Marley WaterGard WG002 User manual

WaterGard™model WG002-WG004-WG007-WG009
INSTALLATION - OPERATION - MAINTENANCE
10000022002 ISSUED 5/2023 READ AND UNDERSTAND THIS MANUAL PRIOR TO OPERATING OR SERVICING THIS PRODUCT.
user manual
MEMBRANE
INLET
PRESSURE
FILTER OUTLET
PRESSURE
PRODUCT
PERMEATE REJECT
WATE R
RECIRCULATION
INLET WATER PRODUCT
INLET WATER
PRESSURE
REJECT
PRESSURE

2
contents
Technical Information..................................................................................................3
System Requirements................................................................................................4
Schematics and Components .................................................................................5
Rigging ..........................................................................................................................7
Physical System Requirements ...............................................................................7
Electrical Requirements.............................................................................................8
Piping Connections....................................................................................................8
Startup and Operation...............................................................................................9
System Shutdown....................................................................................................11
Automatic System Standby and Restart ............................................................11
WaterGard Controls................................................................................................12
Operating Status Messages .................................................................................13
Fault Condition Display...........................................................................................15
Controller Adjustment............................................................................................. 17
Conductivity Calibration .........................................................................................18
Standard Setpoints .................................................................................................20
Troubleshooting........................................................................................................21
Maintenance..............................................................................................................23
Parts List ....................................................................................................................27
System Log ...............................................................................................................28
This manual contains vital information for the proper installation
and operation of the Marley®WaterGard™system. Carefully read the
manual before installation or operation and follow all instructions.
Save this manual for future reference.
Note
Indicates presence of a hazard which can cause severe personal
injury, death or substantial property damage if ignored.
Indicates presence of a hazard which will or can cause personal
injury or property damage if ignored.
Indicates special instructions on installation, operation or mainte-
nance which are important but not related to personal injury hazards.
Warning
Caution
Note
The following defined terms are used throughout this manual to bring attention
to the presence of hazards of various risk levels, or to important information
concerning the life of the product.

3
overview
This User Manual as well as those offered separately on other components,
etc., are intended to assure that the WaterGard system serves you properly
for the maximum possible time. Since product warrantability may well depend
upon your actions, please read this User Manual thoroughly prior to operation.
This User Manual provides information regarding general installation and op-
eration. Any deviation from, change or modification to the User Manual, the
original design conditions or the original intended use of the equipment may
result in improper installation and/or operation.
Any such deviation, change or modification shall be the responsibility of
the party or parties making such deviation, change or modification. SPX
Cooling Tech expressly disclaims all liability for any such deviation, change
or modification. The equipment shall be warranted in accordance with the
applicable SPX Cooling Tech Certification of Limited Warranty.
Technical Information
Specifications
Model WG002 WG004 WG007 WG009
Performance
Nominal Rejection 91%
Rated Product Permeate Flow – gpm*2.2 4.4 7. 3 9.0
Recovery 85-90%
Membranes
Size 4" x 40" 4" x 40" 4" x 40" 4" x 40"
Quantity 2 4 6 18
Type Low fouling spiral-wound composite
Inlet Pressure Range - psig 30-80
* Product permeate flow rate varies with temperature. All models are rated at 60°F (15.5°C).
Product permeate flow for individual elements may vary -20 +25%.
Maximum and Minimum Flow
Model
Product Permeate Flow - gpm Reject
Minimum
gpm
Reject
Maximum
gpm
Minimum 50°F Minimum 60°F Maximum 77°F
WG002 2 2.2 2.75 .22 .61
WG004 4 4.4 5 .44 1.21
WG007 67. 3 8.73 2.01
WG009 8 9.0 10.5 .9 2.48
Table 1
Table 2

4
overview
System Requirements
For WaterGard to function correctly these three items are required:
• A WaterGard-ready Marley LLC (liquid level control) or LLC+u water level
control system is required to communicate correctly.
• Municipal potable water will have residual chlorine levels that are too high
for WaterGard, therefore, a method of removal is required when any water
source has a free residual chlorine level above the requirements shown in
the Feedwater Requirements Table 3. This can either be done by purchas-
ing a carbon tank through SPX Cooling or using liquid chemical chlorine
destruct from a chemical water treater.
• A conductivity blowdown controller is required to monitor the water saving
WaterGard offers. This can be purchased with the WaterGard system.
WaterGard can remove up to 91% of an individual ion. How much of an
individual ion is removed depends on the ion. In some cases, the incoming
water in a galvanized cooling tower may have too low of a calcium value (<
50 ppm as CaCO3) making the water corrosive after WaterGard treatment.
In these situations it is recommended to initially fill the system with untreated
potable water. If the system level is low enough the internal bypass will au-
tomatically fill with mixture of treated and untreated water. Otherwise, if the
system level isn’t low enough the external bypass will need to be engaged.
Once the system is full, WaterGard can be started and operated normally.
For additional information on soft water and its impact on tower metallurgy
consult you Marley sales representative.
WaterGard operates by rejecting ions down a small, concentrated reject waste
stream. This is typically 10-15% of the feedwater stream. Due to this, water
savings are not possible when the evaporative system operates at higher
cycles of concentration. Anything beyond 7 cycles of concentration can result
in increased water usage, not water savings.
Feedwater Requirements
Maximum Chlorine Concentration < 0.1 ppm
Maximum Operating Temperature 113° F
Maximum Feedwater Turbidity 1.0 NTU
Maximum Feedwater SDI 5.0
Oil and Grease Max 0.1 mg/L
Operating pH Range 2-10
Cleaning pH Range 1-12
Sediment Filtration 5 microns
Table 3

5
Schematics and Components
overview
Figure 1
MEMBRANE
INLET
PRESSURE
FILTER OUTLET
PRESSURE
PRODUCT
PERMEATE REJECT
WATE R
RECIRCULATION
INLET WATER PRODUCT
INLET WATER
PRESSURE
REJECT
PRESSURE
26" External Carbon Filter
(if equipped}
54.5"
20"
WG002 and WG004 Component Dimensions (WG004 shown)

6
overview
Schematics and Components
Figure 2
WG007 and WG009 Component Dimensions (WG009 shown)
RECIRCULATION
REJECT
CONCENTRATE
FILTER OUTLET
PRESSURE
INLET WATER
PRESSURE
REJECT
PRESSURE
MEMBRANEINLET
PRESSURE
PROCUCT
PERMEATE
PROCUCT
PERMEATE
INLET WATER
External Carbon Filter
(if equipped}
59.5"
20.5"
60"

7
Rigging
The WaterGard unit should be lifted and moved by a forklift. If the WaterGard
unit is lifted by a crane it should be lifted from the bottom using a platform.
The unit should be secure to the platform using the anchor locations. A test
lift should be done in order to determine the weight centerline.
Do not allow rigging straps to contact system components.
Physical System Requirements
• WaterGard is for indoor use only. If the end user desires the unit to be
placed outdoors it is the sole responsibly of the end user to protect the unit
from freezing and inclement weather conditions.
• Ideally WaterGard should be located out of direct sunlight. If this is not
possible some components may experience discoloration from direct UV
rays due to sunlight. This is mainly an aesthetic issue and won’t adversely
impact performance.
• WaterGard should be located on a level floor or housekeeping pad.
• Floor load rating must be sufficient to accept WaterGard weight.
• The location must be dry and frost-free.
• Normally, inlet feedwater temperature should not exceed 77°F. Water tem-
peratures above this will negatively impact the quality of the water.
• Feedwater to the WaterGard unit must not contain chlorine or oil. For more
information refer to Table 3.
• A floor drain close to the unit is required that can carry away the reject flow
from the WaterGard system. See Table 2 for reject flow requirements.
• The water pressure at the WaterGard inlet when in operation, must be a
minimum of 30 psi, and must not exceed a maximum of 80 psi. If the pres-
sure exceeds the maximum stated pressure, or if it fluctuates to pressures
exceeding 80 psi, install a pressure-reducing valve at the inlet.
• The flow of inlet feedwater supplied to the WaterGard unit shall be an unin-
terrupted flow at 30 psi minimum, and at a minimum flow rate of twice the
rated product permeate water flow of the WaterGard unit purchased. See
Table 2 for minimum flow rates.
• WaterGard should be additionally secured in areas where necessary using
seismic and wind rated anchor bolts and straps. All applicable local codes
shall be followed.
Caution
installation

8
Electrical Requirements
WaterGard’s provided cord serves as the ground. Conduit and water
pipes are NOT an acceptable ground.
• All wiring must be properly sized, rated, and connected in accordance with
local, state, and national electrical codes. The system is pre-wired and tested
at the factory. See provided drawing for additional details.
• The WaterGard unit should be on a dedicated circuit originating at a service
disconnect panel. Refer to unit nameplate for correct voltage information.
• The electrical voltage and phase must match and be verified to the
WaterGard unit that was purchased.
Do not operate pump dry. Damage to pump seal and shaft may occur.
Piping Connections
• All piping, valves, etc. for the product permeate water outlet of the Water-
Gard unit must be made of PVC, PP, PEX, or corrosion-resistant stainless
steel. Local plumbing codes must be observed and followed.
• The carbon filter (if present) must be installed upstream from the
WaterGard unit. This is designed to remove any residual chlorine present in
the feedwater stream. For information on pipe sizes for each unit reference
the installation and/or sales drawing.
Properly secure all pipe runs. Pipe movement may cause damage to
WaterGard and/or pipe. Ensure waste drain line is adequately sized
and free flowing to handle the reject flow. Reject flow rates can be
found in Table 2.
The drain for the WaterGard unit must be designed and constructed to provide
for connection to the sanitary waste system through an air gap of 1"or two
pipe diameters, whichever is larger.
Warning
Caution
Caution
installation
Minimum Gap = 2 x Pipe Dia.
or 1" Whichever is Greater WaterGard Drain
Floor Drain
Optional Elbow
Cut Opening
if Required
Gap
Gap
Gap
Figure 3

9
operation
Startup and Operation
WaterGard membranes cannot be used immediately, they must
be filled with feedwater and allowed to soak for a minimum of 30
minutes, see step 10.
1. Connect the carbon filter (if present) to your potable water supply. The
carbon filter will need to be flushed for 30 minutes before being piped
into WaterGard.
2. If liquid chemical chlorine destruct is being used, setup the system up-
stream of WaterGard and plug in the chemical pump into the provided
electrical receptacle on the WaterGard unit. See the installation drawing
for more info.
3. Connect WaterGard to your potable water supply. If blending both warm
and cold water to improve product’s flow rate, do not exceed 77°F (25°C).
4. Verify the installation of the sediment filter cartridge(s) inside its housing.
5. The reject to drain connection coming out of the WaterGard system is
for reject water. The water from this will go directly to the drain.
6. Connect the WaterGard ready LLC or LLC+u makeup and low level alarm
into the appropriate lead suspended from the WaterGard control panel.
Refer to the WaterGard specific LLC User Manual for more information.
7. The product permeate water hose or piping should temporarily be placed
near the drain to flush any initial impurities from WaterGard before con-
necting the product’s water hose or piping to the point of use or collection
basin.
8. Connect WaterGard to a dedicated electrical power supply. Refer to unit
nameplate for voltage information.
9. Open the WaterGard’s feedwater inlet valve (by others).
10. Press the WaterGard controller button to the ON position. A flush will
occur with another delay before the pump starts. Once the pump delay
starts, turn off WaterGard controller by pressing and holding the system
On/Off button. You may have to repeat more than once to fill WaterGard.
When water flows out of the reject and product permeate outlets, let the
membranes soak for a minimum of 30 minutes.
11. Re-press the WaterGard controller button to the ON position. A 60 second
flush then a 5 second delay will occur before the pump starts.
Note
➠

10
operation
12. Once the pump has started, membrane inlet (pump) pressure should never
exceed 135 psi. Use the valve on the discharge side of the pump to adjust
the pressure to 105 psi. If pressures over 135 psi are observed it could
be an indication of membrane fouling. See Membrane Replacement on
page 24.
13. Allow WaterGard to run for 30 minutes to allow components to fill with
water, purge trapped air and to rinse the membranes of preservatives.
15. Begin to close the reject throttle valve and adjust to a 50:50 ratio flow
through the reject flowmeter compared to the product permeate flowmeter.
16. Once WaterGard has stabilized and all impurities and preservatives have
been flushed, the water will have to stabilized. Set the product perme-
ate water quality alarm value at the desired limit (Refer to the Controller
Adjustments on page 17) and adjust the reject throttle to maximize water
savings.
17. When WaterGard is running stable and within desired water quality limits,
the product permeate hose or piping can be connected to the process
system’s piping or cooling tower collection basin. During the initial fill of the
system, the low-level alarm will be activated, this is by design. This allows
for a blended rapid fill of the system. During this phase, both untreated feed-
water and treated feedwater will be added to the system until the LLC tells
WaterGard to turn off.
18. Record initial operating conditions on the System Log sheet on page 28,
and then periodically afterwards as determined by your Quality Depart-
ment or Facilities Manager.
The operating conditions should be recorded at least once each
day WaterGard is operated.
Note