Calpeda Unimat-E Series Leitfaden

Installation, Operation & Maintenance

Instructions

Please leave this instruction booklet with the end user as it contains

important guarantee, maintenance and safety information

Read this manual carefully before commencing installation.

This manual covers the following products:

Unimat-E35 Duomat-E35

Unimat-E50 Duomat-E50

CE compliant product

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Cont ...

PRODUCT DESCRIPTION

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

and electric motor driven peripheral pump, automated control system consisting of

pressure transducer and water level sensors. The tank includes an AB air gap for category

5 fluid isolation (BS EN 1717).

APPLICATION

The Calpeda Unimat-E & Duomat-E ranges are designed to provide initial system fill and

intermittent water top up 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.

CONTENTS Page

Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Important Facts - read before commencing installation . . . . . . . . . . . . . . . . . . . . . . . 6

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Key Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Environment Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Product Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

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WARNINGS:

This appliance must not be used for any other

application without the written consent of

Calpeda Ltd.

This 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.

Children should be supervised to ensure that they

do not play with the appliance.

This product should not be used for the supply of

water to more than one heating/cooling system at

a time.

The electrical installation must be carried out in

accordance with the current national electrical

regulations.

The electrical installation must be installed by a

qualified person.

The motor is not accessible in normal operating

mode. The unit must only be operated with the

front cover in place.

The electrical installation must be carried out in

accordance with the current national electrical

regulations and installed by a qualified person.

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.

This appliance must be earthed via the supply

cord.

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Cont ...

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.

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Cont ...

CHECKLIST

Note:

Your product may vary slightly from the picture above.

Item Description Qty Item Description Qty

Tank body 1 Fill valve flow restrictor 2

Front cover 1 Rubber hose sealing washer,

to be used with item C 2

Flexible hose, G ½ 15 mm

compression 2 Cable tie 2

M6 screw 1 Instruction book 1

Wall mounting plate 1

Fig. 1

IMPORTANT: With the appliance removed from

its packaging check for any damage prior to

installation. If any damage is found contact

Calpeda Ltd within 24 hours of receipt.

Front cover removed for clarity

Electrical rating

plate & serial

number

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Cont ...

1 IMPORTANT FACTS: READ BEFORE COMMENCING PUMP INSTALLATION

A Water storage capacity.

1.11 The Unimat-E & Duomat-E have a usable water volume of approximately 8 litres;

the length of time the unit 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 shaft seal. See Section 6.26

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 tank body, 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 unit, this will cause damage

and possible leakage.

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

units 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 4.15.

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.

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2 LOCATION - GENERAL

2.11 Location: The preferred location of the unit is either on a solid wall

or on a smooth level floor, both of sufficient strength to support

the filled weight of the unit, close to the water source and a

suitable overflow position (see Section 9 - Technical Specification

for filled weight). The unit must not be installed in a loft space.

It must also be considered that the noise and vibration from

the unit 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 unit 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 unit must be located in a dry, frost free area.

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

Separate the unit from other appliances that generate heat. Do not

block the vent holes on the front cover or the air inlet at the rear.

2.15 Water retention: Site the unit 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 tank has a weir type overflow on the right hand side,

water will be discharged from this area in the event of the failure of the

inlet valve or non-return valves.

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

2.17 Ambient temperature: The unit must be sited in a location where the ambient

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

Fig. 2

300

500

300

150150

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Cont ...

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 pump to the pipework connected

to the appliance outlet. However, care must be taken when mounting the

unit that any noise is not amplified through loose panels or pipework.

2.21 Flexible hose: Only use the hoses supplied with the unit.

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

fitted to allow easy service of the unit. Isolating valves must be mounted where

specified to allow the system isolation and removal of the unit if needed.

See Section 4.15 for installation details.

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3 KEY FEATURES

3.11 The unit comprises of the following main components:-

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

tank with warning pipe and weir overflow and mounting the assembly,

manifold and controller.

2. Pump assembly – One or two brass peripheral pump units powered by

induction motors, with integrated non-return valves and venting screw.

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 – 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/two peripheral pumps. The break tank is supplied with mains water from

either the left or right through a flexible hose connected 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 another flexible hose which can

exit the unit on either the left or right. The pumps are connected 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 continuously 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 pumps

are fitted with non-return valves to ensure system pressure is maintained once

pressurised.

1Fig. 3

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4 INSTALLATION

4.11 Fill valve flow restrictor guidelines: The side entry fill valve must be 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 - To be used for water pressure above 4 bar

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

made using the 15 mm compression flexible hose supplied. Ensure the rubber

sealing washer supplied with the hose is installed when the hose is fitted.

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. 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). See Fig. 6.

Fig. 4

Fig. 5

Fig. 6

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