Ormandy Rycroft Vari-E-Plate Operating & Maintenance Manual

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Vari-E-Plate

Operating &

Maintenance Manual

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Summary of Contents for Ormandy Rycroft Vari-E-Plate

Page 1 Vari-E-Plate Operating & Maintenance Manual...
Page 2: Specification
VERY IMPORTANT - PLEASE READ CAREFULLY Running Section 1 Safety Points Page 1 Start Up Page 1 Working Principles Page 2 Installing Section 2 Sizing and Selection Page 3 Installation Page 5 Operation and Set Up Page 6 Health Section 3 Maintenance Page 14 Service...
Page 3 • During operation, the unit may have very hot or cold surfaces. • The temperature probe is installed directly in the secondary flow. Do not remove when the system is hot, full of water or under any pressure. • Take care when lifting. Only use the designated lifting point. Use only certified lifting equipment capable of lifting the weight. Residual water may also be present and spillage could occur. • Never lift the Ormandy Rycroft Vari-E-Plate by any associated pipework or pipe connections. • Take care when handling, as some edges may be sharp. • The equipment has danger from electricity. Do not remove covers or allow any exposed live parts. Isolate before working on the unit. • The electrical and mechanical functionality must be considered prior to connecting any non factory fitted equipment. E.g. pumps, valves,...
Page 4: Working Principle
Working Principle The unit comprises of a 2-port valve, variable speed primary pump (Single or Dual), a plate heat exchanger, secondary pump and a temperature sensor in the secondary flow. The two port valve opens and closes in line with the secondary demand. As the demand rises, the secondary temperature will start to fall, thus causing the two port valve to open and the variable speed pump to ramp up and deliver the increased demand of primary water. This causes the secondary temperature to rise, closing the two way valve and slowing down the variable speed pump, thus reducing the primary flow. If there is no demand, the two way valve will close and the primary pump will stop, thus maximising energy savings. The Ormandy Rycroft Vari-E-Plate is used as either a stand-alone instantaneous water heater as shown below. Primary Pump Temperature Sensor Primary Feed Secondary Flow Actuator Primary Return Cold Feed Two Way Valve Or in conjunction with a buffer vessel to form a semi-instantaneous water heater. Pressure/Temp Relief Valve Secondary Flow Temperature Gauge Primary Pump Pressure Gauge Temperature Sensor Primary Feed Commissioning Expansion...
Page 5 Installing Sizing and Selection To size a stand alone Vari-E-Plate, use the following demand factors. Table 1 Private Public Slop Kitchen Washing Dish Facility Hand Hand Shower Bath Sink Sink Sink Machine Sink Washer Basin Basin Hospital Residential Hall & Hotel School Sports Centre /Barracks Restaurant University Offices Factory Apartments Sizing Considerations Careful consideration must be given to the sizing of stand alone instantaneous water heaters.
Page 6 These sizes represent the standard range of Vari-E-Plate instantaneous water heaters. For larger requirements for both single and three phase, please contact our technical department. Both Standard and Special designs can be offered to suit your specific requirements. To size a Vari-E-Plate and Buffer Vessel use the following maximum demand rates. Table 3 Private Public Slop Kitchen Washing Dish Load Facility Hand Hand Shower Bath Sink Sink Sink Machine Sink Washer Factor Basin Basin Hospital Residential Hall &...
Page 7: Installation
For larger capacities contact the sales department for advice. Installation Foundation The Ormandy Rycroft Vari-E-Plate should be mounted on prepared foundations that are level. Lifting One lifting hole is provided on the top of the Vari-E-Plate control panel. Avoid the use of chains, as screwed connections may be damaged by the links. Caution: Never lift or move the Vari-E-Plate by its pipework or pipe connections.
Page 8: Operation And Set Up
Operation and Set Up Key to Ormandy Rycroft Vari-E-Plate controls and indicators. On/Off Switch ✓ ✘ Day/Mode Display Value Increase Push Button System Healthy Indicator Time/Alarm Display Step Right Push Button System Fault Indicator Temperature/Parameter Display Value Decrease Push Button Valve Position Bar Display High Temperature Alarm Indicator Mode Select Push button...
Page 9: Operation
Operation The Vari-E-Plate is a self-contained unit, which controls up to two primary and two secondary pumps, together with a two-port valve to provide hot water. When the system is fitted with two primary pumps, they are operated on a shared duty-standby cycle with automatic changeover on pump failure. Switch on via switch (16) The front panel will illuminate. After a few seconds of self checks, the displays will settle to the Day (Time-clock only), Time Temperature . The pumps will start (11), the valve will open (15) and the system healthy indicator (13) will illuminate. The standard temperature setting is 60°C and the unit will run continuously. (24 hour operation). To change any of the default settings, refer to Figure 3 The Vari-E-Plate can be energised by its own internal time clock function, by a remote switch or Building Management System or by a combination of the two. Remote Switch or Building Management System Control The Vari-E-Plate will be turned on when contacts connected to the Remote Enable terminals closed. This allows the user to control the time of day when hot water will be available. When the contact is open the system is turned off. Internal Time Clock Control For this function to work, the Time clock function should be turned on (see Set Up) and the Remote Enable terminals...
Page 10 Set Up The Vari-E-Plate control unit is factory programmed with temperature and control settings that will suit most applications. However, we would recommend that the unit is commissioned to ensure correct operation and maximum efficiency. Contact our Service Department for details. All the values are adjustable so that you can customise the unit to exactly match your system. The set up routine is entered by pressing and holding the Mode push button for three seconds. (10) Press the Step Right Step left push buttons to move forwards and backwards through the sequence. Press the Value Increase Value Decrease push buttons to alter the value shown in the display. Press and hold the Mode push button for 3 seconds to exit the set up routine.
Page 11: System Faults
System Faults When a fault situation is detected, the System Fault (14) indicator will be lit and the internal Fault relay will be energised. The normal time and temperature display will be replaced by an alarm message. The messages and meanings are shown in Figure 2 below. If a system fault occurs when the controller is in the set up routine the System Fault (14) indicator will be lit but the display will not be replaced by an alarm message. The alarm message can be viewed by leaving the Set Up routine. Figure 2 - Alarm Messages First High temperature level detected. Second High temperature level detected - buzzer sounds and the system is automatically shut down. Low temperature detected. Primary Pump No 1 failure - if two primary pumps are fitted Primary Pump No 2 will be energised. Primary Pump No 2 failure - Primary Pump No 1 will be energised. Secondary Pump No 1 (shunt) failure - system is automatically shut down. Secondary Pump No 2 (re-circulation) failure -system is automatically shut down. Thermo-couple failure - the system is automatically shut down. System has been remotely disabled The Second High temperature level alarm will automatically shut the system down and sound a warning buzzer. The buzzer can be silenced by pressing the Reset push button.
Page 12 Set up routine is entered by simultaneously pressing and holding the Mode , Step Left Value (10) Decrease , Push buttons for a minimum of 3 seconds. Press the Step Right Step Left push buttons to move forwards and backwards through the sequence. Press the Value Increase Value Decrease push buttons to alter the value shown in the display. Press and hold the Mode push (10) button for a minimum of 3 seconds to exit the set up routine. Figure 3 - Advanced Set Up Press and hold for a minimum of 3 seconds to enter Advanced Set Up routine.
Page 13: Manual Control
Night Set Back / Pasteurisation When the DIP switch (5) for Night set-back/Pasteurisation is set to the on position and the unit is put into standby via the time-clock. When the pasteurisation temperature is set to above the normal set temperature, the controller will assume pasteurisation and will raise the temperature to the pasteurisation value for one hour, before returning to standby. Alternatively when the set back/pasteurisation value is set to below the normal set value, the controller will assume set back and will lower the temperature to this value until the next scheduled on period. Manual Control The Advanced Set Up routine allows the engineer to position the control valve manually. This feature is active while this set up window is visible. This feature is disabled and control restored to automatic by pressing the Step Left , or Step Right push buttons to display another parameter, or pressing and holding the Mode , push button to exit the advanced set up routine.
Page 14 Factory Default Settings Set Up: Alternative setting record (Date) ........Set Point = 60 ........Time Clock = Off ........Day (Set) = 1 = Mon 7 = Sunday Clock (Set) = Time Day 1 ON 1 = 0000 ........Day 1 OFF 1 = 0000 ........Day 1 ON 2 = 0000 ........Day 1 OFF 2 = 0000 .....
Page 15 Primary Pump Overrun Time = 5 mins ........Primary Pump Overrun Temperature = 40°C ........Secondary Pump Overrun Time = 5 mins ........Secondary Pump Overrun Temperature = 40°C ........Night Set-back/Pasteurisation Temperature = 68°C ........Primary Pump Duty Changeover Time = 9 hrs ........By pressing the reset mode buttons simultaneously for a few seconds, the time clock (10) settings will be returned to the factory default settings. By pressing the reset decrease buttons, the control and alarm parameters will be returned...
Page 16: Maintenance
The linkage should also be tightened to ensure good mechanical contact. Refer to the manufacturer’s instructions. Hi-Limit / Control Valve and Actuator In addition to the above, check that the valve opens and closes by turning the power on and off. Electrical connection should be checked at the actuator. The linkage should also be tightened to ensure good mechanical contact. Refer to the manufacturer’s instructions. Primary Pump Ensure that the pump is on the correct speed setting and that wiring is secure at all terminals. Plate Heat Exchanger A series of contoured plates with ports form a plate pack with flow channels. The hot water flows down alternate channels, while the cold water flows up alternate channels. This creates 100% counter flow. Service Ormandy Rycroft Engineering offers a full and comprehensive range of service and support. This en- compasses the maintenance, commissioning and repair of general water heating equipment, including heat exchangers, boilers, pressurisation units, booster sets and calorifiers. Contact our Sales Department - sales@ormandygroup.com Spares All Vari-E-Plate component parts are available as replacement/spare items. Please quote as much information as possible to allow the supply of the correct part(s). Serial number, photos etc. Contact our Spares Department - spares@ormandygroup.com...
Page 17 Information Specification Power Supply Requirements Voltage: 230 Volts, 50Hz. Nominal current: Maximum 16Amps (Pump and Duty dependant). Inputs Temperature probe: Type J thermocouple (Grounded) via a 12 bit A/D converter (minimum 0.1 °C resolution). Display range: 0 - 250°C Volt Free Contacts To enable from remote source (Time-clock, SCADA,BMS, boiler controls etc) For connection of a supplementary high limit contact or thermostat as a second alarm. Primary Pump(s) fault contact/s. Signal Remote set point adjustment. 4-20mA Scaled 20°C - 100°C. Outputs Pump Supply • Two primary pumps (1 Duty, 1 Standby) single phase 230v 5A Maximum. • Two secondary pumps (1 circulation, 1 shunt ) single phase 230v 5A Maximum. Valve actuator supply •...
Page 18 Duncombe Road, Bradford, England BD8 9TB. Telephone: +44 (0) 1274 490911. Email: sales@ormandygroup.com www.ormandygroup.com...