Tornatech GPL Installation And Maintenance Manual
Electric pump controllers with automatic transfer switch
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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. Technical Documents GPLGLU-Manual-EN v1.3.0.0...
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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 Location ..................................8 Mounting ..................................8 Storage ..................................8 Wiring and Connections ............................. 9 Water Connections .............................. - Page 4 Factory Settings ............................... 32 Factory Settings ............................... 35 Reset to Factory Settings Page ..........................36 Service Page ................................37 New Pump Curve ..............................38 Automatic Pump Curve Mode Disabled ........................39 The Sensors Pages ..............................39 Details of the Debug Page ............................43 Calibration ................................
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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 The Retransfer to the Normal Power source starts when the voltage sensor detects restoration of the Normal Power Source within acceptable limits. The voltage level must rise above the pre-set pickup value (90%) on all phases before the sensor will accept the normal source. When the normal source is accepted by the sensor, the retransfer to normal delay timer starts timing (factory set at 5 minutes).
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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: Wiring And Connections
Wiring and Connections Water Connections The controller must be connected to the pipe system according to the latest edition of NFPA20. The connection to the system pressure is a Male ½ NPT. Electrical Wiring The electrical wiring between the power source and the fire pump controller shall meet the latest edition of NFPA 20, NFPA 70 National Electrical Code Article 695 or C22.1 Canadian Electrical Code, Section 32-200 or other local codes. -
Page 10: Terminal Strip Descriptions
Terminal Strip Descriptions Alarm output terminals (SPDT Relay, 11:Common, 12:Normally Closed, 14: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 11: Terminal Strip Descriptions
Terminal Strip Descriptions 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: ACB limit switch I: ACB shunt trip J: Transfer Switch motor... -
Page 12: 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 13 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 14 Select the controller pressure units, cut-in and cut-out. Verify that all other parameters on the setup page are correct. When satisfied with the controller settings, press the “Home” button on the membrane, then acknowledge the changes by pressing the "Done" button. If the "Done" button is unavailable, ensure that a sufficient authorization code has been entered and that at least all three voltages are valid.
- Page 15 Proceed with the download step to save the report. Press the home page button to verify that the displayed values are correct.
- Page 16 The “First Start up” is now completed. The controller is fully installed and configured.
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Page 17: Main Features
Main Features The ViZiTouch A: Power Available LED: Indicates that power is available. B: Touch Screen: 4.3 inches color touch screen LCD. C: Alarm LED: Indicates if an alarm is active. D: Front USB Connector: USB Device connector used for files download, software update, service reports. E: Home button: Used to navigate to the Home page. -
Page 18: First Setup
S: K-Type Thermocouple connector T: Alarm Bell connector Warning After 2 years of service, the Vizitouch battery may become less efficient and could lose the time after a shutdown. First Setup The First Setup must be done prior to using the controller. Completing the First Setup is the only way to access the homepage and enable the automatic mode of the controller. -
Page 19: Home
Home Home (Membrane button) Home The home page displays all controller statuses and important values of the controller. All voltages, currents, pressure, motor state and status, as well as all timers and motor starting sequences. The entire background will become red if an alarm becomes active. This feature will help the user identify a problem even from a significant distance away from the controller. - Page 20 I: The alarm/warning notification. Warning indicator: Exclamation mark in a yellow round icon. If no alarm is in ACTIVE condition on the controller and at least one warning is ACTIVE or OCCURRED, the warning indicator will be present. Alarm indicator: Exclamation mark in a red triangle icon. As soon as at least one alarm is ACTIVE or OCCURRED, the alarm indicator will be flashing.
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Page 21: Screen Saver
L: The discharge pressure gauge. It allows for a precise reading of the actual system pressure. The red box on the upper left corner of the gauge indicates the value of the Cut-In set point and the green box on the upper right corner represents the Cut-Out set point. -
Page 22: Alarms
Alarms Alarms (Membrane button) 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.
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Page 25: Configuration
Configuration Config (Membrane button) Config Setup all basic configuration parameters. The main configuration page provides a quick means of changing the most common settings. The padlock icon indicates the current authorization level. A locked padlock indicates that only basic settings can be changed. Press on the padlock to enter an authorization code to unlock additional settings. -
Page 26: Numpad Page
Inside the lower box, the Automatic Shutdown may be activated and the duration of the “Run Period Timer” is shown. To edit the “Run Period Timer”, refer to the “Timers” page in the advanced configuration pages. NumPad Page The NumPad is activated every time the user clicks on a white square box representing a number that can be set. On top of the NumPad, the current parameter is shown. -
Page 27: User Login Page / Keypad Page
The Date and Time can be configured by selecting the current month and year by pressing the arrow buttons on each side of the “Month-Year” display and selecting the day of the month by selecting the actual day. The time is set by pressing the two square boxes under the clock;... -
Page 28: Advanced Configuration Page
character and the "CA" button clears the whole text field. Simply click the "OK" button once the value is set. This type of text field is mostly used to generate a digital text indication for a custom alarm input. Advanced Configuration Page Config >... -
Page 29: Timers Page
Most common timers can be configured here. Note that any timer set to 0 will remove the delay in the decision process. Access level 1: - Motor starting and stopping: The sequential start timer set-point, in seconds, will delay an automatic motor starting. The run period timer, in minutes, will delay the stopping of the motor when the automatic run cause of an automatic stop configured controller has returned to normal and that no other run causes are present. -
Page 30: Voltage Calibration
Most common timers for the transfer switch control can be configured here. Note that any timer set to 0 will remove the delay in the decision process. Access level 1: - Cooling Time: Time delay after which a running generator can be shut down when all running causes have return to normal. -
Page 31: Inputs/Outputs Expansion Board 1-2-3-4
Inputs/Outputs Expansion board 1-2-3-4 Config > Advanced > Expansion Board 1-2-3-4 This page allows the configuration of both programmable inputs and outputs available on an IO Expansion board. Two buttons located far right navigates between the input and output section of the page. Input: The input page has four elements: The NO/NC setting, the "Digital Text Indication"... -
Page 32: Update Program Page
The factory settings are always pre-configured at the factory and set the main parameters of the controller. Most of the settings found on this page can only be changed by an authorized Tornatech employee and is protected by a level 8 password. - Page 33 Voltage: Nominal voltage of the controller FLC: Full load current rating of the motor. LRC: Lock rotor current rating of the motor. Unless specified, this value is automatically set to six times the FLC. Phase: Input power number of phases. Frequency: Input power frequency.
- Page 34 Overcurrent: Sets the value in percentage of the motor's Full Load Current (FLA) and its associated delay. If the average current reading is higher than this percentage of the FLA, the alarm/warning will be Activated. Undercurrent: Sets the value in percentage of the motor's Full Load Current (FLA) and its associated delay. If the average current reading is lower than this percentage of the FLA while the motor is running, the alarm/warning will be Activated.
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Page 35: Factory Settings
The factory settings are always pre-configured at the factory and set the main parameters of the controller. Most of the settings found on this page can only be changed by an authorized Tornatech employee and is protected by a level 8 password. -
Page 36: Reset To Factory Settings Page
Transfer trouble time: Delay applied to avoid a false alarm during the transition from one source to the other. After this delay, if the control does not receive a clear position signal (transfer switch in Normal position or Alternate position), it will trigger a transfer switch trouble alarm. Limits switches are installed to indicate the transfer switch position. -
Page 37: Service Page
Config > Advanced > Service The upper left section hosts the Tornatech Inc. business card by default. This image can be changed by the service dealer to incorporate a customized image. The image must have been created by Tornatech Inc., sent to the service dealer and copied on a USB Device. -
Page 38: New Pump Curve
New Pump Curve Config > Advanced > Service > New Pump Curve The Service Dealer “New Pump Curve” Procedure This page allows the user to create a pump curve. At the bottom of the screen, there are 3 buttons: - Reset: Clears the data of the pump curve in progress. - Auto: Uses needed types of transducers to create the pump curve (Discharge pressure, Suction pressure and Flow sensor need to be installed.) - Save: Saves the pump curve and update the pump curve chronological order as displayed in the “History >... -
Page 39: Automatic Pump Curve Mode Disabled
on the controller. -Click on the “Auto” button -A series of validation will take place to ensure all data is valid. -After a pre-defined timer, the ViZiTouch will acquire all data from all sensors and fill the first row of the pump curve table. - Page 41 Important Notice! Every analog sensor cable used for this controller should be shielded. The shield has to be grounded on the motor side. Not complying to these recommendations may affect the controller good functioning and void its warranty. In the ViZiTouch, all sensors refer to analog input connectors on the I/O board. They all have similar settings and configuration.
- Page 42 - Value: Flow value at which the “Flow Start” event will change state. - Timer On: Timer used to buffer the activation of the “Flow Start” signal by the ViZiTouch. Water Level: The “Water Level” sensor shares the same analog input (AI4) as the suction pressure sensor. Only one of them can be installed at all time.
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Page 43: Details Of The Debug Page
- Enable/Disable the corresponding alarm/warning condition by pressing the square button. - Alarm Bell Icon: Activates the bell when the condition occurs. - Alarm Icon: If selected, the occurring condition will be an alarm. If unselected, it will be a simple warning. - RESET: Value at which the condition will go from the “ACTIVE”... -
Page 44: Io Debug
IO Debug Config > Advanced > Debug > IO The small white circle beside each signal is a representation of its state. If the white circle is filled with a green dot, then the signal is activated. Comparing these software signals and the physical state of the signal on the electronic board is the best way to troubleshoot. -
Page 45: Inputs/Outputs Debug
Inputs/Outputs Debug Config > Advanced > Debug > Expansion The small white circle beside each signal is a representation of its state. If the white circle is filled with a green dot, then the signal is activated. The first element in the left column is the indication of whether or not the optional Expansion board is installed. - Page 46 These pages allow 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 I/O board. Lockout is an Input that disables the motor from starting. - Enable in emergency: If checked, this option will prevent the electronic assistance on an Emergency start.
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Page 47: History
History History (Membrane button) History Select specific pages within the History section. Everything related to the statistics, events, pressure, power logs and the download to USB is available within the History page. -Events: This button leads to the “Events” page, which displays the most recent 500 events. Each event log contains the date and time of occurrence as well as a brief description of the event. -
Page 48: Details Of The History Page
Details of the History Page Events Page History > Events Log It shows the last 500 events 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 500 events, visit the “Download to USB Device”... - Page 49 To download information from the ViZiTouch to a USB Device a user with at least a “level 1” password must be logged in. The "Download to USB” button will execute the command. If a USB Device is not present or if there is an error, a message saying “Could not mount USB drive”...
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Page 50: The Statistics
The Statistics First/Last Service Statistics History > Statistics since first/last service The following description applies to two pages, reachable by the “First Service Statistics” and the “Last Service Statistics” button on the History page. All statistics shown here are calculated since the first/last service was done. All dates are in the YYYY.MM.DD format and all time references are in the HH:MM:SS format. -
Page 51: All Time Statistics
-Average: Calculated value of the average temperature during that period displayed in the system actual unit. -Generator( for transfer switch models only): -Last Run: Date and time of the generator/second utility last run. -Run time: Total running time of the generator/second utility during that period. -Transfer Count: Number of times the power was transferred to the alternate side during that period. -
Page 52: Textual Mode
the Navigation Pad Icon in the lower right corner of the screen will pop-up the Navigation Pad functions specific for this page. By pressing the right or left buttons on the navigation pad, the time will shift back or forth by a quarter of the current zoom setting, allowing a quick user-friendly navigation. -
Page 53: Power Curves
Power Curves Graphical Mode History > Power Log Curves The power curve graphical mode contains two vertical axis. The first three curves, as seen on the legend, are the individual phase voltage between lines 1-2, 2-3 and 3-1. In case of fire pump models built with an automatic transfer switch, the phase voltages between lines represent voltage read from the alternate side of the controller when the alternate side is active. -
Page 54: Textual Mode
Textual Mode History > Power Log Text The “Power Log text” shows a table with 10 rows. The total number of rows available is 500 and the logs are sorted in chronological order. To see more logs, please download all logs on a USB Device. Description of the columns : -Date: Date when the log was recorded -Time: Time when the log was recorded... -
Page 55: Pump Curves
Pump Curves History > Pump Curves The vertical axis represents the pressure in the actual unit selected. Its scale is dynamic and will resize depending on the highest recorded value. The horizontal axis represents the flow in the actual unit selected. Its scale is dynamic and will resize depending on the highest recorded value. -
Page 56: 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 57: Pre-Field Acceptance Test
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 58 Tornatech Controller S/N: _________________________________________ Installation address: _________________________________________ _________________________________________ _________________________________________ Check list completed? _____________Yes _____________ No Check list completed by: __________________________________________ Company: __________________________________________ Date: __________________________________________ Witnessed By: __________________________________________ Comments: ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________...
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Page 59: Field Acceptance Test Report
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 60 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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