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Boss MX1-3HL Operation & Maintenance Manual Download Page 4

 

 

 

 

 
 

 

 

 

 

 

www.bssindustrial.co.uk    

 

 

 

We reserve the right to change designs and technical specifications of our products

. 

Rev 2.1  Oct-15     Page 

4

 / 

28

 

 

Contents

 

Customer & Equipment details   

 

 

 

 

 

 

   

2 

Commission Record 

 

 

 

 

 

 

 

 

   

3 

 
About this Manual 

 

 

 

 

 

 

 

 

   

 

 

Where to find more Information 

 

 

 

 

 

   

5

 

Equipment Overview   

 

 

 

 

 

 

 

   

 

 

Principal of Operation   

 

 

 

 

 

 

   

6

 

Important Information   

 

 

 

 

 

 

 

 

 

 

Environment 

 

 

 

 

 

 

 

 

 

7

 

Safety   

 

 

 

 

 

 

 

 

   

7

 

Application 

 

 

 

 

 

 

 

 

   

7

 

Cold Pressures   

 

 

 

 

 

 

   

 

7

 

Installation 

 

 

 

 

 

 

 

 

 

 

 

 

Pipe Connections 

 

 

 

 

 

 

 

 

8

 

Typical Installation Diagram 

 

 

 

 

 

 

   

8 - 9

 

Flow Restrictors  

 

 

 

 

 

 

 

   

9 - 10

 

Mini Clearance and Connection Requirements   

 

 

   

 

11

 

Electrical Power Supply   

 

 

 

 

 

 

 

12

 

Commissioning  

 

 

 

 

 

 

 

 

 

 

 

Pre-Commissioning Checklist 

 

 

 

 

 

 

 

13 

Commissioning   

 

 

 

 

 

 

 

 

14 - 16 

Hydraulic Commissioning 

 

 

 

 

 

 

 

17 - 18

 

Maintenance   

 

 

 

 

 

 

 

 

 

 

 

Maintenance information 

 

 

 

 

 

 

 

19 

Wiring   

 

 

 

 

 

 

 

 

 

 

 

 

Wiring Diagram  

 

 

 

 

 

 

 

 

20 

Spares   

 

 

 

 

 

 

 

 

 

 

 

 

Mini Models (MX1-3HL, MX2-3HL) 

 

 

 

 

 

 

 

21 - 22 

 

Troubleshooting 

 

 

 

 

 

 

 

 

 

23 

Service Log 

 

 

 

 

 

 

 

 

 

 

24 - 25 

Warranty Information   

 

 

 

 

 

 

 

 

26 

 

 
 
 
 
 
 
 
 
 

Summary of Contents for MX1-3HL

Page 1: ...uk We reserve the right to change designs and technical specifications of our products Rev 2 1 Oct 15 Page 1 28 BOSS Mini Mechanical Pressurisation Equipment Mini Models MX1 3HL MX2 3HL Operation Maintenance Manual Rev 2 1 ...

Page 2: ...d engineer Any damage or loss incurred through incorrect commissioning by an unapproved engineer will not be covered by the warranty If you wish for BOSS to arrange this please contact us See contact details Please see the warranty section for details Remember to fill in details for future use for re commission unit Do not use this equipment to fill a system use a WRAS approved filling loop for in...

Page 3: ...OF PRESSURISATION UNIT Site Reference PU Reference Date Commissioned Engineer Name Company PUMP CONTROL PRESSURE SWITCH HIGH LOW PRESSURE SWITCH RANGE HIGH PRESSURE CUT OUT DIFFERENTIAL LOW PRESSURE CUST IN PUMPS NUMBER 1 2 Delete as appropriate LOW PRESSURE DIFF NOTES Commissioning certificate can be obtained please contact BSSrepresentative Engineer Signature Date Customer Signature Date ...

Page 4: ...rtant Information Environment 7 Safety 7 Application 7 Cold Pressures 7 Installation Pipe Connections 8 Typical Installation Diagram 8 9 Flow Restrictors 9 10 Mini Clearance and Connection Requirements 11 Electrical Power Supply 12 Commissioning Pre Commissioning Checklist 13 Commissioning 14 16 Hydraulic Commissioning 17 18 Maintenance Maintenance information 19 Wiring Wiring Diagram 20 Spares Mi...

Page 5: ...TION Important information intended to prevent damage to the equipment system or property IMPORTANT Important information intended to ensure that the equipment functions correctly USEFUL Useful information which may be helpful but is not necessarily required for the unit to function correctly Typography This manual makes use of different typography to identify different types of information Italic...

Page 6: ...hematic shows the internal arrangement of a pressurisation unit The pressurisation unit is fitted with a break tank 1 which is filled from the mains water supply 2 via a float operated valve 3 The break tank is fitted with an overflow 4 in case the break tank overfills and a weir overflow 5 in case the primary overflow fails The pressurisation unit is connected into the heating system 6 via an iso...

Page 7: ...tem in the event of pressure loss due to deaerating and minor system leakage Safety Electrical installation must be carried out by a competent person WARNING LIVE TERMINALS WITHIN THIS EQUIPMENT Isolate the equipment before removing any covers Do Not make any electrical adjustments to the equipment unless it is isolated from the mains electrical supply Do Not operate with the electrical covers rem...

Page 8: ...ipe 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 fitting Non return valves pressure reducing valves and RPZ valves must not be ins...

Page 9: ...ed spur as appropriate Set the range and Diff on the pressure control switch Connect the boiler to the boiler interlock connection block High Low Switches Flow Restrictors Pressurisation equipment fitted with a plastic side entry torbeck valve must be fitted with a filter and depending on the mains water pressure a flow restrictor Failure to do this may result in damage to the equipment Two differ...

Page 10: ...15 Page 10 28 If no restrictor is required the filter must be removed from one of the restrictors and installed on its own The following diagram shows how to remove the filter To install the flow restrictor filter hold it by the tab and push it into the opening of the float valve connection as shown in the diagram below ...

Page 11: ...e installed on the mains water feed for servicing Break Tank Overflow 22 mm Guidance on drainage requirements should be obtained from the local water authority System Connection BSP F The pressurisation unit and expansion vessel should be connected to the system at the same point The point of connection should be in the system return on the suction side of the circulation pump Non return valves pr...

Page 12: ...bly qualified and competent person The mains power supply to the pressurisation unit must be connected into the fused terminal block as shown below On some larger models the fused terminal block is replaced by a fused spur If this is the case the power supply must be connected into the fused spur as shown below It is recommended to supply power to the pressurisation unit via a lockable isolator Th...

Page 13: ... cooling system is fitted with a safety valve and expansion vessel The following conditions must be met for the pressurisation unit and heating cooling system to function correctly If these conditions have not been met it is not advisable to proceed with the commissioning process The system connection has been made into the system return header pump suction There are no non return valves pressure ...

Page 14: ...le bleed any residual air from the pumps Caution do not attempt this operation unless you are trained to do so Note The cold pressure of the system should be set to at least 0 2 bar g above the static height of the system with a minimum permissible set pressure of 0 7 bar g Note The high and low pressure switches are pre set for systems with an anticipated cold fill pressure of 1 0 bar g for other...

Page 15: ... in pressure on the CUT IN scale range scale 2 Set the differential on the DIFF scale High and Low Pressure Settings Boiler control The high pressure switch is pre set to cut out at 3 0 bar g and will not re set until the system pressure has dropped to 2 0 bar g The low pressure switch is pre set to cut out at 0 5 bar g and will not re set until the system pressure has increased to 0 9 bar g These...

Page 16: ...www bssindustrial co uk We reserve the right to change designs and technical specifications of our products Rev 2 1 Oct 15 Page 16 28 To change the pressure gauges see below how to ...

Page 17: ...ensure that it is closed Then turn on the mains water supply and allow the break tank to fill When the float valve operates for the first time it may not close immediately causing the break tank to overfill Once the internals of the valve have been fully wetted this should not occur again 2 Initial Start up Open the internal isolation valve within the pressurisation unit by following the steps bel...

Page 18: ...hed the controller will display the current system pressure The unit is now in normal operation 3 Testing To test the operation of the pressurisation unit while connected to the system the system pressure must be lowered slowly to simulate a minor leak This can be achieved by using a drain point on the system the drain point on the pressurisation unit or by manually opening the safety relief valve...

Page 19: ...he uppermost points of the system The pump float valve ball cock and high Low switches should also be checked at this interval as a minimum Check the internal filters within the break tank are present and clear A visual check of the equipment for corrosion or damage should also be carried out and noted All settings should be recorded and compared to the previous service or commissioning for analys...

Page 20: ...www bssindustrial co uk We reserve the right to change designs and technical specifications of our products Rev 2 1 Oct 15 Page 20 28 Wiring diagram ...

Page 21: ...es show the internal components for the pressurisation equipment Due to continuing development and minor design changes some components may be changed without notice Therefore the drawings may not accurately reflect the current production design If in any doubt about the compatibility of replacement parts please contact BOSS Mini Models MX1 3HL MX2 3HL Image for indication only ...

Page 22: ... M021 3 Brass Nut BSS M006 4 Ball Valve BSS M005 5 40 mm Pressure Gauge c w Capillary BSS M004 6 Rocker switch BSS F014 7 6 mm Poly tube BSS M014 8 8 mm Poly tube BSS M015 9 Pump Control Pressure Switch FC TBV BOSS 10 High Low Pressure Switch FC TBV TWIN 11 Fused Terminal Block BSS R002 12 Pump All Models Model E EP77 BSS M024 13 Flexible Pump Support Bracket BSS M022 14 6mm x 8mm Push Fit Manifol...

Page 23: ...nning continuously Either the system is not full possibly a leak Check the pump pressure switch operation Check the Pressure Reducing Valve operation If the pump does not run Check the pump pressure switch operation Check the pump operation Check the internal filter within the break tank is present and clear If the unit fails to pressurise the system Check the system connection valve is open The o...

Page 24: ...e log should be completed by the service engineer after each annual service Date Range Engineers Name Differential Company Contact Number Comments Date Range Engineers Name Differential Company Contact Number Comments Date Range Engineers Name Differential Company Contact Number Comments Date Range Engineers Name Differential Company Contact Number Comments ...

Page 25: ...Rev 2 1 Oct 15 Page 25 28 Date Range Engineers Name Differential Company Contact Number Comments Date Range Engineers Name Differential Company Contact Number Comments Date Range Engineers Name Differential Company Contact Number Comments Date Range Engineers Name Differential Company Contact Number Comments ...

Page 26: ...cturing defect it will be addressed as described above additional remedial works as a result of misuse incorrect handling incorrect installation or incorrect commissioning then the additional work is chargeable Installation costs and or consequential losses are not covered by this agreement Conditions of warranty DOS Date Of Supply DOC Date Of Commissioning Equipment Conditions Timescale BOSS Pres...

Page 27: ...www bssindustrial co uk We reserve the right to change designs and technical specifications of our products Rev 2 1 Oct 15 Page 27 28 Notes ...

Page 28: ... the right to change designs and technical specifications of our products Rev 2 1 Oct 15 Page 28 28 BSS Industrial Fleet House Lee Circle Leicester LE1 3QQ United Kingdom T 44 116 256 7052 F 44 116 253 1343 E technicalteam bssgroup com ...

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