Instruction Manual

For

YORK Refrigeration Antiscale Equipment

Model Water Manager

Produced by Aqua-Perl Danmark ApS.

Ultrasound by Elma GmbH

Version 1.10 Sept. 2005

YORK Antiscale Equipment: Water Manager

2

Mounted on a stand the Water Manager system with 2 treatment

pipes looks as pictured:

From left is shown: Conductivity sensor, the Min-max water level sensor and a motor valve.

1. Control Box: 300 x 400 x 200 mm IP64, 110/230 Volt 50/60 Hz 2. Pipe make-up water: Straight through, 2 coils. Lenght 650 mm 3. Pipe cooling water: T-mounted, 2 coils, electrode pulse. Lenght 950 mm 4. Ultrasound: 1 x Head in T-piece. Mark Elma 5. Conductivity sensor: 2 x mounted in 40 mm fitting 6. Pump Recirculation: 1 x Grundfos CH-4-20 1x230V, 50 or 60 Hz 7. Motorvalve bleed-off: 2 x Mark Belimo, 1" fullbore, 230 V AC 50/60 Hz, 8. Flow Meters: 3 x Brkert, DN32 fullbore, 9. Ready-made Stand: Components assembled on plate 1300 x 1600 mm

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General The following functions are performed by the Water Manager:

Monitoring of water level Control of make-up water supply Monitoring of conductivity level Control of bleed-off after drain percentage or conductivity Reduction of scale Reduction of bacteria in the cooling water

The Water Manager manages the water flows to and from the condenser. It reduces the scale in the condenser. The Water Manager is environmentally friendly, no chemicals are applied. For use in evaporative condensers and cooling towers is developed a special series named Water Manager. It manages the water on both the input and output side. The Bleed-off is managed simultaneously with the help of a microprocessor. Conductivity measurements are made. The Water Manager is specially designed for use in condensers. Here is the make-up water treated as well as the tank water being circulated for repeated treatment. The system is build with an coil pulse treatment pipe for the make-up water, and a second pipe for the cooling water with coil and electrode pulses as well as 2 ultrasound heads. Dimensioning The Water Manager system is dimensioned to treat the water from all commonly available condensers. A total Water Manager system consist of the following components:

1. 1 Control Box 2. 2 Water Treatment Pipes 3. 1 Ultrasound head 4. 2 Conductivity Sensors 5. 1 Pump for recirculation 6. 1 Motor valve for make-up water 7. 1 Flow Meter for make-up water 8. 1 Motor valve for bleed-off water 9. 3 Flow Meters for water flow control

This description is based on assumption that a Min-Max (VNI) sensor is placed in the tank to monitor the water level. If an floating ball type valve is applied no Min-Max sensor is needed. The four first components are made by Aqua-Perl Danmark ApS. The other components are bought from recognized suppliers. Pump: Grundfos, Motorvalve: Belimo, Flow Meter: Brkert. The dimensioning of the Water Manager is based on the capacity of the condenser. The basic assumption is that 1 kW yield leads to 1.5 liter of evaporation. If the bleed off is 25% of the evaporated water is the consumption of make-up water 1.9 liter (1.5 + 0.375). By the dimensioning is calculated that 50% of the capacity is used to treating make-up water, the rest capacity is used to treating the cooling water in recirculation. In general should the cooling water be circulated once every hour, with a speed not exceeding 2 m. per second. The method of placing two treatment pipes, one for make-up water and one for recirculation, can be recommended for more reasons. Easier installation and better treatment. By the floating ball valve type of water inlet is the two-treatment-pipe model the only feasible method of installation. The treatment device consist of an inner pipe of PVC, around which an cobber coil is laid. The electrode pair is inserted in the top end of the pipe. In the middle is the ultrasound head placed. The outer pipe consist of PVC. The length of 950 mm refers to the mid hole to mid hole distance. The total length is approx 1200 mm. The straight through pipe is 650 mm long.

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Schematic Outline of the Water Manager System

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Installation The Water Manager is installed so that the tank water is circulated constantly through the unit. Make-up water is also treated when entering. The recirculation is maintained by a separate pump.

The stand with the Water Manager mounted on it is normally placed in a room close to the condenser or beside the tank where the cooling water is stored for pumping to the condenser. If the condenser only stores cooling water in its bottom reservoir the make-up water is send through the make-up treatment pipe on the stand. The cooling water is lead from the condenser reservoir through the cooling water treatment pipe by means of the pump, and then back to the condenser reservoir. Bleed-off water is discharged during the process when the bleed-off motorvalve is open. When a separate tank for one or more condensers is employed, then is the Water Manager stand placed close to the tank. Make-up water is fed through the make-up treatment pipe. Cooling water is recirculated through the recirculation treatment pipe and drained as explained before. Practical steps for installation:

1. Connect the water pipes. (40 mm PVC) Upper left: Make-up water. Middle left: Drain water. Lower left: Recirculation Pump. Top left: Make-up water to reservoir. Top right: Recirculation water to reservoir. By use of toilet swimmer water level control the make-up motorvalve will be open constantly. Factory standard. Select in System Mode: Level Sensor Configuration.

2. Connect the Water Level Sensor. (Optional) The common in pin 10 low voltage, Low water level pin 11 and high water level pin 12.

3. Connect the PC or network connection. Install the program. (Optional) 4. Connect the Power supply.

Power 110-240 Volt AC 50/60 Hz. Standard 220 Volt for pump and motorvalves. If using 110 Volt supply make sure that the pump and motorvalves are 110 Volt appliances. Pump standard 50 hz. Install 60 hz pumps in some countries. Be sure that the ultrasound head is connected.

5. Start the Application. Make sure that recirculation water is available. Select drain mode: 1)EC and drain% as backup or 2)drain % only. In System Mode of the Menu. Adjust the EC Factor and Drain %.

M

2 - Treatment pipe3 - Conductivity sensor

1

1 - Control box (Water Manager)

Item list

2

2

4 - Pump for recirculation

4

5 - Valve sparge water

5

6 - Water meter - sparge water

6

7 - Motorvalve - bleed off

7

8 - Water Meter - bleed off

83

9 - Float valve

9

10 - Non return valve

10

10

Evaporative Condenser with De-superheater

To Receiver

Strainer

Discharge line from compressor

kch

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Operation of the Water Manager When operating the Water Manager connected to an evaporative condenser, the following main rule is to be observed: The bleed-off percentage is to be optimized. This means the bleed-off percentage must be sufficient to keep the calcium bicarbonate concentration dissolved in the water at a sufficiently low level, thereby keeping down the calcium carbonate scaling on the coils of the evaporative condenser . The basic rule is that the cooling water is drained off by an conductivity 2,0 times higher than the make-up water. Over time can this ratio be changed depending on the working of the system. It is optional to drain after conductivity or percentage of the make-up water. The Drain % set will always function, and overrule EC draining if it becomes lower than the set drain %. Display

Display The top line of the display indicates the OK status or alarms. The number two line shows if make-up or drain takes place. The third line shows the heading for the values. The bottom line shows the actual values. By scrolling the arrows pushbuttons the four main headings are shown:

1. Drain conditions, EC (Conductivity) Factor and Drain%. 2. Actual Bleed-off flow and total. 3. Actual Make-up Flow, total and EC for make-up water. 4. Actual Recirculation flow and EC for cooling water.

Pushbuttons 1. Drain Mode: To select actual drain level. EC Factor is the conductivity bleed-off level, For

example 2,0 means that bleed-off will start when the conductivity of the cooling water has reached the double of the make-up waters conductivity. Example: Make-up water has EC 0,5 mS, with EC Factor 2,0 drain will start by EC 1,0. (0,5 x 2,0 = 1,0). The Drain % is overruling the EC Factor, it will secure a minimum draining level. (Standard 25%)

2. Make-up: Manual check of the Make-up valve. 3. Bleed-off: Manual check of the Bleed-off valve. 4. Arrow up: For scrolling upwards for menu selection or values. 5. Arrow down: For scrolling downwards for menu selection or values.

YORK Antiscale Equipment: Water Manager

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6. OK: For confirmation of choices. By pressing 5 seconds the programming menu appears: 1: Level Sensor Configuration: On if level sensor is used. 2: System Mode: 1: Choice of drain mode: a) EC Factor and Drain %, b) Drain % only, c) Cool mode with magnetic treatment only. 2: Size of drain portion in liter. Standard 250. 3:.EC Sensor offset. For adjusting EC sensors to actual value. Use separate EC meter. 4: Pump Capacity: Standard Grundfos CH-4-20=4,5 m3/h, 75 gpm. 5: K-factor Recirculation Flow Meter. Standard=28,00 DN32 6: K-Factor Bleed-off Flow meter. Standard = 28,0. 7: K-Factor Make-up Flow meter. Standard = 28,0. 8: EC Sensor Gain:

7. Clr all: To clear the totals of the flow meters. Press 5 seconds. Reset for alarms is made by using the main switch.

By failing recirculation the pump and ultrasound will stop. Pump blocked will appear in the display. Clean the recirculation system and reset the controls.

Summary of Maintenance Sheet for Water Manager 1. Check the Control Box panel for system OK.

2. Check the bleed-off programming. The factory standards are 2,0 as EC factor

and 25% bleed-off.

3. Check the recirculation flow. If no flow for 10 seconds. The alarm is set, and the pump is blocked.

4. Check that the make-up and drain water bleed-off valves are working. Press

button.

5. Check the conductivity sensors. Clean if needed. The sensors are self-calibrating.

6. Control the bleed-off percentage.

7. Inspect the condenser coils for scale building.

8. Make regular recording of the water drain and conductivity meter readings

The conductivity figure (mSiemens/cm) expresses the combined electric conductivity created by all the dissolved salts in the water. To give an example of this: The water solution in a car battery has a very high conductivity figure. Well water is normally within the range of 0,3 to 0,8 mS/cm. The EC factor means how many times the EC of the make-up is increased before draining takes place. If for example the make-up water has an EC of 0,5 and the EC factor is 2, then will draining start by EC 1,0 (0,5 x 2). Warning: If the Ultrasound head is disconnected and power is applied, the ultrasound board will be destroyed. Therefore be sure to remove power from the ultrasound board before disconnecting the ultrasound head.

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Data Sheet for the Water Manager

Treatment Pipe: Condenser Model water Pipe Pump

Max. Cap. (kW) Size m3/h l/min mm long Model

5000 63 5.4 166 950 CH-4-20 10000 75 18.0 300 950 CH-8-20

Pipe Material: PVC, fitting union, 63 and 75 mm pipe. Water conditions: Max. 10 bar, Max. 60degree C. Cord type Coil: 4 wires 0.5 mm, 1.5 m., 2 pair twisted Cord type Electrode: 2 wires 0.5 mm, 1.5 m. Cord type Ultrasound: 2 wires 0.75 mm, 1.5 m.,

Control Box: Size: H: 400 W: 300 D: 210 mm, Approx. 10 kg. Material: Steel (IP 64), Mounting by brackets Power Supply: 1 x 110/230 Volt, 50/60 Hz Internal Voltage: "+/- 12 and 20 Volt, Max 230 VA Programming: In display Wiring diagram: Separate sheet Conductivity sensor: Material: PVC, UL Proof, steel tipped sensors, approx. 0,5 kg.

Mounting: Union 40 mm internal thread

Wiring: Two wires (0.5 mm) 1 m. cord Signal: U - 14 Vss, f - appr. 1.5 K Hz Sinus Water Level Sensor: Type: VNI 3 rods

Material: PVC, UL Proof, 3 PVC covered steel rods Weight: Approx. 1.0 kg. Wiring: Three wires (0.5 mm) Signal: U - 6 Vss, f - approx. 5 K Hz - Sinus Motor valve: Type: Fullbore ball valve. 1"

Material: Steel and stainless steel, threaded end Specifications: Angle:90 degree, F:03, Protection: IP65 Power supply: 1 x 230 volt 50/ 60 Hz, 0,35 Ampere Working time: 40 sec. Water Flow Meter: Signal: Hull generator pulse, DN32 = 28,5 pulse/L

Pump: Type: Horizontal multistage end suction pump CH-4-20

Power supply: 1 x 110 or230 volt 50 or 60 Hz, 540-730 Watt Output: CH-4-20 5m3/h, Fuses:

F4: Ultrasound 1,0 A F F5: Intern Power 3,15 A F F1: Make-up Valve 1,0 AF F2: Bleed- Off Valve 1,0 A F, F3: Circulation Pump 6,3 A F

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Wiring outlay for the Water Manager High Voltage, 14 left Pins 1-3 Power Supply 1: Null 2: Phase 3: Ground 4-5 Pump Power 4: L1 Phase Brown 5: Common Blue 6-8 Bleed-off Valve 6: L1 Phase permanent brown 7: L2 Phase open white 8: Common blue 9-11 Make-up Valve 9: L1 Phase permanent brown 10: L2 Phase open white

11: Common blue 12-14 Alarm 12: CO 13: NC 14: NO potential free and allows 220 Volt. Low Voltage, 28 Right Pins 1-3 Make-up Flow signal 15: + 24V 16: IN Signal 17: Gnd Ground 4-6 Bleed-off Flow signal 18: + 24V 19: 2 IN Signal 20: Gnd Ground 7-9 Recirculation Flow Signal 21: + 24 V 22: 2 IN Signal 23: 3 Gnd Ground 10-12 Water level Sensor 24: Common 25: N1 Low 26: N2 High 13-14 Conductivity EC Make-up Water 27: 1 cable brown 28: cable 2 black 15-16 Conductivity EC Recirculation Water 29: 1 cable 1 brown 30: 2 cable 2 black 17-18 Main Recirculation Magnet Upper part 31: 1 Green cable 32: 2 Yellow cable 19-20 Main Recirculation Magnet Lower Part 33: 1 White cable 34: 2 Brown cable 21-22 Make-up Magnet Upper part 35: 1 Green cable 36: 2 Yellow cable 23-24 Make-up Magnet Lower Part 37: 1 White cable 38: 2 Brown cable 25-26 Electrode Pulse 39: E1 cable 1 40: E2 cable 2 27-28 Ultra Sound outlet. 41: S5 White cable on transducer 42: S6 black cable on transducer.

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Water Manager PC Program Screen

The Water Manager PC program is installed on an ordinary PC. It is connected to a COM or USB port from the RS-485 on the right side of the board. An RS-485 converter must be used. Connection from the top pin: 1: RX-A, 2: RX-B (1 and 2 RS485 receive input) 3: Ground, 4: TX-B 5: TX-A (4 and 5 RS485 Transmit output). When running all relevant data will be displayed on the screen. Alarms are shown in flashing red. The settings may be changed from the PC screen. The PC program can be obtained from the YORK Company .

N

L1

BRN

BLU

Y/G

BR

N

BLU

Y/G

3 x

0,75

mm

L1

L2Circ.pump

P

PE

BR

N

WH

T

BLU

N F PE L1 C

Bleed-offvalve

Make-upvalve

BR

N

WH

T

BLU

L1 L2 C CL2L1 CO NC NO

BR

N

BLK

BLU

BLUBLKBRN

BLU

BLKBRN

BLUBLKBRN

BR

N

BLK

BLU

BR

N

BLK

BLU

123

123

12

3

+ IN GND + IN GND + IN GND C N1 N2 1 2 1 2 1 2

EC Recirc.

EC Make-up

Flow-sensorMake-up

Flow-sensorBleed-off

Flow-sensorRecirc.

Level sensor

EC-sensorMake-up

EC-sensorRecirc.

LevelFlow

Recirc.Flow

Bleed-offFlow

Make-upAlarmMake-upBleed-offPumpMains

3 x

0,75

mm

3 x

0,75

mm

3 x

0,75

mm

3 x

0,75

mm

3 x

0,75

mm

3 x

0,75

mm

2 x

0,75

mm

2 x

0,75

mm

1 1 12 2 2 E1 E2 ST5 ST6

MainMag. N

MainMag. S

Make-upMag. N

Make-upMag. S Electrode

Ultra-Sonic.

STR. FSCM-NR. TEGNINGSNR. REV.

MLESTOK 1:10 PAPIR 1 AF 1

Ultra-Sonic Head

Electrode

Make-upMagnet valve

MainMagnet valve

1

BR

N

BLU

Aqua-Perl Danmark ApSTlf.: +45 7022 6611 WWW.aqua-perl.dk

York Antiscale EquipmentInstallation Diagram for Water Manager

DWG Nr. 051003-001 AD. 3/10-05. by AdL

23456789

RX-B

RX-A

GND

TX-B

TX-A

RS-485

B

A

C

D

ABCD

2 x 2 x 0,22 mmShielded

123456789

USB

PC

CNV-USB-RS485

L2L3

T3 T2 T1Main

Switch

Mains

BR

N

BLK

BLU

BLUBLKBRN

BR

N

BLU

GR

N

YE

L

BR

N

WH

T

BR

N

WH

T

YEL

GR

N

4 x

0,22

mm

4 x

0,22

mm

BR

N

BLU

BLU

BR

N

BLK

WHTBLU

BRN

2 x

0,75

mm

2 x

0,75

mm

Control Box for Water-manager

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

43

44

45

4647

Pair