FLOWTECH flowpress User manual

1
First Publication Date: 01/04/2023
Revision: 1
Revision Date:
OPERATION AND
MAINTENANCE MANUAL
Direct Pressurisation Unit
flow press
©

Flowtech Water Solutions are experts in water services and water booster sets. We have
continuosly supplied a wide range of both standard and custom products since being founded in
1996.
Now established as a major force in the market, partnering nationally with local councils, design
engineers, mechanical contractors, developers, and end users.
Our company has a strong customer service ethos that has been shown in previous projects and
the need to respond quickly to whatever our client’s requirements are. Flowtech Water Solutions will
handle projects from initial enquiry/tender to design and through to order placement and on-site
commissioning followed by an annual maintenance contract if required.
Flowcare
Flowtech operate a network of Service Engineers located throughout the UK. The distribution of
engineers means that in the majority of cases we are less than 4 hours away from aending a
customer call out.
We place great emphasis on providing technical back up to support our Service Engineers and
in resolving some dicult operational and technical issues. We pride ourselves on completing a
project on time, within budget and never leaving a problem unresolved, or a customer waiting. This
quality of service has made us the first choice for our customers.
Congratulations on purchasing your new Flowpress Pressurisation Unit. The following information is
to assist you and to ensure your new unit is installed, operated and maintained correctly to comply
with the manufacturer’s warranty and to give a long working life to provide you with an uninterrupted,
clean and safe water supply.
These instructions are to assist in the installation, Operation and Maintenance of a Flowpress Direct
Pressurisation Unit. Please follow them carefully.
If, having read this Operation & Maintenance Manual, there is any doubt about any aspect of the
equipment, installation or system please don't hesitate to contact our team on the contact details
below.
Flowcare (Service and Technical) Flowtech (Sales)
0333 200 1813 0333 200 1756
[e-mail] [e-mail]
2

Safety
Information
It is essential that correct and safe working practices are adhered to at all times when installing, operating
and/or maintaining any piece of equipment. Always consult safety data sheets, operating and maintenance
manuals, Health & Safety legislation and recommendations and specific requirements of any equipment
manufacturer, site controller, building manager or any other persons or organisation relating to the
procurement, installation, operation and/or maintenance of any piece of equipment associated or in
conjunction with any product provided by flowech Water Solutions.
This document is intended for ALL installers, operators, users and persons carrying out maintenance of this
equipment and must be kept with the equipment, for the life of the equipment and made available to all
persons at all times. Prior to carrying out any work associated with the set it is essential that the following
sheets are read, fully understood and adhered to at all times.
Equipment must only be installed, operated, used, and/or maintained by a competent person. A competent
person is someone who is technically competent and familiar with all safety practices and all of the hazards
involved.
Any damage caused to any equipment by misapplication, mishandling or misuse could lead to risk of
Electrocution, Burns, Fire, Flooding, death or injury to people and/or damage to property dependent upon
the circumstances involved. flowech Water Solutions accepts no responsibility or liability for any damage,
losses, injury, fatalities or consequences of any kind due to misapplication, mishandling or misuse of any
equipment, or as a result of failure to comply with this manual.
Failure to install, operate, use or maintain the equipment in accordance with the information contained within
this document could cause damage to the equipment and any other equipment subsequently connected
to it, invalidating any warranties provided by flowech Water Solutions to the buyer.
Safety Warnings &
Precautions
These instructions should be read and clearly understood before working on the system. Please read this
manual carefully and all of the warning signs aached before installing or operating the equipment keep
this manual handy for your reference. This equipment should be installed, adjusted and serviced by trained
and qualified personnel. Failure to observe this precaution could result in bodily injury.
Customer / Contractor
RESPONSIBILITIES
It is the responsibility of the customer and/or the contractor:
• To ensure that anyone working on the equipment is competent and trained to carry out work on this
equipment and is wearing all necessary protective gear and/or clothing. During maintenance operations
and in any case when the machine is running in various modes, including its normal operating mode,
avoid any clothing or accessories that may get entangled in the moving parts of the machine.
• Is aware of appropriate health & safety warnings.
• Has read the information in this section of the manual.
flowpress Direct O&M Manual 3

Warranty
The Flowtech warranty on equipment supplied covers manufacturing defects, under our standard
terms and conditions of sale, where items with a proven manufacturing defect are replaced at the
point of sale.
In some circumstances it will be appropriate for an engineer visit to review or inspect the product
under warranty. For all engineer visits, requested under alleged warranty, a purchase order is required
to cover work and time that is deemed to be outside of the warranty agreement. If no recognised
commissioning, by a Qualified Person, has taken place, then the warranty may be null and void. If the
unit is identified with a manufacturing defect within the warranty period, then no charge is made for
correcting the defect.
Flowtech reserve the right to supply a replacement product in lieu of an engineer visit. Removal and
reinstallation costs, along with consequential losses are not covered by this warranty agreement.
Flowtech equipment is manufactured to order and is marked with a unique serial number, allowing
traceability to both individual model configurations and the date of manufacture. The warranty, against
manufacturing defects, is for 30 months from date of manufacture or 2 years from date of confirmed
commissioning, whichever is sooner.
For the warranty to be valid it is also taken that there is an appropriate safety valve on the wider
system protecting the equipment. That the equipment is undamaged at the time of installation. That
the equipment is not exposed to adverse environmental conditions. That the equipment is stored and
installed in a frost-free area. That these operating and maintenance instructions are followed. That the
equipment is used for the purpose for which it was designed.
An extended warranty is available by purchasing a separate Flowtech service agreement.
For general Terms and Conditions of this sale, see Terms and Conditions on the Flowtech website.
It is a requirement of your local water authority to disclose the installation location.
To make this easy, you must register your product, activate your warranty and register with your
local water authority.
Failing to disclose the installation location of this product with your local water authority
will lead to invalidation of the Flowtech warranty described above.
Liability
All technical specifications, data and instructions for executable actions and contained herein are
correct at time of publication. This information is the result of our current findings and experience
to the best of our knowledge. We reserve the right to make technical changes subject to the future
development of the Flowtech product referred to in this publication. Hence no rights may be derived
from technical data, descriptions and illustrations. Technical pictures, drawings and graphs do not
necessarily correspond to the actual assemblies or parts as delivered. Drawings and pictures are not
to scale and contain symbols for simplification.
Copyright
All documentation is protected by copyright. Distribution or other forms of reproduction of documents,
even extracts, exploitation or notification of the contents hereof is not permied, where not otherwise
specified. Infringements are liable to prosecution and payment of compensation. We reserve the right
to exercise all intellectual property rights.
4

About this manual
The following pages list the information, specifications, measures and technical data that allow the
relevant personnel to use this product safely and for the intended purpose.
Responsible persons or those engaged by them carrying out the required services must read this
manual aentively and understand it.
Such services include:
Storage, transportation, installation, electrical installation, commissioning and re-starting, operation,
maintenance, inspection, repair and dismantling.
Where the product is to be used in plants/facilities which are not required to comply with local or
harmonised regulations, this document is purely for informative and reference purposes.
As this unit may be subject to unlimited inspection from the local water authority at all times, this
manual must be kept in the immediate vicinity of the installed unit, at least within the confines of the
operations room. Installation classification 2 according to the Annex R of 60730-1
Disregard or lack of aention to the information and measures contained in this manual may pose
a hazard to people, animals, the environment and tangible assets. Failure to observe the safety
regulations and the neglect of other safety measures may lead to significant consequiential loss.
Conventions symbols in this manual
WARNING – Important safety related information intended to prevent injury and/or damage
to the equipment, system or property.
IMPORTANT - Important information intended to ensure that the equipment functions
correctly
USEFUL – Useful information which may be helpful, but is not necessarily required for the unit
to function correctly.
Typography
This manual makes use of dierent typography to identify dierent types of information.
Italics Key words and phrases
(Round Brackets) Used to identify a buon on the digital controller
[Square Brackets] A parameter on the digital controller
<Inequality symbols> A message/fault code displayed on the digital controller
Safety
This equipment is intended to fill and/or top-up sealed water-based heating and cooling systems,
in which temperature-induced changes in the volume of the system water (the heat transferring
agent) is governed by a separate expansion vessel and safety relief valve.
This product is suitable and appropriate for the operation in heat generating systems according to
BS7074, BSEN 12828, BSEN 12952 and BSEN 12953.
The Principal / Operator, will need to consult with a local authorities on any additional safety
measures that are required.
flowpress Direct O&M Manual 5

Incoming Goods
The items delivered must be compared against the items listed on the delivery note and inspected for
conformity. If not in line with the documentation or if the delivery is incorrect in another way, the product
must not be used. The goods may also be warehoused in their packaging. Once it has been removed
from its packaging, the equipment must be put in position, observing standard safety procedures.
Always check the unit for damage and appropriate markings according to Appendix 2: Markings in
this manual.
Operations Location
The responsible person carries the responsibility over the designated plant room that meets all the
requirements stated above.
Definition:
Room which meets the applicable European and local regulations, standards and relevant technical
rules and guidelines of the professional associations for this field of application. For the use of the
Flowpress Direct as prescribed in this manual these rooms generally contain equipment for thermal
generation and distribution, water heating/cooling and top-up, power source and distribution, such as
measuring, control engineering, control technology and IT.
Access for unqualified and untrained persons must be restricted or forbidden
Unit Internal access
The unit internals can be accessed for service or repair, by a Qualified Person. The unit can only be
accessed by using a specialised tool. Any aempts to access the internals of the unit without the correct
equipment will invalidate the Flowtech Warranty and will be classified as use in an improper manner,
according to our Terms and Conditions.
Electrical
Electrical equipment inspections, routine inspection
Without prejudice to the considerations of the insurer/Operator, it is recommended that the electrical
equipment of the Flowpress Direct be inspected and documented together with the heating/cooling unit
no less than every 18 months (see also DIN EN 60204-1 2007).
Emergency STOP / Emergency OFF
To conform with directive 2006/42/EG an EMERGENCY-STOP facility is to be made available during
installation.
Preferably, use a grounded wall socket for the power supply to the unit. The socket must stay accessible.
If the unit is directly connected to the power supply, make sure the power supply line is provided with:
• a high-sensitivity dierential switch (30mA) (residual current device RCD)
• a mains isolator switch with a contact gap of at least 3 mm.
When additional security measures with EMERGENCY-OFF devices are required according to the design
and operation of the heat generator, these are to be installed on-site.
Obvious Misuse
• Operation at incorrect voltage and/or frequency.
• Use in inappropriate system designs.
• Use of unpermied installation materials.
6

Other Hazards
• Overload of construction parts by the presence of unpredictable extreme values.
• Operational continuity at risk in the case of changed, non-permissible ambient conditions.
• Operational continuity at risk in the case of safety-control parts being taken out of service or
malfunctioning.
Non-permied Sta Qualification
Definitions:
• Operator: A person or legal entity who is the owner of the product and uses the aforementioned
product, or is nominated to use it, under the terms of a contractual agreement.
• Principal: The legally and commercially responsible party in the execution of construction projects.
Legally and commercially liable client in the commission of building projects.
• Responsible person: The representative appointed to act by the main contractor or operator.
• Qualified person (QP): A Qualified Person must have undergone advanced technical training
and have sucient experience to independently perform complicated tasks or work associated
with residual hazards. Such experience will in each instance refer to a specific specialism, e.g.
maintenance, working on electrical systems, systems mechanic for wholesome water (potable),
sealed heating/cooling and air conditioning technology. In preparation for impending work, a Qualified
Person must be able to correctly estimate the feasibility, risks and hazards as well as the equipment
required. A Qualified Person is expected to be able to understand complex, minimally prepared plans
and descriptions, and to obtain missing and required detailed information by suitable means.
A competent person is capable of carrying out their duties in an appropriate manner with sucient
expertise in the particular type of system. They should be suitably qualified and/or experienced in closed
systems and be able to demonstrate such on demand. They should have knowledge of the required
safety systems.
In general terms, the competent person should have:
• colleagues with practical and theoretical knowledge and actual experience of the relevant systems;
• access to specialist services, advice and manufacturers' data;
• eective support and professional expertise within their organisation; and
• proper standards of professional integrity.
flowpress Direct O&M Manual 7

Required service Professional group
example
Relevant qualifications
example
Storage transportation Logistics, transport,
warehousing
Transport and warehousing
specialist
Assembly, dissassembly, repairs, maintance.
Re- commissioning aer adding or changing
components. Inspection.
Installation and building
services
HVAC specialist
First commissioning of configured control
unit (generic), re-commissioning aer power
cut, operation (work on the terminal and
Flextronic control unit)
People with operations room
clearance with knowledge
gleaned from this guide.
Electrical installation Electrical engineering Specialist in electrical
engineering/ installation
Initial and re-inspection of electrical systems Qualified person (QP) with
certfication in Electrical
engineering.
Inspection before commissioning and
re-inspection of pressure equipment
Installation and building
services engineering
performed in the context of
technical inspection
Qualified person (QP)
Product Description
The Flowpress Direct is the most compact, wall-mounted, pressurisation unit in the portfolio. The
function of this pressurisation unit is to provide a means of automated water filling and top-up to
sealed heating and cooling systems. The equipment is designed to provide periodic water top-up to
compensate for minor losses in system pressure (e.g. slow leaks, air venting, etc.).
The Flowpress Direct is the latest in pumpless digital pressurisation technology for light commercial and
residential buildings. It’s a slim, wall-mounted pumpless top-up pressurisation unit, with a top-up flow
rate of up to 14 l/min depending on the mains or boosted mains, water pressure. It is designed to be
connected directly to a building’s incoming water supply using the included flexible hose. It is there to fill
and maintain the pressure of a heating or chilled water system without the need for a pump.
This equipment is not designed to cope with sudden, substantial, losses of system pressure (e.g.
manual draining) or major water losses (e.g. large leaks). The equipment is also not intended to be used
for water boosting (potable) applications.
Operating Principle
The following schematic shows the internal arrangement of the pressurisation unit:
1. Water enters the unit via the mains connection, isolation valve (IV) and through the back-flow
preventor.
2. Pressure sensors (P1 & P2) monitor the pressure in the mains water supply system and in the
heating or cooling system.
3. A solenoid inlet valve (S1) and a drain valve (S2) are activated when topping up is required.
4. The automatic air-vent (AAV) removes free air before it enters the sealed heating system.
5. Once the top up cycle is finished, the remaining water in the unit is removed by opening of the drain
valve (S2), to prevent legionella build up.
6. A filter on the mains supply to the unit is already installed. Where debris from the supply pipe is
expected, it is recommended to install an additional filter or Y-strainer on the mains water supply to
the unit.
8

Icon Description
IV Isolation valve
P1 Pressure sensor to
measure mains water
pressure
P2 Pressure sensor to
measure heating system
pressure
S1 Valve to control mains
water inlet, normally
closed (NC)
S2 Valve to control drain
outlet, normally open
(NO)
AAV Automatic float air vent
Y Tundish
Technical Datasheet
General
Size of the unit (Height x Width x Depth) 359mm x 225mm x 141mm
Dry weight 4 kg
Cold water inlet 15mm Compression
System outlet 15mm Compression
Drain (via Tundish) 22mm Compression &
32mm PP push fit &
32mm PP solvent weld
Maximum inlet pressure 6 Bar
Maximum cold fill pressure 5.7 Bar
Maximum design pressure PN10
Nominal flow rate (at 2 Bar) 14l/min
Supply voltage 110/230 Volt
Frequency 50 Hz
Full load current 1 Amp
Fuse rating 5 Amp
Maximum load BMS relays 5 Amp
Protection class IP44
Power consumption (Standby) 2 W
Power consumption (Filling) 19,4 W
Maximum temperature at inlet: 45°C
Maximum temperature at outlet: 90°C
Ambient temperature range: 5°C / 45°C
Temperature 5°C / 45°C
Humidity 60….70% relative humidity, non-considering
Keep the unit in a locked, frost free and dry area, protect the unit from solar & thermal radiation,
vibration, from electrically conductive gases, explosive gas mixtures and aggressive atmosphere.
flowpress Direct O&M Manual 9

Installation Requirements
The Flowpress Direct is a wall mounted unit and should be installed at a suitable eye level, where the
screen is easy to read and maintenance remains practical and possible. The wall of the set-up location
for the Flowpress Direct must be such that stability is guaranteed and maintained.
For general assembly instructions and commissioning steps of the product.
All Flowpress products should be installed by a Qualified Person with regard to the relevant requirements
described in section 5.4: ''Sta qualification''. Check that the installation and other actions prior to use
have been carried out in full (e.g. power supply available and connected, functioning or active fuses,
seal tightness of the equipment). Any damage or loss incurred through incorrect commissioning by an
unapproved engineer will not be covered by the warranty.
The following conditions must be met before starting the commissioning process. Failure to meet
these conditions may result in injury or damage to the equipment, system and/ or property.
Conditions
1. This equipment is designed to be installed in an indoor environment. The unit must be
installed in a frost free environment, away from precipitation and water sprays/jets.
2. The heating/cooling system is fied with an appropriate safety valve and expansion vessel.
3. Non-return valves, pressure reducing valves and RPZ valves must not be installed between
the pressurisation unit and the heating/cooling system. These devices will prevent the
pressure sensor from reading the system pressure.
4. It is essential to have the pressurisation unit and the associated system expansion vessel
connected to the system at the same point, to provide a neutral pressure reading. This
point of connection should be in the system return header, on the suction side of the
circulation pump.
5. All necessary pipe/electrical connections have been made to a local standard.
6. Refer to the appropriate datasheet for the maximum working pressure and temperature of
the pressurisation unit. The conditions at the point of connection to the system must not
exceed these values.
7. The expansion vessel is pre-charged to the correct pressure (equal to Flowpress Direct fill
set-pressure))
It is advisable to fill the heating/cooling system prior to commissioning. If this is not possible, the
Flowpress Direct can be used to fill the system aer commissioning. Depending on the size of the
system, this may take a considerable amount of time.
A mains cable is provided with the unit. A mains cable length of 1,5 meters may not be exceeded if
replacement of a cable is necessary.
Two WRAS approved flexible hoses with isolation valves are provided with the unit. It is essential for the
maintenance of this unit to use hoses provided.
10

Installation Diagram
flowpress Direct O&M Manual 11

Clearance Requirements
Clearance guidelines for service and repair
Hydraulic Connections
From the “Manual-mode” in the controller menu, a testing routine can be triggered to check if the device
is set up correctly and working accordingly. Each actuator (valve) can be operated separately with a
maximum run-time of 2 minutes.
The mains water and sealed system connection to the unit must be made using the flexible hoses with
isolation valves provided.
The drain always has to be connected. There are 3 options to connect the drain:
• With a 22mm copper pipe
The plastic nut provided will secure the pipe in place and create a sealed connection
• With a 32mm push- fit PP pipe
The O-ring provided on the tundish will create a sealed connection with the pipe if positioned in the
lower groove on the tundish, see image below.
• With a 32mm solvent weld PP pipe
The O-ring provided on the tundish will create a sealed connection with the pipe if positioned in the
higher groove on the tundish, see image below.
Drain Connection Options
12

Controller
A clarification of menu icons, function and location can be found in Appendix 1: Icon library.
Identification Description Pinout
A Power indicator (orange=power)
B Status indicator (green=ok automat running)
C Bluetooth Not Availible
D Error/alarm (red=alarm/error active)
E Confirm buon
F Return buon
G Navigation buons
H Screen on/of (hold 8 sec for powerdown)
I Not Availible
J USB-A soware update + logging
CAN Not Availible
RS485 Modbus/Bacnet/HFC over RS485 1 B +
2 B -
3 GND
F1 Fuse 1 (P31&P32) 5x20 5A
F2 Fuse 2 (P33&P35) 5x20 10AT
F3 Fuse 2 (P34&P36) 5x20 10AT
B Mains power connector 1 L
2 N
3 PE
L Mains grommet
P11 Not Availible
flowpress Direct O&M Manual 13

Identification Description Pinout
P15 SELV, System pressure 0-5V 1 + VDC
3 signal
3 GND
P16 SELV, Inlet pressure 0-5V 1 + VDC
3 signal
3 GND
P17 Not available
P18 Not available
P19 Not available
P20 Not available
P21 Not available
P22 Not available
P23 Not available
P24 Not available
P25 Not available
P26 Not available
P27 Fault contact, VFC 1 1 NO
2 COM
3 NC
P28 Not available
P29 Not available
P30 Not available
P31 Power, V3 inlet solenoid valve 1 PE
2 L
3 N
P32 Not available
P33 Not available
P34 Not available
P35 Power, V1 Drain valve 1 PE
2 L
3N
P36 Not available
14

Connectivity Options
Connectivity Options Designated Use
Standard USB (USB-A) For saving the oline log and the configuration
parameters. The second option for this port
is to update the firmware of the controller (to
download a new control SW)
RS-485 The primary designation is to connect the
Flowpress Direct to internet (via Gateway and
HFC protocol).
Alternatively – BMS via Modbus Alternatively –
BMS via bacnet
(only one out of three options at the same time)
Electrical Installation
The provision of power supply, (protective) ground wire connection and line protection must be made
in accordance with the local regulations (responsible power company) and the applicable National
standards. The required electrical information can be found on the product label at the side of the
Flowpress Direct, the terminal plan (labelling) and in “Appendix 3.” Terminal plan. The Flowpress Direct
has been supplied with the correct power supply cable and it is highly recommended to use the cable
provided.
All electrical connections should be carried out by a qualified and authorized electrician in
accordance with the latest issue of the IET regulations. The equipment must be earthed. It is strongly
recommended that a high sensitivity dierential switch (30mA) (residual current device RCD) is fied on
the incoming electrical supply.
Do not remove covers without first ensuring that the electrical supply is suitably isolated and
cannot be switched on.
Do not aempt to supply electricity to the equipment unless the protective covers are correctly
fied and held securely in place.
Cables connected to the controller volt free contacts may be supplied from another source and
may remain live aer the unit is isolated. These must be isolated elsewhere. The user or the installer 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 qualified electrician
The Flowtech equipment must be connected to a mains isolator switch with a contact gap of at least 3
m. It is recommended the switch should be installed within 2m of the equipment.
flowpress Direct O&M Manual 15

Alarm Installation
The installation, data processing and commissioning must
be performed by a Qualified Person. The appropriate national
standards, regulations and rules must be followed.
• Additional cables are not included or supplied by Flowtech
• Flowtech recommends the use of twisted single pair shielded
cable.
• The termination resistor has a value of 120 Ohm.
• The maximum permissible length of cables is 30m.
If controller powered down, than the is P27 normally open
If controller is powered up, than the is P27 normally closed
If controller is in error, than the is P27 normally open.
For additional information on how to connect the the Flowpress
Direct to the internet or BMS, see the connectivity guide.
16

Operation
Below is an overview of how the seings on a pressurisation unit must be considered for normal top-
up operation. Close, conflicting or overlapping seings will cause system instability and nuisance alarm
conditions. If in any doubt please seek advice from a Sealed System professional.
A typical venting allowance is 0.3 bar, added to the static height to give the cold fill pressure.
The Dierential seing represents the allowable pressure loss before the pump activates and restores
the cold fill pressure. The Dierential seing must not be greater than the system venting allowance.
flowpress Direct O&M Manual 17

This will ensure that the system remains fully flooded during normal topup conditions.
Once commissioned, the pressurisation unit should operate without any user intervention.
Under normal operating conditions, the display will show the current system pressure in Bar.
For an overview of the main operation screens, see image below.
A clarification of menu icons, function and location can be found in Appendix 1: Icon library
Home screen
While the unit is filling, the display will show the current status of the unit and its actuators (valves). The
system to which the unit is connected, is monitored and the icon in the top right corner signifies its
status.
Idle screen
When the unit is not active for a period of 30 seconds (standby), the display will show the total top up
amount in litres over a period of 28 days and the date of the next service.
Maintenance screen
Tapping the right arrow buon “>” will show additional parameters like the set pressure, mains pressure,
legionella seing & duration and controller serial number.
Warning screen
Shows every active warning since the last time the warning screen has been cleared.
If the pressurisation unit is showing a fault code on the Home screen display, tapping the le arrow
buon “<” will reveal the active fault message(s). The user can see an extended explanation of the fault
and by pressing the tick-buon “” whilst on the selected fault.
To resolve the fault, simply click the tick-buon “” again and the fault will be cleared.
To exit the extended explanation screen without resolving the fault, press the return- buon " ".
When the fault condition is not resolved it will return on the display. Please use the troubleshooting
guide in Appendix 4 to resolve each fault accordingly.
18

Shut down procedure
The pressurisation unit must be shut-down during any of the following scenarios:
• Work is being carried out on the system.
• Work is being carried out on the pressurisation unit
• The heating/cooling system is being flushed
To shut down the pressurisation unit, please follow the steps below:
1. Isolate the electrical power supply to the pressurisation unit
2. Isolate the mains water supply from the pressurisation unit with the isolation valve in the hose
3. Isolate the pressurisation unit from the system using the isolation valve in the hose
If it is anticipated that the unit will be out of commission for more than 24 hours, it is advisable to
disconnect the hoses from the unit.
Restarting
Aer long periods of downtime
If this downtime was planned or scheduled, turn OFF the control unit and close o the isolating valve
to the system and the isolating valve to the top-up line. Aer that, decompress and then drain the
water area.
We recommend you carry out maintenance before restarting (see chapter 10: Maintenance).
Use the commissioning records for restarting and check especially for changes that can lead to other
operating conditions of the expansion automat (e.g. system pressure).
If the power supply has failed
The controller display will show a system reboot warning, this can be removed in the warning screen.
The target parameters and default seings for pressure and top-up will remain unchanged, meaning
automatic operation will resume automatically when power is restored (control unit ON). Extraordinary
system operating conditions (e.g. cooling to below the default seing) may fall outside the permied
seings of the device (and expansion vessel of the system).
Please ensure that when the system cools down or warms up, the minimum or maximum system
pressure does not exceed or fall below the permied operating pressure.
Check the Flowpress Direct operation once power supply has been restored and, if necessary, set the
actual date and time values (overview menu options).
Maintenance
Electrical supply must be disconnected prior to conducting any maintenance.
Please refer to chapter
9.1 “Shut-down procedure” and follow the steps.
It is forbidden to alter or use non-original components or replacement parts without authorisation.
Such acts may result in serious personal injury and endanger operational safety. They will also render
any claim for damages against product liability void.
It is recommended to contact Flowtech Service (See Appendix 4: Contact) for carrying out these
services.
flowpress Direct O&M Manual 19

Maintenance and Repairs
Maintenance and repairs may only be carried out when the system is shut down or if the Flowpress
Direct is not required to monitor or operate. The power supply must remain o for the period of the
work.
The pressurisation equipment must be taken out of service and guarded against unintentional re-
starting until the maintenance work is finished. Note that the safety circuits and data transmissions
made whilst shuing down could trigger the safety chain or lead to false information to a connected
BMS. Existing instructions for the heating or cooling unit as a whole must be observed. To stop
hydraulic components, block the relevant sections and drain them using the available drain
connections, and relieve the pressure.
When restarting the system some logical errors may arouse that are self-acknowledging or required to
be manually acknowledged.
Improper use of the advanced features can result in a non-functional device. Only service engineers
should use the advanced features.
Maintenance Intervals
Due to variations in operating conditions, and the varying loads placed on pressurisation units, it is
not feasible to provide accurate predictions of component lifespan. The most eective method of
maintenance is to inspect the pressurisation unit for early signs of component failure and take action
accordingly.
Maintenance has to be executed by a Qualified Person, the maintenance protocol should be followed.
An digital service log can be filled out to store the information at time of Maintenance.
The following maintenance procedures should be performed at least once a year:
Maintenance Procedure
Maintenance procedure
1. Interrogate the controller alarm log to help direct the inspection. The log will show any
warnings or alarms that have occurred since first commissioning the unit.
2. Follow chapter 9.1: '' Shut down procedure'', then continue with the steps below.
3. Depressurise and drain the Flowpress Direct G4 unit.
4. Check the filter on the mains inlet for any debris. If needed, remove the filter with pliers,
rinse under the tap and place it back into the mains inlet side before continuing with the
following steps.
5. Check the valves and connections for any traces of leakage or malfunction.
6. Check the connections for any signs of corrosion.
7. Check the wiring for any signs of wear and tear. Signs of overheating, loose wiring, etc.
Any signs of damage requires a replacement of the wiring.
8. Follow the startup procedure in chapter 9.2: ''Restarting''
9. Check the controller for warnings and alarms and clear all before finishing maintenance.
10 Reset the maintenance date on the controller. To do so, Log in on the controller and clear
the maintenance warning in the warning screen. The maintenance date will then auto-
matically switch to the next required maintenance date.
5 Years aer first commissioning, the Flowpress Direct G4 will need an annual service to reset the
reminders for the annual service. It is the end users responsibility to book the annual service to reset
the controller.
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