to drain from the BAF pump interface connection (4)

6 Mount cables and install the control cabinet

9.6.3 Installing the EnwaMatic® BAF control unitThe panel weighs 12 kg, and the minimum space required underneath panel to connect cables is 200mm. Minimum space required in front is 70cm. Door requires at least 90 degree opening angle.

9.6.3.1 Wall mounting brackets

As described in section 5.3.3.1.

9.6.3.2 Installing the control unit

Make sure that the mounting wall can hold the weight of the control unit Do not connect the control unit to the main power (220V). This is to be done during commissioning/ first time start-up.

Electrical connection diagrams are enclosed in Appendix C

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Pos. Description

1 Power Supply

2 Option: Circulation pump (ICP)

3 BAF pump

4 Valve A motor

5 Valve A limit switch

6 Valve B motor

7 Valve B limit switch

8 Valve C motor

9 Valve C motor limit switch

10 Valve D motor

11 Valve D motor limit switch

12 Valve E motor

13 Flow switch BAF

14-18 Blanking plug

19 Option: BMS signals

Fig 35: The connection interface on the bottom side of the EnwaMatic® BAF control cabinet

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Procedure


1

Mount the control unit to the wall, no more than 2 meters from the EnwaMatic® Automatic unit due to length of the signal- and power cables from the automatic valves/ motors, and about 1,5 meters above floor level (Fig 15).

2Connect the wire cable from the BAF pump to the control unit (3) in accordance to the electrical connection diagram in Appendix C.

3Connect the signal- and power cable from valve A to socket (4,5) on the bottom side of the control cabinet

4Connect the signal- and power cable from valve B to socket (6,7) on the bottom side of the control cabinet

5Connect the signal- and power cable from valve C to socket (8,9) on the bottom side of the control cabinet

6Connect the signal- and power cable from valve D to socket (10,11) on the bottom side of the control cabinet

7Connect the power cable from valve E to socket (12) on the bottom side of the control cabinet

8Connect the power cable from the flow switch BAF to socket (13) on the bottom side of the control cabinet

9For connection of the ICP (Circulation Pump) and BMS option (2,19), please follow instruction given in Appendix A: EnwaMatic® Options

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9.7 Commissioning and start-up

9.7.1 Filling up the unit and establish flow through EnwaMatic® BAFFollow the start- up procedure described in section 6.1: “Filling up the unit and establish flow through EnwaMatic®”

The positions of valve D and E during start-up and the Backwash AntiFreeze (BAF) sequence is shown in Fig 36.

Fig 36: The positions of valve D and valve E during the Backwash AntiFreeze (BAF) sequence.

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1) Position of valve D and valve E at start-up and the 1st pump sequence.

2) Position of valve D and valve E during backwash

3) Position of valve D and valve E during the 2nd pump sequence when backwash is completed

9.7.2 To enable the control unit and the Backwash AntiFreeze (BAF) sequence

Procedure (Fig 37)

Step Description

1

Connect the control unit to the main power (220V). Valve C closes.

Status field 1 (F) displays “Off/Stop” Status field 2 (G) displays “no alarm”

2

Push on the menu key “ON” (D). Valve C opens.

When valve C is opened, Status field 1 (F) is changed to “On/Run” The control unit is now enabled and EnwaMatic® BAF is in operation The green status lamp (Fig 32) is lit.

A test sequence should always be run immediately after start-up to ensure the backwash- sequence is functioning as intended.

3Close the shut-off valve on the mains water supply (Figure 9). Run a test sequence (ref. section 9.8.2).

4

When the test sequence is completed, open the shut-off valve on the mains water supply (Fig 9).

The EnwaMatic® BAF is now in operation, and the automatic backwash program is activated.

Recommended backwash schedule after first- time start up is once every 2nd day the first 90 days thereafter once every 14th days.

5

Activate the “2-day” backwash sequence (ref. section 9.8.3).

EnwaMatic® BAF will be running a backwash every 2nd day for 90 days. After this period the unit will automatically be set to standard backwash schedule: once every 14th days.

If needed, the standard backwash schedule can be adjusted. Please contact ENWA for further assistance.

The PLC’s date and time is preset to time zone GMT +1 (Norway). The date and time can be adjusted if the unit is to be run in a different time zone. Please contact ENWA for further assistance.

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Pos. Description

B The control panel

C Display/ Touch screen

D

Menu keys:

- ON

- OFF

- Backwash

- Alarm reset

E ESCAPE key: return to the previous menu/ screen

F Status field 1: On/Off – Run/Stop

G Status field 2:

- “NO ALARM”

- “ALARM”

H Date/ time

I Valve positions (valve A, B and valve C)

J “Enwa Water Treatment” menu fieldK BAF button

Fig 37: The control panel interface enwa.com # 67/94



C

F

D

H

G

I

J

K

B

E

9.8 Operating instructionsFig 38 presents a flow diagram showing how to navigate between the different menus/ screens when EnwaMatic® BAF is in operation.

9.8.1 To enable and disable EnwaMatic® BAF water treatmentWhen there is no flow through the EnwaMatic® BAF unit (valve C is closed) the main screen (home) (Fig 38, 1) displays “Off/Stop” in the status field. When there is no flow, the EnwaMatic® BAF water treatment is disabled.

Procedure (Fig 37)

Step Description

1

Push the menu key “ON” (D). Valve C opens.

When valve C is opened, the status field on the display shows “On/Run” (F), and the green status lamp is lit (Fig 37). EnwaMatic® BAF is now in operation and the automatic backwash sequence is enabled.

2

Push the menu key “OFF” (D). Valve C closes.

When valve C is closed, the status field on the display shows “Off/Stop” (F). No status lamps are lit. EnwaMatic® BAF and the automatic backwash sequence are now disabled.

9.8.2 To activate the test sequence

The test sequence will test all valves in sequence to check if they are functioning correctly. The test last for approx. 10 minutes. Procedure.


1Push the “Enwa Water Treatment” field on the display (1)

The “Enwa Water Treatment” menu (2) will appear on the display.

2

Push the “Push for Test Sequence” button on the display (2).

The button colour will change from green to grey and the test sequence is activated. The orange status lamp is flashing

3

Push “HOME” (2) to return to the main screen (1).

During the test sequence the valves will reposition. This can be observed on the EnwaMatic® unit itself but also on the display (Fig 37, I).

4When the test is completed, the unit is automatically set to “On/Run” (1). The green status lamp is lit (Fig 37) and EnwaMatic® BAF is in operation.

5If one or more of the valves is not functioning, an alarm will be generated. The red status lamp will be lit, the status field change to “Off/Stop” and “alarm” (Fig 37, F, G).

6Follow the procedure given in section 9.8.8:”What to do when an alarm is generated”. Run a new test sequence.

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5: BAF valves

1: Main screen (“home”): on/ run- no alarm

4: Alarm history

2: “Enwa Water Treatment (EWT)” menu 3: Backwash log

Fig 38: Diagram showing how to navigate between the screens when EnwaMatic® BAF is in on/run status

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9.8.3 To activate “2-day” backwash sequence

Procedure (Fig 38)

Step Description


The “EWT” menu (2) will appear on the display.

2

Push the “Push for Startup BW Schedule” button on the display (2).

The button colour will change from green to grey and the backwash sequence is activated. EnwaMatic® will be running a backwash every 2nd day for 90 days. After this period the unit will automatically be set to standard backwash schedule: once every 14th days.

3

Push “HOME” (2) to return to the main screen (home) (1)

During the sequence the status lamp (Fig 32, A) “run” (green) will be lit during operation whilst the status lamp “backwash” (orange) will be lit when a backwash sequence is running.

9.8.4 To deactivate “2-day” backwash sequence

Procedure (Fig 38)

Step Description


The “EWT” menu (2) will appear on the display.

2

Push the “Push for Startup BW Schedule” button on the display (2).

The button colour will change from grey to green and the backwash sequence is deactivated. EnwaMatic® will automatically be set to standard backwash schedule: once every 14th days.

3 Push “HOME” (3) to return to the main screen (home) (1)

9.8.5 “Manual” BackwashFor inspection purpose, a manual backwash can be run whenever the EnwaMatic® BAF is in “On/Run” status.

Do not override the automatic valves manually (by hand) during this process.

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