AQUAMAXX 200L Installation and operation manual

200L, 300L & 450L
AQUAMAXX FIXED & VARIABLE SPEED BOOSTER SET
OPERATING & MAINTENANCE MANUAL

200L, 300L & 450L
1. Introduction
We strongly suggest that the operator carefully reads and follows the information
contained in this instruction manual for the frequency converter.
Symbol used:
This symbol indicates high voltage hazard. It draws attention to components or
procedures that could represent a potential danger to the health and welfare of the
operator.
This symbol is used to draw the operator's attention to situations of potential danger
for people or for operations that could cause damage to the product.
2. Special warnings regarding the frequency converter.
We strongly suggest that the operator carefully reads and follows the information
contained in this instruction manual for the frequency converter.
The FREQUENCY CONVERTER should NEVER be opened or tampered with and
guards that come with it should never be removed.
The frequency converter must be installed, adjusted and maintained by qualified
personnel who understand the risks involved.
The booster set is designed to start automatically. Make hydraulic connections and
to prime the pumps before making any electrical connections.
The connection of the control panels must be performed by a qualified electrician
in accordance with the present electrical standards.
The booster set and control panels must be connected to an efficient earthing
system in accordance with the electrical standards of the country in which it is
installed.
The connection of the earth must be performed first.
The connection of the alarms can distribute power even when the frequency
converter is turned off. Ensure that there is no residual voltage on the terminals
of the alarms. All the power terminals and other terminals must be inaccessible
after installation is completed.
The maximum output frequency must not exceed the design frequency of the pump
being controlled. Operating at a frequency higher than the allowable frequency can
cause higher current absorption and damage to the device.
If it is necessary to remove the frequency converter, remove only the covers
required in order to disconnect the electrical cables. Take care not to damage the
electronic cards.

200L, 300L & 450L
Failure to comply with the safety regulations not only causes risk to personal safety
and damage to the equipment, but also invalidates every right to assistance under
warranty.
They are designed and built to ensure a constant pressure, specifically suitable for
domestic applications and small or medium systems for civil, agricultural or industrial
uses. Booster sets strengths and benefit: constant pressure, low noise operation, low
running costs, low water consumption, protection against dry running. It is
recommended to use the sets with pressure vessel.
Construction features
• Electric pump WRAS approved
• Variable speed inverter designated for each pump
• HDPE plastic water storage tank
• Stainless steel manifolds, threaded
• Ball valves WRAS approved on discharge of each pump
• Check valve included for each inverter with flow passage
• Pressure vessel WRAS approved
Electrical section
• Flow passage Inverter module on the discharge line of each pump.
The FLOW PASSAGE INVERTER system is a device installed in line with the pump's
discharge outlet. It includes a pressure sensor, a flow sensor and an electronic
inverter. Installed on the outlet discharge line of each electronic pump, it controls the
pump's speed rotation which is connected and maintain a fixed pressure at the set
flow rate.
Functioning
During standard operating it is possible: to display the system pressure, to display
motor absorption (if the motor is running), to display the power supply voltage (if the
motor is not running), to display the working frequency, to display any pump alarm
conditions, to put the pump out of service, to set the parameters.

200L, 300L & 450L
Dry running protection
If the system has been stopped due to lack of water, the inverter makes automatic
and predefined times to re-attempt starting.
In use with the inverter and with membrane tanks, is necessary a total volume of the
tank (expressed in litres) not lower than the 10% of the maximum single pump flow
rate. The pump sets are supplied complete with installation / maintenance
instructions and wiring diagram.
The present manual is aimed at giving the necessary information regarding the
installation, use and maintenance of booster sets with variable speed by flow
passage frequency inverter consisting of various pumps.
It is vital that the user reads this manual prior to using the system. Improper use may
cause damage to the machine as well as the lapse of the guarantee. When
requesting information or spare parts from our Sales Department, quote the
exact identification code of the model together with the manufacture number.
This manual, along with any other manuals and other documents which are delivered
with the booster set, is an integral part of the operating instructions. This manual
aims to provide information and instructions essential to adequately perform all
activities related to the use of the product purchased. This manual, and
documentation, are intended to be viewed by all persons involved in the life cycle of
the booster set and therefore must be accessible to the user.
Compliance with all safety requirements is an obligation of the customer.
The following instructions and requirements relate to the standard operations; for
instructions, situations and events that are not covered in the present manual or
sales documents, contact our assistance service.
The installation must be designed and carried out only by qualified technicians;
Errors in the installation or use can cause serious damage to the equipment,
the user system and the people involved.
Do not make any action, maintenance, repairs or modifications that you do not have
specific knowledge or received detailed instructions. If doubts remain, after
consultation with the following paragraphs, consult your supplier.
All operations must be carried out while respecting the safety rules.
Remember that you respect the regulations in force in the country of
installation: if different rules are in force on the same topic, you should always
consider the more stringent requirements.

200L, 300L & 450L
Our products have been manufactured in accordance with the applicable safety
standards in force for which it is recommended the use of all devices or notices in
order that the use does not cause injury to persons or damage to belongings.
Our products were designed for the specific use intended, THEREFORE ANY
OTHER USE THAT IS DIFFERENT AND NOT IN ACCORDANCE WITH WHAT
INDICATED, EXEMPTS DIRECT PUMPS & TANKS LTD FROM RISKS that may
occur. The modification of both mechanical and electrical parts of the machine is
strictly prohibited. The non-compliance exempts Direct Pumps & Tanks from any
responsibility. The responsibility of any operation that has not been authorised in
writing shall fall upon the executor, inasmuch that they become the manufacturer.
Direct Pumps & Tanks except no responsibility whatsoever for possible
damage to the booster set, persons or belongings. The individual safety
standards of the country of destination should be abided by during the use of
equipment.
READ THE INSTRUCTION MANUALS OF EVERY PUMPS, MOTORS, CONTROL
PANELS AND OTHERWISE OF ALL COMPONENTS. FOLLOW THE PROVISIONS
OF THE SAFETY AND PERFORM THE PLANNED MAINTENANCE
RECOMMENDED IN THE INSTRUCTION MANUALS,
Danger, Risk of electric shock Warning
• The set must be fitted in a well-ventilated place, protected from unfavourable
weather conditions.
• When handling the set (tank), lift it from the bottom of the tank and make sure area
where the tank will be sited is clean and level.
• Do not lift the set by the delivery manifold: risk of damage to the inverter modules.
• Position the AquaMaxx set in such a way that any maintenance jobs can be carried
out without difficulty.
• Ensure that the system pipes are independently supported and do not weigh down
on the set manifolds so as to avoid deformation or breaking of any of its
components.
It is also advisable to insert vibration-damping couplings on the system manifolds.

200L, 300L & 450L
Make the intake section following all the precautions necessary to keep load losses
to a minimum and to avoid the formation of air pockets, for example:
• Position the set as close as possible to the power supply source
• Consider a suction pipe diameter never smaller than that of the manifold
• Lay the suction pipe horizontally or sloping slightly upwards towards the set
• Avoid using elbows or couplings that cause sudden changes in direction. If
necessary, use bends with a wide radius
Reassembly & Installation of the AquaMaxx set must be performed by skilled and
authorised installers. During installation, apply all safety behaviours issued by the
competent bodies and suggested by common sense. Install the unit in a dry well-
ventilated place. Rest the unit on a flat, regular and solid surface. The unit can only
be installed in the horizontal position.
REASSEMBLY PROCEDURE SINGLE PUMP
• When the AquaMaxx set arrives on site ensure the pump is in the below
position
• Be ready to install and check the pump is as pictured

200L, 300L & 450L
• A 2L Vessel and T-Piece are supplied loose and it to be fitted to the discharge line.
Example vessel installed vertical
for horizontal discharge, can be
fitted vice versa for vertical
discharge.
Insert power
cable here

200L, 300L & 450L
• Power up the AquaMaxx Set and follow the standard set up process
The units are delivered ready for power supply connection, which must be carried out
by a skilled, authorised installer, in compliance with the Standards in force in the
country of installation. During installation, apply all safety behaviours suggested by
law and common sense. Make sure that the electric power supply network is
protected by ground connections in compliance with Standards.
Check the correspondence between the plate data and line nominal values. Before
making the connections, make sure that the ends of the line wires are not live. Make
the connection when you are sure of the existence of an efficient ground circuit. The
ground wire must be longer than the phase wires and must be the first to be
connected during assembly and the last to be disconnected during disassembly. The
installation of a differential switch is recommended, whose nominal functioning
differential current does not exceed 30 mA (use highly sensitive differential circuit
breakers 30 mA, in Class A or AS).
For booster sets with single phase power supply (versions "M/T") connect
power supply directly to the inverter, as follows:
A: connect power supply cable to inverter (see picture).
B: motor output connection (already connected).
Single-phase power supply: the inverter power supply line voltage can vary in a
range between +/-10% of the plate power supply voltage. The power supply cable
must have 3 wires (2 phase + ground), the section of the cable to use, for line length
up to 30 m, must be at least 2.5mm2. The connection to the power supply line will be
performed on the L, N and GND clamps of the inverter (see upper picture).

200L, 300L & 450L
Connection of signal between inverters (RS485 signal): With reference to
the figure shown above, proceed in the following manner:
- Connect terminal 9 of the inverters together
- Connect terminal 8 of the inverters together
The signal wire must have 2 conductors and the minimum wire cross- section is
0.5 mm2. The maximum distance between inverters connected together in parallel
must not be greater than 10 m.
Connection of the Alarm Signal (MASTER inverter): Referring to the figure shown
above, the terminals to be connected with the signal wire (two conductions, minimum
cross section 0.5 mm2) are 2 and 3 for NC operation, and 2 and 1 for NO operation.
Connection of level sensor or other input signal (MASTER inverter): Referring to the
figure shown above, the terminals to be connected with the signal wire (two
conductions, minimum cross-section 0.5 mm2) are 5 and 4.
E-SERIES is a speed regulator powered in single-phase and three-phase for electric
a.c. single- phase and three-phase motors.
• It keeps the system pressure constant at a value defined by the user, adapting
pump performance to instant request, changing the number of motor revs.
• It carries out continuous controls on electric and functioning parameters, saving the
pumping unit from all common anomalies (over-currents, dry running, etc)
• It works in stand-alone configuration or in parallel with other inverter via serial
connection
(optional module).
• It adapts to all type of systems, even existing, while it simplifies design and
complexity of new systems, thus reducing costs, because it prevents the use of
pressure switches, important expansion
vessels, electric control boards and non-return valve.
• It activates the electric pump with starting ramps at a progressive speed, which limit
current peaks, thus lengthening the life of the
motors and allowing a great energy saving.
1 - Control system
2 - Removable electric connector
3 - I/O power cable bushing
4 - Power board cover
5 - Three-piece joint
6 - Technical data plate
7 - master switch (only versions “M/T”)
8 - Fuse (only versions “M/T”)
9 - Non-return valve unit

200L, 300L & 450L
GENERAL TECHNICAL DATA
- Power supply voltage: single phase 230-115Vac;
- Frequency 50-60 hz
- Maximum working pressure: 10 bar
- Working position: vertical, with intake from the bottom and top exit.
E-SERIES keeps the system pressure constant (at a value defined by the user) on
variation of the flow rate requested, adapting pump performance, via variation of the
number of electric motor revs. The dimensioning of the internal hydraulic passages
and the careful hydraulic design allow the inverter to elaborate flow rates up to 200
l/min with very small pressure drops. In this configuration the system, in addition to
keeping the pressure constant by the frequency modulation of the motors, manages
the alternation of starts, in order to standardize the use of pumps. In Master / Slave
configuration the settings will be executed only on controller defined as Master. The
controller defined Slave will receives automatically settings from the controller defined
Master. If master E-SERIES is turned off, the slave E-SERIES works in a "stand
alone" mode.
For the settings of the E-SERIES please refer to attached document.
Before removing the inverter cover or starting an investigation on
the equipment, the system must be disconnected from the mains
electricity and you must wait 5 mins until the intermediate circuit
condensers, which can reach voltages up to 800V, have the time
to discharge via the built-in discharge resistors.
EMERGENCY STOP
An emergency stop can be performed while the inverter is
running, by pressing the START/STOP key. Installations with
parallel inverters only the MASTER inverter blocks the system.
An emergency stop is performed by pressing the START / STOP
switch on the MASTER inverter. If the START / STOP switch on a
SLAVE inverter is pressed the only effect is that single inverter is
stopped; not the entire system.

200L, 300L & 450L
Before starting up, please read this manual carefully and the instructions of
E- SERIES. In this way incorrect settings and manoeuvres are prevented, which
could cause functioning anomalies. The system must never be started dry for any
reason. Dry running of the pumps, even for very brief periods, can cause irreversible
damage to mechanical sealing and internal rotating couplings. Priming must be
performed before system start- up.
Whenever the equipment is powered by the mains (upon initial installation, following
voluntary shutdown or in the event of a power cut and the subsequent return of
power), it will enter a START phase lasting about ten seconds. Due to the operating
parameters - including its alarm/ blocking conditions - are stored on a non-volatile
memory, the E-SERIES will resume the same operating conditions as when it was
last shut- down (including in the event of accidental power supply failure) after this
10-second start phase.
Where the E-SERIES was ON when the last shut-down occurred, the pump will
activate after these 10 seconds if the pressure detected is less than the
predetermined threshold; you can put the group OUT OF SERVICE prior to the
automatic start-up by hitting START/STOP.
Where the E-SERIES was OFF when the last shut-down occurred, the group will
remain OUT OF SERVICE following the 10-second start phase. To start-up, hit
START/STOP and confirm. In parallel inverter installations, the MASTER inverter
fully controls the SLAVE inverters, which can operate independently only when the
MASTER is turned off.
Priming
A pumping system must never be started dry for any reason. Dry running of the
pumps, even for very brief periods, can cause irreversible damage to mechanical
sealing and internal rotating couplings.
All pumps must be primed before starting the system by unscrewing the filler cap
and filling the pump body with water (and the intake piping connected to it).
When the operation has been completed, tighten the cap and start the pump, with the
cut-off valve in flow almost completely closed, with the system in manual functioning
mode (TEST). If, after a few tens of seconds, the pump is not primed, switch it off,
check that the intake is free, that there are no air pockets upstream from the inlet,
that the body is full of water and then repeat the operation.

200L, 300L & 450L
2L Pressure Vessel
A vessel should always be fitted on the discharge manifold close to the transducer to
stabilize the pressure signal. Unlike conventional fixed speed systems, a large vessel
reservoir is not required. The vessel air charge should be maintained at 0.7 bar
below the systems nominal operating pressure.
e.g. Target System Pressure = 5.0 bar
Vessel Air Pressure = 4.3 bar
Inverter Settings:
See attached E-SERIES operating & maintenance manual.
Pump Details:
See attached operating & maintenance manual.

200L, 300L & 450L
Typical installation example

200L, 300L & 450L
if a specific flow rate and pressure is required, we would recommend you check
with your supplier to ensure the AquaMaxx will meet the demand efficiently.

NOTES

Direct Pumps and Tanks Ltd
Unit 12 Soloman Road | Cossall Industrial Estate
Ilkeston | Derbyshire | DE7 5UA
01159 444474
[email protected]