Dutypoint Scubatank WX User Manual

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ScubaTANK WX

Operation and Maintenance Manual

Document Reference: DOC-WXOM1801

Table of Contents

Operation and Maintenance Manual

ScubaTANK WX1 and WX2

1. Important Safety Information................................................................................................................................. 3

2. Specifications ................................................................................................................................................................9

3. Installation Sequence.............................................................................................................................................. 11

4. Booster Set Commissioning ................................................................................................................................. 17

5. Operating the Pump Set......................................................................................................................................... 21

6. Pressure Vessel.......................................................................................................................................................... 23

7. Booster Set User Maintenance ............................................................................................................................ 25

8. XPW Pump Maintenance....................................................................................................................................... 27

9. Pressure Set Point Adjustment............................................................................................................................ 29

10. Troubleshooting ..................................................................................................................................................... 31

11. VASCO V209 and V214 Pump Controllers ................................................................................................... 37

Dutypoint Limited

Shepherd Road

Gloucester

GL2 5EL

United Kingdom

1. Important Safety Information

1.1 Health & Safety at Work Act 1974

Section 6(a) of this Act requires manufacturers to advise their customers on the safety and the handling precautions to be observed when installing, operating, maintaining and servicing their products. The user’s attention is therefore drawn to the following:

– The appropriate sections of this manual must be read before working on the equipment. – Installation, operating and maintenance must only be carried out by suitably trained/qualified

personnel.

– Normal safety precautions must be taken and appropriate procedures observed to avoid accidents.

Refer to Dutypoint for any technical advice or product information. It is the responsibility of the customer and/or the contractor:

– To ensure that anyone working on the equipment is wearing all necessary protective gear/clothing; – Is aware of appropriate health & safety warnings and to read the information in this manual.

1.2 Safety Messages and Hazard Statement

Table 1.1: Hazard Notice Definitions

Message Level Definition

DANGER A hazardous situation which, if not avoided, will result in death or serious

injury

WARNING A hazardous situation which, if not avoided, could result in death or serious

injury

CAUTION A hazardous situation which, if not avoided, could result in minor injury or

moderate injury ELECTRICAL HAZARD Risks associated with electricity will cause hazards if not properly avoided Note A situation which may arise resulting in undesirable conditions and/or will not

cause direct hazards to persons

1. Important Safety Information

1.3 Qualified Personnel

WARNING

This product is indented for operation by qualified personnel only

– Only qualified personnel are allowed to install or operate this equipment

– Qualified personnel are defined as trained staff, who are authorised to install, commission and maintain

equipment, systems and circuits in accordance with relevant laws and regulations. Personnel must be familiar with the instructions and safety procedures described in this document.

– This product should not be used by anyone with mental disabilities, or anyone without the relevant experience

and knowledge, unless they have received instructions on using the equipment and on the associated risks, or are supervised by a responsible person.

– Children must be supervised to ensure they do not play on or around the equipment.

1.4 Environmental Protection

All local regulations and codes regarding emissions and waste disposal must be followed. This may include: – Reporting of emissions to appropriate authorities – Sorting, recycling and disposal of solid or liquid waste

1. Important Safety Information

– Clean-up of spills – Separate disposal of electrical components from domestic waste

1.5 Mechanical Device Servicing

– Familiarise yourself with the relevant contents of this manual – Installation, maintenance and repair work must only be carried out by trained, skilled and suitably

qualified personnel.

– Disconnect or lock-out the power source to ensure that the item(s) will remain inoperative. Locking

out the equipment by switching off the release mechanism or set value WILL NOT prevent accidental

starting. – Allow the item(s) to cool if over-heated. – CLOSE the isolating valves on the suction and discharge connections of the affected item(s). – If working on pump, VENT slowly and cautiously – Refer to the relevant section of this manual. – DRAIN the pump(s).

1.6 Pump Hand Control Mode (Where Fitted)

In the 'HAND' position the pump(s) controlled by the switch will normally run at full speed and completely independently of any control devices, and can result in pump(s) running against a closed valve head if there is no draw. This can cause the system to be maintained at the maximum pressure produced by the pump plus any incoming pressure and additional pressure caused by water surge and can potentially damage the pump and other parts of the system.

The 'HAND' option should only be used with a competent operator in attendance, or when there is a continued demand sufficient to provide constant flow through the pumps to maintain the running pressure of the system to an acceptable level.

1.7 Personal Protective Equipment

Use personal safety equipment according to the site conditions and employer regulations. This may include, but may not be limited to:

– Hard hat – Safety goggles with side shields – Protective footwear – Protective gloves – Respirator – Ear protection – First aid kid – Safety devices

1.8 Precautions Before Commencing Work

Ensure that the following safety precautions are complied with before commencing work: – Provide a suitable barrier around the work area – Ensure all safety guards and in place and secure – Ensure you have a clear path of exit – Ensure that the product cannot roll or fall over and cause damage to persons or property – Ensure all lifting equipment is in good condition and rated for the intended task – Use a lifting harness, safety line and respirator as required – Allow hot components to cool before handling them – Ensure that product has been thoroughly cleaned – Disconnect and lock out power supply, ensuring that it cannot be accidentally re-connected – Check for any risk of explosion before using hand tools

1.9 Precautions During Work

– Never work alone – Always wear protective clothing and hand protection – Stay clear of suspended loads – Always use appropriate lifting devices – Beware of risks of sudden starts of any automated equipment such as level control – Beware of starting jerks of electric motors - these can be powerful – Do not exceed the stated operating limits of equipment – Do not remove vent plugs from a pressurised system - ensure pressurised components are relieved

of pressure before disassembly

– Ensure guards are in place during operation

1.10 Hazardous Fluids and Chemicals

If hazardous chemicals come into contact with skin or eyes, use the following procedures:

Condition Action

Chemicals or hazardous fluids in eyes

Chemicals or hazardous fluids on skin

1) Hold your eyelids apart forcibly with your fingers

2) Rinse the eyes with eyewash or running water for at least 15 minutes

3) Seek medical attention

1) Remove contaminated clothing

2) Wash the skin with soap and water for at least 1 minute

3) Seek medical attention

1. Important Safety Information

1.11 Electrical Safety - High Voltages

This information is especially applicable when Variable Speed Controllers (Inverters) are fitted to pumps.

When the inverter variable speed drive head is connected to the power supply the components of the power unit as well as certain components of the master control unit – are also connected to the power supply.

DANGER!

Touching these components can seriously endanger life!

– Before removing the frequency inverter cover, the system must be disconnected from the power supply

– After switching off the power supply wait at least 5 minutes before starting work on or in the inverter drive head

- the capacitors in the intermediate circuit must be given time to discharge completely via the discharge restors.

ELECTRICAL HAZARD

Up to 800V can be present - if there are faults this can be higher

– All work carried out when the frequency inverter is open must be performed only by suitably qualified and

properly authorised personnel.

1. Important Safety Information

ELECTRICAL HAZARD

THE SYSTEM MUST ONLY BE OPERATED WHEN IT HAS BEEN CORRECTLY EARTHED AND PIPES BONDED TO EARTH IN ACCORDANCE WITH IEE REGULATIONS

– When connecting external control wires care must be taken not to short circuit adjacent components. Bare

cable ends which are not in use must be insulated.

1.12 Electronic Safety Devices

– Inverter drives contain electronic safety devices which switch off the control element in the event of

a fault developing. – A motor can also be stopped by ‘mechanical blocking’ – If it is switched off electronically, the motor is disconnected from the mains voltage supply via the

electronics in the inverter drive. – Voltage fluctuation and power failures (temporary outages) can cause the motor to switch itself off.

WARNING

A motor will have zero current but will remain energised as it stops

– Take necessary precautions - the motor is not voltage-free in the circuit itself

WARNING

Repair of faults can cause items to start up again unexpectedly

– Ensure the motor is isolated before commencing any work

WARNING

High voltage tests of inverters may damage the electrical components.

– Bridge before the incoming/outgoing terminals L-L2-L3 and U-V-W.

– To avoid incorrect metering by capacitors incorporated in the electronic circuits, isolate the motor from the

inverter drive head.

1.13 Spare Parts

WARNING

Use of non-genuine spare parts may cause damage to equipment, damage to property and voiding of warranty

– Use genuine, Dutypoint-approved spare parts only

– If in doubt, contact Dutypoint Service on 01452 300590.

1. Important Safety Information

1.14 Transportation and Lifting

WARNING: LIFTING HAZARDS

– Stay clear of suspended loads

– Observe accident prevention regulations in force

– Do not damage the cables during transports; so not squeeze, bend or dray the cable

– Always keeps the cable ends dry

– Secure the unit against tipping over and slipping until it is mounted and fixed in its final location

– Lift and handle the product carefully, using suitable lifting equipment (stacker, crane, crane mounting device,

lifting blocks, sling ropes, etc.)

– Always lift the unit by its lifting handle

WARNING: ASSEMBLED SYSTEMS ARE HEAVY

– Failure to properly lift and support this equipment can result in serious physical injury and/or equipment

damage,

– Lift equipment only at the specifically identified lifting points.

– Lifting devices such as eye bolts, slings and spreaders must be rated, selected and used for the entire load being

lifted

– Select the appropriate lifting points

1) Inspect the package a) Inspect the package for damage or missing items upon delivery b) Note any damaged or missing items on the shipping paperwork and contact Dutypoint

immediately

c) File a claim with the shipping company if anything is out of order

d) If the product has been picked up at a distributor, file a claim with the distributor

2) Inspect the unit a) Remove packing materials from the product b) Dispose of all packing materials in accordance with local regulations

c) Inspect the product to determine if any parts have been damaged or are missing

d) If applicable, unfasten the product by removing any screw, bolts or straps. For your personal

safety, be careful when you handle nails and straps.

e) Contact Dutypoint if you have any issues.

1.15 Storage

The product must be stored in a covered and dry location free from heat, dirt and vibrations.

NOTE: Protect the product against humidity, heat sources and mechanical damage NOTE: Do not place heavy weights on the packed product NOTE: See section on storage limits

1. Important Safety Information

2. Specifications

Table 2.2: ScubaTANK WX Range Specifications

Applications Water with no gas or aggressive substances Flow Range 0.8 - 3.1 litres/sec Pressure Range 2.0 - 7.0 bar Liquid

Temperature Ambient

Temperature Humidity Max 50% Controller Type Modus VASCO Protection Low water level via probe control Tank Construction GRP construction

Tank Capacity 175l, 375l, 440l, 490l, 575l, 650l, 750l, 800l, 1,050l, 1,250l,

Inlet Valve ¾” or 1” high flow solenoid valve Discharge WX1 models: 1¼” BSP

Pressure Vessel 12 litre stainless steel

2. Specifications

1°C - 23°C

+5°C - +40°C for indoor installations

25mm insulation (HCFC and CFC free) Base reinforced with encapsulated multi-ply board and fitted with fixing brackets

1,650l or 2,250l

WX2 models: 1½” BSP

2.1 Identifying ScubaTANK Models

Figure 2.1: ScubaTANK Model Codes

WX2-5040-490-AB-HS-RM/2

Product Preﬁx

Number of Pumps

Pump Model

Tank Actual Capacity (litres)

RM = Control panel supplied loose for remote mounting

Options:

AB = Category 5 AB air gap

HS = Horizontally split tank

/2 = Twin Tank System

2. Specifications

Table 2.3: Pump Ratings

Power Supply to

Motor kW

Pump Model

3040-T230 0.55 230/1/50 230/3/50 4.1 3040-T230 0.75 5.2 3080-T230 1.1 7.4 3100-T230 1.5 5.5 5040-T230 0.75 5.0 5060-T230 1.1 7.4 5080-T230 1.5 10.5 5100-T230 2.2 9.0 9040-T230 1.5 10.5 9060-T230 2.2 11.9 9070-T 3 400/3/50 400/3/50 5.9 9090-T 3 6.8

Rating

Control Panel

(V/Ph/Hz)

Power Output from

Inverter to Pump

(V/Ph/Hz)

Figure 2.2: ScubaTANK Components

Control Panel

Inverter

Drives

Pressure

Vessel

Flexible Connector

(supplied loose, do not

bend excessively)

Full Load

Current (A)

Pressure

Transducers

Level Control

Probes

Non-Return

Valves

Submersible

Pumps

Outlet

Solenoid Valve

Isolator and Strainer Incoming Main

(¾” or 1” BSP)

3. Installation Sequence

3.1 Position and Secure the Tank

1) Connect the inlet water supply via an isolation valve;

2) Connect the overflow system to a suitable drain;

3) Connect the warning pipe (where fitted) and pipe to a suitable location;

4) Connect the outlet pipe;

5) Connect the electrical supply cable from a fused supply with correct rating - see Table 3.5:

ScubaTANK Breaker Ratings;

6) Fill the system and vent the pump;

7) Test and commission.

NOTE: The ScubaTANK must be installed on a stable, level surface or plinth capable of

supporting the tank and liquid.

Table 3.4: ScubaTANK Dimensions and Weights

Tank Size

(l)

175 600 × 600 1414 1000 59 234 375 600 × 900 1703 1200 117 492 440 600 × 900 1500 1200 127 492 490 600 × 900 1703 1200 117 492 575 600 × 900 1500 1200 127 492 650 750 × 1200 1703 1200 150 800 750 750 × 1200 1500 1200 160 800 800 1160 × 1160 1503 1000 165 965 1050* 800 × 1500 2003 1500 170 1,220 1250* 1160 × 1160 2003 1500 194 1,444 1650* 1160 × 1500 2003 1500 211 1,861 2250* 1160 × 2000 2003 1500 218 2,468 *Additional overflow warning pipe: ¾” push fit

Footprint

(mm)

Overall

Height (mm)

Height to Top of

Open Tank

(mm)

3. Installation Sequence

Weight

When

Empty (kg)

Weight

When Full

(kg)

NOTE: An additional 250mm minimum clearance is required above the overall height NOTE: Inlet centre: 62mm below the open tank top height

– The area should be dry, frost-free and well ventilated, away from extremes of temperature. All

pipework must be adequately protected from freezing.

– Adequate provision should be made for drainage, leakage damage protection and service access. – The tank is free standing and is provided with fixing feet for secure fastening to the floor.

3.2 Cleaning the Filter

This check is required every 6 months for the first year of operation as the system may still contain sediment. After this, an annual check is normally sufficient to keep the filter clear of sediment.

3. Installation Sequence

Figure 3.3: Filter Cleaning Process

1. Turn isolator level to OFF (position perpendicular to pipework)

4. Replace all parts and turn isolator lever to ON position (parallel to pipework)

3.3 Hydraulic Connection

– All pipework must be in accordance with local Water Authority regulations. – The discharge pipework must be sized according to the system demand. – All pipework must be securely supported and not over-stressed. – The overflow and the warning pipe (if fitted) must be piped to a suitable location.

3. Remove ﬁlter and rinse under water to remove build up

2. Remove hex cap and o-ring

3.4 Electrical Supply

WARNING: ALL ELECTRICAL WORK MUST BE CARRIED OUR BY A SUITABLY QUALIFIED PERSON FOLLOWING THE LATEST IEE REGULATIONS

– The system must only be operated when it has been correctly earthed and pipes bonded to earth in accordance

with the latest IEE regulations

WARNING: CONTROLLER ELECTRIC SHOCK DANGER. THE CONTROLLER CONTAINS HIGH VOLTAGE

– Never open the controller or work with any electrical connections within it unless the electrical supply to the

unit is isolated.

– Wait a further 2 minutes after isolation for the internal circuitry to discharge.

– The electrical supply feed to the ScubaTANK should be a dedicated line to minimise electromagnetic

interference.

– The electrical supply rating must be at least double the FLC, assuming all pumps operate together

(see Table 3.5: ScubaTANK Breaker Ratings.)

– The control panel isolator cable should be connected via a suitably rated external MCB.

Table 3.5: ScubaTANK Breaker Ratings

Single

Pump

Model

3040 4.1 WX1-3040-xxx WX2-3040-xxx 10 (1~) 20 (1~)

Pump

FLC

ScubaTANK

Model

Twin Pump

ScubaTANK

Model

WX1 (Single

Pump)

Breaker

Rating

WX2 (Twin

Pump)

Breaker

Rating

3. Installation Sequence

Single

Pump

Model

3060 5.2 WX1-3060-xxx WX2-3060-xxx 10 (1~) 20 (1~) 3080 7.4 WX1-3080-xxx WX2-3080-xxx 10 (1~) 20 (1~) 3100 5.5 WX1-3100-xxx WX2-3100-xxx 10 (1~) 20 (1~) 5040 5.0 WX1-5040-xxx WX2-5040-xxx 10 (1~) 20 (1~) 5060 7.4 WX1-5060-xxx WX2-5060-xxx 10 (1~) 20 (1~) 5080 10.5 WX1-5080-xxx WX2-5080-xxx 10 (1~) 20 (1~) 5100 9.0 WX1-5100-xxx WX2-5100-xxx 16 (1~) 32 (1~) 9040 10.5 WX1-9040-xxx WX2-9040-xxx 10 (1~) 20 (1~) 9060 11.9 WX1-9060-xxx WX2-9060-xxx 16 (1~) 32 (1~) 9070 5.9 WX1-9070-xxx WX2-9070-xxx 16 (3~) 32 (3~) 9090 6.8 WX1-9090-xxx WX2-9090-xxx 16 (3~) 32 (3~)

NOTE: The probe relay settings are factory preset and should conform with information in

Pump

FLC

ScubaTANK

Model

Twin Pump ScubaTANK

Model

WX1 (Single

Pump)

Breaker

Rating

WX2 (Twin

Pump)

Breaker

Rating

the wiring diagram. Adjustment will invalidate the warranty.

Figure 3.4: Common Fault Volt Free Contact Wiring Details

MAXIMUM 230V - 5AMP

2× BLACK

FROM

INVERTER

3.5 How to Seal a Horizontal Split Tank (Applicable to -HS Models)

NOTE: This section applies only to ScubaTANK WX models with horizontal split tanks.

These have the -HS designation.

WARNING

The flange sealant is very adhesive

2× RED

FROM

INVERTER

– Ensure it is aligned correctly before applying it to the flange.

– Remove paper backing as you progress along the flanges

– Check that you have the correct number of fixing components, i.e. nut, bolt, washers and arboseal.

– Ensure the flanges are free from grease and grit or other substances which may damage or prevent the flange

sealant from sticking,

– Ensure the flange sealant black strip is applied approx 5mm from the inner edge of the flange, water side.

3. Installation Sequence

NOTE: Ensure you follow the procedure according the images and instructions below.

Figure 3.5: Applying split tank sealant

Nut and bolt arrangement. Ensure ﬂanges are clean

and free from grease, grit etc.

✓

When applying sealant to the next ﬂange, ensure a overlap.

Flange sealant overlaps like this.

Note: some sealant may squeeze out from between the ﬂanges. This is normal.

Apply ﬂange sealant ensuring the black strip is water side.

DO NOT LEAVE A GAP BETWEEN SEALS

When the flange seals have been applied to the bottom section, the top section of the tank is carefully lifted onto it. A podger/screwdriver may be used to align the bolt holes by pushing it through the top flange hole, through the flange seal and through the lower flange hole. A bolt may be pushed through to hold it in place while the other holes are located. It is recommended that all bolts are pushed through before tightening begins. Recommended torque: 40Nm (30lb/ft)

3.6 Bolt Tightening Sequence for Split Tank Flange Assembly

After all the nuts have been spun onto the bolts by hand, you may begin tightening sequentially from the first bolt to its diagonal opposite and continue in a clockwise or anticlockwise direction.

1) First time around, just pinch the nuts with a spanner;

2) Second time around, apply 30% recommended torque;

3) Third time around, apply 60% recommended torque;

4) Fourth time around, apply 100% recommended torque.

3.7 Level Probe Details

There are 5 terminals within the probe holder:

3. Installation Sequence

Table 3.6: ScubaTANK Level Probe Holder Details

E1 Solenoid Cut-Off Probe Shortest probe (300mm) E2 Solenoid Cut-In Probe 100mm longer than the cut out probe E3 Low Level Probe 50mm shorter than the common probe E4 Common Probe Longest probe E5 Note used in standard ScubaTANK models

Figure 3.6: ScubaTANK Probes

Table 3.7: ScubaTANK Level Probe Lengths

1050, 1250 ,

ScubaTANK Capacity (l) 175, 800 375, 490, 650

E4 Common Probe Length (mm) PR-6-890 - 890mm PR-6-1090 - 1090mm PR-6-1390 - 1390mm E3 Low Level Probe Length (mm) PR-6-840 840mm PR-6-1040 - 1040mm PR-6-1340 - 1340mm E2 Solenoid Cut-In Probe Length

(mm) E1 Solenoid Cut-Out Probe Length

(mm)

PR-6-400 400mm PR-6-400 - 400mm PR-6-400 - 400mm

PR-6-300 300mm PR-6-300 - 300mm PR-6-300 - 300mm

1650, 2250

3. Installation Sequence

4. Booster Set Commissioning

4.1 Installation and Commissioning Overview

Before shipment, all Dutypoint pump sets are pre-commissioned. Whilst important procedures such as venting and rotational direction checks need to be carried out on site, initial parameters including pressure settings and delay timers will be adjusted to suit the site conditions previously advised to Dutypoint.

In practice, a system can almost invariably be made to perform more efficiently if further re-commissioning is carried out on site.

Please note that engineer visits by Dutypoint are priced at one visit to commission one pump set. If there are multiple units on a site, special terms can be negotiated. To arrange a commissioning visit, please call the Technical Service Help line 01452 300590.

The following checks should be carried out at the initial installation before any run tests are performed.

WARNING

– Ensure that you have read and understood Section 1. Important Safety Information.

4. Booster Set Commissioning

4.2 Pipework and mechanical components

1) Ensure that the mounting area and any associated groundwork provides adequate support for the pump set.

2) Ensure all supports/brackets are in place and secure.

3) Verify all pipe joints are sealed and tight.

4.3 Electrical

WARNING

– These checks MUST be carried out by a competent electrician.

– Ensure that the power source is sufficient to allow the running of two (twin pump sets) or three (triple pump

sets) pumps together.

1) Check the motor voltage and frequency information on all the motor nameplates and on controllers etc. correspond with that of the source power supply.

2) Check that all electrical connections are correctly made and secure. Pay particular attention to Earth and bonding connections.

3) Carry out specific checks for Earth bonding.

4) Carry out NICEIC certification checks as required for the installation, e.g Earth Loop Impedance, Insulation Tests, etc.

5) Carry out any other pre-start checks recommended by the pump manufacturer. Refer to the pump manual in the Appendix of this manual. DO NOT POWER UP AT THIS STAGE.

4.4 Low Level Float Switch Wiring (Optional)

Terminal 1 and 3 require a normally closed contact in order to allow the pump set to operate. To facilitate this the unit will be supplied with a wire loop between 1 and 2. To install a low level float switch this loop has to be removed and the float switch wired to operate as an open on fail scenario.

4. Booster Set Commissioning

If 2 or more float switches are required (due to twin compartment or multiple tanks) all float switches are wired into terminals 1 and 2 in parallel.

Figure 4.7: Terminal Wiring

111234

LOW

LEVEL

FLOAT

4.5 Final Checks Before Commissioning

1) Re-check all equipment for any accidental damage caused during installation.

2) Carry out the pre-charging and venting procedures described next.

4.6 Pressure Vessel Pre-Charging

Figure 4.8: Pressure Vessel Pre-charge

132456789

FAILED SIGNAL

FROM INVERTERS

32 45678 910

If installing a Dutypoint FS-series ﬂoat switch, the following terminals should be used:

BROWN: Terminal 1 BLACK: Terminal 2 BLUE: Not used - terminate safely

Required Pressure (bar)

Before commissioning starts the pre-charge of the pressure vessels should be checked.

On variable speed systems the pre-charge air pressure for vessels should be 90% of the maximum pressure generated by the pump in the pipework system

e.g: If the maximum pressure generated by the pump in a system is 6 bar, this will require a pre-charge pressure of 6 × 90% = 5.4 bar.

To verify the pre-charge pressure:

1) First check that the expansion or pressure vessel(s) are totally drained of water, and that the system is switched off and no electrical parts are live.

2) Locate the charging valve on each vessel, accessed by removing the plastic cover on the top of the vessel

3) Connect a portable pressure gauge with a measuring range compatible with the expected pressures in your application, which has a flexible hose and Schrader-type connector to the charging valve.

4) Check the pre-charge pressure above the diaphragm in each pressure vessel correspond to criteria given in the text above.

5) If necessary, release or add additional air to correct.

4.7 Venting Pumps

It is important to bleed all air from the pump body before initial start-up.

Pre-Charge Pressure (bar)

4.8 Procedure for flooded suction

Flooded Suction is defined as the condition where there is positive pressure on the suction (inlet) side of the pump(s) as is the case where the storage tank water level is at the same or higher level than the pump bleed point.

This procedure should be carried out individually for each pump in the pump set.

1) Open all valves on the suction (inlet) side of the pump.

2) Using the vent screw at the top of the pump (refer to Appendix to locate), allow any air in the pump body and suction pipework to vent to atmosphere.

3) When water (under pressure from the storage tank feeding the pump on the suction side) escapes through the vent screw hole - and no more air bubbles can be seen - close the vent screw.

4) Switch on the electrical supply to the pump motor and start the pump in AUTO mode. As each motor starts verify that the direction of rotation correctly corresponds with the direction of the arrow shown on the body of the pump. If rotation is backward STOP, switch off the pump and investigate.

5) Slowly open the valve on the discharge manifold outlet to the system allowing water to be pumped into the system.

6) Switch off, re-close the discharge valve and repeat steps 3 to 6 several times to ensure that all air is released from the pump body and local pipework.

The above procedure should be carried out individually for each pump in the pump set.

4. Booster Set Commissioning

4.9 Procedure for Lift Suction

Lift Suction is defined where the water storage tank is at a lower level than the pump set. In this case a negative pressure condition may exist at the pump suction.

NOTE: The "Lift Suction" mode of operation requires specific venting procedures. Please call

Dutypoint Systems Technical Support on +44 (0)1452 300590 for advice before attempting to vent the pump(s).

The advised procedure should then be carried out individually for each pump in the pump set.

4.10 Programming the Controller

Dutypoint Systems fit a design of Inverter/Controller that is most suitable for the design duty of the pump set.

Manufacturer’s information for them is detailed in the Appendices to this manual.

Carefully follow the appropriate step-by-step setting-up procedures contained in the manual, ensuring that any data required to be entered by the end user is accurately inserted where requested.

If in doubt please call Dutypoint Systems Technical Support on 01452 300590 for advice.

4.11 Operation and Performance Tests

Having checked that the pump set is installed, pre-charged, vented in accordance with the procedures set out earlier, carry out the following running tests before handing over the pump set for operational use.

1) Run each pump by selecting HAND (Manual) control.

2) Re-select to AUTO mode.

3) Create the conditions for a normal start and run and allow the selected ‘Duty’ pump to run. Whilst running observe the pressure values. Verify the pump motor speeds up / slows down in accordance with the desired control philosophy.

4.12 Duty/Standby Twin Pump Sets

1) On Duty/Standby sets, wait for a normal stop to take place (or create the conditions where this would happen) and check that the ‘Duty’ pump stops. Whilst stopped simulate a fault by inhibiting the ‘Duty’ pump and then recreate the conditions for a normal start to take place. Check that the

4. Booster Set Commissioning

‘Standby’ Pump now starts and runs in place of the inhibited ‘Duty’ pump and observe the pressure values. Verify that the pump motor speeds up / slows down in accordance with the desired control philosophy.

2) Wait for a normal stop to take place (or create the conditions where this would happen) and check the ‘Standby’ pump stops. Whilst stopped undo the inhibit to the ‘Duty’ pump which should now return to normal.

4.13 Duty/Assist Twin Pump Sets

1) For ‘Duty/Assist’ applications, run the system up to pressure using the ‘Duty’ Pump only, then deliberately create the condition(s) which will require the ‘Assist’ Pump to operate as well. (e.g: open taps to reduce the pressure in the system to a point where one pump only cannot maintain the required output. Verify that the ‘Assist’ Pump starts and runs together with the ‘Duty’ Pump and that the desired pressure is duly restored and maintained.

2) Close the taps again (thereby reducing the demand) and check the ‘Assist’ Pump slows down and stops, allowing the ‘Duty’ Pump to continue on its own.

4.14 Commissioning/Handover Check

1) Record any indicated voltage / amperage / pressure data / controller passwords for future reference.

2) Re-check all isolating valves are fully open and replace any cover(s).

3) With all the isolators ON and the switches and/or control programs set to AUTO, the pump set is now fully operational in automatic control mode.

NOTE: No manual operation or attendance is required other than for routine servicing and

maintenance checks. Other than for maintenance purposes, the supply to the Controller(s) and the Pump motor(s) should never be switched off.

5. Operating the Pump Set

5.1 VASCO Display

The display screen on the VASCO is a back-lit LCD displaying 2 rows of 16 digits each. Alarms are indicated by an audible signal.

Figure 5.9: VASCO Control Panel

STOP Motor

5. Operating the Pump Set

Enter

START Motor

Scroll Up/Down

Figure 5.10: Display shown when first powering VASCO

Release of display software

Release of inverter software

NOTE: One pump/VASCO combination will have been set as master (display name 00) and

others as slaves (e.g. display name 01). The term “INV:” will be replaced by the appropriate display name, “00:” or “01:” etc. Various messages are then displayed.

The first row of the display gives the pump status as follows: – Inv: ON XXX.X Hz - VASCO is powered and is powering the motor, showing its frequency – Inv: ON Mot: OFF - VASCO is powered but motor is not running (i.e. motor/pump was stopped due to

minimum frequency being reached).

– Inv: OFF Mot: OFF - VASCO is not powered.

The following end user messages are displayed on the second row by pushing the scroll buttons:

Table 5.8: VASCO End User Messages

Inv: ON/OFF Mot: ON/OFF p = XX.X [bar]

Inv: ON/OFF Mot: ON/OFF f = XXX [Hz]

Inv: ON/OFF Mot: ON/OFF V_in = XX.X [V] I=XX.X

Inv: ON/OFF Mot: ON/OFF cosphi = XXX

Inv: ON/OFF Mot: ON/OFF P = XXXXX [W]

p is the pressure value read by the pressure transducer. By pressing ENTER the pressure set vale is displayed

f value is the supply frequency to the motor. On fox frequency control mode, by pressing ENTER you can change the f value manually (word “set” is displayed), press ENTER again to exit parameter setting (word “set” disappears).

V_in is the line voltage. This value is displayed only if motor is OFF. If motor is NO, A value equal to the absorbed motor current.

cosphi index means the angle phi between the voltage and current absorbed by the motor

P is the power in Watts supplied to the pump

5. Operating the Pump Set

Inv: ON/OFF Mot: ON/OFF STATUS: NORMAL

Inverter Life xxxxx h : xx m

Motor Life p = XX.X [bar]

%f 25 50 75 100 %h XX XX XX XX

XXXXXXXXXXXXXXX XXXXXXXX h : XX m

NORMAL status means no alarms. If an alarm occurs, a message blinks on the display and an audible signal is activated. Pressing ENTER accesses: VASCO lifetime, PUMP lifetime, consumption statistic, alarm list. To return to previous views, press ENTER.

WARNING: ADVANCED PARAMETERS. IMPROPER SETTINGS CAN COMPROMISE THE INTEGRITY AND LIFE OF THE CONTROLLER AND PUMP

– You should only access and adjust parameters if you are trained to do so

– All full description of the advanced parameters is available in the appendix of this manual

– For further assistance, call the Dutypoint Technical Service line of 01452 300590.

Pressing ENTER when you are in the initial display will show the following menus:

Table 5.9: VASCO Menus

MENU’ Motor param.

MENU’ Control. param.

MENU’ IN/OUT. param.

MENU’ Connect. param.

MENU’ Change init.set. param.

Installer password required to enter level 1 (default 001)

Advanced password required to enter level 2 (default 002)

Installer password required to enter level 1 (default 001)

Installer password required to enter level 2 (default 001)

Advanced password required to enter level 2 (default 002)

To exit the Menu level and return to the initial display, press STOP button.

For full details on the VASCO controller see 11

. VASCO V209 and V214 Pump Controllers.

6. Pressure Vessel

The pressure vessel supplied as part of your Dutypoint product is used to absorb and conserve the potential energy of pressurised liquid. Stored energy from liquid under pressure is transferred to the water system when required.

6.1 Installation Safety Notes

These notes are taken from the pressure vessel installation manual: – This product is designed to hold water up to +110°C – Never exceed the maximum working pressure and temperature of the expansion tank; ensure

appropriate controls are installed for this purpose.

– During installation prepare adequate systems for drainage to limit damage caused by leakage from

the tank, draining and venting.

– During installation the installer should account for external stress such as traffic, wind and

earthquakes. – Always install the appliance in conformity to current legislation. – This product must be installed and regularly inspected by qualified personnel only. – The manufacturer shall not be held liable for any personal or material damage caused by the product

if installed and/or used improperly or in way anyhow diversely from manufacturer’s specifications. – Exceeding temperature and pressure limits specified by the manufacturer will give cause to cancel

any guarantee covering the product as well as any manufacturer’s liability. – For fluids other than water, check compatibility before installing. – The appliance must be installed in a safe place with access for authorized personnel only. – The appliance must be protected by an appropriate earthing systems or isolated from the system by

a dielectric joint.

6. Pressure Vessel

6.2 Periodic Maintenance

Periodic maintenance is recommended at least twice a year and should be carried out by authorised specialised personnel only.

1) First check that the expansion or pressure tank is totally drained of water, and that the system is

switched off and no electrical parts are live.

2) Check and, if necessary reset the pre-charge pressure, using the instruction in 4.6 Pressure Vessel

Pre-Charging. Ensure that the pressure does not exceed the value specified in the procedure.

6.3 General Maintenance and Repair

Disconnect all electrical equipment before starting on any maintenance jobs or checking the installation pressure and temperature. The pre-charge pressure should be checked and if necessary corrected during any maintenance work.

6.4 Pressure Vessel Pre-Charge Instructions

1) First check that the expansion or pressure tank is totally drained of water, and that the system is

switched off and no electrical parts are live.

2) Refer to Figure 6.11: Pre-Charging a Pressure Vessel. Remove the air vent cover.

3) Unscrew the air valve cap.

4) Connect a pressure gauge. Verify that the pre-charge pressure is correct. If it is low then the vessel

pre-charge must be corrected by additional inflation of the diaphragm.

5) When the pre-charge pressure is correct replace the air valve cap and vent cover.

6. Pressure Vessel

Figure 6.11: Pre-Charging a Pressure Vessel

6.5 Diaphragm Replacement

To replace a diaphragm:

1) Empty the expansion tank

2) Remove the pre-charging by releasing the air vent.

3) Loosen the M8 screws fastening the flange

4) Remove the flange

5) Extract the diaphragm and replace it

6.6 Installing a Replacement Vessel

Read these instructions carefully before installing the product:

1) Make sure the product is in good condition. If the product is damaged do not start on installation but take it back to the seller for immediate replacement.

2) The product must be installed in the position (vertical or horizontal) specified in the technical specifications.

3) While the system is cold, measure the static pressure with a gauge, at the point where the tank has to be installed.

4) Set the pre-charge pressure, using the procedure earlier in this section. Ensure that the pressure does not exceed the value specified in the procedure.

5) The appliance must be supplied with efficient and sufficient safety and control facilities, in particular the safety valve must be connected to the appliance and be free from interference and must be gauged to the quantity of fluid to be discharged. The safety valve should also be designed to ensure that the pressure does not permanently exceed the maximum tolerated pressure (a temporary pressure peak, limited to 10% of the maximum tolerated pressure, is allowed).

6) Make sure the cap of the valve is fitted tightly after pre-loading and that there is no leakage.

7. Booster Set User Maintenance

Routine user maintenance for Dutypoint pump sets.

Dutypoint pump sets have been designed to keep major maintenance requirements to a minimum. Planned maintenance of the pumps and other principal components should therefore be undertaken at the intervals recommended in the manuals referenced below.

It is essential that a full test following the Pre-Commissioning procedure on is carried out on an annual basis.

In addition, the operator in charge should routinely make visual checks of the equipment during use, noting particularly any unusual noises or vibrations. This will give an immediate indication of any irregularity in the operation of the system.

DANGER!

Do not commence any work until:

– You have read 1. Important Safety Information

– You have the appropriate personal protective equipment

– You have all necessary safety equipment to hand

7. Booster Set User Maintenance

Refer to the appropriate manufacturer’s information that is provided in the appendices of this manual for the equipment being serviced.

Table 7.10: Periodic User Checks for Pump Sets

Timing Checks

Weekly 1) Visually check the complete pump set

2) Observe the running of the pump(s) and note any unusual vibrations or sounds.

Quarterly 1) Visually check the complete pump set

2) Observe the running of the pump(s) and note any unusual vibration, etc.

3) Check the cooling fan and vents on the Control Unit(s) and clear any dust or other obstructions

4) Operate each manual isolating valve three times to ensure continued efficient working

6-monthly The pressure vessel should be drained and the pre-charge pressure checked. See

6.4 Pressure Vessel Pre-Charge Instructions for more details.

12-monthly (essential)

Carry out the full pre-commissioning procedure to verify safe operation - see 4.

Booster Set Commissioning.

7. Booster Set User Maintenance

8. XPW Pump Maintenance

The following information is an extract from the pump manufacturer’s documentation.

8.1 Routine Maintenance

The pump requires no detailed maintenance except to: – Periodically verify that the suction grate is clear – Periodically with the power off, check the condition of the cables and electrical power and earth

connections.

8.2 Pump Replacement

DANGER!

Risk of electric shock

– Before beginning any work on the pump you must isolate the electrical supply and make sure that it cannot be

accidentally reconnected.

– Wait for a further 2 minutes for the internal circuitry to discharge BEFORE opening or working with any electrical

connections.

– It is the installer’s responsibility to ensure that the installation is in compliance with local regulations and all

electrical guidelines.

WARNING

Electrical pumps should never be used outside the limitations described in the technical specifications

– Replacement pumps should remain in their original packaging until installation.

8.3 Replacement Procedure

1) Before installation, check the new pump and verify its integrity and that it is the correct type/rating. Contact the supplier if there are any anomalies.

2) Locate the 4× plastic screw covers protecting the M6 screws securing the tank lid. Remove the covers and screws and lift off the tank lid to access the old pump.

3) Disconnect the pump pipework.

4) Disconnect the pump electrical cable, noting the cable colour coding.

5) Insert the replacement pump into the tank and reconnect the pipework.

6) Feed the pump cable through the watertight glands and make the electrical connections to the controller as noted in step 4 above, verifying that the earth connection is securely made.

7) Fix the power cable to the delivery pipe using suitable strap.

8) Replace the covers on the controller.

9) Test the system, checking rotation direction (see below).

10) When testing is complete, replace the tank lid and screw it down, refitting the plastic caps

WARNING: EXCESSIVE FORCE CAN DAMAGE EQUIPMENT

– To avoid damage, do not use excessive force when screwing the pipe to the pump discharge outlet.

8. XPW Pump Maintenance

8.4 Checking the Direction of Rotation

NOTE: This operation will be performed dry and must not last more than a few seconds.

If the direction of rotation is reversed due to incorrect connection or controller programming, the pump performance will be significantly lower than the nominal values. To verify a correct connection, proceed as follows:

1) Start the electrical pump before it is submerged. Correct rotation is in a counter- clockwise direction as viewed from above.

2) With the pump operating, installed and submerged, use a clamp meter to measure the current. If the rotation is reversed, you will see values about double those indicated on the name plate.

3) Correct before using the system.

9. Pressure Set Point Adjustment

Note: This procedure should only be undertaken by an experienced and qualified installer or engineer. Failure to follow the procedure correctly may cause damage to the product and invalidate any product warranty. The installer is responsible for ensuring that the required value is suitable for the product. Check the appropriate pump curves prior to adjustment.

1) Press STOP button (red)

2) Press the down arrow until you see ‘MENU / ENT TO ACCESS’ then press the ENTER button. Refer to

Figure 5.9: VASCO Control Panel.

3) You will open the ‘INSTALLER PARAMETERS’ or ‘CONTROL PARAMETERS’ menu (depending on model). Press the ENTER button again.

4) You will be promoted to enter the password. Press ENTER again until the last zero flashes, then press the up arrow to show a ‘1’ - the default password is 001. Press ENTER again.

5) Press the DOWN arrow until you see ‘SET VALUE’, then press ENTER again.

6) Use the UP and DOWN arrows to adjust the pressure to the required value.

7) Press ENTER to save the value then:.

– Single pump models: press the RED STOP button three times to return to HOME screen, then

press GREEN START button

– Multi-pump models: press the RED STOP button twice, then ENTER to transfer settings to the

SLAVE inverter(s)

9. Pressure Set Point Adjustment

8) Follow the instructions to adjust the pressure vessel pre-charge to suit the new required value - see

6.4 Pressure Vessel Pre-Charge Instructions.

9. Pressure Set Point Adjustment

10. Troubleshooting

Troubleshooting VASCO-equipped booster sets. The information in this section is common to all VASCO-equipped Dutypoint booster sets. For more detailed troubleshooting information that is specific to the type and model of pump controller used, please refer to the manufacturer’s literature in the Appendix.

WHEN A FAULT FIRST OCCURS:

– Turn off the main power to the pump set and leave off for 1 minute

– Switching power back on and re-energising the system may be sufficient to clear the fault

WARNING: IF PUMP COSPHI IS LOWER THAT THE DRY-RUNNING COSPHI FOR AS LEAST 2 SECONDS, VASCO WILL STOP THE PUMP. VASCO WILL TRY TO RUN THE PUMP AT 10, 20, 40, 80 AND 160 MINUTES, THEN THE PUMP WILL STOP. IF DRY RUNNING PROTECTION OCCURS, VASCO WILL ATTEMPT TO START THE PUMP AUTOMATICALLY

– Cut the power supply before performing any maintenance

– VASCO will stop the pump if the input motor current is higher than the set motor current for an extended time.

By pressing the START button it is possible to run the pump again.

– VASCO will stop the pump if the input voltage is higher than the set voltage for an extended time. By pressing

the START button it is possible to run the pump again. VASCO will stop the pump if the input voltage is lower than the set voltage for an extended time. By pressing the START button it is possible to run the pump again.

Table 10.11: Common Error Messages

Messag

e Possible Cause(s) Solutions

ACTIVE DIG. IN. 1

ACTIVE DIG. IN. 3

Digital input 1 contact is opened - system indicates ‘External On/Off’

Digital input 3 contact is opened - system indicates ‘Low Water Level’

1) Verify that an external signal (e.g. BMS) is set to deactivate the pump set

2) The error should reset automatically when Digital Input 1 contact is closed

1) Check incoming mains pressure is as expected

2) Check water level in tank.

3) The error should reset automatically when Digital Input 3 contact is closed

10. Troubleshooting

Messag

NO WATER(DRY RUN COSPHI)

Possible Cause(s) Solutions

Minimum pressure requirement not reached within set period

Air lock in pump 1) Press the red STOP button on the inverter drive(s) to stop

No water in break tank 1) Check incoming mains pressure is as expected;

1) Turn off main electrical isolator

2) Close discharge isolation valve

3) Vent pumps

4) Turn on main electrical isolator

5) Check unit runs up to set pressure and pump motors shut down

6) Open discharge valve slowly ensuring set pressure is maintained

the unit.

2) Disconnect the pump(s) by loosening the union directly underneath the lid, above the pump discharge pipeline.

3) Lean/tilt the pump(s) over as far as possible to enable air to escape.

4) Reconnect the pump union(s).

5) Press the green START buttons to resume normal operation.

6) Verify normal operation.

2) Check the water level in the tank.

Table 10.12: Fault Finding

Problems Possible Causes Solutions

Pump will not start

Low (or zero) output discharge rate

Pump vibrates and/or is noisy

No electrical power Check and rectify Blown fuse Check and rectify Overload trip/MCB Check and (if necessary) reset the overload trip

value.

The rotating part(s) of the pump is/are partially or completely obstructed e.g: impeller obstructed by foreign matter

Pump not primed - WARNING: running the pump ‘dry’ can cause serious damage to the mechanical seal.

Valve in suction pipework closed or partially closed

Incorrect pump rotation Check and rectify. Pump is cavitating Increase the discharge back pressure slightly by

The rotating part(s) of the pump is (are) partially or completely obstructed. e.g: impeller obstructed by foreign matter.

Motor bearings worn Check and rectify

Strip the pump to inspect and rectify

Having first checked the mechanical seal for damage, prime and air-bleed the pump and try again

Check all appropriate valves are fully open.

progressively closing a manual isolating valve on the discharge side until the cavitation stops.

Strip the pump to inspect and rectify

Problems Possible Causes Solutions

Overload Trip Pipework or the pump chamber has

a partial blockage. Momentary loss of one phase of

power supply Discharge flow rate too high Reduce the discharge flow rate by increasing the

Overload trip setting too low for rated duty

Pump Runs Continuously

Break Tank Overflowing (ScubaTANK WX models only)

Contact Dutypoint Service on 01452 300590

Solenoid valve jammed open due to debris

Probe relay settings have been adjusted

Loss of power to probe relays Check for the two green lights marked ‘Un’. If

Check and rectify

Check and try again

discharge back pressure slightly, progressively closing a manual isolating valve on the discharge side, then try again

Check and (if necessary) reset the overload trip value

Clean the solenoid valve diaphragm by following this procedure:

1) Press red STOP button(s) on inverter control panel(s)

2) Close incoming isolation valve

3) Isolate electrical supply

4) Loosen 4 screws as shown in Figure 10.1

Cleaning Solenoid Valve Diaphragm (ScubaTANK WX Models Only)

5) Remove diaphragm and spring shown in

Figure 1.1: Cleaning Solenoid Valve Diaphragm (ScubaTANK WX Models Only)

6) Remove all dirt from diaphragm and housing

7) Replace all parts

Check the probe relay settings according to

Figure 10.13: Correct Probe Relay Settings (ScubaTANK WX Models Only) in the control

panel. Note: these settings should never normally be adjusted. Only change them to match the required settings shown.

either are not illuminated there is a problem with the power supply to the probe relays. Contact Dutypoint Technical Service on 01452 300590 for assistance.

10. Troubleshooting

Figure 10.12: Cleaning Solenoid Valve Diaphragm (ScubaTANK WX Models Only)

10. Troubleshooting

Figure 10.13: Correct Probe Relay Settings (ScubaTANK WX Models Only)

Sensitivity

Level

0.1

Illuminated when tank is ﬁlling

Water level indicator: off when water level is low

10.1 Fault Codes: Advanced

WARNING

Improper settings can compromise the integrity and life of the controller and pump

– You should only access the Installer and Advanced menus if you are trained to do so;

– A full description of these is available in the Appendix to this manual;

Sensitivity

Level

0.1

– For further assistance, call the Dutypoint Technical Service line on 01452 300590.

Table 10.13: VASCO Controller Alarm Messages

Message Alarm Description Possible Solutions

OVERCURRENT MOT.

Motor overload: input current of the motor is higher than the rated motor current setting parameter. Motor voltage drop caused by the inverter causes the motor input current to be higher than rated. Contact motor manufacturer to check if motor is capable of accepting this current.

– Make sure that the motor current setting

parameter is higher than rated. – Add 15% to the motor current setting – Reset the inverter using the red STOP

button, then attempt to run the pump

system again.

Message Alarm Description Possible Solutions

NO WATER (DRY RUN COSPHI)

OVER TEMP. INV.

NO COMMUNICATI ON

Motor cosphi is lower than the set value of dry running cosphi

Inverter over temperature – Make sure than ambient temperature is

Communication between Master and slave(s) has been interrupted

– Check pump is primed – Check the set value of dry running cosphi.

Dry running cosphi is approximately 60% of the rated cosphi (at rated frequency) listed on the motor plate.

If pump’s cosphi is lower than the set dry-running cosphi for at least 2 seconds, VASCO stops the pump. VASCO will then attempt to run the pump every 10, 20, 40, 80, 160 minutes and then the pump is stopped. Note: see dry running warning statement

Warning: if pump cosphi is lower that the dry-running cosphi for as least 2 seconds, Vasco will stop the pump. Vasco will try to run the pump at 10, 20, 40, 80 and 160 minutes, then the pump will stop. if dry running protection occurs, Vasco will attempt to start the pump automatically.

less than 40°C (104 °F).

– Check if auxiliary cooling fan is working

properly and if mounting space is adequate for proper cooling.

– Reduce the PWM value (Advance

Parameter Menu) – Check the wiring connections – Make sure that Master is not in the menu

level. If so, exit from the menu level. – In the STATUS of the slave (where alarm is

displayed). Try to reset the alarm by

pushing the STOP button. – Check each inverter is addressed correctly:

a) Master = 00

b) Slave 1 = 01

10. Troubleshooting

c) Slave 2 = 02, etc.

MIN. VALUE ALARM

IGBT TRIP ALARM

OVER VOLTAGE Supply voltage too high Check possible causes of over voltage UNDER

VOLTAGE ADDRESS

ERROR ALARM SLAVE XXSlave XX error detected by master Check the status of the slave.

Measured value has reached the lowest value accepted by the system.

The current drawn by the load exceeds the capacity of VASCO. VASCO is still able to continue to power the load for 10 minutes with an output current of 101% of nominal and for 1 minute with an output current of 110% of nominal

Supply voltage too low Check possible causes of under voltage

Same address as other VASCOs in the group

– Check possible causes reaching minimum.

value (i.e. broken pipe, open pressure relief

valve, etc.) – Check the minimum alarm value setting – Increase the ramp-up time – Make sure that the load current is at least

10% below the VASCO nominal current – Check the voltage drop along the supply

cable to the motor

The address of each VASCO needs to be different.

10. Troubleshooting

Message Alarm Description Possible Solutions

SENSOR FAULT Sensor error – Check the pressure transducer

– Check the wiring of the transducer

NO LOAD No load Check is load is properly connected to VASCO

terminals

MAX. VALUE ALARM

KEYBOARD FAULT

ACTIVE DIG.IN.X

Measured value has reached the maximum value accepted by the system.

A button on the keyboard has been pressed for more than 150 seconds.

Digital input X opened/closed Check the input digital configuration (IN/OUT

– Check possible causes of reaching

maximum value – Check the max. alarm value setting – Make sure buttons are not depressed. – If problem persists, call Dutypoint

Technical Service on 01452 300590.

parameters menu)

11. VASCO V209 and V214 Pump Controllers

11.1 Introduction

VASCO is a variable frequency drive designed to control and protect pumping systems by varying the output frequency to the pump. VASCO can be applied to both new and existing pumping systems, and provides:

– energy and cost savings – simplified installation and an overall lower pumping system cost – longer life of the pumping system and relevant components – improved reliability

VASCO, when connected to any pump, manages the system operation to maintain a certain constant physical quantity (pressure, differential pressure, flow, temperature, etc.) regardless of the conditions of use. The pump is operated only when needed thus avoiding unnecessary energy consumption.

VASCO at the same time is able to: – protect the motor from overload and dry running – implement soft start and soft stop to increase the system life and reduce current peaks – provide an indication of current consumption, voltage, and power – maintain a record of run time and display any errors and/or failures reported by the system – control up to two additional pumps at a constant speed (Direct On Line) – connect to other VASCO units for combined operation

Through the use of inductive filters (optional) VASCO eliminates dangerous surges that are induced in long cables, making VASCO suitable for control of submersible pumps.

11.2 Important Safety Information

The manufacturer strongly suggests carefully reading this operation manual before using and installing its products. Any operation (installation, maintenance and repair) must be carried out by trained, skilled, and qualified personnel. Failure to observe and follow the instructions in this manual may result in dangerous and potentially lethal electric shock. Pay attention to all standard safety and accident prevention regulations

DANGER OF ELECTRIC SHOCK

– Disconnect VASCO from the main power supply before commencing any work.

– Do not remove, for any reason, the cover and the cable plate without having first disconnected the device from

the main power supply and having waited at least 5 minutes.

– VASCO and pumping system must be grounded properly before operation. For the entire period VASCO is

powered, high voltage is present on the output terminals of the inverter whether or not the pump is running.

– Tightening all screws on the cover with washers is recommended before powering the device. Otherwise, there

may be a failure to connect the cover to ground, creating the risk of electric shock or even death.

11. VASCO V209 and V214 Pump Controllers

WARNING

– The device must be connected to main power supply via a switch to ensure the complete disconnection from

the network before any operation on the VASCO itself (including visual inspection) and/or on the connected load.

– Avoid any shock or significant impact during transport.

– Check the VASCO immediately upon delivery and check for damage and/or missing parts. If either occurs,

immediately notify the supplier.

– Damages due to transport, incorrect installation, or improper use of the device will null and void the warranty

– Tampering or disassembly of any component will automatically void the warranty.

NOTE: The manufacturer cannot be held responsible for any damages to people and/or

property due to improper use of its products.

11.3 Technical Specifications

P2 motor

Vin ±15%

Model

V209 1 × 230V 1 × Vin 15 9 1.1 4

V214 1 × Vin 20 9 1.1 4.3

[V]

Max V out

[V]

3 × Vin 7 1.5

3 × Vin 11 3

Max I in

[A]

Max I out

[A]

power

[kW]

Weight

[kg]

– Power frequency: 50-60 Hz (±2%) – Max. ambient temperature at nominal current: 40°C (104°F) – Max. altitude at nominal current: 1000 m – Grade of protection: IP55 – RS485 serial communication – auxiliary cooling fan of the VASCO, used in wall mounted applications, has a protection rating of IP54 – VASCO is able to power the motor with a higher current for a short period of time according to the

linear relation: 101% of the nominal current for 10min., 110% nominal current for 1 minute.

11.4 Electrical Wiring

Figure 11.14: Electrical Wiring Board

11. VASCO V209 and V214 Pump Controllers

Power Supply Output

Line: L1, L2, GND 3~ motor: GND, U, V, W

1~ motor: earth, U (running), V (common)

It is recommended to use cable lugs

Fans (Wall Mounted

Installations)

Fan: F1, F2

11. VASCO V209 and V214 Pump Controllers

Figure 11.15: Recommended line and motor cables stripping

Figure 11.16: Control Board Wiring

Analog inputs (10 or 15 Vdc) – AN1: 4-20 mA: sensor 1

– AN2: 4-20 mA: sensor 2 – AN3: 4-20 mA / 0 - 10 Vdc (settable by jumper C.C.): external set – AN4: 4-20 mA / 0 - 10 Vdc (settable by C.C.): trimmer for

frequency regulation / external set 2

Digital inputs: – IN1: motor start & stop

– IN2: value set 1 & 2 switching – IN3: sensor 1 & 2 switching – IN4: motor start & stop + alarms reset –0V

We recommend using only no voltage contacts.Opening or closing the digital contacts (depending on software configuration set (see IN/OUT).

Digital outputs: Motor run signal:

NO1, COM1: closed contact with motor running NC1,COM1: closed contact with motor stopped

Alarm signal: NO2,COM2: closed contact without alarm NC2,COM2: closed contact with alarm or no power supply

DOL1 pump relay: NO3,COM3: closed contact with DOL1 running NC3,COM3: opened contact with DOL1 running

DOL2 pump relay: NO4,COM4: closed contact with DOL2 running NC4,COM4: opened contact with DOL2 running

Relays are no voltage contacts. Max. voltage to the contacts is 250V with maximum current of 5A.

RS485 for combo – S1+

– S1–G

It is recommended to respect the polarity linking more VASCOs in series.

RS485 for ModBus – S2+

– S2–G

It is recommended to respect the polarity

11. VASCO V209 and V214 Pump Controllers

WARNING

The protections required upstream each VASCOs depends on the type of installation, and local regulations.

– We recommend to use overload protection with the characteristic curve of type C and type B circuit breaker,

sensitive to both AC and DC current

11.5 Electromagnetic Compliance

To ensure electromagnetic compatibility (EMC) of the system, it is necessary to apply the following measures:

– Always connect the device to ground. – Use shielded signal cables by placing the screen at one end. – Use motor cable as short as possible (<1 m / <3 ft). For longer lengths, it is recommended to use

shielded cables connecting the screen at both ends

– Separate signal, motor, and power supply cables.

NOTE: To enable the restoration of the display screen when there are electromagnetic

interference, VASCO periodically provides some fast “refresh” of the display.

11. VASCO V209 and V214 Pump Controllers

11.6 Motor Mounted Installation

Figure 11.17: Motor Mounted Installation

WARNING

– Make sure the manufacturer that the electric motor is suited for operation in the inverter

In this application VASCO is cooled by the motor fan. Motor kit (available upon request) allows a solid coupling of the two units and it is composed of:

– n.°4 rods – n.°4 M5 nuts – n.° 4 hooks – n.° 1 cooling ring

NOTE: Make sure to remove the auxiliary cooling fan if VASCO is coupled to a motor. Failure

to do so creates a high risk of overheating the motor and VASCO unit.

11.7 Remote/Wall Mounted Installation

Figure 11.18: VASCO Remote/Wall Mounted Installation

NOTE: Make sure to properly attach the grid of the auxiliary cooling fan

In this application VASCO is cooled independently by its auxiliary cooling fan integrated in the radiator. The wall mounting kit is comprised of:

– n.° 1 auxiliary fan 230V AC (VASCO 209,214) – n.° 4 screws to fix cooling fan – n.° 1 protection grill – n.° 1 metal bracket in AISI 304 – n.° 4 screws to fix VASCO to wall bracket

11.8 Operation and Programming

Setting Parameters are organized in 2 levels:

1) Installer level (MENU’ CONTROL PARAMETERS, MENU’ IN/OUT PARAMETERS, MENU’ CONNECTIVITY PARAM.) A password is required for this level (default 001)

2) Advanced level (MENU’ MOTOR PARAMETERS). A password is required for this level (default 002)

Installer and Advanced levels can be entered only with the correct password; otherwise, it is impossible to set up and/or modify any parameters (they can be only displayed).

The display screen on the VASCO is a back-lit LCD displaying 2 rows of 16 digits each. Alarms are indicated by an audible signal.

11. VASCO V209 and V214 Pump Controllers

Figure 11.19: VASCO Control Panel

STOP Motor

Enter

START Motor

Scroll Up/Down

Figure 11.20: Display shown when first powering VASCO

Release of display software

Release of inverter software

NOTE: One pump/VASCO combination will have been set as master (display name 00) and

others as slaves (e.g. display name 01). The term “INV:” will be replaced by the appropriate display name, “00:” or “01:” etc. Various messages are then displayed.

minimum frequency being reached).

– Inv: OFF Mot: OFF - VASCO is not powered.

The following end user messages are displayed on the second row by pushing the scroll buttons:

11. VASCO V209 and V214 Pump Controllers

Table 11.14: VASCO End User Messages

Inv: ON/OFF Mot: ON/OFF p = XX.X [bar]

Inv: ON/OFF Mot: ON/OFF f = XXX [Hz]

Inv: ON/OFF Mot: ON/OFF Vin = XX.X [V] I=XX.X

Inv: ON/OFF Mot: ON/OFF cosphi = XXX

Inv: ON/OFF Mot: ON/OFF P = XXXXX [W]

Inv: ON/OFF Mot: ON/OFF STATUS: NORMAL

Inverter Life xxxxx h : xx m

Motor Life p = XX.X [bar]

%f 25 50 75 100 %h XX XX XX XX

XXXXXXXXXXXXXXX XXXXXXXX h : XX m

p is the pressure value read by the pressure transducer. By pressing ENTER the pressure set vale is displayed

Vin is the line voltage. This value is displayed only if motor is OFF. If motor is NO, A value equal to the absorbed motor current.

cosphi index means the angle phi between the voltage and current absorbed by the motor

P is the power in Watts supplied to the pump

WARNING: ADVANCED PARAMETERS. IMPROPER SETTINGS CAN COMPROMISE THE INTEGRITY AND LIFE OF THE CONTROLLER AND PUMP

– You should only access and adjust parameters if you are trained to do so

– For further assistance, call the Dutypoint Technical Service line of 01452 300590.

Pressing ENTER when you are in the initial display will show the following menus:

Table 11.15: VASCO Menus

MENU’ Motor param.

MENU’ Control. param.

MENU’ IN/OUT. param.

MENU’ Connect. param.

MENU’ Change init.set. param.

To exit the Menu level and return to the initial display, press STOP button.

Table 11.16: Initial Configuration

When VASCO is switched on for the first time, the initial setting menu is displayed for the initial setting of parameters to configure pump characteristics, pressure sensor range, and system characteristics. If the initial setting procedure is not completed properly, it is impossible to run the pump. Initial setting procedure can be repeated if necessary. The initial setting procedure can be repeated (by using the 2rd level password)

Installer password required to enter level 1 (default 001)

Advanced password required to enter level 2 (default 002)

Installer password required to enter level 1 (default 001)

Installer password required to enter level 2 (default 001)

Advanced password required to enter level 2 (default 002)

to reconfigure VASCO or if VASCO is installed in a different system. A brief description of parameters and their allowable ranges are listed below

Parameter Default Description

Language XXXXXXX

Unit XXXXXXX

Motor Type Single/three phase

Rated Motor Amp. I = XX.X [A]

Rated Motor Freq f = XXX [Hz]

11.9 Control Modes

Mode Name Description Abbreviation

Constant value (default) VASCO changes the pump speed to keep the set value

Fix speed VASCO feeds the pump at set frequency, so the pump speed

Const. value 2 set the two values are selected by opening or closing the digital

Fix speed 2 value Fix speed 2 val: the two values are selected by opening or

External speed control motor frequency by using analogical input AN4 ES

11. VASCO V209 and V214 Pump Controllers

XXXX End user communication language

bar Unit

Three phase

XX Rated current of the motor as per its nameplate indication increased by

50 Rated frequency of the motor as per its nameplate.

Type of motor connected

10%. The voltage drop caused by the inverter leads to higher input current than nominal. Make sure the motor is capable of accepting the increased current.

constant regardless water demand

is kept constant

CV2

input IN2

FS2

closing the digital input IN2

11.10 Parameters

Table 11.17: Control Parameters

Parameter Default Description

Max alarm value XXX.X [bar]

Min alarm value XXX.X [bar]

Ext. set enabling ON/OFF

Set value XXX.X [bar]

10 Maximum value allowed in the system. If the

readen value goes over this value, an alarm occurs and the pump is stopped. Pump is automatically restarted if the readen value goes below the maximum value for a period of at least 5 seconds.

0 Minimum value allowed in the system. If the

readen value goes lower than this value, an alarm occurs and the pump is stopped. Pump is automatically restarted if the readen value goes higher than the minimum value for a period of at least 5 seconds.

OFF Enabling of set value changing by analogue input

AN3.

3 Set value to be kept constant ✓

Control Mode

C V FS CV2 FS2 ES

✓✓✓✓✓

✓✓

11. VASCO V209 and V214 Pump Controllers

Parameter Default Description

Compensation XXX.X [bar]

Set value 2 XXX.X [bar]

Compensation 2 XXX.X [bar]

Set value update XX [s]

Operating freq. XXX [Hz}

Operating freq 2 XXX [Hz}

Freq min control XXX [Hz}

Stop delay XX [s]

Control ramp XXX.X [s]

Delta control XXX.X [bar]

Delta start XXX.X [bar]

Delta stop XXX.X [bar]

Ki Kp and Ki parameters allow the dynamic control Kp

Pump DOL 1 ON/OFF

Pump DOL 2 ON/OFF

COMBO ON/OFF

Address XX

Alternance ON/OFF

Alternance period. ON/OFF

Control Mode

C V FS CV2 FS2 ES

0 Value compensation at the maximum frequency

for each pump. Acting on the green button you can reverse the sign

3 Set value to be kept constant ✓

0 Value compensation at the maximum frequency

for each pump. Acting on the green button you can reverse the sign

5 Time to update set value for compensation. ✓ ✓

50 Frequency value to feed the pump. ✓

50 Minimum frequency below which the pump tries

to stop

5 Delay for which the pump tries to stop below

freq.min.control

20 Ramp time from freq.min.control to min.motor

freq. If, during this time, the read value goes below the (set value - delta control), VASCO powers the motor again; otherwise, VASCO will stop the pump

0.1 Value drop below the set value required to restart the pump during control ramp

0.5 Value drop below the set value required to start the pump from stop condition

0.5 Value increase respect to set value which must be passed so that there is a forced shutdown of the pump

of system by VASCO; set values (Ki=50, Kp=005) are usually enough to get a valid dynamic control.

OFF Function to activate (ON) the first auxiliary pump

DOL 1 (Direct On Line pump)

OFF Function to activate (ON) the second auxiliary

pump DOL 2 (Direct On Line pump).

OFF Enabling or disabling COMBO operation as

described in COMBO chapter

00 VASCO address:

– 00 master – 01 to 07 slaves

OFF Function to allow alternating between the

VASCOs connected in COMBO (or pumps connected in DOL) in order to allow equal use of each pump in the group; master will reorganize the starting priority of the pumps by checking the life of each of them

0 Maximum difference in terms of hours between

VASCOs in the group. 0 stays for 5 minutes

✓

✓✓ ✓

✓✓

11. VASCO V209 and V214 Pump Controllers

Parameter Default Description

Start delay AUX. t = XX [s]

PI control. Direct/Reverse

Periodic autorun t = XX [s]

Dry run cosphi X.XX

Restarts delay XX [min]

0 Delay time with which the slaves start after the

variable speed pump has reached the maximum frequency and the pressure value has fallen below set value – delta control

Direct Direct: increasing motor speed also measured

value increasesReverse: increasing motor speed, measured value decreases.

0 Pump periodic autorun after XX hours of

inactivity. Value 0 makes function disabled.Warning, review the advice in chapter 1

0.65 Cosphi value below which the unit stops the motor and give “no water” alarm

10 Restart delay after a dry running alarm. At each

tentative (max 5) restart delay will be doubled

Table 11.18: Motor Parameters

Parameters Default Description

Rated motor Volt. XXX [V]

Voltage boost XX.X [%]

Rated motor amp. XX.X [A]

Rated motor freq XXX [Hz]

Max motor freq. XXX [Hz]

Min motor freq. XXX [Hz]

Ramp up time XXX.X [sec]

Ramp down time XXX.X [sec]

Ramp f min mot. XXX.X [sec]

PWNM XX.X [kHz]

XXX Motor rated voltage (as shown on motor nameplate).

0% Voltage increase during the motor start up. Warning: An excessive value

can seriously damage the motor. Contact the motor manufacturer for further information

XX Rated motor current as per its nameplate indication increased by 5%.

50 Rated motor frequency as per its nameplate

50 Maximum motor frequency. Note: by reducing the maximum motor

frequency, maximum current will be reduced as well

20 Minimum motor frequency

4 Ramp-up time to reach the speed required to achieve the set pressure (or

frequency value). Longer times delay the system reaching the preset value but better protect system components. Excessively long ramp-up times can create difficulties in VASCO setup, and can also cause false overload alarms.

4 Ramp-down time to reach zero speed. Longer times keep the system

pressurized, while protecting the system components. Excessively long ramp-down times can create difficulties in VASCO setup. Excessively short ramp-down times can cause false overload alarms

1.5 Time to reach the minimum motor frequency and vice versa

8 Carrier frequency (switching frequency). It is possible to choose PWM in

the range of 2.5, 4, 6, 8, 10 kHz Higher values give a more sinusoidal wave with fewer losses for the motor but higher losses for the inverter (increased inverter heating). If long cables are used (>20 m / >76 ft) (submersible pump) it is recommended to install an inductive filter between VASCO and the motor (available upon request) and to set the value of PWM to 2.5 kHz. This reduces the risk of voltage spikes, which can damage motor and cable insulation.

Control Mode

C V FS CV2 FS2 ES

✓✓

✓✓✓✓✓

11. VASCO V209 and V214 Pump Controllers

Parameters Default Description

F/f lin --> quad. XXX [%]

Rotation sense

--> / <--

Autorestart ON/OFF

Table 11.19: IN/OUT Parameters

Parameter Default Description

Unit XXXXX

F. scale sensor XXX.X

Min value sensor XXX.X

Offset input 1 [%]

Offset input 2 [%]

Offset input 3 [%]

Offset input 4 [%]

AN1,AN2 function XXXXXX

Digital input 1 N.O./N.C.

Digital input 2 N.O./N.C.

Digital input 3 N.O./N.C.

Digital input 4 N.O./N.C.

Dig.In2/3 delay [s]

85% V / f characteristic with which VASCO feeds the engine. The linear

characteristic corresponds to constant torque with variable speed. The quadratic characteristic is normally used with centrifugal pumps. The selection of torque characteristic should be done ensuring a smooth operation, a reduction of energy consumption and a lower level of heat and acoustic noise.

--> If, during the test, the motor runs in reverse, it is possible to change the wiring sequence via software without physically changing wires at the terminals.

OFF If ON is selected, after a lack of voltage, VASCO returns to its normal status;

if VASCO was powering the pump before the voltage drop, it resumes powering the pump automatically. Warning: review the safety information earlier in this chapter.

bar Unit [bar,%,ft,in,cm,m,K,F,C,gpm,l/min,m3/h,atm,psi]

16 Sensor full scale

0 Sensor minimum value

20% Zero correction for analogue input 1 (4-20 mA)

(20mA ×20% = 4mA)

20% Zero correction for analogue input 2 (4-20 mA)

(20mA ×20% = 4mA)

0% Zero correction for analogue input 3 (4-20 mA)

(20mA ×20% = 4mA)

0% Zero correction for analogue input 4 (4-20 mA)

(20mA ×20% = 4mA)

Independ ent

N.O. By selecting N.O. (normally open) VASCO runs the motor if the digital

3 Digital input IN2 & IN3 delay

Function logic for analogue input AN1,AN2 (independent, lower value, higher value, difference 1-2)

input 1 is open; motor will be stopped if the digital input 1 is closed By selecting N.C. (normally closed) VASCO runs the motor if the digital input 1 is closed; motor will be stopped if the digital input 1 is opened

input 2 is open; motor will be stopped if the digital input 1 is closed By selecting N.C. (normally closed) VASCO runs the motor if the digital input 2 is closed; motor will be stopped if the digital input 1 is opened

input 3 is open; motor will be stopped if the digital input 1 is closed By selecting N.C. (normally closed) VASCO runs the motor if the digital input 3 is closed; motor will be stopped if the digital input 1 is opened

input 4 is open; motor will be stopped if the digital input 1 is closed By selecting N.C. (normally closed) VASCO runs the motor if the digital input 4 is closed; motor will be stopped if the digital input 1 is opened

Digital input IN1 has 1 second fix delay

Table 11.20: Connectivity Parameters

Parameters Default Description

MODBUS address XXX

MODBUS baudrate XXXXX [bps]

MODBUS data format XXXXX

11.11 Protections and Alarms

Any time a protection occurs a blinking message is displayed together with an audible alarm; on STATUS in the initial view, the protection is displayed; by pressing the STOP button. Only from this position (STATUS) in the initial view is it possible to try to reset the alarm; if VASCO does not reset the alarm it is displayed again together an audible sound.

Alarm Message Alarm Description Possible Solutions

OVERCURRENT MOT. Motor overload: input current of the

UNDER VOLTAGE Supply voltage too low Check possible causes of undervoltage OVER VOLTAGE Supply voltage too high Check possible causes of overvoltage OVER TEMP. INV. Inverter over temperature – Make sure than ambient temperature

NO LOAD No load Check if load is properly connected to the

NO WATER (DRY RUN COSPHI)

SENSOR FAULT Sensor error – Check the transducer

1 MODBUS address from 1 to 247

9600 MODBUS baudrate from 1200 bps

RTU N81 MODBUS data format: RTU N81,

motor is higher than the rated motor current setting parameter. Motor voltage drop caused by the inverter causes the motor input current to be higher than rated. Contact motor manufacturer to check if motor is capable of accepting this current

Motor cosphi is lower than the set value of dry running cosphi

11. VASCO V209 and V214 Pump Controllers

to 57600 bps

RTU N82, RTU E81, ETU O81

– Make sure that the motor current

setting parameter is higher than rated

– Check other possible causes of over

current

is less than 40 °C (104 °F).

– Check if auxiliary cooling fan is working

properly and if mounting space is adequate for proper cooling

– Reduce the PWM value (Advance

Parameter Menu)

VASCO terminals – Check that the pump is primed – Check the set value of dry running

cosphi. Dry running cosphi is approximately 60% of the rated cosphi (at rated frequency) listed on the motor plate

If pump’s cosphi is lower than the set dry-running cosphi for at least 2 seconds, VASCO stops the pump. VASCO tries to run the pump every 10, 20, 40, 80, 160 minutes and then the pump is stopped WARNING: if dry running protection occurs, VASCO will try to start the pump automatically. Be sure to cut power supply to VASCO before performing any maintenance.

– Check the wiring of the transducer

11. VASCO V209 and V214 Pump Controllers

Alarm Message Alarm Description Possible Solutions

MAX. VALUE ALARM Measured value has reached the

MIN. VALUE ALARM Measured value has reached the

IGBT TRIP ALARM The current drawn by the load

NO COMMUNICATION Communication between Master

ADDRESS ERROR Same address as other VASCOs in

KEYBOARD FAULT A Button on the keyboard has been

ACTIVE DIG.IN.X Digital input X opened /closed Check the input digital configuration (IN/OUT

ALARM SLAVE XX slave XX error detected by master Check the status of the slave

maximum value accepted by the system

lowest value accepted by the system

exceeds the capacity of VASCO. VASCO is still able to continue to power the load for 10 minutes with an output current of 101% of nominal and for 1 minute with an output current of 110% of nominal

and slave(s) has been interrupted

the group

pressed for more than 150 seconds

– Check possible causes of reaching max

value – Check the max alarm value setting – Check possible causes reaching min

value (i.e. broken pipe, open pressure

relief valve, etc.) – Check the min alarm value setting – Increase the ramp-up time – Make sure that the load current is at

least 10% below the VASCO nominal

current – Check the voltage drop along the

supply cable to the motor

– Check the wiring connections – Make sure the Master is not in the

Menu level; if so, exit from the level – In the STATUS of the slave (where the

alarm is displayed) try to reset the

alarm by pushing STOP button The address of each VASCO needs to be

different – Make sure buttons are not depressed – Call service assistance

Parameters menu)

11.12 Dry Running

DANGER

If dry running protection occurs, VASCO will attempt to start the pump automatically.

– Be sure to cut power before attempting maintenance

NOTE: If the pump’s cosphi is lower than the dry-running cosphi for at least 2 seconds,

VASCO will stop the pump. VASCO will try to run the pump every 10, 20, 40, 80, 160 minutes and then the pump is stopped

VASCO will stop the pump if the input motor current is higher than the set motor current for an extended time. By pressing the START button it is possible to run the pump again.

VASCO will stop the pump if the input voltage is higher than the set voltage for an extended time. By pressing the START button it is possible to run the pump again. VASCO will stop the pump if the input voltage is lower than the set voltage for an extended time. By pressing the START button it is possible to run the pump again.

11.13 COMBO Function (Systems with multiple pumps)

In the “Control parameters” menu it is possible to enable the COMBO function that allows serial communication between up to 8 VASCOs, each one connected to a pump.

To achieve the COMBO function in a system consisting of several interconnected VASCOs, a pressure sensor is connected to each VASCO. The value of the set pressure is communicated to the slaves via the serial port

11. VASCO V209 and V214 Pump Controllers

Figure 11.21: RS485 Serial Communication

VASCO’s communication is made through a private protocol using the RS485 port. Each VASCO must be connected to each other by using a tripolar cable (0.5 mm2) wired on S+,S-,G pins on control board.

11.14 Master Setup

1) Supply power to the VASCO inverter

2) If not yet completed, perform the initial configuration - see Table 1.3: Initial Configuration

3) Initial view is shown:

4) Scroll until:

5) Press ENT:

6) Press ENT

7) Insert password (default 001).

8) Scroll until:

MASTER: address 00

Inv: ON/OFF Mot: ON/OFF p_mis=XX.X [bar]

Menu ENT to access

Menu Control param.

SLAVE 1: address 01

SLAVE 2: address 02

9) Set ON

10) Set:

11) Press STOP (red button)

12) Press STOP again

11.15 Slave Setup

Follow master setup until point 11.

COMBO ON/OFF

Address xx

Alternance ON/OFF

Start delay AUX t = XX [s]

00 VASCO’s address in parallel operation

– 00: VASCO master

OFF Function to allow alternating between the VASCOs connected in parallel

in orderto allow equal use of each pump in the group; in this way Master will reorganizethe starting priority of the pumps by checking the life of each of them.

0 Delay time with which the slaves start after the variable speed pump has

reachedthe maximum frequency and the pressure value has fallen below set value – deltacontrol.

11. VASCO V209 and V214 Pump Controllers

NOTE: In case of failure of master in a Combo system, will be replaced by slave. As a

consequence, all parameters must be setup independently on each inverter, master mode.

In case of alarm or failure of a pump in a Combo system, this pump’s operation will be replaced (temporary or permanently) by another pump.

In case of failure of master in a Combo system, it will be replaced by the next slave after about 1 minute. In order to enable master replacement Autorestart must be set ON in each slaves

11.16 Troubeshooting

LCD does not switch on after powering the VASCO – Check the connecting flat cable between the

Power line of VASCO is interrupted by the differential protection contactor

When performing sensor test operation, SENSOR OFF alarm occurs

Frequency and pressure oscillation on constant pressure control mode

Measured pressure drops too much before VASCO starts the pump.

Problem Suggested Actions

LCD board (attached to the cover) and the

control board – Check the fuses – Check that the power cables are properly

connected – Check the leakage current to ground of EMC

filter – Following a rapid off/on the power supply, the

differential contact can interrupt the power.

After turning off the VASCO it is

recommended to wait at least 1 minute

before restarting – Check that the sensor cable is properly

connected to the sensor device and to the

VASCO – Make sure that the sensor and its cable are

not damaged – Check that the operating range of sensor is of

4-20 mA type and the value of 15 V is within

the voltage feed range of the sensor – Check if the water tank and its air pressure are

correctly set. It may be necessary to increase

the tank volume or reduce the pre-charge

pressure. – Check the ki & kp parameters (Control

parameters menu). At first, it is suggestible to

increase the Ki value. If it not enough reduce

of one unit the Kp value – Decrease the delta start value (Control

Parameters menu) – Check to see if the water tank and it’s air

pressure are correctly set. It may be necessary

to increase the tank volume or reduce the

pre-charge pressure – Modify the value of ki & kp parameters

(Control Parameters menu). At first, it is

suggestible to reduce the Ki value. If it is not

enough increase of one unit the Kp value

Dutypoint Limited

Shepherd Road

Gloucester

GL2 5EL

United Kingdom

T: +44(0)1452 300592

W: www.dutypoint.com

Dutypoint Scubatank WX User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

ScubaTANK WX

Operation and Maintenance Manual

Table of Contents

Operation and Maintenance Manual

ScubaTANK WX1 and WX2

1.1 Health & Safety at Work Act 1974

1.2 Safety Messages and Hazard Statement

1. Important Safety Information

1.3 Qualified Personnel

1.4 Environmental Protection

1.5 Mechanical Device Servicing

1.6 Pump Hand Control Mode (Where Fitted)

1.7 Personal Protective Equipment

1.8 Precautions Before Commencing Work

1.9 Precautions During Work

1.10 Hazardous Fluids and Chemicals

1.11 Electrical Safety - High Voltages

1.12 Electronic Safety Devices

1.13 Spare Parts

1.14 Transportation and Lifting

1.15 Storage

2. Specifications

2.1 Identifying ScubaTANK Models

3.1 Position and Secure the Tank

3. Installation Sequence

3.2 Cleaning the Filter

3.3 Hydraulic Connection

3.4 Electrical Supply

3.5 How to Seal a Horizontal Split Tank (Applicable to -HS Models)

3.6 Bolt Tightening Sequence for Split Tank Flange Assembly

3.7 Level Probe Details

4.1 Installation and Commissioning Overview

4. Booster Set Commissioning

4.2 Pipework and mechanical components

4.3 Electrical

4.4 Low Level Float Switch Wiring (Optional)

4.5 Final Checks Before Commissioning

4.6 Pressure Vessel Pre-Charging

4.7 Venting Pumps

4.8 Procedure for flooded suction

4.9 Procedure for Lift Suction

4.10 Programming the Controller

4.11 Operation and Performance Tests

4.12 Duty/Standby Twin Pump Sets

4.13 Duty/Assist Twin Pump Sets

4.14 Commissioning/Handover Check

5.1 VASCO Display

5. Operating the Pump Set

6.1 Installation Safety Notes

6. Pressure Vessel

6.2 Periodic Maintenance

6.3 General Maintenance and Repair

6.4 Pressure Vessel Pre-Charge Instructions

6.5 Diaphragm Replacement

6.6 Installing a Replacement Vessel

7. Booster Set User Maintenance

8. XPW Pump Maintenance

8.1 Routine Maintenance

8.2 Pump Replacement

8.3 Replacement Procedure

8.4 Checking the Direction of Rotation

9. Pressure Set Point Adjustment

10. Troubleshooting

10.1 Fault Codes: Advanced

11. VASCO V209 and V214 Pump Controllers

11.1 Introduction

11.2 Important Safety Information

11.3 Technical Specifications

11.4 Electrical Wiring

11.5 Electromagnetic Compliance

11.6 Motor Mounted Installation

11.7 Remote/Wall Mounted Installation

11.8 Operation and Programming

11.9 Control Modes

11.10 Parameters

11.11 Protections and Alarms