Calpeda Duomat-E Series Installation, Operation & Maintenance Instructions Manual Download

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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

Summary of Contents for Duomat-E Series

Page 1: ...struction 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 ...

Page 2: ...rcial 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 locatio...

Page 3: ...y 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 f...

Page 4: ...tallation 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 ...

Page 5: ...to be used with item C 2 Flexible hose G 15 mm compression 2 Cable tie 2 M6 screw 1 Instruction book 1 Wall mounting plate 1 A E C B D H G F I C 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 A D Front cover removed for clarity B E Electrical rating plate serial number G ...

Page 6: ...cure 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 s...

Page 7: ... 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 ...

Page 8: ...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 mus...

Page 9: ...ystem 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 f...

Page 10: ...ssure 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 ...

Page 11: ... 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 unit 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 5 Retain the unit to the wall mounting plate using the si...

Page 12: ...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 12 3 A drain valve must be fitted on the outlet of the unit before the isolation valve See Fi...

Page 13: ...eating 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 unit should be connected to the system return header along with the expansion vessels as specified in BS 7074 See Fig 12 4 16 Typical installation diagram 4 17 Vessel sizing location 1 System expansion vessel sizing should comply with the BS 7...

Page 14: ...hould be fitted with earthing clamps in accordance with current regulations Fig 14 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 suc...

Page 15: ... yellow The wire which is coloured blue must be connected to the terminal which is marked with the letter N or coloured black The 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 unit is fitted with a volt free contact specifically assigned for boiler chiller shut down in the event that the un...

Page 16: ...amage 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 mm2 CSA 3 Insert wire into connector and screw down terminal screws to secure 0 6 Nm max NO NO NO NO Boiler Interlock Common Alarm High pressure alarm Low pressure alarm Fig ...

Page 17: ...nged or is damaged it must be replaced with a special cord assembly available from Calpeda Ltd 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 4 Re insert connector into the correct location on the control board and route the cable to the back of the unit and ...

Page 18: ...g loop if possible If this is not possible the pressurisation unit can be used to fill the system after commissioning has taken place Depending on the size of the system this may take a considerable amount of time The system fill function of the unit will stop after 24 hours if further filling is required reset this function Ensure the heating cooling system is filled and pressurised to the requir...

Page 19: ...isplayed whilst the unit is powered If an alarm or error is raised the red Error light will be displayed A number 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 Scrolls up through menus or increases set values Button B Enters menus or selects values Button C Scrolls down through menus or reduces set values B...

Page 20: ...x Differential pressure 3 see Fig 20 Sets the pressure the unit will turn on at as the system pressure falls Relative to the 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 Hi Alarm 1 see Fig 20 Sets high system pressure alarm Set in 0 05 bar increments above the System pressure 2 Cannot be set below System pressure 0 0...

Page 21: ...ve the accuracy of the pressure setting on lower volume systems Pump start delay Sets the time delay in starting the pump after system pressure differential pressure 3 is reached on falling pressure Adjustable from 3 to 120 seconds pre set to 3 seconds Increasing this time will reduce un wanted unit operation during rapid system pressure fluctuations circulator pump starts Pump test Forces pump 1 ...

Page 22: ...nu 6 23 Advanced setting menu Set Pressure 2 bar Differential 0 2 bar Hi Alarm 2 5 bar Lo Alarm 1 3 bar System fill off Run activity high 1000 Relay allocation Pump fail Relay operation normally open Pass code 0000 not active Run time limit 10 minutes Pump run on delay 10 seconds Pump start delay 3 seconds ...

Page 23: ...r pass code If set Delay Push to test pump Pump activity log Power interrupt log Alarm log Start up screen Pump run time log System fill volume System pressure display Error display System fill status display Pump activity display Pump run time display Alarm reset Controller info display Setting menu Advanced menu Test menu 17 Oct 2019 Passcode change Star Activity High Common relay allocation Pum...

Page 24: ...lose isolation valve on the outlet of the unit Turn the electrical supply ON to the unit The Calpeda start up logo will be displayed and then the Home screen will be displayed The unit will run briefly and then turn off after a pre set run on time Due to the small size of the isolated system the unit will signal a Hi pressure error and the red error light will illuminate on the front of the unit t...

Page 25: ...tor the system pressure and re pressurise the system if the system pressure drops below the system pressure differential pressure See Fig 20 Example System pressure 2 bar differential pressure 0 5 bar pump will start to re pressurise system at 1 5 bar system pressure and stop at a system pressure of 2 bar During the normal filling operation of the pressurisation unit the pressure displayed on the ...

Page 26: ...causing an over pressure within the system or alarms being triggered 7 12 Pump exercise function If the pumps do not need to operate for more than a week both pumps will start for 3 5 seconds to avoid the pump s from seizing due to inactivity 7 13 Fault codes If there is a system fault a red light will be displayed on the front of the unit If the fault alarm is cleared the red light will go out Th...

Page 27: ...DO NOT remove the retaining screws or the membrane cover over the display 8 13 Spares The unit is designed and built to be a reliable and high quality product in the event of spares being required please contact Calpeda Ltd on 01869 241441 230 VAC 1PH 50Hz SUPPLY N E L MAIN WINDING THERMOTRIP START WINDING BLUE BROWN MOTOR 2 THERMOTRIP BLUE BROWN MOTOR 1 PRESSURE TRANSDUCER 4 20mA 0 10 bar COMMON ...

Page 28: ...ssure is increased 4 Open the mains water isolating valve allowing the tank to fill and ensure the fill valve is operating correctly and maintaining the correct water level 5 Check for signs of leakage 6 Open the drain valve on the outlet of the unit 7 Turn on the mains electrical power and ensure both if fitted pumps can run use test pump option if needed and are pumping water to drain 8 Close th...

Page 29: ...ar Ambient air temperature range Min 4 o C Max 40 o C Relative humidity 95 non condensing Min Max water temperature Min 4 o C Max 23 o C Water tank Usable water capacity 8 litres Inlet valve and fill rate Torbeck side entry 12 l min Fluid category CAT 5 type AB air gap with weir Connections Cold water inlet and outlet 15 mm compression x 600 mm flexible hose Overflow G 19 23 mm diameter pipe compr...

Page 30: ... Pressure sensor fault Remove pressure from the unit outlet and verify the displayed pressure is 0 bar Error will be displayed if the sensor signal is outside parameters Replace sensor call Calpeda Ltd High pressure alarm triggered High pressure System pressure too high Check system operation Increase High presure alarm set pressure Sensor error Pressure sensor fault Remove pressure from the unit ...

Page 31: ...ny Engineer System set pressure Differential pressure Hi alarm set pressure Lo alarm set pressure 12 14Service Log Service No 1 Date Engineer name Company name Tel No System pressure bar Differential pressure bar Check 6 months 12 months Condition of wiring Condition of hoses Evidence of leakage Controller fault codes Test pump operation Float valve operation x Level probe operation x Water condit...

Page 32: ...ration Float valve operation x Level probe operation x Water condition x Exp vessel pre charge x Comments Service No 3 Date Engineer name Company name Tel No System pressure bar Differential pressure bar Check 6 months 12 months Condition of wiring Condition of hoses Evidence of leakage Controller fault codes Test pump operation Float valve operation x Level probe operation x Water condition x Exp...

Page 33: ...ration Float valve operation x Level probe operation x Water condition x Exp vessel pre charge x Comments Service No 5 Date Engineer name Company name Tel No System pressure bar Differential pressure bar Check 6 months 12 months Condition of wiring Condition of hoses Evidence of leakage Controller fault codes Test pump operation Float valve operation x Level probe operation x Water condition x Exp...

Page 34: ...ect installation improper use unauthorised repair normal wear and tear and defects which have a negligible effect on the value or operation of the product Reasonable evidence must be supplied that the product has been purchased within the guarantee term prior to the date of claim such as proof of purchase or the product serial number This guarantee is in addition to your statutory rights as a cons...

Page 35: ... 35 Cont NOTES ...

Page 36: ... Machinery Directive 2006 42 EC Low Voltage Directive 2014 35 EU EMC Directive 2014 30 EU EMF Directive 1999 519 EC RoHs Directive 2011 65 EU WEEE Directive 2012 19 EU The company CALPEDA Ltd also decalres that for design and construction verification of the equipment the following standards were applied BS EN 12100 BS EN 809 BS EN 60335 1 BS EN 60335 2 41 BS EN 61000 3 2 BS EN 61000 3 3 BS EN 610...

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