WONDERBALL

AUTOMATIC ON-LINE TUBE CLEANING SYSTEM

环保球冷水机组节能清洗系统

INSTALLATION AND OPERATION MANUAL

安装操作手册
Thank you for purchasing Wonderball On-line Tube Cleaning System.
Do read this manual carefully and thoroughly to obtain the best possible performance before installing Wonderball.
The information contained herein is designed for use with Wonder Ball only.
In case you have any question, please consult your Wonder Ball dealer.
Retain this manual for future reference
AUTOMATIC ON-LINE TUBE CLEANING SYSTEM

INTRODUCTION 3 C WONDERBALL MODBUS COMMUNICATION 33

A WONDERBALL INSTALLATION 5 D WONDERBALL GENERAL TROUBLESHOOTING 36

A.1 MACHANICAL INSTALLATION 8
E APPENDIX 42
A.2 MAIN BODY 8
A.1.2 BALL STRAINER 8
A.1.3 BALL INJECTION NOZZLE 11
A.1.4 ISOLATION VALVE 12
A.1.5 PIPING INSTALLATION 13
A.1.6 PUMP PRMING 13
A.3 ELECTORICAL INSTALLATION 14
A.2.1 GENERAL 14
A.2.2 ELECTRICAL CHECK OUT 14

B WONDERBALL OPERATION 16
B.1 PRESTART 17
B.2 PUMP CHECKLIST 17
B.2.1 BALL INJECTION PUMP TEST 18
B.2.2 BALL COLLECTION PUMP TEST 18
B.3 OPERATION PROCEDURE 19
B.3.1 CONTROL PANEL 19
B.3.2 START STEPS 20
B.3.3 TELEMATIC OPERATION MODE 20
B.3.4 AUTOMATIC OPERATION MODE 22
B.3.5 MANUAL OPERATION MODE 27
B.3.6 OPERATION NOTICE 29
B.4 BALL CHANGING PROCEDURES 30
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产品介绍 3 C 通讯 33

A 环保球安装 5 D 环保球常见故障解决 36
A.1 机件安装 8
E 附录 42
A.2 主机系统 8
A.1.2 滤隔器 8
A.1.3 注入嘴 11
A.1.4 隔离阀 12
A.1.5 管道 13
A.1.6 水泵灌注 13
A.3 电气安装 14
A.2.1 总则 14
A.2.2 电气测试 14

B 环保球运行操作 16
B.1 开机前准备 17
B.2 水泵检查清单 17
B.2.1 注入泵检测 18
B.2.2 回收泵检测 18
B.3 运行操作 19
B.3.1 控制面板 19
B.3.2 开机程序 20
B.3.3 远程操作模式 20
B.3.4 自动操作模式 22
B.3.5 手动操作模式 27
B.3.6 运行提示 29
B.4 更换小球程序 31
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INTRODUCTION 简介
Wonderball On-Line Tube Cleaning System is the 环保球节能清洗系统是一个专为冷水机组提供全自
automatic condenser tube cleaning system of the 动清洗冷凝器管路的操作系统。环保球球体的直径
Chiller. While the Chiller is operating, the Sponge 比冷凝器管路直径大约 1 毫米。当冷水机运作时，
Rubber Balls, which have the diameter 1mm bigger 环保球注入冷凝器管路，橡胶海绵小球在冷凝器管
than the inside diameter of the Condenser Tube, will 路中持续不断地循环，以清除沉积的污垢。这个过
flow along the condenser tubes and cleanse the tube 程可以保持冷凝水和制冷剂之间高效的换热。此清
walls. Consequently, Wonderball will leave the clean 洗方法可以节省高昂的停机人工清洗费用而且使冷
tubes without fouling deposits. Effectively, constant 凝器保持一个高的传热系数。整个系统体积小，可
heat transfer between refrigerant and condenser 靠性高，易于安装维护。全新的环保球节能清洗系
water will be maintained efficiently. Beneficially, the 统适用于已运转或新建的空调系统冷却水系统。
electrical costs will be lowered or, technically, the
Chiller for air-conditioning system will perform in 一套单独的环保球节能清洗系统可以对多达四台冷
accordance with the design performance (Kw / Ton) as 水机组进行清洗。环保球系统可以由手动操作，也
closely as the original design. 可以由自控程序自动操作。环保球的控制系统可以
One set of Wonderball has been designed to clean the 与冷水机组控制系统完全兼容，实现整体自动控制。
Condenser Tubes up to 4 chillers. The cleaning system
can be operated manually by opening the Ball Injection 环保球节能清洗系统主要包括以下组件:
Valve to inject the balls to each Chiller or automatically  环保球主机部分，包括回收器，注入水泵，回
by programming to inject the balls to each and every 收水泵，注入嘴，电控柜；
Chiller one by one as programmed. The Control Panel  环保球滤隔器；
can also be capable to work automatically with the  除污器（可选配）。
Chiller Manager Programmer.
Wonderball Automatic On-line Tube Cleaning System
consists of the main components as follows:
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 WONDERBALL main body, including 环保球节能清洗系统由设计到制造过程均十分严

Collection System, injection Pump, collection 谨，并通过流体力学测试，达到相关标准。并经过
Pump, injection Nozzle, control center; 多年实践，证实了该系统高效的清洗效果和稳定性。
 Ball Strainer ;
 Separator (Optional) . 本手册提供所有重要资料包括安装、运行、以及维
Wonder ball automatic on-line tube cleaning system 修保养等以确保整个系统设备高效运行和经久耐
has been designed, manufactured and passed the 用。
Hydrostatic Test to meet the specified standard.
This manual contains important information for the 使用前请详细参阅。
installation, operation and maintenance to assure the
most effective performance and long durability.
Please read this manual carefully and thoroughly to
obtain the best possible performance.

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AUTOMATIC ON-LINE TUBE CLEANING SYSTEM

A WONDERBALL INSTALLATION
A 环保球安装

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A INSTALLATION A 安装程序
 System Installation  系统安装
Wonderball must be installed by qualified technician. 环保球全自动在线清洗系统必须在有资格认证的技
Please read this manual carefully and thoroughly 术人员在场的情况下才能调试安装。
before doing installation. 在安装环保球全自动在线清洗系统前，请详细阅读
 Supplied components 本手册。并请详细检查设备完好性、组件齐全。
Make sure to check the supplied components and/or  提供的组件
any damage that might be occurred during the 请按装箱清单，清点提供的组件的种类和数量。如
transportation. 有不符请立即向我公司报告。
If any component is missing or damaged, report your 提供的组件在运送过程中有可能发生损坏。在安装
transporter immediately. 系统前，请详细检查。
 Temporary Storage 如发现任何组件有损伤，请立即向运输公司报告。
For your uninstalled Wonderball, all items should be  暂时性贮存
kept in a place where there is good ventilation. 如要拆除环保球全自动在线清洗系统，所有已拆除 In case the drag is used, make sure
Wonderball System should be covered with plastic 的物品必须放置在空气流通、干燥的地方。 the system is tightened before
cover especially the Control Panel to prevent water, 环保球全自动在线清洗系统的所有对外接口应以胶 moving.
dust, and any unclean particle during construction. 纸密封（特别是控制箱要加以保护），以防止贮存过 Do not tie any component or pipe
 Moving the system 程中沾上水气、灰尘或污物。 directly to the sling.
Ball Collection System is fixed on the steel base plate  搬运
(see Fig 1). The system can be removed by using 环保球全自动在线清洗系统已固定安装在底板上 用拖拉器材搬运前，请确定环保
forklift. Make sure the steel base plate is placed （请看图 1）
。该系统可以用铲车搬移。请确定在搬 球全自动在线清洗系统是否已经
carefully on the forks to avoid an unexpected damage 移过程中，底板是否已安全地放在铲车上，以防止 稳固地放好。
from falling down. 不必要的意外损伤。 请勿将任何组件或喉管直接系
In case the sling is used, it must be tightened under 如要用吊索时，请在底板上索紧。 上吊索。
the steel base plate.
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系统 3# 系统 2# 系统 1# 系统 3# 系统 2# 系统 1#
INJECTION VALVE 3
SIGHT GLASS 注入阀 3
观察窗
INJECTION VALVE 2
注入阀 2
COLLECTION VALVE 1
回球阀 A INJECTION VALVE 1
注入阀 1

AIR VENT CONTROL PANEL

自动排气阀 电控柜
INJECTION VALVE B
BALL COLLECTOR 注水阀
回收器 COLLECTION PUMP
回收水泵

COLLECTION VALVE INJECTION PUMP

注入水泵
回水阀

Water pump inlet

DRAIN VALVE
水泵进水口
泄水阀

Water pump outlet

水泵出水口
INJECTION VALVE A
注球阀
BASE PLATE
基座

Fig1 WONDERBALL SYSTEM

图 1 环保球系统组成
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A.1 MECHANICAL INSTALLATION A.1 机件安装

A.1.1 MAIN BODY A.1.1 主机系统
The location for installation should be clean. 安装系统的位置必须整洁。
Leave at least 1 meter distance between the Wonderball 环保球系统与墙壁之间建议预置 1 米的空间，供日
main body and the wall for regular maintenance. The 后作保养维修之用。电控柜的位置必须在容易操作
Control Panel must be easy to access in compliance with 使用的地方。
NEC or LOCAL CODE. 环保球系统的底部应该以混凝土支撑。混凝土的大
The concrete base should be constructed to support the 小必须适当及水平（请看图 2）。
Ball Collection System (see Fig. 2). The size of the 底板与混凝土应以地脚螺栓固定（请看图 3）。另外，
concrete base should be appropriate and must be 底板与混凝土之间应该安装抗震垫以防振动。
leveled.
Be sure to fix the steel base plate of the Ball Collection
System to the concrete base by using metal bolts (see A.1.2 滤隔器
Fig. 3). The Isolation Rubber Pad should be placed 环保球滤隔器主要功能是收集环保球并将之送回收
underneath as a precaution against vibration. 集器。而环保球滤隔器的清洗亦十分容易。
A.1.2 BALL STRAINER 环保球滤隔器包含法兰、垫圈、螺栓、螺母等零件。
The Ball Strainer will capture the balls and separate 在焊接冷凝器管路法兰前，垫圈和隔离阀必须从环
them from the condenser water. The strainer grill can be 保球滤隔中移除，以防止任何因焊接而产生的意外，
easily cleaned through the Hand hole. 使环保球滤隔器损伤。
The Ball Strainer consists of flanges, gaskets and bolts & 焊接完成之后，请先降温，然后用螺栓和螺母将垫
nuts including Isolation Valve. Before welding the 圈、隔离阀等装上，稳固环保球滤隔器
flanges to the condenser water pipe, gaskets and valve
seat must be removed from the Ball Strainer to avoid
any damage from welding. After welding, make sure the
temperature is cooled down before attaching gaskets
and valve seat with bolts tightly. 8
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SIGHT GLASS
CONTROL PANEL 观察镜
电控柜
INJECTION VALVE
注入阀 ANCHOR BOLT
六角螺栓
INJECTION VALVE B M16
注水阀
85mm

COLLECTION VALVE M16

回水阀
CHECK VALVE
止回阀

INJECTION PUMP
注入水泵

Fig.3 ANCHOR BOLT

图 3 混凝土固定螺栓

Fig.2 CONCRETE BASE

图 2 基座安装侧面图
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Note: The Ball Strainer must be installed so that the 应保证滤隔器的环保球收集口和密封口水平或者向

arrowhead, marked on the Ball Strainer, and the flow 下，不得朝上安装。安装环保球滤隔器时，请注意
of the condenser water are in the same direction. (See 印在滤隔器上的箭头必须与冷凝器水流向一致（请
Fig. 4). 看图 4）。

The Ball strainer has been

ISOLATION MAN HOLE
designed to be installed and
隔离阀 检修口
TO MAIN BODY operate horizontally only.
至主机 The man hole and return
pipe should be down or
INJECTION NOZZLE
horizontal, Never install the
注入嘴
Ball strainer vertically
环保球滤隔器出厂默认水
平的安装及运行。（如需垂
直安装请与厂家联系）
应保证滤隔器的环保球回
球口和检修口水平或者向
下，不得朝上安装。
Fig.4 BALL STRAINER INSTALLATION
图 4 滤隔器安装
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A.1.3 BALL INJECTION NOZZLE A.1.3 注入嘴

The Ball Injection Nozzle will send the balls into the 环保球注入嘴能将环保球送到冷凝器管路的注水位
upstream pipe of the condenser.The injection nozzle is 置。注入嘴出口 DN80，与管道连接处 DN65。
in DN80 and the pipe connection is in DN65. 注入嘴建议水平或者竖直安装于冷凝器管路的进水
The Ball Injection Nozzle can be installed horizontally 口和阀门之间，进水口与注入嘴中间不能安装过滤 The Ball Injection Nozzle must turn
or vertically in between the valve and the condenser 网。安装时，应该在环保球注入嘴与冷凝器之间留 against the flow of the condenser
inlet.The piping between installa Nozzle and condenser 有足够空间，以便阀门更容易开启，参见图 5。 water (see Fig. 5) during the welding
inlet shall NOTbe eqwiped with filter. In order to open 在焊接环保球注入嘴到冷凝器水管之前，请移除阀 process ,the red-line mark on the insert
the valve easily, install the Ball Injection Nozzle at 座以防止任何因焊接而产生的意外，令环保球注入 pipe ,must be correspond with the
sufficient distance from the condenser water pipe, see 嘴损伤。 ontside surface of main pipe. to create
Fig. 5. 把环保球注入嘴焊接到冷凝器管路之后，请勿立即 the pressure in the water pipe without
Before welding the Ball Injection Nozzle to the 用螺栓和螺母把阀座装上。必须等降温后才适合。 causing the Venturi Effect and thus
condenser water pipe, the valve seat must be removed ensure good Ball Distribution.
in order to prevent any damage from welding.
After welding the Ball Injection Nozzle to the 安装环保球注入嘴的方向必须与冷凝
condenser water pipe and flange, make sure the 器的水流相逆（请看图五）
。焊接时注
temperature is cooled down before attaching the valve 入嘴红色标识线与主管外壁齐平，如
seat with bolts tightly. 未能依照本手册之程序安装，管路内
所产生的水压将有机会导致注入的环
保球分布不均匀。

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A.1.4 ISOLATION VALVE A.1.4 隔离阀

There are some isolation valves in the connection 环保球系统和冷却水系统的连接部位都设置有隔离
between wonderball and cooling system. The Isolation 阀。隔离阀可以水平或垂直安装，请在隔离阀与冷
Valve can be installed horizontally or vertically. Leave 凝器之间预留足够空间。
（请看图 6） The isolation valve should be
sufficient distant between the Isolation Valve and the 在焊接隔离阀到冷凝器管路前，请移除隔离阀以防 kept open during installation.
condenser water pipe as specified (see Fig. 6). 止任何因焊接而产生的意外，令隔离阀损坏。
隔离阀在安装时应在打开状态。
Before welding the Isolation Valve to the condenser 把隔离阀焊接到冷凝器管路后，请勿立即用螺栓和
water pipe, the valve seat must be removed in order to 螺母把隔离阀装上。必须等降温后才合适安装。
prevent any damage from welding.
After welding the Isolation Valve to the condenser
water pipe, make sure the temperature is cooled down
before attaching the valve seat with bolts tightly

DN65
ISOLATION VALVE
隔离阀

ISOLATION VALVE
TO CONDENSER
隔离阀
至冷凝器
Fig.5 BALL INJECTION NOZZLE INSTALLATION Fig.6 ISOLATION VALVE INSTALLATION
隔离阀
图 5 注入嘴安装 图 6 隔离阀安装
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A.1.5 PIPING INSTALLATION A.1.5 管路

Pipes must be installed by qualified technician. 安装管路必须由具有资格认证的专业人员负责。
Piping Installation must be in compliance with the 安装管路，包括托架和悬架，必须符合规定。 For electric welding, do not
agreement including supports or hangers according to 法兰焊接完毕后，请确定降温后方可将垫圈和螺栓 connect the ground wire to
the standard. 扭紧。 the steel base plate of the
After flange welding, make sure the temperature is 请将环保球收集器的排水管接到最近一层的排水 Ball Collection System in
cooled down before attaching the gasket and bolts 处。 order to prevent any damage
tightly. Connect pipe from Drain at the Ball Collector to 所有与主管连接管路的隔离阀均为 DN65 接口。 to the PLC and accessories
the nearest floor drain. Main body and isolation vales inside the Control Panel.
are DN65 connection. 如用电子焊接时，请勿将地
A.1.6 PUMP PRIMING 线连接到环保球收集器的
Before starting the Ball Collection and Ball Injection A.1.6 水泵灌注 底板，以防止对控制箱里的
Pump, they must be primed every time. If not, the 开启环保球回收水泵和环保球注入水泵之前，必须 电器元件造成损坏。
pumps will be damaged. Priming is operated as 灌注满水。灌注程序如下：
follows:  将水注入水泵时，开启隔离阀；
 Open Isolation Valve on the suction of the pump to
fill with water.  开启水泵上的排气塞子，让空气排放出来。空
 Open Vent Plug at the volute pump for air vent. 气排放完毕后，完全关闭排气塞子；
Close Vent Plug tightly after air venting completely.
 Make sure the pump is operated in the right  检查水泵时，请开启水泵 2 秒以确保水泵在正
direction by jogging for 2 seconds to check the 确的运作方向。散热风扇转向必须跟水泵涡头 Air should be removed from
rotation. The ventilation fan of the motor must 的箭头一致。如果转向不正确，请调整电源相 the pump before it starts.
rotate in the same direction with the arrowhead 位。 启动水泵前必须对水泵进
marked on the pump volute. In case the fan rotates 行排气
in the wrong direction, interchange the electric
wires at the terminal of the motor. 13
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A.2 ELECTRICAL INSTALLATION A.2 电气安装

A.2.1 GENERAL A.2.1 总则
The electrical system must be installed by qualified 电力系统必须由具有资格认证的技术人员负责安
technician. 装。
For effective installation and inspection, Multimeter 为了让安装程序与检验程序更有效率，请备有多用
should be available. 途的电气仪表。
The electrical installation of the Wonder Ball must be 环保球全自动在线清洗系统的电力安装必须符合本
in compliance with NEC Code or local code. 地的法规。
The tolerance of the VOLTAGE supplied to the Wonder 环保球全自动在线清洗系统的供电电压为 380V,频
Ball must be less than 10 % and the tolerance of 率为 50 Hz / 60 Hz。电压供应的偏差不能超过 10％，
FREQUENCY must be less than 5 %. 频率的偏差不能超过 5％。
Name Plate of Wonder Ball is labeled in front of the 在开启电控柜电源前，请再一次检查电压。
control panel to display the details of VOLTAGE, PHASE,
FREQUENCY and the SIZE of Motor used for the Ball
Injection Pump and Ball Collection Pump.
Check the Voltage supplied to the equipment and
Motors on the Name Plate. If anything is incorrect,
consult your wonder ball dealer immediately.
Before supplying the power to the CONTROL PANEL, A.2.2 电气测试
check the VOLTAGE again. 打开箱盖，检查电压和频率。
请确定电控柜里的配件是否正确安装，交流电电源
A.2.2 ELECTRICAL CHECKOUT 线的连接是否已稳固地连接上。
Open the front panel to check VOLTAGE and 电源连接到左下角接线端子上，见下图，电缆采用
FREQUENCY supplied to the Wonder ball. 三相五线制，并注意接线后水泵转向，如果反向，
Make sure all supplied items inside the Control Panel 需调整接线相位。
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are installed properly without any damage and all AC 环保球系统需要连接冷机工作反馈信号，以保证清

power cord connections are connected correctly and 洗系统能与冷机工作同步。请检查来回冷凝器的工
securely. 作反馈信号是否已正确地连接上（信号由用户提
The power should be connected to the connection in 供）。请参考手册附录中的线路图（二）
。
the bottom left of the box (see the mark on the right).
The connection of wire should ensure the fan of pump 检查完毕后，打开电源，电源指示灯会亮起。请关
is running in the correct direction. 闭电控柜面板。确认没有报警信号，然后选择手动
操作模式进行各部分功能检测。
Check the signals to and from the CMS (CHILLER
MANAGER SYSTEM) are connected correctly and
securely, and in accordance with the Terminal Diagram
in APPENDIX.

After checking, close the front panel. Turn on the

Power, POWER ON lamp lights up. Make sure the POWER CONNECTION
ALARM BUZZER does not activate. Turn the selector
电源连接
switch to MANUAL to check the function of
R—Live wire1 火线 1
equipments.
S—Live wire2 火线 2
T—Live wire3 火线 3
N—Neutral wire 零线
PE—Grounding wire 地线

15
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B WONDERBALL OPERATION
B 环保球运行操作

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B WONDERBALL OPERATION B 运行操作

B.1 PRESTART B.1 开机前准备
CHECK THE FOLLOWING ITEMS BEFORE STARTING THE 开启系统前，请检查以下项目：
SYSTEM: 请确定所有隔离阀已开启。
Make sure to open Isolation Valve, Ball Injection 请确定所有管路已经冲洗。
Nozzle valve, and Ball Strainer valve. 请确定管道内无污物。
Make sure all lines have already been flushed. 请确定管路没有漏水和螺栓已经全部扭紧。
Make sure all flushing plates have already been 请确定所有电线已依线路图完全正确地连接到电控
removed. 柜。
Make sure there is no leakage and bolts at the flanges 检查电压、位相和频率是否与控制箱所提供的数据
have been tightened. 相符合，并且记录下来以作参考。
Make sure all electric wires have completely connected
at the Control Panel and the signal lines from BMS, if
any, are in accordance with the circuit B.2 水泵的检查清单
Check the Voltage, Phase and Frequency are in 请确定环保球注入管路和环保球回收管路已经冲洗
accordance with the Data Plate at the Control Panel 干净。
and record for future reference. 请确定管道内没有残留物质。
B.2 PUMP CHECKLIST 检查电压、电流和频率是否与电机铭牌上的数据相
Make sure both injection line and collection line have 符合，并记录下来以作参考。
already been flushed and cleaned. 记录的数据应该在阀门完全开启以及关闭的情况下
Make sure the flushing plate have already been 量度。
removed.
Make sure the electric wires connected to the motor
correspond with the circuit and rotate to the right
direction.
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Check the Voltage, Ampere and Frequency are in B.2.1 注入水泵测试

accordance with the Name Plate at the motor and 开启安装在环保球注入水泵的隔离阀。
record for future reference. 确定所有的隔离阀都已经打开。
The recorded values should be checked at close off 在手动模式下，开启其中一个冷凝器的注入阀门。
valve position and 100% open valve. 请确定环保球注球阀已关。
B.2.1 BALL INJECTION PUMP TEST
Open Isolation Valve on Ball Injection Nozzle. 全闭测试
Open motorized valve of any condenser through 在手动模式下，开启环保球注入水泵。
manual mode. 记录电压和电流。
Make sure ball injection valve B has been closed.
CLOSE OFF TEST 全开启阀门测试
Start ball injection pump through manual mode. 在手动模式下，开启环保球注球阀。
Record voltage and ampere. 在手动模式下，开启环保球注入水泵。
100% OPEN VALVE TEST 记录电压与电流。
Open ball injection valve B and corresponding injection
valve through manual mode. B.2.2 回收水泵测试
Start ball injection pump through manual mode. 开启回收水泵隔离阀和环保球滤隔上的隔离阀。
Record voltage and ampere. 在手动模式下，开启其中一个冷凝器的回球阀门。
B.2.2 BALL COLLECTION PUMP TEST 请确保环保球回水阀已关闭。
Open Isolation Valve and Ball strainer valve.
Open Motorized Valve of any condenser through 全闭测试
manual mode. 在手动模式下，开启环保球回收水泵。
Make sure ball collection valve has been closed. 记录电压与电流。
CLOSE OFF TEST
Start ball collection pump through manual mode.
Record voltage and ampere. 18
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100% OPEN VALVE TEST 全开启阀门测试

Open ball collection valve through manual mode. 在手动模式下，开启环保球回水阀。
Start ball collection pump through manual mode. 在手动模式下，开启环保球回收水泵。
Record voltage and ampere. 记录电压与电流。

B.3 OPERATION PROCEDURE B.3 运行操作

B.3.1 CONTROL PANEL B.3.1 控制面板
See Fig.7 请见图 7

BUZZER
报警指示灯
SCREEN
触摸屏
POWER ON
电源指示灯

SYSTEM RUN
EMERGENCY STOP
系统运行指示灯
急停开关

PRG KEY PRG RUN

启动钥匙 启动指示灯

Fig.7 CONTROL PENAL

图 7 电控柜 19
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B.3.2 START STEPS B.3.2 开机程序

1) Connect the power and turn on the switch in the 1） 接通电源，开启电控柜柜子里的总开关（左上）。
control box. The POWER ON lamp will be on. 此时，电源指示红灯亮起。
Telematic and Automatic
2) Turn on the PRG KEY, then the PRG lamp lights. After 2） 旋转启动钥匙，程序启动指示黄灯亮，程序加载
Operation Mode is for normal
loading, the touch screen starts to work. 25 秒后触摸屏进入工作状态，可进行操作。
operation. Manual Operation
3).There are three operation modes, telematic 3） 环保球全自动在线清洗系统提供手动操作模式、
Mode is for parts test operation.
operation mode, automatic operation mode and 自动操作模式和远程操作模式。正常工作请选用
日常工作选择远程操作或自动
manual operation mode. Telematic and automatic 远程和自动操作模式。当对系统各部分进行检验
操作模式
operation mode is for normal operation and manual 运行时，选用手动操作模式。
各部分检验时选择手动模式
operation mode is for parts test operation.
B.3.3 远程操作模式
B.3.3 TELEMATIC OPERATION MODE 1）触摸屏点击“远程操作模式”，则进入全自动运
1) Touch the Telematic Operation, and then enter 行状态，程序将冷凝器自动全选。并进入时间设定
telematic operation. In this mode, all condensers are 界面，见图 9。点击时间输入框，则可以设定每个清
selected to clean. Set the interval time of every clean 洗循环的时间间隔，回车确定，ESC 取消，BSP 清除
cycle, see Fig.9. Touch the type-in frame and type in 重设。推荐时间间隔如下表:
the time. The recommended time setting is in the
chart below: 清洗冷凝器台数 设定时间间隔
1台 ≤2 小时
Condenser Amount Interval Time Setting 2台 ≤1 小时
1 ≤2h 3台 ≤40 分钟
2 ≤1h 4台 ≤30 分钟
3 ≤40mins
4 ≤30mins

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ENGLISH
2) After setting, please press the START button to run 2）时间间隔输入完毕后，按“开始清洗”，则系统
the system. The running green light is on. 开始清洗，运行指示绿灯亮起。异地运行指示输出
3) All operation order can be done by remote control. 24VDC 信号。
Please refer to the figure below. 3）此时可以通过异地的信号对环保球进行启动、停
止、报警信号复位的操作（人为排除故障后）。接线
图见下图及附录图。

①- Remote START/异地启动
②- Remote STOP/异地停止
③- Remote ALARM RESET/异地报警复位
① ② ③ ④ ⑤ ⑥ ④- 1# Chiller signal/1#冷机运行信号
⑤- 2# Chiller signal/2#冷机运行信号
⑥- 3# Chiller signal/3#冷机运行信号

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B.3.4 SEMIAUTOMATIC OPERATION MODE B.3.4 自动操作模式

1) Touch the Automatic Operation, and then enter automatic 1）触摸屏点击“自动操作模式” ，则进入自动运行状态，
operation, see Fig.8. Please select any condenser to clean, and 见图 8。此时可以选择对某台或某几台冷凝器进行清洗，
then press the Confirm. If the wrong system is selected, press the 可随意组合。如果选择错误，可以选择“重设”，进行
Wonderball should stop before
Reset to select again. 重新选择。
the chiller stop and at least 5
2) Set the interval time of every clean cycle, see Fig.9. The setting 2）选择完成后，按一下“确定”，则进入时间设定界面，
min ahead of the pump stop
method is the same as telematic operation. 见图 9。设定方法与”远程操作模式”相同。
冷机停机前，请先停止环保球
3) The RUN lamp lights. Now, if select the Control Screen, see 3）时间设定好后，选择“开始清洗”则系统开始清洗，
系统，并至少 5 分钟后再停止
Fig.10, all parts working situation will be showed on the screen. 运行指示绿灯亮起。此时，可以选择“监控画面”，屏
冷却水水泵
4) Select the System Condition, the statistic date will be showed, 幕显示如图 10，可以观察到此时各部分工作的状态。
see Fig.11. 4）在监控画面状态下（图 10），选择“系统状态” ，则
Cleaning Count shows the cycles of cleaning this time. 可以进入系统状态显示及数据统计界面，见图 11。
It shows the total cycles in one Power-on period. Once the power 系统本次运行次数，是指系统在不断电运行期间，总的
off, the data will become zero. 运行次数。一旦停机断电，数据将从零开始。
Total cleaning count shows the total cleaning cycles of this 本系统运行次数共计，是指本台设备所进行的清洗循环
system. The maximum value is 999999.Click “Count Reset” to set 的总和，最大值 999999。点击“计数复位”可清 0。
zero. 5）在系统运行过程中，如果想停止，可以在图 9 界面
5) If stop the program when running, please select the Stop 中选择“停止清洗” ，则会显示提示界面，见图 12，
Cleaning in the Fig.9, and then the Fig.12 will 选择“确定”则可以执行。
appears, select the Confirm. 6）如果系统出现故障报警，报警指示灯亮，并蜂鸣。
6) If the system fault and alarm, the mark of Alarm will appear in 图 10 中将显示报警标志，点击可以进入报警界面，如
the Fig.10. Click the Alarm, Alarm Screen will be showed, see 图 13，可以得知故障报警部件。此时，异地报警输出
Fig.13. It is easy to find the fault component of system from the 24VDC 信号。排除故障后，可点击“复位”或输入异地
screen.At this moment,the Remote Alarm(Buzzer) will have 复位信号 24VDC。
24VDC output signal.After the fault is eliminated,click “ Reset”or
input 24VDC signal to remote RECOVER. 22
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Fig.8 AUTOMATIC OPERATION MODE 图 8 自动运行模式

Fig.9 TIME INTERVAL SETTING 图 9 清洗时间间隔设定

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Fig.10 CONRTOL SCREEN 图 10 监控画面

24
Fig.11 CLEANING STATISTIC 图 11 清洗统计
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Fig.12 STOP CAUTION 图 12 停止提示

Fig.13 ALARM SCREEN 图 13 报警界面 25

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A cleaning cycle includes 4 steps, see Fig 14. 清洗的一个周期包括，见工作流程图 14：

 Electronic butterfly valve operates 100s.  蝶阀执行器工作一个行程时间为 100 秒。
 Pump operates 60s.  水泵工作时间为 60 秒。
 The cycle time is 420s.  自动清洗一套机组需要的总时间大约为 420 秒。
 (optional)If an optional solid separator unit is  (选配)如系统配有除污器，回收水泵每次工作
Installed ,the colloction pump will operate 8 时间为 8 分钟。
Minutes every cleaning cycle.

STEP 1（100s） ： STEP 2（60s）： STEP 3（100s） ： STEP 4（60s） ： STEP 5（100s） ：
Injection valve A open Injection pump Injection valve A close Collection pump Collection valve 1 close
Injection valve B open run Injection valve B close run.（8mins）with Collection valve close
Injection valve 1 open Injection valve 1 close Separator unit
Collection valve1 open (optional)
Collection valve open

Fig 14 CYCLE PROCEDURE

第一步（100s）： 第二步（60s）
： 第三步（100s）： 第四步（60s）
： 第五步（100s）：
注入阀开启 注入泵运行 注球阀关闭 回水泵运行。 回球阀 1 关闭
注水阀开启 注水阀关闭 如配有除污器 回水阀关闭
注球阀 1 开启 注入阀 1 关闭 回收泵运行时间
回球阀 1 开启 为 8 分钟
回水阀开启

图 14 单次循环执行程序
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B.3.5 MANUAL OPERATION MODE B.3.5 手动操作模式

1) Select the Manual Operation, the Fig 15 will be 1）选择“手动操作模式”后，进入界面图 15，此时
showed. Now select any condenser Cycle to clean. 可以选择需要循环的冷凝器系统。
2) The Fig. 16 is the cycle control screen. Every part 2）选择某一循环后，则进入循环控制界面，图 16。
can be selected to run independently. 可以单独运行或者停止某一部件。
3) Select the Control Screen, then Fig. 10 will be 3）选择“监控画面”，则可以进入图 10 进行监控，
shown.. If alarm mark appears, click it and enter the 如发生报警，则会出现报警指示，点击后可进入图
Alarm Screen, see Fig .13. Check the fault 13 查询故障部件。
component.

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Fig 15 MANUAL OPERATION CYCLE SELECTION 图 15 手动操作模式下循环选择

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Fig 16 MANUAL OPERATION CYCLE CONTROL W.18.05.15 图 16 手动操作模式选择
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B.3.6 OPERATION NOTICE B.3.6 运行提示

The injection pump and collection pump never operate 环保球系统的注入水泵绝对不会和回收水泵同时运
at the same time. In manual operation mode, if you 行。如果在手动运行模式下，同时选择两个水泵同
select the two pumps together, a Caution will appear, 时运行，屏幕将会出现提示画面，见图 17。
see Fig 17. 正常运行时，都要选择远程控制模式或者自动运行
If manual operation mode is selected under normal 模式。如果运行时，人为地选择了手动运行模式，
operation (either telematic or automatic operation 系统将会出现提示，见图 18。
mode), a notice will be shown, see Fig. 18. 在选择清洗冷凝器时，如果改变选择，需要按动图 8
If the selection of condenser has been changed, 中“重设” ，这时会出现提示图 19。
“Reset” should be pressed, see Fig. 8, and then the Fig.
19 will be shown.

29
Fig17 CAUTION W.18.05.15 图 17 重要提示
AUTOMATIC ON-LINE TUBE CLEANING SYSTEM

Fig 18 CAUTION 图 18 重要提示

30
Fig 19 CAUTION W.18.05.15 图 19 重要提示
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B.4 BALL CHANGING PROCEDURES B.4 更换小球程序

The life span of the ball is approximately 4000-5000 一般情况下，环保球大约循环 4000-5000 次（参见
cycles depending mainly on the cleaning frequency and B.3.4(4)），即需要更换一次，视乎使用环保球全自动
water quality. After the ball is worn out, when its 在线清洗系统的次数多寡和水质情况。其次，每当
diameter is smaller than the inside diameter of the 环保球用久了，能轻易穿过冷凝器铜管的时候，便
condenser tube, new ball has to be replaced for the 须要更换。
best possible performance.
 Make sure that all the balls have been collected at  请确定环保球回收器已回收所有环保球。
the Ball Collector.  进入到手动模式，停止系统运行。
 Stop the system by turning the Selection Switch to  请确定所有环保球的电动阀门和隔离阀已经关
manual mode. 闭。
 Make sure all Motorized Valves are close.  开启环保球回收器的泄水阀进行泄水。
 Open Drain Valve at the Ball Collector.  松开环保球回收器的面盖螺栓。
 Unscrew the top cover of the Ball Collector.  打开环保球回收器的面盖直至排出系统中三分
 Open the top cover of the Ball Collector until the 之一的水才关闭排水阀。
water level is lowered by 1/3. Then close the Drain  点算所有环保球并记录，作参考之用。
Valve.  重新放入相同数量的新环保球于回收器内。
 Collect all used balls and record the amount of  将环保球放在水里并挤压五到十次，让环保球
balls used for future reference. 完全吸收水分。
 Load new balls with the amount used.  关闭环保球回收器面盖时，请确定 O 形圈套在
 Squeeze new balls in the water 5 – 10 times in 沟槽上，才可扭紧。
order that the balls are fully absorbed by water.
 Close the top cover of the Ball Collector and make
sure the O-Ring fit in the groove. Then screw
tightly.

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 Open Isolation Valve. Open Motorized Valve of  开启所有隔离阀。在手动模式下，开启其中一

any condenser through manual mode. Open Air 台冷凝器清洗系统的电动阀门。开启排气阀，
Vent Valve, the air will be vented automatically. 空气便会自动排放。
 When the Ball Collector is fully vented by  透过环保球回收器的观察镜，检查所有气泡是
checking air bubble at the Sight Glass of the Ball 否完全排放，然后关闭排气阀和电动阀门。
Collector, Air Vent Valve and Motorized Valve  选择远程控制模式或自动模式，环保球全自动
close. 在线清洗系统便能按程序自动运作。
 Turn the Selector Switch to Automatic Operation
Mode. Wonderball is ready to operate
automatically as programmed.

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C WONDERBALL MODBUS COMMUNICATION

C 环保球 MODBUS 通讯

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环保球在线自动清洗系统采用西门子 S7-200 CPU 上的通信口 Port0 可以支持 Modbus RTU 协议，作为 ModbusRTU 从站。

S7-200 可以组成 RS-485 基础上的 Modbus RTU 网络。出厂为 DB9 针串口建议采用西门子 Profibus 数据总线连接器

(6ES7972-0BA12-0XA0)作为连接转换。

PORT0 （DB9）
RS485 支 持
modbus RTU 协
议通讯

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AUTOMATIC ON-LINE TUBE CLEANING SYSTEM Modbus address code 1

Type Address code Description Decimal code Access grade
The Modbus parameter
00001 1#系统注球循环运行 0/1 read only
2#系统注球循环运行 0/1 Baud ：19200
00002 read only
00004 1#系统收球循环运行 0/1 read only Addr ：12（出厂默认）
Digital switch 3#系统注球循环运行
00009 0/1 read only Stop ：1
signal 00010 2#系统收球循环运行 0/1 read only
3#系统收球循环运行 Parity ： N
00011 0/1 read only
00012 故障报警输出 0/1 read only Transmission Mode：RTU
00014 4#系统收球循环运行 0/1 read only
Timesout ： 1000ms
00015 4#系统注球循环运行 0/1 read only
00016 排污阀 0/1 read only
10001 4#冷机运行信号 0/1 read only
10002 1#冷机运行信号 0/1 read only
10003 2#冷机运行信号 0/1 read only
Digital switch 0/1
10004 3#冷机运行信号 read only
signal
10005 异地启动 0/1 read only
10006 异地停止 0/1 read only
10007 异地复位 0/1 read only
10008 注入循环水泵运行 0/1 read only
10009 回收循环水泵运行 0/1 read only
40001 循环间隔时 00000/99999 write/read
40004 累计循环计数 00000/99999 write/read
Analog signal
40006 本次循环计数 00000/99999 write/read

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D WONDERBALL GENERAL TROUBLESHOOTING

D 环保球故障排除

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C GENERAL TROUBLESHOOTING

TROUBLE CAUSE SOLUTION

The system does not go to operation. - Power Failure - Check power supply
- Reprogramming control panel by auto mode

- Reset PLC by turn off and on. At PLC Switch or switch of

- PLC Failure (Run led at PLC off)
load on power supply

- Check fuse condition if fuse break down, to change new

- Fuse Failure
one

- Emergency Stop does not recover - Turn the Emergency Stop button and recover system

故 障 原 因 解 决 方 法

环保球自动在线清洗系统没有运行
- 检查电源供应
- 电源出现故障
- 重新在控制箱设定自动模式的运作程序

- 冷凝器总管系统出现故障 - 重新开启冷凝器总管系统

- 环保球主机电路故障 - 若保险丝烧断了，请更换保险丝

- 急停开关没有复位 - 旋转电控柜外急停开关，解除断路

C GENERAL TROUBLESHOOTING

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AUTOMATIC ON-LINE TUBE CLEANING SYSTEM

TROUBLE CAUSE SOLUTION

Ball still stay in ball collector after ball - Isolation valve closed
- Check all isolation valves in fully open
injection pump operation - Ball injection nozzle valve closed

- Motorized valve for condenser closed

- Check all motorized valve by manual mode
- BALL injection valve closed

- Check pump for proper rotation

- Pump runs wrong rotation - If rotation is incorrect, interchange two wires at the motor
terminals

- Air block pump - Vent pump

- 故 障 原 因 解 决 方 法

当环保球注入水泵开启后，环保球仍然 - 注入水泵的隔离阀关闭
- 检查所有隔离阀是否完全开启
保留在环保球回收器内 - 环保球注入嘴隔离阀关闭
- 冷凝器的电动阀门关闭
- 环保球注球阀门关闭 - 在手动模式下检查所有电动阀门
- 注水阀或注入阀关闭

- 检查水泵是否正确方向运作
- 水泵向错误方向运作 - 如水泵并非正确方向运作，可以将发动机末端的电线互
相交换

- 空气阻塞了水泵 - 排出水泵里的空气

C GENERAL TROUBLESHOOTING

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AUTOMATIC ON-LINE TUBE CLEANING SYSTEM

TROUBLE CAUSE SOLUTION

Balls do not return to ball collector after

ball collection pump operation - Isolation valve closed - Check all isolation valve in fully opened

- Motorized valve for condenser closed

- Check all motorized valve by manual mode
- Ball collection valve closed

- Check pump for proper rotation

- Pump run wrong rotation - If rotation is incorrect, interchange
- two wires at the motor terminals.

- Air block pump - Vent pump

故 障 原 因 解 决 方 法

当环保球回收水泵开启后，环保球没有
收到环保球收集器内 - 回收循环上的隔离阀关闭 - 检查所有隔离阀是否完全开启。

- 冷凝器的电动阀门关闭
- 在手动模式下检查所有电动阀门
环保球回球阀或回水阀关闭
- 检查水泵是否向正确方向运作
- 水泵向错误方向运作 - 如水泵并非向正确方向运作，可以将发动机末端的电线
互相交换

- 空气阻塞了水泵的压力 - 排出水泵里的空气

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AUTOMATIC ON-LINE TUBE CLEANING SYSTEM

C GENERAL TROUBLESHOOTING

TROUBLE CAUSE SOLUTION

INJECTION PUMP ALARM

- Electromotor failure - Check electromotor

- Switch can not connect - Check switch

- AC contactor failure - Check AC contactor

故 障 原 因 解 决 方 法

注入水泵报警
- 注入水泵电机故障 - 检查电动机

- 断路器没有闭合 - 检查断路器

- 交流接触器故障 - 检查注入泵交流接触器

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AUTOMATIC ON-LINE TUBE CLEANING SYSTEM

C GENERAL TROUBLESHOOTING

TROUBLE CAUSE SOLUTION

COLLECTION PUMP ALARM

- Electromotor failure - Check electromotor

- Switch can not connect - Check switch

- AC contactor failure - Check AC contactor

- 故 障 原 因 解 决 方 法

回收水泵报警
回收水泵电机故障 - 检查电动机

- 断路器没有闭合 - 检查断路器

- 交流接触器故障
- 检查注入泵交流接触器

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AUTOMATIC ON-LINE TUBE CLEANING SYSTEM

适用于下列型号：

Wonderball Main Body Dimension

AWM11-1C-B AWM12-1C-B AWM14-1C-B AWM35-1C-B

AWM11-2C-B AWM12-2C-B AWM14-2C-B AWM35-2C-B 环保球主机尺寸图（一）

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AUTOMATIC ON-LINE TUBE CLEANING SYSTEM

适用于下列型号：

AWM11-3C-B AWM12-3C-B AWM14-3C-B AWM35-3C-B

Wonderball Main Body Dimension
环保球主机尺寸图（二）
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AUTOMATIC ON-LINE TUBE CLEANING SYSTEM

适用于下列型号：
AWM11-4C-B
AWM12-4C-B
Wonderball Main Body Dimension
AWM14-4C-B
AWM35-4C-B 环保球主机尺寸图（三）
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Model: AWM14-4C-B

Model :AWM14-3C-B
AUTOMATIC ON-LINE TUBE CLEANING SYSTEM

参数表： C

MODEL
AWSH-06 AWSH-08 AWSH-10 AWSH-12 AWSH-14 AWSH-16 AWSH-18 AWSH-20
型号
Size DN150 DN200 DN250 DN300 DN350 DN400 DN450 DN600
A(mm) 102 150 150 150 200 200 200 210
B(mm) 575 750 900 1100 1150 1350 1450 1900

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AUTOMATIC ON-LINE TUBE CLEANING SYSTEM

Including the
Isolation Valve

Including the
Isolation Valve

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 Isolation Valve
provided by
Contractor

Isolation Valve
provided by
Contractor
AUTOMATIC ON-LINE TUBE CLEANING SYSTEM

Wiring by
contractor

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AUTOMATIC ON-LINE TUBE CLEANING SYSTEM

wiring by contractor

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 GW X1 M X2 MV X3
R S T N PE U1 V1 W1 PE U21 V21W21U22 V22 W22 PE 45 05 55 46 05 56 47 05 57 48 05 58 49 05 59 50 05 60

1 2 3 4 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

L1 L2 L3 N PE

3 380VAC+N+PE
50/60HZ
MAIN INCOMMING SUPPLY
3M 3M

INJECTION INJECTION INJECTION COLLECTION INJECTION INJECTION

VALVE 1 VALVE 2 VALVE B VALVE 1 VALVE 3 VALVE A
INJECTION COLLECTION
PUMP PUMP

WONDER BALL
AWM14-3C-B
WIRING DIAGRAM
 P X4
51 05 61 52 05 62 53 05 63 PE 78 79 71 72 11 36 37 38 11 39 11 40 11 41 PE

19 20 21 22 23 24 25 26 27 28 29 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

SYSTEM RUN

ALARM
1# 2# 3#

CHILLER SIGNAL

CHILLER SIGNAL

CHILLER SIGNAL
REMOTE START

REMOTE STOP

REMOTE RECOVER
+
24
DC
COLLECTION COLLECTION COLLECTION
VALVE B VALVE 2 VALVE 3 DRY
CONTACT (+24VDC)

INPUT

BAS TERMINAL SYSTEM

WONDER BALL
AWM14-3C-B
WIRING DIAGRAM
 Wonderball
pipe connection details
2020.11.11
(For those ex-fty on or before 2020/12/31)
 Wonderball

Ball strainer Ball Injection Nozzle

Connect to DN65 pipe

by welding (by others)

DN80 butterfly valve

(wafer type)

(For those ex-fty on or before 2020/12/31) 2020.11.11

 Wonderball

Isolation valve Provided by Contractor

• Wafer type butterfly valve

(DN65)
• PN16
• Come with one pair of DN65
PN16 flange

(For those ex-fty on or before 2020/12/31) 2020.11.11

 Wonderball

DN65 PN16 flange

DN65 PN16 flange

(For those ex-fty on or before 2020/12/31) 2020.11.11