FLOWTECH flowpress Bedienungsanleitung
1
First Publication Date: 01/09/2020
Revision:
Revision Date:
OPERATION AND
MAINTENANCE MANUAL
DS Pressurisation & Dosing Units
Contents
General Information 3
Safety Information 4
Equipment Overview 7
Principal of Operation 7
Installation 8
Typical Installation Diagram 8
Electrical Power Supply 10
Micro Controller 11
Fault contacts 11
Commissioning 12
Controller Overview 13
Controller Programming 14
Program List 15
Hydraulic Commissioning 18
Balancing Valve Seing 21
Open and Close 21
Seing the Flow 21
Notes 21
Operation 23
Fault Codes 23
Shutdown procedure 24
Start-up Procedure 24
Maintenance 25
Wiring diagram 27
Spare Parts 29
FlowpressDS Models 30
Troubleshooting 31
Warranty Details 34
Conditions of warranty 34
2
Definitions of Safety Warnings and
Precautions
WARNING!
Indicates a potentially hazardous situation which, if
not avoided, can result in serious injury or death.
CAUTION!
Indicates a potentially hazardous situation which, if
not avoided. Can result in minor to moderate injury, or
serious damage to the product.
General
Information
These instructions are to assist in the installation of the flowpress DS Pressurisation Units
please follow them carefully.
If, having read this Operation & Maintenance Manual, there is any doubt about any aspect of
the installation please don't hesitate to contact our technical team.
flowpress DS Pressurisation & Dosing Units
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Safety
Information
It is essential that correct and safe working practices are adhered to at all times when installing,
operating and/or maintaining any piece of equipment. Always consult safety data sheets, operating
and maintenance manuals, Health & Safety legislation and recommendations and specific
requirements of any equipment manufacturer, site controller, building manager or any other persons
or organisation relating to the procurement, installation, operation and/or maintenance of any piece
of equipment associated or in conjunction with any product provided by flowech Water Solutions.
This document is intended for ALL installers, operators, users and persons carrying out maintenance
of this equipment and must be kept with the equipment, for the life of the equipment and made
available to all persons at all times. Prior to carrying out any work associated with the set it is essential
that the following sheets are read, fully understood and adhered to at all times.
Equipment must only be installed, operated, used, and/or maintained by a competent person. A
competent person is someone who is technically competent and familiar with all safety practices
and all of the hazards involved.
Any damage caused to any equipment by misapplication, mishandling or misuse could lead to risk of
Electrocution, Burns, Fire, Flooding, death or injury to people and/or damage to property dependent
upon the circumstances involved. flowech Water Solutions accepts no responsibility or liability for
any damage, losses, injury, fatalities or consequences of any kind due to misapplication, mishandling
or misuse of any equipment, or as a result of failure to comply with this manual.
Failure to install, operate, use or maintain the equipment in accordance with the information contained
within this document could cause damage to the equipment and any other equipment subsequently
connected to it, invalidating any warranties provided by flowech Water Solutions to the buyer.
4
SAFETY WARNINGS &
PRECAUTIONS
These instructions should be read and clearly understood before working on the system. Please
read this manual carefully and all of the warning signs aached before installing or operating the
equipment keep this manual handy for your reference. This equipment should be installed, adjusted
and serviced by trained and qualified personnel. Failure to observe this precaution could result in
bodily injury.
WARNING! - Install an emergency stop key separately from the isolator. Rotating
shas can be hazardous.
WARNING! - This equipment has a high leakage current and must be permanently
fixed to earth.
WARNING! - Do not aach or remove wiring or connectors when the power is applied.
Do not check signals during operation. When the power is turned on and the running
command is on, the motor will start rotating. The stop key is only eective when the
function is set. If there is a power failure and an operation instruction is given the unit
may start automatically when the power is reinstated.
WARNING! - Make sure that the input voltage is correct. Be sure to install the unit in
a room that is not exposed to direct sunlight and is well ventilated.
Avoid environments which have a high ambient temperature, high humidity or
excessive condensation. Avoid dust. Corrosive gas, explosive gas, inflammable gas,
grinding-fluid mist and salt damage, etc.
WARNING! - Do not connect the power source to any terminals except power
connectors.
WARNING! - Motor control equipment and electronic controllers are connected to
hazardous line voltages. When servicing drives and electronic controllers, you may be
exposed to components at or above the line potential. Extreme care should he taken
to protect against shock. Dangerous voltage may exist aer the power light is o.
Wait more than 5 minutes aer turning o the power supply before performing
maintenance or inspection. Hazard of electric shock. Disconnect incoming power
before working on this unit.
WARNING! - The inverter should be protected separately against ground fault.
Observe the regional regulations for electrical installation!
flowpress DS Pressurisation & Dosing Units
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CUSTOMER / CONTRACTOR
RESPONSIBILITIES
It is the responsibility of the customer and/or the contractor:
• To ensure that anyone working on the equipment is wearing all necessary protective gear
and/or clothing.
• Is aware of appropriate health & safety warnings.
• Has read the information in this section of the manual.
CAUTION! - It is strongly recommended that all electrical equipment conforms
to National Electrical Codes and local regulations. Only qualified personnel should
perform installation, alignment and maintenance. The manufacturer reserves the right
to alter the technical data in order to make improvements or update information.
CAUTION! - Failure to observe these rules will render the guarantee invalid. The same
applies to repair jobs and/or replacement. Your legal rights are not aected.
CAUTION! - The manufacturer declines all responsibility in the event of damage or
injury caused as a result of tampering with the equipment.
CAUTION! - Do not switch on/o power supply to run/stop the motor/system! Start
the unit only by using run buon or external run command.
We strongly recommend that commissioning and service
work is carried out by the manufacturer’s personnel or
appointed agents ~ please contact our technical sales
department for information on our commissioning and
service contract packages.
6
Equipment Overview
The function of this pressurisation unit is to provide a means of automated water top-up to sealed heating
and cooling systems. The equipment is designed to provide periodic water top-up to compensate for minor
losses insystem pressure (e.g. slow leaks, air venting, etc.).
This equipment is not designed to cope with sudden losses of system pressure (e.g. manual draining) or ma-
jor water losses (e.g. large leaks). The equipment is also not intended to be used for water boosting applica-
tions.
Principal of Operation
The following schematic shows the internal arrangement of a pressurisation unit:
The flowpress DS unit is fied with a break tank (1) which is filled from the mains water supply (2) via
a float operated valve (3). The break tank is fied with an overflow (4) in case the break tank overfills,
and a weir overflow (5) in case the primary overflow fails. Also fied is an additive tank (14). Additive
tank is filled with either glycol or additive, to add to the system a required mixture is required. To do
this two balancing valves areplaced aer each of the tanks to control the mixture water (12) and
Glycol (13). (See mixture table)
The pressurisation unit is connected into the heating system (6) via an isolation valve (7).
The pressure sensor (8) monitors the system pressure.
If the pressure sensor detects a drop in pressure, the pump (9a) will pump water from the break
tank into thesystem. Once the required pressure has been reached, the pump will stop.
On twin pump models, a second pump (9b) is provided. The two pumps will run in a duty/standby
configuration(i.e. the active pump will alternate with each pump start).
The pump(s) are fied with non-return valves (10a, 10b) to prevent backflow.
A drain valve (11) is provided for draining down the unit and for commissioning purposes.
flowpress DS Pressurisation & Dosing Units
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Installation
This pressurisation unit is not designed to be installed in an outdoor environment. The unit must be
installed in a frost free environment, away from precipitation and water sprays/jets. If there isa risk of
flooding, the unit must be installed on a raised plinth.
Please refer to the appropriate datasheet for the maximum working pressure and temperature ofthe
pressurisation unit. The conditions at the point of connection to the system must not exceed these
values.
Pipe Connections
To avoid damaging the float valve, the mains water supply pipe must be flushed before connection to the
pressurisation unit.
All pipe connections must be made with appropriate jointing compound/PTFE tape.
If PTFE tape is used, care must be taken to ensure that the tape does not obstruct the orifice of the fiing.
Non-return valves, pressure reducing valves and RPZ valves must not be installed between the pressurisation
unit and the heating/cooling system. These devices will prevent the pressure sensor from reading the system
pressure.
The pressurisation unit and expansion vessel should be connected to the system at the same point, to provide
a neutral pressure reading. This point of connection should be in the systemreturn, on the suction side of the
circulation pump.
Typical Installation Diagram
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Flowpress DS Clearance and Connection Requirements
Connection Size Notes
Mains Water
Feed
½” BSP M An isolation valve must be installed
on the mains water feed for
servicing.
Break Tank
Overflow
22mm Guidance on drainage
requirements should be obtained
from the local water authority.
System Con-
nection
½” BSP M
/ 15mm
The pressurisation unit and
expansion vessel should be
connected to the system at the
same point.
The point of connection shouldbe
in the system return, on thesuction
side of the circulation pump.
Non-return valves, pressure
reducing valves and RPZ valves
must not be used.
flowpress DS Pressurisation & Dosing Units
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Electrical Power Supply
This equipment must be electrically isolated before removing the covers. Cables connected to the
volt free contacts may be supplied from another source and may remain live aer the unit is isolated.
These must be isolated elsewhere.
All electrical connections must be carried out by a suitably qualified and competent person.
The mains power supply to the pressurisation unit must be connected into the fused terminal
block as shownbelow:
On some larger models, the fused terminal block is replaced by a fused spur. If this is the case, the
power supplymust be connected into the fused spur, as shown below:
It is recommended to supply power to the pressurisation unit via a lockable isolator. This should be
installed within 2m of the equipment.
This equipment can be damaged by the high voltages produced by electrical installation testing
equipment. When performing electrical installation tests, the equipment must be isolated from the
supply.
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