Nexus PSD Manual

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Deaerating Equipment
Nexus PSD
Operation & Maintenance Manual
Rev!3.0!

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Rev 4.0 Mar-16 Page 2 / 35
Customer Details
Please fill in information future reference:
Company: Contact:
Address: Tel No:
Fax No:
Post Code: E-mail:
Equipment Details
Details of model and serial number may be found on the label
Model: Serial No:
Purchase date: Purchased From:
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Note:!
A!competent!and!qualified!mechanical!contractor!must!be!used!to!install,!commission!and!service!this!
equipment.!This!Operation!&!Maintenance!manual!must!be!followed.!!
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For!further!advise!on!installation!please!contact!Nexus!Valve!![1-888-900-0947!-!www.nexusvalve.com]!
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Remember!to!fill!in!installation!and!commissioning!details!for!future!reference.!
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Commissioning Record
Digital!Controller!
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As!Found!
On!Completion!
Start!Pressure!
!
!
PSI!
Stop!Pressure!
!
!
PSI!
Alarm!Pressure!
!
!
PSI!
Normal!Minutes!
!
!
Mins!
Turbo!Hours!
!
!
Hours!
Timeout!Minutes!
!
!
Mins!
Purge!Seconds!
!
!
Secs!
Pump!Count!
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Pump!Hours!
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!
!
Alarm!Count!
!
!
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Power!Interrupted!
!
!
!
Pumps!Sense!
!
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Y/N!
Turbo!Mode!
!
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Y/N!
Service!Reminder!
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Y/N!
ID!Number!!
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Contractor
Signature:
Date:
/
/
Customer
Signature:
Date:
/
/

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Rev 4.0 Mar-16 Page 4 / 35
Contents'
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Customer!Details!...............................................................................................................................................................................................!2!
Equipment!Details!.............................................................................................................................................................................................!2!
Commissioning!Record!......................................................................................................................................................................................!3!
About!this!Manual!.............................................................................................................................................................................................!5!
Conventions!used!in!this!Manual!.................................................................................................................................................................!5!
Typography!...................................................................................................................................................................................................!5!
Where!to!find!more!Information!..................................................................................................................................................................!6!
Equipment!Overview!.........................................................................................................................................................................................!6!
Principal!of!Operation!Vacuum!Deaerator!...................................................................................................................................................!7!
Installation/Capacity!.........................................................................................................................................................................................!8!
Pipe!Connections!..........................................................................................................................................................................................!8!
Typical!Installation!Diagram!Vacuum!Deaerator!..........................................................................................................................................!9!
Floor!Standing!Clearance!and!Connection!Requirements!...............................................................................................................................!10!
Electrical!Power!Supply!..............................................................................................................................................................................!11!
Fault!Contacts!.............................................................................................................................................................................................!12!
Commissioning!................................................................................................................................................................................................!13!
Pre-Commissioning!Checklist!.....................................................................................................................................................................!13!
Controller!Overview!...................................................................................................................................................................................!14!
Deaerator!Controller!Programming!...........................................................................................................................................................!15!
Purge!Seconds!Reference!Times!............................................................................................................................................................!16!
Hydraulic!Commissioning!...........................................................................................................................................................................!17!
Operation!........................................................................................................................................................................................................!19!
For!practical!guidance!on!diagnosing!and!rectifying!faults,!please!refer!to!the!Troubleshooting!section!of!this!manual.!........................!19!
Deaerating!Fault!Codes!..............................................................................................................................................................................!19!
Troubleshooting!..............................................................................................................................................................................................!21!
Maintenance!...................................................................................................................................................................................................!22!
Wiring!location!list!..........................................................................................................................................................................................!25!
Spares!..............................................................................................................................................................................................................!26!
Electrical!Items!...........................................................................................................................................................................................!26!
Deaerator!Unit!................................................................................................................................................................................................!27!
Service!Log!......................................................................................................................................................................................................!28!
Warranty!Statement!.......................................................................................................................................................................................!30!
Warranty!Details!.............................................................................................................................................................................................!31!
Notes!...............................................................................................................................................................................................................!32!
Notes!...............................................................................................................................................................................................................!33!
Notes!...............................................................................................................................................................................................................!34!

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Rev 4.0 Mar-16 Page 5 / 35
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About this Manual
This!Operation!and!Maintenance!Manual!contains!all!the!necessary!information!to!install,!commission,!operate!
and!maintain!Vacuum!Deaeration!equipment.!
It!is!recommended!to!read!all!parts!of!this!manual!before!undertaking!any!work!on!the!equipment.!
Conventions'used'in'this'Manual'
This!manual!makes!use!of!symbols!to!identify!key!pieces!of!information.!Please!take!note!of!the!following!
symbols!and!their!meaning:!
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DANGER!–!Important!safety!related!information!intended!to!prevent!injury!and/or!damage!to!the!
equipment,!system!or!property.!
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CAUTION!-!Important!information!intended!to!prevent!damage!to!the!equipment,!system!or!
property.!
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IMPORTANT!-!Important!information!intended!to!ensure!that!the!equipment!functions!correctly.!
!
USEFUL!–!Useful!information!which!may!be!helpful,!but!is!not!necessarily!required!for!the!unit!to!
function!correctly.!
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Typography'
This!manual!makes!use!of!different!typography!to!identify!different!types!of!information.!
!"#$%&'(!!!Key!words!and!phrases!!
(Round!Brackets)!Used!to!identify!a!button!on!the!digital!controller!!
[Square!Brackets]!A!parameter!on!the!digital!controller!
<Inequality!Symbols>!A!message/fault!code!displayed!on!the!digital!controller!
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Rev 4.0 Mar-16 Page 6 / 35
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Where'to'find'more'Information'
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For!further!information!please!visit!the!Nexus!Valve!Website!at!the!following!URL:!
www.nexusvalve.com!
Alternatively,!please!contact!the!Nexus!Valve!offices!using!the!details!below:!
Phone:! ! 1-888-900-0947!
Email:! ! [e-mail]!
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Equipment Overview
The!function!of!this!equipment!is!to!provide!a!means!of!dissolved!air!removal!from!the!water!used!in!sealed!
heating!and!cooling!systems.!!
This!equipment!is!not!designed!to!cope!with!sudden!losses!of!system!pressure!(e.g.!manual!
draining)!or!major!water!losses!(e.g.!large!leaks).!The!equipment!is!also!not!intended!to!be!used!
for!water!boosting!applications.!

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Rev 4.0 Mar-16 Page 7 / 35
Principal'of'Operation'Vacuum'Deaerator'
The!following!schematic!shows!the!internal!arrangement!of!a!Vacuum!Deaerating!unit:!
Water!is!allowed!into!the!Vacuum!cylinder!through!a!safety!solenoid!(13),!a!pressure!reducing!valve!(14)!
and!a!special!variable!bypass!valve!(15).!
The!pressure!reducing!valve!(14)!is!used!to!limit!the!water!held!within!the!vacuum!cylinder!to!
approximately!18!PSI.!This!is!seen!as!the!first!pressure!step.!
When!the!vacuum!cylinder!is!full!and!registering!a!suitable!start!pressure!(8b)!the!pumps!(9a/9b)!activate.!
At!the!same!time!the!special!variable!bypass!valve!(15)!opens!fully!to!allow!the!cylinder!water!to!be!
completely!flushed!back!into!the!system!by!the!pumps!(9a/9b).!This!purge!cycle!ensures!that!the!
maximum!possible!amount!of!aerated!water!will!be!exposed!to!the!vacuum!process.!
After!the!vacuum!cylinder!has!been!refreshed,!the!variable!bypass!valve!(15)!restricts!the!flow!into!the!
vacuum!cylinder.!The!pumps!(9a/9b)!continue!to!draw!water!out!of!the!cylinder!and!create!a!vacuum!
within!the!cylinder.!The!pumps!(9a/9b)!then!stop!after!a!5!second!dwell!period.!!
The!vacuum!created!within!the!cylinder!is!eroded!by!the!incoming!water!through!the!variable!bypass!valve!
(15) at!a!low!flow!rate,!this!gently!increases!the!pressure!within!the!cylinder!and!forces!the!released!air
pocket!out!through!the!Automatic!Air!Vent!(AAV)!on!top!of!the!cylinder.
The!equipment!is!connected!to!the!main!system!via!2!isolation!valves!(7a/7b)!and!backflow!from!the!
system!is!prevent!by!a!non-return!valve!(10a).!

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Rev 4.0 Mar-16 Page 8 / 35
Installation
This!unit!is!not!designed!to!be!installed!in!an!outdoor!environment.!The!unit!must!be!installed!in!a!
frost!free!environment,!away!from!precipitation!and!water!sprays/jets.!If!there!is!a!risk!of!
flooding,!the!unit!must!be!installed!on!a!raised!heavy!supporting!base.!
Please!refer!to!the!appropriate!datasheet!for!the!maximum!working!pressure!and!temperature!of!
the!pressurization!unit.!The!conditions!at!the!point!of!connection!to!the!system!must!not!exceed!
these!values.!
Unit'Capacity'
One!FPSD-250D!can!handle!a!system!up!to!39,625!gallons!of!system!volume.!Consult!factory!for!
Larger!volumes.!
Pipe'Connections'
Where!applicable,!to!avoid!damaging!the!float!valve,!the!mains!water!supply!pipe!must!be!flushed!
before!connection.!
Deaerating!connections!(2of)!to!the!return!header!must!be!made!in!the!horizontal!plane!to!
prevent!floating!or!heavy!debris!entering!the!pipework!to!this!equipment.!
ü ü!!û û!
All!pipe!connections!must!be!made!with!appropriate!jointing!compound/PTFE!tape.!
If!PTFE!tape!is!used,!care!must!be!taken!to!ensure!that!the!tape!does!not!obstruct!the!orifice!of!
the!fitting.!

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Rev 4.0 Mar-16 Page 9 / 35
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Typical'Installation'Diagram'Vacuum'Deaerator'
Install!PSD!unit!on!vibration!pad!or!4!rubber!isolator!pads!2!“!thick.!
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Rev 4.0 Mar-16 Page 10 / 35
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Floor Standing Clearance and Connection Requirements
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Reference!
Connection!
Size!
Notes!
(
)*'"+,(-.//+&"%./'(
0(1(23(
4567!)89(
-844:-6!84(
;!6(!4-<=>:>(
(6?+(@.%/"(.A(&.//+&"%./('?.B$C(D+(%/("?+(
'*'"+,(E+"BE/F(./("?+('B&"%./('%C+(.A("?+(
&%E&B$#"%./(@B,@G(
4./HE+"BE/(I#$I+'F(@E+''BE+(E+CB&%/J(
I#$I+'(#/C(K5L(I#$I+'(,B'"(/."(D+(B'+CG(
Minimum!20”!!
Minimum!6”!!
Minimum!31.5”!!

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Rev 4.0 Mar-16 Page 11 / 35
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Electrical'Power'Supply'
This!equipment!must!be!electrically!isolated!before!removing!the!covers.!Cables!connected!to!the!
volt!free!contacts!may!be!supplied!from!another!source!and!may!remain!live!after!the!unit!is!
isolated.!These!must!be!isolated!elsewhere.!
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All!electrical!connections!must!be!carried!out!by!a!suitably!qualified!and!competent!person.!!
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The!mains!power!supply!to!the!pressurization!unit!must!be!connected!into!the!fused!terminal!block!as!shown!
below:!
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It!is!recommended!to!supply!power!to!the!Deaeration!unit!via!a!lockable!disconnect.!This!should!
be!installed!within!78”!of!the!equipment.!
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This!equipment!can!be!damaged!by!the!high!voltages!produced!by!electrical!installation!testing!
equipment.!When!performing!electrical!installation!tests,!the!equipment!must!be!isolated!from!
the!supply.!
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Rev 4.0 Mar-16 Page 12 / 35
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Fault'Contacts'
There!are!3!volt!free!fault!contact!which!can!be!used!for!connection!to!a!BMS!system,!or!as!an!interlock.!There!is!
the!Common!Alarm!contact!on!terminals!1!&!2,!the!Sensor!Health!contact!on!terminals!3!&!4!and!the!Pump!
Health!contact!on!terminals!7!&!8.!

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Rev 4.0 Mar-16 Page 13 / 35
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Commissioning
It!is!highly!recommended!to!have!this!equipment!commissioned!by!a!trained!approved!
mechanical!contractor.!Any!damage!or!loss!incurred!through!incorrect!commissioning!by!an!
unapproved!contractor!will!not!be!covered!by!the!warranty.!
Pre-Commissioning'Checklist'
The!following!conditions!must!be!met!before!starting!the!commissioning!process.!Failure!to!meet!
these!conditions!may!result!in!injury!or!damage!to!the!equipment,!system!and!property.!
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Equipment!is!located!in!a!frost!free!area,!away!from!precipitation!and!water!sprays/jets!
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All!necessary!pipe/electrical!connections!have!been!made!to!a!satisfactory!standard!
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The!temperature!and!pressure!at!the!point!of!connection!are!within!the!operating!limits!of!the!
equipment.!
The!heating/cooling!system!is!fitted!with!a!safety!relief!valve!and!appropriately!sized!expansion!vessel!
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The!following!conditions!must!be!met!for!the!equipment!and!heating/cooling!system!to!function!
correctly.!If!these!conditions!have!not!been!met,!it!is!not!advisable!to!proceed!with!the!
commissioning!process.!
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The!system!connection(s)!have!been!made!into!the!system!return!header/pump!suction!
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It!is!advisable!to!fill!the!heating/cooling!system!prior!to!commissioning.!!
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Rev 4.0 Mar-16 Page 14 / 35
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Controller'Overview'
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The!following!image!shows!the!front!of!the!PSD!unit!digital!controller.!Four!buttons!are!provided!for!
programming,!and!an!LED!display!which!shows!scrolling!messages.!
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When!the!controller!is!first!powered!up,!it!will!display!the!controller!version!number.!This!manual!
relates!to!controller!version!6.3.!If!the!controller!is!of!a!different!version,!there!may!be!differences!
in!the!menu!items!available.!
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When!in!normal!operation,!the!controller!will!display!the!current!internal!pressure!of!the!unit.!If!a!fault!occurs,!
the!controller!will!display!a!fault!code!and!produce!an!audible!alarm.!
In!normal!operation,!the!functions!of!the!buttons!are!as!follows:!
Button!
Function!
Press!
Hold!
SET!
-!
Show!Current!System!Pressure!
MUTE!
Mute!Audible!Alarm!
Reset!Unit!
+!
-!
Enter!Programming!Menu!
-!
-!
-!

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Rev 4.0 Mar-16 Page 15 / 35
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Deaerator'Controller'Programming''
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Do!not!alter!any!settings!without!first!understanding!the!implications!of!doing!so.!Incorrect!
settings!may!cause!damage!to!the!equipment,!system!or!property.!
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To!enter!the!programming!menu,!hold!the!(+)!button!until!“enter!code”!appears!on!the!screen,!followed!by!
“0000”!with!a!flashing!cursor!after!the!first!digit.!
To!gain!access!to!the!programming!menu,!one!of!the!following!codes!must!be!entered:!
Customer!Code!is!most!commonly!used!for!setup.!
Customer!Code!
Standard!set!of!options!
2601!
Engineer!Code!
Extended!set!of!options!
4706!
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To!enter!the!code,!change!the!first!digit!with!the!(+)!and!(-)!buttons,!then!press!(SET)!to!move!onto!the!next!
digit.!Repeat!for!all!digits,!then!once!the!correct!code!is!shown!on!the!display,!press!(SET)!to!enter!the!
programming!menu.!
Once!a!correct!code!has!been!entered,!the!first!option![START!PRESSURE]!will!appear!on!the!screen.!
Once!in!the!menu,!the!value!of!the!current!menu!item!can!be!changed!using!the!(+)!and!(-)!buttons.!Once!the!
current!value!has!been!set,!pressing!the!(SET)!button!will!move!on!to!the!next!option.!
It!is!not!possible!to!navigate!backwards!through!the!menu.!To!return!to!a!previous!setting!in!the!
menu,!press!the!(SET)!button!repeatedly!to!scroll!through!to!the!end!of!the!menu,!and!then!re-
enter!the!appropriate!code.!
If!the!controller!loses!power!while!in!the!programming!menu,!all!changes!made!will!be!erased.!To!
confirm!all!changes,!the!end!of!the!menu!must!be!reached,!and!the!“SAVING...”!message!must!be!
displayed.!

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Rev 4.0 Mar-16 Page 16 / 35
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The!table!below!gives!details!of!all!menu!items,!in!the!order!that!they!will!appear:!
#!
Menu!Item!
Function!
Default!Value!
1!
Start!Pressure!!
Internal!Safe!Pressure!Within!The!Vacuum!Cylinder!For!The!
Pumps!To!Start!Circulating!Water!
14!PSI!
2!
Stop!Pressure!!
Internal!Stop!Pressure!For!The!Pumps,!Required!Vacuum!
Pressure!
0!PSI!(LTHW!
Systems)!
-7!PSI!(CHW!
Systems)!
3!
Alarm!Pressure!!
Internal!High!Pressure!Alarm!Setting,!To!Activate!The!Slam-shut!
Solenoid!Valve!
58!PSI!
4!
Normal!Minutes!!
Normal!Interval!Between!Pump!Runs!(De-aeration)!
60!MINS!
5!
Turbo!Hours!
Running!Time!For!Turbo!Mode!Before!Returning!To!Normal!
168!HRS!
6!
Timeout!Minutes!!
Time!Limit!!For!Vacuum!Generation!Or!Restoration!Of!Internal!
Pressure!(Error!Checking)!!
10!MINS!
7!
Purge!Seconds!
Time!Setting!For!Water!To!Be!Re-circulated!Into!The!Main!
System,!Taking!A!Fresh!Sample!
20!SEC!
8!
Pump!Count!!
Pump!Activation!Counter!(Logging)!
-!
9!
Pump!Hours!!
Pump!Cumulative!Hours!Run!Counter!(Logging)!
-!
10!
Alarm!Count!!
Cumulative!Alarm!Counter!(Logging)!
-!
11!
Power!!
Interrupted!!
Cumulative!Power!Off!Counter!(Logging)!
-!
12!
Pump!Sense!
Disabling!this!option!will!stop!the!controller!from!monitoring!
the!pumps!and!generating!<PUMP!FAIL>!faults.!
It!is!not!recommended!to!disable!this!option.!Please!consult!
Technical!Support!before!doing!so.!
y!
13!
Turbo!Mode!
Activation!Option!For!Turbo!Mode!(Commissioning!Setup)!
Y!
14!
Service!!
12!Month!Service!Reminder!!
Y!
15!
ID!Number!
Protocol!ID!Number!
55!
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If!using!the!customer!code,!the!menu!items!12!and!15!are!not!displayed.!!
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The!above!settings!are!all!pre-programmed!in!the!factory!and!should!not!need!to!be!modified!on!
site!with!the!exception!of!the!‘Purge!Seconds’!setting!which!is!system!dependent.!If!these!settings!
appear!to!have!been!reset,!the!most!likely!cause!is!a!power!spike.!If!this!problem!persists,!a!power!
filter!may!be!required.!
Purge'Seconds'Reference'Times'
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Main!System!Pressure!
Purge!Time!
14!to!42!PSI!
20!seconds!
43!to!87!PSI!
30!seconds!
87!to!145!PSI!
40!seconds!

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Rev 4.0 Mar-16 Page 17 / 35
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Hydraulic'Commissioning'
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1-!Venting!the!Vacuum!Cylinder!
Check!the!red!cap!on!the!air!intake!preventer!is!finger!tight.!
Do!not!unscrew!the!red!cap!completely.!Inside!is!a!glass!bead!and!spring!that!prevent!air!being!drawn!
into!the!equipment!at!this!point.!Without!the!spring!and!the!beads!this!device!will!not!function!correctly!
and!the!equipment!as!a!whole!will!be!unusable.!
With!the!equipment!electrically!powered!down!remove!the!coil!from!the!two!Inlet!solenoids!
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Be!careful!not!to!mix!up!the!coils!when!disconnected.!Failure!to!pair!the!correct!coil!with!the!correct!
valve!will!stop!the!unit!from!working.!
With!the!coils!disconnected!use!a!pair!of!Danfoss!override!magnets!(018F0091!Danfoss!part!number)!to!
manually!open!both!of!the!solenoid!valves.!This!allows!the!existing!system!pressure!to!fill!the!vacuum!cylinder!
for!the!first!run.!
Remove!the!override!magnets,!return!the!correct!coil!to!the!correct!valve!and!electrically!switch!the!unit!on.!If!
the!pressure!shown!on!the!de-aerator!display!is!below!the!start!pressure!of!the!equipment!it!may!be!necessary!
to!adjust!the!pressure!reducing!valve!in!between!the!two!inlet!solenoids.!A!setting!on!the!pressure!reducing!
valve!2!to!4!PSI!higher!than!the!start!pressure!is!acceptable,!any!lower!than!this!and!the!equipment!may!become!
intermittent!in!operation.!

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© 2014 Flamco group. All rights reserved.
We reserve the right to change designs and technical specifications of our products.
Rev 4.0 Mar-16 Page 18 / 35
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If!the!Danfoss!magnets!are!not!available!then!it!is!possible!to!vent!the!cylinder!through!the!
internal!0.04”!/!1mm!bypass,!although!this!may!take!a!considerable!amount!of!time.!The!
alternative!to!this!is!to!temporarily!put!live!power!directly!to!the!solenoid!coils!to!force!the!valves!
to!open.!
2-!Bleeding!the!Pumps!(if!required)!
Locate!the!bleed!screw!on!the!pump.!The!following!diagrams!show!examples!of!typical!bleed!screw!locations!for!
most!pumps:!
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Do!not!use!excessive!force!when!tightening!the!bleed!screw!as!this!may!damage!the!pump!casing.!
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If!the!pump!has!a!plastic!bleed!screw!like!the!one!shown!below,!do!not!use!excessive!force!or!
attempt!to!use!any!tools!to!turn!it!as!this!may!irreparably!damage!the!pump!casing.!
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© 2014 Flamco group. All rights reserved.
We reserve the right to change designs and technical specifications of our products.
Rev 4.0 Mar-16 Page 19 / 35
Operation
Once!commissioned,!the!Deaerating!unit!should!operate!without!any!user!intervention.!
For'practical'guidance'on'diagnosing'and'rectifying'faults,'please'refer'to'the'
Troubleshooting'section'of'this'manual.'
Deaerating'Fault'Codes'
Fault!Code!
Description!
Auto/Manual!
Reset!
Error
Incorrect password (Code) entered.
Auto!Reset!
High Pressure
High system pressure, audible alarm sounds. The Safety
Solenoid closes. This alarm will self-reset when the system
pressure returns to normal, audible alarm can be silenced by
pressing “mute”.
Auto!Reset!
Insufficient Vacuum
The low water switch has been activated, either a leak has
occurred or the air non return valve has failed or is missing.
Manual!Reset!
Pump FAIL
Pumps have failed, the pump failure relay closes. The boiler
interlock opens, the audible alarm sounds.
Manual!Reset!
Timeout
Either the pumps have run for too long or the pressure has
not reached the required start pressure for the pump within
the time limit.
Check the internal filter on the PRV and the solenoid valves
for obstruction.
Manual!Reset!
Service
The unit has been in service for 12 months and a routine
inspection is due (User option in menu).
Manual!Reset!
Shutdown!Procedure!
The!deaeration!unit!must!be!shut-down!during!any!of!the!following!scenarios:!
•Work!is!being!carried!out!on!the!system.
•Work!is!being!carried!out!on!the!Deaerating!unit.
•The!heating/cooling!system!is!being!flushed.
To!shut!down!the!equipment,!please!follow!the!steps!below:!
1. Isolate!the!electrical!power!supply!to!the!unit.
2. Isolate!the!unit!from!the!system!using!the!isolation!valves.