Ormandy Rycroft Vari-E-Plate Installation and operation manual

Vari-E-Plate
Operating &
Maintenance Manual

Running Section 1
VERY IMPORTANT - PLEASE READ CAREFULLY
Safety Points 1.1 Page 1
Start Up 1.2 Page 1
Working Principles 1.3 Page 2
Installing Section 2
Sizing and Selection 2.1 Page 3
Installation 2.2 Page 5
Operation and Set Up 2.3 Page 6
Health Section 3
Maintenance 3.1 Page 14
Service 3.2 Page 14
Spares 3.3 Page 14
Information Section 4
Specication        4.1  Page 15
Maintenance
Access
Flow

1
• 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Vari-E-Plate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.
1.1 Safety Points
1. Running
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unitcomprisesofa2-portvalve,variablespeedprimarypump(SingleorDual),aplateheat
exchanger,secondarypumpandatemperaturesensorinthesecondaryow.Thetwoportvalveopens
andclosesinlinewiththesecondarydemand.Asthedemandrises,thesecondarytemperaturewill
starttofall,thuscausingthetwoportvalvetoopenandthevariablespeedpumptorampupand
delivertheincreaseddemandofprimarywater.
Thiscausesthesecondarytemperaturetorise,closingthetwowayvalveandslowingdownthe
variablespeedpump,thusreducingtheprimaryow.Ifthereisnodemand,thetwowayvalvewill
closeandtheprimarypumpwillstop,thusmaximisingenergysavings.TheOrmandyRycroft
Vari-E-Plateisusedaseitherastand-aloneinstantaneouswaterheaterasshownbelow.
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
TwoWay
Valve
PrimaryReturn
Actuator
Primary Feed
Primary
Pump
1.3 Working Principle
Orinconjunctionwithabuffervesseltoformasemi-instantaneouswaterheater.
Temperature
Sensor
SecondaryFlow
Cold Feed
TwoWay
Valve
Primary
Pump
Primary Feed
Actuator
PrimaryReturn

3
TosizeastandaloneVari-E-Plate,usethefollowingdemandfactors.
Facility
Private
Hand
Basin
Public
Hand
Basin
Shower Bath Slop
Sink
Bar
Sink
Kitchen
Sink
Washing
Machine
Lab
Sink
Dish
Washer
Hospital 1 2 4 4 4 10 10 3 10
Residential
Hall & Hotel 1 2 4 4 4 12 10 10 10
School 0.5 3 10 -3 10 3 3 10
Sports Centre
/Barracks 0.5 2 10 -3 12 10 - - 10
Restaurant 0.5 4 - - 12 12 19 - - 10
University 0.5 3 10 -3-10 -3 10
Ofces 0.5 3 3 -3-10 -3 10
Factory 0.5 3 4 -3-10 -3 10
Apartments 1-4 4 3 -3 3 -2
Sizing Considerations
Carefulconsiderationmustbegiventothesizingofstandaloneinstantaneouswaterheaters.
Standarddemandunitsincorporateadegreeofdiversicationthatwouldbeinappropriatefor
continuous use applications. A more desirable method of sizing for continuous applications is to
completeaxturecountandallocateanappropriateowforeachtting.
ItshouldalsobenotedthatshowerdemandsforSchools,SportsCentresandUniversitiesshould
onlybeusedformediumtolargeinstallations.Refertoourdesigndepartmentforfurtherinformation.
Table 1
42singlepersonshowers  42x4 =168
55privatehandbasins  55x1 =55
9publichandbasins   9x2  =18
3slopsinks    3x4  =12
15baths    15x4 =60
Total Demand Units = 313
Theshowerfactorsarebased
upon intermittent use.
Where certain activities may result
inallshowersoperatingtogether,
please contact our sales
department for advice.
Example
FromTable1,a173bedHospitalwardwithshowers,handbasinsandsinks.
2.1 Sizing and Selection
2. Installing
ThecorrectlysizedVari-E-PlatecannowbeselectedfromTable2.
HT Breeze Model Maximum
Demand Units
MaxContinuousDuty
@60°C(litres/sec)
Boiler
Power(kw)
Min Secondary
Volume(litres)
GBPH50 23 0.50 105 75
GBPH100 70 1.00 209 125
GBPH150 130 1.50 313 150
GBPH200 210 2.00 418 200
GBPH250 320 2.50 522 250
GBPH300 480 3.00 627 300
GBPH350 640 3.50 732 350
GBPH400 820 4.00 836 400
Table 2

4
ThesesizesrepresentthestandardrangeofVari-E-Plateinstantaneouswaterheaters.Forlarger
requirementsforbothsingleandthreephase,pleasecontactourtechnicaldepartment.BothStandard
andSpecialdesignscanbeofferedtosuityourspecicrequirements.
To size a Vari-E-Plate and Buffer Vessel use the following maximum demand rates.
Facility
Private
Hand
Basin
Public
Hand
Basin
Shower Bath Slop
Sink
Bar
Sink
Kitchen
Sink
Washing
Machine
Lab
Sink
Dish
Washer
Load
Factor
Hospital 10 15 70 60 50 80 100 40 150 0.7
Residential
Hall & Hotels 10 15 50 50 50 100 80 100 150 0.5
School 5 20 180 40 80 40 40 150 0.8
Sports Centre
/Barracks 5 15 220 40 100 80 100 1
Restaurant 5 25 100 100 140 150 1
University 5 20 220 40 80 40 150 0.8
Ofces 5 10 180 40 40 40 100 1
Factory 5 20 120 50 80 40 100 1
Apartments 5 50 50 40 20 40 20 0.7
Table 3
42singlepersonshowers 42x70 =2940
55privatehandbasins 55x10 =550
9publichandbasins 9x15 =135
3slopsinks 3x50 =150
15baths 15x60 =900
Total Volume = 4675
Load Factor from Table 3 = 0.7
Total Demand Rate 4675 x 0.7 = 3273 litres/hr
Example
The Vari-E-Plate and Buffer Vessel combination, should be sized as follows:
TheBufferVesselCapacity=25%ofthetotalhourlydemand,thereforetherequiredstoragecapacity
=3273x0.25=818litres.TheneareststandardBufferVesselsizesare800and900litres.
Itisrecommendedtogoupinsizeandthereforea900litreBufferVesselshouldbeselected.
The Vari-E-plate can be selected as follows:
Continuoushourlydemand  =3273litres
SpecicHeatCapacityofWater =4.187kj/kg,°C
ColdFeedTemperature  =10°C
SecondaryFlowTemperature =60°C
Thereforetherequiredkwrating =3273x4.187x(60-10)
The nearest standard Vari-E-Plate is a GBPH100 which is rated at 209 kw
3600 = 190.3 kw

5
AVari-E-plateandBufferVesselcombinationisusedwhenwaterdemandisnotconstantbuthighow
frequentlyoccurs.Boilerpowerrequirementsarereducedbystoringhotwaterinthebuffervesselfor
peak demands.
TheVari-E-plateshouldalwaysbeinstalledwithasecondaryreturnlinecomingbackfromthesystem
andintothecoldfeedline,priortotheVari-E-plateorBufferVessel.Thiswillremovenuisancehigh
limittripping,duetotemperatureovershoot,whichwouldoccuriftheunitwasinstalledona‘deadend’
system,whenanoutletwasclosed.Toensurefullheatdissipation,thesecondaryvolumeshouldnot
belessthanthatshowninTable2.
For larger capacities contact the sales department for advice.
Foundation
TheOrmandyRycroftVari-E-Plate should be mounted on prepared foundations that are level.
Lifting
OneliftingholeisprovidedonthetopoftheVari-E-Platecontrolpanel. Avoid the use of chains, as
screwedconnectionsmaybedamagedbythelinks.
Caution: Never lift or move the Vari-E-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Vari-E-Plate.
Allowancesshouldbemadeforexpansionofthepipeseitherbysuitablebendsorexiblejoints.
Tightenangeboltsinadiametricallyoppositesequence,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usetheatmosphericventasanexpansionpipewithdischargebackintothe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Vari-E-Platecanbebledofairforinitialoperation.Itisessentialthattheoodedcantype
pumpmotorswhicharecommonlyusedforallOrmandyRycroftVari-E-Platepumps,arebledofairand
oodedbeforestarting.Seethepumpmanufacturer’sinstructions.
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Vari-E-Plate,toremoveanyforeignmatter.
CloseanymanualairventsandruntheVari-E-Plate.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.
2.2 Installation

6
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ratingplatewillhaveall
the information necessary to rate this supply.
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
2.3 Operation and Set Up
Electrical Connections
Terminal Block
1 2 3
4 5
6
7
8
9 10
11
12
13
15
14
16 ✓
✘
100
50
0
1
3
6
2
54
7
On/Off
Switch
KeytoOrmandyRycroftVari-E-Platecontrolsandindicators.
Mainsin230V
50HZ 1PH
Primary Pump
1230V
5AMax
Primary
Pump
2 Start
Primary
Pump
2 Fault
Primary
Pump
2 Control
Secondary
Pump1230V
5AMax
Secondary
Pump 2 230V
5A Max
AC
Signal
DC
Power
ValveActuator
LimitSwitch
Remote
Enable
VoltFree
Remote
Temp
Display
Remote
Temp
Setpoint
N
LN L
N
L
31
Primary
Pump 1
Start
Primary
Pump 1
Fault
Primary
Pump 1
Control
+VE 0V N
L
+VE 0V +VE 0V
0/2-10V
24V
T
CC
+1 +1
4-20mA
N
L
78910 11 12 13 14 15 22 23 24 25 26 27 28 29 30 16 17 18 19 20 21 32 33 34 35 36 37 38 39 40 41 42 43 44 456
54
321
L N E
0-10V
Primary Pump
2230V
5AMax
0-10V
VoltFree
Fault
Contact
230V5A
AC1Max
High Limit
StatVolt
Free
4-20mA
v- v+
Type J
T/C
Sensor

7
Operation
TheVari-E-Plateisaself-containedunit,whichcontrolsuptotwoprimaryandtwosecondarypumps,
togetherwithatwo-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Vari-E-Plate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Vari-E-Plate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Vari-E-plate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Vari-E-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Vari-E-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.

8
Set Up
TheVari-E-Plate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.
Figure 1 - Set Up Sequence
Press and hold for a minimum of 3 seconds
to enter 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.
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.