Armstrong 3750 User manual

3750 Pulpress
pressurisation
unit
Installation and
operating instructions
File No: 37.858uk
Date: september 02, 2016
Supersedes: 37.858uk
Date: october 05, 2015

contents
1.0 ce conformities 4
2.0 Preface 4
3.0 Introduction 4
4.0 Warnings symbols 4
5.0 Instructions for safe use 4
6.0 Typical chilled–water sealed system 5
7.0 Typical lthw sealed system – max. 100°c 5
8.0 Typical mthw sealed system – max. 120°c 6
9.0 Storage 6
10.0 Limitations 6
11.0 Protection 6
12.0 General notes 6
13.0 Installation 6
13.1 Mechanical 6
13.2 Electrical 6
14.0 Safety regulations 7
15.0 Commissioning 7
16.0 Operation 7
17.0 Heating system 7
18.0 Chiller systems 7
19.0 Controller functions 8
20.0 User interface 9
21.0 Statistics 9
22.0 Parameters 10
23.0 Warnings and alarms 11
24.0 Maintenance checks 13
25.0 Fault finding chart 13

installation &
operating instructions
3750 Pulpress
pressurisation unit
4
please read all these notes carefully,
1.0 ce conformities
lvd bs en 61010-1
Low voltage switchgear bs en 60439-1
Safety of machinery bs en iso 12100-1&2
Safety of machinery bs en 60204-1
Electromagnetic compatibility
Harmonic emissions bs en 61000-3-2
Electrostatic discharge bs en 61000-4-2
Radiated rf immunity bs en 61000-4-3
Fast transient bursts bs en 61000-4-4
Voltage surges bs en 61000-4-5
Conducted rf immunity bs en 61000-4-6
Voltage dips bs en 61000-4-11
Generic immunity bs en 61000-6-1
Generic immunity bs en 61000-6-2
Generic emissions bs en 61000-6-3
Generic emissions bs en 61000-6-4
Safety of stationary circulation bs en 60335-2-51
pumps for heating and service
water installations
2.0 preface
1The 3750 Pulpress pressurisation unit has been designed
for ease of setting and operation
2All packaged pump systems are pre-wired and fully tested,
both hydraulically and electrically, prior to dispatch.
3All parameter data has been entered into the controller
in accordance with the system criteria. Once on-site
connections have been made, and all pre-checks carried
out, the system is ready for commissioning.
4During commissioning if system conditions are found
to vary from those set out in the design criteria, the
parameters can be easily changed
3.0 introduction
1This installation and operation manual contains specific
information regarding safe installation and operation of
the 3750 Pulpress pressurisation unit. These instructions
must be read and understood by anyone responsible for
the installation and maintenance of this equipment.
2 Prior to power being applied, it is essential that all
pre-commissioning procedures are carried out in full.
3Operators and installers must familiarise themselves with
the operation and controls of the equipment.
4.0 warnings symbols
Safety instruction where an electrical hazard is
involved.
Safety instruction where non-compliance would
aect safety.
Safety instruction relating to safe operation of the
equipment. (attention)
5.0 instructions for safe use
1This equipment has been designed for the pressurisation
of sealed heating, chilled water and closed condenser
water systems to the operating conditions shown.
2No installation of this equipment should take place until
this installation, operation and maintenance instructions
has been studied and understoodby the person
responsible.
3Handling, transportation and installation of this equipment
shall only be undertaken with the proper use of lifting gear.
4The set shall not be used for any purpose other than that
for which it was designed and sized.
5The set shall not be operated with the cover
removed and the cover interlocked isolator
overridden.
note:
During normal operation the pumps will only
generate pressures sucient to satisfy system de-
mand. However, abnormal running conditions may
cause closed valve pressures to be experienced.

installation &
operating instructions
3750 Pulpress
pressurisation unit
5
6.0 typical chilled–water sealed system
7.0 typical lthw sealed system – max. 100°c
lock shield valve
evaporator
pump
return
expansion vessels
flow
condenser
chillier
pump
electrical safety interlock
isolating valve non-return valve
chillier
alternative
position
to cooling
tower
cooling load
electrical supply
Air eliminator
see leaflet on air eliminators
signals to bms
3750 pulpress
mains
supply
test
point
system fill
connection
drain cock
Equipment within this
area supplied by others
auto-air
vent with
on-o clock
anti-
gravity
loop
safety
valve
lock shield valve
drain cock
pump
pump
return
expansion vessels
auto-air
vent with
on-o clock
anti-
gravity
loop
flow
heating load
boiler
boiler
controls
thermos
tat
electrical safety interlock
isolating valve non-return valve
Equipment within this
area supplied by others
alternative
position
over temperature
energy cutout
electrical supply
temperature
gauge pressure
gauge signals to bms
3750 pulpress
mains
supply
test
point
system fill
connection

installation &
operating instructions
3750 Pulpress
pressurisation unit
6
8.0 typical mthw sealed system –
max. 120°c
The arrangement of the mthw scheme is similar to the lthw
system above but has, in addition, an intermediate vessel
installed between the expansion vessels and the system
connection. The volume of water contained in this vessel
ensures that the return temperatures at the boiler are not
transferred to the expansion vessel, where damage to the
diaphragm would otherwise occur.
warning notes:
1Packed-gland circulating pumps must not be used in
sealed systems.
2Water treatment must not be added to the system via the
3750 Pulpress break tank.
3No part of the set, expansion vessel, intermediate vessel
or connecting pipe is to be lagged.
4Precautions should be taken to ensure that Lock Shield
Valves are protected against unauthorised closure.
9.0 storage
Store in a dry place. Protect against dirt, damage and frost.
10.0 limitations
1Maximum system working pressure: 10 bar.
2Maximum flow temperature 120°c.
3Electrical supplies: 1phase, 50 or 60 Hz, 220 or 240 volts.
4Power supply fluctuation: +/- 10% maximum.
5Humidity non-condensing: 80% rh up to 31°c
decreasing linearly to 50% rh at 40°c.
6Ambient temperature: -5°c to 40°c.
7Water supply pressure 0.8 bar minimum to 6.8 bar
maximum with ballcock fully open.
8System fill pressure:
8.1 Low pressure pump(s) – 0.5 to 2.5 bar.
8.2 Medium pressure pump(s) – 1.5 to 5.5 bar.
9Maximum water temperature for expansion vessels:
9.1 Continuous – 70°c above this intermediate vessels
must be used.
9.2 Intermittent – 100°c.
10
Maximum total boiler rating – refer to graph pu3750.
11.0 protection
The set must be protected from the formation of condensa-
tion. If there is a likelihood of condensation forming on or in
the control panel then an anti-condensation heater should be
fitted. Contact our service department for details.
12.0 general notes
1The sets comprise one or two pumps operating on a duty/
stand-by arrangement.
2Each set is sized to bs7074 and custom built for a specific
application, any change in the system conditions shown
may necessitate a change in the design or settings.
3System must be completely flushed out, to remove any
metal particles, dirt etc, which may damage the set.
4The system should be pressure tested, to eliminate leaks.
5Under no circumstances must any attempt be made
to introduce water treatment to the system via the
break-tank.
6No part of the set, connecting pipe or expansion vessel(s)
are to be lagged.
7Fill the system via the quick-fill connection. Do not use the
set to fill the system.
13.0 installation
13.1 mechanical
1Install the set on a flat and even surface.
2Site set with sucient space to the front, left and right
sides of the unit for maintenance purposes.
3Connect the cold water mains supply, via a stopcock, to
the ballcock in the break tank. (Water supply pressure 0.8
bar minimum with ballcock fully open).
4Arrange break tank overflow pipe to discharge into a
convenient drain in line with clause 30 of the Water supply
Bye-laws 1989 edition.
5Make a connection from the set to the return side of the
boiler and suction side of the circulating pump(s). If
intermediate vessels are provided these should be fitted
in this connection with the set and expansion vessels
connected to the bottom of the vessel and the system to
the top of the vessel. A manual air vent should be fitted in
the pipe work close to the top of the vessel, see general
arrangement drawing provided. Ensure pump(s) are
vented by loosening the vent cap on top of the delivery
branch of the pump. Care must be taken not to over
tighten the system or water inlet connections.
6Never dry run the pump.
7For wall mounting, wall structure will need to be
determined to select appropriate fasteners. Ensure there
are no pipes or electrical cables running behind where the
wall bracket is to be secured.
13.2 electrical
1The power supply required is 240 volt +/-10%, 1phase,
50 Hz or 60 Hz to suit motors fitted.
2The incoming supply should be connected to the door
interlocked isolator from a local 10 amp switched fused
spur and if possible an elcb unit.

installation &
operating instructions
3750 Pulpress
pressurisation unit
7
3All incoming cable glands should be ip54 rated as a
minimum.
4Wire the set control systems (see enclosed wiring
diagram) from the volt free terminals to the boiler control
system.
5Boiler/chiller interlock provided via normally open volt
free contact.
6The set must be eciently earthed.
attention
It is the user’s or certified electrician’s responsibil-
ity to ensure correct earthing and protection in
accordance with applicable national and local
requirements and standards.
important safety information
1The voltage on the 3750 Pulpress unit is dangerous when
it is connected to the mains. Incorrect installation of the
set may lead to material damage or serious injury or
death. Consequently, you must comply with the
instructions in this manual as well as the local rules and
safety regulations.
2Touching the electrical parts may be fatal, even after
the mains supply has been disconnected, wait at least
4minutes.
3The installation must be fused and isolated correctly.
4Covers and cable entries must be fitted.
14.0 safety regulations
1The 3750 Pulpress unit must be disconnected from the
mains if repair work is to be carried out. Check the mains
supply has been disconnected and the necessary time has
passed (4minutes).
2The correct protective earthing of the equipment must
be established, the user must be protected against supply
voltage, and the set must be protected against overload in
accordance with applicable national and local regulations.
3RCDs (elcb relays), multiple protective earthing or
earthing can be used as extra protection, provided that
local safety regulations are complied with.
15.0 commissioning
1Fill the system with water via the quick fill connector. It is
essential that all air in the system is allowed to escape
freely through automatic air vents and radiator bleeds,
failure to remove air could result in a system malfunction.
2Turn on the water supply feeding the 3750 Pulpress unit
and fill the breaktank.
3Check pumps are primed by loosening cap on the delivery
side of the pump–let water escape until no air is present,
replace caps and pressurize to the ambient temperature
set pressure. “Never dry run the pumps”.
4With cover interlock isolating switch in the o position
switch on the power supply to the unit.
16.0 operation
Turn the main isolating switch to the ‘On’ position. The
system pressure will be displayed on the digital readout. The
unit will automatically maintain pressure in the system as
set out in the design criteria and will only operate when the
pressure falls between the system fill pressure and the pump
cut-in pressure.
17.0 heating system
Start the boiler(s). The water from the system will flow into
the vessel(s) and the system pressure will rise slowly and
settle at a pressure below the maximum pressure shown on
the nameplate. If the boiler safety valve lifts, check the valve
setting and the system details, against the ordering specifica-
tion for the 3750 Pressurisation unit.
18.0 chiller systems
When the chiller(s) are started the water contracts as it cools
and the 3750 pressurisation unit will pass water from the
tank via the pump, to bring the pressure up to the ambient
temperature setting pressure. When the chiller is switched
o the expanding water will pass into the expansion vessel,
the pressure will rise and settle at a pressure below the maxi-
mum pressure shown on the nameplate.
note
On chiller sets, the highest system pressure will occur when
the system is at ambient temperature after operation, where-
as on heating sets the highest pressure occurs at maximum
system operating temperature.
If the system pressure falls due to a slow leak, water in the
expansion vessel(s) will run back into the systems.
If the system leakage continues causing a drop in pressure
below the initial system pressure the pump(s) will start to
restore the initial system pressure.
In the event of a leak exceeding the pump(s) capacity then,
providing the set's volt free contacts have been wired accord-
ingly, the boiler burners will be shut down and the circulating
pumps are stopped. The system should then be closed down
and the leak rectified.

installation &
operating instructions
3750 Pulpress
pressurisation unit
8
19.0 controller functions
Pressure dip delay
No message required, no alert. Should not start the pump
until value parameter [pressure dip delay] seconds have
passed without the pressure coming back to the set point.
Digital display
Showing system pressure, warning codes, alarm codes and
pump run indication.
Pump test
When the controller is in the normal mode (not
programming).
When the up pbutton is pressed and held for 3seconds
Pump 1will run and continue to run until the button is
released.
When the down qbutton is pressed and held for 3seconds
Pump 2will run and continue to run until the button is
released. This will enable the pumps to be tested manually.
Hours run meter(s)
This cannot be reset, showing the number of hours the pump
has been running. (Max. 999 hours).
Pump auto cycle
On two pump sets pumps will auto-cycle increasing service
interval time.
Alarm
Audible alarms on error condition with mute.
pressure
pump 1pump 2 pump 1
time
par 12 - [pulse cycle time] = 1 second
par 11 - [hrs to pulse cycle] = 720 hrs
par 3 - [pressure dip delay] = 5 sec
par 5 - high pressure alarm = mwp(pf1)
par 1 - pump cut out = fill pressure (pi)
par 1 - pump cut in = (pi) - 0.2bar dierential
par 4 - low pressure alarm = static height (ph)

installation &
operating instructions
3750 Pulpress
pressurisation unit
9
20.0 user interface
21.0 statistics
number name type
from s01 to s30 Alarm logging [30] num
s31 Pump 1run time –hrs num
s32 Pump 2run time –hrs num
s01 Most recent alarm
s30 Oldest alarm
Lines "---" = no alarm registered
autotest
device check
normal
view pressure or alarm
Press up or down for 3s = Pump test
Press up and down for 5s = Parameter lock/unlock
Press set for 5s = go to view par
Press down + for 5s = Autotest
Press set and for 5s = go to view stat
Press for 5s = Reset alarm
view stat
display statistics
Time out 20s = go to normal
Press up or down to select statistics
Press set = go to detail stat
view par
display parameter no.
Time out 20s = go to normal
Press up or down to select parameter
Press set = go to change par
change par
display parameter values
Time out 20s = go to normal
Press up or down to change parameter value
Press set = go to view par
Press set for 5s = save and go to view par
detail stat
display statistic values
• Time out 20s = go to normal
•Press up or down to scroll logging
alarm statistics.
• Press set = go to view stat
Enhanced Only

installation &
operating instructions
3750 Pulpress
pressurisation unit
10
22.0 parameters
0= no 1= nc
par
no. parameter type default min max inc unit of measure
device
mode
1Fill pressure (Pi) dec 2.5 124.9 1Bar/25 All
2Pump cut in (Pi-0.2bar) dec 0.2 05.0 1Bar/25 All
3Pressure – dip delay num 5 0 100 1Seconds All
4Low pressure alarm (Ph) dec 2.2 024.9 1Bar/25 All
5High pressure alarm (Pf1) dec 4.0 124.9 1Bar/25 All
6Max pump run time num 15 1990 1Minutes All
7nc no alarm relay num 1* 0 1 1 Numeric All
8Excessive no. of starts num 15 199 1Numeric Enhanced
9Excessive starts – minutes num 60 1720 1Minutes Enhanced
10 Service – months num 12 199 1Numeric Enhanced
11 hrs after which the pump pulse
cycle starts – adjustable in p12 num 720 18640 1Hours Enhanced
12 Pulse cycle time num 1 1 99 1Seconds Enhanced
13 nc no lpr relay num 1* 0 1 1 Numeric Enhanced
14 nc no hpr relay num 1* 0 1 1 Numeric Enhanced
15 nc no pf1 relay num 0* 0 1 1 Numeric Enhanced
16 nc no pf2 relay num 0* 0 1 1 Numeric Enhanced
17 nc no run pump 1relay num 0* 0 1 1 Numeric Enhanced
18 nc no run pump 2relay num 0* 0 1 1 Numeric Enhanced
19 nc no lll relay num 0* 0 1 1 Numeric Enhanced
20 nc no hll relay num 0* 0 1 1 Numeric Enhanced
21 nc no est relay num 0* 0 1 1 Numeric Enhanced
22 nc no comm/power relay num 0* 0 1 1 Numeric Enhanced
23 n/a num 2 1 30 1Days n/a
24 n/a num 2 1 60 1Minutes n/a
25 n/a num 0* 0 1 1 Numeric n/a
26 Lux – digital num 6 0 7 1 Numeric All
27 Number of pumps num 2 1 2 1 Numeric All
28 Device_on_o num 1 0 1 1 Numeric All
29 Address num 1 1 247 1Numeric All
30 ext_relay num 0 0 1 1 Numeric All
99 Firmware release num xx.xx -- -- -- Decimal All
note: (enhanced only)
Parameter 28 indicates the start-up or stand-by status of the controller (1 = on,0 = Stand–by)
Parameter 29 indicates the address of the controller when it is connected in the MODbus mode, (1to 247).
Parameter 30 indicates the communication mode: 0= external relay board present, therefore rs485 mode enabled.
1= MODbus mode enabled. When the external relay board is connected to the MODbus enabled controller please refer to
drawing number px10899 for controller setting instructions.

installation &
operating instructions
3750 Pulpress
pressurisation unit
11
23.0 warnings and alarms
break tank low/high water level
The low water level alarm will be activated should the break
tank level low switch trip.
The controller will display:
low water level
Functions:
• All pump(s) will stop running
• All pump running contacts de-activate
• Activates ‘lll’ alarm on display
• Activates ‘Low Level’ alarm contact. (Enhanced +vfc
version only)
high water level (enhanced only)
Functions:
• All pump(s) will stop running
• All pump running contacts de-activate
• Activates ‘hll’ alarm on display
• Activates ‘High Level’ alarm contact. (Enhanced +vfc
version only)
note:
In a high and low level alarm condition the set will trip and
stop all pumps until the water level returns to normal.
The unit will then auto reset and operate as normal.
low system pressure
The low water pressure alarm will be activated should the
pressure at the transducer drop below the value set in
parameter 4.
Functions:
• Activates ‘lpr’ alarm on display
• Activates ‘Common Alarm’ contact
• Activates ‘Low Pressure’ alarm contact (Enhanced +vfc
version only)
note:
This is an alarm. The set will stop all pumps until the
system pressure returns to normal, if low pressure is due to
a system leak it will need to be rectified and system fill pres-
sure restored.
The unit will then auto reset and operate as normal.
high system pressure
The high system pressure alarm will be activated should
the pressure at the transducer rise above the value set in
parameter 5.
Functions:
• All pump(s) will stop running
• Activates ‘hpr’ alarm on display
• Activates ‘Common Alarm’ contact
• Activates ‘High Pressure’ alarm contact
note:
This is an alarm. The set will stop all pumps until the system
pressure returns to normal.
The unit will then auto reset and operate as normal.
transducer failure
The transducer failure alarm will be activated should the
transducer lose its signal.
Functions:
• All pump(s) will stop running
• Activates ‘sf’ alarm on display
note:
This is an alarm. The fault must be rectified before the unit
can operate as normal.
pump tripped
Any pumps that are tripped during operation, either in hand
or auto, will activate the following:
Functions:
• Pump(s) will stop running.
• Activates ‘pf1’ alarm on display (pump 1)
• Activates ‘pf2’ alarm on display (pump 2)
• Activates ‘pfa’ alarm on display (pump 1& 2)
• Activates pump 1or 2contact. (Enhanced +vfc
version only)
note:
This is an alarm. Standby pump will take over and the set will
operate normally in the event of both pumps being tripped
the fault will need to be rectified and alarm manually reset
before the unit can operate normally.
pump running
Any pumps that are running during operation, either in hand
or auto, will activate the following:
Functions:
• Indicates ‘p1 or p2’ running on display
• Activates relevant ‘Pump Running’ contact (Enhanced +vfc
version only)

installation &
operating instructions
3750 Pulpress
pressurisation unit
12
max pump run time
The maximum pump run time alarm will be activated if the
pump runs for an excessive amount of time.
Functions:
• Pump(s) will stop running
• Activates ‘prt’ alarm on display
note:
This is an alarm. Excessive pump run time may indicate a
system fault, rectify and reset manually.
excessive pump starts (enhanced only)
The excessive pump start alarm will be activated if the pump
starts for an excessive number of times over a certain period
of time.
Functions:
• Pump(s) will stop running
• Activates ‘est’ alarm on display
note:
This is an alarm. Excessive pump starts may indicate a
system fault, rectify and reset manually.
service reminder (enhanced only)
The service reminder warning is displayed ten months after
being activated.
Functions:
• Activates ‘ser’ on display
note:
Call Armstrong service to arrange service visit.
alarms
alarm description pbasic /
enhanced relay buzzer display blinking pump stop reset delay time
High
pressure
High pressure alarm – when the
system pressure is above the
required set point
6basic gyes hpryes yes only
auto 500ms
Low pressure
Low pressure alarm – when the
system pressure is below the
pressure limit
5basic gyes lpryes yes only
auto 500ms
Max. pump
time Max. pump run time alarm 3basic dyes prt yes yes only man ---
Power -
pump 1
Tripped pump alarm
9basic dyes pf1 yes no only
man 500ms
Power -
pump 210 basic dyes pf2 yes no only man 500ms
Power –
pump all 2basic dyes pfa yes yes only man 500ms
Low water Low water alarm – not enough
water in the break tank 7basic dyes lll yes yes only auto 500ms
High water High water alarm 8enhanced dyes hll yes no only
auto 500ms
Pressure
sensor failure
Sensor failure – if the sensor
exceeds the check values 1enhanced dyes sf yes yes only man 1000ms
Service
reminder
Service reminder – when activat-
ed, p10 months will be counted.
Armstrong Service intervention
is required when Reminder mes-
sage is displayed.
11 enhanced no no ser yes no by
pass ---
Excessive
starts
Excessive starts – no more than
p08 starts in p09 hours are
permitted
4enhanced dyes estyes yes only
man ---
p= priority – order of displayed messages 1: High Priority, no.: Lower Priority
relay = g: General (on board), d: Dedicated on expansion board

installation &
operating instructions
3750 Pulpress
pressurisation unit
13
24.0 maintenance checks
Regular checks (Every 3months)
• Check the pump(s) are developing the correct pressure and
are not noisy or vibrating or air-locked.
• Check that the mechanical seal is not leaking.
• Check that the motor is not over heating.
Checks at six monthly intervals
• Check electrical installation thoroughly for defects. Ensure
that the earth connections are making good contact.
• Check that the break tank is clean.
• Check the operation of the high and low pressure set points.
• Check low level float switch, (high if fitted).
Maintenance
For maintenance please contact our service division on
[phone].
25.0 fault finding chart
section problem
1Pump(s) run continuously
2Pump(s) will not run
3High pressure
4Low pressure
5Low water level
1Pump(s) run continuously
symptom/cause action
Very high
leakage rate
Check system for leaks. Check for split
in vessel bag via the air valve. Check
non-return valve is not bypassing
through second pump.
Faulty
electrical circuit
Check that all wiring is in place and not
loose at any connections.
System pressure
setting set
too high
Compare system setting pressure
(System data on display nameplate).
with Fill pressure (Pi) on data plate. To
reset consult Armstrong Service Dept.
2Pump(s) will not run
symptom/cause action
Pump(s) tripped Check miniature circuit breakers and
reset if necessary.
Faulty electrical
circuit
Check that all wiring is in place and
not loose at any connections.
Pump(s) burnt-out
seized
Repair or replace pumps.
3High pressure
symptom/cause action
Incorrect capacity of ves-
sel or larger system than
originally specified
Check system and vessel ca-
pacity by re-calculating sizes.
Failure to maintain air
charge
Isolate and drain the vessel.
Adjust the air charge to match
the fill pressure of the system.
4Low pressure
symptom/cause action
Pump(s) tripped Check miniature circuit breakers and
reset if necessary.
Pump(s) burnt-
out seized
Repair or replace pumps
System leakage
rate very high
Check system for leaks. Check for split
vessel bag via the air valve. Check non-
return valve is not bypassing through
second pump.
No water in tank
or spasmodic
water supply
Ensure that incoming water supply
is functioning i.e. check isolating valve
is open, ballcock operates and water
is clean.
Delivery/suction
isolating valve
closed
Open valves.
Suction strainer(s)
obstructed
Repair or replace strainers.
5Low water level
i) Break tank
symptom/cause action
No water in break
tank or spasmodic
water supply
Ensure that incoming water supply
is functioning (i.e. check isolating
valve is open, ballcock operates and
water is clean).
Incoming water pres-
sure is not sucient
Increase the water pressure,
consult Armstrong Service Dept.
ii) Alarm
symptom/cause action
Faulty electrical
circuit
Check that all wiring is in place and
not loose at any connections.
Broken or damaged
float switch
Replacement float switch required.

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