PRESSCON VERNIT N2 Manuale utente

VERNIT - HORNIT N2(i) expansion

systems

User manual

Type

User manual

Date

18-09-2019

Version / Revision

Version 4.2, Revision 00

Status

Approved

Company

PRESSCON

Location

Honselersdijk

Table of content

Introduction ........................................................................................................................................................... 5

Important to know ................................................................................................................................................. 7

1.1.1 Working with the safety valve .............................................................................................................. 9

1.2 Description of hazard symbols .......................................................................................................................... 9

2 System components .................................................................................................................................. 11

2.1 Nitrogen generator type ECONOMY A ............................................................................................................ 11

2.2 Nitrogen generator type ECONOMY B ............................................................................................................ 12

2.3 Nitrogen generator type ECONOMY DUO ...................................................................................................... 13

2.4 Vacuum- overpressure safety valve and vacuum safety valve ....................................................................... 15

2.5 Vacuum- overpressure safety valve with tracing band ................................................................................... 16

2.6 Pressure sensor ............................................................................................................................................... 17

2.7 Pressure sensor with tracing ribbon ............................................................................................................... 17

3 General operation ....................................................................................................................................... 19

3.1 Operation of the expansion system ................................................................................................................ 19

3.1.1 Compressed air supply ....................................................................................................................... 19

3.1.2 Nitrogen production ............................................................................................................................ 19

3.1.3 Water monitoring ................................................................................................................................. 19

3.1.4 Systems that also regulate the water level (optional) .................................................................... 20

3.1.5 Protection against overpressure and vacuum with VERNIT systems ......................................... 20

3.1.6 Protection against vacuum with HORNIT systems ........................................................................ 21

3.1.7 Leak detection measurement (SLDM or CLDM) for VERNIT systems (optional) ...................... 22

3.1.8 Heating tape at the pressure sensors and vacuum overpressure relief valve (optional) .......... 22

3.1.9 Manual operation of the return valve (optional) .............................................................................. 23

3.2 Assembly of components on the buffer tank .................................................................................................. 24

3.2.1 Vertical buffer tank .............................................................................................................................. 24

3.2.2 Vertical buffer tank in a DUO setup .................................................................................................. 26

3.2.3 Horizontal buffer tank ......................................................................................................................... 27

3.2.4 Horizontal buffertank in a DUO setup .............................................................................................. 29

3.2.5 DUO system for a High and low temperature networks ................................................................ 29

3.3 Schematic overview of the expansion system ................................................................................................ 30

3.3.1 VERNIT 2.0 -30.0 N2(i) system ........................................................................................................ 30

3.3.2 HORNIT 2.0 -30.0 N2(i) system ........................................................................................................ 31

3.3.3 VERNIT 2.0 -30.0 N2(i) DUO system ............................................................................................... 32

3.3.4 HORNIT 2.0 -30.0 N2(i) DUO system .............................................................................................. 33

4 Touchscreen ............................................................................................................................................... 34

4.1 Main screen of the Touchscreen ..................................................................................................................... 34

4.1.1 Main screen lay-out VERNIT ............................................................................................................ 35

4.1.2 Main screen lay-out HORNIT ............................................................................................................ 35

4.2 Icons on the main screen ................................................................................................................................ 36

4.2.1 Compressor ......................................................................................................................................... 36

4.2.2 PSA generator ..................................................................................................................................... 37

4.2.3 Oxygen sensor .................................................................................................................................... 37

4.2.4 Valves ................................................................................................................................................... 37

4.2.5 Overpressure safety relief .................................................................................................................. 38

4.2.6 VERNIT tank malfunction status ....................................................................................................... 38

4.2.7 VERNIT tank water level status ........................................................................................................ 40

4.2.8 HORNIT tank malfunction status ...................................................................................................... 41

4.2.9 HORNIT tank water level status ........................................................................................................ 42

4.2.10 HORNIT pressure tank failure status ............................................................................................... 43

4.2.11 HORNIT druktank waterhoogte status ............................................................................................. 43

4.3 User menu ...................................................................................................................................................... 44

4.3.1 User menu schematic for Touchscreen type (ECONOMY A and ECONOMY DUO) ............... 44

4.4 Service menu ................................................................................................................................................... 45

4.5 Factory menu .................................................................................................................................................. 45

4.6 Standby ........................................................................................................................................................... 45

5. PRESS-display ............................................................................................................................................ 46

5.1 Buttons on the PRESS-display ......................................................................................................................... 46

5.1 Menu structure and access ............................................................................................................................. 47

5.2 User Menu ...................................................................................................................................................... 47

5.3.1 User menu for the VERNIT ECONOMY B systems ....................................................................... 48

5.4 Service Information screen ............................................................................................................................. 49

5.4.1 Service information screen for the VERNIT ECONOMY B ........................................................... 49

5.5 Factory information screen ............................................................................................................................. 50

5.5.1 Factory information screen for the VERNIT ECONOMY B ........................................................... 50

5.6 Service menu ................................................................................................................................................... 51

5.7 Factory menu .................................................................................................................................................. 51

5.8 Standby ........................................................................................................................................................... 51

6 PRESS-control ...................................................................................................................................................... 52

6.1 Types of PRESS-control ................................................................................................................................... 52

7 Alarms and error handling ........................................................................................................................ 53

7.1 Faults and alarms ........................................................................................................................................... 53

7.2 Overriding the boiler alarm relay ................................................................................................................... 54

7.3 Faults and alarm messages ............................................................................................................................. 55

7.3.1 Fault and alarm messages for the PressControl (ECONOMY A and ECONOMY DUO) ............................... 55

7.3.2 Fault and alarm messages for the Touchscreen ............................................................................ 57

7.3.3 Fault and alarm messages for the PRESS-Basic control(ECONOMY B) ....................................................... 60

8 Maintenance and service ................................................................................................................................ 63

8.1 Expansion system maintenance ............................................................................................................................ 63

8.2 Compressor maintenance ............................................................................................................................... 63

9 Warranty ....................................................................................................................................................... 63

10 Appendix .................................................................................................................................................. 65

11 Document history ................................................................................................................................... 65

12 To conclude ................................................................................................................................................... 71

Introduction

The VERNIT HORNIT expansion system monitors and controls the pressure that is present in the expansion chamber of

a central heating system. It is applicable for the central heating systems in the horticulture industry. The system is

comprised out of a nitrogen generator with an air compressor, a set of pressure sensors that measure the water level

and pressure in a buffer tank and a control module that controls the nitrogen generator.

The central heating systems that are used in the horticulture industry store their heat in a vertical or horizontal buffer

tank. The buffer tanks are not fully filled with water but have an expansion chamber above the water. When looking at a

vertical buffer tank the expansion chamber is right above the water inside the tank. When looking at a horizontal buffer

tank the expansion chamber is also right above the water inside the tank but it can also be located in a separate

expansion vessel. The expansion chamber is intended for the water in the central heating system to expand and shrink

when the water is heated up or cooled down. During this process the pressure in the expansion chamber also changes.

The VERNIT HORNIT expansion system monitors the pressure in the expansion chamber. When the pressure becomes

too high then an overpressure valve relieves the extra pressure. When the pressure becomes to low then the VERNIT

HORNIT expansion system will produce nitrogen in order to get the expansion chamber pressurized again. The nitrogen

generator of the VERNIT HORNIT expansion system produces an air mixture with a nitrogen concentration of 99,0 vol. %

N2. The system uses nitrogen because it is an inert gas. Inert gasses have the ability to prevent the formation of rust

when it is available in a high concentration. The VERNIT HORNIT expansion system makes sure that there is always a

blanket of nitrogen present in the expansion chamber within the buffer tank and that it is kept at a steady overpressure.

Next to the pressure management of the nitrogen blanket, the VERNIT HORNIT expansion system also acts as a

monitoring device for the water level in the buffer tank. By using pressure sensors the system determines the height of

the water level. Once the water level becomes too high or too low, the VERNIT HORNIT expansion system will generate

the appropriate fault or alarm messages and can also send a stop signal to other relevant devices. The water level

monitoring is important for the conservation of the buffer tank. It prevents the water level from becoming too high and

damaging the roof of the buffer tank.

It also prevents the water level from becoming too low, which leads to air in the heat supply spray tube and in the central

heating network.

These are important features for maintaining the buffer tank and preserving the central heating system.

Important to know

The expansion systems are produced in 2 different types. Namely, the VERNIT and HORNIT systems. These 2 types

have the following differences.

• VERNIT, the expansion system regulates the pressure of the nitrogen blanket in the vertical heat storage tank.

• HORNIT, the expansion system regulates the total system pressure in a horizontal heat storage tank. This is

done either directly or via an external expansion vessel.

In addition to VERNIT and HORNIT, there are a few additional indications that define the function of the expansion

system. These are:

2.0 – 30.0

The number in the type designation indicates the capacity of the nitrogen generator. This number

represents the flow rate in m³/h that the generator can produce with a purity of 99.0 Vol%N2. The

smallest capacity per generator is 2.0 m³/h and the largest possible capacity is 30.0 m³/h. Larger

capacities are also possible, but several nitrogen generators have to be combined with each other.

H.P.

"High Performance" stands for the design of the PSA tube. Indicates that the PSA applied to the

system was manufactured by PRESSCON. Nitrogen generators from before 2009 do not have this

addition.

ECONOMY

This indicates that the generator is equipped with a valve control system designed for high output

and energy efficiency.

N2i

N2i stands for direct injection of nitrogen. In this case, the expansion system will blow nitrogen

directly into the heat storage tank.

N2 without the "i" stands for an expansion system without direct injection. In this case, the expansion

system uses a separate pressure vessel in which the nitrogen is first stored before it is blown into the

heat storage tank.

A (panel)

The addition "A" indicates that the expansion system is equipped with the A-type control panel which

is the most comprehensive version.

B (panel)

The addition of "B" indicates that the expansion system is equipped with the B-type control panel,

which is a simpler version than the A-type panel.

DUO(panel)

DUO means that the expansion system is suitable for monitoring 2 separate heat storage tanks.

ELC

The expansion system is prepared to operate in an Equal Level Control setup. This function allows

for control of the level difference in two tanks by controlling a pump. For this purpose, the expansion

system will work together with 1 or more expansion systems via CAN-bus.

SLC

The expansion system is prepared to use the Switching Level Control function. This function

generates a switching signal based on the level difference in two tanks. For this purpose, the

expansion system will work together with 1 or more expansion systems via CAN-bus.

SLDM

Leak detection measurement that works on the basis of a 3rd pressure sensor at the bottom of the

vertical buffer tank.

CLDM

Leak detection measurement that works on the basis of information that the system receives from

the horticultural computer. The horticultural computer then indicates the fill level of the vertical buffer

tank.

The type designations described above are compatible with each other according to the matrix below.

VERNIT

HORNIT

N2i

A (panel)

B (panel)

DUO

(panel)

ELC /

SLC

SLDM /

CLDM

VERNIT

N/A

Yes

HORNIT

N/A

Yes

N2i

Yes

N/A

Yes

N/A

Yes

A (panel)

Yes

N/A

Yes

(panel)

Yes

N/A

DUO (panel)

Yes

N/A

Yes

ELC / SLC

Yes

N/A

Yes

SLDM /

CLDM

Yes

N/A

Touchscreen and PRESS-Display

The touchscreen and the PRESS-display are both control units that can be used for the PRESSCON nitrogen

generators. Originally, the PRESS-display was conceived as a multi-purpose digital display showing the water level,

nitrogen blanket pressure and any alarms. The Touchscreen also performs these functions, but offers a more visual

overview of the system and more intuitive controls. The Touchscreen can also be universally used for multiple types of

nitrogen generators.

• The Touchscreen is used as standard for the types VERNIT - HORNIT ECONOMY A and ECONOMY DUO.

Optionally, this display can also be used with a VERNIT ECONOMY B.

• The PRESS-display is used as standard with the VERNIT ECONOMY B

If 2 or more expansion systems are connected to each other via CAN-bus, it is important that the displays within that

network are all of the same type. Touchscreen and PRESS-display do not work together within a CAN-bus network. This

could occur, for example, in an ELC setup.

1.1.1 Working with the safety valve

The safety valve is commonly located on the roof of the buffer tank. When working on the safety valve, the following

hazards should be considered.

Symbol

Description

Applies to

HOT PARTS,

Do not touch parts with bare hands.

Use heat-resistant clothing.

The housing of the safety valve and relieved nitrogen from the

buffer tank. The upper layer of water can heat up the nitrogen in

the safety valve. The housing can then be too hot to touch. The

relieved nitrogen from the vacuum- overpressure safety valve on

top of a vertical buffer tank can also contain steam with a

temperature of 90°C which could cause burn injury. Vacuum safety

valves on the horizontal buffer tanks do not release nitrogen.

ATTENTION! WORKING AT HIGHTS,

Working on the roof of a vertical or horizontal buffer tank is

considered working at heights. Fall protection is recommended

when working on the safety valve.

HIGH PRESSURE, Relief pressure

from components before work is

conducted.

The safety valves on both the vertical and horizontal buffer tanks.

The safety valve on a vertical buffer tank can be depressurized by

hand. The pressure is not higher than 28 mBar. The safety valve

on a horizontal buffer tank can only be depressurized by relieving

water pressure for the buffer tank. The pressure is not higher than

1200 mBar.

1.2 Description of hazard symbols

In addition to the identified risks for the nitrogen generator, compressor and safety valve, the following symbols can also

be applied. When a hazard symbol is encountered, please observe its meaning carefully before further commencing the

work.

Symbol

Description

Symbol

Description

1. OVERPRESSURE VALVE,

Be aware of the sudden relief of

overpressure.

7. HIGH PRESSURE,

Relief pressure from components before work is

conducted.

2. DANGEROUS VOLTAGE,

Forbidden to work on the system if the

power is on.

8. HOT PARTS,

Do not touch parts with bare hands. Use heat-

resistant clothing.

3. DANGEROUS TO INHALE GAS,

Avoid the specified area or wear

appropriate breathing equipment.

9. MOVING PARTS,

Risk of getting stuck or injuries to limbs. Turn the

machine off completely before working on it.

4. NOISE,

Wear ear protection to prevent hearing

damage.

10. ROTATING FAN,

Risk of getting stuck or injuries to limbs. Turn the

machine off completely before working on it.

5.MACHINE WITH AUTOMATIC START,

Machine stops and starts automatically when it

is operating normally. Turn off the machine

completely before working on it.

11. ATTENTION,

Special situation occurs, follow additional instructions.

6. READ THE OPERATING AND

MAINTENANCE INSTRUCTIONS,

It is advised that the maintenance instructions

are read before continuing work.

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