Mikrofill 3 Leitfaden

PRESSURISATION UNIT

MIKROFILL 3 PRESSURISATION UNIT

TECHNICAL DOCUMENTATION

ISSUE 12/15 Rev. 01

INSP I R E D EFFI C IENC Y

TABLE OF CONTENTS

TECHNICAL DOCUMENTATION 03

10.

11.

Technical Data

Electrical Details

Connection Details

Installation

Mains / Boosted Cold Water Supply

Fill Pressure

Connection to the System

Drain

Dimensions

Diagram of a Typical Installation

Wall Mounting Plate Dimensions for Fixing

Electrical Connections

Electrical Diagram

Electrical Data

Keypad Functions

System Data

Power

Down

Service Mode

Status Display

Pressure Correct

System Filling

Filling Stopped due to Low Mains Water Pressure

Frequent Use

Service Mode

Adjusting Settings

Parameter Functions

Fault Diagnosis

Status / Fault Conditions

Status / Fault Conditions continued.

Manual Override

Component List

Maintenance

Removing the Controls Assembly

Cleaning the Solenoid Valves

Cleaning the Inlet Ballofix Valve

Declaration of Conformity

TECHNICAL DATA

04 TECHNICAL DOCUMENTATION

WRAS Approval Number:

ELECTRICAL DETAILS

• Supply Voltage:

• Full Load Current:

• Start Current:

• Fuse Rating:

• Maximum Load BMS Relays:

CONNECTION DETAILS

• Cold Water Inlet:

• System Outlet:

• Drain (via Tundish):

• Maximum Inlet Pressure:

• Maximum Cold Fill Pressure:

•Nominal Flow Rate:

•Dry Weight:

1806078

230 Volt

1 Amp

3 Amp

5 Amp

15mm Compression

¾” BSP

5 Bar

4.7 Bar

14 l/min at 2 Bar

5 kg

TECHNICAL DATA

TECHNICAL DOCUMENTATION 05

The Mikrofill 3 is a fully automatic sealed system filling device and is suitable for the water management in

domestic and commercial heating and cooling systems. It is designed for use in a normal environment. It is not

suitable for installation outside, or in environments where there are excessively cold temperatures.

INSTALLATION

All Mikrofill products should be installed by a competent person with regard to the relevant requirements of

the Health and Safety Regulations, Building Regulations, IEE Regulations, Water Supply (Water Fittings)

Regulations, Water By-laws (Scotland) and any other by-laws or planning requirements.

The Mikrofill 3 is WRAS approved with certificate number 1806078.

It is intended for wall mounting (see page 08) and should be mounted at such a height as to enable the

display to be easily read.

MAINS / BOOSTED COLD WATER SUPPLY

The Mikrofill 3 is designed to be connected directly to the mains cold water supply, or a boosted cold water

supply. The unit is supplied complete with all necessary isolating valves and incorporates a basket filter in the

inlet ballofix valve.

A flexible hose is supplied with the unit which MUST be connected to

the inlet ballofix valve, as shown in the diagram to the left. Failure to

do so may result in damage to the inlet pressure sensor due to water

hammer, resulting in a SENSOR FAILURE. Under such circumstances,

this would not be considered a warranty fault.

The water inlet connection is 15mm compression and should be

connected to the mains cold water supply by 15mm copper pipe or

equivalent approved plastic pipework.

If the Mikrofill 3 is sited some distance from the mains cold water

supply it may be advisable to install a single check valve adjacent to

the mains cold water supply.

To reduce the pressure drop on very long supply routes 22mm supply

pipework is recommended.

FILL PRESSURE

The Mikrofill 3 is capable of filling a system to within 0.3 bar of its

current inlet water pressure.

Where the incoming water pressure exceeds 5 bar please contact

our technical department on 03452 60 60 20 for further installation

information.

FLEXIBLE

HOSE

TECHNICAL DATA

06 TECHNICAL DOCUMENTATION

CONNECTION TO THE SYSTEM

The Mikrofill 3 is connected to the system by way of the 15mm outlet isolation valve. The pipework from the unit

should be made in 15mm copper or similarly approved plastic pipework. A suitable sized expansion vessel

should be incorporated into the system at this point (please refer to the typical installation diagram on page

07 for more information).

Please contact our technical department on 03452 60 60 20 if you require any assistance regarding vessel

sizing.

The final connection into the system should be sized accordingly, recommendations are shown below:

• Vessel size up to ½”

• Vessel size up to ¾”

• Vessel size up to 1”

For vessel sizes in excess of 1000L capacity please contact our technical department.

IMPORTANT NOTE:

DRAIN

Following every fill procedure the unit will discharge a small amount of water, establishing an air break. For this,

the unit is supplied fitted with a ¾” BSP tundish, which must be connected to a suitable drain.

Mikrofill Systems Ltd. cannot accept responsibility for any consequential damage caused by failure to

connect the tundish to a suitable drain.

100L:

300L:

1000L:

(15mm) expansion pipework

(22mm) expansion pipework

(28mm) expansion pipework

The expansion vessel air / nitrogen charge must be set to the same pressure as the cold fill

pressure of the system.

If the installed height of the expansion vessel is different to that of the unit then please

contact our technical department who will advise on the air / nitrogen charge required.

A suitably sized pressure relief / safety valve MUST be fitted on all sealed systems.

TECHNICAL DATA

TECHNICAL DOCUMENTATION 07

DIMENSIONS (IN MILLIMETRES)

DIAGRAM OF A TYPICAL INSTALLATION

Please note that for the purpose of clarity, system valves are not shown. For systems exceeding 90°C contact

our technical department on 03452 60 60 20 for advice.

Further installation guidelines can be found on page 05 of this technical documentation.

TECHNICAL DATA

08 TECHNICAL DOCUMENTATION

WALL MOUNTING PLATE DIMENSIONS FOR FIXING (IN MILLIMETRES)

• A maximum size of No. 8 screws or M4 bolts are to be used.

• A minimum of 25mm clearance either side of the unit is required.

• A minimum of 250mm clearance above the unit is required.

• The unit must be fitted on a sound, solid surface.

262

205

170

177

ELECTRICAL CONNECTIONS

TECHNICAL DOCUMENTATION 09

The Mikrofill 3 requires a permanent 230 V 50 Hz 1 phase fused supply rated at 3 Amp. The unit is internally fused

at 3 Amp (see electrical installation diagram below).

The unit also incorporates two BMS relays offering volt free contacts for the remote indication of low or high

pressure conditions within the system. These relays are also independently fused at 5 Amp to protect the

Mikrofill 3 from external electrical faults. Alternatively, if only a common fault signal is required by the BMS as

opposed to individual low and high alarms, a further volt free relay is included in the unit which can be used

to interlock the boiler or chiller control circuits. Should either the low or high alarm relay operate, then this third

relay will shut down the boiler or chiller and indication of any alarm situation will be shown on the display. The

relays are suitable for use on control voltages up to 250 V.

To access the wiring connections on the Mikrofill 3, the cover on the lower front of the unit will first need to be

removed by unscrewing the PZ2 screw located on the underside. Removing this cover will reveal a 12 way

terminal block, with each connection labelled 1 - 9 for the volt free relays (see electrical installation diagram

below), Live, Earth and Neutral. The wiring can be passed through the cable glands on the underside of the

unit, through an opening in the front casing, then connected as required into the terminal block.

Once the Mikrofill 3 has been correctly connected, the unit is ready for use. Ensure that the unit has a water

supply and that the service valves are open. Check for water leaks, switch on the electrical supply to the unit

and press the central power button on the front of the unit until the display illuminates. After a brief period, the

unit will start to fill the system. Once the system has achieved its set cold fill pressure, the unit will stop filling,

discharge a small amount of water to drain and then go to PRESSURE CORRECT.

ELECTRICAL DIAGRAM (WHEN NOT AT FAULT)

ELECTRICAL DATA

• Supply: 230 V 1 ph 3 Amp.

• Full Load Current: 1 Amp.

• Start Current: 1 Amp.

• Fuse Rating: 3 Amp.

• BMS Relays and Boiler / Chiller Relays: Volt Free Contacts rated at 250 VAC at 5 Amp.

• All relays are independently fused at 5 Amp.

KEYPAD FUNCTIONS

STATUS DISPLAY

10 TECHNICAL DOCUMENTATION

The top line of the display on the Mikrofill 3 will provide information on the current status of the unit as well as

the system that it is managing, providing information on any potential issues and / or faults as and when they

occur.

The following status messages will be displayed on the unit based on current conditions:

If the unit displays any messages other than those detailed above, then there is likely a fault either with the unit

or the system. For a list of possible fault displays, along with causes and remedies, please refer to pages 13 and

14 of this technical documentation.

SYSTEM DATA

This button is used primarily to scroll through the various settings of the unit. Repeatedly pressing this

button will cycle through each setting (see page 12 for information on each of these settings).

Pressing this button whilst the unit is in SERVICE MODE will again cycle through each setting, but in

this mode the settings can now be adjusted (described in further detail on page 11).

When the unit is in SERVICE MODE this button is used to increase parameter values.

POWER

Pressing and holding this button for approximately 2 seconds will turn the unit on or off. When the

unit is powered on, the display should always be illuminated.

NOTE: This button will turn the unit off, but it does not isolate power to the unit.

DOWN

When the unit is in SERVICE MODE this button is used to decrease parameter values. This button can

also be used to view the calibration code for the unit’s pressure sensors by pressing and holding it

down for 2 seconds. The top line of numbers displayed will relate to the calibration of the unit.

SERVICE MODE

This is a multi-function button that, when the unit is in operational mode, is used to mute the audible

alarm conditions. Pressing and holding this button for approximately 8 seconds will put the unit into

SERVICE MODE where various parameters can then be adjusted (described in further detail on

page 11).

PRESSURE CORRECT

The Mikrofill 3 continuously monitors the system pressure. When the system pressure is within set

parameters, the unit will show this message on the display.

SYSTEM FILLING

This message indicates that the unit is currently filling the system to its target fill pressure.

FILLING STOPPED DUE TO LOW MAINS WATER PRESSURE

The Mikrofill 3 continuously monitors the inlet pressure. If this inlet pressure falls below an acceptable

level (within 0.3 bar of the current system pressure) whilst the unit is attempting to fill the system then

the unit will operate a safety shut-down, displaying this message. Once the incoming pressure is

reinstated, the unit will return to operating as normal.

FREQUENT USE

There is a FREQUENT USE setting on the Mikrofill 3 which can be adjusted by accessing the SERVICE

MODE (described in further detail on page 11). If the unit cuts in to top up the system more than the

number of times this setting is set to within a 24-hour period then the unit will alarm and display this

message. This alert is for informational purposes as it informs that the unit is having to top up the

system unusually often, suggesting there may potentially be a leak somewhere on the system.

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