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VEXO X-POT XP+ Operation & Maintenance Manual

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OPERATION &
MAINTENANCE MANUAL
®
www.VEXOint.com
X-POT XP+
O&M Manual
®
technical@VEXOint.com
Last Updated - 11/01/2023
+44 (0)1767 500 150
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  • Page 1 ® OPERATION & MAINTENANCE MANUAL ® www.VEXOint.com X-POT XP+ O&M Manual ® technical@VEXOint.com Last Updated - 11/01/2023 +44 (0)1767 500 150 Page 1...

  • Page 2: Table Of Contents

    WARNING – This equipment must only be used, maintained or serviced by trained competent engineers. If in any doubt please do not touch this equipment. For further advice please contact VEXO International or your reseller for additional information and guidance. ®...

  • Page 3: Safe Working Distance Statement

    ® ® www.VEXOint.com X-POT XP+ O&M Manual ® technical@VEXOint.com Last Updated - 11/01/2023 +44 (0)1767 500 150 Page 3...

  • Page 4: Liability

    All technical information, data and information contained herein are correct at time of publication. This information is the sum of our current findings and experience to the best of our knowledge. We reserve the right to make technical changes subject to the future development of the VEXO product referred to in this publication.

  • Page 5: Copyright

    VEXO International (UK) Ltd. Infringements are liable to prosecution and payment of compensation. We reserve the right to exercise all intellectual property rights.

  • Page 6: Purpose & Use Of This Manual

    ® negotiations or on demand. Training for the required services, installation, dismantling, commissioning, operation, inspection, maintenance and repair remain the responsibility of VEXO or their nominated service partners. Such ® training covers information about on-site requirements rather than performance.

  • Page 7: Transportation, Storage, Unpacking

    If no requirements are set, to operate the equipment minimum requirements are safety goggles, hand protection, well-fitting clothing and sturdy, closed and skid-proof footwear. Exceeding Permitted Pressure &/Or Temperature Levels Equipment used in combination with the VEXO X-POT XP+ must guarantee that the permitted operating ®...

  • Page 8: Safeguards

    These can lead to damage / leakage in water-bearing pipework, loss of stability of the appliance and potentially failure of pressure bearing components. Electrical Equipment Inspections Regardless of the prescriptions of the property insurer / operator it is recommended to inspect demonstrably the electrical equipment of the VEXO ® X-POT XP+ ®...

  • Page 9: Obvious Misuse

    • Use in inappropriate system designs and environments. • Use of non-permitted or inappropriate installation materials. Product Description The VEXO X-POT XP+ is a sealed system, 2 stage side stream filtration and manual chemical dosing unit. ® ® It is a Patented, fully prefabricated, factory tested wall/floor mounted unit incorporating: •...

  • Page 10: Schematics & Component List

    ® Schematics & Component List ISOLATING VALVE ISOLATING VALVE PRESSURE TRANSDUCER 1 DRAIN VALVE (DIRTY FLOW) VEXO X-POT XP+ VESSEL BODY SWING CHECK VALVE ® ® MAGNET GRATE (INTERNAL) ISOLATING VALVE CONTAINING 13 MAGNETS BAFFLE PLATE (INTERNAL) CHEMICAL FILL TUNDISH BAG FILTER &...

  • Page 11: Operating Principles

    The system fluid passes through the hydraulic components in the flow sequence below: The system fluid is drawn from the main system return and into the VEXO X-POT XP+ vessel. The fluid is ®...

  • Page 12: Markings

    ® Product Markings THE FOLLOWING MARKINGS AND WARNINGS ARE INSTALLED ON THE X-POT XP+ UNIT ® ® INTEGRATED ELECTRONIC SIDE STREAM FILTRATION & DOSING UNIT Recommended for use with this product Contact your X-POT XP+ representative for info. Approved by: And more! ®...

  • Page 13: Basic Installation Requirements

    In a frost free area (> 5°C) and must also be protected from adverse environmental conditions. • In a well-lit area to allow for safe changing of the filter media and chemical dosing. • On a flat, horizontal, level, solid floor with access to the electrical panel, pump and VEXO X-POT XP+ vessel ®...

  • Page 14: Commissioning

    E-Pump Pre-Commissioned for each site/project. Please find Pre-Set Configurations for manual Configuration on Page.19 if required. The operator should read this section prior to hand-over of the equipment from the installation operative to be confident on the operation of the Grundfos CRiE Smart E-Pump and the VEXO ® X-POT XP+ ®...

  • Page 15: Control Panel Vexo X-Pot Xp

    1.00l/s 60kPa 132.8 watts The set-point for maximum differential pressure will be set dependent on the Bag Filter installed in the VEXO ® X-POT XP+ Unit. Please find the table below for set-points for corresponding Bag Filter Mesh Coarseness and ®...
  • Page 16 ® 0.50l/s FLOW RATE CLEAN FILTER DIRTY FILTER BLOCKED FILTER STATE BAG FILTER STATE DIFFERENTIAL STATE DIFFERENTIAL DIFFERENTIAL MESH COARSENESS PRESSURE (SET-POINT) PRESSURE PRESSURE 100 Micron 8kPa 10kPa 16kPa 50 Micron 8kPa 10kPa 16kPa 25 Micron 12kPa 15kPa 24kPa 5 Micron 20kPa 25kPa 40kPa...

  • Page 17: Monitoring & Parameters

    ® 2.00l/s FLOW RATE CLEAN FILTER DIRTY FILTER BLOCKED FILTER STATE BAG FILTER STATE DIFFERENTIAL STATE DIFFERENTIAL DIFFERENTIAL MESH COARSENESS PRESSURE (SET-POINT) PRESSURE PRESSURE 100 Micron 12kPa 15kPa 24kPa 50 Micron 12kPa 15kPa 24kPa 25 Micron 28kPa 35kPa 56kPa 5 Micron 40kPa 50kPa 80kPa...
  • Page 18 2. Enable Filtering It is important to visually inspect the electrical connections, components and conduit serving the VEXO X-POT ® unit before commencement of the operation of the unit. It is important to visually inspect the VEXO ® ® X-POT XP+ unit hydronic connections before commencement of the operation of the unit to confirm the ®...

  • Page 19: Pump Configuration

    ® Pump Configuration +24 V* DI4/OC2 Pt100/1000 Pt100/1000 +5 V* +24 V* +24 V*/5 V* +24 V* LiqTec LiqTec +24 V* DI3/OC1 +24 V* +24 V* +24 V*/5 V* +5 V GENIbus A GENIbus Y GENIbus B +24 V +24 V +5 V GDS TX +24 V*/5 V*...

  • Page 20: Pump Connection Table

    ® Pump Configuration Table TERMINAL TYPE FUNCTION TERMINAL TYPE FUNCTION Normally closed GENIbus, A GENIbus, A (+) contact Signal relay 1 Common GENIbus, Y GENIbus, GND (LIVE or PELV) Normally open GENIbus, B GENIbus, B (-) contact Normally closed Ground contact Signal relay 2 Common...

  • Page 21: Signal Cables

    ® Signal Cables • Use screened cables with a cross-sectional area of at least 0.5mm2 and a maximum of 1.5mm2 for the exter- nal on/off switch, digital inputs, set-point, and sensor signals. • Connect the screens of the cables to the frame at both ends with good connections. The screens must be as close as possible to the terminals.

  • Page 22: Setup Guide

    ® Setup Guide - Adjust Pressure Differential Setpoint Home Settings Status Assist StatusS ettingsA ssist Limit-exceeded function Operating Mode Power Consump. Limit 1 exceeded 0.00 w Normal Limit 2 exceeded Diff. press.,pump Operating hours 0.44 bar hours In “Limit-exceeded functions” locate “Limit 1 Home Screen.
  • Page 23 ® Settings Settings Status Assist Status Assist Limit 1 Limit 1 exceeded when Set the limit valve of the selected parameter. Select if “Limit exceeded” should be detected Press OK to start the setting. when the monitored value is above or below the limit.
  • Page 24 ® Settings Settings Status Assist Status Assist Detection delay 1 Reset delay 1 The action at “Limit exceeded” can be delayed. Resetting of the action at “Limit exceeded” can Press OK to start the setting. be delayed. Press OK to start the setting. 3600 3600 25.
  • Page 25 ® Settings Settings Status Assist Status Assist Relay output 1 Relay output 2 Select the function of relay output 1 Select the function of relay output 2 Alarm Pump running Operation Warning Pump Running Limit 1 exceeded In “Relay Output 1” you can In “Relay Output ”...

  • Page 26: Grundfos Pump Configuration

    ® Pump Configuration - Standard Control Panel The pumps are fitted with this control panel as standard. POS. SYMBOL DESCRIPTION Allows radio communication with Grundfos GO Remote and other products of the same type. When you try to establish radio communication between the pump and Grundfos GO Remote or another pump, the green...
  • Page 27 ® Pump Configuration - Constant-Curve Control Mode Pump in constant-curve control mode In constant-curve control mode, the pump performance lies between the maximum and minimum curve of the pump, as seen on the right. Setting to maximum curve: • Press continuously to change over to the maximum curve of the pump (top light field flashes).
  • Page 28 ® Pump Configuration - Advanced Control Panel The pumps can be fit with the advanced control panel as POS. SYMBOL DESCRIPTION an option. Saves changed values, resets alarms and expands the value field. Enables radio communication with Grundfos GO Remote and other products of the same type.
  • Page 29 ® Home Status Settings Assist Set-point Control mode 5.00 bar Const. pressure Operating mode Actual controlled value Normal 4.90 bar POS. SYMBOL DESCRIPTION POS. SYMBOL DESCRIPTION Home Indicates that the pump has This menu shows up to four been stopped via the user-defined parameters.
  • Page 30 ® Pump Configuration - Advanced Control Panel Menu Overview CRE, CRIE, MULTI-PUMP CRNE, SPKE, SYSTEM HOME MTRE • • • CRE, CRIE, MULTI-PUMP STATUS CRNE, SPKE, SYSTEM MTRE Operating status • • • • Operating mode, from • • • •...
  • Page 31 ® Pump Configuration - Control Panel Settings CRE, CRIE, MULTI-PUMP STATUS CRNE, SPKE, SYSTEM MTRE Set-point • • • • Operating mode • • • • Set manual speed • Set user-defined speed • • • Control mode • • •...
  • Page 32 ® CRE, CRIE, MULTI-PUMP STATUS CRNE, SPKE, SYSTEM MTRE • Special functions • • • • Low-flow stop function • • • • Stop at min. speed Pipe filling function • • • • Pulse flowmeter setup • • • •...
  • Page 33 ® Pump Configuration - Grundfos GO Remote The pump is designed for wireless radio or infrared communication with Grundfos GO Remote. Grundfos GO Remote enables setting of functions and gives access to status overviews of functions and gives access to status overviews, technical product information and actual operating parameters. Grundfos GO Remote offers the following mobile interfaces (MI).
  • Page 34 ® Pump Configuration - Grundfos GO Remote Menu Overview CRE, CRIE, MULTI-PUMP CRNE, SPKE, SYSTEM DASHBOARD MTRE • • • CRE, CRIE, MULTI-PUMP STATUS CRNE, SPKE, SYSTEM MTRE “System mode” • • • “Resulting set-point” “Resulting system set-point” • “Actual controlled value” •...
  • Page 35 ® CRE, CRIE, MULTI-PUMP SETTINGS CRNE, SPKE, SYSTEM MTRE • • “Set-point” • “Operating mode” • • • “Set user-defined speed” • • • • “Control mode” • • • • “Setting the proportional pressure” • “Pipe-filling function” • • •...
  • Page 36 ® CRE, CRIE, MULTI-PUMP SETTINGS CRNE, SPKE, SYSTEM MTRE • • “Motor bearing monitoring” “Service” • • “Date and time” • • “Store settings” • • • • “Recall settings” “Undo” • • • “Pump name” • • • “Connection code” •...
  • Page 37 ® Pump Configuration - Function Descriptions Set-point PUMP VARIANT SET-POINT • CRE, CRIE, CRNE, • SPKE, MTRE You can set the set-point for all control modes when you have selected the desired control mode. Operating Mode PUMP VARIANT OPERATING MODE •...
  • Page 38 ® PUMP VARIANT CONTROL MODE • CRE, CRIE, CRNE, • SPKE, MTRE Possible control modes: • "Proportional pressure" • “Constant flow rate” (Const. flow rate) • "Constant pressure" (Const. pressure) • “Constant level” (Const. level) • "Constant temperature" (Const. temp.) •...
  • Page 39 ® Constant Temperature CONSTANT PUMP VARIANT TEMPERATURE • CRE, CRIE, CRNE, • SPKE, MTRE This control mode ensures a constant temperature. Constant temperature is a comfort control mode that you can use in domestic hot-water systems to control the flow to maintain a fixed temperature in the system. See illustration to the right.
  • Page 40 ® Constant Differential Pressure CONSTANT DIFFERENTIAL PUMP VARIANT PRESSURE • CRE, CRIE, CRNE, • SPKE, MTRE The pump maintains a constant differential temperature in the system and the pump performance is controlled according to this. See diagram to the right. △t This control mode requires either two temperature sensors or one differential-temperature sensor.
  • Page 41 ® Constant Level PUMP VARIANT CONSTANT LEVEL • CRE, CRIE, CRNE, • SPKE, MTRE The pump maintains a constant level, independently of the flow rate. Which can be seen to the right. This control mode requires a level sensor. The pump can control the level in a tank in two ways: •...
  • Page 42 ® Constant Curve PUMP VARIANT CONSTANT CURVE • CRE, CRIE, CRNE, • SPKE, MTRE You can set the pump to operate according to a constant curve, like an uncontrolled pump. See diagram to the right. The desired speed can be set in % of maximum speed in the range from 13 to 100 %.
  • Page 43 ® Function The analogue inputs can be set to these functions: - Not active - Feedback sensor; The sensor is used for the selected control mode. - Ext. set-point infl. - Other function. Measured parameter Select one of the parameters listed below, i.e. the parameter to be measured in the system by the sensor connect- ed to the actual analogue input.
  • Page 44 ® Unit SENSOR FUNCTION/ SENSOR FUNCTION/MEASURED PARAMETER MEASURED PARAMETER Pressure bar, m, kPa, psi, ft Level m, ft, in Pump Flow /h, l/s, yd /h, gpm Liquid Temperature °C, °F Other Parameter Electrical signal Select signal type: - 0.5 - 3.5 V - 0 - 5 V - 0 - 10 V - 0 - 20 mA.
  • Page 45 ® If you want to set the Pt100/1000 input for a feedback sensor, we recommend that you do this via the Assisted pump setup menu. If you want to set a Pt100/1000 input for other purposes, you can do this manually. You can set the analogue inputs via the Setup, analogue input menu.
  • Page 46 ® To set a digital input, make the settings below. Function Select one of these functions: Not active. When set to Not active, the input has no function. External stop. When the input is deactivated (open circuit), the pump stops. Min.
  • Page 47 ® Activation delay Select the activation delay (T1). It is the time between the digital signal and the activation of the selected function. Range: 0-6000 seconds. Duration timer mode Select the mode. See diagram to the right. - Not active - active with interrupt (mode A) - active without interrupt (mode B) - active with after-run (mode C).
  • Page 48 ® Possible functions, digital input/output 3 Possible functions, digital input/output 4 FUNCTION IF INPUT FUNCTION IF OUTPUT FUNCTION IF INPUT FUNCTION IF OUTPUT • Not active • Not active • Not active • Not active • External stop • Ready •...
  • Page 49 ® - "Operating" (Operation) "Operating" equals "Running" but the pump is still in operation when the pump is stopped due to low flow. See section "Low-flow detection" on page 46. - "Running" (Pump running) The pump is running. - Warning There is an active warning.
  • Page 50 ® Function of analogue output Actual speed Actual value ACTUAL SPEED (%) “ACTUAL VALUE” SIGNAL SIGNAL RANGE RANGE (V, mA) (V, mA) SENSOR SENSOR 0 - 10 V 10 V 0 - 10 V 10 V 0 - 20 mA 0 mA 10 mA 20 mA...
  • Page 51 ® “Controller” (Controller Settings) “CONTROLLER” PUMP VARIANT (CONTROLLER SETTINGS) • CRE, CRIE, CRNE, SPKE, MTRE • The pumps have a factory default setting of gain (Kp) and integral time (Ti). However, if the factory setting is not the optimum setting, you can change the gain and the integral time: - Set the gain within the range from 0.1 to 20.
  • Page 52 ® CONSTANT DIFFERENTIAL CONSTANT FLOW RATE TEMPERATURE 10 + 5L2 CONSTANT PRESSURE L2: Distance in meters between heat exchanger and sensor. CONSTANT LEVEL General rules of thumb. If the controller is too slow-reacting, increase the gain. If the controller is hunting or unstable, dampen the system by reducing the gain or increasing the integral time.
  • Page 53 ® EXTERNAL SET-POINT PUMP VARIANT FUNCTION • • CRE, CRIE, CRNE, SPKE, MTRE You can influence the set-point by an external signal, either via one of the analog inputs or, if an advanced functional module (FM 300) is fitted, via one of the Pt100/1000 inputs. Before you can enable the function, you must set one of the analog inputs or Pt100/1000 inputs to External set-point function.
  • Page 54 ® - Linear with Stop Fig. “A” In the input signal range from 20 to 100%, the set-point is influenced linearly. If the input signal is below 10%, the pump changes to operating mode Stop. If the input signal is increased above 15%, the operating mode is 100 % 3.5 V changed back to normal.
  • Page 55 ® LIMIT-EXCEEDED PUMP VARIANT FUNCTION • • CRE, CRIE, CRNE, SPKE, MTRE This function can monitor a measured parameter or one of the internal values such as speed, motor load or motor current. If a set limit is reached, a selected action can take place. You can set two limit-exceeded functions mean- ing that you can monitor two parameters or two limits of the same parameter simultaneously.
  • Page 56 ® Detection delay You can set a detection delay which ensures that the monitored parameter stays above or below a set limit in a set time before the function is activated. Resetting delay The resetting delay is the time from which the measured parameter differs from the set limit including the set hysteresis band and until the function is reset.

  • Page 57: Grundfos Eye

    ® Grundfos Eye The operating condition of the pump is indicated by Grundfos Eye on the control panel. Grundfos Eye GRUNDFOS EYE INDICATION DESCRIPTION The power is off. No lights are one. The pump is not running. The two opposite green indicator lights are rotating in the direction of rotation The power is on.
  • Page 58 ® Signal Relays The pump has two outputs for potential-free signals via two internal relays. You can set the signal outputs to Operation, Pump running, Ready, Alarm, and Warning. The functions of the two signal relays appear from the table below; CONTACT POSITION OF SIGNAL RELAYS WHEN ACTIVATED OPERATING...

  • Page 59: Filter Maintenance

    This equipment must only be used, maintained or serviced by trained competent engineers. If in any doubt please do not touch this equipment. For further advice please contact VEXO International (UK) Ltd or your reseller for additional information and guidance. WARNING This equipment uses Rare Earth Magnets with a strong magnetic field.

  • Page 60: To Clean & Replace The Filters

    X-POT XP+ Vessel (3) to drain. ® ® Remove the 1/2” plug and manually open the 1/2” Manual Vent Isolating Valve (15). This will open the VEXO ® X-POT XP+ ® Vessel (3) to atmosphere and will help the VEXO ®...
  • Page 61 28. Manually close the 1” Isolating Valve (10). This will close the VEXO X-POT XP+ Vessel (3) to drain. ® ® 29. Slowly manually open the 1” Isolating Valves (1) on the Dirty Flow into the VEXO ® X-POT XP+ ® . This will now let system water into the VEXO ®...

  • Page 62: Dosing & Water Treatment Additives

    ® Dosing & Water Treatment Additives To manually dose the system, it may only be carried when the system is shut down and the VEXO ® X-POT XP+ ® has been hydraulically isolated from the main system water pressure and also electrically isolated from the main system power supply.

  • Page 63: To Manually Dose The System With Water Treatment Additives

    X-POT XP+ Vessel (3) to drain. ® ® Remove the 1/2” plug and manually open the 1/2” Manual Vent Isolating Valve (15). This will open the VEXO ® X-POT XP+ Vessel (3) to atmosphere and will help the VEXO X-POT XP+ Vessel (3) drain quicker.
  • Page 64 This over-spill will eventually lead to drain. 24. Manually close the 1” Isolating Valve (12) below the Tundish. 25. Replace the 1/2” plug and manually close the 2” Manual Vent Isolating Valve (15). This will close the VEXO ® X-POT XP+ Vessel (3) to atmosphere.
  • Page 65 39. Manually close the 1” Isolating Valve (10). This will close the VEXO ® X-POT XP+ ® Vessel (3) to drain. 40. Slowly manually open the 1” Isolating Valves (1) on the Dirty Flow into the VEXO X-POT XP+ . This will now ® ®...

  • Page 66: Bolt Tightening Notes

    Bolt 4 -> Bolt 10 Sequence F REPEAT 3 TIMES TI GUARANTEE ALL NUTS ARE TO (40NM) FRONT When the VEXO ® X-POT XP+ ® top flange plate is replaced, ensure the seal faces are clean and unobstructed. Ensure the Manual Air Vent spout is positioned directly over the Manual Vent Tundish (13).

  • Page 67: Decommissioning & Dismantling

    This equipment must only be used, maintained or serviced by trained competent engineers. If in any doubt please do not touch this equipment. For further advice please contact VEXO International (UK) Ltd or your reseller for additional information and guidance.

  • Page 68: General Assembly Drawing Vexo X-Pot Xp

    ® ® WEAR APPROPRIATE PPE WHEN WARNING! OPERATING THE VEXO X-POT ® ® INSTALLATION BY QUALIFIED/EXPERIENCE TECHNICIANS ONLY Dimensions Specifications Refer to corresponding letter in drawing above Total unit width (with mounts) 1000mm Connection Size 2” BSP Total Length 650mm...

  • Page 69: General Access Drawing Vexo X-Pot Xp

    ® ® WEAR APPROPRIATE PPE WHEN WARNING! OPERATING THE VEXO X-POT ® ® INSTALLATION BY QUALIFIED/EXPERIENCE TECHNICIANS ONLY NOTE: ALL MEASUREMENTS ARE FOR GUIDANCE Recommended General Access Measurements Refer to corresponding letter in drawing above 1300mm Maximum height of the tundish above ground...

  • Page 70: Declaration Of Conformity

    ® ® www.VEXOint.com X-POT XP+ O&M Manual ® technical@VEXOint.com Last Updated - 11/01/2023 +44 (0)1767 500 150 Page 70...

  • Page 71: Service History

    ® ® WEAR APPROPRIATE PPE WHEN WARNING! OPERATING THE VEXO X-POT ® ® INSTALLATION BY QUALIFIED/EXPERIENCE TECHNICIANS ONLY ® www.VEXOint.com X-POT XP+ O&M Manual ® technical@VEXOint.com Last Updated - 11/01/2023 +44 (0)1767 500 150 Page 71...

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