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PRESSCON VERNIT N2 User Manual

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VERNIT - HORNIT N2(i) expansion
systems
User manual
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User manual
18-09-2019
Version 4.2, Revision 00
Approved
PRESSCON
Honselersdijk

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Summary of Contents for PRESSCON VERNIT N2

  • Page 1 VERNIT - HORNIT N2(i) expansion systems User manual Type User manual Date 18-09-2019 Version / Revision Version 4.2, Revision 00 Status Approved Company PRESSCON Location Honselersdijk...

  • Page 3: Table Of Contents

    Table of content Introduction ................................5 Important to know ..............................7 1.1.1 Working with the safety valve ......................9 Description of hazard symbols .......................... 9 System components ..........................11 Nitrogen generator type ECONOMY A ......................11 Nitrogen generator type ECONOMY B ......................12 Nitrogen generator type ECONOMY DUO ......................
  • Page 4 Main screen lay-out VERNIT ......................35 4.1.1 Main screen lay-out HORNIT ......................35 4.1.2 Icons on the main screen ..........................36 Compressor ............................36 4.2.1 PSA generator ............................. 37 4.2.2 Oxygen sensor ............................ 37 4.2.3 Valves ..............................37 4.2.4 Overpressure safety relief ........................38 4.2.5 4.2.6 VERNIT tank malfunction status .......................

  • Page 5: Introduction

    7.3.1 Fault and alarm messages for the PressControl (ECONOMY A and ECONOMY DUO) ....... 55 Fault and alarm messages for the Touchscreen ................57 7.3.2 7.3.3 Fault and alarm messages for the PRESS-Basic control(ECONOMY B) ............60 Maintenance and service ..........................63 8.1 Expansion system maintenance ..........................
  • Page 6 It also prevents the water level from becoming too low, which leads to air in the heat supply spray tube and in the central heating network. These are important features for maintaining the buffer tank and preserving the central heating system.

  • Page 7: Important To Know

    H.P. "High Performance" stands for the design of the PSA tube. Indicates that the PSA applied to the system was manufactured by PRESSCON. Nitrogen generators from before 2009 do not have this addition. ECONOMY This indicates that the generator is equipped with a valve control system designed for high output and energy efficiency.
  • Page 8 CLDM Touchscreen and PRESS-Display The touchscreen and the PRESS-display are both control units that can be used for the PRESSCON nitrogen generators. Originally, the PRESS-display was conceived as a multi-purpose digital display showing the water level, nitrogen blanket pressure and any alarms. The Touchscreen also performs these functions, but offers a more visual overview of the system and more intuitive controls.

  • Page 9: Working With The Safety Valve

    1.1.1 Working with the safety valve The safety valve is commonly located on the roof of the buffer tank. When working on the safety valve, the following hazards should be considered. Symbol Description Applies to HOT PARTS, The housing of the safety valve and relieved nitrogen from the buffer tank.
  • Page 10 4. NOISE, 10. ROTATING FAN, Wear ear protection to prevent hearing Risk of getting stuck or injuries to limbs. Turn the damage. machine off completely before working on it. 5.MACHINE WITH AUTOMATIC START, 11. ATTENTION, Machine stops and starts automatically when it Special situation occurs, follow additional instructions.

  • Page 11: System Components

    System components The PRESSCON expansion systems consist out of the following components: a nitrogen generator, compressor, safety valve and 2 or more pressure sensors. This chapter describes these components by giving an image of each device and by numbering the most important parts. The compressor is not described because different brands and types can be applied and it is delivered with its own manual.

  • Page 12: Nitrogen Generator Type Economy B

    2.2 Nitrogen generator type ECONOMY B N2 system N2i system Figure 3. N2 ECONOMY B system Figure 4. N2i ECONOMY B system...

  • Page 13: Nitrogen Generator Type Economy Duo

    2.3 Nitrogen generator type ECONOMY DUO N2 system N2i system Figure 5. N2 ECONOMY DUO system Figure 6. N2i ECONOMY DUO system...
  • Page 14 Legend Legend for the nitrogen generator of the types: ECONOMY A, ECONOMY B, ECONOMY DUO. Ref. Description Function Nitrogen output connection Tube which puts out the nitrogen mixture that is produced by the nitrogen generator. This outlet will be connected to the piping that runs to the buffer tank. Please note that this connection is located differently when comparing the N2 and N2i systems.

  • Page 15: Vacuum- Overpressure Safety Valve And Vacuum Safety Valve

    2.4 Vacuum- overpressure safety valve and vacuum safety valve Figure 7. PV 80/25/20-2, PV 150/25/20-2, PV 200/25/20-2 (VERNIT Figure 8. PV 50-2F, PV 80-2F, PV 100- systems) 2F.(HORNIT systems) Legend Legend for the safety valves of the types: PV 80/25/20-2, PV 150/25/20-2, PV 200/25/20-2, PV 50-2F, PV 80-2F, PV 100-2F.

  • Page 16: Vacuum- Overpressure Safety Valve With Tracing Band

    2.5 Vacuum- overpressure safety valve with tracing band For cold environments it is possible to install tracing ribbon around the vacuum- overpressure safety valve to prevent it from freezing. Although the safety valve is designed to withstand a certain level of frost, the additional tracing ribbon is an optional feature that is advisable for environments with long periods of frost.

  • Page 17: Pressure Sensor

    2.6 Pressure sensor Figure 10. Sensor 0-600mBar, 0-1000mBar, 0-1500mBar, 0-1600mBar, 0-2500mBar. Legend Legend for the pressure sensors of the types: 0-600mBar, 0-1000mBar, 0-1600mBar, 0-2500mBar, Ref. Description Function Protection cap cover Plastic cover that slides over the pressure sensor. It clamps onto the protection cap sensor holder.
  • Page 18 Figure 11. Sensor with tracing ribbon Legend Description Function Ref. Tracing ribbon Ribbon that is heated when powered with electricity. Thermostat Thermostat that monitors the surrounding temperature at the sensor and activates the tracing ribbon when the temperature becomes too low.

  • Page 19: General Operation

    General operation 3.1 Operation of the expansion system The expansion systems can be applied in two different ways. The VERNIT type systems take care of regulating the pressure of the nitrogen blanket and monitor the water level in the vertical buffer tank. It also has the capability to regulate the water level if so desired.

  • Page 20: Systems That Also Regulate The Water Level (Optional)

    Systems that also regulate the water level (optional) The PRESSCON expansion system of the ECONOMY –A and –DUO types has the possibility to regulate the water level automatically. This is an optional function that can be used to automatically replenish or drain water from the buffer tank when needed.

  • Page 21: Protection Against Vacuum With Hornit Systems

    3.1.6 Protection against vacuum with HORNIT systems These steps only apply to the HORNIT systems. These systems operate at a pressure between 800 mbar and 1000mbar, the overpressure can only be regulated by using an electrical valve. Step 1. When the total system pressure in the heat storage tank is at the desired level, the nitrogen generator stops. Under the influence of heat, the water expands and the total system pressure increases.

  • Page 22: Leak Detection Measurement (Sldm Or Cldm) For Vernit Systems (Optional)

    3.1.7 Leak detection measurement (SLDM or CLDM) for VERNIT systems (optional) These steps only apply to VERNIT systems with a type A or DUO panel. Leak detection is not possible with a type B panel. It is possible to detect leaking water by using a 3 pressure sensor at the bottom of the buffer tank.

  • Page 23: Manual Operation Of The Return Valve (Optional)

    3.1.9 Manual operation of the return valve (optional) The ECONOMY A and DUO switch panels have the option of being equipped with a manual control for the return valve. In this case, the control panel is equipped with a 3-position switch under the Touch Screen or the PRESS-display. The controller of the return valve can be set in 3 different positions.

  • Page 24: Assembly Of Components On The Buffer Tank

    To be able to measure and regulate the water level and the pressure of the nitrogen blanket there are several components that are needed on the buffer tank for the Presscon expansion system. To get a clear understanding of this, the function and location of the important components are described.
  • Page 25 Optional: sensor for leak detection measurement In addition to the default components on the vertical buffer tank it is optional to feature it with a 3 pressure sensor at the bottom of the tank. This pressure sensor can be used for setting up the leak detection measurement. Since the leak detection measurement is an optional feature it is not mandatory to install it the 3 pressure sensor.

  • Page 26: Vertical Buffer Tank In A Duo Setup

    3.2.2 Vertical buffer tank in a DUO setup The following components are installed on the vertical buffertanks, that are arranged in a DUO setup. Buffertank 1. Buffertank 2. Ref. Description Function Vacuum- overpressure safety Mechanical valve that protects the tank against overpressure and valve vacuum.

  • Page 27: Horizontal Buffer Tank

    ELC configurations in combination with additional buffer tanks. *This component is part of the buffer tank and is not provided nor installed by PRESSCON. 3.2.3 Horizontal buffer tank The following components are installed on the horizontal buffertank by default. Please note that the horizontal buffertank can be installed in 3 different setups.
  • Page 28 Separate expansion vessel Separate vessel in which the water from the buffertank can expand. *This component is part of the buffer tank and is not provided nor installed by PRESSCON. **The applied measuring range depends on the setup of the buffertank.

  • Page 29: Horizontal Buffertank In A Duo Setup

    It is possible to combine a vertical and horizontal buffer tank in a DUO setup. The horizontal buffer tank accommodates the expansion of the low temperature water network and the vertical tank accommodates the expansion of the high temperature water network. The Presscon expansion system will then be built as a HORNIT N2 / N2i ECONOMY DUO type.

  • Page 30: Schematic Overview Of The Expansion System

    VERNIT 2.0 -30.0 N2(i) system Touchscreen Compressor on/off Compressor Compressor status Valve control Nitrogen CAN-bus Drainvalve on/off generator Nitrogen pressure PRESSCON Buffer tank Nitrogen pressure Control vessel (Optional) Analogue water level (PRESS-control minimal) Analogue nitrogen pressure 25 mBar Nitrogen inlet valve...

  • Page 31: Hornit 2.0 -30.0 N2(I) System

    HORNIT 2.0 -30.0 N2(i) system Touchscreen Compressor on/off Compressor Compressor status Valve control CAN-bus Nitrogen Drainvalve on/off generator Nitrogen pressure PRESSCON Buffer tank Nitrogen pressure Control vessel Analogue water level Analogue nitrogen pressure (PRESS-control minimal) Nitrogen inlet valve External generator...

  • Page 32: Vernit 2.0 -30.0 N2(I) Duo System

    Compressor Compressor status Valve control Nitrogen Drainvalve on/off generator Nitrogen pressure PRESSCON Analogue water level for tank 1 or tank 2 Buffer tank Nitrogen pressure DUO Control Analogue nitrogen pressure for tank 1 or tank 2 vessel (Optional) External generator (PRESS-control maximal) Alarm notifIer (Tank 1 &...

  • Page 33: Hornit 2.0 -30.0 N2(I) Duo System

    Compressor Compressor status Valve control Nitrogen Drainvalve on/off generator Nitrogen pressure PRESSCON Buffer tank Analogue water level for tank 1 or tank 2 Nitrogen pressure DUO Control Analogue nitrogen pressure for tank 1 or tank 2 vessel (Optional) External generator (PRESS-control maximal) Alarm notifIer (Tank 1 &...

  • Page 34: Touchscreen

    Touchscreen The touchscreen is the most important control device for reading the statuses and values of the system. The touchscreen has no physical buttons, but only digital buttons on the screen. Touching the buttons and the images on the screen can be used to navigate and adjust the settings. The table below shows the buttons of the touchscreen. 4.1 Main screen of the Touchscreen Every button has a different function, some of them have several functions.

  • Page 35: Main Screen Lay-Out Vernit

    4.1.1 Main screen lay-out VERNIT The structure of the menu is based on the type of system the user has. Press the icons to find out the status of this system. Figure 20. VERNIT 2.0 – 30.0 N2(i) DUO system overview (Only when the VERNIT is installed) 4.1.2 Main screen lay-out HORNIT Figure 21.

  • Page 36: Icons On The Main Screen

    4.2 Icons on the main screen 4.2.1 Compressor The compressor supplies compressed air to the system. The status of the compressor is forwarded to the PressControl. Compressor Description/status • The compressor supplies the compressed air to the system. • When it is colored white, de compressor is working properly.

  • Page 37: Psa Generator

    4.2.2 PSA generator The PSA generator produces nitrogen for the system. The status of the PSA generator is forwarded to the PressControl. PSA generator Description/status PSA generator Description/status • The circle with the cross, • If the system turns red, will start running when there is a malfunction.

  • Page 38: Overpressure Safety Relief

    • When the valve turns red, it means the valve is closed. • When the valve turns green, it means the valve is open. The horizontal valves next tot he tank, regulate the water discharge and supply. The top valve shows the water supply. The lower valve shows the water return.
  • Page 39 Tank Description/status Tank Description/Status • When the tank is • When the tank is represented like this, represented like this, the the tank is functioning tank has a water level properly. failure. • When the tank is • When the tank is represented like this, represented like this, the the tank has a system...

  • Page 40: Vernit Tank Water Level Status

    4.2.7 VERNIT tank water level status Water level • The water level is globally represented by the height of the blue part in the tank. The range is calculated between the ‘water level maximum’ and ‘water level ‘minimum’ settings. This range is divided in 10 parts. Next, the current water level is checked at which part it is. The water level under the tank is also shown.

  • Page 41: Hornit Tank Malfunction Status

    4.2.8 HORNIT tank malfunction status The status of the tank is represented by the color of the tank. Tank Description/status Tank Description/Status • The water level is • When the tank is represented by the represented like this, blue part in the tank. the tank has a water The water level is level failure.

  • Page 42: Hornit Tank Water Level Status

    4.2.9 HORNIT tank water level status Waterhoogte • The water level is globally represented by the height of the blue part in the tank. The range is calculated between the ‘water level maximum’ and ‘water level ‘minimum’ settings. This range is divided in 10 parts. Next, the current water level is checked at which part it is. The water level under the tank is also shown.

  • Page 43: Hornit Pressure Tank Failure Status

    4.2.10 HORNIT pressure tank failure status The status of the tank is represented by the color of the tank. Tank Description/status Tank Description/Status • When it is colored white, • When the tank is represented it is functioning properly. like this, the tank has a water level failure.

  • Page 44: User Menu

    4.3 User menu The User menu contains the basic settings fort he expansion system. In this menu, the user can setup the values such as: Start value, stop value, alarm thresholds for the pressure of the nitrogen blanket, total system pressure and the height of the water level.

  • Page 45: Service Menu

    4.4 Service menu The service menu contains more advanced settings fort he expansion system. This menu is intended for the service engineer, when the system is put into service or to make adjustments during maintenance. The service menu can be accessed by pressing the "service"...

  • Page 46: Press-Display

    Knoppen (toetsenbord en start/stop Info Prog knop) PRESSCON Alarm Reset Netherlands Figure 23. Schematic view of Press-display 5.1 Buttons on the PRESS-display Each button has a different function, some have more than one. The following table describes which function each button has.

  • Page 47: Menu Structure And Access

    5.1 Menu structure and access The PRESS-display software has a specific structure that is described in this chapter. The structure consists of 3 levels and a set of menus for each level. The levels in the software are like user levels. The levels are called: user menu, service menu and factory menu.

  • Page 48: User Menu For The Vernit Economy B Systems

    5.3.1 User menu for the VERNIT ECONOMY B systems Main screen + or – button Press shortly to enter Press + or – button shortly to navigate the user menu. between the settings within the user menu. Waterlevel Nitrogen press Language minimal nominal...

  • Page 49: Service Information Screen

    5.4 Service Information screen This information screen contains the directly measured values from the sensors of the VERNIT or HORNIT expansion system. These are the values to which the VERNIT or HORNIT expansion system responds. These measurements can be viewed in real-time via the Service Information screen. There are no settings available in the Service Information screen that can be changed.

  • Page 50: Factory Information Screen

    5.5 Factory information screen The factory information screen displays the status of all input and output signals of the PRESS-control. It indicates, for example, if a sensor measurement has been received, if an output is active, if an input is active and if nitrogen is being produced or not.

  • Page 51: Service Menu

    5.6 Service menu The service menu contains more advanced settings for the expansion system. This menu is intended for the service technician, when the system is being commissioned or to make adjustments during maintenance. The service menu can Prog be accessed by pressing the button once when the PRESS-display is on the main screen.

  • Page 52: Press-Control

    PRESS-control The PRESS-control is the mainboard that controls the complete expansion system. It processes the measurements of the water level and the pressure of the nitrogen blanket. By means of the measurements, the PRESS-control generates the appropriate output signals to control the nitrogen generator. The PRESS-control is also featured with additional connection terminals for items such as alarm contacts, inputs for several switches or sensors and an analogue output signal with 4…20mA.

  • Page 53: Alarms And Error Handling

    7 Alarms and error handling Faults and alarms The Touchscreen software, the PRESS-display and the PRESS-control can generate error messages and alarms when something is wrong with the system. The difference between an error and an alarm is the seriousness of the problem. An error message is considered to be less serious than an alarm message.

  • Page 54: Overriding The Boiler Alarm Relay

    ATTENTION! Overriding the boiler alarm is not without any risks. It is strongly recommended to consult the technical support of PRESSCON on forehand. If used in an inappropriate situation, damage to the buffer tank and central heating systems cannot be prevented.

  • Page 55: Faults And Alarm Messages

    Faults and alarm messages The following tables show the most important error and alarm messages that may appear on the Touchscreen and PRESS-display. A description is given for each message. The table also indicates for each message whether it is an error and/or an alarm. 7.3.1 Fault and alarm messages for the PressControl (ECONOMY A and ECONOMY DUO) This table of faults and alarms is based on software version: PRESSCONTROL 5.0...
  • Page 56 Error Display Fault Alarm Description Problem Software version difference Software ver. between PressDisplay and the Perform a software update. PressControll Press the B button if you wish to Boiler prot off Boiler protection switched off switch it back on. Span high is lower than Span Span config Check settings low.

  • Page 57: Fault And Alarm Messages For The Touchscreen

    Error Display Fault Alarm Description Problem There are two devices in the Change de device numbers so Double devNr (d) network with the same number. each device is unique. This system operates for only 14 days. Make sure that Service <14 days Call service technician maintenance is conducted within two weeks.
  • Page 58 Error Display Fault Alarm Description Problem One of the devices on the bus has CAN-bus halt CAN-bus halt detected. a fatal CAN error or has rebooted. Communication with RTC not RTC comm. Call a service technician correct Main power error Display was rebooted Check power supply Check the software versions of the...
  • Page 59 Error Display Fault Alarm Description Problem MAC-address MAC address error Call a service technician TCP Tx buffer TCP Rx buffer Check device number on the CAN- Double devNr(d) Double device number detected. Display error Display has an error Call a service technician Test error message for testing Test error purposes.

  • Page 60: Fault And Alarm Messages For The Press-Basic Control(Economy B)

    7.3.3 Fault and alarm messages for the PRESS-Basic control(ECONOMY B) This table of error and alarm messages is based on software version: BasicPControl V2.0 Alarm no. Display message Fault Alarm Description Cause of problem An error occurred while trying to Eeprom address Read/write error in the read 1 or...
  • Page 61 Alarm no. Display message Fault Alarm Description Cause of problem Uart1 txFifo UART1 send buffer is full distortion on info bus Check software version and BasicPControl N/A BasicPController not available CAN-bus connection Software version between Update the software of the PressDisplay and Software ver.
  • Page 62 Alarm no. Display message Fault Alarm Description Cause of problem Check (ext) pressure sensor Regel niv sensor level sensor error. (cable, sensor, connection) Two devices have the same Change device number to a Double dev Nr(d) network number unique number. This system has been operating for 14 days.

  • Page 63: Maintenance And Service

    Revision safety valve Mechanic/Factory* *The revision of the vacuum safety valve for HORNIT systems should be performed at the factory of PRESSCON. The used safety valve can be exchanged directly with a revised safety valve. Replacing the vacuum safety valve on the horizontal buffer tank should be performed by an approved installer who can safely relief the pressure from the tank and the safety valve.
  • Page 64 Regarding the products supplied by PRESSCON in the Netherlands, PRESSCON refers to the general terms of conditions. All offers and agreements relating to goods to be delivered and / or services within the Netherlands are applicable the general terms and conditions for the technology industry, as last filed by the FME-CWM with the court in The Hague.

  • Page 65: Appendix

    10 Appendix In addition to this document, the description of the content extends to the following appendixes: Appendix ID Description Version 11 Document history Version 1.0 to 2.0 indicates : Modification, in lay-out, structure or other major modifications; Version 1.0 to 1.1 indicates : Supplement, a chapter of paragraph has been added to the document;...
  • Page 66 3.1_R01 11-01-2016 Introduction supplemented with text about the HORNIT systems and ST BASIC systems. Chapter 2.4 Nitrogen generator ST BASIC added to the document. History of images supplemented with the relevant documents. Chapter 2.5 -2F vacuum valves added to description of the safety valve. 12-01-2016 Chapter 3.5 till chapter 3.1.5.
  • Page 67 Chapter 6.2 par. 1. Grammar adjusted. 20-01-2016 Adjusted blue colored tables and styling. 21-01-2016 Grammar adjusted in the following chapters: Introduction, chapter 1.1, 1.1.1, 1.1.2, 1.1.3, Chapter 2.0, 2.0 legend, Chapter 3.1.2, 3.1.3, 3.2, Chapter 4.1, 4.2, 4.4, 4.5.2, 4.6.1, Chapter 5.1, Chapter 6.1, 6.3.1, Chapter 7.1, Chapter 8.
  • Page 68 Chapter 3.1.7. Adjusted grammar in the introduction. Step 2. Grammar adjusted. Chapter 3.1.8. step 1. Adjusted description of pressure sensor. Chapter 3.2.1. Added legend with remark on components that PRESSCON does not install. Chapter 3.2.2. Added legend with remark on components that PRESSCON does not install.
  • Page 69 Chapter 6.2. Relocated the ATTENTION block between de first 2 paragraphs. Chapter 9. Adjusted year of signature to 2017. Chapter 4.4 to chapter 4.6 Checked structure of menu’s and info screens with the following software versions: PressControl_V4_0i_R0. / PressDisplay_v4_0i_ENNL_R0. BasicPControl_v2_0g_R0 / BasicPDisplay2_v2_0G_R0 Complete document: Adjusted descriptions of tanks to: Buffer tank, Separate expansion vessel, Compressed air HP vessel, Nitrogen HP vessel.
  • Page 70 Chapter 4.1. Grammar adjusted in text and under descriptions. Chapter 4.3. Grammar adjusted. Chapter 4.4.3. Grammar adjusted in descriptions under 12. Chapter 4.6.1. Grammar adjusted in descriptions under 7. Chapter 4.6.2. Grammar adjusted in descriptions under 6 and 7. Chapter 6.2. Grammar adjusted in warning text. Chapter 6.3.

  • Page 71: To Conclude

    This manual has been written in order to support the mechanic, installer or customer in adjusting, modifying or working with a product of PRESSCON. Its aim is to maintain and possibly improve the quality of its products. If additional information or support is requested then PRESSCON can be consulted through the following information.

This manual is also suitable for:

Hornit n2Vernit n2iHornit n2i

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