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EcoWater CHC Series Service And Troubleshooting Manual Download Page 107

107

Control Station Description

The Control Station has been designed to monitor and control the CHC treatment system. It utilizes a
PLC (Programmable Logic Controller) that has been programmed by EcoWater CHC to meet the
operational requirements. Its screen layout has been designed to minimize the need for customer
interaction as well as minimize confusion in screen function and layout. There are User Screens as
well as Set Up screens. The Set Up screens will be configured at the time of installation and do not
require configuration by the user, for this reason, the Set Up screens are Password protected. The
control station is integrated into the system as shown in this diagram:

F 1

F2

F 3

F4

CHC Power Switch (Optional)

CHC Phase and Overload (Optional)

CHC Pressure Switch (Optional)

CHC Vacuum Switch Optional

Filter Power Switch

Filter Phase and Overload (Optional)

Filter Pressure Switch (Optional)

Filter Back Wash Control

Filter Alarm Monitoring

Conductivity using
Toroidal Conductivity Probe

Blow Down Actuator

Communications Options (RS232, RS485,
Ethernet, Phone Modem, Cell Modem,
Modbus)

Micro SD Memory Card

Alarm Indicator

Alarm Tracking

PLC Basic Specifications

The Control Station operates on 24 Volt DC Power
The Input signals are required to be 20-24 Volt DC
The Outputs utilize relay contacts and can handle up to 120V, 2A power control for each
The display is a monochromatic 3 ½” LCD that is direct sunlight readable.
The operational temperature range for the product exceeds our CHC system specifications.
PLC Make- Horner APG XLT, model number- XE-XT102AB. (

www.heapg.com

)

Refer to the Electrical Schematic for wiring specifications.
There are several Communication Options, refer to EcoWater CHC Service Department for more
information.

Mounting

The Control Station must be mounted in an appropriately rated enclosure. This enclosure could include
a motor starter box or could be enclosed in a separate box to the side. The front panel is rated for
Nema 4X (IP65) use. Please refer to the PLC’s Manual for further specifications.

Summary of Contents for CHC Series

Page 1: ...Basics of Service and Troubleshooting ...

Page 2: ...nformation held herein will grow and be modified with each new understanding of system design that is made This information is not for use as customer documentation and should not be modified as such without the written permission of EcoWater CHC Schertz Texas EcoWater CHC Systems 5850 Corridor Parkway Schertz TX 78154 www ecowaterchc com ...

Page 3: ... ON but No pump operation 45 5 1 3 The skid s pump will not maintain power when your release the ON push button Older cabinet style CHC only 46 5 1 4 The skid s pump will not maintain power when your release the ON push button Older cabinet style CHC only Error Bookmark not defined 5 1 5 The skid s pump pops breakers fuses or thermal overloads frequently 46 5 1 6 Indicator lights are non functiona...

Page 4: ...6 CHC Control Station 64 5 7 CHC Control Station Messages 65 5 7 1 No Filter Backwash BW Failure shown on Control Panel s screen 65 5 7 2 Screen Cleaning Required Message 65 5 7 3 Control Panel Message of Power OFF 66 5 7 4 Control Panel Message of Pressure LO 66 5 7 5 Control Panel Message of Power Failure 66 5 7 6 Control Panel Message of Conductivity HI 66 5 7 7 Control Panel Message of Conduct...

Page 5: ... 3 Timed Power ON OFF Cycling of CHC Treatment 85 6 4 Separator Purge Timer 86 6 5 Freeze Protection Options 87 6 6 Monthly Service Procedure 89 6 7 CYCLES OF CONCENTRATION 92 6 8 Basic Water Chemistry and Understanding the Water Analysis Results 94 6 9 INSTALLATION CERTIFICATE 100 6 10 Water Sampling Instructions 101 6 11 Dip Slide Testing 102 6 12 CSR Form Blank 103 6 13 Procedure for Chemical P...

Page 6: ... on any items found within this skid Servicing of equipment should be completed only in a well ventilated area Most Items located on the skid are Very Heavy Use all appropriate lifting methods and safety precautions while lifting or moving items In case of Fire use appropriate notification methods of local fire departments and facility personnel Turn OFF all power sources immediately DO NOT operat...

Page 7: ...tion valves found on either side of the basket strainer 3 Close the Isolation valves found on the towers if necessary Shutting Down the Filtration Systems upon EMERGENCY 1 Turn the power disconnect OFF on the Filtration Motor Controller Verify the pump has stopped operation look for motor rotation and loss of pressure on gauge 2 Close one of the Isolation valves found on either side of the basket ...

Page 8: ...omated filtration systems added to some CHC offerings These automated systems require appropriate sizing And utilize a screen to capture the debris from the filtration water flow An automated screen cleaning regime is used to clean debris from the screen and flush it to waste We utilized the M100 Filtomat filters and you can learn more from www amiad com or from the appropriate Service Manuals App...

Page 9: ... is a growth of Biological material on surfaces within a system This could include a growth of algae or other films on surfaces that could decrease the efficiency of the system as well as harbor other detrimental bacterial growths like Legionella In many cases a Dispersant must be used to dislodge this film to allow it to be destroyed by the CHC treatment or biocides Blow Down Blow Down is the wat...

Page 10: ... are costly and must be maintained continuously From making sure chemicals are on site at all times to making sure that bacteria does not become resistant to the treatment Chemical treatment regimens must be continuously monitored and adjusted for the changing conditions It is this service that makes most customers loyal to chemical systems while it is also the need for this service that make most...

Page 11: ...omer s site In most cases the customer will be given a copy of this report at the time of service The report is then completed with any appropriate test results Dip Slide Test any appropriate comments and then sent to EcoWater CHC at the end of the week for processing A Service Order will be completed at EcoWater that will include any Water Analysis results and recommendations for continued servic...

Page 12: ... and a fan to move the air The condensers can be used wet with water or dry no water normally only used in the winter time dry Flow Meter CHC has utilized a flow meter to aid in the flow setting through the corrosion rack The normal flow that we try to achieve is 5 to 8 GPM The flow meters are made by Blue and White You must test the flow meter with different flows to verify that the bobbin moves ...

Page 13: ...il by rainwater It contributes to the total hardness but is generally present at much lower levels than Ca Magnesium hardness is a calculated number based on measured total hardness and calcium hardness Magnesium hardness Total hardness Calcium hardness Make Up Water This is the water that is used to refresh the system water Make Up can come from city water reclaimed water well water defrost water...

Page 14: ...by EcoWater CHC to remove lighter than water particles from the filter flow Their housings are always constructed of carbon steel and are orange in color pH The pH is a measure of acidity or alkalinity of water pH 7 is acidic pH 7 is alkaline and pH of 7 is neutral As pH increases water becomes less corrosive but the scaling tendency of some insoluble salts such as calcium carbonate and calcium ph...

Page 15: ...on and maintenance During the quarterly Maintenance the motor s amperage should be read and compared to the motor s rating You should also grease the motor with the required lubricant And clean and paint any rusty CHC system surfaces And review the condition of the towers The customer will receive a copy of the Customer Service Report for their records This service will only be conducted by a qual...

Page 16: ...ttom of a tower s basin towards the suction manifold When ordering a replacement sweeper jet it is very important to replace it with the same GPM flow If you do not recognize the size measure the length as well as the connection size for reference when calling for a replacement Thermal Overload The thermal overload is connected to the motor contactor and its job is to monitor the continuous ampera...

Page 17: ...sformer that creates 120V from the 480 Volt supply Older Older cabinet style CHC units utilize a 50VA transformer that creates 24VAC from the 480 Volt supply Turbo Disks Verify similar to ZGF systems these automated filtration systems also strain out debris from the filtration water flow They also conduct automated back washes to remove debris from the filtration disks Uses of the CHC Technology T...

Page 18: ...ack wash to pass the debris towards the drain Most ZGF systems require at least 115 TDH pumps to guarantee adequate flow force for back washing For more information go to www ZeroGravityFilters com EcoWater CHC has used the Easy Clean single or double element systems Phoenix set of 6 elements they also come in a dual Phoenix systems and the S 2000 units ...

Page 19: ...C Refer to the CHC web site www ecowaterchc com for more information regarding the CHC chamber s configuration and the technology behind its operation Filtration System As water is drawn in from the basin it passes through the main suction pipe and passes through the basket strainer The basket strainer is designed to remove any large particles from the water before the water passes to the pump Iso...

Page 20: ... side and encased in a plastic sheath The controller supplies a high frequency reference voltage to the first toroid or drive coil which generates a strong magnetic field As the liquid containing conductive ions passes thru the hole of the sensor it acts as a one turn secondary winding The passage of this fluid then induces a current proportional to the voltage induced by the magnetic field The co...

Page 21: ...ions surrounding a thin walled glass bulb at its tip The probe produces a small voltage about 0 06 volt per pH unit that is measured and displayed as pH units by the CHC Control Station CHCCS The pH probe is a combination electrode which combines both the glass and reference electrodes into one body It is important that this probe be clean and calibrated at regular intervals please refer to the ap...

Page 22: ...sure Suspended matter is removed from the sump basin via a second side stream loop designed to sweep the debris from the floor of the sump into the automatic filter or centrifugal separator The filter is automatically backwashed to remove solid matter on a timed basis and is then sent to waste Biological Control CHC technology is in sharp contrast to chlorine or bromine treatments that degrade ove...

Page 23: ... a piping system can also cause corrosion by providing an environment in which physical and chemical interactions can occur Several types of system level problems can occur if cooling water systems are left untreated A major source of corrosion is the addition of the bio inhibiting chemicals themselves This is true especially when shocking is required as chemicals lose effectiveness over time and ...

Page 24: ...any training and or safety instructions that may pertain to your work You must follow these instructions at all times and are required to contact your supervisor if any safety requirements are not understood or you will have any problems performing them EcoWater CHC has a Safety Board located in the Hallway to manufacturing for those personnel working within our facility This location includes the...

Page 25: ...t allowed to do any work at a site without the customer being aware of your presence at their facility 8 All PPE must be up to date and inspected before use do not assume that its protection and or function is adequate and safe This includes any customer supplied PPE 9 You must utilize the PPE as instructed 10 You must notify the customer of any possible Hot Work and or use of Hazardous materials ...

Page 26: ...irements that must be used Respirators face shields protective clothing and gloves MAY BE REQUIRED AND MUST be used if recommended by the MSDS sheet or by EcoWater NEVER assume you will be alright ALWAY protect yourself use the prescribed PPE If you will be working on a ladder or scaffolding higher than 10 feet you must work with another person and you must follow tie off rules and use a safety ha...

Page 27: ...L NOT do any electrical work on live circuits You must verify loss of power through the use of a hand held Multi Meter and or verified electrical tester before any work on existing wiring or components is conducted You WILL use Lock Out Tag Out procedures when working on electrical systems within the CHC skid You WILL inspect your test equipment before use You WILL NOT use any test equipment with ...

Page 28: ... your work is being conducted in then you must use someone to monitor the sparks in their entirety until cool on the other side of the obstruction Prevention is always easier than correction of problems created due to Hot Work This includes understanding that any material you will be working on may be hot and could cause other problems as it falls off your work Hot Work Requirements 1 Customer Not...

Page 29: ...dentify the type and magnitude of the energy that the machine or equipment utilizes shall understand the hazards of the energy and shall know the methods to control the energy 3 If the machine or equipment is operating shut it down by the normal stopping procedure depress the stop button open switch close valve etc 4 De activate the energy isolating device s so that the machine or equipment is iso...

Page 30: ...occur in a tank or sump due to the lack of oxygen or inhalation of other harmful gasses or loss of limb or life do not occur due to coming in contact with a moving object Always consult with a customer when entering a confined space and in most cases it will require someone to monitor you from a safe distance during your entry When entering a tank or sump gasses can build up that are harmful to yo...

Page 31: ...mer whenever combustibles may be used Prevention is always easier than correction of problems created due to the inappropriate use of combustibles Hot Work Requirements 1 Customer Notification 2 Locate Fire Alarms and Evacuation Routes 3 Identify Combustibles in an appropriate manner and container 4 Move an appropriate Fire Extinguisher into your work area 5 Control any Combustibles in methods as ...

Page 32: ...s in an appropriate manner and container 5 Move an appropriate Fire Extinguisher into your work area 6 Control any Corrosives in methods as defined on their MSDS 7 Use your PPE 8 Use appropriate ventilation 9 DO NOT use corrosives in manners that are not described on the MSDS 10 Ask Customer about any specialized permits needed for disposal 11 Corrosives must be neutralized before disposal 12 Flus...

Page 33: ... extinguisher to aid in your removal from the area Make sure the fire alarm has been sounded and evacuate to the appropriate location as specified by the customer 4 If you ever have to evacuate locate the customer representative who is responsible for you and check in to make sure they know you have made it out of the building 5 Dispose of the extinguisher as instructed by the Customer Contact Eco...

Page 34: ...d lead will go onto the power or wire or terminal The Display must show the DC Voltage indicator Uses can include measuring the voltage of a battery or DC power supply or a DC control voltage or Analog transmitter signal Voltage AC VAC or V Uses the Probes to measure alternating current voltages The black or red probes must be placed on the powers or power and neutral or power and ground to measur...

Page 35: ... probe s connections and then use one hand with the other probe Never connect the AC Amp Clip to a powered circuit always remove power connect the clip and then turn the power on to measure amperage Never use a DC Amp meter function to measure AC amperage Always replace batteries and fuses with those specified by the manufacturer If your DVM gets wet DO NOT USE IT It is important that you understa...

Page 36: ...36 ...

Page 37: ...37 ...

Page 38: ...The checker can be held in one hand and as it comes close to an AC voltage it will light up and sounds a beep if the checker has that function Safely Using the Voltage Checker Never use any checker that is damaged Never check for voltages if it is raining or you are standing in water Always verify if your checker is good by verifying against a known AC power source Never use both hands to check fo...

Page 39: ...ibrated before you try to use it in front of a customer Safely Using the Conductivity Pocket Tester Always clean and calibrate your tester each week against a new One Shot calibration solution Always verify units of measure when using to validate a Conductivity monitor s values Always rinse your tester before submerging it in the water you want to test Never use your meter to test Acid or Strong B...

Page 40: ...er gel if the gel is no longer clear Apply gel to the pipe being tested before you apply the sensor Apply the sensor onto the pipe in a manner that lines up the sensor as instructed in the manual the sensor must be lined up on the pipe according to the direction of the flow within the pipe Never place the sensor on a pipe directly after a turn in flow or restriction of any type this can cause turb...

Page 41: ... MSDS sheet or by EcoWater NEVER assume you will be alright ALWAY protect yourself use the prescribed PPE If you will be working on a ladder or scaffolding higher than 10 feet you must work with another person and you must follow tie off rules and use a safety harness If you do not have one one will be provided for you or one can be purchased for your use Verify that the specifications meet your i...

Page 42: ...nce where the unexpected energization or start up of the machine or equipment or release of stored energy could cause injury All employees are required to comply with the restrictions and limitations imposed upon them during the use of lockout The authorized employees are required to perform the lockout in accordance with this procedure All employees upon observing a machine or piece of equipment ...

Page 43: ...he machine or equipment is now locked out Restoring Equipment to Service When the servicing or maintenance is completed and the machine or equipment is ready to return to normal operating condition the following steps shall be taken 1 Check the machine or equipment and the immediate area around the machine to ensure that nonessential items have been removed and that the machine or equipment compon...

Page 44: ...tor starter is turned ON that power is available at the outlet terminals of the power disconnect If there is no power at the outlet terminals must be on all three replace the power disconnect 5 If power is available at the outlet terminals of the power disconnect then verify that power is available through the main fuses If power is not available through the fuses replace the fuses and verify oper...

Page 45: ... coming into the motor starter are live It also indicates that the corresponding fuses transformer and power breakers are still OK 2 Verify that the Thermal Overload is not tripped simply press the Reset button to verify If the thermal overload was tripped go to step 8 3 Verify that power is available at the motor starter on all three legs Open the motor starter and with the DVM Digital Volt Meter...

Page 46: ...released 2 Check to see if the vacuum switch has been rewired if it has a blue and brown wire will be wire nutted together in the motor starter If these wires are not connected with the wire nut contact EcoWater CHC Service for the upgrade procedure 5 1 4 The skid s pump pops breakers fuses or thermal overloads frequently 1 Verify that the pump motor s amperage is within the specified FLA as shown...

Page 47: ...ace the indicator with an appropriate matched bulb or LED Be aware that some of the older CHC Older cabinet style units utilize a 24V AC bulb it must be replaced with a like product 2 Always make sure that the plastic cap covering the bulb is not cracked broken or its seal is defective if water or rain gets onto a bulb it will cause the bulb to fail so replace any defective parts found 3 If there ...

Page 48: ...C is available at the Control Station but the display will not respond replace the Control Station To replace the unit disconnect all wire terminals from the unit and then remove the four mounts from each corner of the controller and remove it from the panel Once the new controller has been installed reconnect all terminals and test 4 Contact EcoWater CHC Service if further assistance is needed 5 ...

Page 49: ...the bottom If the pressure remains low verify that the isolation valves around the pump as well as the towers are open If the pump appears to be cavitating verify that there is no o ring or seal failures in the pump suction line If air is ingested the pump pressure could be low If the pressure remains low verify that no blockage exists within the tubing to the gauge If the pressure remains low reb...

Page 50: ... gauge may be the source of the vacuum leak If the gauge has the valve on the back of it simply close off the valve during operation of the CHC skid and then turn off the power to the pump if the reading remains constant then the gauge is not leaking however if the pressure decreases quickly the gauge or valve will required replacement b Blocked tubing To verify if the tubing is blocked first turn...

Page 51: ...valve or Sweeper jets to maintain this operational pressure 5 3 1 Gauge Problems If the gauge is reading high or low turn off all power to the device the gauge is connected to and allow the pressure to stabilize The gauge should return to 0 psi If it does not open the vent at the top of the gauge and allow it to return to 0 psi this may take several minutes If the pressure still remains above or b...

Page 52: ...tors require at least 4 psi differential pressures between the inlet and outlet pressures If the pressures are too low 4 psi verify that there is no obstruction to the flow of the sweeper nozzles this can also be seen by having a closed valve on the discharge of the filter If the differential pressures are to high normally seen in an automated filtration system including Filtomat ZGF and Turbo dis...

Page 53: ...own stream of the filter The ZGF requires 45 psi outlet pressure under normal conditions the Turbo disc requires minimally 32 psi outlet pressure and the Filtomat requires minimally 35 psi ZGF Filters Refer to the appropriate service manual but here are a few thing to look for d Air is required on the majority of the ZGF units It requires minimally 80 psi to operate the system Make sure that air i...

Page 54: ... large debris in this are that can keep the valve from turning k Phoenix Control PLCs If you have a TECO controller it has been modified from the original ZGF controller The Teco controller will indicate that a BACK WASH FAILURE has occurred you will need to verify the appropriate steps if this message appears You could also find a SCREEN CLEANING REQUIRED message This message indicates that great...

Page 55: ...s only one switch is used so upon a failure of the DP switch you can utilize the spare switch to repair the system On newer Filtomat and Orival systems you will notice that both switches are utilized In this case you must replace the DP switch if it fails To adjust the set points of the DP Switch utilize the supplied allen wrench to loosen the screw on the switch slider move the switch towards the...

Page 56: ...ing the timer settings d If a separator is clogging frequently decrease the OFF time and increase the ON time One example may be moving the ON time from 18 seconds to 24 seconds and the OFF time from 6 hours to 4 hours Trial the new settings for a month to see if the clogging has ceased Make further adjustments as needed e Other Separators utilize a continuous drain flow through a bag filter back ...

Page 57: ...close the valve and return to normal operation b There are two possible sites for gauges on a Bag filter housing make sure any gauges that are installed are functional If the gauge is ported into the housing above the top of the filter bag its pressure will rise as the bag blinds off If the gauge is ported into the housing below the top ring of the bag its pressure will fall as the bag blinds off ...

Page 58: ...led though the bag filter To make sure this flow requirement is met utilize an ultrasonic flow meter or only open the valve so that a 3 psi pressure drop from the discharge pressure of the centrifugal separator is seen pressure with valve open versus pressure with valve closed There are two possible sites for gauges on a cartridge filter housing make sure any gauges that are installed are function...

Page 59: ... did not flow to the pumps due to the towers being dry or the customer not opening a valve after cleaning the basket these actions can cause the pump seal to fail Replace the seal 5 Bearing failure on the pump motor if there is excessive noise coming from the pump motor during operation this can cause the movement in the shaft and can cause the seal to fail if there is excessive noise replace the ...

Page 60: ... 2 3 3 2 Close 3 4 4 3 Some of the actuators are 120 VAC while others may be 24VAC or 24VDC It is important to look at the nameplate to define what voltages you will be using for your troubleshooting Use your DVM and verify the signals coming into the actuator is the signal is present and the valve does not open or close replace the actuated valve If your actuated valve is operated by 24 VDC Then ...

Page 61: ...strainer is not clogged If you have good water flow but not through the solenoid then most likely the solenoid is clogged Clean or replace it 5 5 4 Stuck Solenoid Valve If you are getting a control voltage to the coil and the valve appears to not open then this could signal a clog of debris in the valve itself You will need to open the valve and clean it or replace it to fix the problem If a solen...

Page 62: ...r Conductivity Reference found within this manual before you clean a probe Some probes can only be cleaned in one direction 5 6 2 Bleed Set Point The Bleed Set Point has been chosen ahead of time and will not reflect the current COC This set point has been chosen against the worst case water analysis given for that customer DO NOT adjust it each time to control the COC If water quality is better t...

Page 63: ... to the Bleed Relay The Webmaster unit requires programming via a USB cable to set the configuration of the Bleed Relay Most Walchem units are wired directly into the 120V relay found in the motor controller that will remove the control of the blow down actuator away from the Timer The 120 Volt signal from the NO Bleed relay in the controller passes directly to the coil on the relay found in the m...

Page 64: ...n the actuator 5 6 6 CHC Control Station The newer CHC skids utilize the CHC Control Station to monitor the conductivity of the system and control the blow down valve It utilizes a toroidal sensor that needs to be verified each month as well as cleaned at least once every quarter If the conductivity probe fails the conductivity reading will indicate 0 or 32000 You can use the hidden screen to moni...

Page 65: ...he DP switch then it is possible that the switch within the DP switch has failed With a volt meter verify that the switches within the DP switch are closed during operation this requires the DP switch gauge to be indicating over 8 psi If power is not applied to the skid the pressure will be reduced and each DP switch should be open as tested with a conductivity meter Transducer Failure If the filt...

Page 66: ...itiate the pump again If the pump fails to start contact the appropriate personnel to verify the power phases as well as monitor the motor s amperage In many cases problems with the power system due to weather may cause the thermal overload to fail if resetting the overload works please verify the pump motor s amperage if it is within range monitor the function of the system to see if the failure ...

Page 67: ...d Please verify the operation of the blow down valves and filter back wash functions This message could also be shown if low load conditions with the water system are occurring as in winter if the load to the system is too low the conductivity of the water system may not cycle up to the appropriate COC levels This message may continue until the load increases on the water system Monitor the system...

Page 68: ...ct the appropriate personnel to make corrections to plumbing 5 8 4 Valve Leaks or Failure Contact the appropriate personnel to make corrections to plumbing 5 8 5 Internal Valve Leaks In some cases you may find that the blow down actuator has a continuous leak even in the closed position If you find this you will need to replace the blow down valve 5 8 6 Vacuum Leaks Vacuum leaks on the CHC system ...

Page 69: ...amber and removed by filtration CHC has some experience with an Ultrasonic Algae killing systems as well as Copper Silver Ionizers If you are interested about this system contact EcoWater CHC Service for further information 5 9 2 Biofilms This is not a failure The CHC system can only treat water borne growths it cannot treat films growing in the piping or on other surfaces The use of a Biodispersa...

Page 70: ... pump pressure plugged nozzle and or too much back pressure on the chamber c Back Pressure too high or too low Back pressure must only be 2 5 psi if it is too low or too high make sure to adjust d Alignment of Nozzles As the water enters the end bells it should not enter one of the nozzle s channels directly It should however pass directly to the blank area between two channels This verification r...

Page 71: ...nts EcoWater also recommends that a submerged probe is not placed into the tower these types of applications can also give an erroneous measurement value causing cycles to climb c Suction piping too close to Make Up water distribution If the suction piping is too close to the Make Up water s valve you can get a conductivity reading that is diluted with the lower Make Up water s conductivity This w...

Page 72: ...ll deposit in the fill It is important that if the system is cycled frequently that the fans be left on for a period of a few minutes to draw any remaining water from the fill there by decreasing any possible formation of this type of scale 4 Restricted suction piping If the suction piping has become clogged with debris its ability to pass water to the pump is diminished Cleaning or replacement of...

Page 73: ...s not placed into the tower these types of applications can also give an erroneous measurement valve causing cycles to climb c Suction piping too close to Make Up water distribution If the suction piping is too close to the Make Up water s valve you can get a conductivity reading that is diluted with the lower Make Up water s conductivity This will cause the actual tower water s conductivity not t...

Page 74: ... with a pressure washer under normal tower cleaning If Ingestion Scale is found the use of alternate types of filtration may be warranted Examples of Ingestion Scale forming material Concrete dust sand dirt as well as other airborne debris 5 10 5 Overspray Scale Overspray Scale is normal if overspray reaches areas where there is not adequate water flow to keep the surface clean This light misting ...

Page 75: ...s because of the high evaporation rate at this leading edge and the diminished flow that is normally found at this area of the fill as well This type of scale is normally very soft and can be removed with a manual spray nozzle cleaning as needed Example Pictures Soft Sandy Scale buildup Mud like buildup of Soft Scale ...

Page 76: ...76 Soft Scale that is granular but hard from basin Soft Scale from tubes that is very granular ...

Page 77: ...77 Hard Scale from tubes that is hard like Glass ...

Page 78: ...ERENCES The references attached to this document represent the specific CHC products and the literature prepared by CHC all other reference material including service manuals are included on this CD for your use ...

Page 79: ...ble from EcoWater CHC include the following Aluminum Galvanized Mild Steel Mild Steel Copper Stainless Steel Scale Coupon EcoWater will supply Maintenance Agreement customers with two sets of coupons per year The normal coupon selection depends upon the tower type and its use Examples If a customer has an Evaporative Condenser with a Galvanized basin EcoWater CHC will supply a Scale coupon and a M...

Page 80: ... in a vertical position Do not place the orientation of the coupon in a horizontal position if horizontal the coupon can act like a shelf and support debris that maybe detrimental to your test results 9 Secure the holder into place by tightening the holder nut 10 Open the rack s isolation valves 11 Verify that the flow across the coupons is between five and eight GPM as shown on the flow meter 12 ...

Page 81: ... Adjust the flow meter until the five to eight GPM flow rate is achieved 12 Return the coupons to EcoWater CHC for examination and analysis 13 A report will be generated and returned to you with the results ...

Page 82: ...82 6 2 Conductivity Controllers Walchem and LMI ...

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Page 84: ...84 ...

Page 85: ...nsulated and heat taped the CHC systems can use a similar approach Other customers may not need to utilize this approach if they currently drain their systems during the winter and leave our systems Off anyway If the customer stops the CHC and Filtration systems and does not have them winterized or drained the system may freeze and could possibly destroy gauges pipes strainers and even pumps So we...

Page 86: ... with 1 on D representing 1 hour and 10 representing 10 representing 10 hours So if you want 3 hours OFF time you will need to adjust C to 1 10h and D to 3 As long as you remember that the white dial above the blue dial sets the range of the blue dial and you carefully set the white dial you can adjust the timer s ON and OFF times The rate of Flashing of the indicator E represents the status of th...

Page 87: ...s loss of power if power is lost or the pump fails water stops to flow within the system and freeze damage can occur If the pump fails for any reason or power is lost the customer must become aware of the failure and then take action to isolate and drain the piping to ensure against freeze damage b AS IS from factory with uninterrupted power This level although cost effective also has several disa...

Page 88: ...nded periods Heat Tracing and Insulation also requires for the piping of the skid itself to be protected c Upgraded at Factory with Heated Skid Housings This level utilizes a heated skid housing that protects the piping within the skid upon pump failure The design of the skid will be modified to internalize the Flow Meter Conductivity probe and Corrosion Coupon Rack It requires the use of Heat Tra...

Page 89: ...teps to be taken during a Mechanical visit are shown in Blue Steps to be taken during a Quarterly Service are shown in Green Steps to be taken on every visit are shown in Black Make sure the customer end user understands the Service offering and their responsibilities PM s o Define the customers care requirements PM s o Define the outlay of information and reports from EcoWater CHC o Initiate chai...

Page 90: ...tor gauges transducer display returns to zero 17 Verify that the Auto Filter gauges transducer display returns to zero 18 Turn off main power disconnect COMBO 19 Turn off main power disconnect to the CHC Chamber and Filter pumps 20 Open the Motor Starter box MECHANICAL 21 Check all electrical connections MECHANICAL 22 Grease Pump s MECHANICAL 23 Cycle all Butterfly and Ball Valves 24 Valve off the...

Page 91: ... to be taken from each sump sample and results recorded and reported to EcoWater CHC after 48 hours a All results greater than 10 000 need to be photographed and submitted to EcoWater CHC 53 2nd Verification that all valves are in their normal operating position 54 Touch up painting of EcoWater CHC and Filtration components MECHANICAL FSA 55 Repeat the above for Filtration Systems 2 and 3 if appli...

Page 92: ...uents in makeup will still be in basin water The evaporation is the only source for changes in concentration This is true for systems with a successful chemical treatment But for water treated by CHC parts of the dissolved calcium and bicarbonate are transformed into calcium carbonate solids TDS is only good for estimating the cycles EcoWater CHC recommends the use of chloride concentrations to ca...

Page 93: ...on Sulfate 10 ppm as ion The TDS of this water is 89 ppm When using chemical treatment at a cycles of 3 the water chemistry will be like this Calcium 300 ppm as CaCO3 Magnesium 90 ppm as CaCO3 Sodium 21 ppm as ion Bicarbonate 300 ppm as CaCO3 Chloride 75 ppm as ion Sulfate 30 ppm as ion So everything is increased 3 times including TDS TDS 267 ppm However when one uses CHC treatment some Calcium an...

Page 94: ...e terms shown in that analysis you can make sense of your water analysis Example of Water Analysis provided by EcoWater CHC A standard water analysis includes pH alkalinity total hardness calcium hardness magnesium hardness chloride TDS conductivity cycles of concentration and bacteria population Other analyses such as silica zinc copper iron are also performed for some cases ...

Page 95: ... 10 0 0000000001 0 0001 Baking soda Alkaline 11 0 0000000000 1 0 001 Milk of magnesia 12 0 0000000000 01 0 01 Ammonia 13 0 0000000000 001 0 1 Chlorine bleach 14 0 0000000000 001 1 Lye Alkalinity Alk Alkalinity is a measurement of the buffering capability of water with the addition of acid With the addition a certain amount of acid pH can lower dramatically for water with low alkalinity but pH only...

Page 96: ...rs are generally considered to be those waters that require considerable amounts of soap to produce a foam or lather and that also produce scale in hot water pipes heaters boilers and other units in which temperature of water is increased materially The hardness of water varies considerably from place to place In general surface waters are softer than ground waters The hardness of water reflects t...

Page 97: ...H conditions that develop basic materials particularly limestone formations are dissolved The Figure below shows where this originates and how it attacks carbonate minerals Since limestone is not pure carbonate but includes impurities such as sulfates chlorides and silicates these materials become exposed to the solvent action of water as the carbonates are dissolved and they pass into solution to...

Page 98: ... water systems are very susceptible to corrosion Keeping surfaces clean is the most important aspect of preventing corrosion since under deposit corrosion can take place and result in serious damage Corrosion can be uniformly distributed throughout the system or it can be localized causing severe pitting and rapid equipment failure There are various corrosion inhibitors used in chemical treatment ...

Page 99: ...2 Changes in makeup water chemistry This is usually caused by changes in the source of makeup water Well water ground water is generally quite stable for each well but could change significantly from other wells nearby Surface water changes with seasons Some cities use a combination of different water sources for municipal water 3 Changes in hardness and alkalinity in makeup water will changes the...

Page 100: ...vered and that this Equipment has been accepted by the undersigned and is now operational DESCRIPTION Unit Serial Chamber Serial Equipment Located at In the City of County of State of Company Name INSTALLATION INFORMATION Subcontractor Information Plumbing Installation Contractor Telephone Date Electrical Contractor if applicable Telephone Date Operational Information Date System Operational Custo...

Page 101: ...101 6 10 Water Sampling Instructions ...

Page 102: ...HE TEST STRIP TO TOUCH ANYTHING AT THIS POINT 5 Place the test strip into the supplied zip lock bag 6 Label the bag with location sump and date 7 Place the test strip in a location out of direct sunlight for a period of 48 hours This location must have a stable temperature in the range of 77 95 degrees F 8 After 48 hours compare test strip to the results comparison page supplied with the Dip Strip...

Page 103: ...he make up water Consult the Walchem manual on how to set these parameters Prior to starting the passivation process we recommend you blow down the system to well below the conductivity set point so when you start adding chemicals they do not immediately trigger a blowdown Pictures of the tubes condenser or basin cooling tower should be taken prior to passivation and then again after The process i...

Page 104: ...ictures of the same locations as the before pictures Some helpful points 1 Mark the chemical level in the drum by time every so often in order to gauge how much material you are using on a daily basis The process should take 3 5 days so if you are over feeding you may run out of chemical too quickly 2 It is okay to overdose with the 6035 better to overdose than under dose It is not okay to get the...

Page 105: ...05 6 14 CHC Control Station Manual CHC Control Station Technical Manual F1 F2 F3 F4 Monitor Control Station SET UP LOG M ain Version 2A For Distribution to EcoWater CHC Representatives only 7 12 14 Rev C ...

Page 106: ...al application of the CHC Control Station This manual is not intended as a supplement to the Operation Service Manual and should not be released for customer use If the customer has purchased the system and they request information that is shown herein please request the appropriate documentation from EcoWater CHC Service Department ...

Page 107: ...sh Control Filter Alarm Monitoring Conductivity using Toroidal Conductivity Probe Blow Down Actuator Communications Options RS232 RS485 Ethernet Phone Modem Cell Modem Modbus Micro SD Memory Card Alarm Indicator Alarm Tracking PLC Basic Specifications The Control Station operates on 24 Volt DC Power The Input signals are required to be 20 24 Volt DC The Outputs utilize relay contacts and can handl...

Page 108: ... the filter The filter control interfaces with a differential pressure switch DP as well as the back flush solenoids to aid in the control and monitoring of the filter Pump Monitoring The control station can be configured to monitor the power system of the pump this includes the power status of the pump its thermal overload condition as well as monitor the Power Phase condition of incoming power T...

Page 109: ...m screen basic controls of system functions can be changed The functions include Changing the Date and Time Adjusting the Screen Contrast Memory Card Deleting and Formatting and Program uploads from memory card used for updating program ...

Page 110: ...software there are USER screens as well as SET UP or SYSTEM screens All SET UP and SYSTEM screens are protected by passwords and EcoWater CHC recommends that the user is only made aware of those passwords that are appropriate to them That means that if the customer is a Full Service Agreement FSA customer they should only be made aware of the pass words for resetting the User Defaults and that NOT...

Page 111: ...111 ...

Page 112: ...ected The System Screen allows the user to change the date time start and stop the program etc To continue to the Pass Word Screen you must go back to the initial screen and then enter into the Set Up screens This screen appears when the customer tries to enter the System or Set UP Screens By pressing the box an alpha numeric key pad will be shown to allow for input of CODE Once the code is entere...

Page 113: ... will appear as shown FILTER area Within the filter area if the systems are operating within specification the OK will appear If an alarm is active the filter will be shown to the right of the FILTER label and its corresponding Alarm will be shown in this example PUMP OFF is indicated The current Back Wash Counts for each filter are also shown if only one filter is selected only its Back Wash Coun...

Page 114: ...he known conductivity value into the NEW box They can incrementally increase or decrease the value with the UP and Down buttons or they can press the New box on the screen to insert the value directly with a numeric key pad that will appear Once the New value has been selected the SAVE F2 key can be pressed to insert the new value into the calibration scaling of the conductivity probe This screen ...

Page 115: ...115 Help Screen If the HELP soft key is pressed on the Main screen the HELP Screen will be shown The phone number shown on this screen can be installed in the Set Up screens ...

Page 116: ...an change the contrast of the LCD as well as the Removable Media Setting that allows you to format save or Update the systems software with the use of the Micro SD card Contact EcoWater CHC Service for more information if needed about the System This screen automatically appears if you select any of the boxes on the screens that require an input Bleed Set Point Passcode Help Set Up Controller Set ...

Page 117: ...ation s Face plate 3 Turn the Power back ON 4 Once the Initial screen appears Press the Set UP soft key or F2 hard keys 5 The Password screen will appear and enter 5850 into the passcode area 6 Press the Enter soft key or F3 7 The Set Up Screen 1 Select Language screen will appear 8 From this screen and this screen only press the F2 hard key It is not labeled on the screen but it will allow you to...

Page 118: ...If any problems occur or the system does not start operating with the Initiation screen call EcoWater CHC Service for help The software was designed to check its own Check Sum upon power on and if the Check Sum of the running program does not match the stored program the unit will indicate this failure with a CRC Error 17 Once the software is loaded all settings will need to be verified in the Use...

Page 119: ... 24 VDC Signal I3 CHC Pressure CHC Pressure Input 24 VDC Signal I4 Filter Pressure Filter Pressure Input 24 VDC Signal I5 Filter Electrical Filter Electrical Failure Input 24 VDC Signal I6 CHC Electrical CHC Electrical Failure Input 24 VDC Signal I7 Filt 1 BW High Filter 1 BW switch high Input 24 VDC Signal I8 Filt 1 BW Low Filter 1 BW switch low Input 24 VDC Signal H1 Filt 2 BW High Filter 2 BW s...

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Page 121: ...121 Eco Water CHC ...

Page 122: ...122 6 15 Electrical Schematics EcoWater CHC ...

Page 123: ...123 CHC EcoWater CHC CHC CHC ...

Page 124: ...124 EcoWater CHC ...

Page 125: ...125 EcoWater CHC ...

Page 126: ...126 EcoWater C HC ...

Page 127: ...127 CHC ...

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Page 129: ... 1 4 Elbow 3 8 x 1 4 Reducer 3 8 Coupling Hex Bushing 3 8 x 3 8 Elbow Center Weldment Lg Groove Lock Clamp w seal Old Endbell Grommet Brass Nut Endcap Nozzle Nozzle O rings Hex Head Bolts VacTube VacTube O rings New Endbell Sm Groove Lock Clamp w seal Discharge Entry Port in Red ...

Page 130: ...C operation manual example Corrosion Coupon Analysis Walchem Conductivity meter s operation manuals ZGF Manuals all Filtomat Manuals all Turbo Disk looking for Forsta Manual Spears Manual MSDS sheets for Rydlyme D5 and Micronice Spray nozzle worksheet Power schematics DP switch procedure ...

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