Wilo-Comfort Series Pressurisation Unit
en
Installation and operating instructions
4 523 676-Ed.01 / 2012-05-Wilo
Models:
P130-WM
P135
P135-Midi
P160
P180
P230-WM
P235
P235-Midi
P260
P280
P135-TS
P160-TS
P180-TS
1) Installation
1.7
1.1
Wholesome water supply can be connected directly
to the float valve as back contamination is prevented
by the AB airgap within the pressurisation unit. This
unit can be connected to systems up to and
including CAT5.
Location
The following should be considered when chosing
the position of the pump set:
- The area should be dry and well ventilated
- There must be protection against frost
- There must be adequate drainage facilities
- The area must be sucure to prevent
unauthorised access/tampering
- There must be at least 1 meter clear arean in
front of panel and 0.5m at the right hand side
to aid maintenance
1.2
Foundations (Floor standing units only)
Foundations must be ridged and level, a plinth is not
essential though it will assist in keeping the set clear
of any damp. When fixing car must be taken not to
distort the set by tightening unevenly.
1.3
Wall mounts (Wall mounted units only)
Care should be taken to ensure the proposed
mounting location is suitable for bearing the load.
Appropriate wall fixings should be used in all cases.
1.4
Pipework
Pipework connections to the set should be at least
the same size as the connections of the set,. (If you
require different sizes please contact Wilo UK Ltd for
advice)
1.5
Impurities
The water should be clean of all impurities. The sand
content should not exceed 0.01g/l. The size of any
suspended bodies should not be such as to clog or
wear the hydraulic components. On dirty water
applications a filter must be installed on the suction
pipe.
1.6
Electrical connections
The installer must check that the available supply is
compatible with the voltage and frequency stamped
on the CE label. Cable and fuses used for the
incoming electricity supply must be rated to cover all
pumps running. Earth bonding in line with current
IEE regulations is the responsibility of the installer.
Water connections
Attention!
The pressurisation unit must NOT be used to fill the
system. The initial filling of the system must be
carried out by other means.
2.2
Auto Restart
This unit will automatically restart on power up after
mains failure of power down. The BMS volt free
contact 8 can be configured to mains failure if
required.
2.3
Low Pressure (LP
This parameter can be altered in the USER menu. If
the system pressure drops below the LP setting an
audible, visual and volt free alarm activates. If alarm
latching is OFF then the alarm will reset once the duty
pump has increased the pressure past the LP setting.
P180-TS
7.0
6.6
2.7
5.0
OFF
OFF
P160-TS
4.0
3.6
6.7
5.0
OFF
OFF
P135-TS
1.0
0.6
2.7
5.0
OFF
OFF
P280
7.0
6.6
8.7
5.0
OFF
OFF
P260
4.0
3.6
6.7
5.0
OFF
OFF
P235-Midi
1.0
0.6
2.7
5.0
OFF
OFF
P235
1.0
0.6
2.7
5.0
OFF
OFF
P230-WM
1.0
0.6
2.7
5.0
OFF
OFF
These values can be altered in USER mode to suit
particular site conditions by entering the password,
1234, and following the flow diagram.
P180
7.0
6.6
2.7
5.0
OFF
OFF
See fig 1. - These values can be viewed in VIEW mode
by pressing the down arrow and scrolling through the
menu. Pump configuration can be altered between
Hand-Off-Auto in this mode.
P160
4.0
3.6
6.7
5.0
OFF
OFF
Note:
On Twin System Sets each pump if responsible for
one system, therefore no standby pump exists for eith
system.
P135-Midi
1.0
0.6
2.7
5.0
OFF
OFF
Wilo-Pressurisation Units work on closed loop
pressure control via a transducer and electronic
controller. The control philosophy will allow the duty
pump to run ensuring that the CF pressure (Bar) is
constantly met. On two pump systems the duty will
rotate between both pumps after each cycle to
ensure even wear. If the duty pump fails the standby
pump will automatically start
P135
1.0
0.6
2.7
5.0
OFF
OFF
General
P130-WM
1.0
0.6
2.7
5.0
OFF
OFF
2.1
Abv.
CF
LP
HP
ES
SF
AL
Wilo-Pressurisation Units are available in 1 & 2 pump
(Duty/Standby_ configurations)
Bar
Factory Setting
Cold fill pressure
Low pressure alarm
High pressure alarm
Excess starts alarm
System fill
Alarm latching
2) Operation
2.4
High Pressure (HP)
2.9
Pump check
This parameter can be altered in the USER menu.
All Wilo pressurisation units will automatically check
the operation of the pump by running them for a
If the system pressure rises above HP setting the
short period of time if they have been inactive for a
pump stops and an audible, visual and volt free alarm long period of time.
activates. This parameter can be changed by
following flow diagram.
The pump check variables can be altered at time of
commissioning.
If alarm latching is OFF then the alarm will reset once
the system pressure has fallen below the HP setting. 2.10 Alarm latching
2.5
Excess starts (ES)
If OFF then all alarms will reset once alarm condition
has deactivated.
If ON the alarm will activate and stop the pumps if
the pump has started too many times within a set
If ON then alarms will have to be manually reset via
period of time, this will activate an audible, visual and reset button on the front panel.
volt free alarm.
2.11 Alarm log
The excess starts variables can be altered at time of
commissioning.
The alarm log, logs the last 30 alarm events and
these can be viewed from the VIEW or USER mode.
2.6
System fill (SF)
2.12 Volt free contacts
If ON will overide System Leak alarm and allow pump
to run for 24 hours or until the CF pressure has been This unit has the facility for 8 volt free alarms for
met, then the controller returns back to normal
remote monitoring,
operation.
Note:
To be used for initial System Fill during
All contacts are rated at 230V 5 Amp max.
commissioning.
Pump no. 1 fail/trip Normaly open
2.7
Pump trip
Pump no. 1 run
Normaly open
Pump no. 2 fail/trip Normaly open (If fitted)
The FLC of the pump is monitored by the controller
Pump no. 2 run
Normaly open (If fitted)
whilst running and if exceeded will stop the pump
Low Pressure
Normaly open
and activate an audible, visual and volt free alarm. On High Pressure
Normaly open
a 1 pump unit or if both pumps are stopped via a trip Excess Starts
Normaly open
alarm the boiler interlock volt free alarm is also
Low Water
Normaly open
activated.
Boiler Interlock
Normaly closed
2.8
Pump fail
The unit also has one off change over contact that is
The FLC of the pump is monitored by the controller
rated for 230V 10Amp max, which can be
whilst running and if no current is drawn it will stop
programmed at time of commissioning between:
the pump and activate an audible, visual and volt free
alarm. On a 1 pump unit or if both pumps are
- Common pressure alarms
stopped via a fail alarm the boiler interlock volt free
- Mains failure
alarm is also activated.
- Common alarm
3)
Commissioning
3.1
Pre-commissiong checks
• The pressurisation unit is piped up to
system and water is available.
• The unit is wired up correctly in accordance
with wiring diagram, that all connections
are tight and the installation has been earth
bonded to current regulations.
• System has been filled by the system fill
function or quick fill loop
3.2
Commissioning
Calculate the Cold Fill Pressure (CF):
CF= (A + 2.5)/10.2
Bar
Where A is the height of the building above the
pressurisation unit in meters. In cases of Roof Top
plant rooms the minimum CF = 0.8 Bar.
Switch pumps(s) into Auto
Test High Pressure alarm by reducing the HP setting
to 0.5 bar above the CF and running one pump in
Hand.
Test Low Pressure alarm by switching the pumps OFF,
close main discharge valve and slowly drain water
from the system via drain cock until the LP setting
has been reached.
Ensure all settings are returned to normal and all
valves are open.
Check the units and system pipework for any leaks
and flooding.
Warning!
When running the init in System Fill mode the system
leak alarm is switched OFF and the pump will
continue to run if there is a leak int he system.
Check air pressure in vessel whilst empty of water, air Note - Twin System Units (TS):
pressure should be equal to CF pressure, use nitrogen When commissioning any twin system units, the
above steps should be followed for both systems
to increase pressure if necessary.
individually.
Turn switch to OFF position.
Close all isolating valves.
Open any inlet valves to unit and allow break tank to
fill ensuring ball float valve closes before water level
is 25mm below overflow. If water does reach over
flow adjust height of ball float.
Prime each pump in turn, by opening the vent plug
on each pump.
Ensure common main discharge isolating valve is
closed.
Turn switch to ON position.
Key in password, 1234, to enter the Main Menu and
scroll through windows entering settings to suit the
installation, CF as above, LP should be at least 0.2 bar
below CF and HP which should be 0.5 bar below the
setting on system safety valve.
If the system has not been filled by a quick fill loop
the System Fill function can be utilised by selecting
ON. This will allow the pump to run for 24 hours or
until the CF pressure has been met.
4)
Maintenance
Wilo pressurisation units are designed to ensure
minimum maintenance is required. However routine
inspection is necessary and can be carried out by
Wilo, please contact our service department for
details.
Every 6 months:
Check unit for leaks.
Check for corrosion especially on vessel and ensure
water is not present when Schrader valve (on top of
vessel) is pressed down.
Every 12 months:
Check pump set for leaks.
Check for corrosion especially on vessel and ensure
water is not present when Schrader valve (on top of
vessel) is pressed down.
Isolate vessel, drain down, check and recharge vessel
with nitrogen.
Check motor / pump shafts are free to rotate.
Check operation of all valves to ensure they have not
seized and or letting by.
Check operation of pressurisation to ensure it is still
working within design parameters.
Warning!
Wilo would advise that the power to the unit be
isolated before any of the above is undertaken, as
the pump will start automatically.
5)
Written Scheme of Examination
Accumulator vessels are classed as a pressure system
under the Health and Safety Executive ‘Pressure
system safety regulations 2000’. This regulation
imposes a legal requirement on the user/maintainer
to have the equipment inspected by a competent
company on a regular basis as a mandatory duty
under parts 7 & 8 of the regulations.
A supplier / installer may not fall under the category
of user / maintainer, however they are still obliged to
inform the user / maintainer of their legal and
mandatory duties under the HSE Regulation.
Wilo recommend that any vessel over 250 bar / litres
should have a working test every 6 months and a
thorough examination every 24 months.
Bar/Litre = Maximum Working Pressure (Bar) x
Volume of vessel (Litres)
6)
Warranty
This equipment is covered against manufacturing
defects for 12 months from date of purchase.
This warranty covers the replacement of parts or
products, verified as having a manufacturing
defect, when inspected in the factory.
WILO reserve the right to inspect an installation to
verify that the equipment has been installed in
accordance with the written instructions.
Any modifications to the supplied equipment must
be approved in writing; failure to do so will invalidate
the warranty
Site Visit
Before requesting a site visit, the following
information must be available to the service team:
• Article number of the equipment
• A purchase order to cover the work in the event
that no manufacturing defect is found.
• A site contact name and number
• A FULL description of the alleged fault
7)
Fault Finding Chart
Indication
Possible Reason
Action
Pump/s Don’t Run
Power Fail, Pressure not below CFDifferential pressure. Pump Drive fault.
Check: Power to the Unit; Discharge valve is
open; Pressure settings; Electrical connections.
Boiler Not Running.
Power Failure, Low Pressure Alarm.
Check: for Low Pressure Alarm; Electrical
connections.
LCD is blank; Power
Contrast fault. Connection fault, firmware
LED & Backlighting OK lock-up error.
Reset the Display by pressing Reset Key for 5seconds. Check ribbon cable connectors. Reset
the Control PCB by Power-down & Restart.
LCD Blank, No Power Power failure. PCB Failure.
LED or backlighting.
Check: Mains feed to Unit; PCB fuse F3; Ribbon
cable connectors; Electrical connections .
Pump Trip Alarm
Pump draws excessive current.
Reset Alarm. Pump may require servicing. Check:
Pump rotates freely; Water flow.
Pump Fail Alarm
Pump draws zero current.
Check: Fuse (replace if required); Wiring; Pump.
Low Pressure Alarm
System Pressure is below Low Pressure
Alarm setting.
Check: Pumps operate correctly; System for
leaks/flooding; Alarm Latching is OFF.
High Pressure Alarm
System Pressure is above High Pressure
Alarm setting.
Check: Pumps operate correctly; ‘Pump Check’
settings (adjust frequency if required); Discharge
Isolation valve; Alarm Latching is OFF.
System Fill Alarm
Pump has run for 24-hours, with System Fill Check: System Pressure. Reset audible alarm.
active, & not yet reached CFP.
Press Rest Key again to clear Alarm. Switch
System Fill ON if required.
Service Due Alarm
Service Period expired.
Ensure that the Pressurisation unit is serviced.
Low Water Alarm
Water Level in break tank low.
Check mains water inlet. Check ball valve
operation. Check Float switch operation.
High Water Alarm
Water level in break tank high.
Check ball valve operation. Check float switch
operation.
Pump Hunting
Settings incorrect for system. Pressure
Vessel/connection faulty
Check: Settings for Minimum Run & Start Delay;
Discharge valve; NRVs; Pressure vessel
operation & Connection; Transducer wiring
Pumps running
continuously
System Pressure not reaching CF.
Check: System for leaks; NRVs; Pumps;
Transducer & wiring. Check/Adjust System Leak
timer.
Transducer Fail
Excessive pressure rise or fall; Pressure not Check: Discharge valve open; Transducer Wiring;
changing with Pump running
Reading Rises & Falls with pressure changes.
Parameter Flow Chart - Wilo Comfort Series Pressurisation Unit
Wiring Diagram - Wilo Comfort Series Pressurisation Unit