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
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

2
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

3
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.

4
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
45
6
7
8
910
11
12
13
15
14
16 ✓
✘
100
50
0
1
3
6
2
54
7
On/Off
Switch

5
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.

6
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.

7
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

8
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.
Press Value Increase or Value Decrease push
buttons to alter Proportional Band.
Press Value Increase or Value Decrease push
buttons to alter Integral Time.
Press Value Increase or Value Decrease push
buttons to alter Derivative time.
Press Value Increase or Value Decrease push
buttons to alter First level High temperature limit.
Press Value Increase or Value Decrease push
buttonstoalterLowTemperatureLimit.
Press Value Increase or Value Decrease push
buttons to alter High Temperature Limit Time Delay.
Press Value Increase or Value Decrease push
buttonstoalterLowerTemperatureLimitTimeDelay.
Press Value Increase or Value Decrease push
buttonstovaryvalveposition.Figureshows
percentage open. See Manual Control.
Press Value Increase or Value Decrease push
buttons to alter Primary Pump over-run time.
Press Value Increase or Value Decrease push
buttons to alter Primary Pump over-run temperature.
Press Value Increase or Value Decrease push
buttons to alter Secondary Pump over-run time.
Press Value Increase or Value Decrease push
buttons to alter Secondary Pump over-run temperature.
Press Value Increase or Value Decrease push buttons to
alter the Night Set-back/Pasteurisation temperature.
Press Value Increase or Value Decrease push
buttons to alter Primary Pump duty - standby time.
Press and hold Modepushbuttonfor3secondstoexit
Set Up routine.

9
Night Set Back / Pasteurisation
When the DIPswitch (column5inthetablebelow) for Night set-back/Pasteurisation is set to the on
positionandtheunitisputintostandbyviathetime-clock.Whenthepasteurisationvalue(SSBTO)is
settoabovethenormalsettemperature(SSETTO),thecontrollerwillassumepasteurisationandwill
raise the temperature to the pasteurisation value for one hour, before returning to standby, until the
nextscheduledonperiod.
Alternatively,whenthesetbackvalueissettobelowthenormalsetvalue,thecontrollerwillassume
setbackandwilllowerthetemperaturetothisvalueuntilthenextscheduledperiod.
Manual Control
TheAdvancedSetUproutineallowstheengineertopositionthecontrolvalvemanually.Thisfeatureis
activewhilethissetupwindowisvisible.Thisfeatureisdisabledandcontrolrestoredtoautomaticby
pressing the Step Left (6), or Step Right (8) push buttons to display another parameter or pressing and
holding the Mode (10),pushbuttontoexittheadvancedsetuproutine.
(Seepage4forkeytonumberreferences).
Remote Set Point Adjustment
Whena4-20mAsignalisconnectedtotheremoteinput,thesetpointcanbevariedbetween
20degC=4mAandl00degc=20mAattherateof5degreespermilliamp.
Itshouldbenotedthattheexternalcontrolsignalassumescontrolassoonasthemilliamplevelrises
above2mA.Consequently,ifthecontrollerlosesthissignal,itrevertsbacktoit’sowninternalsetpoint.
DIP Switch Settings
ThephysicalcongurationofthesystemandtheNightSet-back/pasteurisationfunctionsare
programmedintothecontrollerbysettingthepositionofeightswitches.Theswitchesarelocatedon
thedisplayprintedcircuitboard.Tochangethepositionoftheseswitches:
1) Isolatethemainssupplytothecontroller.
2) Openthehingeddoor.
3) Removethefourxingscrewsandslidethecontrolfaciaoutoftheenclosuretakingcare
not to pull the connecting cable.
4) Turnthefaciaover.DIPswitchesarelocatedonthebottomedgeofthecircuitboard.
5) Changetheswitchpositionsasrequired(seetablebelow)
6) Replacefacia,closehingeddoorandswitchonthemainssupply.
1 2 3 4 5 6 7 8 Function
 
O 
 
O 
 
O 
 
O 
O 
 
  
 On 
On  
O 
 
Thefollowingtableshowstheswitchcontrols.(Boldpositionsarefactorydefaultvalues).

10
Set Up:
       
          
          
    
    
         
         
         
         
         
         
         
         
         
         
         
         
         
         
         
         
         
         
         
         
         
         
         
         
         
         
         
         
        

           
        
         
         
         
       
      
      
     
Factory Default Settings
Set Set:

11
        
       
       
      
      
      
By pressing the reset (5) and mode (10)buttonssimultaneouslyforafewseconds,thetimeclock
settingswillbereturnedtothefactorydefaultsettings.
By pressing the reset (5) and decrease (9)buttons,thecontrolandalarmparameterswillbereturned
to the factory default settings.

12
Wherepossible,adetailedinspectionoftheBreezeshouldbemadeaftertherstsixmonths.This
willprovideaninsightintofuturerequirementsforefcientmaintenance.IftheBreezeiscleanedand
thereisnosignofcorrosion,itcanbesafelyassumedanannualinspectionwillbesufcientforfuture
servicing. All electrical connections should be checked and tightened if necessary.
Caution:-Maintenanceshouldonlybeperformedbyqualiedpersonnelonly.Electricalworkshouldbe
carriedoutbyaqualiedelectricianinstrictconformancetothelatestrequirements.
InordertomaintaintheBreezeunit,youwillrequireasaminimumthefollowingtoolkit:
• SetofMetricallenKeysuptoM16
• Set of Metric spanners
• SetofScrewdrivers
• Apipewrenchtosuitamaximum50mmnominalpipesize.
• M16frictionratchetandM16deepringspanner(CP-B25toCP-B250)
Controller
The controller is run via an EPROM that stores all the changes to the time programmes and other data.
Aftertherstsixmonths,allconnectionsinthepanelshouldbecheckedandtightenedifnecessary.
Temperature Thermocouple
EnsurethattheThermocoupleconnectionsaresatisfactory.Refertothemanufacturer’sinstructions.
Control Valve and Actuator
Checkthatthevalvewillopenandclosebyusingthemanualfacilityonthecontroller.Electrical
connection should be checked at the actuator. The linkage should also be tightened to ensure good
mechanicalcontact.Refertothemanufacturer’sinstructions.
Hi-Limit / Control Valve and Actuator
Inadditiontotheabove,checkthatthevalveopensandclosesbyturningthepoweronandoff.
Electrical connection should be checked at the actuator. The linkage should also be tightened to ensure
goodmechanicalcontact.Refertothemanufacturer’sinstructions.
Primary Pump
Ensurethatthepumpisonthecorrectspeedsettingandthatwiringissecureatallterminals.
Plate Heat Exchanger
Aseriesofcontouredplateswithportsformaplatepackwithowchannels.Thehotwaterowsdown
alternatechannels,whilethecoldwaterowsupalternatechannels.Thiscreates100%counterow.
Ormandy Rycroft Engineering offers a full and comprehensive range of service and support. This en-
compassesthemaintenance,commissioningandrepairofgeneralwaterheatingequipment,
includingheatexchangers,boilers,pressurisationunits,boostersetsandcaloriers.
AllBreezecomponentpartsareavailableasreplacement/spareitems.Pleasequoteasmuch
informationaspossibletoallowthesupplyofthecorrectpart(s).Serialnumber,photosetc.
Contact our Spares Department - [email protected]
Contact our Sales Department - [email protected]
3.1 Maintenance
3. Health
3.2 Service
3.3 Spares

13
Power Supply Requirements
Voltage:230Volts,50Hz.
Nominalcurrent:Maximum16Amps(PumpandDutydependant).
Inputs
Temperatureprobe:TypeJthermocouple(Grounded)viaa12bitA/D
converter(minimum0.1°Cresolution).Displayrange:0-250°C
Volt Free Contacts
Toenablefromremotesource(Time-clock,SCADA,BMS,boilercontrolsetc)
For connection of a supplementary high limit contact or thermostat as a second alarm.
PrimaryPump(s)faultcontact/s.
Signal
Remotesetpointadjustment.4-20mAScaled20°C-100°C.
Outputs
Pump Supply
• Twoprimarypumps(1Duty,1Standby)singlephase230v5AMaximum.
• Twosecondarypumps(1circulation,1shunt)singlephase230v5AMaximum.
Valve actuator supply
• 24v.a.c20VAMax
• Controlsignal2-10v/0-10.d.c0.1mA,Max.
• Theeffectivecontrolsettingrange0-85°C.
Volt Free Contacts
Changeover fault contact for remote alarm on fault, to SCADA, BMS, Annunciator etc.
Signal
Remoteindicationofprocessvariable.4-20mAscaled0°-100°C.
*NOTE: The volt free contact terminals must not have voltage applied to them.
4.1 Specification
4. Information

Duncombe Road,
Bradford, England BD8 9TB.
Telephone:+44(0)1274490911.Email:[email protected]
www.ormandygroup.com