3750 Pulpress pressurisation unit. Installation and operating instructions

Transcription

1 3750 Pulpress pressurisation unit Installation and File No: uk Date: september 02, 2016 Supersedes: uk Date: october 05, 2015

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3 contents 1.0 ce conformities Preface Introduction Warnings symbols Instructions for safe use Typical chilled water sealed system Typical lthw sealed system max. 100 c Typical mthw sealed system max. 120 c Storage Limitations Protection General notes Installation Mechanical Electrical Safety regulations Commissioning Operation Heating system Chiller systems Controller functions User interface Statistics Parameters Warnings and alarms Maintenance checks Fault finding chart 13

4 installation & 3750 Pulpress 4 please read all these notes carefully, 1.0 ce conformities lvd bs en Low voltage switchgear bs en Safety of machinery bs en iso &2 Safety of machinery bs en Electromagnetic compatibility Harmonic emissions bs en Electrostatic discharge bs en Radiated rf immunity bs en Fast transient bursts bs en Voltage surges bs en Conducted rf immunity bs en Voltage dips bs en Generic immunity bs en Generic immunity bs en Generic emissions bs en Generic emissions bs en Safety of stationary circulation bs en pumps for heating and service water installations 2.0 preface 1 The 3750 Pulpress has been designed for ease of setting and operation 2 All packaged pump systems are pre-wired and fully tested, both hydraulically and electrically, prior to dispatch. 3 All parameter data has been entered into the controller in accordance with the system criteria. Once on-site connections have been made, and all pre-checks carried out, the system is ready for commissioning. 4 During commissioning if system conditions are found to vary from those set out in the design criteria, the parameters can be easily changed 4.0 warnings symbols Safety instruction where an electrical hazard is involved. Safety instruction where non-compliance would affect safety. Safety instruction relating to safe operation of the equipment. (attention) 5.0 instructions for safe use 1 This equipment has been designed for the pressurisation of sealed heating, chilled water and closed condenser water systems to the operating conditions shown. 2 No installation of this equipment should take place until this installation, operation and maintenance instructions has been studied and understoodby the person responsible. 3 Handling, transportation and installation of this equipment shall be undertaken with the proper use of lifting gear. 4 The set shall not be used for any purpose other than that for which it was designed and sized. 5 The set shall not be operated with the cover removed and the cover interlocked isolator overridden. During normal operation the pumps will generate pressures sufficient to satisfy system demand. However, abnormal running conditions may cause closed valve pressures to be experienced. 3.0 introduction 1 This installation and operation manual contains specific information regarding safe installation and operation of the 3750 Pulpress. These instructions must be read and understood by anyone responsible for the installation and maintenance of this equipment. 2 Prior to power being applied, it is essential that all pre-commissioning procedures are carried out in full. 3 Operators and installers must familiarise themselves with the operation and controls of the equipment.

5 3750 Pulpress installation & typical chilled water sealed system flow cooling load Air eliminator see leaflet on air eliminators return electrical supply alternative position pump auto-air vent with on-off clock expansion vessels signals to bms to cooling tower chillier condenser antigravity loop 3750 pulpress evaporator chillier pump mains supply test point isolating valve non-return valve electrical safety interlock drain cock lock shield valve system fill connection Equipment within this area supplied by others 7.0 typical lthw sealed system max. 100 c electrical supply flow pump over temperature energy cutout thermostat boiler boiler controls heating load temperature gauge isolating valve pressure gauge safety valve pump alternative position return auto-air vent with on-off clock antigravity loop electrical safety interlock non-return valve expansion vessels drain cock signals to bms mains supply test point lock shield valve system fill connection 3750 pulpress Equipment within this area supplied by others

6 installation & 3750 Pulpress typical mthw sealed system max. 120 c The arrangement of the mthw scheme is similar to the lthw system above but has, in addition, an intermediate vessel installed between the expansion vessels and the system connection. The volume of water contained in this vessel ensures that the return temperatures at the boiler are not transferred to the expansion vessel, where damage to the diaphragm would otherwise occur. warning notes: 1 Packed-gland circulating pumps must not be used in sealed systems. 2 Water treatment must not be added to the system via the 3750 Pulpress break tank. 3 No part of the set, expansion vessel, intermediate vessel or connecting pipe is to be lagged. 4 Precautions should be taken to ensure that Lock Shield Valves are protected against unauthorised closure. 9.0 storage Store in a dry place. Protect against dirt, damage and frost limitations 1 Maximum system working pressure: 10 bar. 2 Maximum flow temperature 120 c. 3 Electrical supplies: 1 phase, 50 or 60 Hz, 220 or 240 volts. 4 Power supply fluctuation: +/- 10% maximum. 5 Humidity non-condensing: 80% rh up to 31 c decreasing linearly to 50% rh at 40 c. 6 Ambient temperature: -5 c to 40 c. 7 Water supply pressure 0.8 bar minimum to 6.8 bar maximum with ballcock fully open. 8 System fill pressure: 8.1 Low pressure pump(s) 0.5 to 2.5 bar. 8.2 Medium pressure pump(s) 1.5 to 5.5 bar. 9 Maximum water temperature for expansion vessels: 9.1 Continuous 70 c above this intermediate vessels must be used. 9.2 Intermittent 100 c. 10 Maximum total boiler rating refer to graph pu protection The set must be protected from the formation of condensation. If there is a likelihood of condensation forming on or in the control panel then an anti-condensation heater should be fitted. Contact our service department for details general notes 1 The sets comprise one or two pumps operating on a duty/ stand-by arrangement. 2 Each set is sized to bs7074 and custom built for a specific application, any change in the system conditions shown may necessitate a change in the design or settings. 3 System must be completely flushed out, to remove any metal particles, dirt etc, which may damage the set. 4 The system should be pressure tested, to eliminate leaks. 5 Under no circumstances must any attempt be made to introduce water treatment to the system via the break-tank. 6 No part of the set, connecting pipe or expansion vessel(s) are to be lagged. 7 Fill the system via the quick-fill connection. Do not use the set to fill the system installation 13.1 mechanical 1 Install the set on a flat and even surface. 2 Site set with sufficient space to the front, left and right sides of the unit for maintenance purposes. 3 Connect the cold water mains supply, via a stopcock, to the ballcock in the break tank. (Water supply pressure 0.8 bar minimum with ballcock fully open). 4 Arrange break tank overflow pipe to discharge into a convenient drain in line with clause 30 of the Water supply Bye-laws 1989 edition. 5 Make a connection from the set to the return side of the boiler and suction side of the circulating pump(s). If intermediate vessels are provided these should be fitted in this connection with the set and expansion vessels connected to the bottom of the vessel and the system to the top of the vessel. A manual air vent should be fitted in the pipe work close to the top of the vessel, see general arrangement drawing provided. Ensure pump(s) are vented by loosening the vent cap on top of the delivery branch of the pump. Care must be taken not to over tighten the system or water inlet connections. 6 Never dry run the pump. 7 For wall mounting, wall structure will need to be determined to select appropriate fasteners. Ensure there are no pipes or electrical cables running behind where the wall bracket is to be secured electrical 1 The power supply required is 240 volt +/-10%, 1 phase, 50 Hz or 60 Hz to suit motors fitted. 2 The incoming supply should be connected to the door interlocked isolator from a local 10 amp switched fused spur and if possible an elcb unit.

7 3750 Pulpress installation & 7 3 All incoming cable glands should be ip54 rated as a minimum. 4 Wire the set control systems (see enclosed wiring diagram) from the volt free terminals to the boiler control system. 5 Boiler/chiller interlock provided via normally open volt free contact. 6 The set must be efficiently earthed. 2 Turn on the water supply feeding the 3750 Pulpress unit and fill the breaktank. 3 Check pumps are primed by loosening cap on the delivery side of the pump let water escape until no air is present, replace caps and pressurize to the ambient temperature set pressure. Never dry run the pumps. 4 With cover interlock isolating switch in the off position switch on the power supply to the unit. attention It is the user s or certified electrician s responsibility to ensure correct earthing and protection in accordance with applicable national and local requirements and standards. important safety information 1 The voltage on the 3750 Pulpress unit is dangerous when it is connected to the mains. Incorrect installation of the set may lead to material damage or serious injury or death. Consequently, you must comply with the instructions in this manual as well as the local rules and safety regulations. 2 Touching the electrical parts may be fatal, even after the mains supply has been disconnected, wait at least 4 minutes. 3 The installation must be fused and isolated correctly. 4 Covers and cable entries must be fitted safety regulations 1 The 3750 Pulpress unit must be disconnected from the mains if repair work is to be carried out. Check the mains supply has been disconnected and the necessary time has passed (4 minutes). 2 The correct protective earthing of the equipment must be established, the user must be protected against supply voltage, and the set must be protected against overload in accordance with applicable national and local regulations. 3 RCDs (elcb relays), multiple protective earthing or earthing can be used as extra protection, provided that local safety regulations are complied with commissioning 1 Fill the system with water via the quick fill connector. It is essential that all air in the system is allowed to escape freely through automatic air vents and radiator bleeds, failure to remove air could result in a system malfunction operation Turn the main isolating switch to the On position. The system pressure will be displayed on the digital readout. The unit will automatically maintain pressure in the system as set out in the design criteria and will operate when the pressure falls between the system fill pressure and the pump cut-in pressure heating system Start the boiler(s). The water from the system will flow into the vessel(s) and the system pressure will rise slowly and settle at a pressure below the maximum pressure shown on the nameplate. If the boiler safety valve lifts, check the valve setting and the system details, against the ordering specification for the 3750 Pressurisation unit chiller systems When the chiller(s) are started the water contracts as it cools and the 3750 will pass water from the tank via the pump, to bring the pressure up to the ambient temperature setting pressure. When the chiller is switched off the expanding water will pass into the expansion vessel, the pressure will rise and settle at a pressure below the maximum pressure shown on the nameplate. note On chiller sets, the highest system pressure will occur when the system is at ambient temperature after operation, whereas on heating sets the highest pressure occurs at maximum system operating temperature. If the system pressure falls due to a slow leak, water in the expansion vessel(s) will run back into the systems. If the system leakage continues causing a drop in pressure below the initial system pressure the pump(s) will start to restore the initial system pressure. In the event of a leak exceeding the pump(s) capacity then, providing the set's volt free contacts have been wired accordingly, the boiler burners will be shut down and the circulating pumps are stopped. The system should then be closed down and the leak rectified.

8 installation & 3750 Pulpress controller functions pressure par 5 - high pressure alarm = mwp(pf1) par 1 - pump cut out = fill pressure (pi) par 1 - pump cut in = (pi) - 0.2bar differential par 4 - low pressure alarm = static height (ph) pump 1 pump 2 pump 1 time par 3 - [pressure dip delay] = 5 sec par 11 - [hrs to pulse cycle] = 720 hrs par 12 - [pulse cycle time] = 1 second Pressure dip delay No message required, no alert. Should not start the pump until value parameter [pressure dip delay] seconds have passed without the pressure coming back to the set point. Digital display Showing system pressure, warning codes, alarm codes and pump run indication. Pump test When the controller is in the normal mode (not programming). When the up p button is pressed and held for 3 seconds Pump 1 will run and continue to run until the button is released. When the down q button is pressed and held for 3 seconds Pump 2 will run and continue to run until the button is released. This will enable the pumps to be tested manually. Hours run meter(s) This cannot be reset, showing the number of hours the pump has been running. (Max. 999 hours). Pump auto cycle On two pump sets pumps will auto-cycle increasing service interval time. Alarm Audible alarms on error condition with mute.

9 3750 Pulpress installation & user interface normal view pressure or alarm Press up or down for 3s = Pump test Press down + Press up and down for 5s = Parameter lock/unlock Press set for 5s = go to view par Press set and Press for 5s = Autotest for 5s = go to view stat for 5s = Reset alarm view par display parameter no. Time out 20s = go to normal Press up or down to select parameter Press set = go to change par change par display parameter values Time out 20s = go to normal Press up or down to change parameter value Press set = go to view par Press set for 5s = save and go to view par view stat display statistics autotest device check Time out 20s = go to normal Press up or down to select statistics Press set = go to detail stat detail stat display statistic values Time out 20s = go to normal Press up or down to scroll logging alarm statistics. Press set = go to view stat Enhanced Only 21.0 statistics number name type from s01 to s30 Alarm logging [30] num s31 Pump 1 run time hrs num s32 Pump 2 run time hrs num s01 Most recent alarm s30 Oldest alarm Lines "---" = no alarm registered

10 installation & 3750 Pulpress parameters 0 = no 1 = nc par no. parameter type default min max inc unit of measure 1 Fill pressure (Pi) dec Bar/25 All 2 Pump cut in (Pi-0.2bar) dec Bar/25 All 3 Pressure dip delay num Seconds All 4 Low pressure alarm (Ph) dec Bar/25 All 5 High pressure alarm (Pf1) dec Bar/25 All 6 Max pump run time num Minutes All 7 nc no alarm relay num 1* Numeric All device mode 8 Excessive no. of starts num Numeric Enhanced 9 Excessive starts minutes num Minutes Enhanced 10 Service months num Numeric Enhanced 11 hrs after which the pump pulse cycle starts adjustable in p12 num Hours Enhanced 12 Pulse cycle time num Seconds Enhanced 13 nc no lpr relay num 1* Numeric Enhanced 14 nc no hpr relay num 1* Numeric Enhanced 15 nc no pf1 relay num 0* Numeric Enhanced 16 nc no pf2 relay num 0* Numeric Enhanced 17 nc no run pump 1 relay num 0* Numeric Enhanced 18 nc no run pump 2 relay num 0* Numeric Enhanced 19 nc no lll relay num 0* Numeric Enhanced 20 nc no hll relay num 0* Numeric Enhanced 21 nc no est relay num 0* Numeric Enhanced 22 nc no comm/power relay num 0* Numeric Enhanced 23 n/a num Days n/a 24 n/a num Minutes n/a 25 n/a num 0* Numeric n/a 26 Lux digital num Numeric All 27 Number of pumps num Numeric All 28 Device_on_off num Numeric All 29 Address num Numeric All 30 ext_relay num Numeric All 99 Firmware release num xx.xx Decimal All (enhanced ) Parameter 28 indicates the start-up or stand-by status of the controller (1 = on, 0 = Stand by) Parameter 29 indicates the address of the controller when it is connected in the MODbus mode, (1 to 247). Parameter 30 indicates the communication mode: 0 = external relay board present, therefore rs485 mode enabled. 1 = MODbus mode enabled. When the external relay board is connected to the MODbus enabled controller please refer to drawing number px10899 for controller setting instructions.

11 3750 Pulpress installation & warnings and alarms break tank low/high water level The low water level alarm will be activated should the break tank level low switch trip. The controller will display: low water level All pump(s) will stop running All pump running contacts de-activate Activates lll alarm on display Activates Low Level alarm contact. (Enhanced +vfc version ) high water level (enhanced ) All pump(s) will stop running All pump running contacts de-activate Activates hll alarm on display Activates High Level alarm contact. (Enhanced +vfc version ) In a high and low level alarm condition the set will trip and stop all pumps until the water level returns to normal. The unit will then auto reset and operate as normal. low system pressure The low water pressure alarm will be activated should the pressure at the transducer drop below the value set in parameter 4. Activates lpr alarm on display Activates Common Alarm contact Activates Low Pressure alarm contact (Enhanced +vfc version ) This is an alarm. The set will stop all pumps until the system pressure returns to normal, if low pressure is due to a system leak it will need to be rectified and system fill pressure restored. The unit will then auto reset and operate as normal. high system pressure The high system pressure alarm will be activated should the pressure at the transducer rise above the value set in parameter 5. All pump(s) will stop running Activates hpr alarm on display Activates Common Alarm contact Activates High Pressure alarm contact This is an alarm. The set will stop all pumps until the system pressure returns to normal. The unit will then auto reset and operate as normal. transducer failure The transducer failure alarm will be activated should the transducer lose its signal. All pump(s) will stop running Activates sf alarm on display This is an alarm. The fault must be rectified before the unit can operate as normal. pump tripped Any pumps that are tripped during operation, either in hand or auto, will activate the following: Pump(s) will stop running. Activates pf1 alarm on display (pump 1) Activates pf2 alarm on display (pump 2) Activates pfa alarm on display (pump 1 & 2) Activates pump 1 or 2 contact. (Enhanced +vfc version ) This is an alarm. Standby pump will take over and the set will operate normally in the event of both pumps being tripped the fault will need to be rectified and alarm manually reset before the unit can operate normally. pump running Any pumps that are running during operation, either in hand or auto, will activate the following: Indicates p1 or p2 running on display Activates relevant Pump Running contact (Enhanced +vfc version )

12 installation & 3750 Pulpress 12 max pump run time The maximum pump run time alarm will be activated if the pump runs for an excessive amount of time. Pump(s) will stop running Activates prt alarm on display This is an alarm. Excessive pump run time may indicate a system fault, rectify and reset manually. excessive pump starts (enhanced ) The excessive pump start alarm will be activated if the pump starts for an excessive number of times over a certain period of time. Pump(s) will stop running Activates est alarm on display This is an alarm. Excessive pump starts may indicate a system fault, rectify and reset manually. service reminder (enhanced ) The service reminder warning is displayed ten months after being activated. Activates ser on display Call Armstrong service to arrange service visit. alarms alarm description p High pressure Low pressure Max. pump time Power - pump 1 Power - pump 2 Power pump all Low water High pressure alarm when the system pressure is above the required set point Low pressure alarm when the system pressure is below the pressure limit basic / enhanced pump relay buzzer display blinking stop 6 basic g yes hpr yes yes 5 basic g yes lpr yes yes Max. pump run time alarm 3 basic d yes prt yes yes Tripped pump alarm Low water alarm not enough water in the break tank 9 basic d yes pf1 yes no 10 basic d yes pf2 yes no 2 basic d yes pfa yes yes 7 basic d yes lll yes yes High water High water alarm 8 enhanced d yes hll yes no Pressure sensor failure Service reminder Excessive starts Sensor failure if the sensor exceeds the check values Service reminder when activated, p10 months will be counted. Armstrong Service intervention is required when Reminder message is displayed. Excessive starts no more than p08 starts in p09 hours are permitted 1 enhanced d yes sf yes yes 11 enhanced no no ser yes no 4 enhanced d yes est yes yes reset auto auto man man man man auto auto man by pass man delay time 500ms 500ms ms 500ms 500ms 500ms 500ms 1000ms p = priority order of displayed messages 1: High Priority, no.: Lower Priority relay = g: General (on board), d: Dedicated on expansion board

13 3750 Pulpress installation & maintenance checks Regular checks (Every 3 months) Check the pump(s) are developing the correct pressure and are not noisy or vibrating or air-locked. Check that the mechanical seal is not leaking. Check that the motor is not over heating. Checks at six monthly intervals Check electrical installation thoroughly for defects. Ensure that the earth connections are making good contact. Check that the break tank is clean. Check the operation of the high and low pressure set points. Check low level float switch, (high if fitted). Maintenance For maintenance please contact our service division on +44 (0) fault finding chart section problem 1 Pump(s) run continuously 2 Pump(s) will not run 3 High pressure 4 Low pressure 5 Low water level 1 Pump(s) run continuously 3 High pressure symptom/cause Incorrect capacity of vessel or larger system than originally specified Failure to maintain air charge 4 Low pressure symptom/cause Pump(s) tripped Pump(s) burntout seized System leakage rate very high No water in tank or spasmodic water supply Delivery/suction isolating valve closed Suction strainer(s) obstructed action action Check system and vessel capacity by re-calculating sizes. Isolate and drain the vessel. Adjust the air charge to match the fill pressure of the system. Check miniature circuit breakers and reset if necessary. Repair or replace pumps Check system for leaks. Check for split vessel bag via the air valve. Check nonreturn valve is not bypassing through second pump. Ensure that incoming water supply is functioning i.e. check isolating valve is open, ballcock operates and water is clean. Open valves. Repair or replace strainers. symptom/cause action 5 Low water level Very high leakage rate Faulty electrical circuit System pressure setting set too high Check system for leaks. Check for split in vessel bag via the air valve. Check non-return valve is not bypassing through second pump. Check that all wiring is in place and not loose at any connections. Compare system setting pressure (System data on display nameplate). with Fill pressure (Pi) on data plate. To reset consult Armstrong Service Dept. i) Break tank symptom/cause No water in break tank or spasmodic water supply Incoming water pressure is not sufficient action Ensure that incoming water supply is functioning (i.e. check isolating valve is open, ballcock operates and water is clean). Increase the water pressure, consult Armstrong Service Dept. 2 Pump(s) will not run ii) Alarm symptom/cause Pump(s) tripped Faulty electrical circuit action Check miniature circuit breakers and reset if necessary. Check that all wiring is in place and not loose at any connections. symptom/cause Faulty electrical circuit Broken or damaged float switch action Check that all wiring is in place and not loose at any connections. Replacement float switch required. Pump(s) burnt-out seized Repair or replace pumps.

14 toronto 23 bertrand avenue toronto, ontario canada m1l 2p buffalo 93 east avenue north tonawanda, new york u.s.a birmingham heywood wharf, mucklow hill halesowen, west midlands united kingdom b62 8dj +44 (0) manchester wolverton street manchester united kingdom m11 2et +44 (0) bangalore #59, first floor, 3rd main margosa road, malleswaram bangalore, india (0) shanghai no hu hang road, xi du township feng xian district, shanghai p.r.c são paulo rua josé semião rodrigues agostinho, 1370 galpão 6 embu das artes sao paulo, brazil armstrong fluid technology established 1934 armstrongfluidtechnology.com tm