AQUAMAXX TWIN 800L Installation and operation manual

TWIN 800L & 1200L
AQUAMAXX VARIABLE SPEED BOOSTER SET
OPERATING & MAINTENANCE MANUAL

1. Introduction
We strongly suggest that the operator carefully reads and follows the information
contained in this instruction manual for the E Series 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 E Series frequency converter.
We strongly suggest that the operator carefully reads and follows the information
contained in this instruction manual for the E Series frequency converter. The E Series
FREQUENCY CONVERTER should NEVER be opened or tampered with and
guards that come with it should never be removed.
The E Series frequency converter must be installed, adjusted and maintained by
qualified personnel who understand the risks involved.
The AquaMaxx 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 AquaMaxx set and control panels must be connected
to an efficient earthing system first, prior to any other electrical connections in
accordance with the electrical standards of the country in which it is installed.
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 E Series
frequency converter, remove only the covers required in order to disconnect the electrical
cables. Take care not to damage the electronic cards.
TWIN 800L & 1200L

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. AquaBoost sets strengths and benefit: constant pressure, low noise operation,
low running costs, low water consumption, protection against dry running. It’s
recommended to use the AquaBoost sets with the 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.
TWIN 800L & 1200L

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 AquaMaxx 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 AquaMaxx 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 AquaMaxx 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 servicing department.
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.
TWIN 800L & 1200L

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 Ltd from any
responsibility. The responsibility of any operation that has not been authorised in
writing shall fall upon the executor, in as much that they become the manufacturer.
Direct Pumps & Tanks accept no responsibility whatsoever for possible damage to
the AquaMaxx 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 AquaMaxx set must be fitted in a well-ventilated place, protected from unfavourable
weather conditions.
• When handling the AquaMaxx 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 AquaMaxx 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.
TWIN 800L & 1200L

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 AquaMaxx 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
AquaMaxx 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 TWIN PUMP
• When the AquaMaxx set arrives on site it will have been stripped for safety
during transport. Un pack the set and follow the reassembly procedure below.
• Un pack the pump(s) and reconnect to the pipe work in the tank. Make sure the “O”
Rings are sited in the union piece.
TWIN 800L & 1200L
BEFORE AFTER

• Once the pumps are fixed pull back up the excess cable through the grommet on
the tank lid coil up and cable tie neatly.
• Un pack the controller(s) & manifold system and mount vertically and tighten
the unions back up.
• A 2L Vessel and T-Piece are supplied loose and is to be fitted to the discharge line.
TWIN 800L & 1200L
20mm gland for
incoming power cable
into the junction box
• 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 Earth circuit. The
Earth 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 AquaMaxx 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 + Earth), 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 Earth clamps of the inverter (see upper picture).
TWIN 800L & 1200L

Connection of signal between inverters (RS485 signal): With reference to
the figure shown left, 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
left, 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 left, 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
• 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
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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.
TWIN 800L & 1200L

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 which 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 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.
TWIN 800L & 1200L

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.
TWIN 800L & 1200L

Typical installation example
TWIN 800L & 1200L

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.
TWIN 800L & 1200L

NOTES

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