Tornatech VP series Manual

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INSTALLATION AND MAINTENANCE MANUAL FOR
ELECTRIC FIRE PUMP CONTROLLERS
MODEL VPx

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Table of content
GENERAL DESCRIPTION ............................................................................................................................. 6
1. TYPES OF ELECTRIC FIRE PUMP CONTROLLERS........................................................................... 6
1.1. ACROSS-THE-LINE STARTER..................................................................................................... 6
1.1.1. Model VPA: .............................................................................................................................. 6
1.2. REDUCED VOLTAGE STARTER.................................................................................................. 6
1.2.1. Model VPR: AUTOTRANSFORMER STARTER...................................................................... 6
1.2.2. Model VPS: SOLID STATE STARTER..................................................................................... 6
2. METHODS OF STARTING / STOPPING............................................................................................... 7
2.1. methods of starting......................................................................................................................... 7
2.1.1. automatic start.......................................................................................................................... 7
2.1.2. manual start.............................................................................................................................. 7
2.1.3. remote manual start.................................................................................................................. 7
2.1.4. emergency start........................................................................................................................ 7
2.1.5. sequential start......................................................................................................................... 7
2.1.6. weekly start .............................................................................................................................. 7
2.2. methods of stopping....................................................................................................................... 7
2.2.1. manual stop.............................................................................................................................. 7
2.2.2. automatic stop.......................................................................................................................... 7
2.2.3. emergency stop........................................................................................................................ 7
3. variable speed pressure limiting control ................................................................................................. 8
3.1. General.......................................................................................................................................... 8
3.2. VARIABLE speed MODE............................................................................................................... 8
3.3. Preset speed mode........................................................................................................................ 8
3.4. bypass mode.................................................................................................................................. 8
3.5. STOP PUSH BUTTONS................................................................................................................ 8
4. front panel .............................................................................................................................................. 9
4.1. generals......................................................................................................................................... 9
4.2. PRS DISPLAY ............................................................................................................................... 9
4.3. PRS ANNUNCIATORs................................................................................................................... 9
4.3.1. POWER AVAILABLE................................................................................................................ 9
4.3.2. SYSTEM Trouble...................................................................................................................... 9
4.3.3. PHASE REVERSAL................................................................................................................. 9
4.3.4. Low system pressure...............................................................................................................10
4.4. Flange annunciators......................................................................................................................10
4.4.1. BYPASS MODE ......................................................................................................................10
4.4.2. VFD FAILURE.........................................................................................................................10
4.5. Audible alarm................................................................................................................................10
5. alarm contacts.......................................................................................................................................11
6. INSTALLATION.....................................................................................................................................12
7. LOCATION............................................................................................................................................12
8. Mounting................................................................................................................................................12
8.1. wall mounting................................................................................................................................12
8.2. floor mounting...............................................................................................................................12
9. connections...........................................................................................................................................13
9.1. WATER CONNECTIONS..............................................................................................................13
9.2. ELECTRICAL CONNECTIONS ....................................................................................................13
9.2.1. ELECTRICAL WIRING............................................................................................................13
9.2.2. enclosure drilling......................................................................................................................13
9.2.3. INCOMING POWER CONNECTIONS ....................................................................................13
9.2.4. MOTOR CONNECTIONS........................................................................................................13
9.2.5. alarm contact connection.........................................................................................................13

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9.2.6. connection to external device..................................................................................................14
10. START-UP AND TEST PROCEDURES................................................................................................15
10.1. VeRIFICATIONS...........................................................................................................................15
10.1.1. ELECTRICAL INSTALLATION................................................................................................15
10.1.2. PIPING INSTALLATION..........................................................................................................15
10.2. SETTINGS on the electronic boards.............................................................................................16
10.3. DIPSWITCH..................................................................................................................................16
10.3.1. PHASE REVERSAL (Ph Rev).................................................................................................16
10.3.2. RUN PERIOD TIMER (RPT) ...................................................................................................16
10.3.3. SEQUENTIAL START TIMER (Seq Timer).............................................................................16
10.3.4. TEST (Test).............................................................................................................................16
10.3.5. PRESSURE UNIT (Pr Unit).....................................................................................................16
10.3.6. SERIAL (Serial).......................................................................................................................16
10.4. PRS...............................................................................................................................................17
10.4.1. pressure adjustment................................................................................................................17
10.5. SETTINGS on the sequential module (SM1) ................................................................................17
10.6. Timers...........................................................................................................................................17
10.6.1. T1 : Sequential start timer .......................................................................................................17
10.6.2. T2 : minimum run period timer.................................................................................................17
11. Variable speed drive (VFD) settings......................................................................................................18
11.1. NON-critical parameters................................................................................................................18
11.1.1. VFD power up / shutdown.......................................................................................................18
11.1.2. minimum speed.......................................................................................................................18
11.1.3. PRESET speed .......................................................................................................................18
11.1.4. Pressure SETPOINT...............................................................................................................19
11.1.5. gain..........................................................................................................................................19
11.1.6. INTEGRAL TIME.....................................................................................................................19
12. ACTUAL START-UP .............................................................................................................................20
12.1. CHECK MOTOR ROTATION........................................................................................................20
12.2. CHECK WRONG PHASE ROTATION INDICATION....................................................................20
13. PUMP START TEST.............................................................................................................................21
13.1. START FROM START PUSHBUTTON PB1.................................................................................21
13.2. START FROM REMOTE START STATION .................................................................................21
13.3. WATER PRESSURE CONTROL..................................................................................................21
13.3.1. MANUAL SHUTDOWN MODE................................................................................................21
13.3.2. AUTOMATIC SHUTDOWN MODE..........................................................................................22
13.4. START FROM EMERGENCY START HANDLE ..........................................................................22
14. Sequential module Programming instructions.......................................................................................23
14.1. How to adjust date ........................................................................................................................23
14.2. how to program a weekly test .......................................................................................................23
14.3. How to set SM1 in run mode.........................................................................................................24
14.4. How to set run period timer...........................................................................................................24
14.5. How to set SEQUENTIAL START timer........................................................................................24
15. PRS99 Programming instructions..........................................................................................................25
15.1. How to read the display.................................................................................................................25
15.1.1. Top Line ..................................................................................................................................25
15.1.2. SECOND LINE........................................................................................................................25
15.1.3. THIRD LINE ............................................................................................................................25
15.1.4. FOURTH LINE.........................................................................................................................25
15.2. How to adjust the cut in / cut out pressure....................................................................................25
15.3. What is the flashing symbol on the second line ............................................................................26
15.4. Why 'Low System Pressure' LED is flashing.................................................................................26
15.5. How to adjust the date and time....................................................................................................26
15.6. How to print reports.......................................................................................................................27
15.7. How to replace the paper..............................................................................................................28

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15.8. How to replace the ribbon.............................................................................................................28
15.9. How TO RETRIEVE PRESSURE DATA’S FROM RS232 PORT .................................................28
15.10. preventive and maintenance test ..................................................................................................31
15.11. VISUAL INSPECTION ..................................................................................................................31
15.12. OPERATIONAL INSPECTION......................................................................................................31

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GENERAL DESCRIPTION
Model VPx electric fire pump controllers are
designed to automatically start an electric
driven fire pump upon detection of a
pressure drop in the fire protection system. It
is intended to control 3-phase squirrel cage
induction motors and is arranged for
electrical or manual starting and stopping
and for automatic start, controlled by the
pressure sensor. The combination
automatic/non-automatic option provides a
10-minute automatic stop after automatic
start but only after all starting causes have
returned to normal
1. TYPES OF ELECTRIC FIRE PUMP CONTROLLERS
FIRE PUMP CATALOGUE NUMBER
MODEL n° EXAMPLE: VPA-208 / 50 / 3 / 60
VPA
208
50
3
60
Model prefix
Voltage
HP rating
Phase
Frequency
1.1.ACROSS-THE-LINE
STARTER
1.1.1.MODEL VPA:
This model is intended to be used where the
local utility or the capacity of the power
source permits across-the-line starting.
Upon a start command, the controller
connects the variable speed frequency drive
to the motor. The motor ramps up and
adjusts its speed. When the variable speed
drive is bypassed, full voltage is applied to
the motor as soon as the controller receives
a start command.
1.2.REDUCED VOLTAGE
STARTER
These models are intended to be used
where the local utility or the capacity of the
power source does not permit full voltage
starting.
1.2.1.MODEL VPR:
AUTOTRANSFORMER
STARTER
The manual “EMERGENCY RUN” device
will initiate across-the-line starting.
Upon a start command, the controller
connects the variable speed frequency drive
to the motor. The motor ramps up and
adjusts its speed. With any starting method,
and when the variable speed drive is
bypassed, an autotransformer is used to
start the motor at reduced voltage. After a
time delay, the autotransformer is shunted
out and the motor is connected to full
voltage by a closed transition switching
sequence.
1.2.2.MODEL VPS: SOLID
STATE STARTER
The manual “EMERGENCY RUN” device
will initiate across-the-line starting.
Upon a start command, the controller
connects the variable speed frequency drive
to the motor. The motor ramps up and
adjusts its speed.
With any starting method, and when the
variable speed drive is bypassed, a soft
starter is used to supply a ramp-up voltage
to the motor until the motor reaches its full
speed. If the soft starter fails, an across-the-
line starting will be initiated.

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2. METHODS OF STARTING / STOPPING
The controllers are available as combination automatic / non-automatic with provision for manual
or automatic shutdown (automatic shutdown only possible after automatic start)
2.1.METHODS OF STARTING
2.1.1.AUTOMATIC START
The controller will start automatically on low
pressure detection by the pressure sensor
when pressure drops below cut-in threshold.
The controller must be in automatic mode
(Remove jumper IJ2 to disable automatic
start).
2.1.2.MANUAL START
The motor can be started by depressing the
START push button whatever the system
pressure.
2.1.3.REMOTE MANUAL
START
The motor can be started from a remote
location by momentarily closing a contact of
a manual push button.
2.1.4.EMERGENCY START
The motor can be started manually by using
the emergency handle. This handle can be
maintained in a closed position.
Important: to avoid damaging the contactor,
it is recommended to start the motor in the
manor:
1) shutdown the main power by using
the main disconnect means,
2) pull the emergency handle and lock
it in closed position,
3) turn the power back on by using the
main disconnect means.
2.1.5.SEQUENTIAL START
In case of multiple pump application, it may
be necessary to delay the starting of each
motor in case of water pressure drop to
prevent simultaneous starting of all motors.
2.1.6.WEEKLY START
The motor can be started (and stopped)
automatically at the preprogrammed time.
2.2.METHODS OF STOPPING
2.2.1.MANUAL STOP
Manual stop is done by depressing the
INSTANT STOP or DELAYED STOP push
button.
Note : All start conditions must be
disappeared to stop the pump.
2.2.2.AUTOMATIC STOP
The automatic stop is possible only after an
automatic start, and this function must be
activated. When this function is enabled,
the motor is automatically stopped 10
minutes (factory setting) after the restoration
of the pressure (above the cut-out
threshold).
2.2.3.EMERGENCY STOP
The emergency stop is always possible in
any starting conditions and is done by using
the main disconnecting means located on
the door.

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3. VARIABLE SPEED PRESSURE LIMITING CONTROL
3.1.GENERAL
The variable speed pressure limiting control
is enabled if the speed selector switch is in
‘VARIABLE’ or ‘PRESET’position.
While in ‘VARIABLE’ position, the motor
speed varies depending of the pump flow in
order to maintain the pressure at constant
value.
While in ‘PRESET’ position, the motor runs
at a predetermined constant speed.
The variable speed pressure limiting control
is disabled either if the speed selector switch
is in ‘BYPASS’ mode, either if the
emergency start handle is used to start the
motor, or if the variable speed pressure
limiting system failed. In those cases, the
motor is directly connected to the main
power source and motor runs at its
maximum speed.
The speed selector switch is located behind
a breakable and lockable window.
3.2.VARIABLE SPEED MODE
This mode is the normal mode of the
controller and permits the system to work at
its full capability.
The speed selector switch must be in
‘VARIABLE’position. Upon a start demand
(pressure drops below the PRS pressure
threshold, manual start, remote start), the
variable speed drive is energized and the
motor speed ramps up to its minimal speed
in several seconds. Then, the motor speed
is automatically adjusted depending of the
system pressure.
This mode is automatically replaced by the
bypass mode if failure occurs in the variable
speed drive path or if emergency handle is
activated or if the pressure stays below the
PRS pressure threshold for more than 15
seconds.
3.3.PRESET SPEED MODE
In this mode, the speed of the motor is
constant
The speed selector switch must be in
‘PRESET’ position. Upon a start demand
(pressure drops below the PSR threshold,
manual start, remote start), the variable
speed drive is energized and the motor
speed ramps up to the predetermined speed
in several seconds. The speed is constant
and is independent of the system pressure.
This mode is automatically replaced by the
bypass mode if failure occurs in the variable
speed drive path or if emergency handle is
activated.
3.4.BYPASS MODE
This mode is activated when the speed
selector switch is in ‘BYPASS’ position.
Upon a start demand (pressure drops below
the PSR threshold, manual start, remote
start), the variable speed drive is
disconnected and the bypass contactor is
activated to connect the motor to the main
power supply.
This mode is also activated, even if the
selector switch is in variable or preset
position in case of drive failure or
emergency start.
3.5.STOP PUSH BUTTONS
In ‘VARIABLE’or ‘PRESET’ position the
motor stop can be progressive by
depressing the DELAYED STOP push
button. It can be instantaneous too, by
depressing the INSTANT STOP push
button.
Note : In BYPASS mode , the motor can
only be stopped instantaneously, no matter
what push button is used. All start conditions
must be disappeared to stop the pump.

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4. FRONT PANEL
4.1.GENERALS
A display located on the left side is used to
monitor the electrical parameters of the
incoming power and to set the automatic
start pressure threshold. See PRS display
and PRS annunciators. Some others
annunciators are located on the flange of the
controller.
4.2.PRS DISPLAY
The first line shows the power source status.
The three line-to-line voltages and the
frequency of the normal source are
displayed. The last two digits are reserved
to write a status symbol.
The status symbol "W" indicates the source
is in wrong phase sequence.
The status symbol "n" indicates the source
is not acceptable. This non-acceptability
occurs when :
any line voltage drops below 85%,
the frequency is too high or too low,
an unbalance occurs between the three
phases.
The third line is dedicated for the motor and
trouble status. When no trouble, the three
line currents are shown followed by the
elapse time meter of the motor. The elapse
time meter is expressed in hours and tenths
of hours.
If trouble occurs, the two last digits of the
elapse time meter are replaced by a status
symbol. The symbol can be :
P for Pump starting failure (see below)
O for Overcurrent problem (see below)
U for Undercurrent (see below)
T for Transducer problem (see below)
The fourth line is dedicated for the pressure
system status. The first section shows the
cut-out threshold, the second section shows
the cut-in threshold, the third section shows
the system pressure.
'O' means cut-Out which is the value where
the pump has to stop,
'I' means cut-In which is the value where the
pump has to start.
Those values are adjustable on the field by
removing the adjustment cover plate with a
Philips screwdriver. When removed, it is
possible to have access to small switch. The
pressure unit (PSI or kPa) can be selected
on the field.
4.3.PRS ANNUNCIATORS
4.3.1.POWER AVAILABLE
This LED indicates power acceptable on all
3 phases and phase sequence is correct for
the power source.
4.3.2.SYSTEM TROUBLE
This LED indicates unexpected situation
occurring. This LED is flashing and a
flashing symbol appears on the last digit of
the third line. To help the user, the trouble
legend is written on the display (See
troubleshooting hint).
oPfor pump starting failure. This trouble
occurs when the low system pressure
is detected but the current did not
reach 10% of the nominal current after
20 seconds.
oOindicates an over current. This
trouble occurs when the current is over
130% of the nominal current for more
than 20 seconds.
oUindicates an undercurrent. This
trouble occurs when the detected
current is under 30% of the nominal
current for more than 20 seconds.
oTindicates a pressure transducer
problem (PT1 only).
This can occur if :
- the pressure transducer is not
connected (atmospheric pressure)
- the transducer does not send a
correct signal
- a wire to the transducer is cut.
The last trouble is recorded and displayed.
To clear the symbol and the LED, the Reset
Push button must be depressed.
Note : this LED is not activated under drive
failure condition.
4.3.3.PHASE REVERSAL
This LED indicates phase reversal of the
power source.

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4.3.4.LOW SYSTEM
PRESSURE
This LED indicates that pressure drops
below the lowest threshold.
4.4.FLANGE
ANNUNCIATORS
4.4.1.BYPASS MODE
This pilot light indicates when the selector
switch is in bypass mode or when the
bypass contactor is activated.
4.4.2.VFD FAILURE
This pilot light indicates when the drive
failed. This pilot light is reset if the VFD is
reset. To reset the VFD failure, press the
Reset/Silence push button.
A drive failure is initiated by one of the
following conditions :
If the variable speed drive fails for
overload, over-temperature, or other
internal failure;
Within the first 30 seconds of powering
on the controller;
If the variable speed drive is not in
‘ready’ condition in the first 5 seconds
after power up;
If the system pressure has not been
recovered after 15 seconds;
4.5.AUDIBLE ALARM
The audible alarm is triggered when the
bypass mode light or when the VFD failure
light is activated. The alarm can be silenced
by the SILENCE push button. If the alarm is
present more than 24 hours, the audible
alarm will restart sounding.
The audible alarm is also activated when
sequential module is in STOP mode. In this
case, there is no possibility of silencing the
buzzer. The sequential module must be
restarted in RUN mode.