Wilo Comfort Series Manual

Installation, Operation and Maintenance Instructions

For

Comfort Series Pressurisation Units

Models: P135, P235, P160, P260, P180, P280

Date: 07/01/2013

1: Installation

Location

The following should be considered when choosing the position of the pump

set:

The area should be dry and well ventilated.

There must be protection against frost.

There must be adequate drainage facilities.

The area must be secure to prevent unauthorised access / tampering.

Provision for the use of lifting equipment should be made.

There must be at least 1 meter clear area in front of panel and 0.5m at

either side and rear to aid maintenance.

Foundations

Foundations must be ridged and level, a plinth is not essential although it will

assist in keeping the set clear of damp. When fixing care must be taken not to

distort the set by tightening unevenly.

Pipework

Pipework connections to the set should be at least the same size as the

connections on the set, (if you require connections to be smaller contact Wilo

for advice).

Impurities

The water should be clean of all impurities. The sand content should not

exceed 0.01g/l. The size of any suspended bodies should not be such as to

clog or wear the hydraulic components.

On dirty water applications a filter must be installed in the suction pipe.

Electrical Connections

The installer must check that the available supply is compatible with the

voltage and frequency stamped on CE Label. Cable and fuses used for the

incoming electricity supply must be rated to cover all pumps running. Earth

bonding Inline with current IEE regulations is the responsibility of the installer.

Water Connections

Wholesome water supply can be connected directly to the float valve as back

contamination is prevented by the AB airgap within the pressurisation unit, this

unit can be connected to systems up to and including category 5

A quick fill loop by passing the pressurisation unit is not required, the comfort

controller has a system fill feature that allows the unit to fill the system via the

AB air gap over a 24 hour period.

2: Operation

Wilo Pressurisation units sets are available in 1 and 2pump (Duty / Standby)

configurations.

General

Wilo Pressurisation units work on closed loop pressure control via a

transducer and electronic controller. The control philosophy will allow the duty

pump to run ensuring that the CF pressure (Bar) is constantly met. On two

pump systems the duty will rotate between both pumps after each cycle to

ensure even wear. If the duty pump fails the standby pump will automatically

start.

Factory Settings:

Cold Fill Pressure CF 1.0 Bar

Low Pressure Alarm LP 0.6 Bar

High Pressure Alarm HP 2.7 Bar

Excess Starts Alarm ES ON

System Fill SF OFF

Alarm Latching AL OFF

Pump Config PC OFF

These values can be viewed in VIEW mode by pressing the down arrow and

scrolling through the menu. Pump configuration can be altered between Hand-

Off-Auto in this mode.

These values can be altered in USER mode to suit particular site conditions

by entering the password, 1234, and following flow diagram.

Auto Restart

This unit will automatically restart on power up after a mains failure or power

down. The BMS volt free contact 8 can be configured to mains failure if

required.

Low Water

If the water level in the break tank reaches an unacceptably low level, the float

switch is activated which prevents the pumps from running and activates an

audible, visual and volt free alarm

If alarm latching is OFF then the alarm will reset once break tank has been

replenished with water.

Low Pressure (LP)

This parameter can be altered in the User menu.

If the system pressure drops below LP setting an audible, visual and volt free

alarm activates.

If alarm latching is OFF then the alarm will reset once the duty pump has

increased the pressure past the LP setting

High Pressure (HP)

This parameter can be altered in the User menu.

If the system pressure rises above HP setting the pump stops and an audible,

visual and volt free alarm activates. This parameter can be changed by

following flow diagram.

If alarm latching is OFF then the alarm will reset once the system pressure

has fallen below the HP setting.

Excess Starts (ES)

If ON the alarm will activate and stop the pumps if the pump has started too

many times within a set period of time, this will activate an audible, visual and

volt free alarm.

The excess starts variables can be altered at time of commissioning

System Fill (SF)

If ON will overide System Leak alarm and allow pump to run for 24 hours or

until the CF pressure has been met, then the controller returns back to normal

operation.

To be used for initial System Fill during commissioning.

Pump Trip

The FLC of the pump is monitored by the controller whilst running and if

exceeded will stop the pump and activate an audible, visual and volt free

alarm. On a 1 pump unit or if both pumps are stopped via a trip alarm the

boiler interlock volt free alarm is also activated.

Pump Fail

The FLC of the pump is monitored by the controller whilst running and if no

current is drawn it will stop the pump and activate an audible, visual and volt

free alarm. On a 1 pump unit or if both pumps are stopped via a fail alarm the

boiler interlock volt free alarm is also activated.

Pump Check

All Wilo pressurisation units will automatically check the operation of the pump

by running them for a short period of time if they have been inactive for a long

period of time

The pump check variables can be altered at time of commissioning

Alarm Latching

If OFF then all alarms will reset once alarm condition has deactivated

If ON then alarms will have to be manually reset via reset button on the front

panel.

Alarm Log

The alarm log, logs the last 30 alarm events and these can be viewed from

the view or user mode.

Volt free contacts

This unit has the facility for 10 volt free alarms for remote monitoring, please

note all contacts are rated at 230V 5 Amp max.

Pump no. 1 fail/trip normally closed / common / normally open

Pump no. 1 run normally closed / common / normally open

Pump no. 2 fail/trip normally closed / common / normally open (If fitted)

Pump no. 2 run normally closed / common / normally open (If fitted)

Low Pressure normally closed / common / normally open

High Pressure normally closed / common / normally open

Excess Starts normally closed / common / normally open

Low Water normally closed / common / normally open

Boiler Interlock normally closed

The unit also has one off volt free contact that is rated for 230V 10Amp max,

which can be programmed at time of commissioning between

Common pressure alarms normally closed / common / normally open

Mains failure normally closed / common / normally open

Common alarm normally closed / common / normally open

3A: Pre-Commissioning checks

The pressurisation unit is piped up to system and water is available.

The unit is wired up correctly in accordance with wiring diagram, that

all connections are tight and the installation has been earth bonded to

current regulations.

System has been filled by the system fill function or quick fill loop

3B: Commissioning

Calculate the Cold Fill Pressure (CF):

CF= (A + 2.5)/10.2 Bar

Where A is the height of the building above the pressurisation unit in meters.

In cases of Roof Top plant rooms the minimum CF = 0.8 Bar.

Check air pressure in vessel whilst empty of water, air pressure should be

equal to CF pressure, use nitrogen to increase pressure if necessary.

Turn switch to OFF position.

Close all isolating valves.

Open any inlet valves to unit and allow break tank to fill ensuring ball float

valve closes before water level is 25mm below overflow. If water does reach

over flow adjust height of ball float.

Prime each pump in turn, by opening the vent plug on each pump.

Ensure common main discharge isolating valve is closed.

Turn switch to ON position.

Key in password, 1234, to enter the Main Menu and scroll through windows

entering settings to suit the installation, CF as above, LP should be at least

0.2 bar below CF and HP which should be 0.5 bar below the setting on

system safety valve.

If the system has not been filled by a quick fill loop the System Fill function

can be utilised by selecting ON. This will allow the pump to run for 24 hours or

until the CF pressure has been met.

Switch pumps(s) into Auto

Test High Pressure alarm by reducing the HP setting to 0.5 bar above the CF

and running one pump in Hand.

Test Low Pressure alarm by switching the pumps OFF, close main discharge

valve and slowly drain water from the system via drain cock until the LP

setting has been reached.

Ensure all settings are returned to normal and all valves are open

Check the units and system pipework for any leaks and flooding.

Warning

When running the unit in System Fill mode the system leak alarm is switched

OFF and the pump will continue to run if there is a leak on the system

4: Maintenance

Wilo pressurisation units are designed to ensure minimum maintenance is

required. However routine inspection is necessary and can be carried out by

Wilo, please contact our service department for details.

Every 6 months:

Check unit for leaks.

Check for corrosion especially on vessel and ensure water is not present

when Schrader valve (on top of vessel) is pressed down.

Every 12 months:

Check pump set for leaks.

Check for corrosion especially on vessel and ensure water is not present

when Schrader valve (on top of vessel) is pressed down.

Isolate vessel, drain down, check and recharge vessel with nitrogen.

Check motor / pump shafts are free to rotate.

Check operation of all valves to ensure they have not seized and or letting by.

Check operation of pressurisation to ensure it is still working within design

parameters.

Warning

Wilo would advise that power to the unit be isolated before any of the above is

undertaken, as the pump will start automatically.

5: Written Scheme of Examination

Accumulator vessels are classed as a pressure system under the Health and

Safety Executive ‘Pressure system safety regulations 2000’. This regulation

imposes a legal requirement on the user/maintainer to have the equipment

inspected by a competent company on a regular basis as a mandatory duty

under parts 7 & 8 of the regulations.

A supplier / installer may not fall under the category of user / maintainer,

however they are still obliged to inform the user / maintainer of their legal and

mandatory duties under the HSE Regulation.

Wilo recommend that any vessel over 250 bar / litres should have a working

test every 6 months and a thorough examination every 24 months.

Bar/Litre = Maximum Working Pressure (Bar) x Volume of vessel (Litres)

6: Warranty

This equipment is covered against manufacturing defects for 12 months from

date of purchase.

This warranty covers the replacement of parts or products, verified as

having a manufacturing defect, when inspected in the factory.

WILO reserve the right to inspect an installation to verify that the equipment

has been installed in accordance with the written instructions.

Any modifications to the supplied equipment must be approved in writing;

failure to do so will invalidate the warranty

Site Visit

Before requesting a site visit, the following information must be available to

the service team:

Article number of the equipment

A purchase order to cover the work in the event that no manufacturing

defect is found.

A site contact name and number

A FULL description of the alleged fault

7: Fault Finding Chart

Indication

Possible Reason

Action

Pump/s Don’t Run

Power Fail, Pressure not below CF-

Differential pressure. Pump Drive fault.

Check: Power to the Unit; Discharge valve is

open; Pressure settings; Electrical connections.

Boiler Not Running.

Power Failure, Low Pressure Alarm.

Check: for Low Pressure Alarm; Electrical

connections.

LCD is blank; Power

LED & Backlighting OK

Contrast fault. Connection fault, firmware

lock-up error.

Reset the Display by pressing Reset Key for 5-

seconds. Check ribbon cable connectors. Reset

the Control PCB by Power-down & Restart.

LCD Blank, No Power

LED or backlighting.

Power failure. PCB Failure.

Check: Mains feed to Unit; PCB fuse F3; Ribbon

cable connectors; Electrical connections .

Pump Trip Alarm

Pump draws excessive current.

Reset Alarm. Pump may require servicing. Check:

Pump rotates freely; Water flow.

Pump Fail Alarm

Pump draws zero current.

Check: Fuse (replace if required); Wiring; Pump.

Low Pressure Alarm

System Pressure is below Low Pressure

Alarm setting.

Check: Pumps operate correctly; System for

leaks/flooding; Alarm Latching is OFF.

High Pressure Alarm

System Pressure is above High Pressure

Alarm setting.

Check: Pumps operate correctly; ‘Pump Check’

settings (adjust frequency if required); Discharge

Isolation valve; Alarm Latching is OFF.

System Fill Alarm

Pump has run for 24-hours, with System Fill

active, & not yet reached CFP.

Check: System Pressure. Reset audible alarm.

Press Rest Key again to clear Alarm. Switch

System Fill ON if required.

Service Due Alarm

Service Period expired.

Ensure that the Pressurisation unit is serviced.

Low Water Alarm

Water Level in break tank low.

Check mains water inlet. Check ball valve

operation. Check Float switch operation.

High Water Alarm

Water level in break tank high.

Check ball valve operation. Check float switch

operation.

Pump Hunting

Settings incorrect for system. Pressure

Vessel/connection faulty

Check: Settings for Minimum Run & Start Delay;

Discharge valve; NRVs; Pressure vessel

operation & Connection; Transducer wiring

Pumps running

continuously

System Pressure not reaching CF.

Check: System for leaks; NRVs; Pumps;

Transducer & wiring. Check/Adjust System Leak

timer.

Transducer Fail

Excessive pressure rise or fall; Pressure not

changing with Pump running

Check: Discharge valve open; Transducer Wiring;

Reading Rises & Falls with pressure changes.

8: PARAMETER CHART & WIRING DIAGRAM

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