Armstrong 3750 Installation And Operating Instructions Manual

Page 1
3750 Pulpress pressurisation unit
Installation and operating instructions
File No: 37.858uk Date: september 02, 2016 Supersedes: 37.858uk Date: october 05 , 2015
Page 2
Page 3
contents
1.0 ce conformities 4
2.0 Preface 4
3.0 Introduction 4
4.0 Warnings symbols 4
5.0 Instructions for safe use 4
6.0 Typical chilled–water sealed system 5
7.0 Typical lthw sealed system – max. 100°c 5
8.0 Typical mthw sealed system – max. 120°c 6
9.0 Storage 6
10.0 Limitations 6
11.0 Protection 6
12.0 General notes 6
13.0 Installation 6
13.1 Mechanical 6
13.2 Electrical 6
14.0 Safety regulations 7
15.0 Commissioning 7
16.0 Operation 7
17.0 Heating system 7
18.0 Chiller systems 7
19.0 Controller functions 8
20.0 User interface 9
21.0 Statistics 9
22.0 Parameters 10
23.0 Warnings and alarms 11
24.0 Maintenance checks 13
25.0 Fault finding chart 13
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3750 Pulpress pressurisation unit
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please read all these notes carefully,
1.0 ce conformities
lvd bs en 61010-1 Low voltage switchgear bs en 60439-1 Safety of machinery bs en iso 12100-1&2 Safety of machinery bs en 60204-1 Electromagnetic compatibility Harmonic emissions bs en 61000-3-2 Electrostatic discharge bs en 61000-4-2 Radiated rf immunity bs en 61000-4-3 Fast transient bursts bs en 61000-4-4 Voltage surges bs en 61000-4-5 Conducted rf immunity bs en 61000-4-6 Voltage dips bs en 61000-4-11 Generic immunity bs en 61000-6-1 Generic immunity bs en 61000-6-2 Generic emissions bs en 61000-6-3 Generic emissions bs en 61000-6-4 Safety of stationary circulation bs en 60335-2-51
pumps for heating and service water installations
2.0 preface
1
The 3750 Pulpress pressurisation unit 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
3.0 introduction
1
This installation and operation manual contains specific information regarding safe installation and operation of the 3750 Pulpress pressurisation unit. 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.
4.0 warnings symbols
Safety instruction where an electrical hazard is involved.
Safety instruction where non-compliance would aect 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 only 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.
note:
During normal operation the pumps will only generate pressures sucient to satisfy system de­mand. However, abnormal running conditions may cause closed valve pressures to be experienced.
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installation &
operating instructions
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6.0 typical chilled–water sealed system
7.0 typical lthw sealed system – max. 100°c
lock shield valve
evaporator
pump
return
expansion vessels
flow
condenser
chillier
pump
electrical safety interlock
isolating valve
non-return valve
chillier
alternative position
to cooling tower
cooling load
electrical supply
Air eliminator see leaflet on air eliminators
signals to bms
3750 pulpress
mains supply
test point
system fill connection
drain cock
Equipment within this area supplied by others
auto-air vent with on-o clock
anti­gravity loop
safety valve
lock shield valve
drain cock
pump
pump
return
expansion vessels
auto-air vent with on-o clock
anti­gravity loop
flow
heating load
boiler
boiler controls
thermos
tat
electrical safety interlock
isolating valve
non-return valve
Equipment within this area supplied by others
alternative position
over temperature energy cutout
electrical supply
temperature gauge
pressure gauge
signals to bms
3750 pulpress
mains supply
test point
system fill connection
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installation & operating instructions
3750 Pulpress pressurisation unit
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8.0 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.
10.0 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 pu3750.
11.0 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.
12.0 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.
13.0 installation
13.1 mechanical
1
Install the set on a flat and even surface. 2
Site set with sucient 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.
13.2 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.
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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 eciently earthed.
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.
14.0 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.
15.0 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.
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 o position switch on the power supply to the unit.
16.0 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 only operate when the pressure falls between the system fill pressure and the pump cut-in pressure.
17.0 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.
18.0 chiller systems
When the chiller(s) are started the water contracts as it cools and the 3750 pressurisation unit 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 o 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.
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installation & operating instructions
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19.0 controller functions
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.
pressure
pump 1 pump 2 pump 1
time
par 12 - [pulse cycle time] = 1 second
par 11 - [hrs to pulse cycle] = 720 hrs
par 3 - [pressure dip delay] = 5 sec
par 5 - high pressure alarm = mwp(pf1)
par 1 - pump cut out = fill pressure (pi)
par 1 - pump cut in = (pi) - 0.2bar dierential
par 4 - low pressure alarm = static height (ph)
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installation &
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20.0 user interface
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
autotest
device check
normal
view pressure or alarm
Press up or down for 3s = Pump test
Press up and down for 5s = Parameter lock/unlock Press set for 5s = go to view par
Press down + for 5s = Autotest
Press set and for 5s = go to view stat Press for 5s = Reset alarm
view stat
display statistics
Time out 20s = go to normal Press up or down to select statistics Press set = go to detail stat
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
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
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installation & operating instructions
3750 Pulpress pressurisation unit
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22.0 parameters
0 = no 1 = nc
par no.
parameter type default min max inc
unit of measure
device mode
1 Fill pressure (Pi) dec 2.5 1 24.9 1 Bar/25 All
2 Pump cut in (Pi-0.2bar) dec 0.2 0 5.0 1 Bar/25 All
3 Pressure – dip delay num 5 0 100 1 Seconds All
4 Low pressure alarm (Ph) dec 2.2 0 24.9 1 Bar/25 All
5 High pressure alarm (Pf1) dec 4.0 1 24.9 1 Bar/25 All
6 Max pump run time num 15 1 990 1 Minutes All
7 nc no alarm relay num 1* 0 1 1 Numeric All
8 Excessive no. of starts num 15 1 99 1 Numeric Enhanced
9 Excessive starts – minutes num 60 1 720 1 Minutes Enhanced
10 Service – months num 12 1 99 1 Numeric Enhanced
11
hrs after which the pump pulse cycle starts – adjustable in p12
num 720 1 8640 1 Hours Enhanced
12 Pulse cycle time num 1 1 99 1 Seconds Enhanced
13 nc no lpr relay num 1* 0 1 1 Numeric Enhanced
14 nc no hpr relay num 1* 0 1 1 Numeric Enhanced
15 nc no pf1 relay num 0* 0 1 1 Numeric Enhanced
16 nc no pf2 relay num 0* 0 1 1 Numeric Enhanced
17 nc no run pump 1 relay num 0* 0 1 1 Numeric Enhanced
18 nc no run pump 2 relay num 0* 0 1 1 Numeric Enhanced
19 nc no lll relay num 0* 0 1 1 Numeric Enhanced
20 nc no hll relay num 0* 0 1 1 Numeric Enhanced
21 nc no est relay num 0* 0 1 1 Numeric Enhanced
22 nc no comm/power relay num 0* 0 1 1 Numeric Enhanced
23 n/a num 2 1 30 1 Days n/a
24 n/a num 2 1 60 1 Minutes n/a
25 n/a num 0* 0 1 1 Numeric n/a
26 Lux – digital num 6 0 7 1 Numeric All
27 Number of pumps num 2 1 2 1 Numeric All
28 Device_on_o num 1 0 1 1 Numeric All
29 Address num 1 1 247 1 Numeric All
30 ext_relay num 0 0 1 1 Numeric All
99 Firmware release num xx.xx -- -- -- Decimal All
note: (enhanced only)
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.
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installation &
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23.0 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
Functions:
• 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 only)
high water level (enhanced only)
Functions:
• 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 only)
note:
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.
Functions:
• Activates ‘lpr’ alarm on display
• Activates ‘Common Alarm’ contact
• Activates ‘Low Pressure’ alarm contact (Enhanced +vfc
version only)
note:
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.
Functions:
• All pump(s) will stop running
• Activates ‘hpr’ alarm on display
• Activates ‘Common Alarm’ contact
• Activates ‘High Pressure’ alarm contact
note:
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.
Functions:
• All pump(s) will stop running
• Activates ‘sf’ alarm on display
note:
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:
Functions:
• 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 only)
note:
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:
Functions:
• Indicates ‘p1 or p2’ running on display
• Activates relevant ‘Pump Running’ contact (Enhanced +vfc
version only)
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12
max pump run time
The maximum pump run time alarm will be activated if the pump runs for an excessive amount of time.
Functions:
• Pump(s) will stop running
• Activates ‘prt’ alarm on display
note:
This is an alarm. Excessive pump run time may indicate a system fault, rectify and reset manually.
excessive pump starts (enhanced only)
The excessive pump start alarm will be activated if the pump starts for an excessive number of times over a certain period of time.
Functions:
• Pump(s) will stop running
• Activates ‘est’ alarm on display
note:
This is an alarm. Excessive pump starts may indicate a system fault, rectify and reset manually.
service reminder (enhanced only)
The service reminder warning is displayed ten months after being activated.
Functions:
• Activates ‘ser’ on display
note:
Call Armstrong service to arrange service visit.
alarms
alarm description p
basic / enhanced
relay buzzer display blinking
pump stop
reset
delay time
High pressure
High pressure alarm – when the system pressure is above the required set point
6 basic g yes hpr yes yes
only auto
500ms
Low pressure
Low pressure alarm – when the system pressure is below the pressure limit
5 basic g yes lpr yes yes
only auto
500ms
Max. pump time
Max. pump run time alarm 3 basic d yes prt yes yes
only man
---
Power ­pump 1
Tripped pump alarm
9 basic d yes pf1 yes no
only man
500ms
Power ­pump 2
10 basic d yes pf2 yes no
only man
500ms
Power – pump all
2 basic d yes pfa yes yes
only man
500ms
Low water
Low water alarm – not enough water in the break tank
7 basic d yes lll yes yes
only auto
500ms
High water High water alarm 8 enhanced d yes hll yes no
only auto
500ms
Pressure sensor failure
Sensor failure – if the sensor exceeds the check values
1 enhanced d yes sf yes yes
only man
1000ms
Service reminder
Service reminder – when activat­ed, p10 months will be counted. Armstrong Service intervention is required when Reminder mes­sage is displayed.
11 enhanced no no ser yes no
by pass
---
Excessive starts
Excessive starts – no more than p08 starts in p09 hours are permitted
4 enhanced d yes est yes yes
only man
---
p = priority – order of displayed messages 1: High Priority, no.: Lower Priority relay = g: General (on board), d: Dedicated on expansion board
Page 13
installation &
operating instructions
3750 Pulpress
pressurisation unit
13
24.0 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) 845 762 6083.
25.0 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
symptom/cause action
Very high leakage rate
Check system for leaks. Check for split in vessel bag via the air valve. Check non-return valve is not bypassing through second pump.
Faulty electrical circuit
Check that all wiring is in place and not loose at any connections.
System pressure setting set too high
Compare system setting pressure (System data on display nameplate). with Fill pressure (Pi) on data plate. To reset consult Armstrong Service Dept.
2 Pump(s) will not run
symptom/cause action
Pump(s) tripped Check miniature circuit breakers and
reset if necessary.
Faulty electrical circuit
Check that all wiring is in place and not loose at any connections.
Pump(s) burnt-out seized
Repair or replace pumps.
3 High pressure
symptom/cause action
Incorrect capacity of ves­sel or larger system than originally specified
Check system and vessel ca­pacity by re-calculating sizes.
Failure to maintain air charge
Isolate and drain the vessel. Adjust the air charge to match the fill pressure of the system.
4 Low pressure
symptom/cause action
Pump(s) tripped Check miniature circuit breakers and
reset if necessary.
Pump(s) burnt­out seized
Repair or replace pumps
System leakage rate very high
Check system for leaks. Check for split vessel bag via the air valve. Check non­return valve is not bypassing through second pump.
No water in tank or spasmodic water supply
Ensure that incoming water supply is functioning i.e. check isolating valve is open, ballcock operates and water is clean.
Delivery/suction isolating valve closed
Open valves.
Suction strainer(s) obstructed
Repair or replace strainers.
5 Low water level
i) Break tank
symptom/cause action
No water in break tank or spasmodic water supply
Ensure that incoming water supply is functioning (i.e. check isolating valve is open, ballcock operates and water is clean).
Incoming water pres­sure is not sucient
Increase the water pressure, consult Armstrong Service Dept.
ii) Alarm
symptom/cause action
Faulty electrical circuit
Check that all wiring is in place and not loose at any connections.
Broken or damaged float switch
Replacement float switch required.
Page 14
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