KGN pillinger SEM Manual

SEM & SE200 PRESSURISATION SETS
Operating & Maintenance
Original Instructions
Dated: 22.09.2020 –Revision: 1
Ref: OM0003

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Table of Content:
1) Introduction ………………………………………….……………
3
2) Warnings for the Safety of people & Property ………………...
3
3) Overview……….….…………………….…………………………
4
4) Main Components. ……………………………….……………...
5
5) Storage & Handling ……………………………….…….………
6
6) Operating Limits ……………………………………….….………
6
7) Product Identification Code……………….……………………...
7
8) Installation…………………………………………………......…...
7
9) Commissioning…….……………………………….………………
11
10) Operation……………………………………………………………
12
11) Product Specific Manuals…………………………………………
12
12) Maintenance……………….….……………………………………
13
13) Written Scheme of Examination …………………………………
14
14) General Fault-Finding Guidance ………………………….….….
14
15) Ec Declaration of Conformity……………………………………...
16

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1). Introduction:
The information contained within this manual is intended for the installer/user of this equipment to
safely install & operate the products mentioned.
The products are to be installed by a competent person who is familiar with all the required and
relevant regulations.
Failure to install/operate or maintain the equipment in accordance with these instructions could
cause harm, injury to persons or damage to property.
Failure to install/operate/maintain the equipment according to the Operating & Maintenance
instructions could invalidate the warranty as provided by KGN Pillinger.
No liability can be accepted for damage or operation disorders due to neglect, misuse, modification
or use of equipment other than for its intended application.
This information should be read in conjunction with the manufacturers O&M.
2). Warnings for the Safety of People & Equipment:
DANGER:
Failure to observe this caution may result in injury
and/or damage to equipment.
ELECTRIC SHOCK:
Failure to observe this warning may result electric
shock.
WARNING:
Failure to observe this warning may cause
damage/injury to property, environment or person(s).
QR Code:
The codes are scannable via a smart phone or tablets
camera to retrieve specific product details in support of
these instructions.

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3). Overview:
The KGN Pillinger “SE” Electronic range of Pressurisation Units are self-contained, fully automatic,
PLC controlled and designed to maintain the required systems pressure in both heating and chilled
water systems. When the system pressure falls below the required set level, the duty pump will start
and fill the system until the pressure is restored.
The “SE” range consists of:
➢PLC controller.
➢Heavy duty fill pumps.
➢Pipework: Nylon push fit.
➢Pump protection: MCB(s).
➢Pressure regulating valve (TS unit only).
➢Tank low level cut off switch.
➢High and low pressure output.
➢Break tank: One 18 litres (4 gallons).
➢Designed for system pressures up to 6 bar.
➢Automatic pump duty changeover per operation.
➢Pre-assembled with high and low pressure cut out VFC terminals for boiler and chiller
interface.
➢Visual Indications: Illuminated mains on switch, glycerine filled pressure gauge and visual
readout on PLC display.
➢Polypropylene tank incorporating air gap, ball/float valve (DN15 BS21) and overflow
(DN22 BS21).

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4). Main Component Listing – SE200ES Booster Range .
Ref
Component
1
Break Tank
2
Pressure Gauge
3
Low Level Cut Off Switch
4
Pump(s)
5
Inlet
6
Overflow
7
8
PLC Controller
Outlet

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5). Storage & Handling:
➢The SE200ES pressurisation set is packaged in a dedicated cardboard base, surround and
top. (this is to remain in place until ready for install).
➢The product must be stored in a covered and dry location, free from dirt, heat and vibrations.
➢The product must be stored at an ambient temperature between: 5c to 40c.
➢Do not place heavy weights on packaged products as this may cause damage.
If the equipment is to be stored for any length of time all liquids within the pumps & tank
should be drained.
6). Operating Limits:
FLUID TEMPERATURE
-10C to +80C
AMBIENT TEMPERATURE
+5C to +40C
OPERATING PRESSURE
10 bar (Max)
PROTECTION CLASS
IP55
INSULATION CLASS
F
Noise emissions:
Assembled units weigh >38.5kgs.
Failure to properly lift & support these sets can result in serious personal
injury and/or equipment damage. The appropriate rated lifting devices and
methods must be used for & during lifting operations.
<70 dB(A)
Exposure to excessive noise can cause permanent hearing damage.
It is the end users’ responsibility to identify the required legal
requirements, ensuring the appropriate safety equipment (PPE) is
applied and noise control is in place.

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7). Product Identification Code(s).
All KGN Pillinger SE200E pressurisation sets are identified by the below coding, each product will
have this clearly affixed to the set:
SE200 ES TS
-
Twin Pump
Single System
Twin Pump
Dual System
SEM
Pressurisation
Set - Mini
8). Installation
➢Prior to installation the pressurisation set should be thoroughly checked for any damage
during transportation and reported immediately to KGN Pillinger and not installed.
➢The unit is required to be installed in a ventilated, dry frost-free position, allowing 0.5m
clearance on all sides and front to enable general maintenance.
➢Connect the SE200ES pressurisation set water inlet ½”(right side of cabinet) to a suitable
water supply.
➢Install an isolation valve (not provided by KGN) to aid maintenance.
➢Connect to the overflow outlet (right hand side of unit) and position an overflow pipe to be
noticed and rectified (if required).
➢Connect the 15mm compression discharge port (right hand side of cabinet) to the system
inlet.

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Typical MTHW system Install
WARNING:
It is the responsibility of the installer to ensure that the overflow is
able to keep up with the incoming water volume, if not the case then
a pressure reducing valve is advised to reduce the incoming water
volume.
WARNING:
The break tank has a ‘weir slot’as required by the water bylaws to
prevent back flow contamination.
If the inlet ball valve or NRV suffered a catastrophic failure the sized
overflow may not be able to handle the water volume.
In this instance, excess water will be ejected through the weir slot
and onto the plant room floor.

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Electrical Connections
➢The incoming supply must be sized to carry the motor full load current of the pump
(as shown on duty plate).
➢All electrical connections are to be made against the relevant product wiring diagrams.
➢All electrical connections should be sized, installed and protected in accordance with the
requirements of the latest safety standards and any other current local rules and regulations.
➢It’s essential that this equipment is earth bonded to the building earth system.
Controller Connections
All electrical connections must be made by a qualified electrical
in accordance with all local regulations and standards.

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9). Commissioning
If the pumping equipment is not installed, operated and maintained correctly it can lead to failure,
void warranty and cost time and money.
The commissioning of the set assures all systems and components of the equipment supplied are
installed, tested, operated and maintained according to the operational requirements of the system.
The commissioning process comprises of a set of engineering philosophies and procedures that
inspect and test every operational component of the equipment, from individual functions such as
instrumentation and control logic, through to the full operation of the system.
The main objective of commissioning is to provide the safe and orderly handover of the unit to the
customer, guaranteeing its operability in terms of performance, reliability and safety.
We recommend the unit is commissioned and subsequently
serviced biannually by a fully trained KGN Pillinger engineer.

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10). Operation
➢The control of the system is by the use of pressure transducers interfacing with a pre-
programmed intelligent relay.
➢As the pressure in the system falls below the pre-set fill pressure, the pressure will be
detected by the transducer which will enable the duty pump to operate under the dictates of
the settings within the intelligent relay.
➢The pump will then deliver water to the system thereby raising the pressure until the cut-out
pressure is reached at which point the pump will stop.
➢The duty pump will automatically rotate per operation in an attempt to achieve even wear on
the pumps.
➢Should the duty pump fail for any reason, the secondary pump will start as the duty pump.
➢If the pressure within the system goes beyond the pre-set limits, the system pressure alarm
will activate, illuminating the fault codes displayed on the ‘Zelio’, and operating a volt-free
contact (which is usually connected to shut down the burner/chiller).
11). Product Specific Manuals
For further details please refer to the specific manufacturer product manual available via QR code(s)
below or via https://kgnpillinger.co.uk/download-centre/
Manufacturers/ products are identifiable by their product name plates located on the individual
product
Lowara PSAM70 pumps
Scan the code with your smart device camera (or click the code) to
be directed to the product specific operating manual for in-depth
details.

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12). Maintenance
➢The unit is constructed using low maintenance components throughout and should not
require any day to day maintenance. The following is the recommended frequency for
various maintenance tasks.
➢Other items, such as security of fixings, terminations, plant room mechanisms and
accessories are not specified, but should be carried out as a matter of course, as on any
other piece of equipment.
We recommend the unit is inspected frequently and serviced biannually by a fully trained and
qualified - KGN Pillinger engineer.
Monthly checks:
1. Pumps for leakage and quiet running.
2. Check that the motor(s) run without over heating
3. Check for undue noise or vibrations.
Six monthly checks (in addition to monthly schedule):
1. Ensure the break tank is clean and that the correct water level is maintained.
2. Check that the vessel gas pre charge is at the correct pressure.
Failure to maintain the unit(s) may result in partial or complete
failure and cause damage to property.
Do not touch any live parts for at least 8 minutes after switching
off the power.
The electrical system must be isolated prior to carrying out any
works.

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13). Written Scheme of Examination –PSSR2000
Accumulator vessels are classed as a pressure system under the Health and Safety Executive
‘Pressure system safety regulations 2000’.
This regulation imposes a legal requirement on the user/maintainer to have the equipment
inspected by a competent company on a regular basis as a mandatory duty under parts 7 & 8 of the
regulations.
A supplier / installer may not fall under the category of user / maintainer, however they are still
obliged to inform the user / maintainer of their legal and mandatory duties under the HSE
Regulation.
KGN Pillinger recommend that any vessel(s) larger than 250bar/ litres should have a working test
carried out every 6 months and a thorough examination every 24 months.
Bar/Litre = Maximum Working Pressure (Bar) x Volume of vessel (Litres)
14). General Fault-Finding Guidance:
FAULT
POSSIBLE CAUSE
RECOMMENDED ACTION
Pump(s) fails to start:
1). Power supply failure.
2). MCB tripped.
3). Low water level
Reinstate incoming power
supply.
MCB tripped.
Reinstate water supply.
Pump(s) fail to stop:
1). System pressure low due to
large leak.
2). Set point set too high.
Switch unit off, repair leak if
required.
Lower set point.
Pump(s) switches on and
off quickly:
1). Vessel Pre-charge may
2). Mechanical stress on pump.
Replace the seal.
Support the pipe work.
Pumps start frequently:
1). If newly installed, air may still
be present within pipework.
2). Vessel pre-charge is set
incorrect.
The system requires bleeding to
remove air.
The vessels pre-charge requires
adjustment to appropriate level.

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Disposal:
This product and its associated parts must be disposed of in accordance with local regulations,
including all packaging.
K.G. Norman Ltd –t/a KGN Pillinger
Unit 3, 214 Purley Way, Croydon, CR0 4XG - UK

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15). EC Declaration of Conformity