ECOMax HE Manual New

ECOMAX SOLUTIONS PVT LTD
709|Supreme HQ |Near Audi Showroom|

Pune Bangalore Highway |Baner| Pune-411045
E-mail: sales@ecomax.in Phone: +91-20-66248982
Operations & Maintenance Manual
ECOMax-HE®
Automatic Tube Cleaning System
Table of Contents
Introduction ................................................................................................................................. 3
About Us ...................................................................................................................................................................................... 3
Inspection of System .................................................................................................................................................................... 4
Installation Note .......................................................................................................................................................................... 4
Handling of System ...................................................................................................................................................................... 4
P&I Diagram of System ............................................................................................................... 5
Part List....................................................................................................................................... 9
Description of System Components .......................................................................................... 13
1. Ball Trap (A) ...................................................................................................................................................................... 13
2. Ball Collector (B) ............................................................................................................................................................... 13
3. Booster Pumps (C) ............................................................................................................................................................ 13
4. Control Panel (D) .............................................................................................................................................................. 13
5. Control Valves (E) ............................................................................................................................................................. 13
6. Manual Valves (F) ............................................................................................................................................................. 13
7. Manual Valve (H) .............................................................................................................................................................. 13
8. Manual Valves (I) .............................................................................................................................................................. 13
9. Check Valves (G) ............................................................................................................................................................... 14
10. Pressure Gauges (J) .......................................................................................................................................................... 14
11. Balls .................................................................................................................................................................................. 14
Sponge Balls Disposal Procedure ............................................................................................. 14
Installation of Unit ..................................................................................................................... 15
Commissioning Procedure ........................................................................................................ 17
Pre-Commissioning Checks ........................................................................................................................................................ 17
Shutdown ................................................................................................................................................................................... 18
System Maintenance................................................................................................................. 19
Preventive Maintenance Schedule ............................................................................................................................................ 19
Daily Check-up ........................................................................................................................................................................... 19
Weekly Check-up ....................................................................................................................................................................... 20
Monthly Check-up ...................................................................................................................................................................... 20
Quarterly Check-up .................................................................................................................................................................... 20
Yearly Maintenance ................................................................................................................................................................... 20
Annexure A: Components of ECOMax-HE® ............................................................................. 22
Annexure B: HMI Screens Description ...................................................................................... 23
Annexure C: Wiring Diagram..................................................................................................... 30
Annexure D: Trouble Shooting .................................................................................................. 34
Ball Replacement Procedure..................................................................................................... 37
Ecomax Solutions Pvt Ltd., Pune Page 2

Introduction
About Us
ECOMAX SOLUTIONS PVT LTD is a leading company having its headquarters in Pune, INDIA engaged in
manufacturing of ECOMax-HE® Automatic Tube Cleaning System, ECOMax-CT® Electrolytic CT Water
Treatment System for Cooling Towers and ECOMax-CH® Electrolytic Chilled Water Treatment System.
ECOMAX is committed to offer clean technology based innovative solutions which result in substantial
Energy Saving and Water Saving for its clients. It promotes the technologies which are sustainable and
have positive impact on environment resulting into substantial energy and water savings.
ECOMAX was started in April 2014 as ECO GREEN SYSTEMS LLP. Since then it has grown in India & Overseas
market with Hundreds of satisfied customers.
ECOMAX has partnered with Strategic Partners from USA having deep industrial experience across the
globe and with this partnership ECOMAX plan to expand its markets in other geographies across the globe.
System Description
ECOMax-HE® patent pending system uses sponge balls to keep heat exchanger tubes clean. The sponge
balls are injected almost simultaneously at the heat exchanger tube sheet with the help of injection pump
thereby giving effective spread to the sponge balls in various tubes, the sponge balls would pass through
the tubes and clean the fouling /scales/deposits inside the tubes. Once the sponge balls come out of the
heat exchanger tubes they are collected at ball trap, they are sent back to the ball collector with the help
of collection pump. The entire process is a batch operation automatically controlled by PLC and occurs 2-
3 times in an hour. These pumps run hardly for few seconds for injection and collection of sponge balls.
ECOMax-HE® is maintenance free and designed to have long life & trouble free operation.
Fig: Schematic of ECOMax-HE®
The components of ECOMax-HE® are:

1. Injection Pump
2. Collection Pump
3. Ball Collector
4. Ball Trap
5. Programmable Logic Controller (PLC) Panel
6. Multicolor HMI
7. Electrically Operated Control Valves
8. Necessary Valves & Fittings
Inspection of System
Check all items carefully against the Delivery Challan. Inspect all components for damage upon arrival.
Check the unit nameplate after unloading.
Installation Note
Installation is to be performed by qualified personnel who are familiar with local codes, factory standards,
factory safety norms and regulations.
Handling of System
Avoid rough handling of the system. The system should be moved from the base to avoid any damage
during the handling. Carefully lift the system and put it at the specified location.

P&I Diagram of System
1BT-1BC

2BT-2BC

3BT-3BC

4BT-4BC

Part List
Before beginning the installation, verify the availability of all the required parts for the system installation
as per the P&I diagram mentioned in the next section.
Part List for 1BT-1BC
Sr. No. Item Description Quantity Part No. on Diagram

1 Ball Trap 01 A
2 Ball Collector 01 B
 Manual Valves ½” 04 H
3 Skid with following components: 01
Booster Pumps 02 C
PLC Control Panel 01 D
Control Valves 02 E
Manual Valves 1½” 02 F
Pressure Gauges 02 I
4 Other Accessories
Check Valves 1½” (SS)/2” (BS) 02 G
Manual Valves 1½” (SS)/2” (BS) 02 F
Manual Valves 1½” 02
Rubber Bush 04
Mesh Component 01 J


1 Ball Trap 02 A
Booster Pumps 02 C
Control Valves 04 E
4 Other Accessories
Rubber Bush 04
Mesh Component 01 J


1 Ball Trap 03 A
Booster Pumps 02 C
Control Valves 06 E
4 Other Accessories
Rubber Bush 04
Mesh Component 01 J


1 Ball Trap 04 A
Booster Pumps 02 C
Control Valves 08 E
4 Other Accessories
Rubber Bush 04
Mesh Component 01 J

Description of System Components
Systems main components description is given in the following sections.
Component nomenclature mentioned in brackets () directly corresponds to the nomenclature given in

the Schematic Diagram
1. Ball Trap (A)

The function of the Ball Trap is to catch/trap all the sponge balls that are injected into the heat
exchanger/condenser tubes. It is connected on the CW outlet pipe of heat exchanger/condenser. Its
unique design prevents ball loss from the system and ensures that no balls flow to the cooling tower.
2. Ball Collector (B)

Ball Collector located near the condenser is used to house the sponge balls. It has the sight glass which
enables the operator to observe the amount and condition of the balls. The sponge balls return to the
Ball Collector after the operation of each cycle. The sight glass is also used for ball replacement. The
Ball Collector has also the provision for venting the air that might get trapped during start-up and also
the provision for draining the Ball Collector for ball replacement.
3. Booster Pumps (C)

The two booster pumps located on the skid are used for injection and collection of the balls. The
injection and collection pump operate alternatively.
4. Control Panel (D)

Control panel is the heart of the system and it commands all the operations required for the system
automatically. It is located on the skid. The user friendly multicolor HMI guides the operator for
proper functioning of the system. It also gives the alarm for ball replacement.
5. Control Valves (E)

These valves control the flow of water to the Ball Collector and from the Ball Trap. They operate
alternatively for specified time automatically commanded by the PLC.
6. Manual Valves (F)

These valves remain open during regular operation. They are provided, in case the maintenance is
required on the injection, collection line & skid; they can be closed.
7. Manual Valve (H)

These valves remain close during regular operation. If Ball Collector needs to be drained for
any maintenance or if air needs to be vent it can be performed by opening these valves.
8. Manual Valves (I)

These valves remain open & are located below the pressure gauges.

9. Check Valves (G)
The check valves ensure unidirectional flow from the Ball Collector and from the Ball Trap. These
valves are located on the injection and collection line at the outlet of the Ball Collector.
10. Pressure Gauges (J)

These pressure gauges are located on the injection & collection pump to display the pump pressure.
11. Balls
The Sponge Rubber Balls are the key elements of the system and are responsible for cleaning the
tubes. The number of balls & diameter are decided depending on the heat exchanger/condenser
specifications. They are housed in the Ball Collector.
Cleaning Sponge Balls Disposal Procedure

Cleaning sponge balls are made of natural rubber, which is non-hazardous and biodegradable material
& hence those can be disposed off as per the guidelines of local pollution control board authorities.

Installation of Unit
Please read following instructions carefully before beginning the installation of the system on the heat
exchanger/condenser.
ECOMax-HE ATCS comes to you packed in two wooden boxes. The first step begins with unpacking. Un-
pack Box no. 1 and take out the items like Skid, Ball Collector and Fittings Box. Now un-pack Box no. 2 and
take out the Ball Trap & Ball collector stand. Unpack the fittings box and take out the valves & fittings like
swing check valves, manual ball valves and rubber bush.
1. Skid Positioning:
Once the un-packing is done, first fix the location of the Skid at a convenient location. In case of Single
Chiller system, the skid should be placed near the condenser inlet/outlet nozzle. In case of Multiple
Chillers, the skid position should be near the central chiller so that piping connections are minimized.
The skid should be positioned in such a way that the HMI on control panel should be easily accessible
to the operating personnel. Fix the rubber bushes at four corners of the skid.
2. Ball Collector Assembly:

Now Assemble the Ball Collector on Ball Collector stand and position the Ball Collector assembly near the
condenser nozzles, in such a way that the site glass of the ball collector should be easily visible and accessible
from the movement area.
3. Ball Trap Fixing:

Now Check the type of ball trap that is supplied and accordingly decide the position of Ball Trap at
Condenser Outlet Pipe for single chiller and in case of multiple chillers check the tags provided and
accordingly fix the position at condenser outlet pipe for the particular chiller.
Now the fabrication work can be started with ball trap fixing first. Cut the cooling water outlet pipe
after the condenser outlet nozzle at an appropriate position and weld the counter flanges then fix the
ball trap between the counter flanges as per the direction of arrow on the ball trap. Fix the manual ball
valve of appropriate size from fitting box at ball collection nozzle.
4. Tapping for Ball Injection:

Next take a ball injection taping of 1½” for Category-I System (i.e. Up to 600TR Chillers) and 2” for
Category-II System (i.e. 601TR to 1000TR) about 300 mm from the condenser inlet nozzle flange and
then fix the manual ball valve of appropriate size.
5. Tapping for Injection & Collection Pumps:

Take an injection pump tapping of 1½” for Category-I System (i.e. Up to 600TR Chillers) and 1½” for
Category-II System (i.e. 601TR to 1000TR) from Cooling Water Inlet Header. It’s critical to maintain

minimum 2-meter distance between ball injection tapping and injection pump tapping. Fix the manual
ball valves of appropriate size on injection pump tapping.
Next take a collection pump tapping of 1½” for Category-I System (i.e. Up to 600TR Chillers) and 1½”
for Category-II System (i.e. 601TR to 1000TR) on Cooling Water Outlet Header & fix manual ball valve
of appropriate size on collection pump tapping.
6. Fixing of Swing Check Valves:

Fabricate F- Type component of 1½” for Category-I System (i.e. Up to 600TR Chillers) and 2” for
Category-II System (i.e. 601TR to 1000TR) maintaining a gap of 150 mm between top & bottom
branches. In the F-type component the top branch is for injection and bottom branch is for collection.
Now fix the component on ball collector and fix the swing check valves as per the directions shown &
these valves must be fixed horizontally only.
7. Piping Connections for Ball Injection & Collection:

Connect 1½” pipe for Category-I System (i.e. Up to 600TR Chillers) and 2” pipe for Category-II System
(i.e. 601TR to 1000TR) between injection swing check valve and ball injection point at condenser inlet
pipe. Repeat the same process for piping connection between collection swing check valve & ball
collection point on ball trap.
8. Piping Connection from Ball Collector to Skid:

Connect 1½” Pipe for Category-I System (i.e. Up to 600TR Chillers) and 1½” Pipe for Category-II System
(i.e. 601TR to 1000TR) between the connection provided below ball collector and System-I connection
on the skid in case of single system and repeat the same in case of multiple chiller system.
9. Piping Connection from Injection Pump Tapping to Injection Pump:

Connect 1½” pipe for Category-I System (i.e. Up to 600TR Chillers) and 1½” pipe for Category-II System
(i.e. 601TR to 1000TR) between injection pump tapping & Injection Pump suction.
10. Piping Connection from Collection Pump Tapping to Collection Pump:

Connect 1½”pipe for Category-I System (i.e. Up to 600TR Chillers) and 1½” pipe for Category-II System
(i.e. 601TR to 1000TR) between collection pump tapping & collection pump discharge.
11. Flushing of Piping:

Once the Piping is completed flush the fabricated piping and check for leakages in piping connections
if any.
12. Installation of Pressure Gauges:

Install the Pressure Gauges provided with the system on the injection & collection pump
13. Providing Power Supply:
Provide 3 Phase 50/60 Hz 415V AC Raw Power supply to the ECOMax-HE control panel. Use 1.5 Sq.mm
four Core cable for Category-I System (i.e. Up to 600TR Chillers), where connected load is 3.0 HP and
operating load is 1.5 HP.

Use 2.5 Sq.mm four Core cable for Category-II System (i.e. 601TR to 1000TR), where connected load is
6.0 HP and operating load is 3.0 HP.
Connect the power supply cable in the connectors (R, Y, B & N) provided in ECOMax-HE control panel
14. Providing Interlock:

Use 1 Sq.mm two core cable for providing the interlock from chiller control panel to ECOMax-HE
control panel. Connect the cable to connector (X1) in ECOMax-HE control panel in case of single chiller
and in case of multiple chillers at the connectors (X2, X3 and so on) by using Potential Free Contacts or
NO (Normally Open) contact from chiller control panel.
Commissioning Procedure
Pre-Commissioning Checks
1. Check the electric power supply and ensure that the control panel is charged with 3-phase, 415
VAC electric power supply
2. Check all the valves & fittings for leakage & correct if necessary
3. Inspect all water piping for flow direction and correct connections
4. Inspect the check valve on injection pipe and collection pipe for correct direction
5. Check the control valves operation for opening & closing.

Commissioning of ECOMax-HE®
1. Start the condenser pump

2. Initially put 10-20 balls into the Ball Collector, ensure the balls are squeezed in the water before
putting them into the Ball Collector as shown in below pictures:
X
3. Open all the 1½”/2” & 1”/ 1½” Manual ball valves installed on the interconnected piping.
4. Ensure that the pump MPCBs and 230 VAC MCB are ON before starting the power supply to the
control panel
5. Switch ON the supply to the control panel and set all the timing such as Injection and Collection
time, Time between the cycle & Ball Circulation time as per ECOMax-HE® guidelines
6. Perform manual operation of the cycle to check if the balls are injected and collected properly
7. Perform automatic operation and adjust the timing for the smooth operation of system
8. Put all the required number of balls into the Ball Collector necessary for routine operation as
specified by ECOMax-HE® at the time of commissioning
9. Perform 3-4 automatic operation
Shutdown
Before shutting down the system make sure that the balls are in the Ball Collector and none of the two
(Injection or collection) cycle are in operation if yes then let the operation get completed and then switch
OFF the power supply to the control panel with the help of switch located on the control panel.
1. Switch OFF the power supply to the control panel

2. Close the Manual valves on skid
3. Close Manual valves on ball injection and ball collection pipe
4. Perform the operation that operator wants to do (like ball replacement, any maintenance etc)

System Maintenance
Preventive Maintenance Schedule

PREVENTIVE MAINTENANCE SCHEDULE
Operations Daily Weekly Monthly Annually
General
- Check Injection & Collection cycle operation once X
- Check quantity of balls from site glass provided on the ball collector X
- Check ECOMax-HE® is running on that chiller whose interlock is active X
- Check operation of Injection & Collection control valve X
- Clean Ball Collector for any dirt X
- Check for leakage X
- Visually inspect system for any loose or damaged component X
- Clean sight glass from inside & outside for clear vision X
- Check for normal operation of system X
Electrical
- Check interlock terminals for tightness, tighten if necessary X
- Check terminals for tightness, tighten if necessary X
- Clean control panel from inside & outside X
Components
- Clean Ball Trap screen if necessary X
Note:
1. Weekly operations include all daily operations.
2. Monthly operations include all weekly operations.
3. Quarterly operations include all Monthly operations
4. Annual operations include all weekly, monthly and quarterly operations.
Daily Check-up
1. Look through the Ball Collector’s sight glass, verify it has required number of sponge balls
2. Wait for the injection cycle to start
3. Once injection cycle starts verify that balls are injected and released into the heat
Exchanger/condenser
4. Wait till the end of the operation
5. Visually confirm that the balls have returned to the Ball Collector
If the sponge balls have returned, the system is functioning properly

Weekly Check-up
1. Count the number of balls through sight glass
2. If quantity of balls seems low compared to that recommended during installation, add new
sponge balls in the Ball Collector
Balls addition is to be done by opening sight glass on Ball Collector. Repeat daily checkup and
ensure balls have returned.
Monthly Check-up
1. Physically check the balls quantity & condition of the balls
2. If ball quantity & condition is Okay, continue with the same balls
3. If ball quantity is less & add the balls to make up the quantity
4. If the balls are hard or worn out change the complete ball quantity
Quarterly Check-up
1. Compulsorily replace the entire quantity of the balls with new balls
Yearly Maintenance
Clean the Ball Collector and Ball Trap as per the guidelines mentioned below:
1. Shut down the system
2. Close the water connections
3. Drain the water from Ball Collector
4. Remove sight glass and clean the Ball Collector & connect it back after cleaning
5. For Ball Trap drain the condenser and ensure no water is present inside the Ball Trap
6. Open the Ball Trap from ball exit side, visually inspect the screen inside for any cleanliness
7. Clean them if necessary and put them back in position & fix all the parts to their respective
positions
 Important Notes
 If the number of balls returned back to the Ball Collector are less than the normal quantity,
does not indicate that system is not operating properly
 If no balls are there in the Ball Collector after the complete operation of the system, refer
Trouble Shooting page for guidelines or contact Ecomax office representative
 Warning:
If the chiller runs without the ECOMax-HE® for a number of days, condenser tubes will
develop a layer of scale that cannot be removed by the sponge balls. If this happens,
the heat exchanger/condenser must be opened and descaling/cleaning should be done.
The chiller should be restarted with ECOMax-HE®.

For Any Type of Fault Regarding ECOMax-HE® Identified and Not Resolved, Please Contact ECOMAX SOLUTIONS PVT LTD Office with following
escalation matrix:
Level :- 1
Contact
Region Base location State/Cities Covered Name Designation details Email ID
Haryana, Jammu & Kashmir, Himachal
Pradesh, Punjab, Rajasthan, Uttar Pradesh,
North Delhi Bihar, Uttarakhand Abhilash Thakur Service Engineer 9595114198 abhilasht@ecomax.in
East Delhi West Bengal, Jharkhand Abhilash Thakur Service Engineer 9595114198 abhilasht@ecomax.in
Gujarat-Ahmedabad Ahmedabad, Gandhinagar, Vadodara Akshay Bharsakle Service Engineer 9881388252 guj@ecomax.in
Gujarat-Ankleshwar Madhya Pradesh, Ankleshwar, Bharuch Avinash Kokate Service Engineer 9175481233 guj1@ecomax.in
West
Maharashtra-Pune Chhattisgarh, Maharashtra Angad Deshmukh Sr. Service Engineer 8668231961 angadd@ecomax.in
Maharashtra-Pune Pune Satish Rajurkar Service Engineer 8999791245 seho1@ecomax.in
Bangalore Karnataka, Kerala, Tamilnadu Vishnu Ramachandran Service Engineer 9995341740 vishnur@ecomax.in
South
Hyderabad Telangana, Andhra Pradesh Santosh Tallikar Asst Manager 9518314029 santosht@ecomax.in
Level :- 2
Region Base location Name Designation Contact details Email ID

North & West Pune Kishor Nimkarde Asst-Service Manager 9518344560 kishorn@ecomax.in
East & South Hyderabad Santosh Tallikar Asst-Service Manager 9518314029 santosht@ecomax.in
Level :- 3
Region Base location Name Designation Contact details Email ID

India Pune Deepak Waghmare Head-Service 9607933395 deepak@ecomax.in

Annexure A: Components of ECOMax-HE®
Ball
Ball Collecto
Trap
Skid with
Control
Panel

Annexure B: HMI Screens Description
The Control Panel consists of a multicolor screen touch HMI which is composed of following screens:
A. Home Screen:
This screen displays the number of existing system and their status of operation. If the buttons
(1/2/3/4) turns green means the particular systems are in operation. The numbers shown are for
count down for next cycle
Also the screen has the function of manual operation of system which can be accessed by inserting
the password on same screen.

B. Operational Screen:
I. Injection Cycle Screen:
This screen shows the injection cycle operation and total time for injection of the balls in CW inlet
pipe of heat exchanger/condenser & ABCDEFGHIJ where it shows on which chiller the cycle is in
operation
II. Ball Circulation Screen:
This screen shows the ball circulation time and after completion immediately the collection cycles
starts & ABCDEFGHIJ where it shows on which chiller the cycle is in operation.

III. Collection Cycle Screen:
This screen shows the collection cycle operation and total time for collection of the balls from Ball
Trap to Ball Collector & ABCDEFGHIJ where it shows on which chiller the cycle is in operation.
C. Input Screen:
This is screen where the time for system operation & ball replacement is set. This screen is
password protected and time can be changed by authorized person only.
D. Log Screen:

This screen displays Number of cycles performed by system in the said system working hours
Ball Replacement (BR 1/2/3/4):
After the specified number of cycles, the system gives an alarm for ball replacement due for the
respective chillers (BR 1/2/3/4). After this alarm balls need to be replaced & (BRD 1/2/3/4) buttons
are used to reset the ball replacement timer once the ball replacement is done.
E. Valves Operation Screen:
This screen displays number of times the valves have operated in the said system working hours
F. Alarm Screen:

This screen displays the different type of alarms for the fault that may occur in the system and
red bar will scroll for the particular alarm on each screen.
G. System Information Screen:
This screen displays the Model No., Serial No., Year of Manufacturing., and Date of commissioning
of the system.
H. Manual Operation Screen:

This screen is used to take the cycle manually; this screen is password protected & pops up when
the password is inserted on the Home Screen.
I. Balls Information Screen:
This screen displays the Balls Diameter & No. of Balls required for the system.

J. System Name Screen:
You can give names to system 1/2/3/4 as per your chiller number so that any person can
understand on which chiller system is operational.

Annexure C: Wiring Diagram

Annexure D: Trouble Shooting
Sr. No. Type of Fault Additional Check How to Determine the Fault Reason Solution
1 Pumps not 1.1 Check supply to the Controller and wire connection Controller not working 1.1.1 Check & Repair/Replace the
operating between pumps if all ok still not running Controller
1.2 If supply ok controller working & still pump not Pump Problem 1.2.1 Check & Repair/Replace Pump
working Motor
Pump not giving desired 1.3 Open the air vent on pump discharge & check for Air in condenser inlet pipe 1.3.1 Open the air vent on pump
pressure airlock discharge slightly & remove the airlock &
operate the pump
1.4 Open the pump impeller & check for any dirt or Dirt or welding particle 1.4.1 Ope the pump impeller, clean it &
welding particle stuck inside stuck inside the pump then operate the pump
impeller
Pump Motor Heating Up 1.3 Please check the pump discharge pressure for Pump is running at very less 1.3.1 Throttle the valve on pump
measuring the head at which pump is operating by head discharge for additional head so that
referring the pump curve pump will operate at desired head
2 Injection Balls are in Ball Collector 2.1 Make sure all manual valves on skid, Injection & Manual Valve on Injection 2.1.1 Open all manual valves on Injection
Problem collection pipe are open and Injection Pump is line/Skid/Injection Pump line, Skid & Injection Pump suction
operating at full load & designed head by checking the suction tapping point is tapping point or clean the pump impeller
current from control panel with multimeter & observe closed or there is dirt inside for any dirt inside it
pump head from pressure gauge at pump discharge if it the pump impeller
doesn’t see 2.1.1
2.2 Again do manual operation & make sure manual Swing Type Check Valve is 2.2.1 Clean the Swing Type Check Valve
valves on skid, Injection & collection pipe are open and choked because of dirt on injection line for any dirt / replace it.
control valve on injection line is open & still balls not
injected see 2.2.1
2.3 Again do manual operation & make sure manual Injection Control Valve not 2.3.1 Check connection between control
valves on skid, Injection & collection pipe are open and opening or partially valve & control panel or repair/replace
control valve on injection line is open if it doesn’t see opening the actuator/control valve on injection
2.3.1 line
2.4 Again do manual operation and still no injection of Collection Control Valve 2.4.1 Check connection between
balls, close manual valve on collection line before opening fully or partially control valve & control panel or replace
control valve and re-operate. If balls are injected see the actuator/control valve on collection
2.4.1 line

2.5 Retry manual operation, still no injection balls, Wrong connections from 2.5.1 Correct the connections or again
check during injection if two control valves of injection ECOMax-HE control panel upload the program for smooth
are open at a time if yes then see 2.5.1 to control valve or problem functioning
in PLC program logic
3 Collection 3.1 Make sure manual valves on skid, collection line & Manual Valve on Collection 3.1.1 Check all manual valves on skid,
Problem collection pump discharge tapping on condenser line/Skid/Collection Pump collection line & collection pump
outlet line are open. Run the system again by pressing discharge tapping point is discharge tapping on condenser outlet
the manual operation button on the panel. At the end closed or there is dirt inside line are open or clean the pump impeller
of injection cycle, check collection pump is operating the pump impeller for any dirt inside it
at full load & designed head by checking the current
from control panel with multimeter & observe pump
head from pressure gauge at pump discharge. Wait till
the end of cycle, if the balls don’t return to Ball
Collector then see 3.1.1
3.2 Run the system again by pressing the manual Swing Type Check Valve is 3.2.1 Clean or Change Swing Type Check
operation button on the panel. At the end of injection choked on injection pipe Valve on injection pipe
cycle, close manual valve on injection pipe. Wait till because of dirt
the end of cycle, if the balls return to Ball Collector-
Check the Swing Type Check Valve on injection pipe is
functioning properly.
3.3 Run the system again by pressing the manual Swing Type Check Valve is 3.2.1 Clean or Change Swing Type Check
operation button on the panel. At the end of injection choked on collection pipe Valve on collection pipe
cycle, close manual valve on injection pipe. Wait till because of dirt
the end of cycle, still balls don't return to Ball
Collector- Check the Swing Type Check Valve on
collection pipe is functioning properly.
If balls have not returned 3.4 Retry manual operation and partially open the ½” Airlock in collection pipe 3.4.1 Check for water leakage on
to Ball Collector, check valve on Ball Collector & release the air. If balls return collection pipe.
the Ball Collector if there to Ball Collector then re-operate and no ball collection
is air inside it if yes then then there is water leakage on collection pipe
see #3.4. If there is no air
in Ball Collector then see
#3.4.1
3.5 Retry manual operation, if balls still don’t return to Check the water quality 3.5.1 Replace the old balls with new balls
the Ball Collector, check the condition of balls if
they are spongy or became hard. If balls have
became hard see 3.5.1

3.6 Retry manual operation, if balls still don’t return to Balls inside the condenser 3.6.1 Restart the chiller and condenser
the Ball Collector, check whether chiller & condenser as chiller was stopped after pump & take the injection & collection
pump was stopped when injection cycle was initiated balls were injected cycle
by system if yes then see 3.6.1
3.7 Retry manual operation, if balls still don’t return to Due to less distance 3.7.1 Shift the Injection pump suction
the Ball Collector, check the distance between Injection between Injection Pump tapping at 2-3 meters from Ball injection
Pump suction tapping and Ball injection point on suction tapping and Ball point on condenser inlet line or weld a
condenser inlet pipe if it is less than 2 meters then see injection point balls going in reducer with mesh on the bigger of it at
3.7.1 injection pump suction pipe injection pump suction tapping.
3.8 Retry manual operation, if still balls don’t return to Wrong connections from 3.8.1 Correct the connections or again
the Ball Collector, check during collection if two control ECOMax-HE control panel upload the program for smooth
valves of collection are open at a time if yes then see to control valve or problem functioning
3.8.1 in PLC program logic
3.9 Retry manual operation, if still balls don’t return to Balls gone to panel cooling Blind the taping on condenser cover &
the Ball Collector, check if the chiller condenser has pipe heat exchanger as that is shift the panel cooling pipe at minimum
going to panel cooling heat exchanger the least resistance path distance of 1 meter from ball injection
point by taking a taping on condenser
inlet pipe
3.10 Retry manual operation, if still balls don’t return to Tubes not cleaned properly Open condenser cover from both sides,
the Ball Collector, check whether tubes are clean & or tubes are blocked either clean the condenser tubes, check the
checked properly from both sides of condenser if not from front side or backside tubes with id gauges & retry the cycle
then see 3.10.1
3.11. Retry manual operation, if still balls don’t return Condenser pump not giving Clean the strainer/Design a proper pump
to the Ball Collector, check the dP across condenser if it the desired flow because of for required flow & head/ Run the pump
is not sufficient than what is required then see 3.11.1 either strainer after pump is on full frequency to get the desired flow
chocked or pump design is
not proper to give desired
flow or pump flow is
controlled VFD by adjusting
its frequency
4 Interlock 4.1 If interlock cable is connected between Chiller panel Interlock connection is not 4.1.1 Check the interlock connection and
Problem & ECOMax-HE panel while chiller is running and still proper connect the wire between chiller panel
cycle not started see 4.1.1 potential free contact & system panel.
Re-operate to check

Ball Replacement Procedure
Prior to Inserting/Replacing balls, make sure to squeeze the balls in water to thoroughly soak them,
the balls should then sink in the water and not float as shown in the pictures below:
X
1. Shut off the power supply from the control panel.
2. Close Manual Valves located on pipelines at Injection & Collection above Ball Collector.
3. Close Manual Valves located on pump suction pipeline
1. Open the air vent valve located at the top of Ball Collector
2. Drain the water from the Ball Collector completely by opening the drain valve
3. Open the Site Glass located on the Ball Collector
4. Take out the old set of balls and compare them with new set of balls for any reduction in the diameter.
Replace the old balls having reduced diameter with new balls
5. If the quantities of balls are less, then add new balls to make-up the required number of balls.
6. Put back the Site Glass on the Ball Collector and tighten the bolts properly so that there is no leakage
7. Close the drain and air vent valves located on Ball Collector
8. Open manual valves located on pipelines at pump suction, Injection & Collection above Ball Collector.
9. Partially open-air vent valve located on Ball Collector to release air in Ball Collector and then close it.
10. Start the power supply to the control panel
11. Verify that the balls are injected into condenser
12. Observe one complete cycle of operation
13. Visually confirm that the balls have returned to Ball Collector.

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ECOMAX SOLUTIONS PVT LTD

709|Supreme HQ |Near Audi Showroom|

Operations & Maintenance Manual

Ecomax Solutions Pvt Ltd., Pune Page 2

Fig: Schematic of ECOMax-HE®

The components of ECOMax-HE® are:

Ecomax Solutions Pvt Ltd., Pune Page 3

Ecomax Solutions Pvt Ltd., Pune Page 4

Ecomax Solutions Pvt Ltd., Pune Page 5

Ecomax Solutions Pvt Ltd., Pune Page 6

Ecomax Solutions Pvt Ltd., Pune Page 7

Ecomax Solutions Pvt Ltd., Pune Page 8

Part List for 1BT-1BC

Sr. No. Item Description Quantity Part No. on Diagram

3 Skid with following components: 01

PLC Control Panel 01 D

Manual Valves 1½” 02 F

Check Valves 1½” (SS)/2” (BS) 02 G

Manual Valves 1½” (SS)/2” (BS) 02 F

Manual Valves 1½” 02

Ecomax Solutions Pvt Ltd., Pune Page 9

Sr. No. Item Description Quantity Part No. on Diagram

3 Skid with following components: 01

PLC Control Panel 01 D

Manual Valves 1½” 02 F

Check Valves 1½” (SS)/2” (BS) 04 G

Manual Valves 1½” (SS)/2” (BS) 04 F

Manual Valves 1½” 02

Ecomax Solutions Pvt Ltd., Pune Page 10

Sr. No. Item Description Quantity Part No. on Diagram

3 Skid with following components: 01

PLC Control Panel 01 D

Manual Valves 1½” 02 F

Check Valves 1½” (SS)/2” (BS) 06 G

Manual Valves 1½” (SS)/2” (BS) 06 F

Manual Valves 1½” 02

Ecomax Solutions Pvt Ltd., Pune Page 11

Sr. No. Item Description Quantity Part No. on Diagram

3 Skid with following components: 01

PLC Control Panel 01 D

Manual Valves 1½” 02 F

Check Valves 1½” (SS)/2” (BS) 08 G

Manual Valves 1½” (SS)/2” (BS) 08 F

Manual Valves 1½” 02

Ecomax Solutions Pvt Ltd., Pune Page 12

Component nomenclature mentioned in brackets () directly corresponds to the nomenclature given in

1. Ball Trap (A)

2. Ball Collector (B)

3. Booster Pumps (C)

4. Control Panel (D)

5. Control Valves (E)

6. Manual Valves (F)

7. Manual Valve (H)

8. Manual Valves (I)

Ecomax Solutions Pvt Ltd., Pune Page 13

10. Pressure Gauges (J)

Cleaning Sponge Balls Disposal Procedure

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2. Ball Collector Assembly:

3. Ball Trap Fixing:

4. Tapping for Ball Injection:

5. Tapping for Injection & Collection Pumps:

Ecomax Solutions Pvt Ltd., Pune Page 15

6. Fixing of Swing Check Valves: