Tornatech GPL Manual

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INSTALLATION AND MAINTENANCE MANUAL FOR
ELECTRIC PUMP CONTROLLERS
WITH AUTOMATIC TRANSFER SWITCH
MODEL GPL + GLU

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GPLGLU-Manual-EN v1.3.0.0
Table of Contents
1. Introduction
2. Installation
3. Main Features
4. Home
5. Alarms
6. Configuration
7. History
8. Technical Documents

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Table of Contents
Introduction......................................................................................................................................................................5
Types of Limited Service Fire Pump Controllers .......................................................................................................5
Types of Automatic Transfer Switch..........................................................................................................................5
Methods of Starting/Stopping.....................................................................................................................................5
Installation.......................................................................................................................................................................8
Location......................................................................................................................................................................8
Mounting ....................................................................................................................................................................8
Storage.......................................................................................................................................................................8
Wiring and Connections.............................................................................................................................................9
Water Connections.....................................................................................................................................................9
Electrical Wiring .........................................................................................................................................................9
Electrical Connections................................................................................................................................................9
Energy Consumption..................................................................................................................................................9
Sizing..........................................................................................................................................................................9
Incoming Power Connections ....................................................................................................................................9
Motor Connections.....................................................................................................................................................9
Terminal Strip Descriptions......................................................................................................................................10
Terminal Strip Descriptions......................................................................................................................................11
Quick Start-Up Guide...............................................................................................................................................12
Main Features ...............................................................................................................................................................17
The ViZiTouch..........................................................................................................................................................17
First Setup................................................................................................................................................................18
Home.............................................................................................................................................................................19
Home (Membrane button)........................................................................................................................................19
Screen Saver ...........................................................................................................................................................21
Alarms...........................................................................................................................................................................22
Alarms (Membrane button) ......................................................................................................................................22
Configuration.................................................................................................................................................................25
Config (Membrane button).......................................................................................................................................25
NumPad Page..........................................................................................................................................................26
Date and Time Page................................................................................................................................................26
User Login Page / KeyPad Page .............................................................................................................................27
Advanced Configuration Page .................................................................................................................................28
Details of the Advanced Configuration Page...........................................................................................................28
Timers Page.............................................................................................................................................................28
Timers Page.............................................................................................................................................................29
Voltage Calibration...................................................................................................................................................30
Current Calibration...................................................................................................................................................30
Inputs/Outputs Expansion board 1-2-3-4.................................................................................................................31
Update Program Page .............................................................................................................................................32

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Factory Settings .......................................................................................................................................................32
Factory Settings .......................................................................................................................................................35
Reset to Factory Settings Page ...............................................................................................................................36
Service Page............................................................................................................................................................37
New Pump Curve.....................................................................................................................................................38
Automatic Pump Curve Mode Disabled...................................................................................................................39
The Sensors Pages..................................................................................................................................................39
Details of the Debug Page.......................................................................................................................................43
Calibration................................................................................................................................................................43
IO Debug..................................................................................................................................................................44
Inputs/Outputs Debug..............................................................................................................................................45
Interlock Lockout......................................................................................................................................................45
History...........................................................................................................................................................................47
History (Membrane button) ......................................................................................................................................47
Details of the History Page ......................................................................................................................................48
Events Page.............................................................................................................................................................48
Download to USB Device.........................................................................................................................................48
The Statistics............................................................................................................................................................50
First/Last Service Statistics......................................................................................................................................50
All Time Statistics.....................................................................................................................................................51
Pressure Curves ......................................................................................................................................................51
Graphical Mode........................................................................................................................................................51
Textual Mode ...........................................................................................................................................................52
Power Curves...........................................................................................................................................................53
Graphical Mode........................................................................................................................................................53
Textual Mode ...........................................................................................................................................................54
Pump Curves ...........................................................................................................................................................55
Technical Documents....................................................................................................................................................56
Pre-Field Acceptance Test.......................................................................................................................................57
Field Acceptance Test Report..................................................................................................................................59

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Model GPL+GLU limited service fire pump controllers are designed to start an electric motor driven fire pump. It can
either start the fire pump manually through the local start pushbutton or automatically through the sensing of a
pressure drop in the sprinkler system. The fire pump controller is supplied with a pressure transducer. The fire
pump can be stopped manually with the local stop pushbutton or automatically after the expiration of a field
programmable timer. In both cases, stopping is only allowed if all starting causes have disappeared.
Types of Limited Service Fire Pump Controllers
FIRE PUMP CATALOG NUMBER
MODEL No. EXAMPLE: GPL - 208 / 15 / 3 / 60
Model Prefix GPL
Voltage 208 V
HP Rating 15 HP
Phase 3
Frequency 60 Hz
Types of Automatic Transfer Switch
TRANSFER SWITCH CATALOG NUMBER
MODEL No. EXAMPLE: GPL+GLU - 480 / 20 / 3 / 60
Model Prefix GPL+GLU
Voltage 480 V
HP Rating 20 HP
Phase 3
Frequency 60 Hz
Methods of Starting/Stopping
The controllers are available as combination automatic / non-automatic with provision for manual or automatic
shutdown (an automatic shutdown is only possible after an automatic start).
METHODS OF STARTING
AUTOMATIC START
The controller will start automatically on low pressure detection by the pressure sensor when the pressure drops
below the cut-in threshold.
MANUAL START
The motor can be started by pressing the START push button, regardless of the system pressure.
REMOTE MANUAL START
The motor can be started from a remote location by momentarily closing a contact of a manual push button.
REMOTE AUTOMATIC START, DELUGE VALVE START
The motor can be started from a remote location by momentarily opening a contact connected to an automatic
device.
EMERGENCY START
The motor can be started manually by using the emergency push button. This button can be maintained in a closed
position.
Introduction

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Important: to avoid damaging the contactor, it is recommended to start the motor in this manner:
1) Shutdown the main power by using the main disconnect means,
2) Push the emergency button and lock it in closed position,
3) Turn the power back on by using the main disconnect means.
SEQUENTIAL START
In case of a multiple pump application, it may be necessary to delay the automatic (pressure drop) starting of each
motor to prevent simultaneous starting of all motors.
WEEKLY START
The engine can be started (and stopped) automatically at the preprogrammed time.
TEST START
The motor can be started manually by pressing the run test button.
METHODS OF STOPPING
MANUAL STOP
Manual stop is done by pressing the priority STOP push button. Note that pressing the stop push button will
prevent the motor from restarting as long as the button is pressed, plus a two second delay.
AUTOMATIC STOP
Automatic stop is possible only after an automatic start and this function has been activated. When this function is
enabled, the motor is automatically stopped 10 minutes after the restoration of the pressure (above the cut-out
threshold) given that no other run cause is present.
FLOW STOP, HIGH ZONE STOP
If the controller has been started by the FLOW/ZONE START/STOP input and the signal has returned to normal,
the motor will be stopped given that no other run cause is present.
EMERGENCY STOP
The emergency stop is always possible in any starting condition and is done by using the main disconnecting
means located on the door.
Transfer switch operation Sequence
TRANSFER TO ALTERNATE POWER SOURCE
The Transfer to Alternate Power Source starts automatically when at least one of the following conditions are
present:
- Normal Power voltage falls below 85% of nominal voltage,
- Normal Power Phase Reversal is detected,
- Transfer Switch Test push button is pressed.
When an under voltage condition on any phase of the Normal Power source is detected by the sensor, a 3 second
normal power source outage delay timer starts timing.
If the normal source voltage rises above the sensor dropout setting before the 3 second time delay expires, the
transfer sequence is cancelled.
If the Normal Power source voltage is still below the sensor dropout setting (85%) when the time delay expires, a
relay is deactivated sending a signal to start the generator set. At the same time, a voltage and frequency sensor
begins monitoring the Alternate Power Source. The sensor will accept the alternate power source only when both
voltage and frequency reach a pre-set pickup value. An approximate 15 second time span occurs because the
engine-driven generator cranks, starts and runs up to nominal pickup value.
When the Alternate Power Source is within acceptable limits (above 90% of the nominal voltage) for a certain set
time (factory set at 3 seconds), the transfer to alternate power source is initiated.
The transfer switch will remain in the alternate power source position until the normal source is restored.
RETRANSFER TO NORMAL
Important: The transfer switch will stay in alternate position, if the motor is running, for as long as the alternate
power source is within acceptable limits. The retransfer sequence is enabled if the motor is not running.

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The Retransfer to the Normal Power source starts when the voltage sensor detects restoration of the Normal Power
Source within acceptable limits. The voltage level must rise above the pre-set pickup value (90%) on all phases
before the sensor will accept the normal source.
When the normal source is accepted by the sensor, the retransfer to normal delay timer starts timing (factory set at
5 minutes). This delay can be by-passed by pressing on the count-down timer displayed on the screen (if a flashing
“X” is displayed).
This delay prevents immediate load retransfer to the normal source. The delay insures that the normal power
source has stabilized before reconnection of the Fire Pump Motor. If the normal source voltage falls below the pre-
set dropout value before the time delay expires, the timing cycle is reset to zero. If the alternate power source fails
during the timing cycle, the load is immediately retransferred to the normal source, if that source is acceptable.
The Automatic Transfer Switch is now feeding the Fire Pump Motor from the Normal Power Source again.
Upon retransfer to the normal source, the 5 minute cooling timer starts counting down, keeping the engine running
during this cool-down period. This delay can be by-passed by pressing on the count-down timer displayed on the
screen (if a flashing “X” is displayed).
After the time delay, the relay is re-activated to shut down the engine-driven generator. All circuits are reset for any
future normal source failure.
Every time the transfer switch needs to change from one power source to the other, a running motor is stopped
during the transfer to prevent instant across the line starting of an already turning motor. If the motor still needs to
run when the transfer sequence has completed (plus a factory set 2 second timer), the motor will be restarted
following its default start-up sequence.

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The GPL electric fire pump controller is cULus listed, FM certified and is intended to be installed in accordance with
the latest edition of the Standard of the National Fire Protection Association for the Installation of Centrifugal Fire
Pumps, NFPA20 (Centrifugal Fire Pumps) and
in USA National Electrical Code NFPA 70
in Canada Canadian Electrical Code, Part 1
others * Local Electrical Codes *
*Only American and Canadian applicable codes have been considered during the design of the controllers and
the selection of components.
Except in some cases, the controller is also seismic approved and has been tested in accordance with the ICC-ES
AC156, IBC 2015 & CBC 2016 standards. Proper installation, anchoring and mounting is required to validate this
compliance report. Refer to this manual and drawings to determine the seismic mounting requirements and location
of the center of gravity (you may need to contact factory). The equipment manufacturer is not responsible for the
specification and performance of anchorage systems. The structural engineer of record on the project shall be
responsible for anchorage details. The equipment installation contractor shall be responsible for ensuring the
requirements specified by the structural engineer of record are satisfied. If detailed seismic installation calculations
are required, please contact the manufacturer for the performance of this work.
Location
The controller shall be located as close as practical to the motor it controls and shall be within sight of the motor.
The controller shall be located or protected so that it will not be damaged by water escaping from the pump or pump
connections. Current carrying parts of the controller shall be not less than 12 in. (305 mm) above the floor level.
Working clearances around the controller shall comply with NFPA 70, National Electrical Code, Article 110 or
C22.1, Canadian Electrical Code, Article 26.302 or other local codes.
The controller is suitable for use in locations subject to a moderate degree of moisture, such as a damp basement.
The pump room ambient temperature shall be between 39°F (4°C) and 104°F (40°C).
The standard controller enclosure is rated NEMA 2. It is the installer's responsibility to insure that either the
standard enclosure meets the ambient conditions or that an enclosure with an appropriate rating has been
provided. Controllers must be installed inside a building and they are not designed for outside environment. The
paint color may change if the controller is exposed to ultraviolet rays for a long period of time.
Mounting
The fire pump controller shall be mounted in a substantial manner on a single incombustible supporting structure.
Wall mounted controllers shall be attached to the structure or wall using all four (4) mounting ears provided on the
controller with hardware designed to support the weight of the controller at a height not less than 12 in. (305 mm)
above floor level. Floor mounted controllers shall be attached to the floor using all holes provided on the mounting
feet with hardware designed to support the weight of the controller. The mounting feet provide the necessary 12 in.
(305 mm) clearance for current carrying parts. For seismic applications, the mounting arrangement should be rigid
wall and base only. The structural engineer of record on the project shall be responsible for anchorage details.
Storage
If the controller is not installed and energized immediately, Tornatech recommend following the instructions from the
chapter 3 of the NEMA ICS 15 standard.
Installation

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Wiring and Connections
Water Connections
The controller must be connected to the pipe system according to the latest edition of NFPA20. The connection to
the system pressure is a Male ½ NPT.
Electrical Wiring
The electrical wiring between the power source and the fire pump controller shall meet the latest edition of NFPA
20, NFPA 70 National Electrical Code Article 695 or C22.1 Canadian Electrical Code, Section 32-200 or other local
codes. Electrical wiring shall be typically sized to carry at least 125% of the full load current (FLC or FLA) of the fire
pump motor.
Electrical Connections
A licensed electrician must supervise the electrical connections. The dimension drawings show the area suitable for
incoming power and motor connections. No other location shall be used. Only watertight hub fittings shall be used
when entering the cabinet to preserve the NEMA rating of the cabinet. The installer is responsible for adequate
protection of the fire pump controller components against metallic debris or drilling chips. Failure to do so may
cause injuries to personnel, damage the controller and subsequently void warranty.
Energy Consumption
Standby power: 13W
Sizing
Incoming power terminals on the controller are suitable to accept wire based on that selection with insulation not
less than 60°C. (Refer to terminal diagram for terminal sizes.)
The electrical wiring between the fire pump controller and the pump motor shall be in rigid, intermediate, or liquid
tight flexible metal conduit or Type MI cable and meet the requirements of NFPA 70 National Electrical Code or
C22.1 Canadian Electrical Code or other local codes.
The number of conductors required is :
- For 3 phases motor: 3 wires plus a ground sized at 125% of full load current.
- For single phase motor: 2 wires plus a ground sized at 125% of full load current.
Incoming Power Connections
Incoming normal power is to be connected to terminals located on the disconnecting means IS.
- For 3 phases motor: identified L1-L2 and L3.
- For single phase motor: identified L1 and L3
For the transfer switch, incoming alternate power is to be connected to terminals located on the disconnecting
means AIS (transfer switch side).
- For 3 phases motor: identified AL1-AL2 and AL3.
- For single phase motor: identified AL1 and AL3
Motor Connections
Motor connections are connected to terminals identified by:
- T1-T2 and T3 located on main contactor (1M).
It is the responsibility of the installer to obtain connection information on the motor and to assure that the
motor is connected as per motor manufacturer recommendations. Failure to do so may cause injuries to
personnel, damage the motor and/or the controller and subsequently void warranty on both items.

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Terminal Strip Descriptions
Alarm output terminals (SPDT Relay, 11:Common,
12:Normally Closed, 14:Normally Open):
A: Motor Run
B: Power Available (Failsafe relay)
C: Phase Reversal
D: Pump Room Alarm
E: Motor Trouble
F: Factory Reserved
Field input terminal (Dry Contact Only: Voltage Free):
G: Remote Manual Start (NO)
H: Lockout (NO)
I: Remote Automatic Start (NC)
J: Deluge Valve (NC)
K: Factory Reserved 3 (NO)
L: Flow/Zone Start/Stop (NO)
M: Factory Reserved 2 (NO)
N: Factory Reserved 1 (NO)
Factory IO:
O: Motor Run auxiliary contact
P: Main Coil power relay
Q: Delay Coil power relay
R: Water Level/Suction Pressure sensor
S: Spare Temperature/Flow sensor
T: PT1 Discharge Pressure sensor
U: PT2 Discharge Pressure sensor (redundant opt. only)
V: Not used
W: Not used
X: Factory Reserved
Y: 24VAC input power
Z: CANBUS to IO cards
AA: Emergency Handle limit switch
AB: CANBUS to ViZiTouch
AC: Ground Fault
AD: Input Current sensing
AE Ground
AF Input Voltage sensing