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

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

EnwaMatic Bespoke BS 300 Contents Declaration of conformity: 2 Pressure test certificate: 3 Contacts: 4 Installation notes: 5 Installation schematic: 6 Actuator switch positions: 7 EnwaMatic Operation: 8 Flow diagram: Service / Backwash: 9 Control panel operation: 11 Maintenance & Troubleshooting: 13 Pump data sheets 16 Wiring diagrams: 20

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EnwaMatic Bespoke BS 300 Contact details Enwa Water Technology (UK) Unit A, Scotlands Industrial Estate Coalville, Leicestershire, LE67 3JJ Office: 01530 830 354 Project Manager: James Townley, 0787 9648006, j.townley@enwa.co.uk Commissioning Manager: Mark Griffiths, 07500 330 383, m.griffiths@enwa.co.uk Service & Aftersales: Cher Watkins, c.watkins@enwa.co.uk UK Manager: Glenn Simpson, g.simpson@enwa.co.uk 4

EnwaMatic Bespoke BS 300 Installation Notes Refer to installation schematic: The unit should connect to two DN50 / 2 isolation valves on the main district heating scheme (DHS). Flow through the vessel is driven by a dedicated circulation pump: Grundfos CRI 20-1. Inlet / outlet line size is DN50 / 2. Mains water and drain is DN25 / 1. A boosted mains water supply is used to backwash the filter media. A DN25 / 1 isolating valve is provided on the break tank inlet. This feeds a 570 litre insulated GRP break tank via a solenoid valve (24 vdc, NC). This valve is linked to the control panel and programmed such that the valve will only open during backwash and where the break tank is below a set level. Additional security is provided by an additional float level switch. The tank is fitted with a raised inlet chamber and weir to provide Fluid Category 5 backflow prevention. A submersible pump within the break tank provides sufficient flow and head to backwash the filter at 85 l/min. The Lowara Genyo pump controller is energised during the backwash cycle only and is activated by pressure drop as the valves move into backwash positions. The unit drain (backwash outlet) should discharge to a suitable floor drain ideally such that the flow is visible to the operator. This drain will be tested to ensure it is capable of receiving flows up to 85 l/min for 15 minutes. It is critical that this drain is not blocked or impaired in any way. All pipework and components are stainless steel, with the exception of the solenoid valve (mains water supply), which has a brass body. Insulation: The vessel has internal, 100mm insulation. External pipework requires insulation by the installer post commissioning. The main power supply required is 20 A, 230V, single phase. The schematic shows the 230V, 24 VDC and signal cabling. All pumps are powered from the main control panel. A local isolator switch on the incoming supply should be installed close to the installation. 5

P MANUAL VALVE MOTORISED VALVE WAFER NON RETURN PRESSURE GAUGE PIPEWORK BY INSTALLER 20 A 230 V 50 HZ 230V ELECTRICAL BY INSTALLER CONTROL PANEL 2" BSP-F BESPOKE BS 300 BMS 24 VDC ACTUATOR AND SENSOR CABLING GRUNDFOS CRI 20-1 2" BSP-F TO FLOOR OR DRAIN SAMPLE VALVE FLOW INDICATOR DN50 DHS INLET C 1/2 " BSP-F VESSEL INLET P 2" BSP-F VESSEL OUTLET AIR VENT STRAINER BYPASS A D FLOW REG MCW REG BACKWASH OUTLET 1" BSP-F INSTALLATION SCHEMATIC DHS OUTLET 2" BSP-F MCW INLET 1" BSP-F PUMP DN25 DN50 DN25 TO DRAIN 1" BSP-F DN25 SOLENOID VALVE FC5 BREAKTANK + BOOSTER PUMP ASSEMBLY DAB PULSAR 30/80 MCW SUPPLY SCREENED OVERFLOW DN50 PLASTIC DRAIN JT 4.6.15 6 CONTROLLER 1" BSP-M B1 B2

EnwaMatic Bespoke BS 300 Actuator switch positions Actuator handles are mounted in line with the valve stem, such that a closed valve handle is perpendicular to the pipe on which it is mounted. The green mark indicates the required contact status (S1>S3) for a closed valve. Actuators are set up by ENWA at commissioning. STATUS OFF RUN BACKWASH ACTUATOR A ACTUATOR B1/B2 ACTUATOR C ACTUATOR D 7

EnwaMatic Bespoke BS 300 Operation The EnwaMatic Bespoke BS 300 is a dedicated side stream filtration / water treatment unit for the DHS. A small percentage of the main flow is diverted through the vessel, such that total system volume is turned over 1-2 times per day. Side-stream filtration to less than 5 microns. Inhibition of corrosion maintaining a dissolved iron level of < 1.0 mg/l. Regulation of hardness and scaling through calcite / dolomite media filtration. Removal of air through integral air separation device. Environmental restriction of bacterial growth. Normal operation: During normal operation, water enters the top of the vessel, passing through specialist filter media, reaction media and gravel base layers to a strainer on the bottom outlet. Debris is progressively collected by the filter media as it passes through the bed. The flow rate is 200 l/min. This equates to position 7-8 on the sight flow indicator. Flow rate through the unit can be observed on the sight flow indicator and adjusted using the flow regulator valve on the central column (see mechanical schematic). This is a fully automated backwash system, requiring no on-site operation or maintenance. Isolation: The unit should be isolated by: Pressing Off on the control panel PLC interface. Closing the main system isolation valves. Turn off control panel prior to undertaking any work on the equipment. The unit can be isolated for several days without a deterioration in water quality. If prolonged periods of isolation are required, please contact ENWA for advice. Automated backwash: Backwashing is set at the control panel for 2 week intervals as default. This will be reviewed at commissioning and on follow-up visits. The actuator positions and direction of water flow during service and backwash are shown in the enclosed drawing. 8

SERVICE BACKWASH ACTUATOR POSITIONS DIRECTION OF FLOW BESPOKE BS 300 JT - 4.6.15 9

The sequence is: 1) Circulation pump is switched off. 2) Unit isolation valves (Valves C & D) close. Green light on panel goes out. 3) Valve B1 and the additional drain isolation Valve B2 move to backwash positions. 4) Valve A moves to backwash position. (MCW isolation open). Orange light on panel. 5) Breaktank pump is activated and backwash commences. This lasts for 10-15 minutes. 6) Unit returns to service. Pump is switched on. The additional isolation valves have been included to increase system security. The unit cannot return to service if these valves are not closed. Fluid Category 5 (FC5) break tank and booster pump: EM BS 300 units require a higher flow rate than can normally be supplied directly by a mains water connection. To accommodate this, and to meet Water Regulations concerning connection to mains water, a break tank is employed. The tank is filled by a servo type solenoid valve. This valve is normally closed, requiring a 24 vdc supply from the control panel to open. This can only happen during backwash and when the tank is below the solenoid activation level. A submersible pump (DAB Pulsar 30/80) within the tank provides the required backwash flow rate and is controlled by a pressure switch within the Lowara Genyo pump controller. This controller is only energized during the backwash process. A hall effect level sensor controls the solenoid operation and provides a high & low level alarm. An additional float level switch provides a back-up high level alarm, which will shut down the water supply. Failure of the FC5 device to correctly operate for the required time period during the backwash cycle will generate an alarm. Status of the solenoid valve, level sensor and pump controller are displayed on the PLC. Backwash Flow Rate: The flow rate is set on the regulating valve adjacent to Valve A. ENWA will set this flow at commissioning, with final adjustment on the follow-up visit, when the unit has been in service for several weeks. The drain will be tested and confirmed capable of receiving this flow rate. Circulation pump: Refer to attached data sheets. This is a fixed speed pump, controlled via the control panel. Flow through the unit is confirmed by a flow switch and will provide an alarm if no flow is registered past a set delay period. Status of pump and flow switch are displayed on the PLC screen. Manual over-ride: It is possible to manually operate the valves, but this is not recommended for normal operation. Valves are moved by depressing the black button on the orange Belimo casing and turning the black handle on the actuator. The panel must be switched off to override the permanent 24 vdc supply, designed to keep valves closed. 10

EnwaMatic Bespoke BS 300 Control Panel Operation Indicator lamps are provided for basic Run, Backwash and Fault status. These outputs are linked to relays which provide volt free contacts for BMS connection. PLC display (HMI): Bespoke, project specific software is installed to control and monitor the installation. The HMI has 5 direct switch inputs: ON OFF BACKWASH ALARM RESET ESC - returns panel to normal operation after alarms or manual shut-down. - provides manual shutdown, without loss of power. Pumps are switched off. All valves are closed. - allows user to initiate a complete automated backwash cycle. - investigate and reset alarms. - return from menus. In standby mode the PLC will display the ENWA logo only. Touch the screen to access the main HMI display. The various status indicators are shown above. 11

Alarm menu: Pressing the HMI button ALARM RESET allows any alarms generated to be investigated. Pressing the magnifying glass icon on the screen will expand any alarm groups. Pressing the Reset screen button will clear the alarm if the cause has been rectified or is currently inactive. Unless the cause is immediately apparent and can be safely restored, please contact ENWA for further assistance. Pressing ALARM RESET when no current alarms are present allows the alarm history to be seen. Alarm conditions: Alarm ID: Description: Notes: 000 Alarm Valve A Valve in wrong position for current status 001 Alarm Valve B Valve in wrong position for current status 002 Alarm Valve C Valve in wrong position for current status 003 Alarm Valve D Valve in wrong position for current status 004 Alarm pump UPS Pump not started in RUN status 006 Break tank low level Tank level has remained low beyond pre-set delay period. 017 Backwash duration alarm Solenoid valve not activated for pre-set period during backwashing. 023 Alarm Flow Switch Run Lack of flow in RUN, with pre-set delay period 024 Alarm circuit breaker Tripped MCB s in control panel. Additional options: Pressing the control panel icon on the HMI screen accesses additional options. Select Backwash Log to view history. Press the ESC button to return. The Test sequence is a partial test only and is not recommended post commissioning. Users should press the Backwash button to observe a complete test cycle. Settings requires a password number and is not recommended for normal operation. ENWA can advise if further access is required for example to change backwash dates. In general, the correct settings are established at commissioning and refined on the initial follow-up visits. Further adjustment should not be required, and may affect correct operation of the unit and break tank. 12

EnwaMatic Bespoke BS 300 Maintenance & Troubleshooting On site maintenance: There is no on-site maintenance requirement. It is recommended only that routine checks are made when visiting the plantroom: Visible flow: Position 7-8 on the sight flow indicator. Green light on control panel. PLC HMI display On, status Run. Any problems should be reported to ENWA. Warranty / Maintenance Agreement: The standard warranty on all equipment supplied is 2 years from delivery: The unit will operate under the additional water treatment warranty for 15 months post commissioning. Any problems should be reported directly to ENWA, who will advise or attend as required. After this time, regular annual servicing by ENWA should be carried out to check all components, clean the filter media, top up reaction media and analyse system water. This service extends the warranty on the water treatment process for additional 12 month periods. Any problems arising during these periods should again be reported to ENWA. Spares: There is no requirement to hold spares on site. Side stream filtration / water treatment provides long term management of water quality. Units do not need to operate continuously and can remain isolated for extended periods once established. ENWA hold most components in stock for immediate dispatch. Grundfos pumps have a lead time of 2 weeks. 13

Troubleshooting: Lack of flow through unit: Check panel status and program condition. Check main system isolation valves. Check circulation pump is running: Check indicator status on PLC. Visually check rotation through top cover. Check flow regulating valve is open. Check actuator positions. (Refer to enclosed drawing) Report to ENWA. Control panel: No green light: Check power supply. Is the LCD display active? Check panel status and program condition. Unit may be in initial stage of backwash. Max duration 2 mins. Check actuator positions. Report to ENWA. Orange light: Unit is in backwash. This should continue for 10-15 minutes maximum. light: Check alarm condition message. Reset if cause is clear and can be safely rectified. Otherwise: => Isolate unit and report to ENWA 14

Backwash / Break Tank faults: Lack of flow during backwash: Check HMI display indicator status for breaktank pump controller. Check mains water supply isolation valve. Check position of regulating valve adjacent to Valve A. Check actuator positions. Visual check of break tank level and float switch position. Check panel status: Incorrect valve positions, high / low tank level or solenoid inactivation will generate an alarm after a pre-set period. Report to ENWA. Low break tank level alarm: Break tanks may reach low level during normal operation. In this case the pump will switch off and wait for the tank to refill, resetting automatically. If the tank level remains low beyond a preset time period, an alarm will be generated. Check mains water supply isolation valves. Ensure position of regulating valve adjacent to Valve A is not altered. Visual check of tank level and float switch position. Report to ENWA. Break tank duration alarm: The PLC will check that the breaktank has been active for a minimum time period during backwashing. If this has not been achieved by the end of the process, an alarm will be generated. Check mains water supply isolation valves. Check position of regulating valve adjacent to Valve A. Check HMI display indicator status for breaktank pump controller and solenoid status. Visual check of tank level and float switch position. Report to ENWA. 15

Position Qty. Description 1 CRI 20-1 A-FGJ-I-V-HQQV Product No.: 96500314 Note! Product picture may differ from actual product Vertical, multistage centrifugal pump with suction and discharge ports on same the level (in-line) enabling installation in a horizontal one-pipe system. Pump materials in contact with the liquid are in stainless steel. A cartridge shaft seal ensures high reliability, safe handling and easy service and access. Power transmission is via a split coupling. Pipework connection is via combined DIN-ANSI-JIS flanges. The pump is fitted with a 1-phase, foot-mounted, fan-cooled asynchronous motor. Liquid: Pumped liquid: Water Liquid temperature range: -20.. 90 C Liquid temp: 20 C Density: 998.2 kg/m³ Technical: Speed for pump data: Rated flow: Rated head: Shaft seal: Approvals on nameplate: Curve tolerance: Materials: Pump housing: Impeller: 2789 rpm 21 m³/h 9.5 m HQQV CE,TR ISO 9906:1999 Annex A Stainless steel DIN W.-Nr. 1.4408 ASTM A 351 CF 8M Stainless steel DIN W.-Nr. 1.4301 AISI 304 Installation: Maximum ambient temperature: 40 C Max pressure at stated temp: 16 bar / 90 C 16 bar / -20 C Flange standard: DIN Pipe connection: DN 50 Pressure stage: PN 16 Flange size for motor: FT115 Electrical data: Motor type: 90SB IE Efficiency class: NA Number of poles: 2 Rated power - P2: 1.1 kw Power (P2) required by pump: 1.1 kw Mains frequency: 50 Hz Rated voltage: 1 x 220-230/240 V Rated current: 7,40/6,70 A Starting current: 390 % Printed from Grundfos CAPS [2014.04.042] 16

Description Value General information: Product name: CRI 20-1 A-FGJ-I-V-HQQV Product No: 96500314 EAN number: 5700396199245 Price: On request Technical: Speed for pump data: 2789 rpm Rated flow: 21 m³/h Rated head: 9.5 m Impellers: 01 Shaft seal: HQQV Approvals on nameplate: CE,TR Curve tolerance: ISO 9906:1999 Annex A Stages: 2 Pump version: A Model: A Materials: Pump housing: Impeller: Material code: Code for rubber: Stainless steel DIN W.-Nr. 1.4408 ASTM A 351 CF 8M Stainless steel DIN W.-Nr. 1.4301 AISI 304 I V Installation: Maximum ambient temperature: 40 C Max pressure at stated temp: 16 bar / 90 C 16 bar / -20 C Flange standard: DIN Connect code: FGJ Pipe connection: DN 50 Pressure stage: PN 16 Flange size for motor: FT115 Liquid: Pumped liquid: Water Liquid temperature range: -20.. 90 C Liquid temp: 20 C Density: 998.2 kg/m³ Electrical data: Motor type: 90SB IE Efficiency class: NA Number of poles: 2 Rated power - P2: 1.1 kw Power (P2) required by pump: 1.1 kw Mains frequency: 50 Hz Rated voltage: 1 x 220-230/240 V Rated current: 7,40/6,70 A Starting current: 390 % Cos phi - power factor: 0,98/0,99 Rated speed: 2770 rpm Motor efficiency at full load: 73-71 % Enclosure class (IEC 34-5): 55 (Protect. water jets/dust) Insulation class (IEC 85): F Motor protec: PTO Motor No: 85215705 Others: Minimum efficiency index, MEI : 0.7 Net weight: 47 kg Gross weight: 60 kg Shipping volume: 0.09 m3 H [m] 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 CRI 20-1, 1*230 V, 50Hz Pumped liquid = Water Liquid temperature = 20 C Density = 998.2 kg/m³ 0 0 5 10 15 20 25 P [kw] 1.4 1.2 1.0 0.8 0.6 0.4 0.2 0.0 Q [m³/h] P1 P2 eta [%] 100 90 80 70 60 50 40 30 20 10 0 NPSH [m] 7 6 5 4 3 2 1 0 Printed from Grundfos CAPS [2014.04.042] 17

96500314 CRI 20-1 50 Hz 139 178 281 G 1/2 G 1/2 413 G 1/2 18.5 x 21.8 90 127 165 130 200 300 26 65 120.5 215 248 Note! All units are in [mm] unless others are stated. Disclaimer: This simplified dimensional drawing does not show all details. Printed from Grundfos CAPS [2014.04.042] 18

96500314 CRI 20-1 50 Hz Note! All units are in [mm] unless others are stated. Printed from Grundfos CAPS [2014.04.042] 19

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CIRCULATION BREAKTANK (LOWARA) 21

Com NC 47 48 MOTOR A MOTOR B1 MOTOR B2 MOTOR C MOTOR D Date: ENWA WATER TREATMENT S SOLENOID VALVE PLC SETTINGS: H HALL EFFECT LEVEL SENSOR SET JUMPERS JP1 & JP2 TO 'A' - ANALOGUE INPUT MOVE CABLE 38 FROM PLC TERMINAL 13 (I6) TO TERMINAL 4 (I15) Project: Specification: BREAKTANK FLOAT LEVEL SERVICE FLOW SWITCH BESPOKE PANEL WIRING BESPOKE BREAKTANK + SOLENOID HALL EFFECT LEVEL SENSOR BAF / MOG PANEL UPGRADE BMS VFC 'Run' Project No: Page No: 10 BMS VFC 'Backwash' BMS VFC 'Fault' 49 NO 46 Black Black 1 Black 2 Black 1 Black 2 Com NC NO Com NC 13 14 15 17 18 25 27 30 37 38 39 40 41 42 43 44 45 NO Black Purple Black 1 Black 2 Brown 28 Black Purple Black 1 Black 2 Black 1 Black 2 1 2 3 S1 S2 S3 Drawn by: Verified by: Date: Drawing type: JT 24.2.15 JS 24.2.15 Electrical drawing Drawing No: Rev: 532869 - BS 1 22 17 S3 S2 16 Purple Purple S1 15 3 14 2 13 Black Black 1 12 S3 S2 11 Purple Purple S1 9 3 8 2 7 Black Black 1 11 S3 S2 10 Purple Purple S1 9 3 8 2 7 Black Black 1 6 S3 5 S2 4 S1 3 2 Black Black Purple Purple 3 2 1 1

* VIEW FROM INSIDE PANEL POWER IN BESPOKE BS 300 CIRC PUMP A SIG A 24V BT PUMP B1 SIG B1 24V C SIG CABLE ENTRIES B2 24V B2 SIG C 24V BT FLT HE LEV D 24V D SIG FLOW BMS SOL JT 4.6.15