Installation, Operation & Maintenance InstructionsMicron+… · into full alarm mode. PressVal...

Installation, Operation & Maintenance Instructions

PressVal Micron Rev 1

Hoval LtdNorthgateNewarkNottsNG24 1JNTel: (01636) 672711Fax: (01636) 673532e-mail: [email protected]

PressVal Micron Pressurisation Units

2

Hoval PressVal Pressurisation Equipment

1. Introduction 3

2. Description 4

3. Delivery & Nameplates 5

4. Technical Details 6-11

5. Installation Details 12

6. Pressure Settings 13

7. Commissioning 14-17

8. Operation and Fault Codes 18-19

9. Maintenance 20

10. Wiring diagrams 21-22

11. Notes 23-27

Contents


1. Introduction

These instructions have been written to give a brief description of the PressVal Micron pressurisation units their instal-lation, commissioning, operation and subsequent maintenance.

The installation of pressurisation units and their ancillary equipment is normally carried out by the Heating Engineer, and for the purpose of this manual he is regarded as the installer, and, as such, it is his responsibility to ensure that he has read and understood the contents of this manual before installing the boiler.

It is essential that each unit has all services connected to it before commissioning.

A note should be entered below by the person responsible for the plant, giving the pressurisation unit model, refer-ence ‘K’ number, WO number, Serial No. These numbers are indicated on the nameplate which is located on the front of the break tank, inside the cabinet.

For completion by Plantroom Attendant

Unit Model: Serial No:

K No: WO No:

Commissioning Date

For technical, servicing or parts enquiries, tel-ephone, fax or e-mail to Hoval

quoting the model(s) & K number, as above

The installation should be in accordance with current I.E.E. Regu-lations, relevant British Standard and Codes of Practice, Building Regulations and Local Authority Bylaws.

Hoval Engineers will normally commission the pressurisation unit and if the heating engineer is present at the time, he will be instructed on the day-to-day operation of the unit. If this is not possible, or additional training is required, this can be arranged through Hoval.

The units pressure settings are recorded on the commission-ing report and a copy of this will be issued for retention with this manual (see example).

4


2. Description.

Hov

al

PressVal Micron

SM Micron Pressurisation unit and expansion vessels all skid mounted

CH Micron Pressurisation unit andexpansion vessels all fitted within a cabinet.

PressVal Micron Features All enclosed type unit with polyester powder coated finish in Hoval colours. No side access required to cabinet. Quick release removeable door and electrical access panel. WRC listed controls and fittings. Break tank filter. Type “A” air gap. Illuminated on/off switch. Combined lockshield / drain valves. Centrifugal pump on 125 & 225 units, Turbine pump on 180 & 280 units 1/50/220-240v supply Power supply 12v ac for all controls. Safe low voltage Relay switching 230v ac 8 amp Dual or single pump control Pump monitoring for no current or too much current draw. 4 Digit display with scrolling, to display status and alarm modes. Internal alarm with mute function. Hi/Lo water detection with alarm and auto reset. No volt free out Hi pressure alarm with volt free Lo pressure alarm with volt free Pump trip volt free x 2 Sensor fail volt free Logging for no of times each pumps has run, number of alarms and number of times power fail. Main setpoint with adjustable diff Hi and Lo alarm setpoints with manual reset. Max time run for pumps Alternates pumps each time its activated. Password entry Visual pressure reading. All volt free outputs can also be powered with a rating upto 8 amps for warning lamps or alarms. If 1 pumps fails the other will cut in displaying P1 fail P2 go activating the P1 trip relay. If P2 fails the unit locks out and goes into full alarm mode.

PressVal Micron Controller

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PressVal Micron

DescriptionApplicationPressVal pressurisation equipment is de-signed to provide automatic make-up and pressure for sealed heating, chiller, and condensor systems.

General DetailsThe PressVal Micron pressurisation unit is a microprocessor controlled unit. Single and twin pump options are available to work up to the following pressures:

Pump Pump Maximum Model Type Pressure 125 Single 2.5 225 Twin 2.5 180 Single 8.0 280 Twin 8.0 130 Single 3.0 230 Twin 3.0

Expansion vesselsStandard expansion vessels with fixed diaphragm are available as follows:

Vessel Vessel Maximum Volume Configuration Pressure 2-1000 litres Vertical 6 bar110-1000 litres Vertical 10 bar

Non standard expansion vessels with interchangeable diaphram, inspection cover and pressure gauge are available as follows:

Vessel Vessel Maximum Volume Configuration Pressure 80-8000 litres Vertical 6 bar 80-8000 litres Vertical 10 bar 400-12500 litres Horizontal 6 bar 400-10000 litres Horizontal 10 bar

Details of the expansion vessels are shown on pages 9 and 10

Equipment ConfigurationsPressVal Micron equipment is supplied in the following configurations:

FS Micron Pressurisation unit with free standing expansion vessels.

Mini Micron Wall mountedpressurisation unit with separate expansion vessels for small systems.

PressVal MicronPressVal Micron

Hoval


The pressurisation unit and its associated equipment are normally delivered by our own transport on a mutually agreed date.

The unit can be offloaded by a crane lorry if specifically booked at the time of ordering, (this is normally an extra). The equipment is normally supplied on a pallet for offloading via a fork lift truck. It can be craned off using slings.

On delivery, the installer should check all items against the delivery note and should then store them in a safe and dry place.

The model type and size is detailed on the units nameplate. A copy of this is stuck to the packaging for easy reference.A typical nameplate is detailed right.

From the model reference you can work out the specification of the unit:

3. Delivery & Nameplates

Delivery

Model: PressVal FS Micron 425/1.0-225

Product Range

Configuration

Type of Control

Expansion vessel volume (litres)

Expansion vessel gas charge (bar)

Number of pumps

Maximum Cold fill pressure (metres wg)

Hoval Ltd. Northgate, Newark, Notts. NG24 1JN Tel: (01636) 672711. Fax: (01636) 673532

Model: PressVal FS Micron 425/1.0-225Serial No. HFS 04501Contract No. K64000Supply: 1ph / 50Hz / 230VWO No. WO 05000

Made in UK

Nameplates

Each expansion vessel will have its own data plate. An example of which is shown on the right.

Hoval Ltd. Northgate, Newark, Notts. NG24 1JN Tel: (01636) 672711. Fax: (01636) 673532

Type: PressVal 425/1.0

Volume: 425 litres

Gas charge: 1.0 bar

Max working pressure: 6 bar

Max temperature: 70 oC

Standard: BS4814

Serial number: K64000

Date of supply: 02/04

Made in UK

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PressVal FS Micron

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PressVal Micron

Hoval Hoval

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PressVal Micron

Hoval

Models

PressVal FS Micron 35











Models

PressVal FS Micron 2x425




4. Technical Details

Connections (All units)

1. System connection 1/2”bsp M

2. Expansion vessel connection 1/2”bsp F

3. Cold mains connection 1/2”bsp M

4. Overflow 22mm

5. Cable entry

Front View Side View

Front View Side View

Service connections (rear view)

1 234

5

AB

C

D

EF

EF

B

C

D

A

PressVal FS Micron Type 35 50 80 110 140 200 300 425 600 800 1000 2x425 2x600 2x800 2x1000

Dimensions:

A 781 822 904 469 869 869 985 1175 1175 1175 1175 1975 1975 1975 1975

B 375 375 375 375 375 375 375 375 375 375 375 375 375 375 375

C 945 945 945 945 945 945 945 945 945 945 945 945 945 945 945

D 416 473 540 780 950 1296 1330 1180 1540 1890 2270 1180 1540 1890 2270

E 465 465 465 465 465 465 465 465 465 465 465 465 465 465 465

F 396 437 519 484 484 484 600 790 790 790 790 790 790 790 790

Dry Weight:

(125 single pump unit) 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26

(225 twin pump unit) 35 35 35 35 35 35 35 35 35 35 35 35 35 35 35

(180 single pump unit) 27 27 27 27 27 27 27 27 27 27 27 27 27 27 27

(280 twin pump unit) 37 37 37 37 37 37 37 37 37 37 37 37 37 37 37

(Expansion vessel - 6 bar) 12 15 22 29 33 42 57 76 93 182 211

Clearance / Access (All units)

Rear clearance: 100mm is required at the back of the pressurisation unit to pipe up.Front clearance: 600mm is required in front of the pressurisation unit for access to the unit.Side clearance: No side clearance requiredTop clearance: 400mm is required above the pressurisation unit for access to the electrical panel.


PressVal SM Micron

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PressVal Micron

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PressVal Micron

Hoval

Hov

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PressVal Micron

Hoval Hoval

A

A

B

B

C

B

C

D

A

E

F

C

D

E

F

E




2. Expansion vessel connection 1/2”bsp F


4. Overflow 22mm

5. Cable entry

Service connections (rear view)

1 234

5

PressVal SM Micron Type 25 50 80 110 140 200 300 425 600 800 1000 2x425 2x600 2x800 2x1000

Dimensions:

A 685 685 1000 1000 1000 1000 1000 1170 1170 1170 1170 2000 2000 2000 2000

B 375 375 375 375 375 375 375 375 375 375 375 375 375 375 375

C 945 945 945 945 945 945 945 945 945 945 945 945 945 945 945

D 945 945 1095 1095 1100 1446 1480 1330 1660 2030 2420 1330 1660 2030 2420

E 465 465 465 465 465 465 465 465 465 465 465 465 465 465 465

F 465 465 600 600 600 600 600 800 800 800 800 800 800 800 800

Dry Weight:

(125 single pump unit) 42 47 76 91 99 106 136 156 191 226 246 291 324 392 431

(225 twin pump unit) 51 56 85 100 108 115 145 165 200 235 255 300 333 401 440

(180 single pump unit) 43 48 77 92 100 107 137 157 192 227 247 292 325 393 432

(280 twin pump unit) 53 58 87 102 110 117 147 167 202 237 257 302 335 403 442

Clearance / Access (All units)Rear clearance: 100mm is required at the back of the pressurisation unit to pipe up.Front clearance: 600mm is required in front of the pressurisation unit for access to the unit.Side clearance: No side clearance requiredTop clearance: 400mm is required above the pressurisation unit for access to the electrical panel.

Models

PressVal SM Micron 2x425




Models

PressVal SM Micron 25


F

Models










8


PressVal CH Micron

A B

C

PressVal CH Micron Type 25 35 50 80 110 140 200 300 425 600

Dimensions:

A 680 680 680 680 680 680 730 730 940 940

B 680 680 680 680 680 680 730 730 940 940

C 1200 1200 1200 1200 1590 1590 1970 1970 1800 2290

Dry Weight:

(125 single pump unit) 85 87 91 96 115 119 139 171 216 258

(225 twin pump unit) 94 96 100 105 124 128 148 178 225 267

(180 single pump unit) 86 88 92 97 116 120 140 172 217 259

(280 twin pump unit) 96 98 102 107 126 130 150 180 227 269

1

3

2

4




3. Overflow 22mm

4. Electrical terminal box

Clearance / Access (All units)Front clearance: 600mm is required in front of the pressurisation unit for access to the unit.Rear clearance: No rear clearance required**Side clearance: No side clearance required**Top clearance: No top clearance required**

** Note clearance for pipe work and electrical cables will have to allowed for. Entry into the unit is left for the contractor to decide.

PressVal Mini Micron

PressVal MicronPressVal Micron

Hoval

480

210 150




3. Overflow 22mm

4. Cable entry

Clearance / Access (All units)Front clearance: 600mm is required in front of the pressurisation unit for access to the unit.Rear clearance: No rear clearance requiredSide clearance: 100mm left side clearance required to pipe upTop clearance: 300mm top clearance required for electrics

4

3

1

2

Only suitable for use with expansion vessels up to 300 litres

Electrical details:1ph / 50Hz / 230V

48 W motor, Fuse 3ADry Weight: 6kg



Standard Range

High Pressure Range

SpecificationSteel Construction: To BS 4814:1990Sizes up to 80 litre: Deep Drawn with separate clench joint as defined in BS 4814:1990Sizes 110 to 1000: All weldedDiaphragm: Flexible rubber with stress free rolling action* Max temp: Temperature of fluid in contact with diaphragm. The use of these vessels in systems operating at higher temperatures can be achived with the use of an intermediate vessel.Sizes up to 25 litres: Mounting brackets available on request.

PressVal Model 110 140 200 300 425 600 800 1000Volume (litres) 110 140 200 300 425 600 800 1000

Max pressure (bar) 10 10 10 10 10 10 10 10

Max temperature (oC) 70* 70* 70* 70* 70* 70* 70* 70*

System Conn’ (C) (bsp) 1” 1” 1” 1” 1” 1” 1” 1”

Dimensions:

Diameter (D) (mm) 484 484 484 600 790 790 790 790

Height (H) (mm) 780 950 1296 1330 1180 1540 1890 2270

Dry weight (kg) 38.5 44.6 49.3 73.7 105.5 132.0 181.8 211.0

PressVal Model 2 4 8 12 18 25 35 50 80 110 140 200 300 425 600 800 1000Volume (litres) 2 4 8 12 18 25 35 50 80 110 140 200 300 425 600 800 1000

Max pressure (bar) 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6

Max temperature (oC) 70* 70* 70* 70* 70* 70* 70* 70* 70* 70* 70* 70* 70* 70* 70* 70* 70*

System Conn’ (C) (bsp) 3/4” 3/4” 3/4” 3/4” 3/4” 3/4” 3/4” 3/4” 1” 1” 1” 1” 1” 1” 1” 1” 1”

Dimensions:

Diameter (D) (mm) 194 194 245 286 328 358 396 437 519 484 484 484 600 790 790 790 790

Height (H) (mm) 152 257 280 313 306 359 416 473 540 780 950 1296 1330 1180 1540 1890 2270

Dry weight (kg) 2.2 3.1 4.4 5.8 7.5 9.6 11.8 15.1 22.1 29.0 32.5 41.6 56.9 76.4 92.9 181.8 211.0

PressVal 2 to 25

C

D

H

PressVal 110 to 1000

H

D

C

PressVal 35 to 80

D

C

H

Hoval

PressVal standard expansion ves-


Hoval

Hoval

Hoval

DrainCock

Lock Shield Valve

Recommended piping for expan-sion vessels.

AAV

Anti-gravity loop

10


C

Hoval

ODH

L

Non standard vertical expansion vessels

Non standard vertical expansion vessels

Non standard horizontal expansion vessels

PressVal HHH

Non standard horizontal expansion vessels

HovalPressVal VHH

PressVal Model VHH 80 400 600 800 1000 1200 1600 2000 2800 3500 5200 6700 8000Volume (litres) 80 400 600 800 1000 1200 1600 2000 2800 3500 5200 6700 8000 Max pressure (bar) 6 6 6 6 6 6 6 6 6 6 6 6 6 Max temperature (oC) 70* 70* 70* 70* 70* 70* 70* 70* 70* 70* 70* 70* 70* Diameter (D) (mm) 550 750 750 750 750 1000 1000 1200 1200 1200 1500 1500 1500Height (H) (mm) 660 1335 1755 2155 2710 1940 2440 2180 2800 3600 3420 4310 5090Dry weight (kg) 45 115 145 180 215 285 340 425 510 620 1050 1200 1410

PressVal Model HHH 400 600 800 1000 1200 1600 2000 2800 3500 5200 6700 8000 10000 Volume (litres) 400 600 800 1000 1200 1600 2000 2800 3500 5200 6700 8000 10000 Max pressure (bar) 10 10 10 10 10 10 10 10 10 10 10 10 10 Max temperature (oC) 70* 70* 70* 70* 70* 70* 70* 70* 70* 70* 70* 70* 70* Diameter (D) (mm) 750 750 750 750 1000 1000 1200 1200 1200 1500 1500 1500 1500 Height (H) (mm) 980 980 980 980 1230 1230 1450 1450 1450 1700 1700 1700 1700 Length (L) (mm) 1130 1560 2030 2530 1865 2385 2100 2765 3430 3380 4250 5030 6165Dry weight (kg) 170 225 275 330 462 585 730 875 1025 1692 1972 2342 2540

PressVal Model HHH 400 600 800 1000 1200 1600 2000 2800 3500 5200 6700 8000 10000 12500Volume (litres) 400 600 800 1000 1200 1600 2000 2800 3500 5200 6700 8000 10000 12500Max pressure (bar) 6 6 6 6 6 6 6 6 6 6 6 6 6 6Max temperature (oC) 70* 70* 70* 70* 70* 70* 70* 70* 70* 70* 70* 70* 70* 70*Diameter (D) (mm) 750 750 750 750 1000 1000 1200 1200 1200 1500 1500 1500 1500 1500Height (H) (mm) 980 980 980 980 1230 1230 1450 1450 1450 1700 1700 1700 1700 1700Length (L) (mm) 1130 1560 2030 2530 1865 2385 2100 2765 3430 3380 4250 5030 6165 7615Dry weight (kg) 142 175 225 268 370 440 540 635 745 1192 1382 1622 1892 2050

PressVal Model VHH 80 400 600 800 1000 1200 1600 2000 2800 3500 5200 6700 8000Volume (litres) 80 400 600 800 1000 1200 1600 2000 2800 3500 5200 6700 8000 Max pressure (bar) 10 10 10 10 10 10 10 10 10 10 10 10 10Max temperature (oC) 70* 70* 70* 70* 70* 70* 70* 70* 70* 70* 70* 70* 70* Diameter (D) (mm) 550 750 750 750 750 1000 1000 1200 1200 1200 1500 1500 1500Height (H) (mm) 660 1335 1755 2155 2710 1940 2440 2180 2800 3600 3420 4310 5090Dry weight (kg) 45 115 145 180 215 285 340 425 510 620 1050 1200 1410

OD

H

PressVal non standard expansion vessels


C

Hoval PressVal VHH (vertical) and HHH (horizontal) expansion vessels are complete with interchangeable diaphragm, inspection cover and pressure gauge.

Vessel size (litres) System connection (C) 80 DN50 400 - 3500 DN65 5200 - 12500 DN100


PressVal V Intermediate vessels

PressVal Model V 100 200 350 500 750 1000 1250 1600 2000 2500Volume (litres) 100 200 350 500 750 1000 1250 1600 2000 2500 Max pressure (bar) 10 10 10 10 10 10 10 10 10 10 Max temperature (oC) 160 160 160 160 160 160 160 160 160 160 Diameter (D) (mm) 305 457 559 672 741 741 741 905 1072 1072 Height (H) (mm) 1760 1620 1830 1830 2170 2910 3410 3060 2750 3250 Connection (C) (bsp/PN16) 1.1/2” 1.1/2” 2” 2” 65 65 65 80 80 80Dry weight (kg) 120 130 150 210 275 398 478 640 789 960

Key Features Vessels up to 7 Bar g and 120°C are constructed to BS 853. Vessels above 7 Bar g and/or 120°C are constructed to PD5500:2000. Tall slim design encourages thermal stratification with the inlet at the top and the outlet at the bottom to prevent natural circulation. Test certificates available. System connections shown in table are general and may change to suit installation. Other vessels are also available, i.e. storage and chilled water buffer vessels. Other vessels and volumes can be made to suit specific needs.

DescriptionHoval PressVal Intermediate Vesselsprovide effective temperature reductionof expanded water in systems operating above 90°C. Installed between the sys-tem return and the expansion vessel(s), the Hoval PressVal Intermediate Vessel prevents high temperature expansion water coming into contact with the ex-pansion vessel diaphragm.Please note that to aid heat dissipation, the intermediate vessel, together with the pipework to and from it, should not be insulated.For HTHW systems, use a Nitropressurisation unit, details on request.

C

D

H

PressVal Model V 100 200 350 500 750 1000 1250 1600 2000 2500Volume (litres) 100 200 350 500 750 1000 1250 1600 2000 2500 Max pressure (bar) 7 7 7 7 7 7 7 7 7 7 Max temperature (oC) 120 120 120 120 120 120 120 120 120 120 Diameter (D) (mm) 305 457 559 672 741 741 741 905 1072 1072 Height (H) (mm) 1760 1620 1830 1830 2170 2910 3410 3060 2750 3250 Connection (C) (bsp/PN6/16) 1.1/2” 1.1/2” 2” 2” 65 65 65 80 80 80Dry weight (kg) 120 130 150 210 275 398 478 514 720 891

SizingIntermediate vesselvolume (litres)

% of expansion volume athighest system temperature (see table below)

=

Flow temperature % of expansion oC volume 90-110 15 111-125 25 126-140 40

Please Note that intermediate vessels are only required on systems operating above 90 oC boiler flow temperature. Small systems may have sufficient volume in the pipe work to the expansion vessel, on these oc-casions an intermediate vessel may not be required. For confir-mation please call Hoval Techni-cal.

PressVal intermediate vessels


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5. Installation Details Pressure equipment directive

Code of Practice: Refer to B.S. 7074.

Regulations and Standards covering Sealed System Equipment: HSE-PM5 Guidance Document. Water Bye-Laws.

HSE Pressure Systems and Transport-able Gas Container Regulations. (Expan-sion vessels do not currently require any routine inspection or checking under the written scheme of examination).


6. Pressure Settings

Before you can commission the Press-Val Micron pressurisation unit you will need to know the following pressure settings:

Cold fill pressure.

High cut out pressure.

Low cut out pressure.

Cold fill pressure.The cold fill pressure is the initial pres-sure that the pump needs to generate to pressurize a system at its highest point.

On LTHW systems this should be set at 0.3 bar above the static height pressure, this extra pressure will allow any air to be expelled from the highest point of the system. For example a system with a static height of 10 metres has an approximate static pressure of 1.0 bar. So the cold fill pressure should be set at 1.30 bar.

On MTHW systems operating above 100oC it is necessary to ensure that the water at the highest point in the system does not flash off to steam. Therefore it is necessary to add an anti-flash margin pressure on to the static height pres-sure. The table right shows the anti-flash pressure at differing flow tempera-tures. For example on a system with a static height of 10 metres and operating at 120oC flow, the cold fill pressure would be 3.30 bar

High pressure cut out .The high pressure cut out setting is the maximum pressure that the system will run at before it locks out. This is a safety feature to prevent over pressurizing a system.The high pressure cut out should be set 0.3 bar below the safety valve setting.

Low pressure cut out .The low pressure cut out setting is the minimum pressure that the system will run at before it locks out. This is a safety feature to prevent the system from run-ning without sufficient water in it.The low pressure cut out should be set 0.3 bar below the cold fill pressure.

Operating pressure.On a pressurized system the pressure will vary between the high and low pres-sure settings. This is dependent on the mean system temperature.

Maximum operating pressure.The maximum operating pressure of a system is the lowest maximum operating pressure that any component in the system is suitable for. This may be the boiler or a vessel or an indirect calorifier etc.

Final (hot) operating pressure.The final (hot) operating pressure depends on how the expansion vessel(s) have been sized. The smaller the expansion vessel volume is the greater the final working pressure will be.

On systems where the cold fill pressure is close to the maximum operating pressure you can expect to see a large expansion vessel volume in relation to the system volume.

To check the size of the expansion vessels you can use the following calculation:

VesselSize = System water content x Coefficient of expansion

Expansion vessel efficiency

Exp

ansi

on c

oeffi

cien

t

Coefficient of expansion

Please note that for systems con-taining antifreeze the coefficient of expansion will increase. Details of the different expansion coefficients can be found in BS7074.

VE = Final pressure - Cold fill pressureFinal pressure

Expansion vessel size

Expansion vessel efficiency

(bar abs)

Ant-flash Margin at flow Temp

oC Bar 100 0.78 101 0.85 102 0.92 103 0.99 104 1.03 105 1.12 106 1.18 107 1.23 108 1.32 109 1.38 110 1.47 111 1.53 112 1.62 113 1.70 114 1.78 115 1.86 116 1.94 117 2.03 118 2.13 119 2.22 120 2.30 121 2.40 122 2.50 123 2.62 124 2.70 125 2.81 126 2.92 127 3.05 128 3.16 129 3.35 130 3.36 131 3.50 132 3.65 133 3.76 134 3.86 135 4.01 136 4.15 137 4.26 138 4.45 139 4.56 140 4.74

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Control UnitPower to the unit is controlled via a on/off switch located next to the controller.This is not an integral part. The unit be-comes live once power is supplied.

The unit will not register until the system is full of water and pressure is sensed at the transducer. It will give the reading below and sound an audible alarm. This prevents the unit being used to fill the system. Once the system is filled the unit can be programmed.

Gaining access to the programme and stored information.To enter the programme mode and to set the unit up a password needs to be entered.The password is common on all unitsPress + & - keys.Simultaneously and hold for 2 seconds. Then release. Then enter the code shown on right using the + & - and set keys again.

The first reading is the number of times pump 1 has run.This scrolls on the screen.

It can register up to 999 starts

Technical details• Power Supply: AC 12v +/-10% 50/60 Hz• Pressure Sensor: simulated with a Trimmer/ DC12V supply• Range of Measurements: 0-9.9 Bar• Alarm Outputs: All normally open, AC 250v 8A• Boiler Interlock: Normally Closed, AC 250v 8A• Audible Alarm: Internal Buzzer• Suitable for plantroom temps: 0-50oC

• Suitable for plantroom humidity: 30-85% without condensation

7. Commissioning

1 2 3 4

Key Key Function 1 Displays pressure value/ Parameter memorization 2 Buzzer mute / Instrument reset / Pump 1 override 3 Parameter value increase by 0.1 bar 4 Parameter valve decrease by 0.1 bar


By pressing the Set Key you will move to the next reading. This is the number of alarms registered.

This can register up to 9999 alarms

By pressing the Set Key you will move to the next reading. This is Pump 2.As the unit autocycles this will be differ-ent to pump 1.

It will be within 1 digit unless pump 1 has been operated manually. The unit will always start on pump 1 after power failure as well.Pump 2 cannot be operated manually

By pressing the Set Key you will move to the next reading. This is the number of power interruptions registered.

This can register up to 9999 interruptions.

7. Commissioning

16


By pressing the Set Key you will move to the next setting:High pressure alarmIt is prefixed with letter H

By using the +/- key the correct pres-sure can be entered

To accept the setting and move to the next setting press the set key.

By pressing the Set Key you will move to the next setting:Low pressure alarmIt is prefixed with letter L

By using the +/- key the correct pres-sure can be entered

To accept the setting and move to the next setting press the set key

By pressing the Set Key you will move to the first setting:Fill pressure.It is prefixed with letter P

By using the +/- key the correct pressure can be entered

To accept the setting and move to the next setting press the set key.

At this point if the p1 Override is pressed the pump will run

7. Commissioning

By pressing the Set Key you will move to the next setting:Pump on/off differentialIt is prefixed with letter D

By using the +/- key the correct differ-ential can be entered

It can be altered any amount as long as it does not conflict with any other setting

To accept the setting and move to the next setting press the set key


By pressing the Set Key you will move to the next setting:Max Pump run timeIt is prefixed with the letters DELP

By using the +/- key the correct value can be entered in 10 minute increments

It can be set between 0-990 mins. Set-ting at 0 disables the function.

RECOMMEND SETTING 10 MINUTES

To accept the setting press set.

The unit will then scroll SYS GO and start to operate

7. Commissioning

18


8. Operation & Fault Codes

To display the actual working pressure press the Actual pressure button.

The pressure will be shown in bar g.

To override pump 1 press P.1 OVERRIDE button. Pump 1 should run.

L.P. Fault occurs if a leak is too great for the pump to keep up the unit will go into “Low pressure” lock out. If wired back to the boilers / BMS system this will shut down the boiler / chiller / condenser plant.

Check the pressure settings and check for leaks within the system.

H.P. Fault occurs if the pressure in the system rises above the high pressure setting.

Check the pressure settings and system temperature. Check expansion vessel sizing. Ensure diaphragm is not leaking. Check expasion vessel gas charge, you will need to isolate and drain the vessel down before checking the pressure.

L.H.2.O. Low water in break tank.

Check incoming water mains. Check ball / float valve.

Operation

Fault Codes


H.H2O. High water in break tank.

Check ball / float valve.

P.1.Fail Fault occurs if pump number one fails.

Check the pump.

P.2.Fail Fault occurs if pump number one fails.

Check the pump.

DEL.P1 or P2. Max pump run time has elapsed for either pump 1 or 2.

Check system for major leaks.

ERR.1 Full fault condition.

Check system pressure. Check sen-sors. Cjeck pumps. Check water supply. Check electrical supply.

To reset switch unit of and on.

Fault Codes

8. Operation & Fault Codes

20


FUNCTIONS OF THE KEYS

“SET” KEY

• Allows to store data in the EEPROM during parameter programming, to pass on to next parameter for programming, and to exit from the instrument SETUP mode

“BUZZER MUTE / RESET / P 1. OVERRIDE” KEY

• Press and release during an alarm condition to stop buzzer• Press for about two seconds to reset instrument (not in the parameter programming mode)• Press during parameter programming to activate the PUMP 1 override mode (message: P1 GO) – Note: this can only be done

with parameters P., H., L., and d.

“SETUP + “ KEY

• No function during normal controller activity• Increases the parameter value by 0,1 bar during parameter programming• By parameter dEL.P. increases the parameter value in 10 minute-steps to a max of 990 minutes

“SETUP – “ KEY

• No function during normal controller activity• Decreases the parameter value by 0,1 bar during parameter programming • By parameter dEL.P. decreases the parameter value in 10 minute-steps to a minimum of 00 minutes (disables the parameter)

“SETUP + ” and “SETUP – “ KEYS pressed simultaneously

• Depress simultaneously, and then release to enter the parameter configuration menu. In this phase any alarms are deactivated and all relay contacts are open. Exiting the parameter configuration phase with the “SET” key also resets the instrument.

9. General Microprocessor Information

PARAMETER CONFIGURATION

Code Description Limits Resolution Description

P. Mid Set Point 0.0…(H.-0.1) 0.1 bar This is the ideal pressure that must be reached after an intervention of pump 1 or 2.H. High pressure (P.+0.1)…9.9 0.1 bar This is the maximum limit pressure value of the water in the system.L. Low pressure 0.0…(P.-0.1) 0.1 bar This is the minimum limit pressure value of the water in the system.d. Differential 0.0…L. 0.1 bar This is the value which, when subtracted from the Mid Set Point “P.”, fixes the intervention threshold limit value of the controller. dEL.P. Max pump activity time 00…990 min 10 minute-step increases to max 990 minutes



TROUBLE SHOOTING

ALARM MESSAGES (Note: the alarm messages listed below are the single alarms that can appear together with other alarms and in that case are then the sum of each alarm condition)

Alarm Messages Cause Controller Intervention H. H2O Float intervention at MAX FLOAT LEVEL Opens the relay of PUMP 1 or PUMP 2 . L. H2O Float intervention at MIN FLOAT LEVEL Opens the relay of PUMP 1 or PUMP 2 . H.P. Exceeding the upper plant water pressure limit Activates the acoustic signal, closes the High PRESSURE relay, opens the BOILER relay. L.P. Exceeding the lower plant water pressure limit Activates the acoustic signal, closes the LOW PRESSURE relay, opens the BOILER relay. P.1 FAIL Pump 1 failure Closes the PUMP 1 FAILURE relay (however, the plant is operating correctly). P.2 FAIL Pump 2 failure Closes the PUMP 2 FAILURE relay (however, the plant is operating correctly). P.1 FAIL P.2 FAIL Both pumps are defect Activates the acoustic signal, closes the PUMP 1 FAILURE relay, closes the PUMP 2 FAILURE relay, opens the relay of PUMP 1 or PUMP 2, opens the BOILER relay. dEL. P1 dEL.P. parameter time setting reached Activates the acoustic signal, opens the relay of PUMP 1, opens the BOILER relay. dEL. P2 dEL.P. parameter time setting reached Activates the acoustic signal,

Besides the alarm signals, the controller can give six warning messages as indicated below.

WARNING MESSAGES

Warning Messages Meaning

SYS. GO Normal plant operation, closes the boiler relay

P.1 GO PUMP 1 running, closes the boiler relay

P.2 GO PUMP 2 running, closes the boiler relay

Err. Wrong password

Err. 1 Sensor failure, closes the sensor failure relay

Cod. Appears for 1 second before password insertion

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Maintenance periodPressVal pressurisation equipment should be periodically checked once per heating season.Maintenance checksThe following checks should be carried out:1) Drain down expansion vessels and test gas charge in vessel. This should be the same as detailed on the expansion vessel dataplate. Over time the gas charge in the vessel will permiate through the diagragm. If the gas charge is less than the stated pressure pump air back in the vessel using a compressor. 2) Check ball valve operates3) Check pumps operate. This can be done by isolating the unit on its lock shield valve and opening the drain valve.4) Check number of times the pumps have operated by following the comssioning procedure.5) Check settings are the same as on the commissioning report.6) Check level sensors operate by draining down the break tank.

9. Maintenance

Procedures

1. 2601 = password for access to the parameter menu.2. Password input procedure:a) simultaneously depress + and – pushbuttons briefly;b) on release the “Cod.” will be displayed; c) four zeros (“0000”) will be displayed and the first one in the blinking mode; d) use the + or – pushbutton to select the correct value; e) push the SET button to confirm the value;f) now the second “0” will blink;g) proceed like in d), e);h) now the third “0” will blink; etc, etc. 3. If the password is wrong, “Err.” will be displayed.4. If the password is correct, “P1” will be displayed for 1 second, and then the number of PUMP 1 start-up times. (To reset this number

to 0000, press the RESET pushbutton for 1 second).5. By pressing SET, “P2” will be displayed for 1 second and then the number of PUMP 2 start-up times. (To reset this number to

0000, press the RESET button for 1 second).6. By pressing SET, “ALL.” will be displayed for 1 second and then the number of times the controller had an alarm. (To reset this

number to 0000, press the RESET button for 1 second).7. By pressing SET, “L.PO.” will be displayed for 1 second and then the number of power black outs. (To reset this number to 0000

, press the RESET button for 1 second).8. By pressing SET, “P. _._” (the formerly selected two numbers) will be displayed that refer to the Mid Set Point parameter. To increase

or decrease this value, press the + or – pushbutton; once the correct value has been reached, press SET to confirm this value and to pass on to the successive parameter.

9. “H. _._” (the formerly selected two numbers) will be displayed that refer to the High Pressure parameter. To increase or decrease this value, press the + or – pushbutton; once the correct value has been reached, press SET to confirm this value and to pass on to the successive parameter.

10. “L. _._” (the formerly selected two numbers) will be displayed that refer to the Low Pressure parameter. To increase or decrease this value, press the + or – pushbutton; once the correct value has been reached, press SET to confirm this value and to pass on to the successive parameter.

11. “d. _._” (the formerly selected two numbers) will be displayed that refer to the Differential parameter. To increase or decrease this value, press the + or – pushbutton; once the correct value has been reached, press SET to confirm this value and to pass on to the successive parameter.

12. “dEL.P.” will be displayed for 1 second and the max time (in 10 minute-step increases to max 990 minutes) of pump activity can be set by pressing the + or – pushbutton; once the correct value has been reached, press SET to confirm. When setting the value to “00” the parameter is disabled.

Jumper

Select the type of pumps to be controlled by either removing or inserting the jumper, i.e., - REMOVE the jumper when using the big pumps (Model: 12HS MkIII 230V a.c. - current limit values: Min 700 mA, Max not con-

sidered)- INSERT the jumper when using the small pumps (Model: EP7 - current limit values: Min 200 mA, Max 500 mA)This selection can be made by either - shutting down the power supply to the controller and then removing or inserting the jumper, or- by removing or inserting the jumper when the controller is turned on and then pressing the RESET pushbutton.

Default parameter values (by EEPROM data loss)

P.1 = 0000, P.2 = 0000, ALL. = 0000, L.PO. = 0000, P. = 1.0, H. = 1.5, L. = 0.5, d. = 0.2, dEL.P. = 30



11. Wiring Diagram (Single Pump Units)

Procedures

1. 2601 = password for access to the parameter menu.2. Password input procedure:a) simultaneously depress + and – pushbuttons briefly;b) on release the “Cod.” will be displayed; c) four zeros (“0000”) will be displayed and the first one in the blinking mode; d) use the + or – pushbutton to select the correct value; e) push the SET button to confirm the value;f) now the second “0” will blink;g) proceed like in d), e);h) now the third “0” will blink; etc, etc. 3. If the password is wrong, “Err.” will be displayed.4. If the password is correct, “P1” will be displayed for 1 second, and then the number of PUMP 1 start-up times. (To reset this number

to 0000, press the RESET pushbutton for 1 second).5. By pressing SET, “P2” will be displayed for 1 second and then the number of PUMP 2 start-up times. (To reset this number to

0000, press the RESET button for 1 second).6. By pressing SET, “ALL.” will be displayed for 1 second and then the number of times the controller had an alarm. (To reset this

number to 0000, press the RESET button for 1 second).7. By pressing SET, “L.PO.” will be displayed for 1 second and then the number of power black outs. (To reset this number to 0000

, press the RESET button for 1 second).8. By pressing SET, “P. _._” (the formerly selected two numbers) will be displayed that refer to the Mid Set Point parameter. To increase

or decrease this value, press the + or – pushbutton; once the correct value has been reached, press SET to confirm this value and to pass on to the successive parameter.

9. “H. _._” (the formerly selected two numbers) will be displayed that refer to the High Pressure parameter. To increase or decrease this value, press the + or – pushbutton; once the correct value has been reached, press SET to confirm this value and to pass on to the successive parameter.

10. “L. _._” (the formerly selected two numbers) will be displayed that refer to the Low Pressure parameter. To increase or decrease this value, press the + or – pushbutton; once the correct value has been reached, press SET to confirm this value and to pass on to the successive parameter.

11. “d. _._” (the formerly selected two numbers) will be displayed that refer to the Differential parameter. To increase or decrease this value, press the + or – pushbutton; once the correct value has been reached, press SET to confirm this value and to pass on to the successive parameter.

12. “dEL.P.” will be displayed for 1 second and the max time (in 10 minute-step increases to max 990 minutes) of pump activity can be set by pressing the + or – pushbutton; once the correct value has been reached, press SET to confirm. When setting the value to “00” the parameter is disabled.

Jumper

Select the type of pumps to be controlled by either removing or inserting the jumper, i.e., - REMOVE the jumper when using the big pumps (Model: 12HS MkIII 230V a.c. - current limit values: Min 700 mA, Max not con-

sidered)- INSERT the jumper when using the small pumps (Model: EP7 - current limit values: Min 200 mA, Max 500 mA)This selection can be made by either - shutting down the power supply to the controller and then removing or inserting the jumper, or- by removing or inserting the jumper when the controller is turned on and then pressing the RESET pushbutton.

Default parameter values (by EEPROM data loss)

P.1 = 0000, P.2 = 0000, ALL. = 0000, L.PO. = 0000, P. = 1.0, H. = 1.5, L. = 0.5, d. = 0.2, dEL.P. = 30

White

Brown

Yellow

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11. Wiring Diagram (Twin Pump Units)

White

Brown

Yellow


12. Notes

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12. Notes


12. Notes

PressVal Micron Rev 1

Hoval LtdNorthgateNewarkNottsNG24 1JNTel: (01636) 672711Fax: (01636) 673532e-mail: [email protected]: www.hoval.co.uk

England

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