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TANKMATIC TANK LEVEL/TEMPERATURE
Head Office: AGM House, London Rd, Copford, Colchester, Essex CO6 1GT UK
Manchester Office : Unit 10, Wheel Forge Way, Ashburton Road West, Manchester. M17 1EH
INSTRUCTIONS FOR
GENERAL SAFETY INFORMATION, WARNINGS & CAUTIONS
INSTALLATION
THE USER
SERVICING
DISPOSAL
MONITORING/CONTROL UNIT
WITH SMART RELAY CONTROL
MODELS: MG‐L, MG‐T, MG‐LT
ISSUE 16 23/4/18
Tel: 01206 215121 Email: aftersales@agm‐plc.co.uk
Tel: 0161 226 4727 Email: aftersales@agm‐plc.co.uk
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Table of Contents
Summary of Contents for Aquatech Pressmain MG-L
- Page 1 INSTRUCTIONS FOR 0. GENERAL SAFETY INFORMATION, WARNINGS & CAUTIONS 1. INSTALLATION 2. THE USER 3. SERVICING 4. DISPOSAL TANKMATIC TANK LEVEL/TEMPERATURE MONITORING/CONTROL UNIT WITH SMART RELAY CONTROL MODELS: MG‐L, MG‐T, MG‐LT ISSUE 16 23/4/18 Head Office: AGM House, London Rd, Copford, Colchester, Essex CO6 1GT UK Tel: 01206 215121 Email: aftersales@agm‐plc.co.uk ...
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Page 2: Table Of Contents
Tankmatic Smart Relay CONTENTS 0. GENERAL SAFETY INFORMATION ......3 WARNINGS ....................3 CAUTIONS FOR INSTALLATION ............... 4 0.2 CAUTIONS FOR OPERATION/USER ..............6 CAUTIONS FOR MAINTENANCE ..............6 INSTALLATION INSTRUCTIONS ............8 GENERAL ........................8 ... -
Page 3: General Safety Information
Tankmatic Smart Relay 0. GENERAL SAFETY INFORMATION These instructions are intended for the installer/operator/user/maintenance of this equipment and must be kept with the equipment, for the life of the equipment and made available to all persons. Please read GENERAL SAFETY INFORMATION 0.0, WARNINGS 0.1 and CAUTIONS 0.2, 0.3 & 0.4 before doing anything else, and then follow them carefully. The unit must only be installed/operated/used/maintained by a competent person; A competent person is someone who is technically competent and familiar with safety practices and the hazards involved. Hydraulic Accumulators/Expansion Vessels installed as part of/in conjunction with this equipment, with Pressure x Volume above 250 Bar‐litres, require regular formal inspection by a competent person. This is a Legal Requirement under the “Pressure Systems Safety Regulations” (PSSR) and the Owner/User should be made aware of their responsibility for this. (see section 3. Servicing). Failure to install/operate/use/maintain the equipment as recommended below could cause damage to the equipment any anything subsequently connected to it, and invalidate the warranty provided by AquaTech‐Pressmain to the buyer. Any damage caused to the equipment by misapplication, mishandling or misuse could lead to risk of Electrocution, Burns, Fire, Flooding or injury to people or property dependent upon the circumstances involved. This equipment MAY contain moving/rotating parts that must remain guarded. Removal of or missing guards could lead to serious personal injury. This equipment automatically restarts after a power interruption. We accept no responsibility or liability for any consequences or damage/losses due to misapplication, mishandling or misuse of the equipment. It should be noted that the assembly of pressure equipment on site under the responsibility of the user (or his representative) is not subject to the Pressure Equipment Directive 97/23/EC. (National ... -
Page 4: Cautions For Installation
Tankmatic Smart Relay 0.1.7 The equipment must not be pressurised beyond the maximum working pressure as stated on pressure sensors/temperature sensors/pumps/pipework/vessels/control panel otherwise serious mechanical damage/destruction could occur causing injury to people or property. 0.1.8 The equipment must not be heated/chilled beyond the maximum/minimum working temperature as stated on pressure sensors/temperature sensors/pumps/pipework/vessels/control panel otherwise serious mechanical damage/destruction could occur causing injury to people or property. 0.1.9 Any damage to equipment, sensors, pumpset, vessels, pipework or system components caused by misapplication, mishandling or misuse could lead to Electric shock hazard, Burns hazard, Fire hazard, Flooding hazard or cause injury to people or property. 0.1.10 This equipment may contain moving/rotating parts that must remain guarded. Removal of or missing guards could lead to serious personal injury. 0.1.11 Pressure vessels must never be disassembled whilst in use, they contain high pressure air/gas charge which could cause injury to people or property. 0.1.12 Pump motors with lifting eyes; the lifting eyes are only suitable for lifting motors NOT the entire pump assembly. This could cause injury to people or property. 0.1.13 Ensure the base/foundation/plinth/wall to which the equipment is to be attached is sufficiently strong enough to carry the entire mass of the equipment including the water that it will contain under worst‐case fault conditions. E.g. fully saturated pressure vessel with no air charge, break tank full to overflowing, etc. Failure to observe this could cause serious mechanical damage/destruction resulting in injury to people or property. 0.1.14 This equipment contains a fluid which may under certain circumstances leak/drip/spray fluid (e.g. servicing, repair or malfunction). Ensure any fluid discharge will not cause damage to the surroundings by taking appropriate action. E.g. install in a place that will not be damaged by leakage or install in a bunded area with adequate drainage. 0.2 CAUTIONS FOR INSTALLATION 0.2.1 READ GENERAL SAFETY INFORMATION 0.0, WARNINGS 0.1 and CAUTIONS 0.2, 0.3 & 0.4 0.2.2 The unit should only be installed/operated by a competent person; A competent person is someone ... - Page 5 Tankmatic Smart Relay 0.2.9 Ensure the electrical supply is the correct voltage, current, frequency and type for the equipment supplied and that suitable circuit protection equipment is installed in the supply. Incorrect electrical installation could be an electric shock/burns/fire hazard. 0.2.10 When accessing the control panel to make electrical connections adopt anti‐static procedures e.g. wear anti‐static earthed wristband, to avoid risk of damaging the controller. 0.2.11 All products that are packaged to include Pressure vessel(s)/Hydraulic Accumulator(s)/Expansion Vessel(s) are classed as “Assemblies” under the Pressure Equipment Directive (PED). Where units are despatched with “Loose” vessel(s) for assembly on site it is absolutely essential that they be installed as detailed in the instructions using the fittings provided where appropriate. Failure to observe this will nullify compliance with the PED and may present a safety hazard. Your warranty may also be affected. 0.2.12 Where Hydraulic Accumulator(s)/Expansion Vessel(s) are supplied as a loose item, they must be installed/connected correctly before operating the equipment, otherwise serious damage from over‐ pressure/pump overheating could occur. 0.2.13 Do not operate this equipment/pumpset prior to commissioning (section 2.2) This could cause irreparable damage to sensors/equipment/pumpset/pipework/system components. 0.2.14 Isolate the sensors/equipment/pumpset before pressure testing system. Excess pressure could irreparably damage the pressure transducer, pressure switches (where fitted) and the diaphragms of pressure vessel/hydraulic accumulators. 0.2.15 Where applicable it is the installers’ responsibility to ensure subsequent pipework etc can accept the pressures generated by the equipment/pumpset and to install an overpressure safety device into the system with due respect to the suction pressure present on the pumpset, the pump closed valve pressure stated on the pump, the maximum working pressure stated on any of the attached pressure vessels and any other device connected to the system e.g. boilers, calorifiers etc. 0.2.16 When chlorination of the system is carried out, ensure that any residual chlorine is removed by thorough flushing as detailed in the HSE approved code of practice L8, to avoid damaging the sensors/equipment/pumpset. The normal level of chlorination is up to 2 parts per million (ppm), but shock dosing for sterilization purposes, at 25‐50 ppm for 24‐48 hours is acceptable as long as all chlorine is removed once the process is complete. Chlorination beyond these limits could seriously damage sensors/pumpset components and WILL NOT be covered by the warranty. 0.2.17 The installer/user is responsible for the installation of the correct earthing and protection according to ...
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Page 6: Cautions For Operation/User
Tankmatic Smart Relay Electromagnetic disturbance – first environment (residential areas) –restricted distribution. Immunity to Electromagnetic disturbance – second environment (industrial areas) – unrestricted distribution, corresponding to CISPR 11, class A, group 1. Inverter motors > 5.5kW for installation in first environment (residential areas) require additional EMC filter to obtain class B, group 1 status. 0.2.27 EMC ‐ With respect to BS EN61000‐3‐2 this equipment is defined as ‘professional equipment’ and therefore the installer/user may need to seek permission from the supply utility to connect this equipment to the public low voltage mains supply. 0.2.28 Where “Expansion vessels” are used on Domestic hot water systems (DHWS) or LTHW heating system pressurisation units, the temperature of the fluid returning to the vessels should not exceed 70 degrees Centigrade as this could damage the vessel diaphragm. Where the temperature exceeds 70C an intermediate cooling vessel should be fitted. 0.2.29 Where applicable Drain cocks/valves and air bleed screws must not be left open as this could cause flooding. 0.3 CAUTIONS FOR OPERATION/USER 0.3.1 READ GENERAL SAFETY INFORMATION 0.0, WARNINGS 0.1 and CAUTIONS 0.2, 0.3 & 0.4 0.3.2 The unit should only be operated/used by a competent person; A competent person is someone who is technically competent and familiar with safety practices and the hazards involved. 0.3.3 The Owner/User of this equipment has a Legal Responsibility to ensure that it is subject to regular formal inspections. See Section 3. Servicing, for details. 0.3.4 Where Hydraulic Accumulator(s)/Expansion Vessel(s) are supplied as a loose item, they must be installed/connected correctly before operating the equipment, otherwise serious damage from over‐ pressure could occur. 0.3.5 The equipment must not be used/run until commissioned by an authorised AquaTech‐Pressmain agent, this could irreparably damage the sensors/pump set and/or system components/pipework connected to it. 0.3.6 The controller/pumpset should be left switched ON with the pumps (where fitted) switched to AUTO for normal operation. 0.3.7 The pumpset (where appropriate) should not be left in “Hand” operation for more than 1 minute. This ... - Page 7 Tankmatic Smart Relay 0.4.6 Where appropriate; Do not vent air from air valves on vessels. These are for adjustment of pre‐set cushion pressures. If wrongly adjusted this will lead to incorrect operation of the pumpset and possible damage to pumps, pipework and system components from overheating and over‐pressure. 0.4.7 Switch OFF equipment before accessing pumps and/or control panel/sensors etc. Aquatech‐Pressmain Instruction manual\Tankmatic smart relay MG‐LT ...
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Page 8: Installation Instructions
Tankmatic Smart Relay 1. INSTALLATION INSTRUCTIONS 1.1 GENERAL These instructions are intended for the installer of this Level/Temperature Monitoring or control unit. Please follow them carefully. Failure to install the equipment as recommended could invalidate the warranty provided by AquaTech‐Pressmain to the buyer. 1.2 ADDITIONAL WARNINGS AND CAUTIONS 1.2.1 READ GENERAL SAFETY INFORMATION 0.0, WARNINGS 0.1 and CAUTIONS 0.2, 0.3 & 0.4 1.2.2 Installation of this equipment assumes prior correct and safe installation of the tank(s) and that you are aware of all safety practices and hazards involved with the tank(s). 1.2.3 When installing sensors if you are unsure of any aspect you must seek the advice of the tank manufacturer before commencing any modifications/alterations to the tank in order not to compromise its performance. 1.2.4 Level sensors must not be subjected to more than 1.5 times the rating of the sensor; otherwise irreversible damage may be done. 1.2.5 Temperature sensors must remain submerged at all times. 1.2.6 When chlorination of a tank is carried out, ensure that any residual chlorine is removed by thorough flushing as detailed in the HSE approved code of practice L8, to avoid damaging the submersible sensors. The normal level of chlorination is up to 2 parts per million (ppm), but shock dosing for sterilization purposes, at 25‐50 ppm for 24‐48 hours is acceptable as long as all chlorine is removed once the process is complete. 1.3 PROCEDURE 1.3.1 SENSORS Sensors are available in standard form for attaching externally to the side of the tank, or submersible form for suspending in the tank contents. 1.3.1.1 Standard Sensors ‐ externally mounted Standard Level Sensor for monitoring liquid level: ... - Page 9 Tankmatic Smart Relay Stilling tube where used: Cut the stilling tube to the required length; glue stilling tube to lower flange of connection box or monitor. If adequate height is available do this before mounting the flange on top of tank. Alternatively this could be done from inside an empty tank. Monitoring unit Wall mounted connection box Max. Distance 5.0 m Standard Level & Temperature sensor 0.0 Mtr ref. Fig 1a Tank with standard Level and Temperature sensors 2" Stilling tube containing submerged level and temperature sensors Sensor weight...
- Page 10 Tankmatic Smart Relay 25mm dia hole to Drill and tap 4 off M4 fixing pass submersible sensor holes or fit clench nuts to fix through. connection box to tank Connection box must be positioned over the hole to seal. Pass submersible cable through this gland into tank, and connect to terminals as required 45mm...
- Page 11 Tankmatic Smart Relay 1.3.2 MONITORS AND DISPLAY PANELS Monitoring units are mounted on a wall suitable for connection to the sensors. (see note 1.3.3.6) Remote display units are wall mounted where required. 1.3.3 ELECTRICAL 1.3.3.1 READ GENERAL SAFETY INFORMATION 0.0, WARNINGS 0.1 and CAUTIONS 0.2, 0.3 & 0.4 1.3.3.2 All wiring must comply with the latest edition of local wiring regulations. 1.3.3.3 Wear anti‐static wrist strap at all times to avoid static discharge causing problems with the built in electronic program. 1.3.3.4 For Tankmatic Panels that do not include pumps: Protection for the mains supply line to the unit ‐ Recommended circuit breaker 16Amp Type B or 10 Amp Type C. 1.3.3.5 Connect incoming electrical mains supply to identified terminals in the monitoring unit (see Fig 3a or wiring diagram supplied). Ensure voltages and frequency indicated are correct and wiring diagrams correspond with supply mains data and that the supply fuse ratings are correct for the total current rating of the equipment provided. 1.3.3.6 Connect Sensors to monitoring unit terminals, via a connection box when provided. (see Fig.3b or wiring diagram) 1.3.3.7 For wiring between sensors, monitoring units, connection boxes, and remote display units use 0.75mm minimum CSA with screen, e.g.”CY” cable, earthed at panel end only. Screen earth should ideally be 360 degree termination to steel enclosure or alternatively to earth stud. Any unused cores must be earthed at panel end only. An alternative to screened cable is to use individual cores in EXCLUSIVE steel conduit. 1.3.3.8 Where remote signals are required connect terminals in monitoring unit to remote display panel, heeding note 1.3.3.7 (see wiring diagram provided) 1.3.3.9 Complete any required earth bonding. ...
- Page 12 Tankmatic Smart Relay L+ M I1 I2 I3 I4 I5 I6 I7 I8 L1 N + + - DC 12/24V INPUT 8xDC (I7.I8 0..10V) Input Output AC 120/230V DC 24V/1.3A System is OK Level/Temp. 50 cm 18 °C Power OUTPUT 4xRELAY/10A Volt free relay outputs 230VAC 10A max ...
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Page 13: User Instructions
Tankmatic Smart Relay 2. USER INSTRUCTIONS 2.1 CUSTOMER ASSURANCE AQUATECH‐PRESSMAIN ASSURE YOU THAT IF ANY PART OF THIS EQUIPMENT BECOMES DEFECTIVE DUE TO FAULTY MANUFACTURE OR MATERIALS WITHIN 24 MONTHS FROM THE DATE OF INVOICE, THE PART WILL BE REPAIRED OR REPLACED. The only conditions are: ‐ The equipment must have been installed, commissioned, operated and maintained as recommended by AquaTech‐Pressmain. The equipment must not have been neglected, misused, modified, or used for any other purpose than its original application. The commissioning should be carried out within 6 months of the date of invoice by an authorised AquaTech‐ Pressmain agent. This Assurance does not apply to those items not supplied by us or to defects arising from parts not made or approved by AquaTech‐Pressmain. The individual manufacturers own policies for dealing with defects will apply. Any part repaired or replaced under these Assurances will be covered for the balance of the appropriate Assurance period. If we have any disagreement about these Assurances which we are unable to resolve we will both abide by the decision of an agreed Arbitrator or, if we are unable to agree, one appointed by the Building and Engineering Services Association (B & ES) Arbitration Scheme Rules. ... -
Page 14: Commissioning
Tankmatic Smart Relay 2.2 COMMISSIONING Whilst this equipment has been tested in the factory to the required settings (detailed in operating parameters at the back of instruction manual), it is impossible to simulate the actual on‐site conditions, especially if they are unusual. Also, the settings may have been disturbed since leaving the factory. Therefore we strongly recommend the equipment is commissioned by our authorised agent who will prepare the equipment, make any necessary adjustments and leave it in operational order. Commissioning is a requirement to validate the Warranty (see Customer Assurance) Prior to requesting an engineer to attend the site for commissioning, the client must ensure that; the equipment has been correctly installed including completion of wiring all sensors and remote display panels etc; any necessary chlorination or other treatment has been completed; an adequate water supply and permanent electricity supply are available. 2.3 OPERATING INSTRUCTIONS This equipment is for monitoring and/or controlling the liquid level and/or temperature, in up to 2 storage tanks. These instructions relate to standard AquaTech‐Pressmain equipment and do not necessarily contain details of all possible variations/modifications and custom built variants requested by our customers. The level and/or temperature are displayed on a 4‐line LCD display mounted inside the control panel, viewable through a clear Perspex lid. Individual alarm conditions for example, high and low level and/or high and low temperature can be set and displayed on the LCD display. Relay outputs are provided for connection to BMS systems for remote monitoring of tank conditions as specified during quotation. Other features (e.g. audible alarm, tank “normal” condition, solenoid valve actuation signal, pump start/stop, 7 day 24 hour timed operations, etc) can be programmed at time of order. See appropriate equipment specification and/or wiring diagram provided for features of the equipment supplied. The model number “MG1‐“ represents 1 tank; “MG2‐“ represents 2 tanks “‐L” represents Level monitoring; “‐T” represents Temperature monitoring “‐LT” represents Level and Temperature monitoring 2.3.1 ADDITIONAL WARNINGS & CAUTIONS 2.3.1.1 ... - Page 15 Tankmatic Smart Relay 2.3.2.2 To access the stop/set parameters/clock menu to access the stop/set parameters/clock menu etc, Press V to press the <ESC> key and <up arrow> key at the same time Clock then ESC for Stop/ Or, Params Menu press the <down arrow> repeatedly ,(this scrolls through any fault messages) until the clock is displayed. Mo 08:15 Note: to get to the clock, it may require pressing <left> or <right> arrows 2003‐09‐22 if Inputs, Outputs, Markers or Cursor are displayed! Inputs > Outputs > Markers > Cursor > I Q ESC+C 0….123456789 0….123456789 0….123456789 ^ 1...0123456789 ...
- Page 16 Tankmatic Smart Relay HighLvel then press the <OK> key to display parameter name. Press <up arrow> On = 100 to display the next parameter or <OK> to set the parameter. Off = 100 Ax = 21 e.g. to SET the High Level Alarm parameter, press the <OK> key to display parameter values. Press <left/right arrow> to select the digit to alter, followed HighLvel By the <up/down arrow> to alter value. Press <OK> to set the parameter. On =+00100 Important Note: the values MUST remain “+” do not set them to “‐“. Off =+00100 The ON / OFF parameters Must be set to the same value. Ax =+00021 Ignore Ax. LowLevel Press <up arrow> to display the Low Level Alarm parameter, On = 25 The ON / OFF parameters must be set to the same value. Off = 25 Ignore Ax. Ax = 21 HighTemp On = 22 Press <up arrow> to display the High Temperature Alarm parameter, Off = 22 The ON / OFF parameters must be set to the same value. Ax = 15 Ignore Ax. ...
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Page 17: Alarms
Tankmatic Smart Relay 2.4 ALARMS SYSTEM ALARM Display giving type of fault and volt‐free output signal (where fitted) Info Follows and audible alarm (where fitted). > 30cm Automatic reset of alarms is provided > 0C Note: fault messages are scrolled through automatically. If more than 1 fault message is activated then all messages will be LOW WATER scrolled through. TEMPERATURE > 30cm Please note: The alarm screens shown on the unit are dependent on the > 0C unit type, i.e. 1 or 2 tanks, Level and/or Temperature etc. ** System Alarm Message ** Cause Check Float valve sticking closed. LOW WATER LEVEL/LOW LEVEL Tank level at/below low water Incoming water supply interrupted APPROACH level/low level approach setting or insufficient to keep up with outgoing demand. Float valve sticking open. Outgoing ... -
Page 18: Servicing
Tankmatic Smart Relay 3. SERVICING 3.1 MAINTENANCE AND CARE OF YOUR EQUIPMENT The AquaTech‐Pressmain equipment that is described in this instruction booklet has been manufactured and tested to the highest standards of design and quality. It will give trouble free operation over many years provided it is maintained regularly from when it is commissioned. To keep it operating efficiently in a safe, economical and environmentally friendly condition, regular maintenance is an essential part. AquaTech‐Pressmain along with its’ service division, Acorn Pressurisation Services are the official providers of commissioning and maintenance services. (see below). Several companies operating under the Aquatronic Group Management structure are available to fulfil a wide range of servicing and maintenance requirements, as detailed below. 3.2 LEGAL REQUIREMENTS Hydraulic Accumulators/Expansion Vessels installed as part of/in conjunction with this equipment, with Pressure x Volume above 250 Bar‐litres, require formal inspection in accordance with a “Written Scheme of Examination”. This is a Legal Requirement on the part of the Owner/User under the “Pressure Systems Safety Regulations” (PSSR). A “Written Scheme” and regular inspection can be provided by either Acorn Pressurisation Services (combined maintenance and inspection) or ESIS Ltd (inspection only), see details below. Plant Servicing & Inspection ACORN PRESSURISATION SERVICES, AGM House, Essex, CO6 1GT. Ph: 01206 215151 10 Wheel Forge Way, Manchester. M17 1EH. Ph: 0161 226 4727 Acorn provides maintenance and installation of all types of packaged water pumping equipment for building services. Its specialist fields are Pressure booster equipment and sealed systems for heating and chilled water distribution systems. Regular servicing of any plant for essential services is vital because wear and tear are very gradual processes. With preventative maintenance, the costs are small and benefits in reliability, safety and economy can be significant. Acorn Pressurisation Services can provide a complete package of schemes for preventative maintenance on all AquaTech‐Pressmain and other makes of equipment. Pressure Vessel Inspection ESIS ENGINEERING SAFETY & INSPECTION SERVICES LTD, AGM House, London Rd, Copford, Colchester, Essex, CO6 1GT. Phone: 01206 215141 ... -
Page 19: Disposal
Tankmatic Smart Relay 4. DISPOSAL Disposal of this product or parts of it must be carried out in accordance with the following guidelines: Use the local public or private recycling/waste collection service. In case such a recycling/waste collection service does not exist or cannot handle the materials used in this product, please deliver the product or any hazardous material from it to your nearest AquaTech‐ Pressmain office. EU Declaration of Conformity We, Aquatronic Group Management Plc, declare that the equipment detailed below: TANKMATIC LEVEL/TEMPERATURE MONITORING/CONTROL UNIT MODELS: MG‐L, MG‐T, MG‐LT. When installed and used in accordance with the instruction manual provided is in conformity with the following standards: BS EN 60204‐1:2006, BS 61000‐6‐1:2001, BS 61000‐6‐3:2001 Following provisions of European Directives: Low Voltage Directive 73/23/EEC and 93/68/EEC, Electro Magnetic Compatability Directive 89/336/EEC with amendments 92/31/EEC. 26.08.04 I.D.Taylor, I.Eng.MIET. Director Aquatronic Group Management Plc Aquatronic Group Management Plc T/A AquaTech‐Pressmain AGM House, London Rd, Copford, Colchester, Essex CO6 1GT UK Telephone: 01206 215121 Aquatech‐Pressmain Instruction manual\Tankmatic smart relay MG‐LT ... -
Page 20: Operating Parameters
Tankmatic Smart Relay OPERATING PARAMETERS SERIAL No. MODEL THE SERIAL & MODEL NUMBERS MUST BE QUOTED WHEN REQUESTING ASSISTANCE ELECTRICAL DATA: Supply ……….. volts ……….. Ph ……… Hz Full load current of unit ……… Amps Max. unit loading: ……... Control Voltage 24 volts DC PARAMETERS as factory set as amended on commissioning Tank 1 Tank 2 Tank 3 Tank 4 PARAMETER Tank 1 Tank 2 Tank 3 Tank 4 Low level ON/OFF Low level approach ON/OFF...
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