Transcript
SPARTAN CONTROLS LTD
AQUAMASTER Pressurisation Unit
Installation Operation & maintenance Instructions Spartan Controls Ltd Waterside Tomo Trading Estate Packet Boat Lane Cowley Uxbridge Middlesex UB8 2JP Tel 01895 440428 Fax 01895 440431 E-mail
[email protected]
Page 2 Please read carefully STORAGE 1. Store in a dry place 2. Protect against dirt and damage GENERAL NOTES 1 The Aquamaster set includes one or two pumps operating on a duty or duty/standby basis, and are employed to maintain the pressure setting within a closed loop heating or chilled water system. 2 Each set is custom built for a specific application and any changes in the system may necessitate a change in the settings. 3 The system must be completely flushed out, to remove any metal particles, dirt, ect., which may damage the set. 4 The system should be pressure tested to eliminate all leaks. 5 Important a) Under no circumstances, must any attempt be made to introduce water treatment other than anti-freeze to the system via the break tank. b) No part of the set connecting pipe or expansion vessel to be lagged. INSTALLATION 1 Install the Aquamaster to the wall, direct, or bracketed, making sure the unit is level. 2 Connect the cold water mains supply, via a stop cock, to the ball cock in the break tank. Water supply pressure 0.8 bar minimum 3 Arrange break tank overflow pipe to discharge into a convenient drain in line with clause 30 of the water supply bye-laws 1989 edition. 4 Make the connection from the set to the return side of the boiler and the suction side of the pump at the neutral point of the system. The connecting pipe to the system should be sized to give a total resistance under 0.14 Bar
ELECTRICAL 1 The power supply required is 230V/1 phase/50Hz 2 The supply should be connected via a 13 amp fused isolator switch. 3 Wire the set volt free interlock connections from the set to the boiler control system. 4 The set must be EFFICIENTLY EARTHED. OPERATION The sequence of operation is as follows:a) Heating system With the system fully pressurised to the ambient temperature set pressure, the boiler(s) can be started. With thermal expansion, the water from the system will flow into the expansion vessel, and the system pressure will rise slowly, settling at a pressure below the setting of the boilers pressure relief valve. If the pressure relief valve lifts, check the expansion vessel residual air pressure, and the setting of the pressure switch controlling the pump. b) Chiller systems When the system is started up, the water contracts as it cools and the set will pass water from the tank via the pump. This will bring the pressure up to the ambient temperature pressure setting. When the chiller is switched off the expanding water will pass into the expansion vessel. The pressure will rise and settle at a pressure below the maximum shown on the pressure relief valve.
PLEASE NOTE In the event of a water leak in the system(s) exceeding the pump capacity, the pressure will drop and the low pressure switch on the set will contact. This will send the interlock signal to the control panel, the system should then be closed down and the leak rectified.
Page 3 SET MAINTAINANCE 1 If it is required to remove the pump or break tank, isolate the electricity and water supply, drain the break tank and remove the faulty item. 2 Should it be necessary to work on any other item, first close the main system down and allow the temperature to come down to ambient. Isolate the set and release the water via the drain valve. 3 After re-assembly, fill the break tank, start the set and allow it to pressurise. After, open the system isolation valve. The system is now ready for operation. 4 Check operation of the float mechanism an adjust accordingly. 5 Approximately every 6 months, or in the event of failure, a thorough examination of the installation should be conducted. 6 In the event of replacing the expansion vessel membrane, the inside of the vessel should be clean and dry. It should also be checked for corrosion. 7 During servicing, we recommend that the valve to the system is shut, and then allow 50 litre of water to be pumped to waste. This will purge the break tank with fresh water and check the operation of the set. 8 To check the pressure in the expansion vessel, shut the system down and allow it to settle at ambient temperature. Then isolate the set, switch off power to the unit, and drain off all water in the unit via a drain cock. The vessel charge pressure can then be checked, and adjusted accordingly. This pressure must be the same as the cold fill pressure to the system. PUMP MAINTENANCE 1 Pump and motors within the Aquamaster are not repairable, and a new unit must be fitted. 2 Please also replace the diode on the mains supply to the pump from the control board
NOTE:THE USE OF ANY SPARE PARTS NOT SUPPLIED BY SPARTAN CONTROLS LTD WILL INVALIDATE THE GUARENTEE AND PRODUCT RESPONSIBILITY OF SPARTAN CONTROLS LTD. METHOD STATEMENT FOR COMMISSIONING 1 Power supply Check that the power supply is correctly made up and that the voltage matches the details on the motor name plate. 2 Pipe connection Check the unit for correct pipe configuration, and that the expansion vessel and system connections are correct. 3 Float valve operation Check the positioning of the float valve within the tank and ensure correct fill level is reached. Check supply pressure from water mains is adequate, (0.8-6.0 Bar) 4 Vessel Air Pressure Check the vessel pressure before filling the unit and system, and ensure the air pressure is the same as cold fill pressure. 5 Pumps No venting is necessary as the pump is self priming, and will pull the water through. 6 Pressure Switches Check pressure switches are set correctly, and that high and low limits have been set as required. 7 Non return valve Check if NRV’s are functioning correctly. This can be achieved by pressurising the unit and allowing the set to cut out on pressure. I fthe pressure drops then the NRV has failed. 8 Leak check Finally, check the whole unit for any leaks, this should be done by operating the unit to full pressure and allowing at least 10 minutes before inspection. 9 If the volt free interlock is fitted, check the function of the unit by simulating low/high pressure conditions via the pressure switches.
Page 4 AQUAMASTER FAULT FINDING CHART 1
Pump runs continuously
Symptom/cause Very high leakage rate
Faulty electrics
Set pressure too high
2
Pump will not run
Symptom/cause Pump(s) tripped Faulty electrics
Pump burnt out/seized
3
Action Check for system leaks. Check for split vessel bag. Check NRV is not leaking Check wiring for any loose connections, and fuses are not blown on PCB Check pump pressure switch settings with commission sheet
Action Check fuses on PCB Check for any loose or burnt wires in pump. Check diode on pump live feed Repair or replace pump
High pressure
Symptom/cause Incorrect air capacity of expansion vessel
Pumps running continuously
Action Check calculation of system expansion, and air pressure set correctly in vessel. Check setting of control pressure switch
4
Low Pressure
Symptom/cause Pump(s) tripped
Pump(s) burnt out System leakage very high rate Low break tank water level Deliver suction valve closed Suction from tank blocked Pressure switch fault
5
Action Check fuses on PCB and that pump has not seized Repair or replace pump Check system for leaks, check NRV not letting by Ensure water mains is ok and that ball valve works Open all valves Clean/replace suction pipwork Check pressure switch is set correctly and operating ok
Volt free contact
Symptom/cause Not switching off boiler/chiller
Action Check normally open or normally closed contacts are operating ok
PLEASE NOTE FAILURE TO COMMISSION UNIT BY A SPARTAN CONTROLS LTD REPRESENTATIVE MAY INVALIDATE WARRANTY If you are still having difficulties, please call Spartan Controls Ltd, 01895 440428/446788 to arrange for a service engineer to call.
