INSTALLATIONPROCEDURE

EQOBRUSH
FORHEATEXCHANGERSAND
CONDENSORS

PROJECT:
PROJECTNo.:

EQOBRUSHINSTALLATIONMANUAL
 TableofContent

INTRODUCTION 3
MATERIALCHECK 3

1) INSTALLLATIONOFSOCKETS,BASKETS&BRUSHES 4
PROCEDURE 4
FINISHING 7

2) REMARKSONINSTALLATIONOFVALVE 8

3) INSTALLATIONOFCONTROLPANEL 9

4) SAFETYFEATURES 11
A. MOTORCURRENTCONTROL 11
B. RUNWAYCONTROL 12

5) STARTUP/OPERATION/MAINTENANCE 13
A. STARTUP 13
B. AUTOMATICOPERATION 13
C. SERVICEANDMAINTENANCE 13
1. BRUSHANDBASKET 13
2. VALVEANDACTUATOR 13
D. NOTESTOOPERATOR 13

Appendices:
Wirediagram
ReversedWireDiagram

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INTRODUCTION:
Tostarttheinstallationofthebrushcleaningsystemtheheatexchangersinterior
mustbereachablewithoutcovers.Ifonheight,theownermustplaceasafe
scaffoldingtoreachthepipeplates.
Considersafetyofinstallationstaffbymakingsure:
Workingspaceissafelyaccessible
Workersaresecuredwhenworkingonscaffoldingorheights
Sufficientlightintheworkingareatoensuresafetyandqualityofwork
Arrangeforproperventilation

MATERIALCHECK:
CheckiftheBILLOFQUANITY(BOQ)matcheswiththeheatexchanger.

ConfirmthePackinglistdetailswiththeBOQ.Theprovidedcomponents
basicallyconsistoffollowingcomponents:
o Basketsandbrushes
o Reversingvalve
o Actuator(geareddriveforreversingvalve)
o Positionswitch
o Controlbox
o Utilitymaterials(fasteners,cement,cups)

Checkthepipeendwithasocketifthesizingiscorrect.Thesocketendmustgo
smoothinthepipeandstopatthefirstringonthesocket.

Checkthebrushsizebyputtingonebrushinapipe.Thebrushhairmustbe
slightlyoversizedtotheinnerpipediameter.

NOTEIMPORTANT

Makesureallelectricalinstallation
worksareexecutedbyqualified
electricalinstallationpersonnelonly.

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SECTION1: INSTALLLATIONSOCKET,BASKET&BRUSH:

NOTE:
Instructionstobefollowedcarefullytoavoidperformanceloss!Weactually
recommendownersverificationofthequalityofthesocketinstallation.Glue
residueswillobstructbrusheswhichinturnleadtonontreated(dirty)pipesand
possibleunnecessarypressurelossesintheinstallation.

UNITPREPARATION:
Thesocketswillbegluedinthepipesendwithspecialmetalcement.
Thereforethepipeendsneedtobefreefromburrsandgreaseoroil.Beforestarting
thepipeendsneedtobeextracleanedwithPC444CleaningCompound,Solvent
Soluble,GreaseEmulsifyingorequivalentcleaningcompound.
Thepurposeofcleaningcompoundsistoremoveoil,greaseandotherforeign
matterfrompipeendstoensuregoodcontactbetweenthecementandtheinner
pipewall.

PROCEDURE:
Thebrushes,socketsandholderscleaningcloth,cement,papercupsandbrushesare
allprovidedwiththesystemcomponents.Thecleaningsolventneedstobesupplied
bytheowner.

Cleanabout100pipesstartingfromthebottomoftheheatexchanger.

Thecementwillholdsmoothfor30to45min.Preparesmallportions(accordingto
cupsize)havesmoothmaterialavailableatalltimesthroughouttheinstallation
process.

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Mixofblackcementwithwhitehardenerandstiritproperlywiththesupplied
spatula.

Stirtillyouhaveacoherentmass.Duetothechemicalreactionthecementgets
warm.

Withthebrushsuppliedputathinlayerofglueontheringedendofthesocket.
Makesureallringsarecoveredincement.

Gluepencilandbasketholder Cementonbrush

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Applycementonbasketholder Basketholderwithcementlayer

Makesurethatthereisnoglueinsidethebrushchannel.Removegluefrominsideof
brushchannel.

Pushinthebasketholderintothepipeplate.Usehandtoolwhenrequired.

Acementringformsaroundtheholder.

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FINISHING:

Onceallthesocketsareinplace,putinthebrushesatoneend.ONEbrushforeach
pipe.
Onceallthebrushesareinplaceputontheholderandcheckeverysocket,brush
andholderisplacedproperly.
Thecementneedsabout24hourstosetbeforetheheatexchangercanbeused.

Wellgluedsockets.

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SECTION2: INSTALLATIONOFVALVE

INSTRUCTIONANDREQUIREMENTSOFVALVE

Thevalveshouldbeinstalledinthepipingsystemasperdrawingsprovided.Any
typeofstructuretosupportthevalvebodymaybeadded.

Thebottomorbacksideofthevalve(thesidethatconnectstoheat
exchanger/condenser)canbeinstalledinthepipeworkwithoutextraprecautions,
whilethetoporfrontsideofthevalve(atthecoverflangewhereactuatoristobe
installed)thepipingMUSTBEINSTALLEDWITHOUTSTRESSORANYFORCESONTHE
VALVEBODY.

Demountablepipesectionattheinletandoutletfromthevalvefront(SeeFigure1)
isrequired.
Duringinstallationofactuatorandpositionindicatorthemainfeedandreturnpipe
needtoberemovedtoinspecttheinnerbodywhilesettingtheendpositionsof
theactionradiusoftheinsidevalve.
(forhorizontallyinstalledreversingvalves,thesettingofendpositionsneedstobe
completedbeforeinstallingconnectorelbowsontopofthevalve).

TheTeflongliderringinsidetheswingboxshouldbeinthecenteroftheflange
connection.IftheTeflonringisvisible,thevalveiseitherundersteeredorover
steered.Thisshouldbecorrectedwiththesettingsinthecontrolpanel.

Correctundersteeredandoversteeredpositionsasmarkedbelow.

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SECTION3: INSTALLATIONPLCCONTROLPANEL

Installthepanelaccordingthegivenelectricaldetailsandapplythepowerlinesas
welltheconnectionofthemotortothepanel(RST0GR)andthepositionindicator
(8x0.75mm2).

Confirmthatthecontrolpanelreceivespower.

Actuator&PositionIndicator:
Connectthecablesaccordingthediagram(appendix1)andcheckifpowerisbrought
tothepanel.

WARNING:Donotstickanybodypartsintothereversingvalvewhenactuatoris
powered

Afteractuatorandpositionindicatorareproperlymountedandallwiringsare
connectedaccordingtothediagram,followbelowstepstoadjustpositionindicator
whichcontroltheinitialalignmentpositionofvalveinlet/outletholesandswingbox
holeofthevalve.

ThePLCcontrolpanel(5valvesetup)

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Remark: PLCwillautomaticactivatesevery4hourstocompleteacleaning
cycle.Itisprogrammedtorecordthenumberofautomaticcycles
completed(downloadabletoPCwithspecificsoftware)

NOTE: Confirmthepositionoftheswingboxinoperationmode(whichis
wheretheSwingboxcomestorestafteritsinitialrunthatitmakes
whenthesystemispoweredup).
Flowthroughthevalveshouldbestraight,FrontInisstraightopposite
Backoutandviceversa.Ifthisisnotthecase,rearrangewiring
accordingtoreversewirediagraminappendix2.
.

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SECTION4: SAFETYFEATURES

A. MotorCurrentControl.
EveryValvehasadedicatedcurrentcontrolfuseinstalledinthecontrolbox.

Incasetheswingboxisobstructed(byexternalobjectsinthevalve)duringits
movement,theincreasedpowerconsumptionintheactuatorwilltriggertheswing
boxtoreturntoitsstartingposition(eitheroperationalorcleaningposition).The
alarmlightwillblinkandthesystemneedstoberesetforittoresumeoperations.


Motorcurrentresetbutton




Resetofthealarmbyreleasing
theovercurrentrelay.

Iftheproblempersistsitmaybenecessarytoremovethefeedpipesfromthefront
ofvalveandcheckfordebrisblockingtheswingbox.

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B. RunwayControl.

Therunwaytimeisthetimetheswingboxneedstotravelfromstarttoendposition.
ThemaximumrunwaytimeissetinthePLC.
RunwaytimeisdifferentforeachvalvesizeandispreprogrammedintoPLC.

Iftherunwaytakeslongerthenprogrammed,thesafetycontrolwillruntheswing
boxbacktoitsstartingpositionandtriggerthealarm.

Thesystemneedstoberesetforittoresumeoperations.

Iftheproblempersistsitmaybenecessarytoremovethefeedpipesfromthefront
ofvalveandcheckfordebrisblockingtheswingbox.

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SECTION5: STARTUP/OPERATION/MAINTENANCE

A) STARTUP

Tostartupthewatersystemfollowtheinstructionsfromthechiller/heatexchanger.

Makesurethevalveandflangeconnectionsdonotleakandthattherearenoair
buffersinthepipework.(Installairrelievevalvestherewherenecessary).
Oncethesystempump(s)isrunningforawhilethefirstcleaningcyclescanbe
activatedbyhand.Monitorthevalvebehaviorduringoperationandconfirmthatthe
swingboxrunssmoothly.Ifnot,theremaystillbeairlocksinthesystem.

Letthepumprunandtryagainaftersometime.

B) AUTOMATICOPERATION

Oncethepowerisactivatedandthesystemrunssmooth,every4hourstherewillbe
anautomaticcleaningcycle.ThetimeofthecycleisstoredinthePLChistory.

C) SERVICEANDMAINTENANCE

BrushesandBaskets
Thesystemismaintenancefreeandruns1to2yearswithoutanyattention.
Every2to5yearstheheatexchangerheadsshouldbeopenedtocheckthe
conditionofthepipes,brushesandbaskets.
Replaceinternalcomponentsifrequired.

ValveandActuator
Theactualrunningtimeoftheactuatorisquitelimited:+/2minutesadayor+/12
hoursperyear.
Anoilreplacementintheactuatorisadvisedevery2yearsdependingonthe
ambientconditionsofthevalve/actuatorset.ContactWATCOformoredetails.

D) NOTES

EQOBRUSHavoidsfoulingandscalingdepositstosettleintheheat
exchanger/condenserpipes.However,EQOBRUSHdoesnotremovedepositsin
pipesthathavealreadyhardened.

Installaftercleaningoronnewequipment
Itisthereforestronglyrecommendedtoinstalltheunitsonlyoncleanheat
exchangersystems(eitherimmediatelyaftermanualcleaningoronnew
equipment).

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 OperateonlywithactiveEQBreversingvalve
Wealsorecommendnotrunningtheheatexchangersystemwithoutactivating
thereversingvalveoverperiodslongerthan12hoursasthismayallowcalcium
depositstodepositandharden.

HeatExchangerwhennotinuse
DuringperiodswhenHeatExchangerorCondenserisnotinusewerecommend
to:
Keepsystem(HeatExchangerandReversingValve)filledwithwater
Donotstopthereversingvalvefrommovinginitssetinterval.Thiswillminimize
riskofvalvegettingstuckinitspositionoverprolongedperiodoftime

Waterinletstrainer
Toremovepossibleforeignobjectsobstructingthevalveitisnecessaryto
disconnectthepiping,hencethisrequiresastopoftheinstallation.Wesuggest
regularcheckingtopreventthis(mostlycausedbydefectstrainersatthewater
inlet)fromhappening.

Placementofcontrolbox
TheEQOBRUSHsystemcanoperatecompletelyindependentanddoesnot
interferewithanyofthethermalsystemsconnectedtotheheatexchangeror
condenser.Itisthereforenotnecessarytoconnecttootheroperationalcontrol
systemsinuse.However,wedostronglyrecommendinstallingthecontrolboxin
apositionwhereitisclearlyvisibletotheoperatingstaffastoensureanyblinking
alarmtobevisible.

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