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www.wolseley.co.uk

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

Rev 8.1 Oct-15 Page

About this Manual

This Operation and Maintenance Manual contains all the necessary information to install, commission, operate
and maintain Flexfiller pressurisation equipment.

It is recommended to read all parts of this manual before undertaking any work on the equipment.

Conventions used in this Manual

This manual makes use of symbols to identify key pieces of information. Please take note of the following
symbols and their meaning:

DANGER – Important safety related information intended to prevent injury and/or damage to the
equipment, system or property.

CAUTION - 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.

Italics

Key words and phrases

(Round Brackets)

Used to identify a button on the digital controller

[Square Brackets]

A parameter on the digital controller

<Inequality Symbols> A message/fault code displayed on the digital controller

Where to find more Information

For further information please visit the following Website at the following URL:

www.pipecenter.co.uk

Содержание MAXI D125

Страница 1: ...to change designs and technical specifications of our products Rev 8 1 Oct 15 Page 1 42 JET Digital Pressurisation Equipment MAXI Models D125 D225 D150 D250 MD Models 125 225 150 250 Mini Models 130D 230D Operation Maintenance Manual Rev 8 1 ...

Страница 2: ...al number may be found on the label Model Serial No Purchase date Purchase From Note It is highly recommended to have this equipment commissioned by a Wolseley approved engineer Any damage or loss incurred through incorrect commissioning by an unapproved engineer will not be covered by the warranty If you wish for Wolseley to arrange this please contact us See contact details Please see the warran...

Страница 3: ...Bar PUMP SENSE YES NO Delete as appropriate FLOOD LIMIT Minutes SENSOR TYPE 0 1 2 Delete as appropriate PUMP 1 COUNT SPC CONTROLLER NO PUMP 1 HOURS GLYCOL UNIT NO PUMP 2 COUNT ID NUMBER PUMP 2 HOURS RELAY INVERSION YES NO Delete as appropriate ALARM COUNT OVERUN POWER INTERRUPTED PRESSURE ALARM AUTO RESET YES NO Delete as appropriate PULSE YES NO Delete as appropriate EXCESSIVE START YES NO Delete...

Страница 4: ...ents 9 MD Clearance and Connection Requirements 10 Mini Clearance and Connection Requirements 11 Electrical Power Supply 12 Fault Contacts 13 Commissioning Pre Commissioning Checklist 14 Controller Overview 15 Controller Programming 16 Program List 17 19 Hydraulic Commissioning 20 24 Operation Fault Codes 25 Shutdown Procedure 26 Start Up Procedure 26 Maintenance Maintenance information 27 28 Wiri...

Страница 5: ...revent injury and or damage to the equipment system or property CAUTION 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 dif...

Страница 6: ...ssurisation 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 isolation valve 7 The pressure sensor 8 monitors t...

Страница 7: ... 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 instal...

Страница 8: ...lude an integral filter The selection of the appropriate flow restrictor is based on the maximum mains water pressure at the point of installation Please refer to the following table for selection Mains Water Pressure Requirement Below 1 Bar No Restrictor Install Filter Only 1 4 Bar Low Pressure Restrictor coloured Above 4 Bar High Pressure Restrictor white If no restrictor is required the filter ...

Страница 9: ...led on the mains water feed for servicing Break Tank Overflow 22mm Guidance on drainage requirements should be obtained from the local water authority System Connection BSP M 15mm 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 pressu...

Страница 10: ...led on the mains water feed for servicing Break Tank Overflow 22mm Guidance on drainage requirements should be obtained from the local water authority System Connection BSP M 15mm 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 pressu...

Страница 11: ...talled on the mains water feed for servicing Break Tank Overflow 22mm 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 pressure...

Страница 12: ...y 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 This...

Страница 13: ...s There are 6 volt free fault contacts which can be used for connection to a BMS system or as a boiler interlock These are terminals 1 12 located on the digital controller With the exception of the Common Alarm it is possible to convert all other fault contacts to normally closed For further information please refer to the commissioning section of this manual ...

Страница 14: ...its of the pressurisation unit The heating 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 suctio...

Страница 15: ...it will display the controller version number This manual relates to controller version 8 0 If the controller is of a different version there may be differences in the menu items available When in normal operation the controller will display the current system pressure If a fault occurs the controller will display a fault code and produce an audible alarm In normal operation the functions of the b...

Страница 16: ...t digit with the and buttons then press SET to move onto the next digit Repeat for all digits then once the correct code is shown on the display press SET to enter the programming menu Once a correct code has been entered the first option COLD FILL will appear on the screen Once in the menu the value of the current menu item can be changed using the and buttons Once the current value has been set ...

Страница 17: ... and the pressurisation pumps will not run The recommended setting is 0 5 Bar below the COLD FILL pressure It is not possible to enter a value higher than the current COLD FILL value 0 5 Bar 4 DIFFERENTIAL The differential between the cut in and cut out pressures of the pressurisation pumps The cut in pressure will be equal to the COLD FILL pressure minus the differential pressure For example if t...

Страница 18: ...are more than 3 individual pump runs within an 8 hour period the unit will register an EXCESSIVE DEMAND alarm Enabling this option may cause false alarms on some systems NO 14 SERVICE When enabled a service reminder will be displayed after 12 months from when the option was enabled To reset the service reminder set the value to NO and exit the menu Then re enter the menu and set the value to YES a...

Страница 19: ... NO 21 ADDITIVE Not required on standard Pressurisation unit NO 22 ID NUMBER A user configurable identification number This option does not serve any functional purpose 01 23 RELAY INVERSION When enabled all normally open fault contacts i e all except the common alarm are converted to normally closed NO 24 OVERRUN Allows the pump to continue running for a set period of time after the required pres...

Страница 20: ...ow 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 Bleeding Pumps This step is only necessary for Flexfiller and Midi units For Mini units move on to the next step Make sure that the internal isolation valve within the pressuri...

Страница 21: ...hose to the hose tail on the drain valve and put the other end to drain Then using the cap off the isolation valve open the drain valve Locate the bleed screw on the pump The following diagrams show examples of typical bleed screw locations for most pumps Do not use excessive force when tightening the bleed screw as this may damage the pump casing ...

Страница 22: ...ll force pump 1 to run and holding down the SET button will force pump 2 to run If the controller is older than V6 1 then there is no way to force pump 2 to run via the controller To force the second pump to run the unit must be isolated and the live wires in terminals 13 and 14 must be swapped over The second pump then becomes pump 1 and can be forced to run via the controller To bleed the pumps ...

Страница 23: ...SURE fault and the pumps will not run To clear this fault either increase the system pressure using a filling loop or enable the system fill option on the pressurisation unit If the system pressure is above the high pressure alarm setting the controller will display a HIGH PRESSURE fault To clear this fault use a suitable drain point to remove water from the system until the system pressure equals...

Страница 24: ... quickly If the system pressure falls below the low pressure set point a low pressure fault will be displayed and the pumps will not run The pressurisation unit is not designed to cope with a sudden loss of system pressure which would be symptomatic of a catastrophic failure such as a burst pipe Once the system pressure has fallen below the cold fill setting by an amount equal to the differential ...

Страница 25: ...used on the digital controller Fault Code Description Auto Manual Reset LOW PRESSURE The system pressure is below the LOW PRESSURE set point User Defined HIGH PRESSURE The system pressure is above the HIGH PRESSURE set point User Defined LOW H20 The break tank low level float switch has been activated Auto Reset HIGH H20 The break tank high level float switch has been activated Auto Reset P1 FAIL ...

Страница 26: ... for more than 24 hours it is advisable to drain the water from the break tank Start up Procedure Attention This procedure is for restarting the unit after being shutdown as described above For initial start up and commissioning procedures please refer to the Commissioning section of this manual To restart the pressurisation unit please follow the steps below 1 Perform a visual inspection of the u...

Страница 27: ... another gauge Interrogate Controller The digital controller keeps a log of the number of pump starts and total hours run for each pump as well as the number of alarm activations and power interruptions It is advisable to take a note of these figures when servicing the unit as they may be helpful in diagnosing potential issues Fields are provided in the service log for these figures It is advisabl...

Страница 28: ...t or debris in the water or deposits on the sides of the tank the tank should be drained down and cleaned Check Strainer Flexfiller units only Flexfiller pressurisation units are fitted with a mesh strainer in the connection at the bottom of the break tank This should be removed and inspected Depending on the condition this part may need to be cleaned or replaced Check Expansion Vessel Pre Charge ...

Страница 29: ...www wolseley co uk We reserve the right to change designs and technical specifications of our products Rev 8 1 Oct 15 Page 29 42 Wiring diagram ...

Страница 30: ...www wolseley co uk We reserve the right to change designs and technical specifications of our products Rev 8 1 Oct 15 Page 30 42 Wiring location list ...

Страница 31: ... 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 Flamco Image for indication only Description Part Code 1 Digital Controller MICRO CONTROL 2 Electrical Plate Fuse Block and 15V PSU SA 000 EP 001 SINGLE PUMP or 002 TWIN PUMP 3 Power...

Страница 32: ... Code 1 Pump Model 125D 225D Pedrollo PQA60 BSS PQA 60 Pump Model 150D 250D Pedrollo PQ81B BSS PQ81b Pump Model 280DS Pedrollo PQA90 FC039 2 Non Return Valve FC SC1 3 Braided Hose BSS FLEXHOSE 4 Pressure Transducer 0 10 Bar 1 6V 1 6V TRANSDUCER 5 Combined Isolation Drain Valve FCCG NO 6 Float Valve BSS P33 7 Overflow Connection BSS M021 8 Mesh Strainer N A 9 Float Switch BSS RO12 10 Ball Valve BSS...

Страница 33: ...on only Description Part Code 1 Pump Model 125D 225D Pedrollo PQA60 BSS PQA 60 Pump Model 120D 250D Pedrollo PQ81B BSS PQ81b 2 Non Return Valve FC SC1 3 Braided Hose BSS FLEXHOSE 4 Pressure Transducer 0 10 Bar 1 6V 1 6V TRANSDUCER 5 Mini Float Valve BSS M003 6 Combined Isolation Drain Valve FCCG NO 7 Overflow Connection BSS M021 8 Mesh Strainer N A 9 Float Switch BSS R012 ...

Страница 34: ...ode 1 Pump All Models Model E EP77 BSS M024 2 Pressure Transducer 0 10 Bar 1 6V 1 6V TRANSDUCER 3 Ball Valve BSS M005 4 Overflow Connection BSS M021 5 Mini Float Valve BSS M003 6 Float Switch BSS R012 7 8mm Poly tube BSS M015 8 BSP M x 8mm Push Fit BSS M007 9 8mm Push Fit Tee BSS M008 10 8mm Hose Tail BSS M023 11 BSP F Tee BSS P62 12 Brass Locking Nut BSS M006 13 Flexible Pump Support BSS M022 ...

Страница 35: ...ble the SYSTEM FILL option The SPC CONTROLLER option is enabled Disable the SPC CONTROLLER option The LOW PRESSURE set point is too high Review the system specifications HIGH PRESSURE fault is displayed The internal isolation valve within the unit is closed Open the internal isolation valve The system pressure has risen above the HIGH PRESSURE set point Decrease system pressure using a suitable dr...

Страница 36: ...lace digital controller HIGH H20 fault is displayed A non standard electrical connection has been made into terminals 21 22 Remove all non standard electrical connections The digital controller has failed Replace digital controller Pressure reading does not match actual system pressure The internal isolation valve within the unit is closed Open the internal isolation valve The SENSOR TYPE option i...

Страница 37: ...rk A pump non return valve has failed Replace non return valve The expansion vessel has failed or lost its pre charge Check the expansion vessel pre charge and re charge if necessary The point of connection of the unit is too far away from the expansion vessel Move unit expansion vessel connection points closer together The buttons on the digital controller do not respond The plastic housing of th...

Страница 38: ...co uk We reserve the right to change designs and technical specifications of our products Rev 8 1 Oct 15 Page 38 42 Service Logs This service log should be completed by the service engineer after each annual service ...

Страница 39: ...www wolseley co uk We reserve the right to change designs and technical specifications of our products Rev 8 1 Oct 15 Page 39 42 ...

Страница 40: ...any service visit is chargeable If a defect is identified as a manufacturing 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 Supp...

Страница 41: ...www wolseley co uk We reserve the right to change designs and technical specifications of our products Rev 8 1 Oct 15 Page 41 42 Notes ...

Страница 42: ...eserve the right to change designs and technical specifications of our products Rev 8 1 Oct 15 Page 42 42 Wolseley Centre Harrison Way Leamington Spa Warwickshire CV31 3HH United Kingdom T 44 0870 8506538 W www jetrange co uk ...

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