Alfalaval AquaFirst Manual

DOC-1361 Rev: Sep, 2017, Soft V4
Installation, service and operating instruction Alfa Laval AquaFirst
Domestic hot water supply

Alfa Laval AquaFirst
Installation, service and operating instruction
1
Contents
1AquaFirst general presentation...........................................................................................3
1.1 Product overview AquaFirst ......................................................................................................................4
2Operating principle...............................................................................................................5
3Installation.............................................................................................................................6
3.1 Unpacking/Preparation/Mounting..............................................................................................................6
3.2 Commissioning..........................................................................................................................................6
3.3 Installation of an AquaFirst Direct (Instantaneous) units ..........................................................................7
3.4 Installation of an AquaFirst Indirect (Semi-Instantaneous) unit ................................................................8
3.5 Measure sketch Aqua First 2000 & 4000 Direct version*..........................................................................9
3.6 Measure sketch Aqua First 2000 & 4000 Indirect version*.................................................................... 10
3.7 Measure sketch Aqua First 6000 & 8000 Direct version*....................................................................... 11
3.8 Measure sketch Aqua First 6000 & 8000 Indirect version*.................................................................... 12
4Electrical installation..........................................................................................................13
4.1 Regulator Components .......................................................................................................................... 13
4.2 Electrical wiring diagram ........................................................................................................................ 14
4.3 Wiring details.......................................................................................................................................... 15
4.3.1 Power terminal on PCB..................................................................................................................... 15
4.3.2 230V 3 points actuator terminals on PCB......................................................................................... 15
4.3.3 Low voltage outputs on PCB............................................................................................................. 15
4.3.4 Low voltage inputs (contacts / Sensors) on controller ...................................................................... 15
5User instruction operator control panel Micro 3000.........................................................16
5.1 Home screen.......................................................................................................................................... 17
5.2 Command symbols................................................................................................................................. 17
5.3 Setting the time and date ....................................................................................................................... 18
5.4 Changing the Date format...................................................................................................................... 18
5.5 Setting the Daylight Saving Time........................................................................................................... 18
5.6 Saving changes...................................................................................................................................... 18
6End user mode....................................................................................................................19
6.1 Set the hot water temperature................................................................................................................ 19
6.2 Time programs ....................................................................................................................................... 19
6.3 Changing time and temperature in a time program................................................................................ 20
6.3.1 Special days...................................................................................................................................... 20
6.4 Making a Quick temperature change ..................................................................................................... 21
7Technician menu, total read and write level .....................................................................22
7.1 Login....................................................................................................................................................... 22
7.2 The technician Main menu ..................................................................................................................... 22
7.3 Configuration menu................................................................................................................................ 23
7.4 S1 Menu Secondary Outlet.................................................................................................................... 24
7.5 Thermal Treatment Menu....................................................................................................................... 24
7.6 Safety Function....................................................................................................................................... 25
7.7 Eco-Booster Function............................................................................................................................. 25
7.8 Fouling function...................................................................................................................................... 26
7.9 230V Triac menu.................................................................................................................................... 26
7.10 Pumps Menu .......................................................................................................................................... 27
7.11 Autotest menu ........................................................................................................................................ 28
7.12 Clear alarm menu................................................................................................................................... 29
8Service Menu .................................................................................................................30
8.1 Change password for technician level ................................................................................................... 30
8.2 Login installer ......................................................................................................................................... 30
8.3 Menu Continue....................................................................................................................................... 31
8.4 Operating hours...................................................................................................................................... 32
8.5 Trending parameters.............................................................................................................................. 33
8.6 Display the trend buffer .......................................................................................................................... 34
8.7 Point Data............................................................................................................................................... 34

Alfa Laval AquaFirst
Installation, service and operating instruction
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9Alarm menu ...................................................................................................................35
10 Parameters list....................................................................................................................36
11 Factory RESET....................................................................................................................37
12 Modbus................................................................................................................................38
12.1 Modbus communication ......................................................................................................................... 38
12.2 Connecting multiple Micro 3000 control boxes ...................................................................................... 38
12.3 Change Modbus parameters.................................................................................................................. 39
12.4 Modbus slave communication parameters............................................................................................. 40
13 Trouble shooting.................................................................................................................41
14 Maintenance and repairs....................................................................................................42
14.1 Open the control box.............................................................................................................................. 43
14.2 Change fuses ......................................................................................................................................... 43
14.3 Pumps’ number ...................................................................................................................................... 44
14.4 Add a recycling pump to an AquaFirst Direct......................................................................................... 44
14.5 Add an extra pump................................................................................................................................. 44
14.6 Add an extra sensor ............................................................................................................................... 44
14.7 230V Triac output................................................................................................................................... 45
14.8 Relay 1 and 2 contacts........................................................................................................................... 45
14.9 Remote Control contact.......................................................................................................................... 45
14.10 Clean plate heat exchangers.................................................................................................................. 46
14.11 Technical data........................................................................................................................................ 46
14.12 Spare parts-Aqua First 2000 & 4000...................................................................................................... 47
14.13 Spare parts Aqua First 6000 & 8000...................................................................................................... 48
15 Commissioning report........................................................................................................49
16 Declaration of conformity...................................................................................................50
17 Warranty..............................................................................................................................51
17.1 How to contact Alfa Laval....................................................................................................................... 51

Alfa Laval AquaFirst
Installation, service and operating instruction
3
1 AquaFirst general presentation
Alfa Laval AquaFirst is a compact tap water system product including a heat exchanger, motorised control
valve and managed primary and secondary pumps, as per versions. It is equipped with a control box including
a dedicated PCB and communicant temperature controller. Piping is made of specially designed brass parts.
AquaFirst has been tested hydraulically and electrically at the factory.
The AquaFirst is available in two plate sizes:
•M3H for model FI2000 and FI4000.
•M6M MH/ML for model FI6000 and FI8000.
There are in total 40 models of the AquaFirst, 12 direct and 24 indirect. All types can have single or double
pumps.
Option:
•rock wool insulation with cladded aluminium sheet
The AquaFirst has to be connected to a primary heating source, like a boiler or a heat exchanger. The
secondary side is connected to cold water inlet and to domestic hot water network, see flowcharts for more
details.
The tap water module is designed for indoor installation, for example in a plant room. The ambient temperature
in the room must be min 0°C and max 40°C, max humidity 85% without condensation.

Alfa Laval AquaFirst
Installation, service and operating instruction
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1.1 Product overview AquaFirst
AquaFirst 2000 & 4000
AquaFirst 6000 & 8000
Picture 1
Picture 2
1
Control Box including Micro3000
6
Secondary charging pump
2
Signal actuator
7
Safety valve
3
Secondary charging pump
8
3-port mixing control valve
4
Temperature sensor S1
9
Plates Heat Exchanger with
Insulation (optional)
5
Primary single or double pump
(as per version)

Alfa Laval AquaFirst
Installation, service and operating instruction
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2 Operating principle
Picture 3
Picture 4
Picture 5
Picture 6
Picture 7
Picture 8
•The primary water enters the 3 port modulating valve (1) and leaves through the fitting (2).
•Cold water enters at bottom part (3) and leaves at the required temperature at high part (4).
•The secondary circuit should be equipped with a recirculation or a charging pump,
•Modules suitable for 230V 1 phase / 50 Hz + Earth,
•Make sure power supply in the field corresponds to the above voltage,
•A fuse protection should be provided on site.
•Relays: Volt Free Contacts (VFCs), 2 Amps maxi, each under 230 V.

Alfa Laval AquaFirst
Installation, service and operating instruction
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3 Installation
The installation work must be carried out by an authorized installation contractor.
The temperature and the pressure of the water are very high. Only qualified technicians are
allowed to work with the AquaFirst. Incorrect operation may cause serious personal injury and
result in damage to the building.
Minimum pressure/temperature on primary side : 1.0 bar/ 2°C, 1.5 bar / 110°C
Maximum pressure/temperature on primary side :10 bar /110°C
Maximum pressure on secondary side : 10 bar/ 100°C
3.1 Unpacking/Preparation/Mounting
•Rinse the pipes, before connecting them to the tap water module.
Pipe works may contain solid particles that could block or prevent the modulating valve to operate correctly.
•Pipe the primary and the secondary of the module.
•Fill-up both sides progressively with water.
•Purge air at high parts.
•Purge all the pump bodies.
•Switch the power on.
•Check controller setting and enable the required functions.
3.2 Commissioning
Before installation this manual must be read.
The controller has been set at the factory. If any function needs tuning, values can be changed with reference
to this manual for parameter setting. Initially, the commissioning process should be carried out with the factory
settings.
Fill out the form in chapter 15 Commissioning report.

Alfa Laval AquaFirst
Installation, service and operating instruction
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3.3 Installation of an AquaFirst Direct (Instantaneous) units
The tap water modules should be installed according to the following schematics.
Picture 9
REP
DESIGNATION
REP
DESIGNATION
A
Primary inlet
HE
Heat Exchanger (PHE)
B
Primary Outlet
PP
Primary pump (single/double)
CW
Cold water inlet
PR
Recycling pump (option)
V3V
Mixing 3 port control valve with actuator
V
Manual gate valve
PRV
Pressure relief valve
S1
DHW temperature sensor (master)
The primary water tank limits available generator capacity.
Picture 10

Alfa Laval AquaFirst
Installation, service and operating instruction
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3.4 Installation of an AquaFirst Indirect (Semi-Instantaneous) unit
Recycling flow rate PR must be < 60% PC flow rate.
Protect the storage tank by installing the added safety valve. Pressure gage=tank MAX working pressure and
can be different from tap water module’s safety valve pressure gauge. The safety vaIve protects the storage
vessel and not the tap water system.
Secondary charging pumps have the following limitations as per water quality:
pH 6 to 9 and TH<25 French degrees (25°TH) or 14 German degrees (14°dH).
Picture 11
REP
DESIGNATION
REP
DESIGNATION
A
Primary inlet
HE
Heat Exchanger (PHE)
B
Primary Outlet
PP
Primary pump (single/double)
VR
Setting valve
PC
Charging Pump (1 or 2)
CW
Cold water inlet
PR
Recycling pump (on installation)
V3V
Mixing 3 port control valve with actuator
V
Manual gate valve
PRV
Pressure relief valve
S1
DHW temperature sensor (master)

Alfa Laval AquaFirst
Installation, service and operating instruction
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3.5 Measure sketch Aqua First 2000 & 4000 Direct version*
Picture 12
* Pump type, single or double

Alfa Laval AquaFirst
Installation, service and operating instruction
10
3.6 Measure sketch Aqua First 2000 & 4000 Indirect version*
Picture 13
* Pump type, single or double

Alfa Laval AquaFirst
Installation, service and operating instruction
11
3.7 Measure sketch Aqua First 6000 & 8000 Direct version*
Picture 14
* Pump type, single or double

Alfa Laval AquaFirst
Installation, service and operating instruction
12
3.8 Measure sketch Aqua First 6000 & 8000 Indirect version*
Picture 15
* Pump type, single or double

Alfa Laval AquaFirst
Installation, service and operating instruction
13
4 Electrical installation
Power supply the control box with 230V 50 Hz + Earth, using electric protection in the main
electric power box. Micro 3000 box is a secondary electrical control box.
Human protections and protection against short circuits and over intensity must be installed in the
main electric box.
4.1 Regulator Components
Picture 16
1
Controller, Micro 3000
3
Power Supply
2
Main switch
4
Printed Circuit Board

Alfa Laval AquaFirst
Installation, service and operating instruction
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4.2 Electrical wiring diagram
NOTE: When the remote control contact is open, the unit operates normally. If it is closed the unit is in standby.
Picture 17
Earth or Ground wiring on the PCB IS MANDATORY. It must be connected to terminal No.3.
Remote contact:
If contact closed, the unit is in standby mode. If contact open, the unit is operating normally.

Alfa Laval AquaFirst
Installation, service and operating instruction
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4.3 Wiring details
4.3.1 Power terminal on PCB
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
N
Ph
╧
N
Ph
╧
N
Ph
╧
N
Ph
╧
N
Ph
╧
230V Main
Power supply
Pump 1
(Primary)
Pump 2
(Primary)
Pump 3
(Secondary)
Pump 4
(Secondary)
Control box power supply: 230V 50Hz + Ground terminals 1,2 and 3.
Terminals 4 to 15 are dedicated to P1, P2, P3, P4 230V power supply.
Do not exceed 3A per pump.
4.3.2 230V 3 points actuator terminals on PCB
16
17
18
19
N
Ph
+
-
230V 3 points actuator
Opening of the actuator is made sending 230V pulses between terminals 16 (N) and 18 (+).
Closing of the actuator is made sending 230V pulses between terminals 16 (N) and 19 (-).
Terminal 17 (permanent Phase) can be used with return to zero (RTZ) actuators.
3 points 230V and 0-10V signals (or pulses) are sent continuously even if they are not wired.
4.3.3 Low voltage outputs on PCB
20
21
22
23
24
25
26
27
28
29
0V
S/S
0V
S/S
NO
C
NC
24Vac
AO1 (0-10V)
0V
Pump 1
Start / Stop
N/A
Pump 2
Start / Stop
N/A
Relay 1 contact
NO or NC to
choose
0-10V DC actuator, 24V AC 5VA power
supplied
0V is common on both signals
4.3.4 Low voltage inputs (contacts / Sensors) on controller
31
33
35
36
37
40
41
42
46
47
GND
Bi1
Ipso
P3
Ipso
P4
GND
UI1
S1
UI2
S2
UI3
S3
Ipso
P1
Ipso
P2
Common
Remote
Contact*
Secondary
pump(s) default
input contact(s)*
Common
Temperature
sensor(s)
input(s)*
Secondary
pump(s) default
input contact(s)*
*For each of these inputs / outputs, the second wire must be connected to the common terminal
37 or 31 as per available space.
There is no polarity on all contacts and temperature sensors.
Temperature sensors’ inputs except S1 are already wired. To add a temperature sensor, remove
existing wire from the terminal and isolate its end. Connect the sensor’s wire instead and its
second wire to common terminal, 31 or 37.

Alfa Laval AquaFirst
Installation, service and operating instruction
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5 User instruction operator control panel Micro 3000
Picture 18
Button
Function
Rotary button for scrolling through the menus. Access sub-menus and change settings
by pressing it.
To activate the line or change a highlighted value, simply press the wheel.
Works like an Enter key.
Press to exit a level and return to the previous menu/parameter.
Works like an ESC key.
Press to access the maintenance / monitoring menu.
NOTE: Requires a password.
Press to go to the Home screen, Main Menu
Press to access the Alarm Menu.
Not used
Not used
Relay 1 activated. By default set to General Default. The parameter is set in the
Configuration menu.
Relay 2 activated. By by default set to High temp Alarm. The parameter is set in the
Configuration menu.
Active data transmission
Active data reception
Alarm indicator
The Control box is switched on.

Alfa Laval AquaFirst
Installation, service and operating instruction
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5.1 Home screen
When starting up the Micro 3000 controller the Home Screen menu displays on the screen.
Picture 19
1
Date / hour
4
Access level:
Locked=restricted
Key= total (3333)
2
DHW temperature
5
Command symbols
3
DHW Set point
The controller has password protection, allowing accesses to different menus.
•End user level- requires no login. Marked with a locker in the upper right corner.
•Technician level- access to all menus requires login. Marked with a key in the upper right corner.
NOTE: if there is an ongoing alarm when starting up the AquaFirst, an alarm text will be displayed on the
screen. Press the House button to enter the Home screen.
5.2 Command symbols
Auto
Datapoint is in automatic operation and can be switched into manual operation.
Manual
Datapoint in manual operation and can be switched into automatic operation.
Today function
Datapoint value can be overridden for a particular time period within the next 24 hours.
Datapoint must have a daily time program assigned.
Time Program
Datapoint has a daily time program assigned. Daily time program can be selected and edited.
Edit
Item (datapoint, time program etc.) can be edited.
Add
Item (datapoint, time program etc.) can be added to a list e.g. datapoint can be put to a list of
trended datapoints.
Deleted
Item can be deleted
Enable/disable
•Checked: item is enabled
•Unchecked: item is disabled

Alfa Laval AquaFirst
Installation, service and operating instruction
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5.3 Setting the time and date
1. Turn the wheel anticlockwise to highlight the line with time and
date at the top of the screen. Press the wheel to enter the
Date/Time menu.
2. Press the wheel to change the first variable, the year.
3. When the year flashes, increase or reduce the set value by
rotating the wheel.
Once the right value is displayed, press the wheel to confirm the
setting. Next parameter to change starts to flash.
4. Proceed in the same way to set the month, date
and time (hour: minute).
5.4 Changing the Date format
In the Date/Time menu the date format can be changed.
Choose between the following formats:
•yyyy-mm-dd
•mm-dd-yyyy
•dd-mm-yyyy
•dd.mm.yyyy
•dd/mm/yyyy
5.5 Setting the Daylight Saving Time
Summer time
Changing between summer/winter time can be automatic or turned off.
You can also define the dates for changes if they are altered.
The default settings for summertime is:
Last Sunday in March to last Sunday in October.
5.6 Saving changes
Once a value has been changed and confirmed by pressing the wheel, the corresponding change will be
immediately updated.
Press the or to return to the home screen.