OPERATIONAL MANUAL FOR

HYDROBALL SYSTEM

Telephone

+65 6338 8033

24-hr Line

+65 9191 9555

Website

www.hbt.com.sg

Email

sales@hbt.com.sg

Address

Joo Chiat Complex

Blk 1 Joo Chiat Road #04-1019

Company Reg No. 200300791R

Singapore 420001

Description of the HydroBall System and its Components

1.1

Components of HydroBall System

WRP
BRP

WSP
BSP

Hydroball System uses sponge balls to prevent scaling & fouling inside the heat exchanger
tubes of the water-cooled condenser or chiller.
It consists of 3-way motorised valve, four hand valves, two swing check valves, Ball Catch,
Ball Station, flow switch and Programmable Logic Controller (PLC).
There are four linkage pipes: Water Supply Pipe (WSP), Ball Supply Pipe (BSP), Water
Return Pipe (WRP) & Ball Return Pipe (BRP).

1.1.1

Valves

HydroBall System consists of a 3-way motorised valve, four hand valves and 2 swing
check valve.
There are 4 hand valves along each of the 4 pipes Water Supply Pipe (WSP), Ball Supply
Pipe (BSP), Water Return Pipe (WRP) & Ball Return Pipe (BRP).
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Hand valves are used for isolating the HydroBall System during maintenance such as
replacement of sponge balls or servicing of valves.

3-way motorised valve

1.1.2

Hand valve

Check valve

Water Flow Control Switch

The Water Flow Control Switch is mounted along the horizontal section of
condenser water supply pipe (CWS). It is activated whenever there is water flowing in
the condenser supply pipe and the Programme Logic Control will activate whenever
water flow control switch is activated.
1.1.3

Programmable Logic Controller

The Programmable Logic Controller (PLC) serves to operate, control and

monitor the system. It signals the 3-way motorised valve to allow the sponge balls to
complete the cleaning cycle from the Ball Station to the condenser tubes and back to the
Ball Station.
The operation modes automatic or manual can be selected via a selector switch. It is
set default at the automatic mode. The cleaning system is continuously controlled by
the control system. All sequences to be started are controlled by the PLC.

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1.1.4

Cleaning Balls

The sponge balls which are made rubber foam, are soft, elastic and non-abrasive. They
should have approximately the same density as water.
It is important to use the correct type and size for effective cleaning. The diameter of the
cleaning balls should be slightly bigger than the internal diameter of the condenser tubes
for effective removal of the microfilm from the inner surface of the heat-exchanger tubes
and to prevent scaling deposits from accumulating.

1.2

Working Principle of HydroBall System

When the PLC signals the 3-way motorised valve to open at position 1 (POS1), please refer
to page cooling water rushes into the Ball Station via WSP forcing the cleaning balls to
enter the BSP, into the condenser supply pipe before passing through the condenser tubes to
scour off any fouling deposits along these tubes.
After leaving the condenser tubes, the sponge balls get collected at the Ball Catch along the
Condenser Return Pipe. PLC then signals 3-way motorised valves to open at position 2
(POS2). The cycle is completed when the balls get sucked back into the Ball Station. PLC
then signals 3-way motorised valves to open at position 3 (POS3) and it is ready for the
next cleaning cycle at the interval of 30 mins.
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Operation of the HydroBall System

2.1

Recommended Practice

For best results in preventing the formation of scales and fouling deposits, HydroBall Technics
recommends the following:

Operate the HydroBall system in tandem with the chiller.

Change the sponge ball every 6,000 cycles.
The number of sponge balls should be put into the Ball Station is based on 15% to 30%
of number of condenser tubes,

2.1.1

Basic positioning of component

All components have been installed as per layout.

Main Switch On

Control panel

Selector Switch in Automatic Position

2.2

Ball Station

Sponge balls of the correct type and size are in Ball

Station

Hand Valves

All the 4 manual ball valves are in open position.

Electrical Wiring

All wires have been properly connected and tested

by the contractor. Ensure there is no loose electrical
wire or cable.

Operational Sequence
Run the central air-conditioning system.
Make sure the Pressure Release Valve is shut.

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Open the manual ball valves (hand valves) one by one slowly and carefully.

Switch on the power supply to the PLC, turn to Auto mode for the HBT system to
begin operation.

3-way motorised valve is activated by the PLC Controller to allow cooling water to flow
from the condenser water supply pipe into the Ball Station. The water pressure from the
condenser supply pipe pushes the cleaning balls from the Ball Station into the condenser.
As the cleaning balls leave the condenser, they get trapped within the aperture funnel of
the Ball Catch. When the 3-way motorised valve change to position 2, the cleaning balls
leave the Ball Catch to return to the Ball Station via the Ball Return Pipe.

The cleaning balls remain in the Ball Station until the next cleaning cycle.
The routine cleaning operation should be repeated after 30 mins by presetting the
cleaning cycle interval at the Programme Logic Controller.

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2.3

Replacements of Sponge Balls

Control panel

Switch off the main power supply

Valves

Shut all the 4 manual ball valves

(hand valves)

Pressure Release
Hose at Ball Station

Open the pressure release valve slowly.

(Position pressure release pipe carefully to avoid wetting the
floor. If a pail is available, use it to collect the water released
from the ball station)

Ball Station cover

Loosen the bolts to remove the cover of the Ball station.

Sponge Balls

Remove all the used balls, and replace them with new ones.

After removing the sponge balls, check diameter of sponge balls and see if there is any wear and tear. Soak
the new cleaning balls sufficiently to remove the tiny air pockets within them.

Ball Station cover

After replacing the sponge balls, put back the transparent

cover of the Ball Station and tighten the bolts. The bolts
should be tightened evenly.

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Pressure Release
Mechanism at Ball
Station

Check to make sure the pressure release valve is in close

position.

Valves

Open all the 4 manual ball valves (hand valves)

Pressure Release or
venting Mechanism
at Ball Station

Open the pressure release valve slowly and carefully to allow

the trapped air pockets to escape. Then close the valve
gently.

Control panel

Switch on the main power supply and select the automatic

operation mode.

The cleaning system will then start automatically.

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Operating Modes of Programmable Logic Controller

The system can either be set to Auto or Manual Mode depending on your operating requirements. Auto
Mode gives you a hassle free operation while Manual Mode gives you certain flexibility in controlling the
system.

Power Indicator
Power Indicator turns ON when the system power is ON
Power Indicator turns OFF when the system power is OFF
Position Indicator (SEND, RETURN and REST)
3 Lighted Pushbutton Switch turn ON when the system power is ON
3 Lighted Pushbutton Switch turn OFF when the system power is OFF
Lighted Pushbutton Switch blinks while the respective valve is turning to its position
Lighted Pushbutton Switch stays ON when the respective valve reach its position
3 Lighted Pushbutton Switch blink at the same time when the valve did not reach its position
Auto/Manual Selector
Select to Auto to run in Auto Mode
Select to Manual to stop the Auto Process:
press SEND pushbutton to turn the valve to position 1
press RETURN pushbutton to turn the valve to position 2
press REST pushbutton to turn the valve to position 3
Counter Indicator
Display the total cleaning cycle count
Reset Button
To reset the cycle count to zero
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3.1

Auto Mode

The system starts and stops continuously in the preset sequence. The cleaning procedure is started
as the following:

Switch on to operational Automatic Position by turning the control knob on the panel
to AUTO

The manual control buttons to control position of the 3-way motorised valve will be
disabled under the Auto Mode

The automatic mode is the default-operating mode under normal condition. The system will begin
operating automatically when the chiller starts running.

3.2

Manual Mode

The Position 1, Position 2 and Position 3 of the 3-way motorised valve can be selected using the
relevant push buttons. Signal lights indicate the on/off status of the position.
The manual mode is selected when:

Testing and Commissioning

Replacement of sponge balls
Re-starting after lengthier non-operational periods

The manual mode is not a default operating mode and shall only be used to switch the cleaning
system into the basic condition for maintenance and testing purposes.
The system is set to Manual Mode by turning the control knob to MANUAL.

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Operational Troubleshooting
Possible Problems

Solution

Programme Logic
Controller

No supply voltage to panel

Check main supply

Clear short circuit
Check relay and fuse
(Use a meter to check if theres
electric current)

- Connecting pipelines
WSP, WRP, BSP & BRP

Leaking of water

Replace leaking components or

worn out gaskets between flanges
joints. Tighten joints. For threaded
joints, used proper sealant or tape.

- Valves

Flow Switch not activated

Check if chiller is in operation

3-way motorised valve is partially

jammed or failed to open fully

May need to rectify or change valve

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Company Reg No. 200300791R

Schematic of HydroBall System

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