e.s.t User Manual - Water Treatment Asia
Contents
1. 6 e Tank n O e Tank Internals and Accessories e Electrical and Control Systems mn s can 6 Components of the EST System is svcsscosoncnssncnavercaanensnnaamannnussinmenaneteenauenneunaohanmamnebomanenatcunene A Peripheral Systems 090909999009009090000009000009099000900909000009000000000009000000090090000099000090000090000000000900000000000000900000090000090909000000900000000000099000090090900000990000090900009099009009 Installation Procedure 9 90909090000090000090090009000000900900000900009099009000000000009000000900000909000009000900000900000909000000900000900000000909000009000000000900090000000000000009000009000900000000000099009 YONA oiii E A EEE AEE EA E EES EE EEEE AE EEE EEE A E AEE A E N e Operating Principle TT e Operating monitoring and control a i e Operation Procedure sm tua RE tUm mi e Monitoring EST Operation e A ERR E e Power Supply Panel s MEER 13 EE SUN Parameters cementite neat nan 14 Electrodes oon EM BM BAM 14 Shutdown Procedure s 14 e Opening the EST Unit 14 Closing the EST IPIE een ene ee Dna BEEN 14 Dismantling the EST scraper motor oo ccc cscscsssssesssessessesssessessessecsssssssssessssusessessessesussnsessessessseneeseesseseeseeseenseseeeneeneenees 15 8 System Settings e Using the display to Sd Settings s m 16 e Fl2. ELGRESSY ENGINEERING SERVICES LTD gt M BITTE ERO LU LILL di RR Xii i Electrochemical System for Scale Removal amp Disinfection Water Treatment Motor Version About This Document The Elgressy EST unit is electrolysis equipment involving the chemical decomposition of salts by electrical current The unit has been designed and manufactured for safe operation by the user This user guide is intended for service technicians of the EST system It must be read carefully before installing and operating the unit Elgressy Engineering Services Ltd POB 132 Tel Mond 40600 ISRAEL www elgressy com ENGINEERING SERVICES LTD EST User Manual AZ E LG R ESSY 000000900009000909900000900000009900000900009000000000009090000009000009000900000090900090090900000000000099000000090000090000090090000000000000090000900000000900000009009000009090000000900000090000900090900009000000009090900009000000009000000009000009000000009090000000000000900000000900000909000000000000000090000009900009099 Contents e OW O se IS ocumen 00000999090000000990090000090909090900000000990000000099000000090990000000090009000009009090000000099900000000990900000009900000000990909909000000090909000000009900000000909000000009090900 Safety Warning s D 2 The EST System An Overview bases e SCP Optional Add on sini D 3 Technical Specifications ssssssssssee m
3. Engineering Services Ltd POB 132 Tel Mond 40600 ISRAEL www elgressy com ENGINEERING SERVICES LTD 5 Connect the electrical feed to the appropriate connections in the power supply unit For 1 phase system use connections L N E on the right side For 3 phase system connect to TB3 R S T N and the earthing to the earthing bar 6 Connect the circulation pump to the TB2 points 3 4 5 7 Operation Operating Principle The EST unit operates using the electrolysis principle Water flows through the tank continuously as electrical current flows between the cathode the tank and the anode electrodes inserted in the tank and causes the dissociation of the salts in the water into ions The cations are attracted to the tank wall while the anions are attracted to the anodes The cations include among others the calcium which is the scale builder in the water This calcium combines with carbonates present in the water and controlled scale is produced on the wall of the tank The qualities of this controlled scale prevent it from adhering firmly to the tank wall thus allowing for its scraping and flushing In some cases SCP must be added to enhance the EST effect The SCP is an electrolysis unit that releases controlled metal ions into the water These ions affect the scale in such a way that settlement of it will be prevented The operation of the EST unit is cyclic At a predetermined time the system automatically scrapes an
4. This timer is not accessible from the Interactive display but it can be accessed from the HMI This timer is normally set to 6 seconds and in most cases should not be tempered with However if itis needed the setting may be changed via the HMI Washing Cucle ILLU Flushina Time F2 Ait sec Adjusting Current and Voltage Prior to shipping voltage is set to its maximum while current settings may change according to the conductivity resistivity of the water at your site When starting the system you must check both current and voltage are adequate see below To do so press F1 on the display unit and follow the instruction on it EST User Manual AZ E LG R ESSY Elgressy Engineering Services Ltd POB 132 Tel Mond 40600 ISRAEL www elgressy com ENGINEERING SERVICES LTD Typically you will not need to adjust the voltage but only the current When starting the system the voltage will adjust itself according to the water conductivity and will be lower than 30V If the current at this stage is not at the maximum allowed by the power supply see table below it must be adjusted Increasing the current will also increase the voltage according to the mathematical equation describing the relationship between current and tension V IR where V voltage I current and R resistivity Both current and voltage should be set to the maximum possible according to your EST system ESSA 50V DC 16 or 25amp according to your site s config
5. While the EST system is working do the following e Perform a manual flush to verify the system is working properly see the section Using the display to adjust settings To activate the display press F1 The display operation is self explanatory After pressing F1 follow the instructions on the display unit for any change you wish to make Flushing the EST Unit in chapter 8 for detailed instructions e Theinlet valve has closed e The drain valve has opened A A EE es NM Elgressy Engineering Services Ltd POB 132 Tel Mond 40600 ISRAEL www elgressy com ENGINEERING SERVICES LTD 0900009000000090990000090900000900099000000909900000000000000000000090000900099000009090000009000000000900000000009000900000090000090090000000000000000000900000000090000090090000090000000000000000000000900000900000000909000009000000000000000099000009000000000900000000000009000000009000000000000009000000009000009900009099 e All timers have started counting this is shown on the HMI screen on your computer e verify that the scraper motor is revolving e Read amps and voltage for details refer to the section Monitoring EST Operation in chapter 7 It is highly recommended to measure the amps on each of the electrodes e When the system stopped flushing verify that the scraper stopped e Using the manometer on the air intake system verify that the air pressure is sufficient e The EST air intake system is equipped with an air filter which contai
6. automatic solenoid valve the air to its drain valve if air actuated must be connected to the EST s inlet valve by the air tubes so that it will drain during the EST flushing at the same time when the EST inlet valve is closed To start the SCP open its electrical panel and switch the main breaker on The SCP will start operating The current and the voltage must be adjusted Two options exist A Automatic adjustment This can be done if the a flow meter on the make up water inlet is existing and has a 4 20 ma signal In such a case the signal must be connected to a designated place in the SCP panel and automatic control over the current will be exercised B Manual adjustment 1 Open the panel to detect a potentiometer marked as Amp Adj 2 Turn the potentiometer by hand watching the 10 red leds on the panel Each led corresponding to 1amp Adjust the current to specific instructions provided to you by the manufacturer 3 Adjust the voltage to maximum using the Volt Adj button that is also located on the panel SCP Maintenance The SCP add on requires only two maintenance operations e As the anode of the SCP is a sacrificial anode dissolving slowly into the water you must verify with the manufacturer the life span of the anode Be sure to replace the anode in time A Fault indicating light on the panel gives pre warning of the anode being close to it end e f not connected to the EST s drain valves the SCP must
7. 009000000000000909009000009000009000900900900000909000000000000009000000009000090900090000090900000000000009000900000900000900000900900000900000000000000900000000000009090000090090000009000000009000009000009009200900090000000000000000000090900000000009 EST User manuel AZ E LG R ESSY Elgressy Engineering Services Ltd POB 132 Tel Mond 40600 ISRAEL www elgressy com ENGINEERING SERVICES LTD How to Use This Document This document consists of six parts The following list provides general guidelines as to how this document is organized as well as the procedures you are expected to encounter throughout your handling of the EST system Part 1 Getting to Know the EST System and Its Environment chapters 2 5 e Chapter 2 The EST System An Overview e Chapter 3 Technical Specifications e Chapter 4 Components of the EST System e Chapter 5 Peripheral Systems Part 2 Installation chapter 6 The installation process consists of seven steps e Step 1 Preparing the Installation Site e Step 2 Unpacking and Positioning the System e Step 3 Setting Up the System e Step 4 Connecting the System to Water e Step 5 Setup Electrical Connections Part 3 Operation chapters 7 9 e Step 1 Understanding the Operating Principle chapter 7 e Step 2 Activating the EST system chapters 7 and 8 This is done in two stages Stage 1 Starting The EST System e Stage 2 Adjusting System Settings e Step 3 Monitoring the EST system cha
8. 09000000000000000000000099000090000000009000000000000090000000090000000090000009000000009000009900009099 The HMI screen shows the system and its connections Also one can see on the screen all system display information The drawing also shows the circulation pump and optional dosing pump for acid dosing when the case calls for one The table on the right hand side of the screen shows e The Water Make up flow to the cooling tower m hr and the total quantity M e Inlet Calcium hardness as measure in the water at EST start up and inserted manually e EST circulation pump flow as inserted by the supplier e Next Flushing time represent the time until the next Flushing starts e pH and Conductivity as measure by electrodes where applicable When no measurement is done this display will show 000 e Power supply data as measured by the system Amps and Volts On the top of the screen there is a PARAMETERS button Clicking on this button with will open a parameter screen as shown in drawing No 4 This screen is used to adjust parameters A second button is for alarms Pushing this button will open the alarm list where active alarms are shown and where alarms can be acknowledged In addition the system is equipped with an Interactive Display unit mounted on the door of the panel This unit monitors the machine operation locally and can be used to adjust parameters and control the system Drawing 4 Parameters screen back Pa
9. ING SERVICES LTD 00000909099090009099000000000000990000090000900000000090009000009090000090009000000909000000900000000900000909000090009000009000009090000000000000000000090000000009000009009000009090000000900000090000900090900009009000000900900009000000009000000009000000000000090900000000000009000000009000009090000000090000000009000009900009099 c Put the tank gasket on its place d Put the lid with the scraper adaptor on a 150mm spacer on the tank e According to the type of electrode place the electrode gaskets in their place correctly to prevent water leaking through the electrodes connection Double check that they are indeed in place f Screw the electrodes back to place Important During the process of electrodes installation ensure the electrode s do not touch the walls of the tank or get scratched by touching any metal pieces Tip Every time you dismantle the electrodes you must replace the gaskets g Remove the spacer and slide the lid to its place making sure that the scraper adaptor fits into place If it does not fit you will not be able to close the lid Fasten the bolts around the lid Note the adaptor ties into the scraper shaft with a split piece Half of it is on the scraper shaft and the other half on the adaptor shaft h Connect to electricity Note that the direction of rotation for the motor should be clockwise Dismantling the EST scraper motor In case there is a need to fully remove the
10. an even after a long period of operation If they are not clean contact the electrode manufacturer 7 Manually clean the internal wall of the tank from any scale traced 8 Clean the scraper disc from any residue 9 Upon completion of this thorough cleaning return the cover and fasten the bolts to its place For detailed instructions refer to the section Closing the EST Unit in chapter 7 10 Re connect the EST system to the electricity and process streams 11 Start up the EST unit For detailed instructions refer to the Operating in chapter 7 09090900000909900000900900900990900090900000000000090990900000900009000909090000090909000090000009000900000900090090090090090000090000090000000000000009000000000909000000909900000000000900090000090009009009009000900000900000000000000909000000000000009090900009099000000000000000000000900900900200000900000900000000000000000000000000000 ELGRESSY ENGINEERING SERVICES LTD EST User Manual Elgressy Engineering Services Ltd POB 132 Tel Mond 40600 ISRAEL www elgressy com 10 Troubleshooting the EST EST Red Light On The red light is activated when the system or part of it fails An alarm list is available on the HMI and it will indicate the type of alarm and list the alarm cause Low Voltage Minimum voltage value is set on the parameter table in the HMI If the voltage will be lower than the set value the system will indicate a low voltage alarm The cause of such a situation may be
11. ball EST 10 1 5 air operated double acting with limit switch for inlet valve only Connections threaded to BSP Air intake Pressure reducing valve with pressure gauge connection 6 mm quick joint Air release intake valve ARI 34 Model AV 10 rated for 140psi PN 10 Solenoid Valves 24 volts for inlet and outlet pH meter Thermo lpfa PH 500 or equivalent Flow meter Arad Dalia equipped with pulse reading switch or magflow meter Electrical and Control Systems Operation 110V 60Hz for the USA 220V 50Hz for Europe China Far East Control Lambda 24V DC 3 1A Electrolysis Power Supply Lambda GEN 750 EST 25 Maximum of 30V DC 16amp or 25amp according to application EST 15 Maximum of 30V DC 16amp or 25amp according to application PLC for Automatic control SAIA PCD 3 wide area equipped with cellular modem Interactive Display Delta TO2 Electrical connection required 3ph 380V 25Amp 09090900000990000090090090099000090900009090000000090900009009000090009090900009099090000900000090009000009000009009009009000009009000090000000000090000000000000909090000990090000000000900090000090009009009009000900000900000000000000090000000000000090900000090900000000900000090900000900000900292000009000009000000000000000900000000000000 EST User Manual AZ E LG R ESSY Elgressy Engineering Services Ltd POB 132 Tel Mond 40600 ISRAEL www elgressy com ENGINEERING SERVICES LTD Elgressy Engineering Services Lt
12. be manually drained once a week Nx E E MEN Elgressy Engineering Services Ltd POB 132 Tel Mond 40600 ISRAEL www elgressy com ENGINEERING SERVICES LTD 12 Drawings Drawing 1 Parts of the EST Drawing 2 EST and SCP water connections Drawing 2A One EST unit with multiple cooling towers Drawing 2B One cooling tower with multiple EST units in parallel Drawing 3 HMI Drawing 4 Parameters screen Drawing 5 Mounting of the EST lid EST User Manual EA E LG R ESSY Elgressy Engineering Services Ltd POB 132 Tel Mond 40600 ISRAEL www elgressy com ENGINEERING SERVICES LTD
13. ctuator using the same solenoid that operates the inlet valve so that the inlet and the outlet valves operate together Important When connecting the outlet of the EST to a pressurized line be sure to add a relief valve to the piping upstream just before the outlet valve The relief pressure rating should be 6 bar Tip It is recommend that you add a filter of at least 80 100 microns suitable to the line size at the outlet of the EST A cyclone type separator such as the Hydrocyclon Sand Separator of Netafim USA www netafim com may be used 6 Connect the air supply to the air intake item 7 on drawing 1 The air intake is equipped with a filter and water trap Step 5 Setup Electrical Connections When performing this step it is recommended that you refer to the electrical panel drawing This drawing can be found in a designated pocket on the inside of the panel 1 Open the door sheltering the power supply box 2 Remove the plastic cover at the bottom to expose the electrical connections 3 Some of the screws may have become loose during the shipping Verify that all visible wires are tightly screwed and tighten those which are not 4 If not already connected connect the electrode s to the power supply using the wires supplied with unit The connection point is on the left side of the power supply control panel Note that the side of the power supply unit is already connected to the tank pee a ELGRESSY Elgressy
14. d POB 132 Tel Mond 40600 ISRAEL Components of the EST System This chapter describes the components of the EST system For better understanding you should use drawing 1 which maps out the components of system Accordingly components are numbered in this chapter in correlation with the numbering on the drawing 1 Reaction tank serves as cathode 2 Electrodes anodes according to your EST model EST 25 20r 3 electrodes depending on your site s requirements EST 15 2 electrodes EST 10 Electrode 3 Scraper motor for scraper operation Scraper made of polypropylene mounted inside the reaction tank 5 Water inlet valve The inlet valve is air operated All valve connections are threaded to BSP The valve s size is dependent on the EST model EST 25 2 EST 15 2 6 Drain valve The valve is air operated and includes a restriction valve to slow the air flow into the valve hence slowing the valve motion All valve connections threaded to BSP For all EST models the valve s size is 2 7 Automatic control electrical panel with a stabilized current drawings are attached to the panel The panel includes the following 7 1 Power supply for 30V and up to 25 amps of direct current 7 2 PLC to control the operation of the unit including the circulation pump 72 Interactive display unit for local control of the unit 7 4 Contactor to circulation pump 255 pH meter 7 6 Main Electrical connection 380V 25 Amp 8 Wate
15. d flushes the tank to remove the scale that has been produced on its walls While flushing the top motor revolves the scraper to achieve a better cleaning of the tank walls When the flushing has finished the inlet valve opens the drain valve closes the scraper motor stops and the normal flow of water through the unit is resumed When the cooling tower or any other system serviced by the EST unit is out of service or shut down for more than a few hours the EST must also be stopped and disconnected and drained Important Never leave the EST full of standing water and connected to the electricity for more than 3 hours This could produce hydrogen which is a potentially dangerous element Operating monitoring and control facilities The EST unit is controlled automatically by a PLC It is possible to monitor the machine operation and make adjustments to the settings using an interactive display or an interactive HMI on any computer Drawings 3 amp 4 show the screen and the parameter table Drawing 3 HMI Time For The Next Washing Time For Current Washing 00 Sec EST User Manual o Z ELGRESSY Elgressy Engineering Services Ltd POB 132 Tel Mond 40600 ISRAEL www elgressy com ENGINEERING SERVICES LTD 0900009000000090900000909000009000900000090900000000000000090000000000090009000000909000000900000000090000000000900090000009090000900900000000000000000000900000000090000090090000090090000000000000000000090000090000000
16. e connected to a dedicated circulation line using its own circulation pump from and to the cooling tower see drawing 2 n eers Elgressy Engineering Services Ltd POB 132 Tel Mond 40600 ISRAEL www elgressy com ENGINEERING SERVICES LTD 2 Connect incoming water line from the pump discharge to the inlet valve 5 It is recommended to allow for a sample point at this location in order to monitor incoming water Important The pump should be positioned below the water surface of the tower basin 3 Connect the treated water line to the outlet connection 9 It is recommended to allow for a sample point at this location in order to monitor treated water 4 Connect the drain valve 6 to the drainage system It is recommended to allow for a sample point at this location in order to monitor the drained water Note If more than one unit is supplied for a single application the units should be connected in parallel as per drawing 2b Important The return pipe from the system to the cooling tower basin has to be above the surface of the water in the tower basin in order to provide an air gap Tip Where the outlet line from the EST must be connected to a pressure line it is recommended to add an actuated outlet valve As a minimum a non return valve should be used 5 n case an actuated outlet valve is required at your site connect the air lines to the outlet valve actuator in parallel to the inlet valve a
17. e other electrodes in the system Thus you must measure the current on each electrode The total current of the system should be divided equally between the electrodes 0 2 amps If the difference is bigger than this you should suspect a problem in the electrode that pulls the least amount of amps in the system A faulty electrode must be replaced Refer to the sections Shutdown Procedure Opening the EST Unit and Closing the EST Unit in this chapter below for detailed procedures Shutdown Procedure Typically you would not need to shut down the system other than for troubleshooting or maintenance purposes 1 Flush the EST manually according to the manual flush procedure described in the Manual Flushing subsection in chapter 8 2 Switch off the power to the EST This will disconnect the power supply all elecrical facilities including the EST circulation pump 3 Drain the tank using the manual switch on the drain valve solenoid 4 f you need to clean the tank or if you anticipate the unit to be idle for a few hours you must drain the tank To do so push the manual knob of the outlet valve s solenoid and hold until the tank is empty 5 If the shutdown has been performed due to unusual circumstances or for a long period of time open and clean the tank This should be done by authorized personnel Opening the EST Unit 1 Disconnect the EST unit from its power source 2 Dismantle the electrode s The electrodes are attached
18. em as desired For detailed instructions see section Adjusting Timers in chapter 8 Monitoring EST Operation There are three items that should be monitored on a regular basis e Power supply panel e System parameters e Electrodes Power Supply Panel The power supply panel contains four indicator lights e 3 phase lights R S T indicates that the system is operating e The red light indicates failure Ph Conductivity meter indicate pH or conductivity if electrode has been installed Interactive display unit normally in sleeping position It is recommended to check that these are live once a day To wake up the display press F1 EST User Manual E E LG R ESSY Elgressy Engineering Services Ltd POB 132 Tel Mond 40600 ISRAEL www elgressy com ENGINEERING SERVICES LTD 090000900909090009099000090000000990000090000900000000000909000009000009009000000900900009009000000090900009090000000009000000909000090900000000900000009000009000900000090000090900000909000000900090000000090009000009000000900909090000900000000900000009000000000000090000000000000090000000090000090000000000000000900000090900009999 System Parameters System parameters are displayed and adjusted on the Interactive display mounted on the panel Electrodes The electrodes are guaranteed for 3 years However it may happen that an electrode is corroded during normal operation When this happen the electrical current it will pull will be lower than the current pulled by th
19. er Manual E E LG R ESSY Elgressy Engineering Services Ltd POB 132 Tel Mond 40600 ISRAEL www elgressy com ENGINEERING SERVICES LTD 5 Activate manual flushing See section Using the display to adjust settings To activate the display press F1 The display operation is self explanatory After pressing F1 follow the instructions on the display unit for any change you wish to make EST sistem Om FL DR Vot 0 0 Paranetas Bam Flushing the EST Unit in chapter 8 for detailed instructions After one manual flush the system will resume automatic normal operation The system is now operating and will flush automatically according to factory settings Stage 2 Adjusting System Settings The setting of the various parameters has been adjusted in the factory before shipping This is a standard setting and can be changed from either the interactive display on the panel door or from a computer 1 Verify the current of the unit is at maximum allowed by the power supply If necessary adjust it See section Adjusting Current and Voltage in chapter 8 for detailed instructions Note It is impossible to adjust the current when the water conductivity is very low as the voltage tends to turn to maximum 30V This may happen when starting the system In such cases you must wait until the tower water concentrates and the voltage drops before you can make any adjustments 2 Verify timers are adjusted adequately If necessary adjust th
20. high salt concentration To correct this situation increase the number of flushings per day Excessive High Voltage When measuring voltage by either an external voltmeter or the voltmeter on the unit where available occasionally you may find the system has reached an excessively high voltage up to the maximum of 30V When this occurs the current will no longer be constant and will tend to reduce and cannot be adjusted in the normal manner Excessively high voltage may result in two cases e Upon start up if the water has a very low content of salts and conductivity is very low If this is the case check that indeed the all other drains except for the EST drain are closed reduce the number of flushings per day allow the EST system to continue working and check the voltage again every few of hours If voltage reading has not returned to normal within 48 hours contact your service company Scale has accumulated on the tank wall and has not been properly removed Verify that the scraping system is operating properly To do so a Activate a manual flush refer to the section Using the display to adjust settings To activate the display press F1 The display operation is self explanatory After pressing F1 follow the instructions on the display unit for any change you wish to make Flushing the EST Unit Press F9 b Listen for any unusual noises Typically if a problem occurs in the scraping system it will generate uncharac
21. ns a drainage nozzle Drain the water in the air filter cup by pushing the knob e If the system includes the SCP option the SCP drain will open when the EST inlet closes Thus when doing manual flushing to the EST watch also the drainage of the SCP that will occur when the EST inlet valve closes e Turn off the EST system and then do the following e Verify that the connecting bolts of the electrodes are tightly secured This is important in order to prevent water from seeping onto the top side of the electrodes e Verify that the external tips of the electrodes are impeccably clean If stained or damaged contact your supplier to investigate the cause and how to repair or replace them Turn the system back on to resume normal operation EST Semi annual Maintenance At least twice a year the system requires a thorough cleaning Semi annual maintenance should be performed only by the manufacturer s authorized representative Shut down the EST system refer to the Shutdown Procedure in chapter 7 for detailed instructions Disconnect the system from the source of power 1 2 3 Disconnect the system from the water and air supply 4 Disconnect the electricity from the electrode s 5 Open the EST unit For detailed instructions refer to the section Opening the EST Unit in chapter 7 Important Take extra care to avoid damaging the electrodes during this operation 6 Verify that the electrode s are clean They must appear cle
22. pter 7 You will also need to be acquainted with the following procedures chapter 7 e Shutdown Procedure e Opening the EST Unit e Closing the EST Unit Part 4 Maintenance chapter 9 There are two types of maintenance operations you will be required to carry out e EST Bi weekly Maintenance e EST Semi annual Maintenance For this purpose you will use these operational procedures chapter 7 e Shutdown Procedure e Opening the EST Unit e Closing the EST Unit Part 5 Troubleshooting the EST System chapter 10 This part provides you with instructions for possible malfunction symptoms Part 6 The SCP SCP Option chapter 11 If you have ordered this add on you will need to know e The SCP Operating Principle e How to install operate and adjust the SCP add on detailed in the section Getting the SCP Add on to Work e SCP Maintenance operations EST User Manual Elgressy Engineering Services Ltd POB 132 Tel Mond 40600 ISRAEL www elgressy com AZ ELGRESSY ENGINEERING SERVICES LTD 09000090900090009099000009000000099000009000090000000000090900000000000900900000090900009009000000009000009900000009000009000009090900000000900000009000009000900000090000090090000009090900009009000900090000900090000090900000009090000090000000090000000090000009000000009090000000000000900000000900000900000090000000000090000009900009099 Safety Warning The EST is electrolysis equipment involving the chemical decomposition by electrical c
23. r outlet allowing water to flush from the reaction tank The water outlet is 2 in diameter and it is threaded to BSP 9 Air release intake valve ARI 34 for protection of the tank 10 Flow meter for Cooling Tower make up water inlet Drawing 1 Parts of the EST Reaction tank Electrodes Scraper motor Scraper Water inlet valve Drain valve Air intake Power supply ee ee s Water outlet valve 10 Air release intake valve EST Auto Manual 2009 AZ ELGRESS ENGINEERING SERVICES LTD The EST is installed as part of a more complex system This system includes e Circulation pump to pump water from the cooling tower sump to the EST This is not part of the EST supply but must be supplied by the user e Recommended pump sizing is dependent on your system s model Note that Pump head must be suitable for the system EST 25 25 35 mv hr EST 15 15 25mv hr e Filter or centrifugal separator connected at the outlet of the EST to prevent suspended solids from returning to the cooling water main cycle This is not a must but nice to have e Optional SCP system to treat high silica problems e Piping system to connect all equipment must be supplied by the user according to the EST supplier instruction e Additional instruments may include flow meter for the EST circulation conductivity meter deposit monitor and Electrode for the pH meter The meter is supplied with the unit These are good to have but not essen
24. rameters Senis 56 Sed T se Flushing Time Eareina iach Forcing wasn ni UT DII Operation Procedure There are two stages in operating the EST system Stage 1 Starting The EST System in which you turn the system on and verify it is working properly Stage 2 Adjusting System Settings in which you adjust any settings you feel are inadequate for your site s specific considerations This step is not imperative for the operation of the EST unit but is highly recommended for optimal use of the EST system Stage 1 Starting The EST System 1 Before start up stop any blow down other than the blow down from the EST unit such as blow down from the cooling tower It is absolutely necessary that all blow down is controlled by the EST 2 Verify that the direction of the dedicated circulation pump impeller rotation is correct 3 Discontinue any chemical additives to the cooling tower 4 Verify the EST unit is connected to power and is working the operation green light should be on If it is not yet connected turn it on using the main breaker The pump and unit will start operating 900900909000090090090020000099000090000090000000009000000900900000009090000900000000000090009000009000009002920090090000090000000000000009090000000900000009099000009090000000090000000090000090000090020090009000009009000000000000090900000000900000000900000900000000900900009009000009000009090009200900090090009000000000000000900000000009 EST Us
25. scraper motor from the lid you must open the top nut This will release the parts on the top side of the lid Note that the gear fits into the top nut and will slide out easily Opening the bottom nut will release the adaptor from the lid Drawing 5 Mounting of the EST s lid MOTOR CONNECTION m d TOP NUT SPLIT CONNECTOR _ TOP COVER EST LI a D TOP COVER BOTTOM NUT PRESSING SPRING ADAPTOR SHAFT BOTTOM COVER SPLIT CONNECTOR SPLIT CONNECTOR BOTTOM COVER SCRAPER ADAPTOR COVERS CLOSED SCRAPER ADAPTOR COVERS OPEN SCRAPER 090909000009900000900090090090900009090900009090000000090900009009000090009090000909909000090000009000900000900000900900900900090009090000000000000009000000000000090909000090090000000000000900000900090009009009000900090090000000000000090000000000000090900000090900000000000000090000090000090029200000909000090000000000000090900000000000000 ELGRESSY ENGINEERING SERVICES LTD EST User Manual Elgressy Engineering Services Ltd POB 132 Tel Mond 40600 ISRAEL www elgressy com 8 System Settings The EST is factory set for standard operation However in some cases the flushing time the current or the scraping time must be adjusted to improve the system results Using the display to adjust settings To activate the display press F1 The display operation is self explanatory After pressing F1 follow the instructions on the display unit for any change
26. stallization of scale The SCP contains a sacrificial electrode that releases metal ions into the water in a very controlled manner The electrolytic reaction chamber is hydraulically connected to the EST system but electrically controlled from the flow meter of the make up water to the systern The ions released into the water perform as antiscalant thus facilitating a more effective treatment of scale precipitation and prevention of silica crystallization in water systems The SCP electrolytic system consists of an anode specially composed of materials that interrupt the silica scale crystallization e 0909090000099090000900090090099090009090000909000000009090909000009000090009090900009099000009000000900090000090000090090090090000090900000000000000900000000000009099000099090000000000000900000900900900900900090009009000000000000009000000000000009090000009000000000900000009000009000009002000009000009000000000900000090900000000000000 EST User Manual AZ E LG R ESSY Elgressy Engineering Services Ltd POB 132 Tel Mond 40600 ISRAEL www elgressy com ENGINEERING SERVICES LTD 3 Technical Specifications Tank Design Pressure 6 bar 88psi Operating Pressure Maximum of 6 bar 88 psi Material Carbon steel epoxy painted on external side Electrodes Proprietary and patented metallurgy Scraper Patented Polypropylene shaft and scraper are operated by motor Min operating pressure 2 bar 29 5 psi Valves Inlet amp drain 2
27. teristic noises c Check air pressure Malfunctioning of Inlet or Drain Valve Malfunctioning of the inlet valve the drain valve may be caused by a faulty solenoid which interrupts normal air flow thus failing to activate the valves Verify air pressure is as specified under chapter 3 Technical Specifications To do so use the manometer on the air intake system If air pressure is sufficient verify that the solenoid valves controlling air flow to the inlet and outlet valves are functional The solenoid valves are located on the outer side of the panel Each solenoid valve has a switch that can be used for manual control of the system by either pushing or turning it e Push the switch to allow a single pulse of air pressure This would cause the matching valve to operate If the valves had not started their operation the solenoid valve is faulty and must be replaced e If you are still uncertain you may turn the solenoid valve s switch to change its operation from automatic to manual By doing so the open or closed position of the solenoid is constant until changed again manually When this test is finished you must make sure the solenoid has been turned back to it s autornatic position wm r n MEN Elgressy Engineering Services Ltd POB 132 Tel Mond 40600 ISRAEL www elgressy com ENGINEERING SERVICES LTD Note It is strongly advised that you only push the necessary switch rather than turn it so as to a
28. tial For a flow scheme of the entire system including EST refer to drawing 2 Drawing 2A One EST unit with multiple cooling towers MAKE UP WATER CIRCULATING PUMP Drawing 2B One cooling tower with multiple EST units in parallel COOLING TOWER P CIRCULATING PUMP 50 m3 h 2 x TO DRAIN x lt DRAIN VALVE E EST User Manual E E LG R ESSY Elgressy Engineering Services Ltd POB 132 Tel Mond 40600 ISRAEL www elgressy com ENGINEERING SERVICES LTD a Installation Procedure Important Before installing the EST make sure the peripheral systems are all in place and that you fully understand how the EST must be connected Step 1 Preparing the Installation Site No special preparation is required for installing the EST units as the EST unit can be installed on a concrete floor or any other flat surface However it is recommended to elevate the EST on small concrete blocks to raise it above the floor It is highly recommended to shelter the EST from the weather If the EST system cannot be located indoors ensure it is placed under a water proof cover to shelter it from rain Also protect the system from freezing temperatures Make sure that the EST is installed in a ventilated area Step 2 Unpacking and Positioning the System The system is packed in a wooden box and is shipped in a horizontal position To unpack the system 1 Remove the top cover of the wooden case The EST
29. to the lid by a screw located in the connection box In order to separate the electrodes from the lid open the connection box disconnect the electrical wire and unscrew the electrodes Let the electrodes fall into the tank 3 Take off the lid of the tank including the scraper motor together with the scraper adaptor as marked on the drawing To do so a Open the lid bolts b Lift the lid high enough to pull the adaptor out of the tank and place carefully aside c Pull the electrodes and put aside Tip It is best to prepare a cushioned surface or a sponge on which you can place these parts avoiding any harm d Pull the scraper and place aside Closing the EST Unit Refer to drawing No 5 1 Verify the unit is disconnected from power source 2 Mount the scraper To do so a Slide the scraper into the tank and put it in it s place The bottom tip of the scraper must fit the hole drilled for it in the scraper base b Slide the electrodes into the tank inside the scraper 090909000009900000900090090099000090900009000000000909090009009000090009090000909900000900000090009000009000009009009009000900090900000000000000000000000000009090000990090000000000900090000090009009009000009000900090900000000000009000000000000009090000009090000000090000000090000090000090029200000900000900000000000000000000000000000 EST User Manual E E LG R ESSY Elgressy Engineering Services Ltd POB 132 Tel Mond 40600 ISRAEL www elgressy com ENGINEER
30. top side is indicated on the wooden box 2 Remove any loose parts and set them aside 3 Turn the box vertically in order to remove the unit from it Place the legs of the unit securely on the floor Important On occasion specific instructions are shipped with the system which must be followed in addition to instructions detailed in this user quide Step 3 Setting Up the System The EST is shipped with all internal parts mounted in it 1 If you have not yet done so position the unit s in their designated location It is highly recommended to secure the base to the floor by bolts It is also recommended that each unit be lifted about 10cm 4 inches above the floor on small concrete blocks so that the unit s legs will not be damaged by possible dripping or water accumulation on the floor Unit must be leveled appropriately Note Where more than one unit is supplied for a single application connect the EST units in parallel see drawing 2B When one EST serves few cooling towers connect the towers in parallel see drawing 2A Please consult with the supplier for specific details The units are ready for operation Step 4 Connecting the System to Water When performing this step it is recommended you use drawing 2 to facilitate the connection of the EST system to its peripheral system 1 Connect piping as applicable according to the scheme in drawing 2 Note When employing the EST system in a cooling tower the EST must b
31. uration Eo TIS 50V DC 16 or 25amp according to your site s configuration EST TO 50V DC 12 amp Using the computer HMI to adjust the settings The system can be adjusted using a web HMI Human Machine Interface To log on to the HMI you need to connect your computer to the internet as per instructions that will be provided upon supply of the system The interactive HMI will be shown on the screen of the logged in computer Refer to drawings 3 amp 4 The main screen shows the operation of the unit Pressing the button Parameters will open the parameters screen In order to adjust parameter put the curser on the value window and insert the desired parameter Calibrating Air Pressure The air intake system includes a manometer so you can easily verify that air pressure is sufficient The calibrating valve is located at the head of the air filter It has been pre calibrated for suitable pressure If for any reason you need to increase air pressure turn the valve clockwise The air intake system is also equipped with an air filter which contains a drainage nozzle To drain the water in the air filter cup simply push the knob Draining the water will leave the cup empty as it should be 79 Maintenance The system requires two maintenance procedures bi weekly and semi anually EST Bi weekly Maintenance There is no required order in which you must perform the following operations However be sure that you perform them every two weeks
32. urrent The unit has been designed and manufactured for safe operation by the user This document discusses only the EST system Any handling of the electrical system the panel electrical connection and other items connected to electricity must be done by a registered authorized electrician For a safe and long lasting operation please follow all instructions detailed in this manual Throughout the installation operating or maintenance procedures if in doubt please contact the manufacturer or service company The EST System An Overview The EST treatment system provides controlled electrolysis in a controlled reaction chamber to prevent scaling and control bacteria algae and slime formation that arise in cooling water systems of various sizes and types It can be applied to numerous facilities including air conditioning systems process cooling ammonia cooling and compressed air cooling EST eliminates the need for costly and hazardous chemicals to treat cooling water chemicals that are eventually drained as wastewater Because it uses no chemicals the EST system discharges only clean water and consequently results in considerable savings in water sewage and other costs The EST anti scale treatment unit is used alone in most facilities to prevent general scale formation Other units in the system SCP and can be added to enhance the EST performance SCP Optional Add on The SCP system was developed to prevent the cry
33. ushing the EST Unit 16 Manual Flushing 16 e Adjusting Timers O M e Adjusting Current and d usage n HH e Using the computer HMI to adjust the ENRE EMI 17 e Calibrating Air Pressure e Da 9 OF A EST Bi weekly Maintenance iii 17 EST Semi annual Maintenance 18 10 Troubleshooting the EST 19 EST Red Light On wo sana 19 e Low Voltage s 19 Excessive High Voltage s 19 e Excessively high voltage may result in two cases s 19 e Malfunctioning or Inlet or Drain Valve or PISTON asso encore tectum tette uter ntenrabancemesi TO 11 The SCP Option sss 20 5P Operating Principle sse siansiemermesisimorsisaninisansineanan inaaianei niea s 20 e GETTING the SCP Add on to Work s 20 e SCP Maintenance 00990909000909000000009090990000909009900000900000000900090009000900000009090000090000900000900090000009000000090000090090000000909900000900000009000909000009000000000000000900000090090900000090000000099 e rawings eccc5c006 006000000000000000060099 090090000000090009000909009000900000000000000000000000000090 09000009000000000000000000929 09060090000009000009000900090009000900000000000000000000000099 0000000900000000000000000099 9009090990000990000090020090009090000900000090000000009000000009000009000900
34. void leaving the system in a non automated operating mode If all the above are in order check for blockage in the valve or the pipe leading to it Leakage of water from the air release valve Remove the air release valve and check that the ball inside can move freely If faulty replace air release valve In sufficient drain Check functioning of drain valve see above Check water pressure to the system J 11 The SCP Option The EST system may be supplied with the SCP unit according to your order The main purpose for SCP unit is to prevent silica settlement and enhance the performance of the EST The SCP is equipped with a self sacrificing anode that dissolves into the water and creates a coagulation flocculating agent The silica particles as well as other particles attach themselves to the flocculating agent creating flocks that settle in a quiet flow area mainly in the tower basin or in the EST and the SCP tanks The solids created are softer than the original solids and are removed more easily SCP Operating Principle The SCP is a very simple electrolysis system It comprises an 8 vessel one electrode 2 inlet nozzle 2 drain air operated valve and a power supply The power supply is very simple designed for 10amp 20V DC All other specifications are similar to those of the EST system Getting the SCP Add on to Work Connect the SCP to water either before or after the EST As the SCP is normally not equipped with
35. you wish to make Flushing the EST Unit When flushing begins the pump stops the inlet valve part 5 on drawing 1 closes and the drain valve part 6 opens The top motor part 3 then activates the scraper part 4 which begins to scrape the scale from the tank s walls After a previously set period of time T2 see below the water inlet valve part 5 opens and the circulation pump starts to allow for the flushing of the scale The drain valve remains open for a previously set time Subsequently after T3 is reached see below the drain valve closes the motor stops and the EST resumes normal operation The EST is set for automatic flushing It is possible to override this automatic flushing and perform Manual flushing Manual Flushing To initiate a manual flush press F9 on the display unit Adjusting Timers Three timers control the EST T1 the period of time between flushings This timer is called Washing Cycle timer T2 the duration of the draining This timer is called Draining Time timer To adjust these timers press F1 to initiate the display and follow the instructions on it Normal draining time is 0 5 minute T3 the duration of the flushing This is called Flushing Time timer To adjust these timers press F1 to initiate the display and follow the instructions on it The minimum flushing time is 0 5 minute and the maximum is 15 minutes Scraping Time An internal timer fixes the movement of the scraper
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