Adey Mini 130 Bedienungsanleitung

Installation and servicing

Mini 130/230

Digital Pressurisation Unit

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CONTENTS Page

Checklist .......................................................................... 4

Important Facts - read before commencing installation ............................... 5

Location ........................................................................... 6

Key Features ....................................................................... 8

Installation ........................................................................ 9

Electrical Installation ............................................................... 13

Commissioning .................................................................... 17

Operation .......................................................................... 21

Maintenance ....................................................................... 22

Environment Protection ............................................................ 23

Technical Specification ............................................................. 24

Trouble Shooting ................................................................... 25

Product Log ....................................................................... 26

Guarantee ......................................................................... 29

PRODUCT DESCRIPTION

Heating and cooling system pressurisation top up unit with integral water storage tank and

electric solenoid piston pump, automated control system consisting of pressure transducer

and water level switch. The tank includes an AB air gap for category 5 fluid isolation (BS EN

1717).

APPLICATION

The ADEY® Pressurisation Unit, (APU) Mini range is designed to provide intermittent water

top up only to compensate for intermittent losses in system pressure in heating and cooling

systems in commercial or industrial applications. These could include slight leaks, air venting,

etc. The units are not designed to deal with sudden losses of system pressure due to

major water losses over extended periods. They are also not to be used for water boosting

applications.

STORAGE

If this product is not to be installed immediately on receipt, ensure that it is stored in a dry,

frost and vibration free location in its original packaging.

WARNINGS:

zThe electrical installation must be carried out in accordance with the current

national electrical regulations.

zThe electrical installation must be installed by a qualified person.

zThe motor is not accessible in normal operating mode. The unit must only be

operated with the front cover in place.

zIn the interests of electrical safety a 30 mA residual current device (R.C.D.

not supplied) should be installed in the supply circuit. This may be part of a

consumer unit or a separate unit.

zThis appliance must be earthed via the supply cord.

zThis appliance must not be used for any other application without the written

consent of ADEY Commercial Limited.

zThis appliance can be used by children aged from 8 years and above and

persons with reduced physical, sensory or mental capabilities or lack of

experience and knowledge if they have been given supervision or instruction

concerning use of the appliance in a safe way and understand the hazards

involved. Children shall not play with the appliance. Cleaning and user

maintenance shall not be made by children without supervision.

zChildren should be supervised to ensure that they do not play with

the appliance.

zThis product should not be used for the supply of water to more than one

heating/cooling system at a time.

Please read installation details carefully as they are intended to ensure this product

provides long, trouble free service. Failure to install the unit in accordance with the

installation instructions will lead to invalidation of the warranty.

Read this manual carefully before commencing installation.

This manual covers the following products:

Mini 130

CP1-03-04911

Mini 230

CP1-03-04912

As a WEEE producer, ADEY Commercial Limited are obligated to finance the collection,

treatment & recovery of WEEE, and our compliance under these regulations is ensured

via our work with our WEEE Compliance Scheme of choice, B2B Compliance.

THIS PRODUCT COMPLIES WITH CURRENT EU PRODUCT LEGISLATION

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Item Description Qty Item Description Qty

APU 1 Fill valve flow restrictor, blue 1

Front cover 1 Rubber hose sealing washer, to

be used with item C 1

Flexible hose, G ½ 15 mm

compression 1 Cable tie 2

M6 screw 1 Instruction book 1

Wall mounting plate 1

1 IMPORTANT FACTS: READ BEFORE COMMENCING PUMP INSTALLATION

A Water storage capacity.

1.11 The APU Mini has a usable water volume of approximately 2 litres; the length

of time the APU takes to pressurise a system will be dependent on the pressure

differential between the cold fill and set pressures and also the refill rate of the tank.

1.12 Ensure the pumps are primed as described in the priming section before

starting, to avoid causing damage to the pump. See Section 6.20 Hydraulic

commissioning.

B Water temperature

This unit is designed to pump cold water only which should not exceed the following

values:

1.13 The maximum allowable water temperature is 23 oC (see Technical Section).

1.14 The minimum allowable water temperature is 4 oC.

C Pipework - General

1.15 Do not drill holes or put fastenings into the APU Mini tank, this will cause

leakage.

1.16 Secure pipework: Ensure pipework to and from pump is independently

supported & clipped to prevent forces being transferred to inlet and outlet

branches of the unit. Do not secure pipework to the APU Mini, this will cause

damage and possible leakage.

1.17 Flux: Solder joints must be completed and flux residues removed prior to APU

Mini installation (flux damage will void any warranty).

1.18 Pipework design: Care should be taken in the design of pipework runs to

minimize the risk of air locks e.g. use drawn bends rather than 90obends.

1.19 DO NOT introduce solder flux to flexible hose, tank, pump or any

parts manufactured from plastic.

1.20 DO NOT allow contact with oil or cellulose based paints, paint thinners or

strippers, acid based descalents or aggressive cleaning agents.

1.21 DO NOT bend the flexible hose beyond 90o. It must be installed as

detailed, DO NOT kink. See Installation Section 4.14.

D Plumbing installation regulations

1.22 The plumbing installation must comply with the current water and building

regulations.

1.23 The plumbing installation must be installed by a qualified person.

E System filling

1.24 The APU Mini is NOT DESIGNED TO FILL THE SYSTEM FROM EMPTY.

It is only intended to top up the system after occassional water leakage.

Systems should be filled via a dedicated filling loop.

Fig. 1

IMPORTANT: With the appliance removed from its packaging check for any damage prior

to installation. If any damage is found contact ADEYCommercial Ltd within 24 hours of

receipt.

A D

Front cover removed for clarity

Electrical rating

plate & serial

number

CHECKLIST

Note: Your product may vary slightly from the picture above.

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2 LOCATION - GENERAL

2.11 Location: The APU Mini must be located on a solid wall of sufficient

strength to support the filled weight of the APU Mini, close to the

water source and a suitable overflow position (see Section 10 -

Technical Specification for filled weight). The APU Mini must not be

installed in a loft space. It must also be considered that the noise

and vibration from the APU Mini may be transmitted through the

structure it is sited on. Ensure the minimum clearance requirements

are followed to allow servicing of the unit.

2.12 Access and minimum clearance requirements: For emergencies

and maintenance the APU Mini must be easily accessible and have

the minimum clearance around it as laid out in Fig. 2. Additional

access to the front of the unit will be required to operate the keypad

and view the display.

2.13 Protection: The APU Mini must be located in a dry, frost free area.

2.14 Ventilation: Ensure an adequate air flow to cool the APU Mini.

Separate the APU Mini from other appliances that generate heat.

Do not block the vent holes on the front cover.

2.15 Water retention: Site the APU Mini in a location where in the

unlikely event of a water leak, any spillage is contained or routed

to avoid electrics or areas sensitive to water damage. As part of

the AB airgap (CAT 5 fluid isolation) the APU Mini has a weir type

overflow on the front, water will be discharged from this area in the

event of the failure of the inlet valve or non-return valve.

2.16 Supply inlet pressure: The water supply inlet pressure must not exceed 7 bar.

2.17 Ambient temperature: The APU Mini must be sited in a location where the

ambient temperature does not drop below 4 °C or exceed 40 °C.

2.18 Pipework: For optimum performance inlet and outlet pipework must be a

minimum of 15 mm pipe.

2.19 Static outlet pressure: The static outlet head must be 3 metres below pump

maximum cold fill pressure (vertically above the appliance).

2.20 Noise: A flexible hose is supplied as standard which will minimise the

transmission of noise and vibration from the APU Mini pump to the

pipework connected to the appliance outlet. However, care must be taken

when mounting the APU Mini that any noise is not amplified through loose

panels or pipework.

2.21 Flexible hose: Only use the ADEY hose supplied with the APU Mini.

2.22 Isolating valves: Separate system isolating valves (non-restrictive) must be

fitted to allow easy service of the APU Mini. Isolating valves must be mounted

where specified to allow the system isolation and removal of the APU Mini if

needed. See Section 4.14 for installation details.

300

500

300

150 150

Fig. 2

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3 KEY FEATURES

3.11 The APU Mini comprises of the following main components:-

1. Moulded tank – Main body of the APU, comprising of an integrated water

tank with warning pipe and weir overflow and mounting the solenoid

piston pumps, manifold and controller.

2. Pump assembly – One or two piston pump units mounted into the

moulded tank with vibration isolating rubber mounts.

3. Outlet manifold – Brass manifold with pressure transducer used to monitor

system pressure and connection to the pump(s)

4. Programmable controller – Intuitive, user set controller, allowing system set up

and easy alarm connection.

5. Wall mounting plate – Robust stainless steel wall mounting plate allowing

quick, easy installation and removal if needed.

6. Moulded cover – Moulded acrylic capped ABS cover retained to the

moulded tanks with Dual LockTM fastening system for quick and easy

access.

3.12 Principle of operation: The pressurisation unit consists of a break tank and

one or two piston pumps. The break tank is supplied with mains water from

the left to a float valve and includes an overflow and weir to maintain an AB air

gap in the tank. The unit is connected to the heating/chiller system

via a flexible hose which can exit the unit on either the left or right. The

pumps are connected via a flexible hose to the tank via a rubber connector.

A pressure transducer monitors system pressure and if a reduction in system

pressure is detected, the controller runs the pumps until the system is re-

pressurised to the required pre-set level. If the unit only has a single pump

connected it will run on a 30 minutes on/30 minutes off basis until this level

is reached, if the unit is a twin pump model the pumps run in duty standby

mode (the controller will alternate which pump starts first to even the

wear on the pumps). The manifold is fitted with a non-return valve to ensure

system pressure is maintained once pressurised.

4 INSTALLATION

4.11 Fill valve flow restrictor guidelines: Ensure side entry fill valve is fitted

with the correct filter and flow restrictor combination (dependant on the

mains water pressure) into the G ½ threaded tail as outlined below:

Coloured insert - To be used for water pressure between 1 and 4 bar

White insert - The APU Mini is pre fitted with the white high pressure insert.

Change if the unit is slow to fill or the water pressure is low (below 4 bar).

4.12 Cold mains feed connection: The connection to the cold water mains inlet is

made using a suitable fitting to the G ½ male thread on the left hand side of

the APU Mini. When tightening ensure the fill valve within the tank is not

rotated. If the valve is rotated it may not function correctly with the risk

of flooding. (Do not overtighten).

4.13 Wall plate fixing:

1. When installing the APU Mini on a wall ensure suitable fixings for the wall

structure are used and are suitable to support the unit when fully filled with

water (see technical section for filled weights). The holes in the wall plate are

6 mm in diameter, the maximum permissible screw head height is 3 mm.

2. All holes in the wall mounting plate must have fixings used in them as per

the image below, do not leave out fastenings as this will compromise the

integrity of the wall plate.

3. Ensure you have sufficent room around the area you are mounting the APU

Mini to allow installation, servicing and operation. See section 2.12.

4. Ensure wall plate is fixed to a flat vertical wall and the top of the plate is

horizontal.

1Fig. 3

6Fig. 4

Fig. 5

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5. Retain the APU Mini to the wall mounting plate using the single M6

retaining screw at the top of the wall plate.

6. Fit the plastic cover by pressing as indicated below with the palm of the

hand until the Dual LockTM is heard to ‘click’.

4.14 Pipework connections & guidelines:

1. Before connecting the APU Mini to the system ensure that system flushing

has been performed correctly and all foreign matter, including pipe scale,

has been removed.

Note: Foreign material from the system coming into contact with the

expansion vessel bladder could cause premature failure of the expansion

vessel.

2. Isolating valves MUST be installed on the unit inlet and outlet, before

connection to the flexible hoses to allow the unit to be isolated if required.

The isolation valve on the outlet should be of a lockshield type. See

Fig. 10.

3. A drain valve must be fitted on the outlet of the APU Mini before the

isolation valve. See Fig. 10.

4. The connection to the heating/chilling system is also made with the

supplied flexible hose and a 15 mm compression fitting. The hose is

made water tight with a sealing washer on assembly, nip tight to 4 to

5 Nm for water tight seal. (Do not overtighten).

5. The connection to the heating/chilling system can be made to the left

or right hand side by routing the flexible hose supplied as detailed below.

Fig. 6

Fig. 7

Fig. 9Fig. 8

Cable tie

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6. The flexible hose and any wiring can be retained in the desired position

using cable ties and the two metal cable retention points on the top left

and right of the APU tank. See Figs. 8 & 9.

7. The warning pipe should be connected to a suitable drain via a tundish

enabling visual warning of an overflow condition. The overflow fitting is

designed to use 19 to 23 mm diameter plastic waste pipe or connect to

G ¾ threaded pipe. Ensure there is a demountable joint in the pipe to

allow the removal of the APU Mini if needed.

8. Non-return valves, pressure reducing valves and RPZ valves MUST NOT

be installed between the APU Mini and the heating/cooling system. These

devices will prevent the pressure sensor from reading the system pressure

and will lead to incorrect operation of the unit.

9. The APU Mini should be connected to the system return header along with

the expansion vessels as specified in BS 7074. See Fig. 10.

4.15 Typical installation diagram:

4.16 Vessel sizing & location:

1. System expansion vessel sizing should comply with the BS 7074 Expansion

Vessel sizing calculation.

2. The pressurisation unit and expansion vessels should be connected to the

system at the same point, to provide a neutral pressure reading.

3. A lockshield valve and drain valve should be installed at the inlet of each

expansion vessel to allow for servicing.

5 ELECTRICAL INSTALLATION / EARTHING

5.11 Regulations: The electrical installation must be carried out in

accordance with the current national electrical regulations and

installed by a qualified person.

5.12 Safety: In the interests of electrical safety a 30 mA residual current

device (R.C.D. not supplied) should be installed in the supply circuit.

This may be part of a consumer unit or a separate unit.

5.13 Before starting work on the electrical supply ensure power supply is

isolated.

5.14 DO NOT allow the supply cord to contact hot surfaces, including the

motor shell, pump body or pipework. The cord should be safely

routed and secured by cable clips.

5.15 Adjacent pipes: Adjacent suction and delivery pipes should be fitted with

earthing clamps in accordance with current regulations (Fig. 12).

5.16 Earthing: This appliance must be earthed via the supply cord.

5.17 Pipework: Copper or metallic pipework must have supplementary earth

bonding where the continuity has been broken by flexible hoses or plastic

components.

5.18 Additional earthing: Certain installations may require additional earthing

arrangements such as equipotential bonding. Reference should be made to

the relevant regulations concerning this subject to ensure compliance.

5.19 Connections: The APU Mini must be connected to a dedicated fused SPUR via

a lockable isolator to avoid authorized disconnection.

5.20 The electrical connection must be made adjacent to (not behind) the APU

Mini to allow disconnection of the electrical supply should the pump module need to

be removed for service or maintenance.

Fig. 10

Fig. 11

APU Mini

Warning pipe

Drain

valve

Isolation valvesExpansion

vessel

Return

header

Lockshield

valve

Drain valve

Earth continuity

connection

Fig. 12

Flexible

hose

Metallic

pipework

Metallic

pipework

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5.21 Wiring of connection unit:

WARNING: This appliance must be earthed.

The wires in the mains lead (supply cord) are coloured in accordance with the

following code:

Green and Yellow: Earth

Blue: Neutral

Brown: Live

As the colours of the wires in the mains lead of this appliance may not

correspond with the coloured markings identifying the terminals in your

connection unit proceed as follows:

zThe wire which is coloured green and yellow must be connected to the

terminal in the connection unit which is marked with the letter E or by the

earth symbol: or coloured green or green and yellow.

zThe wire which is coloured blue must be connected to the terminal which

is marked with the letter N or coloured black.

zThe wire which is coloured brown must be connected to the terminal

which is marked with the letter L or coloured red.

5.22 Boiler interlock safety function:

The APU Mini is fitted with a single volt free contact specifically assigned for

boiler/chiller shut down in the event that the APU Mini detects system

pressure above the Hi alarm pressure or below the Lo alarm pressure.

The boiler interlock contact will be open circuit below the Lo alarm pressure

and above the Hi alarm pressure.

When the system pressure is in its normal operating pressure range (above Lo

alarm pressure and below Hi alarm pressure settings) the contact is

closed circuit

Always refer to the boiler/chiller manufacturer’s instructions for correct

integration.

5.23 Boiler interlock connections:

The circuit connected to the relay is limited to 5 Amps, 230 V a.c.

maximum. The Installer MUST fit a 5 Amp fuse in the circuit to the alarm

relay to protect the APU Mini from damage.

For connection of output relays follow the steps and images below:

1) Remove the required green connector from the right hand side of the

control board.

2) Strip 6-8 mm insulation from the end of the connection wire

(Max 1.5 mm2CSA).

3) Insert wire into connector and screw down terminal screws to secure

(0.6 Nm max.).

Boiler Interlock

Fig. 13

Fig. 14

Fig. 15

Fig. 16

- 16 - - 17 -

4) Re-insert connector into the correct location on the control board and route

the cable to the back of the APU Mini and secure with a cable tie to the

retainer.

5.25 Supply cord replacement:

The supply cord and internal wiring within the terminal box are routed

and secured to ensure compliance with the electrical standard EN 60335-

1. It is essential that prior to any disturbance of this internal wiring, all

cable routing and securing details are carefully noted to ensure re-

assembly to the same factory pattern is always maintained.

If the supply cord is to be changed or is damaged, it must be replaced

with a special cord assembly available from ADEY or one of their approved

repairers. On disassembly note the cord retention and routing system.

Re-assemble to the same pattern. For information on cable connection

consult the wiring diagram.

Model Fuse Size (AMPS)

All models 5

5.24 Fuses: The following fuse size should be used:

6 COMMISSIONING

6.11 Pre-commissioning checklist:

Before starting the commissioning process the following conditions must be

met. If these conditions are not adhered to, damage to the equipment,

system and property may result.

zEnsure the unit is sited in a frost free area, away from precipitation and

water sprays/jets.

zAll necessary pipe/electrical connections should have been made to a

satisfactory standard by a qualified person.

zThe temperature and pressure at the point of connection are within the

operating limits of the pressurisation unit.

zThe heating/cooling system is fitted with a safety valve and expansion

vessel sized appropriately.

6.12 In order for the pressurisation unit and heating/cooling system to function

correctly the following conditions must be met. If these conditions have not

been met, the commissioning process should not continue.

zEnsure the system connection has been made into the heating/chiller

system return header.

zEnsure Non-return valves, pressure reducing valves or RPZ valves are NOT

installed between the pressurisation unit and the heating/cooling system.

zThe expansion vessel is pre-charged to the correct pressure (equal to

initial system design pressure).

6.13 Prior to commissioning, fill the heating/cooling system via a filling loop. The

APU Mini is NOT designed to fill the system from empty, it is only intended to

top up the system after occasional water leakage.

zEnsure the heating/cooling system is filled and pressurised to the required

cold fill pressure, with the water at approximately ambient temperature.

zEnsure the system is dosed with a suitable corrosion inhibitor. Note the

APU Mini is not designed for dosing chemicals into the system, this must

be done via other means.

6.14 Expansion vessel setting:

zTo set or check the expansion vessel charge pressure the lock-shield

valve between the APU Mini and the vessel must be closed and the

vessel drained using the drain valve.

zA suitable gauge should be used to check the charge pressure.

zIf the charge pressure is too high it can be reduced by releasing air from

the vessel pre-charge valve or by using a pressure gauge with an integral

air release valve.

zIf the charge pressure is too low a small increase can be provided using a

car foot pump otherwise an oil free compressor or nitrogen bottle is

recommended.

zWhen the correct pressure is set the Schrader valve protective cap must

be replaced.

zCheck the integrity of the pipe-work. Ensure the lock-shield valve

between the system and the expansion vessel is open and the drain

valve is closed.

Fig. 17

Retainer

Cable tie

- 18 - - 19 -

6.15 Controller overview

The pressurisation unit controller is designed to be intuitive to use and allows

functions and alarms to be set by the installer/user.

The functions are set using the 3 buttons (A, B, & C) on the front of the

controller and with the help of on screen prompts via the back lit LCD display.

On the front of the APU a green ‘power on’ light will be displayed whilst the

unit is powered. If an alarm or error is raised the red ‘Error’ light will be

displayed.

A number of pressure set points can be set using the menus, these set points are

detailed below, 1 to 4 and in the description of the function.

Button A Enters menus or selects values.

Button B Scrolls down through menus or reduces set values.

Button C Scrolls up through menus or increases set values.

6.16 Function list & explanation

The functions are contained within an initial display and a settings menu.

6.17 Initial display

On start up, and during normal operation, if the APU has had no button inputs

for 1 minute, the system pressure will be displayed (see Section 7.11).

6.18 Setting of APU Mini see Fig. 19

To access the setting of the APU Mini see the following procedure:

1 Press and hold button A for 5 seconds.

2 P1 will be displayed and the red Error light will slowly flash. See Fig. 20.

3 Using buttons B & C select the P function required.

4 Press button A to enter the function.

5 Using buttons B & C increment the value required up and down.

6 Press button A to confirm setting.

7 Press and hold button A until the red Error light stops flashing and the APU

Mini reverts to normal operation. This operation will save the changed

values.

P1 System pressure (2)

see Fig. 18

Sets the required system pressure. Set in 0.1 bar

increments up to the maximum set value for the APU model.

APU 130 & 230, 3.0 bar max.

P2 Differential pressure (3)

see Fig. 18

Sets the pressure the APU will turn on at as the system

pressure falls. Relative to the set system pressure. Set in

0.05 bar increments below the System pressure (2), cannot

be set above 0.1 bar below the System pressure (2).

P3 Hi Alarm (1)

see Fig. 18

Sets high system pressure alarm. Set in 0.05 bar increments

above the System pressure (2). Cannot be set below System

pressure + 0.5 bar. Alarm auto resets when system pressure

is reduced below alarm level.

If no button inputs are received within 1 minute the APU Mini will revert to

normal operation and the red Error light will stop flashing.

Note – Pumps do not operate when in the setting menu.

The following functions can be set and modified:-

TIME

PRESSURE

HIGH ALARM SET VALUE (1)

LOW ALARM SET VALUE (4)

SYSTEM PRESSURE SET VALUE (2)

DIFFERENTIAL SET VALUE (3)

PUMP 'OFF'

PUMP 'ON'

NORMAL OPERATION

SYSTEM

PRESSURE

Fig. 18

Fig. 19

AB C

Fig. 20

AB C

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