Altecnic Matrix Maxi Guide

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:
Matrix Maxi 180D
Pt. No. 121-1021
Matrix Maxi 280D
Pt. No. 121-1022
2
CE compliant product
Matrix Maxi

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PRODUCT DESCRIPTION
Heating and cooling system pressurisation top up unit with integral water storage tank and electric
motor driven peripheral pump, automated control system consisting of pressure transducer and
water level sensors. The tank includes an AB air gap for category 5 fluid isolation (BS EN 1717).
APPLICATION
The Matrix Maxi range is designed to provide initial system fill and intermittent water top up
to compensate for intermittent losses in system pressure in heating and cooling systems in
commercial 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 location in its original packaging.
CONTENTS Page
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Important Facts - read before commencing installation ................................5
Location .......................................................................6
Key Features ...................................................................8
Installation .....................................................................9
Electrical Installation ............................................................11
Commissioning .................................................................15
Operation .....................................................................22
Maintenance ...................................................................24
Environment Protection ..........................................................25
Technical Specification ...........................................................26
Trouble Shooting ................................................................28
Product Log ....................................................................29
Guarantee .....................................................................32

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WARNINGS:
zThis appliance must not be used for any other application
without the written consent of Altecnic Limited.
zThis appliance can be used by children aged from 8 years
and above and persons with reduced physical, sensory or
mental capabilities or lack of experience and knowledge
if they have been given supervision or instruction concerning
use of the appliance in a safe way and understand the
hazards involved. Children shall not play with the appliance.
Cleaning and user maintenance shall not be made by
children without supervision.
zChildren should be supervised to ensure that they do not
play with the appliance.
zThis product should not be used for the supply of water to
more than one heating/cooling system at a time.
zThe electrical installation must be carried out in accordance
with the current national electrical regulations and installed
by a qualified person.
zThe motor is not accessible in normal operating mode. The
unit must only be operated with the front cover in place.
zThe electrical installation must be carried out in accordance
with the current national electrical regulations and installed
by a qualified person.
zIn the interests of electrical safety a 30 mA residual current
device (R.C.D. not supplied) should be installed in the supply
circuit. This may be part of a consumer unit or a separate
unit.
zThis appliance must be earthed via the terminal block.
Please read installation 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.

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CHECKLIST
Note:
Your product may vary slightly from the picture above.
Item Description Qty Item Description Qty
Matrix Mini 1 Top cover 1
Front cover 1
AC
B
Fig. 1
IMPORTANT: With the appliance removed from its packaging
check for any damage prior to installation. If any damage is
found contact Altecnic Ltd within 24 hours of receipt.
C
B
Inlet
Overflow
Outlet
Electrical rating
plate and serial
number
A

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1 IMPORTANT FACTS: READ BEFORE COMMENCING PUMP INSTALLATION
A Water storage capacity.
1.11 The Matrix Maxi has a usable water volume of approximately 18 litres; the length of time
the Matrix Maxi takes to pressurise a system will be dependent on:-
The pressure differential between the cold fill and set pressures and also the refill rate of
the tank
1.12 Ensure the pumps are primed as described in the priming section before starting, to
avoid causing damage to the pump shaft seal. See Section 6.26 Hydraulic commissioning.
B Water temperature
This unit is designed to pump cold water only which should not exceed the following values:
1.13 The maximum allowable water temperature is 23 oC (see Section 10).
1.14 The minimum allowable water temperature is 4 oC.
C Pipework - General
1.15 Do not drill holes or put fastenings into the Matrix Maxi tank, this will cause leakage.
1.16 Secure 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 Matrix Maxi, this will cause damage and possible leakage.
1.17 Flux: Solder joints must be completed and flux residues removed prior to Matrix Maxi
installation (flux damage will void any warranty).
1.18 Pipework design: Care should be taken in the design of pipework runs to minimize the
risk of air locks e.g. use drawn bends rather than 90obends.
1.19 DO NOT introduce solder flux to flexible hose, tank, pump or any parts
manufactured from plastic.
1.20 DO NOT allow contact with oil or cellulose based paints, paint thinners or
strippers, acid based descalents or aggressive cleaning agents.
1.21 DO NOT bend the flexible hose beyond 90o. It must be installed as detailed,
DO NOT kink. See Installation Section 4.15.
D Plumbing Installation Regulations
1.22 The plumbing installation must comply with the current water and building regulations.
1.23 The plumbing installation must be installed by a qualified person.

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2 LOCATION-GENERAL
2.11 Location: The preferred Matrix Maxi location is on a smooth level floor, of
sufficient strength to support the filled weight of the Matrix Maxi, close to
the water source and a suitable overflow position (see Section 10 - Technical
Specification for filled weight). The Matrix Maxi must not be installed in a
loft space. It must also be considered that the noise and vibration from
the Matrix Maxi may be transmitted through the structure it is sited on.
Ensure the minimum clearance requirements are followed to allow servicing
of the unit
2.12 Access and minimum clearance requirements: For emergencies and
maintenance the Matrix Maxi must be easily accessible and have the
minimum clearance around it as laid out in Fig. 2.
Additional access to the front of the unit will be required to operate the
keypad and view the display.
2.13 Protection: The Matrix Maxi must be located in a dry, frost free area.
2.14 Ventilation: Ensure an adequate air flow to cool the Matrix Maxi. Separate
the Matrix Maxi from other appliances that generate heat. Do not block the
vent holes on the front cover.
2.15 Water retention: Site the Matrix Maxi in a location where in the unlikely
event of a water leak, any spillage is contained or routed to avoid electrics or
areas sensitive to water damage. As part of the AB airgap (CAT 5 fluid
isolation) the Matrix Maxi has a weir type overflow on the front, water will
be discharged from this area in the event of the failure of the inlet valve
or non-return valves.
2.16 Supply inlet pressure: The water supply inlet pressure must not exceed 7 bar.
2.17 Ambient temperature: The Matrix Maxi must be sited in a location where the ambient
temperature does not drop below 4 °C or exceed 40 °C.
2.18 Pipework: For optimum performance inlet and outlet pipework must be a minimum of
15 mm pipe.
Fig. 2
300
150
150
300
500
Dimensions in mm

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2.19 Static outlet pressure: The static outlet head must be 3 metres below pump maximum
cold fill pressure (vertically above the appliance).
2.20 Isolating valves: Separate system isolating valves (non-restrictive) must be fitted to allow
easy service of the Matrix Maxi. Isolating valves must be mounted where specified to
allow the system isolation and removal of the Matrix Maxi if needed. See Section 4.15 for
installation details.

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3 KEY FEATURES
3.11 The Matrix Maxi comprises of the following main components:-
1. Cabinet – The cabinet of the Matrix Maxi houses the water break tank, controller,
pumps and pipework. the cabinet is manufactured in corrosion resistant stainless
steel.
2. Pump assembly – One or two brass peripheral pump units powered by induction
motors, with integrated non return valves and venting screw. Mounted to a
removable mounting plate to allow easy maintenance if required.
3. Programmable controller – Custom designed, user set controller, allowing system set
up and easy alarm connection.
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 the right 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 the connection on the right hand
side of the cabinet. The pumps are connected to the tank via flexible hoses.
A pressure transducer monitors system pressure and if a reduction in system pressure is
detected, the controller runs the pumps until the system is re-pressurised to the required
pre-set level. If the unit only has a single pump connected it will run continuously until
this level is reached, if the unit is a twin pump model the pumps run in duty standby
mode (the controller will alternate which pump starts first to even the wear on the
pumps). The pumps are fitted with non-return valves to ensure system pressure is
maintained once pressurised.
1
Fig. 3 2
3

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4 INSTALLATION
4.11 Cold mains feed connection: The connection to the cold water mains inlet is made using
the upper G ½ male threaded connection. See Fig. 4. 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.
4.12 Floor installation:
1. Ensure the Matrix Maxi is located so it cannot be kicked or knocked over.
2. Ensure the floor surface on which the Matrix Maxi is located is flat and level.
3. If possible locate the unit against a wall for added stability.
4. If the Matrix Maxi is located in an area that might be subjected to flooding, mount
the Matrix Maxi on a raised plinth.
4.13 Pipework connections & guidelines:
1. Before connecting the Matrix Maxi to the system ensure that system flushing has
been performed correctly and all foreign matter, including pipe scale, has been
removed.
Note: Foreign material from the system coming into contact with the expansion
vessel bladder could cause premature failure of the expansion vessel.
2. Isolating valves MUST be installed on the unit inlet and outlet, to allow the unit to be
isolated if required. The isolation valve on the outlet should be of a lockshield type.
See Fig. 5.
3. A drain valve must be fitted on the outlet of the Matrix Maxi before the isolation
valve. See Fig. 5.
Fig. 4
Warning pipe
Main cold feed

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4. The warning pipe should be connected to a suitable drain via a tundish enabling
visual warning of an overflow condition. The overflow fitting is designed to
use 19 to 23 mm diameter plastic waste pipe or connect to G ¾ threaded pipe.
Ensure there is a demountable joint in the pipe to allow the removal of the Matrix
Maxi if needed. See Fig. 4.
5. Non-return valves, pressure reducing valves and RPZ valves MUST NOT be installed
between the Matrix Maxi and the heating/cooling system. These devices will
prevent the pressure sensor from reading the system pressure and will lead to
incorrect operation of the unit.
6. The Matrix Maxi should be connected to the system return header along with the
expansion vessels as specified in BS 7074. See Fig. 5.
4.16 Typical installation diagram:
4.17 Vessel sizing & location:
1. System expansion vessel sizing should comply with the BS 7074 Expansion Vessel
sizing calculation.
2. The pressurisation unit and expansion vessels should be connected to the system at
the same point, to provide a neutral pressure reading.
3. A lockshield valve and drain valve should be installed at the inlet of each expansion
vessel to allow for servicing.
Fig. 5
Fig. 6
Matrix Maxi Warning pipe
Drain
valve
Isolation
valves
Expansion
vessel
Return
header
Lockshield
valve
Drain valve

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5 ELECTRICAL INSTALLATION / EARTHING
5.11 Regulations: The electrical installation must be carried out in accordance with
the current national electrical regulations and installed by a qualified person.
5.12 Safety: In the interests of electrical safety a 30 mA residual current device
(R.C.D. not supplied) should be installed in the supply circuit. This may be
part of a consumer unit or a separate unit.
5.13 Before starting work on the electrical supply ensure power supply is isolated.
5.14 DO NOT allow the supply cord to contact hot surfaces, including the motor
shell, pump body or pipework. The cord should be safely routed and secured
by cable clips.
5.15 Adjacent pipes: Adjacent suction and delivery pipes should be fitted with earthing
clamps in accordance with current regulations (Fig.7).
5.16 Earthing: This appliance must be earthed via the terminal block under the top cover.
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
such as equipotential bonding. Reference should be made to the relevant regulations
concerning this subject to ensure compliance.
5.19 Connections: The Matrix Maxi must be connected to a dedicated fused spur via a
lockable isolator to avoid unauthorized disconnection.
5.20 The electrical connection must be made adjacent to (not behind) the Matrix Maxi to
allow disconnection of the electrical supply should the pump module need to be
removed for service or maintenance.
Earth continuity
connection
Fig. 7
Metallic
pipework

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5.21 Wiring of connection unit:
WARNING: This appliance must be earthed.
This product range must be permanently connected to fixed wiring and is provided with a
set of terminals which allow the connection of a flexible supply cord.
Select a supply cord and fuse size based on the full load current and the surrounding
conditions and wired with the following code:
Green and Yellow: Earth
Blue: Neutral
Brown: Live
As the colours of the wires in the mains lead of this appliance may not correspond with
the coloured markings identifying the terminals in your connection unit proceed as
follows:
zThe wire which is coloured green and yellow must be connected to the terminal in
the connection unit which is marked with the letter E or by the earth symbol: or
coloured green or green and yellow.
zThe wire which is coloured blue must be connected to the terminal which is marked
with the letter N or coloured black.
zThe 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 Matrix Maxi is fitted with a volt free contact specifically assigned for boiler/chiller
shut down in the event that the Matrix Maxi detects system pressure above the Hi alarm
pressure or below the Lo alarm pressure.
The boiler interlock contact will be open circuit below the Lo alarm pressure and above
the Hi alarm pressure.
When the system pressure is in its normal operating pressure range (above Lo alarm
pressure and below Hi alarm pressure settings) the contact is closed circuit
Always refer to the boiler/chiller manufacturer’s instructions for correct integration.
Fig. 8
20 mm Fuse
Brown: Live
Green and Yellow: Earth
Blue: Neutral

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5.23 Alarm and boiler interlock connections:
Circuits connected to the relays are limited to 5 Amps, 230 V a.c. maximum.
The Installer MUST fit a 5 Amp fuse in the circuit to the alarm relay to
protect the Matrix Maxi from damage.
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 2.5 mm2CSA).
3) Insert wire into connector and screw down terminal screws to secure (0.6 Nm max.).
NC
NO
NO
NO
Boiler Interlock
Common Alarm
High pressure alarm
Low pressure alarm
Fig. 9
Fig. 10
Fig. 11
Fig. 12

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5.26 Supply Cord Replacement:
The supply cord and internal wiring within the terminal box are routed and
secured to ensure compliance with the electrical standard EN 60335-1. It
is essential that prior to any disturbance of this internal wiring, all cable
routing and securing details are carefully noted to ensure re-assembly to
the same factory pattern is always maintained.
If the supply cord is to be changed or is damaged, it must be replaced with a special cord
assembly, please contact Altecnic Ltd for further details.
On disassembly note the cord retention and routing system. Re-assemble to the same
pattern.
For information on cable connection consult the wiring diagram (Section 8.12).
4) Re-insert connector into the correct location on the control board and route the
cable to the back of the Matrix Maxi and exit the cabinet via one of the 20 mm holes
and a suitable cable retention and sealing system to either the left or right hand side.
Blank off the remaining unused cabinet holes with the blind grommets supplied. See
Fig. 13.
Model Fuse Size (AMPS)
All models 5
5.24 RS 485 Modbus – BMS Connection:
Not functioning on this revision of the product.
5.25 Fuses: The following fuse size should be used:
Fig. 13
Blind
grommet

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6 COMMISSIONING
6.11 Pre-commissioning checklist:
Before starting the commissioning process the following conditions must be met. If these
conditions are not adhered to, damage to the equipment, system and property may
result.
zEnsure the unit is sited in a frost free area, away from precipitation and water sprays/
jets.
zAll necessary pipe/electrical connections should have been made to a satisfactory
standard by a qualified person.
zThe temperature and pressure at the point of connection are within the operating
limits of the pressurisation unit.
zThe heating/cooling system is fitted with a safety valve and expansion vessel sized
appropriately.
6.12 In order for the pressurisation unit and heating/cooling system to function correctly the
following conditions must be met. If these conditions have not been met, the
commissioning process should not continue.
zEnsure the system connection has been made into the heating/chiller system return
header.
zEnsure Non-return valves, pressure reducing valves or RPZ valves are NOT installed
between the pressurisation unit and the heating/cooling system.
zThe expansion vessel is pre-charged to the correct pressure (equal to initial system
design pressure).
6.13 Prior to commissioning fill the heating/cooling system via a filling 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.
zEnsure the heating/cooling system is filled and pressurised to the required cold fill
pressure, with the water at approximately ambient temperature.
zEnsure the system is dosed with a suitable corrosion inhibitor. Note the Matrix Maxi
is not designed for dosing chemicals into the system, this must be done via other
means.
6.14 Expansion vessel setting:
zTo set or check the expansion vessel charge pressure the lock-shield valve between
the Matrix Maxi and the vessel must be closed and the vessel drained using the drain
valve.
zA suitable gauge should be used to check the charge pressure.
zIf the charge pressure is too high it can be reduced by releasing air from the vessel
pre-charge valve or by using a pressure gauge with an integral air release valve.
zIf the charge pressure is too low a small increase can be provided using a car foot
pump otherwise an oil free compressor or nitrogen bottle is recommended.
zWhen the correct pressure is set the Schrader valve protective cap must be replaced.
zCheck the integrity of the pipe-work. Ensure the lock-shield valve between the
system and the expansion vessel is open and the drain valve is closed.

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6.15 Controller overview
The Matrix Maxi controller is designed to be intuitive to use and allows functions and
alarms to be set by the installer/user. It also allows faults to be monitored and logged to
enable easier system fault diagnosis.
The functions are set using the 4 buttons (A, B, C & D) on the front of the controller and
with the help of on screen prompts via the back lit LCD display. On the front of the
Matrix Maxi a green ‘power on’ light will be displayed 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.
Button D Returns to previous menu
TIME
PRESSURE
HIGH ALARM SET VALUE (1)
LOW ALARM SET VALUE (4)
SYSTEM PRESSURE SET VALUE (2)
DIFFERENTIAL SET VALUE (3)
PUMP 'OFF'
PUMP 'ON'
SYSTEM FILL MODE NORMAL OPERATION
SYSTEM PRESSURE
Fig. 14
Fig. 15
A
B
C
D

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Cont ...
6.16 Function list & explanation
The functions are contained within an initial display and 3 menus:-
Setting menu (pass code protected) see Section 6.18.
Advanced setting menu (pass code protected) see Section 6.19.
Test menu (pass code protected) see Section 6.20.
6.17 Initial display
On start up, and during operation, if the Matrix Maxi has had no button inputs for
1 minute, a home screen (see Section 7.11) will be displayed with system pressure,
tank water level, any active alarm and any pump that is operating at the time.
By using buttons A & C to scroll up or down the following screens will be displayed:-
System pressure
Active errors
System fill status
Pump activity
Pump run time
Alarm reset
6.18 Setting menu
(Pass code protected, if set)
The following functions can be set and modified:-
System pressure (2)
see Fig. 14
Sets the required system pressure. Set in 0.1 bar increments up to
the maximum set value for the Matrix model. Matrix Maxi 180D & Matrix
Maxi 280D - 8.0 bar max.
Differential pressure (3)
see Fig. 14
Sets the pressure the Matrix Maxi 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. 14
Sets high system pressure alarm. Set in 0.05 bar increments above
the System pressure (2). Cannot be set below System pressure + 0.5 bar.
Alarm auto resets when system pressure is reduced below alarm level.
Lo Alarm (4)
see Fig. 14
Sets low system pressure alarm. Set in 0.05 bar increments below
the System pressure (2) - Differential pressure (3) - 0.05 bar. Alarm auto
resets when system pressure is increased above alarm level
System fill
Turns on system fill option. System fill option will turn off once the
System pressure (2) has been reached or a period of 24 hours has passed
since it was set to ‘on’. Lo alarm and Max runtime functions are disabled
whilst System fill is turned on. Pumps will stop if the System pressure (2)
or Hi alarm pressure (1) is reached.
Start Activity High
Alarm triggered if the Matrix Maxi starts more than the preset
limit in 24 Hours.
Set to minimum of 100 starts per 24 hrs. Set in increments of 100.

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6.19 Advanced setting menu
(Pass code protected, if set)
The following functions can be set and modified:-
6.20 Test Menu
(Pass code protected, if set)
The following functions can be set and modified:-
Common alarm relay allocation
Can be set to operate if one of the following alarms activate:-
Low water
Pump fail
Pump run time
Pump activity high
Sensor error
Common relay operation Allows the relay to operate either as normally open or normally closed.
Run time limit
Sets the maximum time a pump can run before the pump run time alarm
is activated. Set in increments of
10 minutes up to 60 minutes maximum. Disabled when the System fill
option is turned on.
Passcode change Sets a 4 digit passcode, defaults to 0000 (off). Can be user set to limit
access to Setting, Advance setting and Test menus.
Pump run on delay
Sets the time the pump will continue to run after the system pressure (2)
is reached on rising pressure. Adjustable from 3 to 120 seconds, pre-set
to 10 seconds. Reducing this time will improve 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 Matrix Maxi operation during rapid system pressure fluctuations
(circulator pump starts)
Pump test Forces pump 1 (LH) or 2 (RH) to run for 5-10 seconds to enable operation
of the pump to be confirmed.
System fill volume Monitors the volume of water pumped into the system since it was last
reset. Displayed in cubic metres (1m³ = 1000 litres). Can be user reset.
Fill rate Monitors the rate at which water is flowing into the system and is
displayed as a real time flow rate (l/min).
Power interrupt log
Monitors how long the electrical power has been applied to the Matrix
Maxi. Resets when power is removed or during a power cut. No user
input.
Controller info Displays software revision and pump set up. No user input.
Alarm log Displays the last 4 alarm events. Can be user reset.
Pump run time log Displays how long each pump has run. Can be user reset
Pump activity log Displays which pump has run and how long it ran for. Can be user reset.

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6.21 Pre-set values
The Matrix Maxi will be delivered with the following pre-set values:-
6.22 Setting menu
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

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Cont ...
6.24 Controller menu diagram
Power ‘on’
Home screen
Setting menu
Advanced menu
Test menu
Set system
pressure
Set differential
pressure
Set Hi alarm
Set Lo alarm
System Fill
`
Pump run on
delay
Alarm relay
operation
Run time limit
Enter pass
code
(If set)
Delay
Push to test
pump
Pump activity
log
Power
interrupt log
Alarm log
Start up screen
(logo)
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
18 March 2019
Passcode
change
Star Activity
High
Relay
allocation
Pump start
delay
Fig. 16