Operation & Installation Manual for Wave Pool

2016

WAVEPOOL 2016

Arihant industrial industrial corporation corporation ltd. INFUN PARK EQIUPMENT 1/1/2016

ARIHANT INDUSTRIAL CORPORATION LIMITED

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Document name: WAVE POOL MANUAL

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ARIHANT INDUSTRIAL ARIHANT INDUSTRIAL CORPORATION CORPORATION LIMITED Arihant Complex Complex NH8, Sativali Sativali (E) Thane-401208 Maharashtra INDIA www.arihant.com www.arihan t.com

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Table of Contents A.)Technical Specification Specification .................................................................................................................................1 1.) Area. 2.) Wave pattern. 3.) Machine room layout. 4.) Equipment.

B.) Installation ....................................................................................................................................................18 1.) Flapper boxes. 2.) Bellows placement. 3.) GRP ducting. 4.) Blower Placement. 5.) Compressor Assembly 6.) Pneumatic assembly. 7.) Electrical Panel Assembly C.) How to operate your WAVE POOL ............................................................................................................47

D.) How to maintain your WAVE POOL .........................................................................................................48 1.) Compressor maintenance. 2.) Electrical panel maintenance. 3.) Blower maintenance. 4.) Festo Cabinet & Pneumatic maintenance. 5.) Flapper Box Maintenance.

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WARNING Safety First! When installing, operating, or servicing the equipment, always use proper safety procedures in accordance with State and Local laws and regulations. To avoid injury to yourself, others, or damage to the equipment, adhere to the following safety practices. PERFORM ALL COMBINED CHECKS MENTIONED IN THE BOOKLET DURING COMMISIONIN COMMISIONING! G!

1. Always use qualified personnel and technicians for installation, maintenance, and servicing of Electrical control panels, Pneumatic system, blowers and motors. Electrical connections, servicing and maintenance should be performed only by properly trained, t rained, certified technician. 2. Always disconnect the electrical power at the main line before working on the motor and / or blower assembly. Take special precautions to ensure that the t he power cannot be turned “ON” while you are working on the motor or blower assembly. Observe proper Lockout / tag out procedures. 3. Do not operate the blower assembly without the inlet cover installed, or with the Blower inlet unprotected by a proper filter element assembly. Inlet Failure to operate blowers without proper guarding could result in personal injury or death. 4. Do not operate the blower with w ith the discharge outlet open. Failure to operate blowers under a working load could result in high current draw, damaging the motor and electrical systems. 5. Always keep hands, tools, long hair, loose clothing, neckties, jewelry or similar loose items away from all moving or rotating parts. 6. Always check the three phase availability & ensure the t he Power supply voltage is 415 volts.

7. Do not attempt to do any work on flapper unit system while it’s on motion. Before doing any work on flapper unit system please make it sure that the ball valve (air-line) should be closed and the power lines are “off “position

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Equipment Arrival and Inspection: Inspection : 

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At the time of receipt, fully inspect Wave pool equipment, equipment, enclosure, and all contents for shipping damage or missing components. Checks the part list to confirm that all equipment’s and parts have been received. If any equipment or parts are damaged or missing due to shipping please feel free to contact ARIHANT contact ARIHANT Customer care telephone no. +91-7507778271/72/73/74 or email : [email protected] Care should be exercised to not drop or damage the blower assembly, air compressor Unit and flapper box unit when moving it.

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Welcome to ARIHANT WATER MOVERS We manufacture one of the best wave pool equipment systems in the world. ARIHANT has been the name in Manufacturing WATER PARKS & its equipment’s for over 27 years. Our products are the choice of leading Water parks, resorts and organizations worldwide because of unsurpassed performance, service and leading edge innovation. Proper installation, operation and maintenance of Wave pool equipment equipment system will ensure years of reliable and trouble free service.

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Total Area

-: 9570 Square Meters

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Machine Room Area


Water Body Area


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Beach Area


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No. Of Chamber

-: 18 Chambers

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Total Power Required

-: 830 HP

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Total Water Volume

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31,74,500 Liters

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1.)

WAVE POOL LAYOUT

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2.)

MACHINE ROOM LAYOUT:

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1.)BLOWERS: 1.) BLOWERS: 08Nos

Technical parameters: 1. Capaci Capacity: ty: 25000 25000 cubi cubicc m./Hr m./Hr.. 2. Static Static Pres Pressur sure: e: 762 762 mm (30 (30 “) WG. @ 20 deg. C. 3. Fan Fan speed speed:: 2450 2450 4. a) b) c) d)

Blow Blower er Moto Motor: r: BHP/BK BHP/BKW W : 86.75/ 86.75/64. 64.72 72 Top speed: 113.8 m/sec m/sec Effi Effici cien ency cy:: 80 % Static load of fan with motor: motor: 1120Kg. e) Dynamic Dynamic load load of fan with motor: motor: 1456 Kg.

7.) Casing: Casing: 5 mm thk. 8.)Impeller a.) B.P. & Blades Blades : 4 mm b.)Shroud b.) Shroud : 3.15 mm

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There are two types of blower used a.)Left hand sided blower b.)Right hand sided blower. The blower type is determined on the motor placement either right or left from the pool end. The motor on left is a LHS type blower and the motor on right is a RHS type blower. To reduce vibration and sound transmission, the blower assembly is mounted on a base frame, with rubber anti-vibration fixings. The blowers have specially made SS-430 Rotors for corrosive environment. The blower actuation system is pneumatically operated for automatic and quick and precise response

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2.)COMPRESSOR: 2.) COMPRESSOR: 1 NO.

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The compressor is an electric motor driven, single stage screw compressor, complete with accessories accessories piped, wired and baseplate mounted. It is a totally self contained air compressor package. The standard compressor is designed to operate in an ambient range of 2_C to 40_C (35.6_F – 104_F) with a special option package available to operate in ambient temperatures ranges from 2_C up to 50_C (35.6_F up to 124_F). The maximum temperature is applicable to either version up to a maximum elevation of 1000m (3280ft) above sea level. Above this altitude significant reduction in maximum allowable ambient temperature is required. Compression in the screw type air compressor is created by the meshing of two (male & female) helical rotors. The air/coolant mixture discharges from the compressor into the separation system. This system removes all but a few PPM of the coolant from the discharge air. The coolant is returned to the cooling system and the air passes through the after cooler and out of the compressor. compressor. Cooling air is moved through the coolers by the cooling fan and discharged from the machine. The power transmission from the drive motor to the air end male rotor is by pulley and belts. The constant auto tensioning system, using air-end mass torque and gas 12


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arm, ensures that the belts are always under the correct tension, eliminating the need for adjustment and maximizing the life of the belts. By cooling the discharge air, much of the water vapor naturally contained in the air is condensed and may be drained from the downstream piping and equipment. The coolant system consists of a sump, cooler, thermostatic valve and a filter. When the unit is operating, the coolant is pressurized and forced to the compressor bearings. The compressor load control system is automatic on–off line. line. The compressor will operate to maintain a set discharge line pressure and is provided with an auto restart system for use in plants where the air demand varies sufficiently to allow a compressor to shut down and save power. Significant system volume will assist this and is recommended. The compressor basic connection is as follows: 

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The assembly is much further explained in detail in the manual sent along with the compressor equipment. Ref. name: 5434052 Pegasus Ops Manual & Parts book 05 latest.

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3.)CONTROL 3.) CONTROL PANEL

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The control panel we have used is of size 2700 x 2000 x 600 The Control Panel (CP) is a completely wired panel mounted inside the room. It consists of MCBs, 24VDC SMPS, Relay Cards, PLC, HMI, Cable Trays, DIN Rails, and the necessary wiring. The PLC-I/O’s PLC-I/O’s are connected to the field through various signal conditioning cards. The PLC is interfaced to all motors, through their respective feeders. The CP communicates to the Wave pool System Control by HMI provided on CP.

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The Programmable Logic Controller (PLC) is at the heart of all the controls and sequencing of the CP. It generates the necessary sequence sequence for generating patterns in wave pool. The main CPU of the Mitsubishis PLC used for Wave pool System. The PLC has one comm. Ports – which is used for communicating to the HMI. The PLC has memory to store its logic as well as some data. Most of the control signals inside and outside the CP need 24 V DC. For this purpose, we have used two redundant SMPS to generate the regulated 24 V DC from 110 V AC. The PLC, HMI, Relay Cards, and most of the other controls work on 24 V DC. The equipment controlled are : 1. 8 blowers 2. 1 compressor 3. 3 Junction boxes. (Pneumatic control) 4. Flapper box actuators. The panel has name plates both in English as well as in Vietnamese font for easy understanding.

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4.)  

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FLAPPER BOXES.

There are a total of 18 flapper boxes used in the wave pool. Each flapper box is used as an actuator to let air in and let air out from the duct to the wave pool. We have used S.S flapper boxes which are easy to install and operate.

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5.)PNEUMATIC 5.) PNEUMATIC CABINETS:

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There are total of 3 junction boxes made from Festo used. Festo cabinets are junction boxes for pneumatic actuation. Each pneumatic cabinet has 10 solenoid valves electrically operated and controlled by the control panel directly.

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6.)HIGH 6.) HIGH PRESSURE DUCTS.

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GRP (Glass Reinforced Plastic) ducting is designed and made for high pressure air generated from the blowers. There are total of 72 duct pieces:

1.) 90 deg. – bend with flanges. : 2.) TEE – 800 x 316 -1000Lg: 3.) TEE – 1000 x 600 -1000Lg: 4.) Reducer 629 x 396 – 1000Lg: 5.) Extension 800 x 687 Lg.: 6.) Extension Extensio n 600 x 1000 Lg.: 7.) Duct 990 x 20 thk. :

18 no. 18 no. 8 no. 8 no. 16 no. 4 no. 2 no.

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We will start with the installation process now. The manual will provide you easy and specific steps for installing of wave pool equipment’s.

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Flapper boxes.

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As mentioned previously our flapper boxes are stainless steel precise pneumatically pneumatically operated. Now as they say “Your house gets as strong as your foundation.” The foundation.” The first thing to check is the foundation. The placement of wave chamber has to be according to the drawings provided. Re verify with the detail drawings provided for the chambers. Refer drawing no. IF/**/**/1516/A33-CL-03 If the chambers are not according to the dimensions re correct the placement before placing the flapper boxes. Once it’s done. Cut the base gaskets into required size strips and stick it to the flapper box base. Place the flapper boxes on respective coordinates as shown in the reference drawings.

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Make sure to check the LHS flapper or RHS flapper before placement.

Please note DO NOT ANCHOR the flapper boxes as of yet.

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Bellows.

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Once the flapper boxes are placed in the determined location we shall place the bellows over it as shown in the drawings. We will be using M12 X 75 SS BOLTS. We will be using Rubber Gasket – OD 525 X ID 359 X 3 Thk. Provided with the equipment’s.

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3.)

GRP DUCTING 

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Once the bellows are fixed appropriately, we need to proceed to ducting. Our ducts are made of G.R.P (GLASS REINFORCED PLASTIC) and are very simple to install. We will begin the ducting from the center point of the assembly. Our ducting is well over 35 m, in order to maintain precision and an inline assembly we will begin from the center. The ducting will be done as per the following reference drawing.

The no’s mentioned in the drawing are marked on the ducts provided at the site with proper matching done in house by us to reduce the stress on site. We will begin from the actuator no. 9, 10. The ducts we will begin with are  90deg. Bend: I, J.  Tee-800 x 316: (20-21);(21-22)  Extension- 800 x 687 Lg.: (19-20) ; (22-23)

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Types of ducts that were mentioned before will be used in sequence as mentioned here. We will begin from flapper box bellows and end at Blower bellows. a.)90 a.) 90 bend with flange.

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The 90deg bend GRP duct is nut bolted to the bellow with M12 bolts same as the flapper boxes. Both the bellow and the 90 deg. Bend use the same size gasket. The 90 deg. Bend comes with a 350NB pipe size. All nut bolts need to be fixed.

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b.)OUTLET b.) OUTLET TEE DUCT - 800 x 316

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The tee support to assemble 1 st is the connection (20-21) as shown in the drawing. The 90 deg. Bend name ‘I’ needs to be assembled with tee duct no. 20-21. The ducts are center marked which need to be matched during assembly. The ducts need to be provided with support to sustain the self-weight of the assembly, we can use scaffolding, chain pulley or any form of support to maintain proper alignment.

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c.) EXTENSION- 800 x 687 Lg.: (19-20) ; (22-23)

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Extension duct no. (19-20) is assembled with TEE duct no. 20-21. We use a gasket as shown in the diagram. The supports scaffolding or any other form of support needs to be added as per the requirement throughout the ducting assembly.

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D.) DUCT FLANGES & SUPPORT

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After the extension is connected we go on further to assemble the vertical supports and duct flanges We first connect the duct flange as shown in the drawing and then we assemble vertical ducting support. We do not anchor the supports to the ground but let it rest on it and sustain the entire weight, with or without scaffolding support as per requirement.

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E.) INLET TEE DUCT: 800 X 600 – 1000Lg.

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The inlet TEE duct assembly is as per the drawing. The inlet TEE 800 x 600– 600– 1000 Lg. is used in the assembly total quantity is 8no.s placed at the specified locations: 1.) 4-3 2.) 8-9 3.) 13-14 4.) 18-19 5.) 23-24 6.) 28-29 7.) 33-34 8.) 38-39

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The inlet duct assembly has two types of connections: 1.)Inlet 1.) Inlet duct assembly – extension– blower

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The assembly as shown in the diagram is placed at the following locations out of the ones mentioned above: 1.) 8-9 2.) 18-19 3.) 28-29 4.) 38-39 The gaskets used are: 1.) Gasket OD 769 x ID 600 x 3 THK – 2 no. 2.) Gasket 536 x 769 x 3 THK - 1no.

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2.)Inlet 2.) Inlet duct assembly- blower:

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Similar to duct inlet assembly with a reducer + extension connection, we have a duct inlet assembly with only reducer as shown in the drawing. The only reducer NO EXTENSION assembly uses 2 different gaskets a.) Gasket: OD 790 x ID 600 x 3 THK. – 1 no. b.) Gasket: 536 x 769- 3THK – 1 no.

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F.) OUTLET DUCT ASSEMBLY

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Now as per the previous connections made we have to make the assembly as per the drawing. The drawing shows the outlet duct assembly which will be same for all the actuator pairs. As follows: 1.) 42-41 & 41-40 2.) 37-36 & 36-35 3.) 31-31 & 31-30 4.) 27-26 & 26-25 5.) 22-21 & 21-20 6.) 17-16 & 16-15 7.) 12-11 & 11-10 8.) 7-6 & 6-5 9.) 2-1 & 1-0

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G.) DUCT END CAP:

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For the both ends of the duct in order to cover them we put a lid on the duct. The end cap as shown in the diagram is bolted in two places as mentioned: 1.) 41-42 2.) 0 - 1

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Now as per the ducting placement we get the final location of the blowers. As per the detail drawings given the blower foundation were previously marked and now require verification. As per our assembly, if the foundations are missed out we need to move and place the entire assembly as per the requirement; this is why we kept the entire assembly unanchored. While erecting the equipment, please maintain the bottom foundation should be flat/ zero level using a spirit level indicator.

Supply cable should be of adequate size to carry the full load current and enough to carry the starting current without excessive voltage drop. After our placement is done properly we need to anchor the assembly.

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Use foundation bolts of M16 x 400 long for blower mounting sent along with the equipment. We first begin with the blowers, then flapper boxes, then vertical duct supports. Now our assembly mechanically is complete, now we need to move further to the pneumatics.

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First step is to locate flappers in the 90 deg. position as required. And tighten all the bolts required.

Second step is to mount cylinder eye rod on pin.

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Step three is to fix the cylinder on the flapper box base plate.

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Step four is to Lock Shaft end at Cylinder Eye Rod with Cir-clip.

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We have used ‘Ingersoll‘Ingersoll-Rand’ screw screw compressor 30HP with 118 cfm capacity. The compressor is microprocessor based and is directly controlled by the control panel provided with the equipment’s.

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Fig: The Compressor microprocessor microprocessor interface. 

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The microprocessor provided input can be used during maintenance mode rest the time is directly panel operated. The highly sophisticated compressor has been provided with 2 air receiver tanks of 0.5 cu. Mtr. Capacity. The plumbing of compressor needs to be done from Compressor to air receiver tanks on site. Cooling air is drawn in at the end of the machine package passing through the filter and cooler before being discharged from the top of the machine. Care should be taken to avoid blocking the airflow, or causing any restriction in excess of the maximum backpressure allowed for ducting. Do not direct the airflow at face or eyes. The operation & maintenance manuals are provided along with the equipment explain the entire installation is good detail.

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Pneumatic assembly assembly is the most crucial part for the operation of the wave pool. Our wave pool has a simple assembly as follows. Compressor and the receiver tanks provide the air pressure required to operate the entire pneumatic assembly. The compressor provides air by a GI pipe line of 40 NB across to three junction boxes of FESTO.

The GI pipe of 40 NB gets a T- joint cut off at three places for the three junction boxes. The cut offs are provided with a water separator at each input of the line to drain off the water in the compressed air and increase the life of the equipment. The pneumatic connections are done with the PU 10 tube size from the GI ball valve reducer to Festo cabinet box. The Festo cabinet boxes are electrically operated with pneumatic pneumatic output. The outputs are attached to the wave pool actuators via pneumatic terminals provided inside the boxes.

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Fig.: Pneumatic cabinet connections. 

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The wave pool pneumatically is operated , more specifically for : 1.) The flapper box actuators. 2.) The blower actuators The pneumatic terminals are connected by a PU 8 size tube. All cabinet outputs are provided in PU 8 size tubing.

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There are 10 pneumatic output terminals in each box. i. 6 terminals are used for flapper box actuators ii. 3 terminals are used for Blower actuators. iii. 1 terminal is kept spare. One cabinet controls 6 flapper flapper box actuators actuators out of 18 and 3 blower actuators actuators out of 8 Each box has one spare port & the final Festo box has 2 spare ports left.

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Your wave pools most important part is the electrical panel. The entire wave pool control and safety is dependent on the electrical panel operation. A separate room has been provided for the placement of electrical panel away from the dust and common access of personnel. The wave pool electrical cable distribution is as follows :

The cable size will be as mentioned in the diagram.

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1. BLOWER ELECTRICAL CONNECTIONS: 

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This centrifugal blower cannot be operated until the electrical connections, and proper phase wiring have been determined for correct blower rotation. After proper electrical connections have been made, correct blower rotation will need to be verified. Read and strictly follow all “Safety First” procedures. Switch off, and disconnect electricity at the circuit where the electrical connections are to be made. Ensure that the power cannot be turned ‘on’ while you are working on the machine. Follow the wiring diagram on the motor nameplate when making all necessary electrical connections. The wiring diagram and motor specifications are provided at the end of these instructions. Also, ensure that the motor is grounded in the event of a short. Refer to motor nameplate for power supply requirements. requirements. Install an appropriate power switch to the unit. Ensure that all electrical connections are tight and well insulated to protect against moisture. Important: After making electrical connections, proper electrical phase rotation must be determined. Correct motor shaft rotation is on right direction. Bump start the motor a few times to determine the direction. Then turn all electrical power “OFF”. Take care to ensure power cannot be turned be turned back on while you continue the installation. Check spring loaded blower foundation bolts.

2. Festo cabinet electrical connections: The Festo electrical connections are very easy to do. Each solenoid valve comes with its own terminal as shown in the diagram. The connection wiring from the control panel to the cabinet is properly named using ferules as mentioned in the diagrams. Each terminal output has a ferule no. which is marked at both start from the cable alley and end at the cabinet input. 

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There are 3 Festo cabinets each cabinet controls 6 Flapper box actuators and 3 blowers. The connections are as follows

Fig: junction box 1 wiring detail.

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Fig: Festo box wiring.

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3.ELECTRICAL 3. ELECTRICAL PANEL PLC CONTROL:

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The electrical panel can take input from two sources. 1.) PLC HMI screen. The panel comes with an HMI screen for easy accesses and control. The HMI is a touch screen input mounted on the electrical panel door; you need not open the door for operating the wave pool. The PLC input logic is defined and explained in detail with printed manuals for the operation of the wave pool. The PLC logic is very user friendly and specific. 

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2.) Tabular input. The wave pool can also be controlled by TABLETS. The panel is provided with two ‘LENOVO TAB 2 A7’ devices. The PLC inputs can be provided from any location around the wave pool in a radius of 100 m from the panel. The tablets require WI-FI for operation which is also provided by Arihant itself. We provide you with a WI-FI Router connected to the PLC panel wirelessly. We provide with additional 2 WI-FI boosters as well to maintain a proper signal all throughout the area. In addition to all three devices we provide you enclosure designed to protect and mount the mentioned devices with the equipment. 

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Now finally the most exciting part of the entire process, the wave pool operation. The fruit of all the hard work done in the installation will be reaped. The wave pool is extremely easy to operate and handle. The wave pool shall be operated in the following steps: 1.) Turn ON the power supply for the electrical panel. The electrical panel indicators will turn on and show the voltage and current which is available. 2.) Once the panel power is on, move to the HMI screen for operating the wave pool. 3.) Before starting with the operation on HMI these points are to be considered.

 Auto/Maintenance Switch Auto/Maintenance selector switch is provided on each blower. When the actual operation is going on, the user has to give command from HMI. While giving that command, blowers should be selected as AUTO mode on the panel. If any blower is selected in MAINTENANCE mode then that particular blower cannot be started from HMI. This Auto/Maintenance selector witch is provided only for maintenance purpose. The mode of operation is always has to be AUTO mode. If there is any maintenance or manual operation is required, then only the mode of blower has to be Maintenance mode. At that time, that particular blower won’t get turn ON after giving command from HMI. All blowers should always be selected in AUTO mode.

 Programmable Logic Controller The Programmable Logic Controller (PLC) is at the heart of all the controls and sequencing of the CP. It generates the necessary sequence for generating patterns in wave pool. The main CPU of the Mitsubishi PLC used for Wave pool System. The PLC has one comm. Ports – which is used for communicating to the HMI. The PLC has memory to store its logic as well as some data.

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 HMI The Human Machine Interface is nothing but the user operated interface which is provided on the panel. All commands of operations are given from HMI. FP3070TN HMI is used in this panel. HMI is having touch screen so that user can operate the system very efficiently.

Fig 2.2 Human Machine Interface (HMI)

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 Operating Instructions

– for the Wave pool System:

At the time when Panel gets powered ON, the start-up screen appears on HMI. The fig 3.1 is the welcome screen; it appears when the panel is powered ON. This screen appears for specific delay and goes to the next screen.

Fig 3.1 Welcome Screen

After welcome screen the system will ask for authorized login. Based on the requirements of the various operational modules, the Wave-pool System has access rights for two users. Every user has to login before, he can access any of the menu. The user needs to click on the Login option on Menu Screen shown in Fig. 3.2. Username and password is settable, without authorized User ID and password system cannot be operated.

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Fig 3.2 Login Screen

The fig 3.3 is a popup message which appears when the username and password is invalid .

Fig 3.3 wrong Password

After successful login fig 3.4 Menu screen will appear from where all the commands and settings in the system are done. In this screen User will get five options which are as follows. 1. AUTO MODE 2. MANUAL MODE 3. SETTINGS 4. LOGGED DATA 5. LOGOUT

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Fig 3.4 Menu Screen

The system has the following modes of Operation. 

Manual Mode

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Auto Mode

The operational mode would be selected through an AUTO / MANUAL selector button provided on the HMI screen.

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MANUAL Mode

To operate the system in the MANUAL mode, user needs to press the Manual button on HMI menu screen.

Fig 3.5 Manual Mode selection button

This is a MANUAL mode of operation it actuates the system based on the commands received from the screen Buttons on HMI. 

AUTO Mode

To operate the system in the AUTO mode, user needs to press the Auto button on HMI menu screen.

Fig 3.6 Auto Mode selection button

This is an Automatic mode of operation; it actuates the system based on the pre-program.

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 Operation Instructions in Manual Mode 

Inspection

After selecting the manual button from the Menu screen, the fig 3.7 the daily Inspection screen is appear. It is a reminder message to the user about the system prerequisite. By pressing OK button it will go to the next screen.

Fig 3.7 Daily Inspection Screen

The above fig 3.8 is the weekly Inspection screen .It is a reminder message to the user about the system prerequisite. This message will appear once in a week. by pressing OK button it will go to the next screen.

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Fig 3.8 weekly Inspection Screen

The fig 3.9 is the monthly Inspection screen. It is a reminder message message to the user about the system prerequisite. This message will appear once in a month. by pressing OK button it will go to the next screen.

Fig 3.9 Monthly Inspection Screen Compressor

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After Pressing Manual Mode and OK button in Inspection messages this screen will appear.

Fig 3.10 Manual Compressor Screen (OFF state)

In this screen compressor can be ON/OFF by pressing RUN button shown above.

Fig 3.11 RUN button

On this screen user can see the “SYSTEM OFF” indication in Red color, Red colored Compressor, RUN button and Emergency Stop button. As soon as the RUN button will press, the Compressor turns ON. Whether Compressor is turning ON or OFF is visually indicated on the same screen. As soon as the compressor turns ON the “SYSTEM OFF” is changed into “SYSTEM ON” indication which is green in color. Also the color of Compressor is changed into Green from Red.

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RUN indication below RUN button is also turn into STOP for indication to stop the compressor. compressor. As soon as the STOP button will press the compressor will turn off. As shown below:

Fig 3.12 Manual Compressor Screen (ON state)

The screen has two arrow buttons at the top which indicates previous screen and next screen.

Fig 3.13 Previous screen

3.14 Next Screen

In case of Emergency user can press the Red Emergency Stop provided on the screen to stop all the operations.

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Fig 3.15 Emergency Stop button 

Blowers and Actuators

After Pressing Next button on Compressor Compressor Screen Fig 3.16 Blower Screen will appear.

Fig 3.16 Manual Blower/Actuators screen-1

User can ON the particular blower by pressing OFF/ON button provided on this screen. It is necessary to ON blower before actuator. As soon as you activate the Blower the particular Actuator will be accessible. Actuator ON command will be given after blower ON command.

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Initially the button which activates the blower is of Red color and indicates OFF, that means the current state of the blower is OFF.

Fig 3.17 OFF button for Blower

As soon as user pressed the button, the Blower turns ON and button changes its color in green and indicates ON.

Fig 3.18 ON button for Blower

The blower itself indicates its current state by changing its color. When the Blower is OFF the blower is of Red color. As soon as the Blower gets ON, it changes its color into Green, as shown:

Fig 3.19 Blower OFF

Fig 3.20 Blower ON

For Actuators the button is provided to ON actuator. Initially the button which activates the Actuator is of Red color and indicates OFF, that means the current state of the Actuator is OFF.

Fig 3.21 OFF button for Actuator

As soon as user presses the button, the Actuator turns ON and button changes its color in green and indicates ON.

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Fig 3.22 ON button for Actuator

The Actuator itself indicates its current state by changing its color. When the Actuator is OFF the Actuator is of Red color. As soon as the Actuator gets ON, it changes its color into Green, as shown:

Fig 3.23 Actuator OFF

Fig 3.24 Actuator ON

For Example: (This example is only for visual indication) If the user turns ON 4 Blowers and 3 Actuators then the screen will be appear as:

Fig 3.25 Manual Blower/Actuator screen (in process)

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If all the Blowers and Actuators Turns ON then the screen will appear as:

Fig 3.26 Manual Blower/Actuator screen-2

In case of Emergency user can press the Red Emergency Stop provided on the screen to stop all the operations.

Fig 3.27 Emergency Stop button

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Solenoid Valves

After pressing next screen sequence pattern sequence screen will be appear as per fig 3.10.

Fig. 3.28 Pattern Sequence manual

The screen is appears as above. On this screen the pattern sequence and time to run the system is displayed on the right side of the screen. In this table, pattern sequence and time is already present. This sequence and time is arranged by previous command. If user defined any pattern sequence and particular time in its previous operation then same pattern sequence and time is maintained in this screen. If user wants new pattern sequence no. with time in minutes required to run the particular sequence, then user can enter required pattern sequence and its particular time. For Example: If the screen is appeared on HMI with the above pattern sequence and user wants to change the sequence of the pattern and run time of particular pattern, users have to click on pattern no.

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As soon as user clicks on pattern no. the pop up screen will appear having numerical keys. By entering the required no. for pattern user can change the pattern sequence. The same process is to change the run time of the patterns. Total RUN time of sequence is variable. Below screen is an example of such sequence selection:

Fig 3.29 Pattern sequence manual (pattern and time entry)

Above screen indicated 18 Solenoid valves. Initially all 18 Solenoid Valves are in OFF state. Thus those Valves are indicted in Red Color. After pressing START button, pattern runs according to the sequence with the time entered by users.

Fig 3.30 START button

The Solenoid Valves are alternately turning ON and OFF according to the running pattern. This indication is provided on HMI screen. When a particular Solenoid Valve is turns ON then that Solenoid Valve changes into green color from red color.

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Fig 3.31 Solenoid Valve OFF

Fig 3.32 Solenoid Valve ON

For example: Consider below screen for further explanation:

Fig 3.33 Pattern sequence manual (running pattern)-1

In fig. we can say that the eighth pattern is running. The Solenoid Valves are alternately turning ON and OFF as per the eighth pattern. So the continues changing colour can be observed on screen. Current pattern no will be displayed in the block. The current pattern name is also displayed besides the current pattern number. At the pattern sequence table a Red dot is also provided to indicate the current pattern.

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User can enter pattern no. in between the pattern sequence is going on. For example:

Fig 3.34 Pattern sequence manual (running pattern)-2

In above fig. the operation is started. After some time user entered pattern number 9 at the place of pattern number 4. So after pattern 3, pattern 9 started. The current pattern box is also indicates i ndicates pattern pattern number 9 along with the name of the pattern i.e. “DIAGONAL”. After completion of pattern number 9 the next pattern will start i.e. pattern number 5. If pattern sequence is entered as ZERO (0) then sequence will be stopped, no matter how much time you entered. The total operation will get stop. As shown:

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Fig 3.35 Pattern sequence manual (0 pattern entry)

If user wants to skip any pattern in between the running process then enter ZERO (0) at the time block of that particular pattern which user wants to skip. As shown:

Fig 3.36 Pattern sequence manual (0 time entry)

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Whenever the changes made in the screen by entering pattern sequence or pattern running time, user have to press save button which is at the bottom of the screen.

Fig 3.37 SAVE button

By clicking this SAVE button, the entered value is save in the system and also this pattern number, pattern name and time for pattern running is visible on tab which is remote control for this operation. So the user of that tab can also see the changes made in the pattern sequence. The similar save button is also provided on the web screen. We will discuss about that function later. In case of Emergency user can press the Red Emergency Stop provided on the screen to stop all the operations.

Fig 3.38 Emergency Stop button

After completion of the entire process user has to go to previous screen that is manual mode Blower screen by pressing previous arrow button. On that screen user has to turn OFF all the Activated Blowers Manually. (Blower should turn OFF first before turning OFF the Actuators). After turning OFF all the blowers, user has to stop all the actuators. For this command “Actuator Stop” button is provided on the screen.

Fig 3.39 Actuator Stop button

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By pressing this button the Actuators will get turn OFF. By pressing this button the entire system will turn OFF the main menu screen will appeared.

 Operation Instructions in Auto Mode 

Compressor

After selecting the Auto button from the Menu screen fig 3.4, the daily Inspection screen as per fig 3.5 will appear. It is a reminder message to the user about the system prerequisite. By pressing OK button it will go to the Auto screen, fig 3.11.

Fig. 3.40 Compressor Auto Mode OFF state

After pressing RUN on this screen System will RUN in automatic mode.

Fig 3.41 RUN button

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On this screen user can see the “SYSTEM OFF” indication in Red color, Red colored Compressor, RUN button and Emergency Stop button. As soon as the RUN button will press, the Compressor turns ON. Whether Compressor is turning ON or OFF is visually indicated on the same screen. As soon as the compressor turns ON the “SYSTEM OFF” is changed into “SYSTEM ON” indication which is green in color. Also the color of Compressor is changed into Green from Red. RUN indication below RUN button is also turn into STOP for indication to stop the compressor. compressor. As soon as the STOP button will press the compressor will turn off. As shown below:

Fig 3.42 Compressor Auto mode ON state

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Blowers and Actuators

First compressor ON command will be given by PLC. After some delay it will go to next screen fig 3.43 Blower On screen where 7 Blowers gets ON depends on sequence.

Fig. 3.43 Blower and Actuator OFF Auto (initial display)

Initially blowers are getting ON one by one. The Blowers which are on Manual mode selected on feeder will not get on by PLC. After all required blowers are getting ON there is a time delay to actuate the actuators.

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Fig 3.44 Blower ON Auto

In above screen, user can visualize that all required blowers are turning ON and there is some time delay provided by system to actuate all the Actuators. After a given time delay all the actuators of respective blowers get on immediately. On same screen user can visualize the ON/OFF state of Blowers and Actuators. As shown in fig. 3.45:

Fig 3.45 Blower and Actuator ON Auto

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The blower itself indicates its current state by changing its color. When the Blower is OFF the blower is of Red colored. As soon as the Blower gets ON, it changes its color into Green, as shown:

Fig 3.46 Blower OFF

Fig 3.47 Blower ON

The Actuator also itself indicates its current state by changing its color. When the Actuator is OFF the Actuator is of Red colored. As soon as the Actuator gets ON, it changes its color into Green, as shown:

Fig 3.48 Actuator OFF

Fig 3.49 Actuator ON

Compressor on time delay, Blower on time delay, actuator on time delay is specified in Settings.

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Sequence Selection

After turning ON all the Blowers and Actuators, the next screen is appeared on the HMI for sequence selection. Here user can further select the mode of operation. op eration.

Fig 3.50 Sequence selection screen

On this screen user can further select the mode of operation. User can either select Auto mode or Manual mode. If user select Manual mode by pressing Manual mode button then the next screen will appear, this is manual pattern sequence screen that we discussed before in section. 3.3.1.4 Solenoid Valves. And if user selects Auto mode by pressing Auto mode button then new screen will appear having Auto pattern sequencing.

Fig 3.51 Manual Sequence selection button

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Fig 3.52 Auto Sequence selection button



Solenoid Valves

After selecting Auto mode in sequence selection screen, Fig.3.53 i.e. pattern sequence on screen will appear. Here automatically pattern will be loaded in sequence i.e. from sequence 1 to 9. Initially the screen is appeared as below:

Fig. 3.53 Pattern Sequence Auto

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On this screen user can see the 18 Solenoid Valves, pattern sequence list, current pattern number and name, START command button, SAVE button to save entered data and Emergency Stop button. The Solenoid Valves are alternately turning ON and OFF according to the running pattern. This indication is provided on HMI screen. When a particular Solenoid Valve is turns ON then that Solenoid Valve changes into green color from red color.

Fig 3.54 Menu Screen

Fig 3.55 Menu Screen

The 18 Solenoid Valves are provided for visual indication of running pattern.

For example: If pattern number 3 that is “DIAMOND 3” is going on than the screen will be appeared as:

Fig 3.56 Pattern Sequence Auto (running pattern)-1

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At this time the current pattern number and pattern name is displays on screen. User can enter any pattern number at any sequence number. For time duration of each pattern in the sequence, user has to enter time in the setting menu. In setting menu screen “AUTO SEQUENCE CHANGE DELAY” option is provided. If user enters 5 minutes in that setting screen then each pattern will run for 5 minutes in AUTO mode. There are total 9 patterns in the sequence so the total run time of the sequence will be 45 minutes. For example:

Fig 3.57 Pattern Sequence Auto (running pattern)-2

In above screen we can see that user entered pattern 7 at the place of pattern 4. As soon as user entered the pattern number, the pattern name is also changes simultaneously. If user enters 0 at the place of pattern number then the running pattern will get stop and user has to turn ON the system again from beginning.

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Fig 3.58 Pattern Sequence Auto (0 pattern entry)

After pressing START button, pattern runs according to the sequence entered by users.

Fig 3.59 START button

Whenever the changes made in the screen by entering pattern sequence or pattern running time, user have to press save button which is at the bottom of the screen.

Fig 3.60 SAVE button

By clicking this button the entered value is save in the system and also this pattern number, pattern name and time for pattern running is visible on tab which is remote control for this operation. So the user of that tab can also see the changes made in the

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pattern sequence. The similar save button is also provided on the web-screen. We will discuss about that function later. User can change the pattern changing time in Settings menu. User can change any next pattern to be run by TAB provided .  SETTINGS On main menu screen the Setting option is provided. The overall setting of the system is provided in this setting menu.

Fig. 3.61 setting button 

Time Delay Setting

As soon as this button will press the user can visualize the setting menu screen. Compressor ON delay, Actuator ON delay, Blower ON delay, Blower OFF delay and Auto sequence change delay are provided on settings window as on fig. 3.62.

Fig. 3.62 Settings1

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All these parameter settings are only provided for Auto mode operation. As we discussed earlier that after pressing the RUN button in Auto mode operation the Compressor will get turn ON after some time delay all the required Blowers turn ON and then all the particular Actuators will get turn ON. During this operation all three major components will get turn ON in particular time delay. User can enter this time delay form this screen as: i] Compressor ON delay ii] Blower ON delay iii] Actuator ON delay After completion of Auto mode operation, the blowers turn OFF automatically with some time delay. This time delay is also entered form this screen as: i] Blower OFF delay After all the Blowers get turn OFF, all the particular Actuators and Compressor will get turn OFF immediately. So there is no such provision for Actuator OFF and Compressor OFF. On this setting screen, another option is provided as “Auto Sequence Change Delay”. In this option user can enter the total running time of single sequence sequence in Auto mode.

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Chan Ch ange ge Pas Pass swor d Se Sett ttii n g

On setting menu screen the password setting option is also provided. By selecting change password button user can change his/her password. On setting screen the “Change Password” option is provided at the right bottom side of the screen. User can visualize Change password screen by pressing the button as shown below:

Fig. 3.64 Change Password button

By pressing above button user can change his/her password from this screen as shown:

Fig. 3.65 Change Password

 How to change password: Steps to change user password: 1) First enter valid user name at the user name option. 2) Then enter valid current password which user wants to change. 

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3) Then enter new password. 4) After entering the entire data, user have to press save button. 5) If the current username and current password is wrong then it shows the popup massage “WRONG USER ID OR PASSWORD” as shown:

Fig. 3.66 Wrong Password

After pressing the save button user have to login from the same screen by pressing “Login” button. 

Valve ON/OFF Time Delay Setting

On setting menu screen the two arrows are provided for previous screen and for next screen. By pressing next arrow button, the next setting screen will be appeared on the HMI. On this screen user can see the ON/OFF time of valve for each particular patterns. Total 9 patterns are there in the system. On this screen there are 6 patterns and other 3 patterns are on next screen. Every pattern has different valve ON/OFF time and that time can be change from this settings screens as shown in fig 3.67 and fig 3.68.

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Fig. 3.67 Valve On/Off time settings 1

Fig. 3.68 Valve On/Off time settings 2

Steps to set Valve ON/OFF time: 1) Go to setting menu by pressing Setting button from main menu screen. 2) Press next arrow button, first 6 patterns with Valve ON/OFF time is appeared on HMI. 3) By pressing next button, last 3 patterns with Valve ON/OFF time is appeared on HMI. 4) Now click on the number which user wants to change. 5) A popup screen will appeared with numerical keypad. 6) Enter the ON/OFF time for each particular blower, if user wants to change. 7) User has to enter the number as follows: a. If user wants to enter 5 in the box then he/she has to enter 50 in while entering the number. b. Whatever number user enters, the decimal will shift one place before last number. c. If user enters 50 then the display will shows 5.0. If user enters 67 then the display will shows 6.7. d. That means if user wants 3 sec in the box then he/she has to 30 while entering the time, so after entering 30 the display will shows 3.0 8) After entering required ON/OFF time for particular patterns user has to press SAVE button of particular screen, on which user made any changes.

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User has to press SAVE button which is provided on the bottom of the two screens. By pressing this button the entered ON/OFF time value is also loaded in the web screen on tab which is remote control for this operation. So the user of that tab can also see the changes made in the pattern sequence. The similar save button is also provided on the web screen. We will discuss about that function later.



D ate and Ti T i me Setti n g

On HMI user can see the current date and time on every screen. If user wants to change Date and Time the following procedure has to be follow: Steps to change Date and Time: 1) Go to setting menu by pressing Setting button from main menu screen, the time delay screen will be appeared. 2) Press next button twice at the top of the screen. As soon as user press the next ing screen will appeared. As shown: button twice, the “DATE AND TIME” sett ing

Fig. 3.69 Date and Time setting

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3) ON this screen, there is six Data entry blocks are provided. 3 are for Date as Day, Month and Year. And other 3 are for time as Hour, Minute and Seconds. Seconds. 4) By pressing left and right arrow keys user can change the Date and time 5) After entering the required Date and Time parameters user has to press previous button to go to the main menu screen.



USB Upload

On the screen of date and Time setting, USB upload button is provided. This button is only used by the Authorized person. If there is any problem occurred in the application of HMI then this application is uploaded in the USB Stick provided by Arihant Industrial Corporation Ltd. or downloaded the new application from The same USB stick if current application having any problem. SHOW and HIDE button which are provided on this screen is used for visibility of NEXT button which is provided on web screen on tab which is remote control for this operation. We will discuss about this function later. 

LOGGED DATA

As we discuss, in this panel there are 8 blowers on which the system is running. The selection blowers for operation are done automatically by the system. So the selection of particular blowers for operation is different for different days. So there is provision on HMI to see which blower run for how much time in single day, in a week and in a month. To see that data user has to go to main menu screen. On this screen “LOGGED DATA” option is provided. By pressing that button the next screen will appears on the HMI as below:

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Fig. 3.70 Blower Logged data

On this screen user can press either the two buttons . Daily Log Weekly and Monthly Log

 



Daily Log

As soon as user press the “Daily Log” button the “Blower 1” screen will appears. On this screen the log of running time is displayed date wise for particular blower. As shown:

Fig. 3.71 Blower Logged data (Daily)

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For other blowers, user has to press next button on the screen. By pressing this button user can visualize the running time data for Blower 1 to Blower 8. 

Weekly and Monthly Log

As soon as user press the “Weekly and Monthly Log” button the “Blower 1” screen will appears. On this screen the log of running time is displayed in two different columns. First column is for weekly log and second column is for monthly log. For particular Blower, the running time logged data is displays till first date of the week in weekly data log column. And the running time logged data is displays till first date of the month in Monthly data log column. As shown:

Fig. 3.72 Blower Logged data (Weekly and Monthly)

For other blowers, user has to press next button on the screen. By pressing this button user can visualize the running time data for Blower 1 to Blower 8.

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

WEB SCREEN

As we discuss earlier that, the system can be operated by HMI. The user can give command on HMI screen and by that commands the whole system can run. But the HMI is provided on Control panel which is located far away from the actual wave pool site. While running the patterns the waves are generated in the wave pool. The sequence of the wave pattern is already entered on HMI. As soon as the START button is pressed the sequence is getting started. As we discuss the user can manually change the pattern sequence before or during the pattern RUN. But sometimes there is need of changing the pattern sequence at the wave pool side because of the customer requirement or any other reason, and then this signal cannot easily pass to user which is at the control panel room or will take a time to convey that signal. At that time the external remote control is provided to change the pattern sequence suddenly whenever it’s required. External remote control is nothing but a tab which has to be use by the other user who will be at the actual site of wave pool. This control is wireless and communicated with HMI trough Wi-Fi connectivity.

 CONNECTIVITY. 

HMI to Router:

The external on site remote control is nothing but a tab which is operated by user other than HMI operator. This control is wireless and connected to HMI via WiFi. There is a router which is placed at a site of the system and this router is the important mode of connectivity. This router is connected to HMI by communication cable. This communication cable is nothing but general Ethernet connecting cable. This router is placed at the open space. After turning ON the router, this router creates its own server with the field of connectivity.

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Fig. 3.73 Router



Router to Tab (external remote control)

Tab is provided for the external control for the system. The provided Tab is nothing but the remote control for the user who operates from the actual site of the system. From this tab user can only change the pattern sequence and time. User can set the ONOFF time for Valves for all 9 patterns. But this Tab user can not START the system. User has to turn ON Wi-Fi mode in the tab. If the user is new for this server then server will ask password. User has to enter the valid password to connect with the server. After entering valid password, the Tab is automatically connected to the router via Wi-Fi connectivity.

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Fig. 3.74 Tab (external remote control)

After connecting with server, user has to open any internet browser (mostly Google Chrome is preferable). After After opening of the browser, enter enter “192.168.0.2” “192.168.0.2” on search bar. bar. After searching above address, address, a login screen is appeared in the browser. User has to enter valid user ID and password for further operation. If user enters wrong user ID or password then this screen is repeatedly coming until user enters correct ID and password. After entering the correct user ID and password the next screen is appeared on the Tab which is the main menu screen for operation. This application is having two screens.

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OPERATION On OPERATION On web screen: 

Web screen – screen – 1 1

Fig. 3.75 Pattern Sequence Running

Fig. 3.75 shows the initial web screen which is appeared on the Tab. User of this Tab cannot start the system, but that user can change in the pattern sequence while running the system. On this screen user can see pattern sequence, the time for each pattern, current running pattern number, emergency stop button, Solenoid valve ON/OFF indication, and type of patterns. The first column is for pattern sequence entry. As shown in above fig. the first pattern is 7, then 6 and so on. This pattern can be entered from the Tab by user. After entering the required pattern user has to click the SAVE button provided on the screen. As soon as the user pressed the SAVE button the entered data will be loaded in HMI screen so that the HMI user also can see the new entered data.

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As we discuss earlier that, on pattern screens of HMI there is provision of SAVE button. As soon as the SAVE button pressed by the user, the entered data will be loaded in the tab. So the Tab user also can see the entered data on the pattern sequence. The number of running pattern is shown in current pattern box. The ON and OFF condition of Solenoid Valves is also indicated on this screen. The pattern name and number is also displayed on the screen for user to get to know the pattern number and name. In case of Emergency user can press the Red Emergency Stop provided on the screen to stop all the operations. The next button is provided to go to the next screen on which the ON/OFF time of valve can be entered by the user for each particular pattern. 

Web screen – screen – 2 2

Fig. 3.76 Valve ON/OFF time for each pattern

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The screen shown in fig 3.76 is the next web screen on the Tab. As soon as user presses the next button on the main menu screen on Tab, this screen will appeared. This is same as “Valve ON/OFF time delay” setting screen on HMI. The user of this remote control can change the ON/OFF time of the Valves. After entering the ON/OFF time, user has to press SAVE button. As soon as the SAVE button will press the entered data is also loaded in the HMI screen. So the HMI user also can visualize the updated Time entry. Previous button is provided to go back to the main menu screen. 

SHOW and HIDE button:

As we discuss earlier about SHOW and HIDE button on the “Date and Time setting” screen. Those two buttons are used for the visibility of NEXT button on main menu screen on Tab. On HMI the Valve ON/OFF time is have to set before running the patterns. User cannot access the setting screen while the sequence is running. So HMI user can make the NEXT button on web screen visible or invisible. If the user presses the button HIDE in setting screen then NEXT button will not emerge on the web screen. So the Tab user cannot change the Valve ON/OFF time in between the sequence running.

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Now in order to have a smooth working of your wave pool we need to do regular maintenance checks and follow all the safety and operation instructions. Each of the equipment of the wave pool comes with its own set of maintenance procedures which needs to be followed. These are the following few set of instructions which need to be followed on daily basis: 1. Flapper box & GRP G RP Ducting: a) Check all the nut and bolt of the ducting to ensure it is properly tightened on daily basis. b) Grease Oil Plummer Block/Bearings on weekly basis. 



2. Pneumatic connections: a) Check all the solenoid operated valves. b) Check any air leakage c) Check all the pneumatic cylinders to ensure it is moving freely. 3. Compressor : a) Check the coolant level and replenish if necessary. necessary. b) Visual check of machine for any leaks, dust build up or unusual noise or vibration c) Report immediately, contact Ingersoll– Ingersoll–Rand authorized distributor for assistance if in doubt d) Drain air receiver of condensate, or check that automatic drain is operating e) Visual check condition of package pre– pre –filter, Blow clean if needed f) If the air filters indicator locks into the red position before the 3000hour/1 year change out period out period,, check the Condition of filter. Change the air filter if needed. Dusty environments require require more frequent replacement or, optional high dust filter g) (The indicator should be checked with unit stopped.

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4. Blower: a) Check if the fan rotates freely without metallic noise. b) Check Discharge line is properly closed by Damper or any other means. c) When run for half an hour, blower should be stopped and checked. d) Check bearing is at a normal temperature, by touch of hand. e) Ensure area around the blower and compressor is free from rags, tools, debris and flammable on explosive materials. 5. Electrical panel maintenance: maintenance: Daily: a.) Check 3 phase Power supply. b.) Check if starter is provided for motors to provide sufficient starting time c.) Check all incoming and outgoing cable and connection, connection, if loose, tighten t ighten It Properly. d.) Check the blower motor fan over heating e.) Check the motor condition. f.) Check motor cable connections, tighten it properly. o

Monthly: g.) Check the main control panel and clean all-star/delta contactors.(Use CRC contact cleaner) h.) Check star / delta operation for the blower i.) Examine visually “Earth Connections” and over all condition of condition of blowers, motors and its cables. j.) Check the motor winding insulation resistance. o

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Operation & Installation Manual for Wave Pool

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