AQUATECH AquaBreak AB5 Firmware update
INSTRUCTIONSFOR
0. GENERALSAFETYINFORMATION,WARNINGS&CAUTIONS
1. INSTALLATION
2.THEUSER
3. SERVICING
4. DISPOSAL
AQUABREAKAB5BREAKTANK&PUMPSET
FORBACKFLOWPROTECTIONTOFLUIDCATEGORY5
ISSUE318/07/2017
HeadOffice:AGMHouse,LondonRd,Copford,Colchester,EssexCO61GTUK
Tel:01206215121Email:aftersales@agm‐plc.co.uk
ManchesterOffice:Unit10,WheelForgeWay,AshburtonRoadWest,Manchester.M171EH
Tel:01612264727Email:aftersales@agm‐plc.co.uk
Page|2
AquaTech-Pressmain Instruction Manual\AquaBreak
Thesepumpsetsareusedforincreasingthesupplypressureofcoldpotablewaterwhilstalsoprovidingback
flowprotectiontofluidcategory5.
CONTENTS
0. GENERAL SAFETY INFORMATION .............................. 3
0.1WARNINGS .................................................................................................... 4
0.2CAUTIONSFORINSTALLATION ........................................................................ 4
0.3CAUTIONSFOROPERATION/USER ................................................................... 6
0.4CAUTIONSFORMAINTENANCE ....................................................................... 6
1.
INSTALLATION INSTRUCTIONS ........................................................... 7
1.1ADDITIONALWARNINGS ............................................................................................... 7
1.2ADDITIONALCAUTIONS ................................................................................................ 7
1.3PROCEDURE ................................................................................................................. 7
1.3.1OFF‐LOADINGATSITE ............................................................................................ 7
1.3.2LOCATION ............................................................................................................ 8
1.3.3FIXING .................................................................................................................. 8
1.3.4PIPEWORK ............................................................................................................ 9
1.3.5FLOWTHROUGHVESSELS .................................................................................... 10
1.3.6ELECTRICAL ......................................................................................................... 10
2.
USER INSTRUCTIONS ......................................................................... 12
2.1CUSTOMERASSURANCE ............................................................................................. 12
2.2COMMISSIONING ....................................................................................................... 13
2.3OPERATINGINSTRUCTIONS ......................................................................................... 14
2.3.1ADDITIONALWARNINGS ...................................................................................... 14
2.3.2ADDITIONALCAUTIONS ....................................................................................... 14
2.3.3NORMALOPERATION .......................................................................................... 14
2.3.4TROUBLESHOOTINGGUIDE ................................................................................. 15
2.4MAINTENANCEINSTRUCTIONS .................................................................................... 16
2.4.1ADDITIONALCAUTIONS ....................................................................................... 16
2.4.2PROCEDURE ........................................................................................................ 16
3.
SERVICING ........................................................................................... 17
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3.1MAINTENANCEANDCAREOFYOUREQUIPMENT ......................................................... 17
3.2LEGALREQUIREMENTS ............................................................................................... 17
3.3SERVICECONTACTS .................................................................................................... 17
4.
DISPOSAL ............................................................................................. 17
EU DECLARATION OF CONFORMITY ...................................................... 18
OPERATING PARAMETERS ...................................................................... 18
0.GENERALSAFETYINFORMATION
Theseinstructionsareintendedfortheinstaller/operator/user/maintenanceofthisequipmentand
mustbekeptwiththeequipment,forthelifeoftheequipmentandmadeavailabletoallpersons.
PleasereadGENERALSAFETYINFORMATION0.0,WARNINGS0.1andCAUTIONS0.2,0.3&0.4
beforedoinganythingelse,andthenfollowthemcarefully.
Theunitmustonlybeinstalled/operated/used/maintainedbyacompetentperson;Acompetent
personissomeonewhoistechnicallycompetentandfamiliarwithsafetypracticesandthehazards
involved.
HydraulicAccumulators/ExpansionVesselsinstalledaspartof/inconjunctionwiththisequipment,
withPressurexVolumeabove250Bar‐litres,requireregularformalinspectionbyacompetent
person.ThisisaLegalRequirementunderthe“PressureSystemsSafetyRegulations”(PSSR)and
theOwner/Usershouldbemadeawareoftheirresponsibilityforthis.(seesection3.Servicing).
Failuretoinstall/operate/use/maintaintheequipmentasrecommendedbelowcouldcause
damagetotheequipmentanyanythingsubsequentlyconnectedtoit,andinvalidatethewarranty
providedbyAquaTech‐Pressmaintothebuyer.
Anydamagecausedtotheequipmentbymisapplication,mishandlingormisusecouldleadtorisk
ofElectrocution,Burns,Fire,Floodingorinjurytopeopleorpropertydependentuponthe
circumstancesinvolved.
Thisequipmentcontainsmoving/rotatingpartsthatmustremainguarded.Removaloformissing
guardscouldleadtoseriouspersonalinjury.
Thisequipmentautomaticallyrestartsafterapowerinterruption.
Weacceptnoresponsibilityorliabilityforanyconsequencesordamage/lossesdueto
misapplication,mishandlingormisuseoftheequipment.
Itshouldbenotedthattheassemblyofpressureequipmentonsiteundertheresponsibilityofthe
user(orhisrepresentative)isnotsubjecttothePressureEquipmentDirective97/23/EC.(National
legislationcoveringassemblyonsitewillapply)
Thelatestversionofthisinstructionmanualwithuptodatesafetyinformationcanbedownloaded
fromourwebsiteatwww.aquatechpressmain.co.uk
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0.1 WARNINGS
0.1.1 Donottouchanylivepartsforatleast5minutesafterswitchingofftheelectricitysupply.Failureto
observethiswillconstituteasevereElectricshockand/orBurnshazardandmaybelethal.
0.1.2 Theequipmentisonlysuitableforearthreferencedsuppliesandmustbepermanentlyearthedto
avoidElectricshockhazard.
0.1.3 Metalparts(e.g.heatsinks)mayreachtemperaturesof90degreescentigradeandwillconstitutea
Burnshazard.
0.1.4 Theequipmentmustnotbepressurisedbeyondthemaximumworkingpressureasstatedon
pumps/pipework/vessels/controlpanelotherwiseseriousmechanicaldamage/destructioncould
occurcausinginjurytopeopleorproperty.
0.1.5 Theequipmentmustnotbeheated/chilledbeyondthemaximum/minimumworkingtemperature
asstatedonpumps/pipework/vessels/controlpanelotherwiseseriousmechanical
damage/destructioncouldoccurcausinginjurytopeopleorproperty.
0.1.6 Anydamagetoequipment,pumpset,vessels,pipeworkorsystemcomponentscausedby
misapplication,mishandlingormisusecouldleadtoElectricshockhazard,Burnshazard,Firehazard,
Floodinghazardorcauseinjurytopeopleorproperty.
0.1.7 Thisequipmentmaycontainmoving/rotatingpartsthatmustremainguarded.Removalofor
missingguardscouldleadtoseriouspersonalinjury.
0.1.8 Pressurevesselsmustneverbedisassembledwhilstinuse,theycontainhighpressureair/gas
chargewhichcouldcauseinjurytopeopleorproperty.
0.1.9 Ensurethebase/foundation/plinth/walltowhichtheequipmentistobeattachedissufficiently
strongenoughtocarrytheentiremassoftheequipmentincludingthewaterthatitwillcontain
underworst‐casefaultconditions.E.g.fullysaturatedpressurevesselwithnoaircharge,breaktank
fulltooverflowing,etc.Failuretoobservethiscouldcauseseriousmechanicaldamage/destruction
resultingininjurytopeopleorproperty.
0.1.10 Thisequipmentcontainsafluidwhichmayundercertaincircumstancesleak/drip/sprayfluid(e.g.
servicing,repairormalfunction).Ensureanyfluiddischargewillnotcausedamagetothe
surroundingsbytakingappropriateaction.E.g.installinaplacethatwillnotbedamagedbyleakage
orinstallinabundedareawithadequatedrainage.
0.2 CAUTIONSFORINSTALLATION
0.2.1 READGENERALSAFETYINFORMATION0.0,WARNINGS0.1andCAUTIONS0.2,0.3&0.4
0.2.2 Theunitshouldonlybeinstalled/operatedbyacompetentperson;Acompetentpersonissomeone
whoistechnicallycompetentandfamiliarwithsafetypracticesandthehazardsinvolved.
0.2.3 Donotliftthepumpsetbypipework.Liftthepumpsetbythecontainerpalletusingapallet/forkliftor
cranebypassingstropsunderneaththeskidusingaspreaderbar.Failuretoutilisethesefacilitieswill
resultindamagetothepumpset.
0.2.4 Storeinadryplacetoavoiddampconditionsdeterioratingtheequipment.
0.2.5 Protectagainstdirt,damageandfrost.Itisabsolutelyessentialthatnoforeignmattersuchaspipe
threadswarf,weldingslag,gritorstonesareallowedtoentertheset.Debrisofthistypecancause
severedamagetothemechanicalseals,diaphragmsandimpeller.Frost/freezingwilldamage
pumps/pipeworkandcontrolpanelcomponents.
0.2.6 Theequipmentisonlysuitableforinstallationinaclean,dustfreeindoorenvironment,withadequate
protectionfromheatandfrost,andsufficientventilationtoensurecoolingofthemotors.Ambientair
temperatureshouldbebetween5and40degreescentigrade,non‐condensating.Operationoutsideof
theseconditionscouldseriouslydamagetheequipment.
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0.2.7 Iftheequipmentweretobestoredortakenoutofserviceforaperiodoftime(e.g.1weekormore),
thenwewouldrecommenddrainingtheequipmentofallwater/liquid(withdueregardtoanylocal
regulations)topreventfrostdamagetocomponents.Whenrestartingisrequiredwewould
recommendcommissioningbyourauthorisedserviceagent.
0.2.8 Ensurethebase/foundation/plinth/walltowhichtheequipmentistobeattachedhassufficientmass
comparedtotheequipment,inordertoavoidnoise/vibrationtransmission.E.g.themassofthebase
shouldbeatleastfivetimesthemassoftheequipment.
0.2.9 Ensuretheelectricalsupplyisthecorrectvoltage,current,frequencyandtypefortheequipment
suppliedandthatsuitablecircuitprotectionequipmentisinstalledinthesupply.Incorrectelectrical
installationcouldbeanelectricshock/burns/firehazard.
0.2.10 Whenaccessingthecontrolpaneltomakeelectricalconnectionsadoptanti‐staticprocedurese.g.
wearanti‐staticearthedwristband,toavoidriskofdamagingthecontroller.
0.2.11 AllproductsthatarepackagedtoincludePressurevessel(s)/HydraulicAccumulator(s)/Expansion
Vessel(s)areclassedas“Assemblies”underthePressureEquipmentDirective(PED).Whereunitsare
despatchedwith“Loose”vessel(s)forassemblyonsiteitisabsolutelyessentialthattheybeinstalled
asdetailedintheinstructionsusingthefittingsprovidedwhereappropriate.Failuretoobservethis
willnullifycompliancewiththePEDandmaypresentasafetyhazard.Yourwarrantymayalsobe
affected.
0.2.12 WhereHydraulicAccumulator(s)/ExpansionVessel(s)aresuppliedasalooseitem,theymustbe
installed/connectedcorrectlybeforeoperatingtheequipment,otherwiseseriousdamagefromover‐
pressure/pumpoverheatingcouldoccur.
0.2.13 Donotoperatethisequipment/pumpsetpriortocommissioning(section2.2)Thiscouldcause
irreparabledamagetoequipment/pumpset/pipework/systemcomponents.
0.2.14 Isolatetheequipment/pumpsetbeforepressuretestingsystem.Excesspressurecouldirreparably
damagethepressuretransducer,pressureswitches(wherefitted)andthediaphragmsofpressure
vessel/hydraulicaccumulators.
0.2.15 Itistheinstallers’responsibilitytoensuresubsequentpipeworketccanacceptthepressures
generatedbytheequipment/pumpsetandtoinstallanoverpressuresafetydeviceintothesystem
withduerespecttothesuctionpressurepresentonthepumpset,thepumpclosedvalvepressure
statedonthepump,themaximumworkingpressurestatedonanyoftheattachedpressurevessels
andanyotherdeviceconnectedtothesysteme.g.boilers,calorifiersetc.
0.2.16 Whenchlorinationofthesystemiscarriedout,ensurethatanyresidualchlorineisremovedby
thoroughflushingasdetailedintheHSEapprovedcodeofpracticeL8,toavoiddamagingthe
equipment/pumpset.Thenormallevelofchlorinationisupto2partspermillion(ppm),butshock
dosingforsterilizationpurposes,at25‐50ppmfor24‐48hoursisacceptableaslongasallchlorineis
removedoncetheprocessiscomplete.Chlorinationbeyondtheselimitscouldseriouslydamage
pumpsetcomponentsandWILLNOTbecoveredbythewarranty.
0.2.17 Theinstaller/userisresponsiblefortheinstallationofthecorrectearthingandprotectionaccordingto
validnationalandlocalstandards.Alloperationsmustbecarriedoutbyasuitablyqualifiedperson.
0.2.18 Theequipmentisonlysuitableforearthreferencedsuppliesandmustbepermanentlyearthedto
avoidelectricshockhazard.
0.2.19 TheequipmentmustbepermanentlyearthedwithappropriatesizedEarthing.
0.2.20 Werecommendtheuseofa30mARCDtoprovideelectricalsafety.
0.2.21 Neverperformhighvoltageresistancetestsoncontrolpanels,variablespeeddrives/motorswithout
firstdisconnectingthepanel/drive/motorfromthecircuitbeingtestedasthiswilldamagethebuiltin
electroniccomponents.
0.2.22 Metalparts(e.g.heatsinks)mayreachtemperaturesof90degreescentigrade.
0.2.23 Where“Expansionvessels”areusedonDomestichotwatersystems(DHWS)orLTHWheatingsystem
pressurisationunits,thetemperatureofthefluidreturningtothevesselsshouldnotexceed70
degreesCentigradeasthiscoulddamagethevesseldiaphragm.Wherethetemperatureexceeds70C
anintermediatecoolingvesselshouldbefitted.
0.2.24 Where“Expansionvessels”areusedonDomestichotwatersystems(DHWS)orLTHWheatingsystem
pressurisationunits,theglycolcontentinthewatermustnotexceed50%.
0.2.25 Draincocks/valvesandairbleedscrewsmustnotbeleftopenasthiscouldcauseflooding.
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0.2.26 EnsuretheYstrainer(100um)andisolationvalveisinstalledontheinlettothebreaktank,failureto
installthesewillcausethesolenoidtojambandoverflowthebreaktank.
0.2.27 Ensureapressurereducingvalvesetatamaximumof3.0Barisinstalledontheinlettothebreaktank
ifthemainswatersupplypressureexceeds3.0Bar.
0.3 CAUTIONSFOROPERATION/USER
0.3.1 READGENERALSAFETYINFORMATION0.0,WARNINGS0.1andCAUTIONS0.2,0.3&0.4
0.3.2 Theunitshouldonlybeoperated/usedbyacompetentperson;Acompetentpersonissomeonewhois
technicallycompetentandfamiliarwithsafetypracticesandthehazardsinvolved.
0.3.3 TheOwner/UserofthisequipmenthasaLegalResponsibilitytoensurethatitissubjecttoregular
formalinspections.SeeSection3.Servicing,fordetails.
0.3.4 WhereHydraulicAccumulator(s)/ExpansionVessel(s)aresuppliedasalooseitem,theymustbe
installed/connectedcorrectlybeforeoperatingtheequipment,otherwiseseriousdamagefromover‐
pressurecouldoccur.
0.3.5 Thesetmustnotberununtilcommissioned,thiscouldirreparablydamagethepumpsetand/or
systemcomponents/pipeworkconnectedtoit.
0.3.6 ThepumpsetshouldbeleftswitchedONfornormaloperation.
0.3.7 Ensurepumpsethasanadequatewatersupplyatalltimestopreventdryrunningcausingpumpseal
damageandwaterleakage.
0.3.8 Donoattempttostartpumpswithoutliquidinvolutes(pumpsmustbefullyprimed,see1.2.2);
mechanicalsealsmusthaveafilmofliquidbetweenfacesforproperoperationandtoprevent
damage.
0.3.9 Minimumflowrate:Duetotheriskofoverheating,donotusethepumpataflowbelowtheminimum
flowrate.Forcoldwaterthisisgenerally10%ofthepumpflowrateasdisplayedonthepumpdata
plate,onthepumpbody.
0.3.10 Portabletelephonesorotherelectro‐magneticequipmentmustnotbeusednearthesettoavoid
corruptionofprogramandunpredictableoperationofunit.
0.4 CAUTIONSFORMAINTENANCE
0.4.1 READGENERALSAFETYINFORMATION0.0,WARNINGS0.1andCAUTIONS0.2,0.3&0.4
0.4.2 Theunitshouldonlybeoperated/maintainedbyacompetentperson;Acompetentpersonissomeone
whoistechnicallycompetentandfamiliarwithsafetypracticesandthehazardsinvolved.
0.4.3 Topreventseizing,pumpsetsmustnotbeleftunusedforlongperiods(e.g.1week).
0.4.4 Thepumpsmustberunregularlytoavoidstagnationofwaterinthepumps/pipework(e.g.daily).
0.4.5 Donotventairfromairvalvesonvessels.Theseareforadjustmentofpre‐setcushionpressures.If
wronglyadjustedthiswillleadtoincorrectoperationofthepumpsetandpossibledamagetopumps,
pipeworkandsystemcomponentsfromoverheatingandover‐pressure.
0.4.6 SwitchOFFpumpsetbeforeaccessingpumpsand/orcontrolpanel.
0.4.7 Thepumpinletstrainermustbeperiodicallycleaned.
0.4.8 Themainswaterinletstrainermustbeperiodicallycleaned.
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1. INSTALLATIONINSTRUCTIONS
Theseinstructionsareintendedfortheinstallerofthispressureboosterset.Pleasefollowthem
carefully.
Theunitshouldonlybeinstalledbyacompetentperson;Acompetentpersonissomeonewhois
technicallycompetentandfamiliarwithsafetypracticesandthehazardsinvolved.
Failuretoinstalltheequipmentasrecommendedbelowcouldinvalidatethewarrantyprovidedby
AquaTech‐Pressmaintothepurchaser.
1.1 ADDITIONALWARNINGS
READGENERALSAFETYINFORMATION0.0,WARNINGS0.1andCAUTIONS0.2,0.3&0.4
1.2 ADDITIONALCAUTIONS
1.2.1 READGENERALSAFETYINFORMATION0.0,WARNINGS0.1andCAUTIONS0.2,0.3&0.4.
1.2.2 EnsuretheYstrainer(100um)andisolationvalve(suppliedaslooseitem)isinstalledontheinletto
thebreaktank(seefig1.3),failuretoinstallthesewillcausethesolenoidtojambandoverflowthe
breaktank.
1.2.3 Ensurethequickreleasefilter(suppliedaslooseitem)isinstalledinthebreaktankoverflowwarning
pipe(seefig1.3)
1.2.4 Mainswaterpressuretounitshouldbebetween1.0and3.0Bar.Ensureapressurereducingvalveset
atamaximumof3.0Barisinstalledontheinlettothebreaktankifthemainswatersupplypressure
exceeds3.0Bar.
1.2.5 Ensurethepumpisprimedbeforestartingotherwisethepumpsealwillbedamagedandcausealeak
(seefig1.1a).
1.2.6 Themaximumstaticoutletpressureis12metresforAB5‐45(heightfromthepumpdischargetothe
highestpointofthesystempipework),or8metresforAB5‐35.
1.2.7 Ensurethecontrolvesselairchargeissetcorrectly(1.3Bar)otherwiseerraticoperationwilloccur
(pumpwillnotstart/stopcorrectly).
1.2.8 Werecommendsystempipeworkshouldbe22mmonlyreducingto15mmattheterminalfitting.
1.2.9 Ensurethepressurevesselthatisfactoryfittedtothepumpassemblyisstilltightaftertransit,it
shouldbehandtightonly,DONOTovertightenthepressurevessel,thiswillleadtodamagetothe
vessel/fittingandsubsequentleakage(seeFig1.1b).
Fig1.1aPumpprimingplug Fig1.1bVesselhandtightonly
1.3 PROCEDURE
1.3.1 OFF‐LOADINGATSITE
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Donotliftpumpsetbypipework.Liftthepumpsetbythecontainerpalletusingapallet/forkliftor
cranebypassingstropsunderneaththeskidusingspreaderbar.
Failuretoutilisethesefacilitiescouldresultindamage.
1.3.2 LOCATION
Ifthesetistobeinstalledinanunheatedroom,ensurethatthereisadequatefrostprotection.
Thelocationoftheequipmentshouldhaveadequatedrainage,bundingorotherappropriate
measurestoprotectassetsandthebuildingfabricintheeventofleakageorwaterspillage.Failureto
providesuchmeasuresmayresultinwaterdamagetopropertyandassets.
Ensurethatlocationforpumpsetprovidesadequateclearspacetoaccommodateunitwithreasonable
accesstoallparts;AquaTech‐Pressmainrecommendaminimumdistanceof500mmallround.There
mustbesufficientroomto:‐
fullyopenpaneldoor;
liftandwithdrawpumps;
withdrawdiaphragmsfromvessels.
AnyHydraulicAccumulatorsuppliedshouldbelocatedasnearaspossibletothedischargesideofthe
pumpset.
ShouldanyoftheselocationconditionsnotbesatisfiedAquaTech‐Pressmainreservetherightto
chargelabouronanywarrantyworkrequiredonthepumpset.
1.3.3 FIXING
Lugsareprovidedforwallfixingonthebackofthepanel.
Installthesetonaflat,evenandlevel
surface,inalocationthatiseasilyaccessible.Iffloormountedtheninstallonaraisedplinthtokeep
setabovedampfloor.
Locateunitinposition.Ifnecessary,levelbyinsertingpackingstripsadjacenttoboltpositions.Firmly
attachpumpsettowall/base.
Fig.1.2
15mm mains water
Connection.1-3Bar
230VAC single
phase 6A supply
Mains power switch
22mm Overflow
Warning pipe with
Quick release filter
22mm system
connection
700/750
mm
High
300mm Wide
(630mm incl.
strainer &
overflow)
200mm
Deep
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Fig.1.3a&bMainswaterconnectionshowingstrainerandisolatingvalveinstalled&Quickreleasefilter
attachedtooverflowwarningpipe(suppliedloose).
1.3.4 PIPEWORK
Fig.1.4TypicalPipeworkarrangement
1.3.4.1 Ensuretheisolationvalve&strainer(suppliedloose)isfittedtothemainswaterinlet.Particles/debris
mustnotenterthemainswatersolenoidvalve,otherwiseitmaystickopenandcause
leakage/flooding.
1.3.4.2 Mainswaterpressureshouldbe1Barminimum,3Barmaximum.Ifthepressureexceeds3Barthena
pressurereducingvalve(notsupplied)mustbefittedbeforethemainswaterinlettothepumpset.
1.3.4.3 Ensurethequickreleasefilter(suppliedaslooseitem)isinstalledinthebreaktankoverflowwarning
pipeandconnectedtodrainwithanair‐breake.g.tundishinaconspicuouslocation.
1.3.4.4 Undernocircumstancesfitanextranon‐returnvalve,tothedischarge,asitmayinterferewiththe
correctoperationofthenon‐returnvalvealreadyfittedasstandardinthepumpset.
1.3.4.5 Connectsitepipeworktomainswaterinletanddischarge,ensuringadequatesupportisprovidedto
avoidimposingpipestrainonpumpset.Theconnectingpipeworkshouldnotbesmallerthanthatof
thepumpseti.e.15mmmainswaterinlet,22mmdischarge
1.3.4.6 WhereHydraulicAccumulator(s)/ExpansionVessel(s)aresuppliedasalooseitem,theymustbe
installed/connectedcorrectlybeforeoperatingtheequipment,otherwiseseriousdamagefromover‐
pressure/pumpoverheatingcouldoccur.
1.3.4.7 Allhydraulicaccumulatorsandexpansionvesselsfittedtothesystemmusthaveisolatinganddrainoff
valvestoenablethemtobeservicedandremovablepipeworktoenablethediaphragmtobe
replaced.
Discharge
Isolating
valve
Level
Control
Pump
Max. static
height 8~12 metres
Overflow
Warning
Isolating
valve &
strainer
(supplied) solenoid
valve
control
vessel
Extent of
AquaBreak
Pumpset
Pressure reducing
valve if needed
(not supplied)
strainer
in pump
suction
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Fig.1.5a&bIsolationvalveonpipework&Flexiblehosewithdraincockonvessel(non‐flowthroughvessel
shown)
1.3.5 FLOWTHROUGHVESSELS
Someinstallationsrequireflowthroughvessel(s)suppliedlooseforsitefittingintothedischargepipeworkviaa
flowjetisolationanddrainvalve.Thenumberandsizeofvesselssuppliedvariesaccordingtositeconditions.
Ensure“O‐ring”isinplaceinsidevalvetopreventleakage.
Fig.1.6a&bFitflowthroughvesselintodischargesystempipeworkflowjetvalve.
Setupthevesselsotheairchargefillingvalve(top)isaccessibleforfuturemaintenance.Allvesselsmusthave
isolatinganddrainoffvalvesfittedtoenablethemtobeserviced.
Settheaircushionpre‐chargepressuretothecorrectlevel(seesection2.4),dependentontheapplication
requiredforthevessel.RefertotheOperatingparametersatthebackofthismanualorcontactAquatech‐
Pressmainforadvice.
1.3.6 ELECTRICAL
WARNING:DONOTTOUCHANYLIVEPARTSFORATLEAST5MINUTESAFTERSWITCHING
OFFTHEPOWERTOALLOWCAPACITORSTODISCHARGE
READGENERALSAFETYINFORMATION0.0,WARNINGS0.1andCAUTIONS0.2,0.3&0.4
1.3.6.1 AllwiringmustcomplywiththelatesteditionoflocalwiringRegulations.
1.3.6.2Wearanti‐staticwriststrapatalltimestoavoidstaticdischargecausingproblemswiththebuiltin
electronicprogram.
1.3.6.3 ConnectincomingelectricalmainssupplytoidentifiedterminalsonisolatorIS1incontrolpanel(see
fig.1.7).Ensurevoltagesandfrequencyindicatedonthemotornameplatesandwiringdiagrams
correspondwithsupplymainsdataandthatthesupplyfusetype&ratingiscorrectforthetotal
currentratingoftheequipment.
1.3.6.4 Completeanyrequiredearthbonding.
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Supply
240VAC
6A 50Hz
(black) N
(black) L
(G/Y)
IS1
v
I
L
CB1
E(G/Y)
T1A
L
Break
Tank
Stop/Start
Filling
Solenoid
Probes
B3
B2
B1
B2 B3B1
Level Control Relay
set to "FS" (filling short delay)
medium sensitivity 75k
(range 5k-150k)
Solenoid
Valve (n.c)
min commax
SV1
LR1
A1 A1 14
14 N
B1 B2 B3
A1
N
Fig.1.7TypicalexampleofAquaBreakelectricalconnections.
Fig.1.8TypicalexampleofAquaBreakpumpmotorterminalboxconnections.
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2. USERINSTRUCTIONS
2.1 CUSTOMERASSURANCE
AQUATECH‐PRESSMAINASSUREYOUTHATIFANYPARTOFTHISEQUIPMENTBECOMESDEFECTIVEDUETO
FAULTYMANUFACTUREORMATERIALSWITHIN12MONTHSFROMTHEDATEOFINVOICEOR12MONTHS
FROMDATEOFCOMMISSIONINGBYAUTHORISEDAQUATECH‐PRESSMAINAGENT,THEPARTWILLBE
REPAIREDORREPLACED.
Theonlyconditionsare:‐
Theequipmentmusthavebeeninstalled,commissioned,operatedandmaintainedasrecommendedby
AquaTech‐Pressmain.
Theequipmentmustnothavebeenneglected,misused,modified,orusedforanyotherpurposethanits
originalapplication.
Thecommissioningshouldbecarriedoutwithin6monthsofthedateofinvoicebyanauthorisedAquaTech‐
Pressmainagent.
ThisAssurancedoesnotapplytothoseitemsnotsuppliedbyusortodefectsarisingfrompartsnotmadeor
approvedbyAquaTech‐Pressmain.Theindividualmanufacturersownpoliciesfordealingwithdefectswill
apply.
AnypartrepairedorreplacedundertheseAssuranceswillbecoveredforthebalanceoftheappropriate
Assuranceperiod.
IfwehaveanydisagreementabouttheseAssuranceswhichweareunabletoresolvewewillbothabideby
thedecisionofanagreedArbitratoror,ifweareunabletoagree,oneappointedbytheBuildingand
EngineeringServicesAssociation(B&ES)ArbitrationSchemeRules.
TheseAssurancesareinadditionto,anddonotdetractfrom,thecontractualrightsyouhaveunderStatute
oratcommonlaw.
Failuretocomplywiththeinstallation,commissioningandmaintenanceprocedureswillinvalidatethe
warranty.
ForfulldetailspleaseseetheAquaTech‐Pressmain"CONDITIONSOFSALE"
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AquaTech-Pressmain Instruction Manual\AquaBreak
2.2 COMMISSIONING
Theunitshouldonlybecommissionedbyacompetentperson;Acompetentpersonissomeonewhoistechnically
competentandfamiliarwithsafetypracticesandthehazardsinvolved.
2.2.1 READGENERALSAFETYINFORMATION0.0,WARNINGS0.1andCAUTIONS0.2,0.3&0.4.plusthe
additionalwarningsandcautions1.1&1.2
2.2.2 Thispumpsethasbeentestedinthefactorypriortodelivery.However,itisimpossibletosimulatethe
actualon‐siteconditions,especiallyiftheyareunusual.Thereforewecan(ifrequired)commissioned
thepumpset,makeanynecessaryadjustmentsandleavethesetinoperationalorder.Pleasesee
contactinformationattheendofthismanual.
2.2.3 Shouldyouwishtocommissionthepumpsetyourself,thenpleasefollowtheinstructionsbelow:You
mustensurethat;
2.2.3.1 theequipmenthasbeencorrectlyinstalled;
2.2.3.2 awrittenschemeofexaminationhasbeenobtainedwhererequiredunderthePressureSystems
SafetyRegulations;
2.2.3.3 anynecessarychlorinationorothertreatmenthasbeencompleted;
2.2.3.4 thesystempipeworkhasbeenthoroughlyflushedpriortofinalconnectionofthepumpsettoensure
anycontaminants/chemicalresiduesandforeignparticleshavebeencompletelyremoved;
2.2.3.5 anadequatewatersupply(1to3Bar)andpermanentelectricitysupply(230vac1phase50Hz6Amp)
areavailable;
2.2.3.6 thepipeworketcinthebuildingbeingservedbythepumpsetiscapableofacceptingthegenerated
pressures.
2.2.4 withthepowerandwaterOFF,checktightnessofallmechanicalandelectricalconnections,toensure
theyhavenotloosenedduringtransit.
2.2.5 withthepumpsetswitchedoff(IS1)andthemotorcircuitbreakerswitchedoff(CB1),closethe
dischargeisolatingvalve.
2.2.6 closethemainswaterinletisolatingvalve,checkandcleanthestrainer,re‐installstrainerensuringitis
leakfree.
2.2.7 checkthecontrolvesselairchargeiscorrect(1.3Bar)whenthereisnopressureonthedischarge.
2.2.8 checkandcleanpumpsuctionstrainer/inletfilter(SeeFig2.1)
2.2.9 slowlyopenmainswaterinletvalve,switchonunittoallowsolenoidvalvetoopenandfillthemains
waterbreaktank.
2.2.10 ensurethepumpisprimed(filledwithwater)beforestartingotherwisethepumpsealwillbe
damagedandcauseittoleak(seefig1.1a).
2.2.11 oncethepumpisfullyprimed,switchthepumpmotorcircuitbreaker(CB1)onandallowthepumpto
pressuriseagainstthecloseddischargevalve.Thepumpshouldstopwhenclosedvalvepressurehas
beenachieved(plusashortrunontime).
2.2.12 ensureallsystemoutletsareclosed,SLOWLYopenthepumpsetdischargevalvetoallowthepumpto
pressurisethesystempipework.Checkforleaksandrepairthem.
2.2.13 openandcloseeachsystemoutletinturnallowingwatertoflowfromeachoutletuntilalltheairis
purged.Aseachoutletisopenedandclosedthepumpshouldstartandstop(stopsafterashorttime
delay).
2.2.14 ifanyoutletonthesystemisopenedandclosedthisshouldcausethepumptostartandstopandthe
breaktanktorefillasnecessary.Ifthisissothenthepumpsetisworkingnormally.
2.2.15 checkfornormaloperationandthatnoleaksarepresent,checkallisolationvalvesonthepumpset
areopenandallcoversarefixedinplacebeforeleavingtheinstallationunattended.
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AquaTech-Pressmain Instruction Manual\AquaBreak
2.3 OPERATINGINSTRUCTIONS
Thesepumpsetsareusedforincreasingthesupplypressureofcoldpotablewaterwhilstalsoprovidingback
flowprotectiontofluidcategory5.
Theunitshouldonlybeoperatedbyacompetentperson;Acompetentpersonissomeonewhoistechnically
competentandfamiliarwithsafetypracticesandthehazardsinvolved.
2.3.1 ADDITIONALWARNINGS
DONOTTOUCHANYLIVEPARTSFORATLEAST5MINUTESAFTERSWITCHINGOFFTHEPOWER
READGENERALSAFETYINFORMATION0.0,WARNINGS0.1andCAUTIONS0.2,0.3&0.4.
2.3.2 ADDITIONALCAUTIONS
2.3.2.1 READGENERALSAFETYINFORMATION0.0,WARNINGS0.1andCAUTIONS0.2,0.3&0.4.
2.3.2.2 Ensurethepumpisprimedbeforestartingotherwisethepumpsealwillbedamagedandcausealeak.
2.3.2.3 Sealfacesarelubricatedbythepumpedliquid,assuchnewsealswillleakslightlyuntil“run‐in”there
aftertheleakageshouldbesmallenoughtoevaporateandremainun‐noticed.
2.3.3 NORMALOPERATION
Thispumpsetincreasesandmaintainsthesupplypressuretoapreset'Duty'pressurewhilstalsoprovidingback
flowprotectiontofluidcategory5.
Thepumpsetconsistsofapumpwithbuiltinpressureandflowswitches,amainswaterbreaktankwithsolenoid
fillingvalveandcontrols,allmountedinasteelenclosuretogetherwithassociateddischargevalveandexternal
mainswaterisolationvalve&strainer.Thepumpsetcanbewallorfloormounted.
2.3.3.1 For“normal”operation,allpumpsetinletanddischargevalvesshouldbeleftopen,allhydraulic
accumulator/expansionvesselisolatingvalvesshouldbeleftopen,anddraincock/valvesshouldbe
leftclosed.Shoulditbenecessarytohaveasituationthatisnot“normal”operation,thenwewould
stronglyrecommendattendancetositebyourtrained/authorisedservicepersonnel.Pleasecontact
AquaTech‐Pressmainformoredetails.
2.3.3.2 Onceinstalledandcommissionedcorrectly,thepumpsetautomaticallystartsandstopsthepumpas
systemoutletsareopenedandclosed.Thebreaktankautomaticallyfillsasandwhenrequired.
2.3.3.3 Dryrunprotection.Thepumphasautomaticdryrunprotectionbuiltinshouldthemainswater
breaktankrundryforanyreason.Dependentupontheinstalledpumptype,twoscenarioscanoccur
followinginitiationofdryrunprotection.1)Thepumpwillstopandlock‐out,thisrequiresmanually
restartingbyswitchingoffthepowersupplyfor10secondsthenswitchingbackonagain.2)Thepump
willautomaticallyattempttorestartevery5minutesfor3attemptsbeforeshuttingdownand
requiringmanuallyswitchingoff,wait10seconds,switchontoreinitiatethestartsequence.
Ifthepumpcontinuestoinitiatethedryrunprotectionthenitmayneedtobeprimedagain(see
commissioning2.2),haveablockedstrainerornowaterisenteringthebreaktank.
2.3.3.4 Thetanklevelcontrolrelay(LR1)controlstheoperationofthesolenoidvalve.TheLEDindicatorisOFF
whenthereisnopower,slowflashingforONwithtankfull,fastflashingforshorttimingperiod,
permanentlylitforONandfillingtank.
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AquaTech-Pressmain Instruction Manual\AquaBreak
2.3.4 TROUBLESHOOTINGGUIDE
Symptoms PossibleCause Check
Nowater,pumpwillnotstart
Electricalsupplyoff
Checkpowersupply,electrical
isolator,fuses,RCD,motorcircuit
breaker,wiringconnections
Pumpseized(motorbuzzes)
Pumphasnotbeenrunregularly
(weekly).ContactAquatech
Pressmainservice
Pumpseized(internalmotor
thermotripoperated)
Pumphasnotbeenrunregularly
(weekly).ContactAquatech
Pressmainservice
Dryrunprotectioninitiated(see
2.3.3.3)
Breaktankisempty,checkinlet
valve/strainerandsolenoidvalve
operation.Checkmainswater
supply.Checkpumpsuction
strainer/inletfilter
Maximumsystemheadexceeds8m
forAB5‐35or12mforAB5‐45.
PumpstartPressureswitchwillnot
operateifmaximumsystemheadis
exceeded.
Pumpstoppedonlowwater(dry
run),nowaterinbreaktank
TankLevelControlrelayfault,switch
poweroff,wait10secondsand
switchpoweronagaintoreset
controlrelay.
Nowater,pumpdoesrun Pumpair‐locked
Vent/primepumptoremoveallair.
Checkpumpsuctionstrainer/inlet
filter
Reduced/intermittentflow
Pumppartiallyair‐locked Vent/primepumptoremoveallair
Mainswater/Pumpinletstrainer
blocked/partiallyblocked
Cleanmainswater/pumpinlet
strainer(section2.4)
Airinsystem Purgeairfromallsystempipework
Dryrunprotectioninitiated(see
2.3.3.3)
Breaktankisempty,checkinlet
valve/strainerandsolenoidvalve
operation.Checkmainswatersupply
Pumpcontinuestorunwithall
outletsclosedorpumpcyclesonand
off(hunts)
Leakinsystem Checkallsystempipeworkand
outletsforleak
Controlvesselair‐chargeincorrect Checkairchargepressureinvessel
Jammedflowswitch
Removedischargehoseandcheck
flowswitchforfreemovement,no
debris
Jammednon‐returnvalve Removenon‐returnvalveandcheck
forfreemovement,nodebris
Damagedfloworpressureswitch ContactAquatechPressmainservice
Ifaproblempersists,contactAQUATECH‐PRESSMAINservicedepartmentquotingtheserial
numberWN:_______(oncontrolpanelfascia)
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AquaTech-Pressmain Instruction Manual\AquaBreak
2.4 MAINTENANCEINSTRUCTIONS
DONOTTOUCHANYLIVEPARTSFORATLEAST5MINUTESAFTERSWITCHINGOFFTOALLOWCAPACITORSTO
DISCHARGE.
Theunitshouldonlybemaintainedbyacompetentperson;Acompetentpersonissomeonewhoistechnically
competentandfamiliarwithsafetypracticesandthehazardsinvolved.
2.4.1 ADDITIONALCAUTIONS
2.4.1.1 READGENERALSAFETYINFORMATION0.0,WARNINGS0.1andCAUTIONS0.2to0.4.
2.4.2 PROCEDURE
Every6monthsthepumpsetshouldbemaintainedbyauthorisedAquaTech‐Pressmainserviceagents‐see
Servicing(Section3.)
Pumpinletfilter/suctionstrainer
Thepumpinletfiltershouldberegularlycheckedtoremoveanybuild‐upofdebris.
Fig2.1Pumpinletfilter/suctionstrainer
Mainswaterinletstrainer
Themainswaterinletstrainershouldberegularlycheckedtoremoveanybuild‐upofdebris.
Fig2.2Mainswaterinletisolationvalve&strainer
Controlvessel
AirChargePressure.Thecorrectchargepressureprovidesreliableoperationofthesystemandaprolonged
lifetimeofthediaphragm.Thisshouldbecheckedregularlytoavoidproblemssuchasunstablepumpoperation.
1. Toadjustairchargepressure:switchoffthepumpset,releasesystempressureonwatersidebyopeninga
systemoutlet,andleaveopen.Thewaterinsidethebladderwillbepushedbackbytheairchargepressure.
Removecaponthefillingvalve,setairchargepressurerefillingusingdryairornitrogen.Screwcapfirmlyon
fillingvalve.Closethesystemoutlet.Closepumpsetdischargevalve,switchpumpsetbackonandslowly
opendischargevalvetothesystem.
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AquaTech-Pressmain Instruction Manual\AquaBreak
3. SERVICING
3.1 MAINTENANCEANDCAREOFYOUREQUIPMENT
TheAquaTech‐Pressmainequipmentthatisdescribedinthisinstructionbooklethasbeenmanufacturedand
testedtothehigheststandardsofdesignandquality.Itwillgivetroublefreeoperationovermanyyearsprovided
itismaintainedregularlyfromwhenitiscommissioned.Tokeepitoperatingefficientlyinasafe,economicaland
environmentallyfriendlycondition,regularmaintenanceisanessentialpart.
AquaTech‐Pressmainalongwithits’servicedivision,AcornPressurisationServicesaretheofficialprovidersof
commissioningandmaintenanceservices.(seebelow).
SeveralcompaniesoperatingundertheAquatronicGroupManagementstructureareavailabletofulfilawide
rangeofservicingandmaintenancerequirements,asdetailedbelow.
3.2 LEGALREQUIREMENTS
HydraulicAccumulators/ExpansionVesselsinstalledaspartof/inconjunctionwiththisequipment,withPressure
xVolumeabove250Bar‐litres,requireformalinspectioninaccordancewitha“WrittenSchemeofExamination”.
ThisisaLegalRequirementonthepartoftheOwner/Userunderthe“PressureSystemsSafetyRegulations”
(PSSR).A“WrittenScheme”andregularinspectioncanbeprovidedbyeitherAcornPressurisationServices
(combinedmaintenanceandinspection)orESISLtd(inspectiononly),seedetailsbelow.
PlantServicing&Inspection
ACORNPRESSURISATIONSERVICES,
AGMHouse,Essex,CO61GT. Ph:01206215151
10WheelForgeWay,Manchester.M171EH.Ph:01612264727
Acornprovidesmaintenanceandinstallationofalltypesofpackagedwaterpumpingequipmentforbuildingservices.Its
specialistfieldsarePressureboosterequipmentandsealedsystemsforheatingandchilledwaterdistributionsystems.
Regularservicingofanyplantforessentialservicesisvitalbecausewearandtearareverygradualprocesses.
Withpreventativemaintenance,thecostsaresmallandbenefitsinreliability,safetyandeconomycanbesignificant.Acorn
PressurisationServicescanprovideacompletepackageofschemesforpreventativemaintenanceonallAquaTech‐Pressmain
andothermakesofequipment.
PressureVesselInspection
ESISENGINEERINGSAFETY&INSPECTIONSERVICESLTD,
AGMHouse,LondonRd,Copford,Colchester,Essex,CO61GT.
Phone:01206215141
UnderthePressureSystemsSafetyRegulations,expansionvesselsandhydraulicaccumulators,generally250bar‐litresand
greater,andprotectiondevices,requireaWrittenSchemeofExaminationbeforetheycanbeoperated.ESISInspectionand
InsuranceServicesLimitedspecificationscanprovidethemeanstocomplywiththeseregulations.Theseservicescanbe
extendedtocoverotherunitse.g.airpressurereceiversetc.
3.3 SERVICECONTACTS
Forserviceduringwarrantyperiodcontact:AQUATECH‐PRESSMAINServiceDepartment
HeadOfficeTel:01206215121 ManchesterOfficeTel:01612264727
Forregularservicing,contactservicedivision:ACORNPRESSURISATIONSERVICES
HeadOfficeTel:01206215151 ManchesterOfficeTel:01612264727
whowillbepleasedtogiveyouexpertadviceonthisoranyotherservicingmatter.
4. DISPOSAL
Disposalofthisproductorpartsofitmustbecarriedoutinaccordancewiththefollowingguidelines:
Usethelocalpublicorprivaterecycling/wastecollectionservice.
Incasesucharecycling/wastecollectionservicedoesnotexistorcannothandlethematerialsusedinthis
product,pleasedelivertheproductoranyhazardousmaterialfromittoyournearestAquaTech‐Pressmain
office.
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AquaTech-Pressmain Instruction Manual\AquaBreak
EUDeclarationofConformity
We,AquatronicGroupManagementPlc,declarethattheEquipmentdetailedbelow:
BREAKTANKANDPUMPSET
MODEL:AquaBreakAB5
ComplieswiththerequirementsofthefollowingEuropeanDirectives:
MachineryDirective2006/42/EC
LowVoltageDirective2014/35/EU
ElectroMagneticCompatibilityDirective2014/30/EU.
7/12/16
I.D.Taylor,I.Eng.MIET,Director
AquatronicGroupManagementPlc
T/AAquaTech‐Pressmain
AGMHouse,LondonRd,Copford,Colchester,EssexCO61GTUK
Telephone:01206215121
OPERATINGPARAMETERS
SERIALNo.MODELAB5
THESERIAL&MODELNUMBERSMUSTBEQUOTEDWHENREQUESTINGASSISTANCE
ELECTRICALDATA:
Supply 230 volts 1 Ph 50 Hz
Fullloadcurrentofpumpset 6 Amps
Max.pumpsetloading: 0.55 Kw Methodofstarting: DOL
NOISELEVEL:lessthan70db(A)unlessotherwisestated……………………
NOMINALFLOWRATE:0to26litres/min
PRESSURESETTINGS:
ASFACTORYSET
PumpDutypressure
AB5‐45
1.5Bar
(AB5‐35)
(1.0Bar)
Controlvessel: 1.3Bar (1.0Bar)
Pumpclosedvalvepress. 4.5Bar (3.6Bar)
Oncommissioningitmaybefoundnecessarytomodifythesesettings.Providingthisinformationisleftwith
theequipment,thefigureswillbeupdatedbythecommissioningengineer.
Updatedbycommissioningengineer……………………………………………Date………………...
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