FLOWTECH Flowpress Mini Single User manual

First Publication Date: 25/04/2022
Revision:
Revision Date:
Product may dier from images shown
OPERATION AND
MAINTENANCE MANUAL
Mini Single and Twin Pump
Digital Pressurisation Unit

PRODUCT DESCRIPTION
Heating and cooling system pressurisation top up unit with integral water storage tank and electric
motor driven peripheral pump, automated control system consisting of pressure transducer and
water level sensors. The tank includes an AB air gap for category 5 fluid isolation (BS EN 1717).
APPLICATION
The Flowpress Mini range is designed to provide initial system fill and intermient water top up
to compensate for intermient losses in system pressure in heating and cooling systems in
commercial or industrial applications. These could include slight leaks, air venting, etc. The units are
not designed to deal with sudden losses of system pressure due to major water losses over
extended periods. They are also not to be used for water boosting applications.
STORAGE
If this product is not to be installed immediately on receipt, ensure that it is stored in a dry, frost and
vibration free location in its original packaging.
CONTENTS Page
Checklist 5
Important Facts - read before commencing installation 6
Location 7
Key Features 9
Installation 10
Electrical Installation 14
Commissioning 18
Operation 25
Maintenance 27
Environment Protection 28
Technical Specification 29
Trouble Shooting 30
Product Log 31
Guarantee 34

Definitions of Safety Warnings and
Precautions
WARNING!
Indicates a potentially hazardous situation which, if
not avoided, can result in serious injury or death.
 CAUTION!
Indicates a potentially hazardous situation which, if
not avoided. Can result in minor to moderate injury, or
serious damage to the product.
General
Information
These instructions are to assist in the installation of the flowpress mini single and twin pump
Pressurisation Units please follow them carefully.
If, having read this Operation & Maintenance Manual, there is any doubt about any aspect of
the installation please don't hesitate to contact our technical team.
flowpress Mini Digital Pressurisation Unit

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.

CUSTOMER / CONTRACTOR
RESPONSIBILITIES
It is the responsibility of the customer and/or the contractor:
• To ensure that anyone working on the equipment is wearing all necessary protective gear
and/or clothing.
• Is aware of appropriate health & safety warnings.
• Has read the information in this section of the manual.
CAUTION! - It is strongly recommended that all electrical equipment conforms
to National Electrical Codes and local regulations. Only qualified personnel should
perform installation, alignment and maintenance. The manufacturer reserves the right
to alter the technical data in order to make improvements or update information.
CAUTION! - Failure to observe these rules will render the guarantee invalid. The same
applies to repair jobs and/or replacement. Your legal rights are not aected.
CAUTION! - The manufacturer declines all responsibility in the event of damage or
injury caused as a result of tampering with the equipment.
CAUTION! - Do not switch on/o power supply to run/stop the motor/system! Start
the unit only by using run buon or external run command.
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


We strongly recommend that commissioning and service
work is carried out by the manufacturer’s personnel or
appointed agents ~ please contact our technical sales
department for information on our commissioning and
service contract packages.

flowpress Mini Digital Pressurisation Unit

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WARNING!:
• This appliance must not be used for any other application without the wrien consent
of Flowtech Water Solutions Ltd.
• Children shall not play with the appliance. Cleaning and user maintenance shall not be
made by children.
• Children should be supervised to ensure that they do not play with the appliance.
• This product should not be used for the supply of water to more than one heating/
cooling system ata time.
• The electrical installation must be carried out in accordance with the current national
electrical regulations.
• The electrical installation must be installed by a qualified person.
• The motor is not accessible in normal operating mode. The unit must only be
operatedwith the front cover in place.
• The electrical installation must be carried out in accordance with the current national
electrical regulations and installed by a qualified person.
• In the interests of electrical safety a 30 mA residual current device (R.C.D. not
supplied) should be installed in the supply circuit. This may be part of a consumer unit
or a separate unit.
• This appliance must be earthed via the supply cord.
Please read installation details carefully as they are intended to ensure this product
provides long, trouble free service. Failure to install the unit in accordance with the
installation instructions will lead to invalidation of the warranty.

CHECKLIST
IMPORTANT: With the appliance removed from its packaging check for any damage prior to
installation. If any damage is found contact Flowtech Water Solutions Ltd within 24 hours of
receipt.
Item Description Qty Item Description Qty
A Flowpress Mini 1 F Fill valve flow restrictor, blue 1
B Front cover 1 G Rubber hose sealing washer, to
be used with item C
1
C Flexible hose, G 1/2 15mm
compression
1 H Cable tie 2
D M6 screw 1 I Instruction book 1
E Wall mounting plate 1
Note:
Your product may vary slightly from the picture above.
flowpress Mini Digital Pressurisation Unit

1 IMPORTANT FACTS: READ BEFORE COMMENCING PUMP INSTALLATION
AWater storage capacity.
1.11 The Flowpress Mini has a usable water volume of approximately 2 litres; the length
of time the Flowpress Mini takes to pressurise a system will be dependent on:-
The pressure dierential between the cold fill and set pressures and also the
refill rate of the tank
1.12 Ensure the pumps are primed as described in the priming section before
starting, to avoid causing damage to the pump. See Section 6.20 Hydraulic
commissioning.
B Water temperature
This unit is designed to pump cold water only which should not exceed the following values:
1.13 The maximum allowable water temperature is 23 ºC (see Technical Section).
1.14 The minimum allowable water temperature is 4 ºC.
C Pipework - General
1.15 Do not drill holes or put fastenings into the Flowpress Mini tank, this will cause leakage.
1.16 Secure pipework: Ensure pipework to and from pump is independently supported
& clipped to prevent forces being transferred to inlet and outlet branches of the unit. Do not
secure pipework to the Flowpress Mini, this will cause damage and possible leakage.
1.17 Flux: Solder joints must be completed and flux residues removed prior to Flowpress Mini
installation (flux damage will void any warranty).
1.18 Pipework design: Care should be taken in the design of pipework runs to minimize the
risk of air locks e.g. use drawn bends rather than 90º bends.
1.19 DO NOT introduce solder flux to flexible hose, tank, pump or any parts
manufactured from plastic.
1.20 DO NOT allow contact with oil or cellulose based paints, paint thinners or
strippers, acid based descalents or aggressive cleaning agents.
1.21 DO NOT bend the flexible hose beyond 90º. It must be installed as
detailed, DO NOT kink. See Installation Section 4.14
D Plumbing installation regulations
1.22 The plumbing installation must comply with the current water and building
regulations.
1.23 The plumbing installation must be installed by a qualified person.
E System filling
1.24 The Flowpress Mini is NOT DESIGNED TO FILL THE SYSTEM FROM EMPTY.
It is only intended to top up the system aer occassional water leakage.
Systems should be filled via a dedicated filling loop.
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2 LOCATION - GENERAL
2.11 Location: The Flowpress Mini must be located on a solid wall of sucient strength to
support the filled weight of the Flowpress Mini, close to the water source and a suitable
overflow position (see Section 10 - Technical Specification for filled weight). The
Flowpress Mini must not be installed in a lo space. It must also be considered that
the noise and vibration from the Flowpress Mini may be transmied through the structure
it is sited on. Ensure the minimum clearance requirements are followed to allow servicing
of the unit.
2.12 Access and minimum clearance requirements: For emergencies and maintenance
the Flowpress Minimust be easily accessible and have the minimum clearance
around it as laid out in Fig. 2. Additional access to the front of the unit will be required to operate
the keypad and view the display.
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2.13 Protection: The Flowpress Mini must be located in a dry, frost free area.
2.14 Ventilation: Ensure an adequate air flow to cool the Flowpress Mini.
Separate the Flowpress Mini from other appliances that generate heat.
Do not block the vent holes on the front cover.
2.15 Water retention: Site the Flowpress Mini in a location where in the unlikely event of a water leak,
any spillage is contained or routed to avoid electrics or areas sensitive to water damage. As part of
the AB airgap (CAT 5 fluid isolation) the Flowpress Mini has a weir type overflow on the front, water
will be discharged from this area in the event of the failure of the inlet valve or non-return valve.
2.16 Supply inlet pressure: The water supply inlet pressure must not exceed 7 bar.
2.17 Ambient temperature: The Flowpress Mini must be sited in a location where the
ambient temperature does not drop below 4 °C or exceed 40 °C.
2.18 Pipework: For optimum performance inlet and outlet pipework must be a minimum of 15 mm
pipe.
flowpress Mini Digital Pressurisation Unit

2.19 Static outlet pressure: The static outlet head must be 3 metres below pump
maximum cold fill pressure (vertically above the appliance).
2.20 Noise: A flexible hose is supplied as standard which will minimise the transmission of noise and
vibration from the Flowpress Mini pump to the pipework connected to the appliance outlet. However,
care must be taken when mounting the Flowpress Mini that any noise is not amplified through loose
panels or pipework.
2.21 Flexible hose: Only use the hose supplied with the Flowpress Mini.
2.22 Isolating valves: Separate system isolating valves (non-restrictive) must be fied to allow easy
service of the Flowpress Mini. Isolating valves must be mounted where specified to allow the system
isolation and removal of the Flowpress Mini if needed. See Section 4.14 for installation details.

3 KEY FEATURES
3.11 The Flowpress Mini comprises of the following main components:-
1. Moulded tank – Main body of the Flowpress Mini, comprising of an integrated water tank with
warning pipe and weir overflow and mounting the solenoid piston pumps, manifold and controller.
2. Pump assembly – One or two piston pump units mounted into the moulded tank with vibration
isolating rubber mounts.
3. Outlet manifold – Brass manifold with pressure transducer used to monitor system pressure and
connection to the pump(s)
4. Programmable controller – The designed, user set controller, allowing system set up and easy
alarm connection.
5. Wall mounting plate – Robust stainless steel wall mounting plate allowing quick, easy installation
and removal if needed.
6. Moulded cover – Moulded acrylic capped ABS cover retained to the moulded tanks with Dual
LockTM fastening system for quick and easy access
3.12 Principle of operation: The pressurisation unit consists of a break tank and one or two piston
pumps. The break tank is supplied with mains water from the le to a float valve and includes
an overflow and weir to maintain an AB air gap in the tank. The unit is connected to the heating/
chiller system via a flexible hose which can exit the unit on either the le or right. The pumps are
connected via a flexible hose to the tank via a rubber connector.
A pressure transducer monitors system pressure and if a reduction in system pressure is detected,
the controller runs the pumps until the system is re- pressurised to the required pre-set level. If the
unit only has a single pump connected it will run on a 30 minutes on/30 minutes o basis until this
level is reached, if the unit is a twin pump model the pumps run in duty standby mode (the controller
will alternate which pump starts first to even the wear on the pumps). The manifold is fied with a
non-return valve to ensure system pressure is maintained once pressurised.
flowpress Mini Digital Pressurisation Unit

4 INSTALLATION
4.11 Fill valve flow restrictor guidelines: Ensure side entry fill valve is fied with the correct filter and
flow restrictor combination (dependant on the mains water pressure) into the G ½ threaded tail as
outlined below:
Coloured insert - To be used for water pressure between 1 and 4 bar
White insert - The Flowpress Mini is pre fied with the white high pressure insert.
Change if the unit is slow to fill or the water pressure is low (below 4 bar).
4.12 Cold mains feed connection: The connection to the cold water mains inlet is made using a
suitable fiing to the G ½ male thread on the le hand side of the Flowpress Mini. When tightening
ensure the fill valve within the tank is not rotated. If the valve is rotated it may not function correctly
with the risk of flooding. (Do not overtighten).
4.13 Wall plate fixing:
1. When installing the Flowpress Mini on a wall ensure suitable fixings for the wall structure are
used and are suitable to support the unit when fully filled with water (see technical section
for filled weights). The holes in the wall plate are 6 mm in diameter, the maximum permissible
screw head height is 3 mm.
2. All holes in the wall mounting plate must have fixings used in them as per the image below,
do not leave out fastenings as this will compromise the integrity of the wall plate.
3. Ensure you have sucent room around the area you are mounting the Flowpress Mini to
allow installation, servicing and operation. See section 2.12.
4. Ensure wall plate is fixed to a flat vertical wall and the top of the plate is horizontal.

5. Retain the Flowpress Mini to the wall mounting plate using the single M6 retaining screw at
the top of the wall plate.
6. Fit the plastic cover by pressing as indicated below with the palm of the hand as until the
Dual LockTM is heard to ‘click’.
flowpress Mini Digital Pressurisation Unit

4.14 Pipework connections & guidelines:
1. Before connecting the Flowpress Mini to the system ensure that system flushing has been
performed correctly and all foreign maer, including pipe scale, has been removed.
Note: Foreign material from the system coming into contact with the expansion vessel
bladder could cause premature failure of the expansion vessel.
2. Isolating valves MUST be installed on the unit inlet and outlet, beforeconnection to the
flexible hoses to allow the unit to be isolated if required.
The isolation valve on the outlet should be of a lockshield type. See Fig. 10.
3. A drain valve must be fied on the outlet of the Flowpress Mini before the isolation valve.
See Fig. 10.
4. The connection to the heating/chilling system is also made with the supplied flexible hose
and a 15 mm compression fiing. The hose is made water tight with a sealing washer on
assembly, nip tight to 4 to 5 Nm for water tight seal. (Do not overtighten).
5. The connection to the heating/chilling system can be made to the le or right hand side by
routing the flexible hose supplied as detailed below.

6. The flexible hose and any wiring can be retained in the desired position using cable ties
and the two metal cable retention points on the top le and right of the Flowpress Mini tank.
See Figs. 8 & 9.
7. The warning pipe should be connected to a suitable drain via a tundish enabling visual
warning of an overflow condition. The overflow fiing is designed to use 19 to 23 mm
diameter plastic waste pipe or connect to G ¾ threaded pipe. Ensure there is a demountable
joint in the pipe to allow the removal of the Flowpress Mini if needed.
8. Non-return valves, pressure reducing valves and RPZ valves MUST NOT be installed
between the Flowpress Mini and the heating/cooling system. These devices will prevent the
pressure sensor from reading the system pressure and will lead to incorrect operation of the
unit.
9. The Flowpress Mini should be connected to the system return header along with the
expansion vessels as specified in BS 7074. See Fig. 10.
4.17 Vessel sizing & location:
1. System expansion vessel sizing should comply with the BS 7074 Expansion
Vessel sizing calculation.
2. The pressurisation unit and expansion vessels should be connected to the
system at the same point, to provide a neutral pressure reading.
3. A lockshield valve and drain valve should be installed at the inlet of each
expansion vessel to allow for servicing.
flowpress Mini Digital Pressurisation Unit

5 ELECTRICAL INSTALLATION / EARTHING
5.11 Regulations: The electrical installation must be carried out in accordance with the
current national electrical regulations and installed by a qualified person.
5.12 Safety: In the interests of electrical safety a 30 mA residual current device (R.C.D.
not supplied) should be installed in the supply circuit.
This may be part of a consumer unit or a separate unit.
5.13 Before starting work on the electrical supply ensure power supply is isolated.
5.14 DO NOT allow the supply cord to contact hot surfaces, including the motor shell,
pump body or pipework. The cord should be safely routed and secured by cable clips.
5.15 Adjacent pipes: Adjacent suction and delivery pipes should be fied with
earthing clamps in accordance with current regulations (Fig. 12).
5.16 Earthing: This appliance must be earthed via the supply cord.
5.17 Pipework: Copper or metallic pipework must have supplementary earth bonding where the
continuity has been broken by flexible hoses or plastic components.
5.18 Additional earthing: Certain installations may require additional earthing arrangements such as
equipotential bonding. Reference should be made to the relevant regulations concerning this subject
to ensure compliance.
5.19 Connections: The Flowpress Mini must be connected to a dedicated fused spur via a lockable
isolator to avoid authorized disconnection.
5.20 The electrical connection must be made adjacent to (not behind) the Flowpress Mini to allow
disconnection of the electrical supply should the pump module need to be removed for service or
maintenance.
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5.21 Wiring of connection unit:
WARNING: This appliance must be earthed.
The wires in the mains lead (supply cord) are coloured in accordance with the
following code:
Green and Yellow: Earth
Blue: Neutral
Brown: Live
As the colours of the wires in the mains lead of this appliance may not correspond with the coloured
markings identifying the terminals in your connection unit proceed as follows:
• The wire which is coloured green and yellow must be connected to theterminal in the
connection unit which is marked with the leer E or by theearth symbol: or coloured
green or green and yellow.
• The wire which is coloured blue must be connected to the terminal which is marked with the
leer N or coloured black.
• The wire which is coloured brown must be connected to the terminal which is marked with the
leer L or coloured red.
5.22 Boiler interlock safety function:
The Flowpress Mini is fied with a single volt free contact specifically assigned for boiler/
chiller shut down in the event that the Flowpress Mini detects system pressure above the Hi
alarm pressure or below the Lo alarm pressure.
The boiler interlock contact will be open circuit below the Lo alarm pressureand above the
Hi alarm pressure. When the system pressure is in its normal operating pressure range
(above Lo alarm pressure and below Hi alarm pressure seings) the contact is closed circuit
Always refer to the boiler/chiller manufacturer’s instructions for correct integration.
flowpress Mini Digital Pressurisation Unit

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5.23 Alarm and boiler interlock connections:
The circuit connected to the relay is limited to 5 Amps, 230 V a.c.
maximum. The Installer MUST fit a 5 Amp fuse in the circuit to the
alarm relay to protect the Flowpress Mini from damage.
For connection of output relays follow the steps and images below:
1) Remove the required green connector from the right hand side of the control board.
2) Strip 6-8 mm insulation from the end of the connection wire (Max 1.5 mm2 CSA).
3) Insert wire into connector and screw down terminal screws to secure (0.6 Nm max.).

4) Re-insert connector into the correct location on the control board and route
the cable to the back of the Flowpress Mini and secure with a cable tie to the retainer.
5.24 Fuses: The following fuse size should be used:
Model Fuse Size (AMPS)
All models 5
The supply cord and internal wiring within the terminal box are routed and secured
to ensure compliance with the electrical standard EN 60335-1. It is essential that
prior to any disturbance of this internal wiring, all cable routing and securing details
are carefully noted to ensure re-assembly to the same factory paern is always
maintained.
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5.25 Supply cord replacement:
If the supply cord is to be changed or is damaged, it must be replaced with a special cord assembly
available from Flowtech Water Solutions or one of their approved repairers.
On disassembly note the cord retention and routing system. Re-assemble to the same paern.
For information on cable connection consult the wiring diagram.
flowpress Mini Digital Pressurisation Unit

6 COMMISSIONING
6.11 Pre-commissioning checklist:
Before starting the commissioning process the following conditions must be met. If these conditions
are not adhered to, damage to the equipment, system and property may result.
• Ensure the unit is sited in a frost free area, away from precipitation and water sprays/jets.
• All necessary pipe/electrical connections should have been made to a satisfactory standard by a
qualified person.
• The temperature and pressure at the point of connection are within the operating limits of the
pressurisation unit.
• The heating/cooling system is fied with a safety valve and expansion vessel sized appropriately.
6.12 In order for the pressurisation unit and heating/cooling system to function
correctly the following conditions must be met. If these conditions have not
been met, the commissioning process should not continue.
• Ensure the system connection has been made into the heating/chiller system return header.
• Ensure Non-return valves, pressure reducing valves or RPZ valves are NOT installed between the
pressurisation unit and the heating/cooling system.
• The expansion vessel is pre-charged to the correct pressure (equal to initial system design
pressure).
6.13 Prior to commissioning, fill the heating/cooling system via a filling loop. The
Flowpress Mini is NOT designed to fill the system from empty, it is only intended to
top up the system aer occasional water leakage.
• Ensure the heating/cooling system is filled and pressurised to the required cold fill pressure, with
the water at approximately ambient temperature.
• Ensure the system is dosed with a suitable corrosion inhibitor. Note the Flowpress Mini is not
designed for dosing chemicals into the system, this mustbe done via other means.
6.14 Expansion vessel seing:
• To set or check the expansion vessel charge pressure the lock-shield valve between the
Flowpress Mini and the vessel must be closed and the vessel drained using the drain valve.
• A suitable gauge should be used to check the charge pressure.
• If the charge pressure is too high it can be reduced by releasing air from the vessel pre-charge
valve or by using a pressure gauge with an integral air release valve.
• If the charge pressure is too low a small increase can be provided using a car foot pump
otherwise an oil free compressor or nitrogen bole is recommended.
• When the correct pressure is set the Schrader valve protective cap must be replaced.
• Check the integrity of the pipe-work. Ensure the lock-shield valve between the system and the
expansion vessel is open and the drain valve is closed.