AQUATECH AquaBreak AB5 Firmware update

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INSTRUCTIONSFOR
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 0. GENERALSAFETYINFORMATION,WARNINGS&CAUTIONS
1. INSTALLATION
2.THEUSER
3. SERVICING
4. DISPOSAL
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AQUABREAKAB5BREAKTANK&PUMPSET
FORBACKFLOWPROTECTIONTOFLUIDCATEGORY5
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ISSUE318/07/2017
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HeadOffice:AGMHouse,LondonRd,Copford,Colchester,EssexCO61GTUK
Tel:01206215121Email:aftersales@agm‐plc.co.uk
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ManchesterOffice:Unit10,WheelForgeWay,AshburtonRoadWest,Manchester.M171EH
Tel:01612264727Email:aftersales@agm‐plc.co.uk

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Thesepumpsetsareusedforincreasingthesupplypressureofcoldpotablewaterwhilstalsoprovidingback
flowprotectiontofluidcategory5.
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CONTENTS
0. GENERAL SAFETY INFORMATION .............................. 3 
0.1WARNINGS .................................................................................................... 4
0.2CAUTIONSFORINSTALLATION ........................................................................ 4
0.3CAUTIONSFOROPERATION/USER ................................................................... 6
0.4CAUTIONSFORMAINTENANCE ....................................................................... 6
1.  INSTALLATION INSTRUCTIONS ........................................................... 7 
1.1ADDITIONALWARNINGS ............................................................................................... 7
1.2ADDITIONALCAUTIONS ................................................................................................ 7
1.3PROCEDURE ................................................................................................................. 7
1.3.1OFF‐LOADINGATSITE ............................................................................................ 7
1.3.2LOCATION ............................................................................................................ 8
1.3.3FIXING .................................................................................................................. 8
1.3.4PIPEWORK ............................................................................................................ 9
1.3.5FLOWTHROUGHVESSELS .................................................................................... 10
1.3.6ELECTRICAL ......................................................................................................... 10
2.  USER INSTRUCTIONS ......................................................................... 12 
2.1CUSTOMERASSURANCE ............................................................................................. 12
2.2COMMISSIONING ....................................................................................................... 13
2.3OPERATINGINSTRUCTIONS ......................................................................................... 14
2.3.1ADDITIONALWARNINGS ...................................................................................... 14
2.3.2ADDITIONALCAUTIONS ....................................................................................... 14
2.3.3NORMALOPERATION .......................................................................................... 14
2.3.4TROUBLESHOOTINGGUIDE ................................................................................. 15
2.4MAINTENANCEINSTRUCTIONS .................................................................................... 16
2.4.1ADDITIONALCAUTIONS ....................................................................................... 16
2.4.2PROCEDURE ........................................................................................................ 16
3.  SERVICING ........................................................................................... 17 

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3.1MAINTENANCEANDCAREOFYOUREQUIPMENT ......................................................... 17
3.2LEGALREQUIREMENTS ............................................................................................... 17
3.3SERVICECONTACTS .................................................................................................... 17
4.  DISPOSAL ............................................................................................. 17 
EU DECLARATION OF CONFORMITY ...................................................... 18 
OPERATING PARAMETERS ...................................................................... 18 
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0.GENERALSAFETYINFORMATION 
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 Theseinstructionsareintendedfortheinstaller/operator/user/maintenanceofthisequipmentand
mustbekeptwiththeequipment,forthelifeoftheequipmentandmadeavailabletoallpersons.
PleasereadGENERALSAFETYINFORMATION0.0,WARNINGS0.1andCAUTIONS0.2,0.3&0.4
beforedoinganythingelse,andthenfollowthemcarefully.
 Theunitmustonlybeinstalled/operated/used/maintainedbyacompetentperson;Acompetent
personissomeonewhoistechnicallycompetentandfamiliarwithsafetypracticesandthehazards
involved.
 HydraulicAccumulators/ExpansionVesselsinstalledaspartof/inconjunctionwiththisequipment,
withPressurexVolumeabove250Bar‐litres,requireregularformalinspectionbyacompetent
person.ThisisaLegalRequirementunderthe“PressureSystemsSafetyRegulations”(PSSR)and
theOwner/Usershouldbemadeawareoftheirresponsibilityforthis.(seesection3.Servicing).
 Failuretoinstall/operate/use/maintaintheequipmentasrecommendedbelowcouldcause
damagetotheequipmentanyanythingsubsequentlyconnectedtoit,andinvalidatethewarranty
providedbyAquaTech‐Pressmaintothebuyer.
 Anydamagecausedtotheequipmentbymisapplication,mishandlingormisusecouldleadtorisk
ofElectrocution,Burns,Fire,Floodingorinjurytopeopleorpropertydependentuponthe
circumstancesinvolved.
 Thisequipmentcontainsmoving/rotatingpartsthatmustremainguarded.Removaloformissing
guardscouldleadtoseriouspersonalinjury.
 Thisequipmentautomaticallyrestartsafterapowerinterruption.
 Weacceptnoresponsibilityorliabilityforanyconsequencesordamage/lossesdueto
misapplication,mishandlingormisuseoftheequipment.
 Itshouldbenotedthattheassemblyofpressureequipmentonsiteundertheresponsibilityofthe
user(orhisrepresentative)isnotsubjecttothePressureEquipmentDirective97/23/EC.(National
legislationcoveringassemblyonsitewillapply)
 Thelatestversionofthisinstructionmanualwithuptodatesafetyinformationcanbedownloaded
fromourwebsiteatwww.aquatechpressmain.co.uk
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0.1 WARNINGS
0.1.1 Donottouchanylivepartsforatleast5minutesafterswitchingofftheelectricitysupply.Failureto
observethiswillconstituteasevereElectricshockand/orBurnshazardandmaybelethal.
0.1.2 Theequipmentisonlysuitableforearthreferencedsuppliesandmustbepermanentlyearthedto
avoidElectricshockhazard.
0.1.3 Metalparts(e.g.heatsinks)mayreachtemperaturesof90degreescentigradeandwillconstitutea
Burnshazard.
0.1.4 Theequipmentmustnotbepressurisedbeyondthemaximumworkingpressureasstatedon
pumps/pipework/vessels/controlpanelotherwiseseriousmechanicaldamage/destructioncould
occurcausinginjurytopeopleorproperty.
0.1.5 Theequipmentmustnotbeheated/chilledbeyondthemaximum/minimumworkingtemperature
asstatedonpumps/pipework/vessels/controlpanelotherwiseseriousmechanical
damage/destructioncouldoccurcausinginjurytopeopleorproperty.
0.1.6 Anydamagetoequipment,pumpset,vessels,pipeworkorsystemcomponentscausedby
misapplication,mishandlingormisusecouldleadtoElectricshockhazard,Burnshazard,Firehazard,
Floodinghazardorcauseinjurytopeopleorproperty.
0.1.7 Thisequipmentmaycontainmoving/rotatingpartsthatmustremainguarded.Removalofor
missingguardscouldleadtoseriouspersonalinjury.
0.1.8 Pressurevesselsmustneverbedisassembledwhilstinuse,theycontainhighpressureair/gas
chargewhichcouldcauseinjurytopeopleorproperty.
0.1.9 Ensurethebase/foundation/plinth/walltowhichtheequipmentistobeattachedissufficiently
strongenoughtocarrytheentiremassoftheequipmentincludingthewaterthatitwillcontain
underworst‐casefaultconditions.E.g.fullysaturatedpressurevesselwithnoaircharge,breaktank
fulltooverflowing,etc.Failuretoobservethiscouldcauseseriousmechanicaldamage/destruction
resultingininjurytopeopleorproperty.
0.1.10 Thisequipmentcontainsafluidwhichmayundercertaincircumstancesleak/drip/sprayfluid(e.g.
servicing,repairormalfunction).Ensureanyfluiddischargewillnotcausedamagetothe
surroundingsbytakingappropriateaction.E.g.installinaplacethatwillnotbedamagedbyleakage
orinstallinabundedareawithadequatedrainage.
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0.2 CAUTIONSFORINSTALLATION
0.2.1 READGENERALSAFETYINFORMATION0.0,WARNINGS0.1andCAUTIONS0.2,0.3&0.4
0.2.2 Theunitshouldonlybeinstalled/operatedbyacompetentperson;Acompetentpersonissomeone
whoistechnicallycompetentandfamiliarwithsafetypracticesandthehazardsinvolved.
0.2.3 Donotliftthepumpsetbypipework.Liftthepumpsetbythecontainerpalletusingapallet/forkliftor
cranebypassingstropsunderneaththeskidusingaspreaderbar.Failuretoutilisethesefacilitieswill
resultindamagetothepumpset.
0.2.4 Storeinadryplacetoavoiddampconditionsdeterioratingtheequipment.
0.2.5 Protectagainstdirt,damageandfrost.Itisabsolutelyessentialthatnoforeignmattersuchaspipe
threadswarf,weldingslag,gritorstonesareallowedtoentertheset.Debrisofthistypecancause
severedamagetothemechanicalseals,diaphragmsandimpeller.Frost/freezingwilldamage
pumps/pipeworkandcontrolpanelcomponents.
0.2.6 Theequipmentisonlysuitableforinstallationinaclean,dustfreeindoorenvironment,withadequate
protectionfromheatandfrost,andsufficientventilationtoensurecoolingofthemotors.Ambientair
temperatureshouldbebetween5and40degreescentigrade,non‐condensating.Operationoutsideof
theseconditionscouldseriouslydamagetheequipment.

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0.2.7 Iftheequipmentweretobestoredortakenoutofserviceforaperiodoftime(e.g.1weekormore),
thenwewouldrecommenddrainingtheequipmentofallwater/liquid(withdueregardtoanylocal
regulations)topreventfrostdamagetocomponents.Whenrestartingisrequiredwewould
recommendcommissioningbyourauthorisedserviceagent.
0.2.8 Ensurethebase/foundation/plinth/walltowhichtheequipmentistobeattachedhassufficientmass
comparedtotheequipment,inordertoavoidnoise/vibrationtransmission.E.g.themassofthebase
shouldbeatleastfivetimesthemassoftheequipment.
0.2.9 Ensuretheelectricalsupplyisthecorrectvoltage,current,frequencyandtypefortheequipment
suppliedandthatsuitablecircuitprotectionequipmentisinstalledinthesupply.Incorrectelectrical
installationcouldbeanelectricshock/burns/firehazard.
0.2.10 Whenaccessingthecontrolpaneltomakeelectricalconnectionsadoptanti‐staticprocedurese.g.
wearanti‐staticearthedwristband,toavoidriskofdamagingthecontroller.
0.2.11 AllproductsthatarepackagedtoincludePressurevessel(s)/HydraulicAccumulator(s)/Expansion
Vessel(s)areclassedas“Assemblies”underthePressureEquipmentDirective(PED).Whereunitsare
despatchedwith“Loose”vessel(s)forassemblyonsiteitisabsolutelyessentialthattheybeinstalled
asdetailedintheinstructionsusingthefittingsprovidedwhereappropriate.Failuretoobservethis
willnullifycompliancewiththePEDandmaypresentasafetyhazard.Yourwarrantymayalsobe
affected.
0.2.12 WhereHydraulicAccumulator(s)/ExpansionVessel(s)aresuppliedasalooseitem,theymustbe
installed/connectedcorrectlybeforeoperatingtheequipment,otherwiseseriousdamagefromover‐
pressure/pumpoverheatingcouldoccur.
0.2.13 Donotoperatethisequipment/pumpsetpriortocommissioning(section2.2)Thiscouldcause
irreparabledamagetoequipment/pumpset/pipework/systemcomponents.
0.2.14 Isolatetheequipment/pumpsetbeforepressuretestingsystem.Excesspressurecouldirreparably
damagethepressuretransducer,pressureswitches(wherefitted)andthediaphragmsofpressure
vessel/hydraulicaccumulators.
0.2.15 Itistheinstallers’responsibilitytoensuresubsequentpipeworketccanacceptthepressures
generatedbytheequipment/pumpsetandtoinstallanoverpressuresafetydeviceintothesystem
withduerespecttothesuctionpressurepresentonthepumpset,thepumpclosedvalvepressure
statedonthepump,themaximumworkingpressurestatedonanyoftheattachedpressurevessels
andanyotherdeviceconnectedtothesysteme.g.boilers,calorifiersetc.
0.2.16 Whenchlorinationofthesystemiscarriedout,ensurethatanyresidualchlorineisremovedby
thoroughflushingasdetailedintheHSEapprovedcodeofpracticeL8,toavoiddamagingthe
equipment/pumpset.Thenormallevelofchlorinationisupto2partspermillion(ppm),butshock
dosingforsterilizationpurposes,at25‐50ppmfor24‐48hoursisacceptableaslongasallchlorineis
removedoncetheprocessiscomplete.Chlorinationbeyondtheselimitscouldseriouslydamage
pumpsetcomponentsandWILLNOTbecoveredbythewarranty.
0.2.17 Theinstaller/userisresponsiblefortheinstallationofthecorrectearthingandprotectionaccordingto
validnationalandlocalstandards.Alloperationsmustbecarriedoutbyasuitablyqualifiedperson.
0.2.18 Theequipmentisonlysuitableforearthreferencedsuppliesandmustbepermanentlyearthedto
avoidelectricshockhazard.
0.2.19 TheequipmentmustbepermanentlyearthedwithappropriatesizedEarthing.
0.2.20 Werecommendtheuseofa30mARCDtoprovideelectricalsafety.
0.2.21 Neverperformhighvoltageresistancetestsoncontrolpanels,variablespeeddrives/motorswithout
firstdisconnectingthepanel/drive/motorfromthecircuitbeingtestedasthiswilldamagethebuiltin
electroniccomponents.
0.2.22 Metalparts(e.g.heatsinks)mayreachtemperaturesof90degreescentigrade.
0.2.23 Where“Expansionvessels”areusedonDomestichotwatersystems(DHWS)orLTHWheatingsystem
pressurisationunits,thetemperatureofthefluidreturningtothevesselsshouldnotexceed70
degreesCentigradeasthiscoulddamagethevesseldiaphragm.Wherethetemperatureexceeds70C
anintermediatecoolingvesselshouldbefitted.
0.2.24 Where“Expansionvessels”areusedonDomestichotwatersystems(DHWS)orLTHWheatingsystem
pressurisationunits,theglycolcontentinthewatermustnotexceed50%.
0.2.25 Draincocks/valvesandairbleedscrewsmustnotbeleftopenasthiscouldcauseflooding.