Dutypoint MiniBreak Manual

MiniBreak CAT 5 tank and booster set
Date 17/09/19 - Revision A
DOC-MBOM1901
Operating and maintenance instructions

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MiniBreak CAT 5 tank and booster set
Original Instructions
Date: 19/11/2018 - Revision C
Operating and maintenance instructions
Warning Symbols
Safety instruction where noncompliance would affect safety.
Safety instruction where electrical hazard is involved.
Safety instruction where noncompliance could cause damage to the equipment.
Instruction for safe use
This product has been designed for boosting cold water to the operating conditions shown and
creating an air gap arrangement that provides category 5 back flow protection.
This product should not be installed until this leaflet has been studied carefully.
Handling, transportation and installation of this equipment should only take place with the proper
use of lifting equipment. This product must be stored in a dry, frost-free environment.
Noise Emissions
This equipment operates at a noise level lower than 70dBA.
Protection degree IP54
Introduction
This leaflet contains information to enable the safe installation and operation of the products mentioned above.
The following instructions must be read and understood by all persons responsible for the installation, operation
and maintenance of this product.
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Installation
The Dutypoint MiniBreak tank booster set is despatched mounted on a wooden pallet and
covered in a protective film, it is recommended that the unit be retained in the protective
packaging until the product is to be installed. The unit will arrive pre-packaged and wired ready
for installation. This product has been fully run tested at our works under simulated site
conditions. The unit should be thoroughly checked for physical damage that may have been
caused during transit. If the unit is found to have damage it must be reported immediately and
should not be installed.
The unit should be sited in a dry, frost-free environment wall mounted in a position that will
allow adequate room for general maintenance and service.
Electrical connections
The cable used for the incoming supply must be of adequate size to carry the motor full load
current. This is shown on the duty plate. A high sensitivity differential switch (0.03A) is also
recommended.
All connections must be made using the appropriate wiring drawings for the equipment being
installed, with particular attention being paid to the supply voltages.
Never operate this product with the pump controller front panel or the motor terminal
cover removed.
It is essential that this equipment is earthed to the building earth system.
Pump operates at 230v 50Hz
The base frame must be earth bonded directly to the building earth system.
The power supply wiring should be arranged such that it enters the enclosure
through appropriate cable gland and then enters the pump controller through its
cable gland.
Water supply and system connection
Connect the Dutypoint MiniBreak tank booster water inlet 15mm compression (left side of
cabinet) to a suitable water supply The inlet should be provided with an isolation valve to aid
maintenance. If the pressure available at the ball valve is below 0.3 bar, a low pressure orifice
must be obtained and fitted.
Extend the 22mm plastic overflow pipe from the left hand side of the unit to a position where
an overflow will be noticed and rectified.
It is the responsibility of the installer to ensure that the overflow is able to keep up with the
incoming water volume, if this is not the case then a pressure reducing valve should be fitted
to reduce the incoming mains water volume
Connect the discharge port 15mm push fit (right hand side of cabinet) to the system inlet.
Draining the break tank can be achieved by isolating the suction line ball valve on the flexible
connector and removing the flexible end attached to the pump, the flexible connector can then
be positioned over a container to collect the drained water.
Inexperienced users
This product must be operated by qualified personnel only.
Be aware of the following precautions:
This product is not to be used by anyone with physical or mental disabilities, or anyone without
the relevant experience and knowledge, unless they have received instructions on using the
equipment and on the associated risk or are supervised by a responsible person.
Children must be supervised to ensure that they do not play on or around the product.
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1. Ensure the water tank is clean.
2. With the power supply off. Open the water supply to the water tank and fill with water until the
ball valve closes and stops further filling. Check the water level is correct and all joints are
sound.
3. Check the pump has been fully evacuated of all air by removing the bleed screw of the pump
and allow water to escape until no air is present, replace the bleed screw.
4. Open discharge valve and power the product, the pump should then start to run and push all
air out of the discharge system, when free of air close the discharge valve and the flow will
stop and the pump will switch off after approximately 10 seconds.
Operation
When a draw off point connected to the system is opened the pressure will start to fall and the pump will start
to pressurise the system. The pump will continue to run until demand ceases completely and flow has stopped
(< 3l/m) the pump will run for approximately 10 seconds and will then shutdown.
The pressure will now be sitting at the pump closed valve head value.
Lack of water
If the pump controller senses a lack of water the pump will be stopped automatically after approximately 10
seconds and the red failure light will be illuminated.
If the water supply comes back online and a discharge is open the pump controller will automatically reset and
start the pump.
If the water supply has been reinstated and the pump has not started automatically the reset button can be
operated which will cause the pump to run for approximately 10 seconds and prime the system, if successful the
pump will then operate normally.
Maintenance
Routine check (6 monthly intervals)
1. Check the pump produces the correct pressure.
2. Check that the pump operates without undue noise or vibration.
3. Check the break tank is clean and that the correct water level has been maintained.
4. Check that all screws are tight on electrical components.
5. Check that the earth connections are tight and making good contact.
Pump removal
Isolate power supply feeding pump set.
Isolate water inlet feeding pump set.
Open an outlet to release system pressure
Isolate the valve located on each flexible connector and remove the flexible from the pump suction and
discharge ports, the pump can now be un-bolted from the base and pulled forward.
The electrical cable can now be removed from the pump terminal box.
The new pump can now be fitted reversing the above procedure.
The break tank is constructed to have a weir slot as required by the water bylaws to prevent back flow contamination, if
the inlet ball valve or NRV suffered a catastrophic failure the overflow may not be able to keep up with the inflow in
which case excess water will be ejected through the weir slot and onto the plant room floor, if this is not acceptable then
consideration should be given to fitting the wash down set onto a tray with overflow to a drain.
Volt Free Contacts – Pump Running
Both open and closed volt free contacts are available which indicate if the pump is running. See appropriate
drawing for volt free contact wiring configurations. Rating 1A 50v maximum.
Commissioning
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REVISION No. DATE
NOTES
Mains water supply 15mm
Overflow/Warning 22mm
System
connection
15mm push fit
Clearance required for access
Front 500mm
Sides 200mm
Top 500mm
Wall mounting
fixing holes
4xM8fixingbolts
482
Access to Cold water break tank
under top cover
338
NOTE.
Installation of this product should not be carried
out until the installation and operating instruction
have been read and fully understood.
Installation Notes.
1. This product should be installed in a dry frost free environment.
2. It is recommended that the system should be cleaned to BS5449 part 1 1990 before connection
3. Isolating valves must be fitted to all connecting pipework to aid servicing
4. The system pipework should be sized to pass the required flow rate without excessive frictional loss
5. Electrical connections should be carried out by a qualified electrical engineer in accordance with
local site regulations and the latest issue of the IEE regulations.
6. Cold water supply minimum operating pressure at ball valve 0.3 bar. lower pressures will require
a low pressure seat to be fitted to the ball valve.
7. The 22mm overflow pipe should be extended to a position where an overflow will be noticed and rectified.
1 metre of
3 core 1mm2 cable
Electrical connections
Supply
230v single phase + Earth
Connect to a suitable thermal switch or fused supply
A high sensitivity differential switch is also recommended (0.03A)
Pump controller
L
N
E
L
N
EM
Pump motor
U
V
E
Volt free contact
box
Terminals 1 & 2 close for pump run
Terminals 1 & 3 open for pump run
Relay
Gland for wiring
to volt free contact
642
270
532
420
225
Weir at
opposite end

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1. Ensure the water tank is clean.
2. With the power supply off. Open the water supply to the water tank and fill with water until the
ball valve closes and stops further filling. Check the water level is correct and all joints are
sound.
3. Check the pump has been fully evacuated of all air by removing the bleed screw of the pump
and allow water to escape until no air is present, replace the bleed screw.
4. Open discharge valve and power the product, the pump should then start to run and push all
air out of the discharge system, when free of air close the discharge valve and the flow will
stop and the pump will switch off after approximately 10 seconds.
Operation
When a draw off point connected to the system is opened the pressure will start to fall and the pump will start
to pressurise the system. The pump will continue to run until demand ceases completely and flow has stopped
(< 3l/m) the pump will run for approximately 10 seconds and will then shutdown.
The pressure will now be sitting at the pump closed valve head value.
Lack of water
If the pump controller senses a lack of water the pump will be stopped automatically after approximately 10
seconds and the red failure light will be illuminated.
If the water supply comes back online and a discharge is open the pump controller will automatically reset and
start the pump.
If the water supply has been reinstated and the pump has not started automatically the reset button can be
operated which will cause the pump to run for approximately 10 seconds and prime the system, if successful the
pump will then operate normally.
Maintenance
Routine check (6 monthly intervals)
1. Check the pump produces the correct pressure.
2. Check that the pump operates without undue noise or vibration.
3. Check the break tank is clean and that the correct water level has been maintained.
4. Check that all screws are tight on electrical components.
5. Check that the earth connections are tight and making good contact.
Pump removal
Isolate power supply feeding pump set.
Isolate water inlet feeding pump set.
Open an outlet to release system pressure
Isolate the valve located on each flexible connector and remove the flexible from the pump suction and
discharge ports, the pump can now be un-bolted from the base and pulled forward.
The electrical cable can now be removed from the pump terminal box.
The new pump can now be fitted reversing the above procedure.
The break tank is constructed to have a weir slot as required by the water bylaws to prevent back flow contamination, if
the inlet ball valve or NRV suffered a catastrophic failure the overflow may not be able to keep up with the inflow in
which case excess water will be ejected through the weir slot and onto the plant room floor, if this is not acceptable then
consideration should be given to fitting the wash down set onto a tray with overflow to a drain.
Volt Free Contacts – Pump Running
Both open and closed volt free contacts are available which indicate if the pump is running. See appropriate
drawing for volt free contact wiring configurations. Rating 1A 50v maximum.
Commissioning
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Q= Flow Rate H= Total manometric head HS = Suction height Tolerance of charactic curves in compliance with EN ISO 9906 App A.
Model Power Input
Current Q
m3/h 00.1 0.3 0.6 0.9 1.2 1.5 1.8 1.9
Single-phase kW l/m 0 2 5 10 15 20 25 30 32
MBI-35M 0.37 2.5A H metres 40 38 35 29 23.5 18 12. 57 5
Dimensional drawing
RECOMMENDED
CLEARANCE FOR ACCESS
Specifi cation

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14. EC Declaration of Conformity
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14. EC Declaration of Conformity
We: Dutypoint Limited
Of: Shepherd Road, Gloucester, GL2 5EL, United Kingdom
In accordance with the following directives:
• 2006/42/EC: Machinery Directive
• 2014/30/EU: Electromagnetic Compatibility Directive
Hereby declare that the equipment:
Is in conformity with the applicable requirements of the following documents:
• EN 809:1998+A1:2009: Pumps and pump units for liquids - Common safety requirements
• EN 60204-1:2006: Safety of machinery - Electrical equipment of machines - Part 1: General requirements
• EN ISO 12100:2010: Safety of machinery - General principles for design
• EN 61000-6-2:2005: Electromagnetic compatibility (EMC) — Part 6-2: Generic standards
• EN 61000-6-4:2007: Electromagnetic compatibility (EMC) — Part 6-4: Generic standards
I hereby declare that the equipment described above has been designed to comply with the relevant sections of the
above referenced specifications. The unit complies with all applicable essential requirements of the directives.
Russell Freeman, Director
Description Dutypoint Cat 5 tank & pumpset
Product Range MiniBreak

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General fault finding guide
Fault Possible Cause Remedy
Pump fails to start Power supply failure Reinstate incoming power supply
Pump controller has no lights on Isolator fuse blown/MCB
tripped Replace fuse /reset MCB
Pump fails to stop
User point left open causing
flow to take place Close user point
Leak in system Switch unit off until leak is
repaired
Pump runs but will not make
pressure
Pump air locked Vent pump
Passing too much water Check system for leaks
Pump overheating Pump partially seized Remove pump and check for sediment
build up or foreign objects
Break tank overflowing Leaking ball valve
Non-return valve letting by
Replace ball valve seal
Pump stops and pressure
drops immediately Non-return valve letting by Replace non-return valve
in pump controller unit
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Replace/clean non-return valve in
the pump controller

Dutypoint Limited
Shepherd Road
Gloucester
GL2 5EL
United Kingdom
T: [phone]
W: www.dutypoint.com