GENERIC MANUAL - FOR REFERENCE ONLY. ALL BESPOKE UNITS WILL HAVE PROJECT SPECIFIC DETAILS

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EnwaMatic® Bespoke BS 300

Contents

Declaration of conformity: 2

Pressure test certificate: 3

Contacts: 4

Installation notes: 5

Installation schematic: 6

Actuator switch positions: 7

EnwaMatic Operation: 8

Flow diagram: Service / Backwash: 9

Control panel operation: 11

Maintenance & Troubleshooting: 13

Pump data sheets 16

Wiring diagrams: 20

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EnwaMatic® Bespoke BS 300

Contact details

Enwa Water Technology (UK) Unit A, Scotlands Industrial Estate Coalville, Leicestershire, LE67 3JJ

Office: 01530 830 354

Project Manager: James Townley, 0787 9648006, j.townley@enwa.co.uk

Commissioning Manager: Mark Griffiths, 07500 330 383, m.griffiths@enwa.co.uk

Service & Aftersales: Cher Watkins, c.watkins@enwa.co.uk

UK Manager: Glenn Simpson, g.simpson@enwa.co.uk

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mailto:j.townley@enwa.co.ukmailto:m.griffiths@enwa.co.ukmailto:c.watkins@enwa.co.ukmailto:g.simpson@enwa.co.uk

EnwaMatic® Bespoke BS 300

Installation Notes

Refer to installation schematic:

The unit should connect to two DN50 / 2” isolation valves on the main district heating scheme (DHS).

Flow through the vessel is driven by a dedicated circulation pump: Grundfos CRI 20-1.

Inlet / outlet line size is DN50 / 2”. Mains water and drain is DN25 / 1”.

A boosted mains water supply is used to backwash the filter media. A DN25 / 1” isolating valve is provided on the break tank inlet. This feeds a 570 litre insulated GRP break tank via a solenoid valve (24 vdc, NC). This valve is linked to the control panel and programmed such that the valve will only open during backwash and where the break tank is below a set level. Additional security is provided by an additional float level switch.

The tank is fitted with a raised inlet chamber and weir to provide Fluid Category 5 backflow prevention.

A submersible pump within the break tank provides sufficient flow and head to backwash the filter at 85 l/min. The Lowara Genyo pump controller is energised during the backwash cycle only and is activated by pressure drop as the valves move into backwash positions.

The unit drain (backwash outlet) should discharge to a suitable floor drain – ideally such that the flow is visible to the operator. This drain will be tested to ensure it is capable of receiving flows up to 85 l/min for 15 minutes. It is critical that this drain is not blocked or impaired in any way.

All pipework and components are stainless steel, with the exception of the solenoid valve (mains water supply), which has a brass body.

Insulation:

The vessel has internal, 100mm insulation.

External pipework requires insulation by the installer post commissioning.

The main power supply required is 20 A, 230V, single phase. The schematic shows the 230V, 24 VDC and signal cabling.

All pumps are powered from the main control panel.

A local isolator switch on the incoming supply should be installed close to the installation.

5

A

D

C

B1 B2

VESSEL OUTLET

VESSEL INLET

AIR VENT

STRAINER

P

BACKWASH OUTLET

TO DRAIN

GRUNDFOS CRI 20-1

TO FLOOROR DRAIN

DN50

DN25

DN25

DN50

FLOWINDICATOR

SAMPLEVALVE

DHSINLET

FLOW REG

BYPASS

MCWREG

DHSOUTLET

MCWINLET

P

MANUAL VALVE

MOTORISED VALVE

PRESSURE GAUGE

WAFER NON RETURN

2" BSP-F2" BSP-F

2" BSP-F

1" BSP-F

1" BSP-F

1/2 " BSP-F

DN50PLASTIC

SCREENEDOVERFLOW

DRAIN

DAB PULSAR 30/80

PUMPCONTROLLER 1" BSP-M

1" BSP-FMCW SUPPLY

DN25

SOLENOID VALVE

20 A230 V50 HZ

BMS

24 VDC ACTUATORAND SENSOR CABLING

CONTROL PANEL

FC5 BREAKTANK +BOOSTER PUMP ASSEMBLY

2" BSP-F

INSTALLATION SCHEMATICBESPOKE BS 300

JT 4.6.15

PIPEWORK BY INSTALLER

230V ELECTRICAL BY INSTALLER

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EnwaMatic® Bespoke BS 300

Actuator switch positions

Actuator handles are mounted in line with the valve stem, such that a closed valve handle is perpendicular to the pipe on which it is mounted.

The green mark indicates the required contact status (S1>S3) for a closed valve.

Actuators are set up by ENWA at commissioning.

STATUS OFF RUN BACKWASH

ACTUATOR A

ACTUATOR B1/B2

ACTUATOR C

ACTUATOR D

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EnwaMatic® Bespoke BS 300

Operation

The EnwaMatic® Bespoke BS 300 is a dedicated side stream filtration / water treatment unit for the DHS. A small percentage of the main flow is diverted through the vessel, such that total system volume is turned over 1 - 2 times per day.

Side-stream filtration to less than 5 microns. Inhibition of corrosion – maintaining a dissolved iron level of < 1.0 mg/l. Regulation of hardness and scaling through calcite / dolomite media filtration. Removal of air through integral air separation device. Environmental restriction of bacterial growth.

Normal operation:

During normal operation, water enters the top of the vessel, passing through specialist filter media, reaction media and gravel base layers to a strainer on the bottom outlet. Debris is progressively collected by the filter media as it passes through the bed.

The flow rate is 200 l/min. This equates to position 7- 8 on the sight flow indicator.

Flow rate through the unit can be observed on the sight flow indicator and adjusted using the flow regulator valve on the central column (see mechanical schematic).

This is a fully automated backwash system, requiring no on-site operation or maintenance.

Isolation:

The unit should be isolated by:

Pressing ‘Off’ on the control panel PLC interface. Closing the main system isolation valves. Turn off control panel prior to undertaking any work on the equipment.

The unit can be isolated for several days without a deterioration in water quality. If prolonged periods of isolation are required, please contact ENWA for advice.

Automated backwash:

Backwashing is set at the control panel for 2 week intervals as default. This will be reviewed at commissioning and on follow-up visits. The actuator positions and direction of water flow during service and backwash are shown in the enclosed drawing.

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BESPOKE BS 300

JT - 4.6.15

ACTUATOR POSITIONS DIRECTION OF FLOW

SERVICE BACKWASH

9

The sequence is:

1) Circulation pump is switched off.2) Unit isolation valves (Valves C & D) close. Green light on panel goes out.3) Valve B1 and the additional drain isolation Valve B2 move to backwash positions.4) Valve A moves to backwash position. (MCW isolation open). Orange light on panel.5) Breaktank pump is activated and backwash commences. This lasts for 10 - 15 minutes.6) Unit returns to service. Pump is switched on.

The additional isolation valves have been included to increase system security. The unit cannot return to service if these valves are not closed.

Fluid Category 5 (FC5) break tank and booster pump:

EM BS 300 units require a higher flow rate than can normally be supplied directly by a mains water connection. To accommodate this, and to meet Water Regulations concerning connection to mains water, a break tank is employed.

The tank is filled by a servo type solenoid valve. This valve is normally closed, requiring a 24 vdc supply from the control panel to open. This can only happen during backwash and when the tank is below the solenoid activation level.

A submersible pump (DAB Pulsar 30/80) within the tank provides the required backwash flow rate and is controlled by a pressure switch within the Lowara Genyo pump controller. This controller is only energized during the backwash process.

A hall effect level sensor controls the solenoid operation and provides a high & low level alarm.

An additional float level switch provides a back-up high level alarm, which will shut down the water supply.

Failure of the FC5 device to correctly operate for the required time period during the backwash cycle will generate an alarm.

Status of the solenoid valve, level sensor and pump controller are displayed on the PLC.

Backwash Flow Rate:

The flow rate is set on the regulating valve adjacent to Valve A. ENWA will set this flow at commissioning, with final adjustment on the follow-up visit, when the unit has been in service for several weeks. The drain will be tested and confirmed capable of receiving this flow rate.

Circulation pump:

Refer to attached data sheets. This is a fixed speed pump, controlled via the control panel. Flow through the unit is confirmed by a flow switch and will provide an alarm if no flow is registered past a set delay period. Status of pump and flow switch are displayed on the PLC screen.

Manual over-ride:

It is possible to manually operate the valves, but this is not recommended for normal operation.

Valves are moved by depressing the black button on the orange Belimo casing and turning the black handle on the actuator. The panel must be switched off to override the permanent 24 vdc supply, designed to keep valves closed.

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EnwaMatic® Bespoke BS 300

Control Panel Operation

Indicator lamps are provided for basic ‘Run’, ‘Backwash’ and ‘Fault’ status. These outputs are linked to relays which provide volt free contacts for BMS connection.

PLC display (HMI):

Bespoke, project specific software is installed to control and monitor the installation.

The HMI has 5 direct switch inputs:

ON - returns panel to normal operation after alarms or manual shut-down. OFF - provides manual shutdown, without loss of power.

Pumps are switched off. All valves are closed. BACKWASH - allows user to initiate a complete automated backwash cycle. ALARM RESET - investigate and reset alarms. ESC - return from menus.

In standby mode the PLC will display the ENWA logo only. Touch the screen to access the main HMI display. The various status indicators are shown above.

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Alarm menu:

Pressing the HMI button ‘ALARM RESET’ allows any alarms generated to be investigated.

Pressing the magnifying glass icon on the screen will expand any alarm groups.

Pressing the ‘Reset’ screen button will clear the alarm – if the cause has been rectified or is currently inactive. Unless the cause is immediately apparent and can be safely restored, please contact ENWA for further assistance.

Pressing ‘ALARM RESET’ when no current alarms are present allows the alarm history to be seen.

Alarm conditions:

Alarm ID: Description: Notes: 000 Alarm Valve A Valve in wrong position for current status 001 Alarm Valve B Valve in wrong position for current status 002 Alarm Valve C Valve in wrong position for current status 003 Alarm Valve D Valve in wrong position for current status 004 Alarm pump UPS Pump not started in RUN status 006 Break tank low level Tank level has remained low beyond pre-set

delay period.

017 Backwash duration alarm Solenoid valve not activated for pre-set period during backwashing.

023 Alarm Flow Switch Run Lack of flow in RUN, with pre-set delay period 024 Alarm circuit breaker Tripped MCB’s in control panel.

Additional options:

Pressing the control panel icon on the HMI screen accesses additional options.

Select ‘Backwash Log’ to view history. Press the ‘ESC’ button to return.

The ‘Test sequence’ is a partial test only and is not recommended post commissioning. Users should press the ‘Backwash’ button to observe a complete test cycle.

‘Settings’ requires a password number and is not recommended for normal operation. ENWA can advise if further access is required – for example to change backwash dates. In general, the correct settings are established at commissioning and refined on the initial follow-up visits. Further adjustment should not be required, and may affect correct operation of the unit and break tank.

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EnwaMatic® Bespoke BS 300

Maintenance & Troubleshooting

On site maintenance:

There is no on-site maintenance requirement.

It is recommended only that routine checks are made when visiting the plantroom:

• Visible flow: Position 7-8 on the sight flow indicator.• Green light on control panel. PLC HMI display ‘On’, status ‘Run’.

Any problems should be reported to ENWA.

Warranty / Maintenance Agreement:

The standard warranty on all equipment supplied is 2 years from delivery:

The unit will operate under the additional water treatment warranty for 15 months post commissioning.

Any problems should be reported directly to ENWA, who will advise or attend as required.

After this time, regular annual servicing by ENWA should be carried out to check all components, clean the filter media, top up reaction media and analyse system water. This service extends the warranty on the water treatment process for additional 12 month periods. Any problems arising during these periods should again be reported to ENWA.

Spares:

There is no requirement to hold spares on site.

Side stream filtration / water treatment provides long term management of water quality. Units do not need to operate continuously and can remain isolated for extended periods once established. ENWA hold most components in stock for immediate dispatch. Grundfos pumps have a lead time of 2 weeks.

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Troubleshooting: Lack of flow through unit: Check panel status and program condition. Check main system isolation valves. Check circulation pump is running: Check indicator status on PLC. Visually check rotation through top cover. Check flow regulating valve is open. Check actuator positions. (Refer to enclosed drawing) Report to ENWA. Control panel: No green light: Check power supply. Is the LCD display active? Check panel status and program condition. Unit may be in initial stage of backwash. Max duration 2 mins. Check actuator positions. Report to ENWA. Orange light: Unit is in backwash. This should continue for 10-15 minutes maximum. Red light: Check alarm condition message. Reset if cause is clear and can be safely rectified. Otherwise: => Isolate unit and report to ENWA

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Backwash / Break Tank faults: Lack of flow during backwash: Check HMI display indicator status for breaktank pump controller. Check mains water supply isolation valve. Check position of regulating valve adjacent to Valve A. Check actuator positions. Visual check of break tank level and float switch position. Check panel status: Incorrect valve positions, high / low tank level or solenoid inactivation will generate an alarm after a pre-set period. Report to ENWA. Low break tank level alarm: Break tanks may reach low level during normal operation. In this case the pump will switch off and wait for the tank to refill, resetting automatically. If the tank level remains low beyond a pre-set time period, an alarm will be generated. Check mains water supply isolation valves. Ensure position of regulating valve adjacent to Valve A is not altered. Visual check of tank level and float switch position. Report to ENWA.

Break tank duration alarm: The PLC will check that the breaktank has been active for a minimum time period during backwashing. If this has not been achieved by the end of the process, an alarm will be generated. Check mains water supply isolation valves. Check position of regulating valve adjacent to Valve A. Check HMI display indicator status for breaktank pump controller and solenoid status. Visual check of tank level and float switch position. Report to ENWA.

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Printed from Grundfos CAPS [2014.04.042]

Position Qty. Description1 CRI 20-1 A-FGJ-I-V-HQQV

Note! Product picture may differ from actual product

Product No.: 96500314

Vertical, multistage centrifugal pump with suction and discharge ports on same the level (in-line)enabling installation in a horizontal one-pipe system. Pump materials in contact with the liquid are instainless steel. A cartridge shaft seal ensures high reliability, safe handling and easy service andaccess. Power transmission is via a split coupling. Pipework connection is via combined DIN-ANSI-JISflanges.

The pump is fitted with a 1-phase, foot-mounted, fan-cooled asynchronous motor.

Liquid:Pumped liquid: WaterLiquid temperature range: -20 .. 90 °CLiquid temp: 20 °CDensity: 998.2 kg/m³

Technical:Speed for pump data: 2789 rpmRated flow: 21 m³/hRated head: 9.5 mShaft seal: HQQVApprovals on nameplate: CE,TRCurve tolerance: ISO 9906:1999 Annex A

Materials:Pump housing: Stainless steel

DIN W.-Nr. 1.4408ASTM A 351 CF 8M

Impeller: Stainless steelDIN W.-Nr. 1.4301AISI 304

Installation:Maximum ambient temperature: 40 °CMax pressure at stated temp: 16 bar / 90 °C

16 bar / -20 °CFlange standard: DINPipe connection: DN 50Pressure stage: PN 16Flange size for motor: FT115

Electrical data:Motor type: 90SBIE Efficiency class: NANumber of poles: 2Rated power - P2: 1.1 kWPower (P2) required by pump: 1.1 kWMains frequency: 50 HzRated voltage: 1 x 220-230/240 VRated current: 7,40/6,70 AStarting current: 390 %

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http://product-selection.grundfos.com/product-detail.html?productnumber=96500314&freq=50&lang=ENU

Printed from Grundfos CAPS [2014.04.042]

H[m]

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

Q [m³/h]0 5 10 15 20 25

eta[%]

0

10

20

30

40

50

60

70

80

90

100

CRI 20-1, 1*230 V, 50Hz

Pumped liquid = WaterLiquid temperature = 20 °CDensity = 998.2 kg/m³

P[kW]

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

NPSH[m]

0

1

2

3

4

5

6

7P1

P2

Description Value

General information:Product name: CRI 20-1 A-FGJ-I-V-HQQVProduct No: 96500314EAN number: 5700396199245Price: On request

Technical:Speed for pump data: 2789 rpmRated flow: 21 m³/hRated head: 9.5 mImpellers: 01Shaft seal: HQQVApprovals on nameplate: CE,TRCurve tolerance: ISO 9906:1999 Annex AStages: 2Pump version: AModel: A

Materials:Pump housing: Stainless steel

DIN W.-Nr. 1.4408ASTM A 351 CF 8M

Impeller: Stainless steelDIN W.-Nr. 1.4301AISI 304

Material code: ICode for rubber: V

Installation:Maximum ambient temperature: 40 °CMax pressure at stated temp: 16 bar / 90 °C

16 bar / -20 °CFlange standard: DINConnect code: FGJPipe connection: DN 50Pressure stage: PN 16Flange size for motor: FT115

Liquid:Pumped liquid: WaterLiquid temperature range: -20 .. 90 °CLiquid temp: 20 °CDensity: 998.2 kg/m³

Electrical data:Motor type: 90SBIE Efficiency class: NANumber of poles: 2Rated power - P2: 1.1 kWPower (P2) required by pump: 1.1 kWMains frequency: 50 HzRated voltage: 1 x 220-230/240 VRated current: 7,40/6,70 AStarting current: 390 %Cos phi - power factor: 0,98/0,99Rated speed: 2770 rpmMotor efficiency at full load: 73-71 %Enclosure class (IEC 34-5): 55 (Protect. water jets/dust)Insulation class (IEC 85): FMotor protec: PTOMotor No: 85215705

Others:Minimum efficiency index, MEI ≥: 0.7Net weight: 47 kgGross weight: 60 kgShipping volume: 0.09 m3

17

http://product-selection.grundfos.com/product-detail.html?productnumber=96500314&freq=50&lang=ENU

Printed from Grundfos CAPS [2014.04.042]

Note! All units are in [mm] unless others are stated.Disclaimer: This simplified dimensional drawing does not show all details.

96500314 CRI 20-1 50 Hz

178

139

130200300

65120.5215248

G 1/2 G 1/2

G 1/218.5 x 21.8

281

413

26

90

165

127

18

Printed from Grundfos CAPS [2014.04.042]

Note! All units are in [mm] unless others are stated.

96500314 CRI 20-1 50 Hz

19

20

CIR

CU

LATI

ON

B

RE

AK

TAN

K (L

OW

AR

A)

21

25 27 41 42 43 44 46 47 4945 48

Co

m

NC

NO

Co

m

NC

NO

Co

m

NC

NO

BMSVFC

'Run'

BMSVFC

'Backwash'

BMSVFC

'Fault'

Bla

ck 1

SOLENOID VALVE

S

37 38

HALL EFFECTLEVEL SENSOR

H

39 40

SERVICEFLOW SWITCH

PLC SETTINGS:SET JUMPERS JP1 & JP2 TO 'A' - ANALOGUE INPUT

MOVE CABLE 38 FROM PLC TERMINAL 13 (I6) TO TERMINAL 4 (I15)

1 2 3 S1

S2

S3

Bla

ck

Red

Whi

te

Pur

ple

Re

d

Whi

te

Bla

ck

Re

d

Whi

te

Pur

ple

Whi

te

1 2 3 4 5 6

MOTOR A

1 2 3 S1

S2

S3

Bla

ck

Re

d

Whi

te

Pur

ple

Re

d

Whi

te

Bla

ck

Re

d

Whi

te

Pur

ple

Whi

te

7 8 9 10 11

MOTOR B1

1 2 3 S1

S2

S3

Bla

ck

Re

d

Whi

te

Pur

ple

Re

d

Whi

te

Bla

ck

Re

d

Whi

te

Pur

ple

Whi

te

7 8 9 11 12

MOTOR B2

1 2 3 S1

S2

S3

Bla

ck

Re

d

Whi

te

Pur

ple

Re

d

Whi

te

Bla

ck

Re

d

Whi

te

Pur

ple

Whi

te

13 14 15 16 17

MOTOR C

1 2 3 S1

S2

S3

Bla

ck

Re

d

Whi

te

Pur

ple

Re

d

Whi

te

Bla

ck

Re

d

Whi

te

Pur

ple

Whi

te

13 14 15 17 18

MOTOR D

Bro

wn

28 30

BREAKTANKFLOAT LEVEL

Bla

ck 2

Bla

ck 1

Bla

ck 2

Bla

ck

Bla

ck 1

Bla

ck 2

Bla

ck 1

Bla

ck 2

Bla

ck 1

Bla

ck 2

Drawn by: Verified by: Date: Drawing type:

ENWAWATER TREATMENT

Project:

Specification:

Project No:

Page No:

Drawing No: Rev:

Date:

JT 24.2.15 JS 24.2.15 Electrical drawing

BESPOKE PANEL WIRING

10

532869 - BS 1

BESPOKE BREAKTANK + SOLENOIDHALL EFFECT LEVEL SENSORBAF / MOG PANEL UPGRADE

22

POWERIN

CIRCPUMP

BTPUMP

* VIEW FROM INSIDE PANEL

A24V

B124V

C24V

ASIG

B1SIG

CSIG

SOLB224V

B2SIG

D24V

DSIG

BTFLT

HELEV

FLOW

BMS

CABLE ENTRIESBESPOKE BS 300

JT 4.6.15

ENWA Manual Arla Stourton Iced WaterFront Page_edited-3Decl Conformity Arla 2Arla Pressure Testing Certificate 13.3.15ARLA IW Master DocumentARLA Mech SchemArla ELEC SchemARLA Service backwash flowsGrundfos CRI 20-1 single phaseENWA Power wiring Arla IWARLA IW panel wiring 26.3.15

EM BS West Hendon DHS FlowWH ContentsWH Master DocumentWest Hendon Installation schematicWest Hendon panel wiring 4.6