Ormandy group Breeze Installation and operation manual

Breeze

Plate Heat Exchanger

Operating &

Maintenance Manual

VERY IMPORTANT - PLEASE READ CAREFULLY

Running Section 1

Safety Points 1.1 Page 1

Start Up 1.2 Page 1

Working Principles 1.3 Page 2

Installing Section 2

Installation 2.1 Page 3

Operation and Set Up 2.2 Page 4

Health Section 3

Maintenance 3.1 Page 12

Service 3.2 Page 12

Spares 3.3 Page 12

Information Section 4

Specication        4.1  Page 13

1. Running

1.1 Safety Points

• During operation, the unit may have very hot or cold surfaces.

• Thetemperatureprobeisinstalleddirectlyinthesecondaryow.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

certiedliftingequipmentcapableofliftingtheweight.Residualwater

may also be present and spillage could occur.

• NeverlifttheOrmandyRycroftBreeze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ttedequipment.E.g.pumps,valves,

actuators etc.

• PowersupplyandcontrolsignalcablesMUST be segregated as far as is

reasonably practical.

• Shielded control cables must be used.

• Localauthorityregulationsmustbefollowedatalltimes.

• Ensurealloperationsarecarriedoutbysuitablytrained/qualied

personnel.

Checks Complete (✓)

Check that electrical installation is complete.

Check that the mechanical installation is complete.

Checkthatthesystemhasbeenushed,butNOT through the plate pack and

that there are no leaks.

Check that any air has been eliminated from the system.

Checkthatvalvesareopenedintherequiredsequence.

1.2 Start Up

TheBreezecomprisesofaSupapacPlateHeatExchanger,eithera3portor4portcontrolvalve,

primary pump, temperature sensor and PID controller, all mounted on a skid base.

Motorised3or4portcontrolvalves,allowrapidadjustmentoftheprimaryheatinputtomatch

changesinsecondaryhotwaterdemand.

TheBreezeissuppliedwithoutinsulationandthedesignensuresthattheoutlettemperaturedoesnot

fallbelowthesetpoint(60°Cdefault)butcanbeadjustedtosuitcustomerrequirementsand

consequentlyreducestheriskoflegionnairesdisease.

Providingtheclassofaccommodationanddetailsofthenumberandtypeofxturesareknown,

OrmandyRycroftwillbepleasedtorecommendtheoptimumsizeoftheBreeze.

With buer vessel to form a semi-instantaneous water heater

3 Port Valve

Primary

Flow

Primary

Return

Secondary

Inlet

Secondary

Outlet

Control

Stat

PHE

4 Port Valve

Primary

Flow

Primary

Return

Secondary

Inlet

Secondary

Outlet

Control

Stat

PHE

1.3 Working Principles

SecondaryFlow

Temperature Gauge

Pressure Gauge

Expansion

Vessel

Expansion

Relief

Valve

Lockshield

Valve

Cold Feed

Non-Return

Valve

Circulating

Pump

Secondary

Shunt Pump

Drain

Pressure/Temp

Relief Valve

Temperature

Sensor

Commissioning

Valve

Drain

Plug

Primary

Return

Actuator

Primary

Feed

Primary

Pump

Foundations

The Ormandy Rycroft Breeze should be mounted on prepared foundations that are level.

Lifting

One lifting point is provided on the top of the Breeze control panel bracket.

Avoid the use of chains as the links may cause damage.

Caution: Never lift or move the Breeze-Plate by its pipework or pipe connections.

Pipework

Makesurethatthepipeworkangesaresquareandcorrectlyspacedbeforeboltingup.Ensurethat

theweightofthepipeworkistakenbyexternalsupportsandnotbytheOrmandyRycroftBreezeplate

connection.Allowancesshouldbemadeforexpansionofthepipes,eitherbysuitablebendsor

exiblejoints.Tightenangeboltsinadiametricallyoppositesequenceandnotconsecutivelyround

eachange.

Connections

ThethreadedconnectionmaybesealedwithPTFEtape.Flangedconnectionsshouldbesealedwitha

suitable gasket and sealing agent.

Liquid Expansion

Changesinvolumewithtemperaturemustnotbeoverlooked.Thesystempressurewillrise

dramaticallyifthereisnowhereforwatertoexpand.Itisnotadvisabletouseareliefvalveasa

meansofreleasingtheexcesswater.

Ventedsystemsexpansionisviatheventpipewhichdischargesbackintotheatmospherictank.

Unventedsystemsrequireaseparateexpansiontank.

Venting

VentvalvesmustbettedatthehighestpointintheconnectingpipeworksothattheOrmandyRycroft

Breeze can be bled of air prior to operating. It is also essentialthattheoodedcantypepump

motors,whicharecommonlyusedformostOrmandyRycroftBreezeunitsarealsobledofair

before use.

2. Installing

2.1 Installation

Filling

Beforellingthesystem,checkthatthedrainvalveisclosedandallairventsareopen.

Flush out the system before installing the Ormandy Rycroft Breeze-Plate to remove any foreign

matter. Close any manual air vents and run the Breeze. Crack the vents to release air.

Caution: Do not ll the system too quickly, otherwise pockets of air may become trapped.

Do not ush the system through the plate heat exchanger, as this could result in the plates

becoming blocked or cause a loss in performance.

The Electrical connections are located in the terminal compartment. A description of the terminals can

be found on the inside of the terminal compartment cover.

Connectasinglephase230V50HzsupplytotheMainsInputterminals.Themaximumfullloadcurrent

is16A,withthemajorityofunitsbeingconsiderablyless.

Iftheunitistobecontrolledremotely,connecttheremotecontrolswitchorcontactstotheRemote

enableterminals.Iftheunitistobecontrolledlocally,talinkbetweentheseterminals.

Do NOT apply voltage to these terminals!

Voltage free fault relay contacts are provided for Remote Fault Indication.

13 System Healthy Indicator

14 System Fault Indicator

15 ValvePositionBarDisplay

16 On/Offswitch

1 Day/Mode Display

2 Time/Alarm Display

3 Temperature/Parameter Display

4 High Temperature Alarm Indicator

5 ResetPushButton

6 StepLeftPushButton

7 Value Increase Push Button

8 Step Right Push Button

9 Value Decrease Push Button

10 ModeSelectPushbutton

11 Pump Energised Indicator

12 PowerOnIndicator

Terminal Block

2.2 Operation and Set Up

Electrical Connections

Key to Ormandy Rycroft Breeze controls and indicators.

1 2 3

910

16 ✓

✘

100

On/Off

Switch

Operation

TheBreezeisaself-containedunit,whichcontrolsuptotwoprimaryandtwosecondarypumps

togetherwitha3or4-portvalvetoprovidehotwater.Whenthesystemisttedwithtwoprimary

pumpstheyareoperatedonasharedduty-standbycyclewithautomaticchangeoveronpumpfailure.

a) Remote Switch or Building Management System Control

 TheBreezewillbeturnedonwhencontactsconnectedtotheRemote Enable terminals are

 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.

b) 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 should be linked.

 UnderTimeclockcontroltheBreezewillbeturnedonandoffatpresettimesoftheday. 

 Uptotwoonandtwoofftimescanbeprogrammedforeachdayoftheweek.

 Thesystemcanbere-activatedafterithasautomaticallyswitchedoffbypressingthe

Value Increase (7)pushbutton.Eachpressofthispushbuttonwilladd30-minuteincrementsto

 atotal,whichisshownintheTime/Alarmwindow.PressingtheValue Decrease (9) push button

 willsubtract30-minuteincrementsfromthetotaltime.

 Thetimevaluecountsdownandwhenthetimeshownhaselapsed,theunitwillrevertto

normal time clock operation.

c) Remote Switch and Internal Time Clock Control

 Forthisfunctiontowork,theTimeclockfunctionshouldbeturnedon(seeSetUp)anda

remote ControlswitchshouldbeconnectedtotheRemote Enable terminals.

 UnderTimeclockcontroltheBreezewillbeautomaticallyturnedonandoffatpreset 

 timesoftheday.Uptotwoonandtwoofftimescanbeprogrammedforeachdayoftheweek.

When contacts connected to the Remote Enable terminalsareopenedtheBreeze-Platewillbe

turned off.

When remotely enabled and the system has turned off under time clock control, it can be

re-activated by pressing the Value Increase (7)pushbutton.Eachpressofthispushbuttonwill

 add30-minuteincrementstoatotal,whichisshownintheTime/Alarmwindow.Pressingthe

Value Decrease (9)pushbuttonwillsubtract30-minuteincrementsfromthetotaltime.

 Thetimevaluecountsdownandwhenthetimeshownhaselapsed,theunitwillswitchoffand

 reverttonormaltimeclockoperation.However,whenthesystemhasbeenturnedoffunder

remote control, it cannot be re-activated by pressing the Value Increase (7) push button.

Switchonviaswitch(16)

Thefrontpanelwillilluminate.Afterafewsecondsofselfchecks,thedisplayswillsettletotheDay (1)

(Time-clockonly),Time (2) and Temperature (3).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Breeze-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.

Set Up

TheBreeze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efciency.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 (10) push button for three seconds.

Press the Step Right (8) and Step left (6)pushbuttonstomoveforwardsandbackwardsthroughthe

sequence.PresstheValue Increase (7) or Value Decrease (9)pushbuttonstoalterthevalueshownin

the display. Press and hold the Mode (10)pushbuttonfor3secondstoexitthesetuproutine.

Thesystemcontinuestocontrolwhenthecontrollerisinthesetuproutine,allowingadjustmentsto

bemadeonthey

Figure 1 - Set Up Sequence

Press and hold for a minimum of 3 seconds

to enter Set Up routine.

Press Step Righttomovetorstvalue.

Press Value Increase or Value Decrease

pushbuttonstoalterwatertemperature.

Press Value Increase to turn Time

clock function on or off.

Press Value Increase or Value Decrease

to change Day number.

Press Value Increase or Value Decrease

push buttons to change time. Press and

hold push button for rapid change.

Press Value Increase or Value Decrease

push buttons to change the time of the

rsttimedonandoffperiod.Pressand

hold push button for rapid change.

Press Value Increase or Value Decrease

push buttons to change the time of the

second timed on and off period. Press and

hold push button for rapid change.

Press Step Right push button to set the

on-off times for day 2, day 3, day 4 etc.

Press and hold Value Select push button

foraminimumof3secondstoexitSetUp

routine.

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.

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tted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 (5) push button. When the fault has

been diagnosed and corrected, the system can be re-activated by pressing the Reset (5) push button

again.Thiscanonlybeperformedwhenthetemperatureshavereturnedtonearnormal.Alltheother

alarmswillautomaticallyresetwhentheproblemhasbeencorrected.Alarmsconstantlyre-occurring

couldindicatethatthesystemhasbeenincorrectlycongured.

Advanced Set Up Routine

Thesystemissuppliedwithdefaultsettings,whichsuitmostapplications.Theadvancedsetupfeature

allowsInstallersandEngineerstotailorthesettingstosuitparticularinstallations.Thesystem

continuestocontrolwhenthecontrollerisintheadvancedsetuproutine,soresultsofadjustments

can be seen immediately. In addition, manual control of the valve position is available.

Figure 2 - Alarm Messages

The set up routine is entered by simultaneously pressing and holding the Mode (10), Step Left (6) and

Value Decrease (9), Push buttons for a minimum of three seconds. Press the Step Right (8) and Step Left

(6)pushbuttonstomoveforwardsandbackwardsthroughthesequence.PresstheValue Increase (7)

or Value Decrease (9)pushbuttonstoalterthevalueshowninthedisplay.PressandholdtheMode (10)

pushbuttonfor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.

Press Step Rightpushbuttontomovetotherst

setting value.