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Tornatech GPL Installation And Maintenance Manual

Electric pump controllers with automatic transfer switch
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INSTALLATION AND MAINTENANCE MANUAL FOR
ELECTRIC PUMP CONTROLLERS
WITH AUTOMATIC TRANSFER SWITCH
MODEL GPL + GLU
1

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Summary of Contents for Tornatech GPL

  • Page 1 INSTALLATION AND MAINTENANCE MANUAL FOR ELECTRIC PUMP CONTROLLERS WITH AUTOMATIC TRANSFER SWITCH MODEL GPL + GLU...
  • Page 2 Table of Contents 1. Introduction 2. Installation 3. Main Features 4. Home 5. Alarms 6. Configuration 7. History 8. Service 9. Download Manuals 10. Language 11. Technical Documents GPLGLUV2-Manual-EN v2.1.0.0...

  • Page 3: Table Of Contents

    Table of Contents Introduction ..................................5 Types of Limited Service Fire Pump Controllers ....................... 5 Types of Automatic Transfer Switch .......................... 5 Methods of Starting/Stopping ............................. 5 Installation ..................................8 FCC Regulations and Radio Standards Specification (RSS) Rules ................8 Location ..................................
  • Page 4 Transfer Switch parameters and timers ........................33 Inputs..................................34 Outputs ..................................35 Factory Settings ............................... 36 I/O Card Info ................................37 Network ..................................37 Interlock Lockout ..............................38 Reboot ViZiTouch ..............................38 History ................................... 39 History (Menu) ................................39 Events Page ................................40 Pressure Curves ..............................

  • Page 5: Introduction

    Introduction Model GPL+GLU limited service fire pump controllers are designed to start an electric motor driven fire pump. It can either start the fire pump manually through the local start pushbutton or automatically through the sensing of a pressure drop in the sprinkler system. The fire pump controller is supplied with a pressure transducer. The fire pump can be stopped manually with the local stop pushbutton or automatically after the expiration of a field programmable timer.
  • Page 6 Important: to avoid damaging the contactor, it is recommended to start the motor in this manner: 1) Shutdown the main power by using the main disconnect means, 2) Push the emergency button and lock it in closed position, 3) Turn the power back on by using the main disconnect means. SEQUENTIAL START In case of a multiple pump application, it may be necessary to delay the automatic (pressure drop) starting of each motor to prevent simultaneous starting of all motors.
  • Page 7 RETRANSFER TO NORMAL Important: The transfer switch will stay in alternate position, if the motor is running, for as long as the alternate power source is within acceptable limits. The retransfer sequence is enabled if the motor is not running. The Retransfer to the Normal Power source starts when the voltage sensor detects restoration of the Normal Power Source within acceptable limits.

  • Page 8: Installation

    Installation The GPL electric fire pump controller is cULus listed, FM certified and is intended to be installed in accordance with the latest edition of the Standard of the National Fire Protection Association for the Installation of Centrifugal Fire Pumps, NFPA20 (Centrifugal Fire Pumps) and...

  • Page 9: Mounting

    The structural engineer of record on the project shall be responsible for anchorage details. Storage If the controller is not installed and energized immediately, Tornatech recommend following the instructions from the chapter 3 of the NEMA ICS 15 standard.

  • Page 10: Incoming Power Connections

    Incoming Power Connections Incoming normal power is to be connected to terminals located on the disconnecting means IS. - For 3 phases motor: identified L1-L2 and L3. - For single phase motor: identified L1 and L3 For the transfer switch, incoming alternate power is to be connected to terminals located on the disconnecting means AIS (transfer switch side).

  • Page 11: Terminal Strip Descriptions

    Terminal Strip Descriptions Electric IO Board Alarm output terminals (DPDT Relay, C:Common, NC:Normally Closed, NO:Normally Open): A: Motor Run B: Power Available (Failsafe relay) C: Phase Reversal D: Pump Room Alarm E: Motor Trouble F: Factory Reserved Field input terminal (Dry Contact Only: Voltage Free): G: Remote Manual Start (NO) H: Lockout (NO) I: Remote Automatic Start (NC)

  • Page 12: Terminal Strip Descriptions

    Terminal Strip Descriptions Transfer Switch IO Board Outputs terminals: A: Transfer Switch in Alternate Position B: Transfer Switch in Normal Position C: Alternate Circuit Breaker Status D: Start/Stop Generator Signal Factory IO: E: Alternate position limit switches F: Normal position limit switches G: AIS/ACB limit switches H-I-J: Transfer Switch motor K: CANBUS: UP to ViZiTouch, DOWN to Exp.

  • Page 13: Quick Start-Up Guide

    Quick Start-Up Guide The rating label is the most important label. It must be read carefully to ensure the compatibility between the controller and the installation. Verify that the controller is installed securely on the wall, or optionally on the mounting stand. Make sure to drill holes for the motor and power connections and run the cables inside the panel, all in accordance with the specifications in order to minimize interference with other equipment.
  • Page 14 Connect the normal input power, the alternate input power and the motor on their respective terminals. Secure with the appropriate torque as indicated on the torque label and verify all connections. Secure the doors in the closed position then put the normal power circuit breaker disconnecting means in the ON position.
  • Page 15 Press “Motor Rotation” Press the “Start” button to start the electric motor and validate that the electric motor is rotating in the correct direction. If it is not rotating in the correct direction adjus the motor connections as per below. Press the “Stop” button to stop the electric motor.
  • Page 16 sensing line. - Choose the desired units of measurement for pressure reading. - Adjust, if required, the range of the digital pressure gauge at Max. Pres. - Insert the Cut-Out and Cut-In pressure values of the fire pump. - Insert, if so desired, the Cut-Out and Cut-In pressure values of the jockey pump. Note: The jockey pump Cut-Out and Cut-In values must be set at the jockey pump controller itself.
  • Page 17 The “First Start up” is now completed. The controller is fully installed and configured.

  • Page 18: Main Features

    Main Features The ViZiTouch A: Power LED 3 colors: Pulsing green if the ViZiTouch is properly powered. B: Start button: Used to manually start the motor. C: Stop button: Used to stop the motor if all starting conditions are gone. D: Transfer Switch Test Button: Used to test the transfer switch sequence.

  • Page 19: Home

    Home Home (Menu) Home The home page displays all controller statuses and important values of the controller. This includes all voltages, currents, pressures, motor state and status, as well as all timers and motor starting sequences. A: Navigation bar: Pressing this icon will open a navigation menu on the left side of the screen: 1-Go to Home page 2-Go to Alarms page 3-Go to Configuration page...
  • Page 20 LOAD SHED: The transfer switch has transferred to the alternate position and the motor starting is delayed to reduce the load on the alternate power source. This functionality is optional. LOCKED ROTOR CURRENT (not on GPL models): A locked rotor current alarm has not been cleared on the alarms page and prevents the motor from starting.

  • Page 21: Screen Saver

    M: Timers. The sequential start timer (on-delay) will start timing upon an Automatic start request (pressure drop, deluge valve or remote auto signal). The motor will only start if the request stays active for the duration of this timer. The “Duration” of the run period timer (off –delay) for automatic shutdown will start timing once the start request disappears.

  • Page 22: Alarms

    Alarms Alarms (Menu) Configuration > Advanced > Alarms Displays the list of currently active and occurred alarms. An alarm is called ACTIVE when its triggering condition is still valid. An alarm is called OCCURRED when its triggering condition has been active, but is no longer true. Alarms representing serious concerns are colored RED.
  • Page 23 - Fail to start: Activates if there is and under-current draw of two phases when the motor should be running. A 20 seconds factory set delay is used to give the motor enough time to start before signalling this alarm. - Transfer Switch Trouble**: Activates upon detection of any of the following incoherent transfer switch data: The alternate position and normal position limit switches are both activated.
  • Page 24 - Low ambient temperature: Activates when the ambient temperature is below the factory set value (5 Celsius). - High ambient temperature: Activates when the ambient temperature is above the factory set value (40 Celsius). - Control Voltage Not Healthy: Activates when the 24VAC power input to the IO cards is below the acceptable functional range.

  • Page 25: Configuration

    Configuration Config (Menu) Config The main configuration page is used to setup all basic configuration parameters and provides a quick means of changing the most common settings. There are seven (7) access parameter boxes; Pressure, Periodic Test, Run Test, Automatic Shutdown, Date & Time, Advanced and User Login.

  • Page 26: Numpad Page

    Advanced: Go to the advanced configuration pages. Date & Time Configuration: Select to display the Date Time page. NumPad Page The NumPad is activated every time the user presses on a white square box representing a number that can be set.

  • Page 27: User Login Page / Keypad Page

    changes. A dialog box will appear to confirm the change “Date and Time”. The user may cancel the changes by pressing the “Cancel” button. Please note that changing the date and time will have an effect on the logs chronology. The time zone can also be changed using the box in the bottom-right corner.

  • Page 28: Advanced Configuration Page

    Other KeyPads: The KeyPad is activated every time the user presses on a grey rectangle box with white text representing a text that can be set. The “X” button allows the user to cancel editing the value. The back arrow erases the last entered character.

  • Page 29: Sensor Selection

    Sensor Selection Config > Advanced > Sensors All analog sensors, voltage sensors, a current sensor and a Ground fault sensor can be calibrated by accessing this page. The Analog Input 1 is dedicated to the Pressure Transducer 1. The other Analog Input depends on the controller options.
  • Page 30 For better results, use two points that are far apart, but in the normal range of the sensor. For the pressure transducer PT1, the low point (zero) is automatically acquired during first power up. It can be re- acquired by pressing the blue round arrow. The high point needs to be entered in order to calibrate the sensor. To calibrate the line voltage sensor, use an external voltmeter that is already calibrated.

  • Page 31: Alarms

    To calibrate the current sensor, use an already calibrated current clamp. With the control panel under voltage and the motor not powered, enter “0” in the white box under “Desired”. Press the higher “Read all” button. Start the motor by pressing the manual start button on the ViZiTouch and wait for the motor to reach the full speed. Take a reading with the current clamp on one line and press the lower “Read all”...
  • Page 32 Start Test: The alarm can be tested using this button.This test will only announce the chosen alarm. It will activate the bell if the alarm is audible and will activate any output relays associated with this alarm. The test will not activate other common alarms or other components.

  • Page 33: Control Timers

    Control Timers Config > Advanced > Control Timers This page is used to adjust the timers. Sequential Start Timer This timer sets the time delay between a demand becoming active and the starting of the engine. (Optional). Time Range: 0-3600 Seconds Run Period Timer This timer sets the time the engine will keep running after the demand is resolved.

  • Page 34: Inputs

    Normal Dropout Voltage: Percentage of nominal voltage under which the normal power source will be disqualified (after expiration of the Normal outage delay). Normal Outage Delay: Delay after which the normal power can be disqualified. This can only happen if the voltage has been below the Normal Dropout Voltage the whole duration of the delay.

  • Page 35: Outputs

    Outputs Config > Advanced > Outputs This page is used to see the logic of the signals that will activate the Outputs on the IO board and to test those Outputs. The TB6 output can also be configured from this page. Electric card outputs: - SV - ST...

  • Page 36: Factory Settings

    - Pressure Actuated Controller: Enable the automatic controller to start following a pressure drop. It is possible to reload a past configuration by pressing the "reload configuration" button. Dates with an "*" are settings following a "Service". Do not change a parameter on this page without previously consulting a Tornatech representant.

  • Page 37: I/O Card Info

    I/O Card Info Config > Advanced > IO Card Info This page is used to visualize the ViZitouch and the IO Card registers by pressing on the blue arrows on the right of the screen. Expansion Cards can also be installed via this page. Network Config >...

  • Page 38: Interlock Lockout

    Interlock Lockout Config > Advanced > Interlock Lockout This page is used to configure the Lockout input and the Interlock output parameters. To be active those options need to be assigned to an Input or an Output on the IO board. Lockout is an Input that prevents the motor from starting.

  • Page 39: History

    History History (Menu) History This page is used to access all data related to events, statistics, pressure history, power logs and the downloading of this information via one of the two USB ports. -Events: This button leads to the “Events” page, which displays the events from the most recent 500 logs. Each event log contains the date and time of occurrence as well as a brief description of the event.

  • Page 40: Events Page

    Events Page History > Events The Events Page shows the events from the last 500 logs which occurred in chronological order. The first column is the date, the second one is the time of occurrence and the third column is the “Event message”. To obtain a log that is older than thoses events, visit the “Saved Logs”.

  • Page 41: Power Curves

    This table allows viewing of the exact values used to generate the Pressure Curves with the precise time. Pressing the blue button on the top left corner will return to the graph page. Power Curves History > Power Curves On this page, a graphic of the 3 line voltages, the 3 line currents and the motor running through time can be viewed. By pressing on the screen, the caption will disappear or will be displayed.

  • Page 42: Saved Logs

    This table allows viewing of the exact values used to generate the Power Curves with the precise time. Press the blue button on the top left corner to return to the graph page. Saved Logs History > Saved Logs This page is used to access all past log files. Each log file is a CSV file containing the time, the date, the Cut-in, the Cut-out, the system pressure, the 3 line voltages and currents, the engine run signal, the jockey pump run signal and the log event message.

  • Page 43: Pump Curves

    The logs are arranged chronologically. To select the displayed data, press on the filter icon in the top center of the screen. From this page, the selected values will be displayed. Press on “Log File” at the top left of the screen to go back to the logs table.

  • Page 44: Statistic

    Statistic History > Statistics This page leads to 3 other Statistics pages: “All Time Statistics”, “First Service Statistics” and “Last Service Statistics”. All Time Statistics History > Statistics > All Time Statistics The “All Time Statistics” contains two parameters: - Since: The date the controller has been powered for the first time. - On Time: The amount of time the controller has been On for.

  • Page 45: First Service Statistics

    First Service Statistics History > Statistics > First Service Statistics This page allows the user to view the “First Setup Statistics”. The parameters are: From: - Since: Date of the first setup - On Time: Time the controller spent On, in DAYS-HOURS:MINUTES-SECONDS Motor: - On Time: Time the motor spent On, in DAYS-HOURS:MINUTES-SECONDS - Start Count: Number of times the motor has started...

  • Page 46: Last Service Statistics

    Last Service Statistics History > Statistics > Last Service Statistics This page allows the user to view the “Last Setup Statistics”. The parameters are the same as the ones from the “First Setup Statistics” page but from the “Last Service”. Download History >...

  • Page 47: Service

    The “Nameplate Information” page contains all the information found on the nameplate. The Jockey Pump Cut-Out and Cut-In can be set on this page. It is possible to install a custom Service card on this page. Contact Tornatech for more information.

  • Page 48: Download Manuals

    Download Manuals Pressing on the question mark will redirect to the download page. A pdf version of the manual can be downloaded on an USB device.

  • Page 49: Language

    Language The language displayed on the ViZiTouch can be selected on this page.

  • Page 50: Technical Documents

    Technical Documents Patents Country Title Grant No Mechanical activator for contactor 2741881 Mechanical activator for contactor US8399788B2 Mechanical activator for electrical contactor 165512 Mechanical activator for electrical contactor 165514 Mechanical activator for electrical contactor D803794 Mechanical activator for electrical contactor Patent pending 002955393- Mechanical activator for electrical contactor...
  • Page 51 Pre-Field Acceptance Test TORNATECH MODEL GPL WITH OR WITHOUT GPU TRANSFER SWITCH ELECTRIC FIRE PUMP CONTROLLER PRE- FIELD ACCEPTANCE TEST CHECK LIST Note: This document should be an official indication of whether or not the installation and general condition of the equipment is adequate for a field acceptance test. This document should also aid the individual responsible for executing the field acceptance test to decide whether or not to carry out the field acceptance test of the equipment.
  • Page 52 Tornatech Controller S/N: _________________________________________ Installation address: _________________________________________ _________________________________________ _________________________________________ Check list completed? _____________Yes _____________ No Check list completed by: __________________________________________ Company: __________________________________________ Date: __________________________________________ Witnessed By: __________________________________________ Comments: ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________...
  • Page 53 Field Acceptance Test Report TORNATECH MODEL GPL WITH OR WITHOUT GPU TRANSFER SWITCH ELECTRIC FIRE PUMP CONTROLLER FIELD ACCEPTANCE TEST REPORT Complete this first section if it was not completed during the Pre-Field Acceptance test Note: A manual or automatic start must only be executed if the motor and the pump have been cleared to be started by their respective official service technicians.
  • Page 54 Power Available connected? _____Yes _____ No Phase Reversal connected? _____Yes _____ No Other contacts supplied and connected? _____Yes _____ No Tornatech Controller S/N: _________________________________________ Installation address: _________________________________________ _________________________________________ Field Acceptance Test completed? _____Yes _____ No Field Acceptance completed by: __________________________________________...

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