FLOWTECH flowpress WMDA User manual

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First Publication Date: 01/09/2020
Revision:
Revision Date:
OPERATION AND
MAINTENANCE MANUAL
WMDA Single & Twin Pump
Pressurisation Units

Contents
General Information 3
Safety Information 4
Equipment Overview 8
Principal of Operation 8
Installation 9
Pipe Connections 9
Typical Installation Diagram 9
Flow Restrictors (ECO & WMDA Models Only) 9
WMDA Clearance and Connection Requirements 11
Electrical Power Supply 12
Micro Controller 13
Fault contacts 13
Commissioning 14
Pre-Commissioning Checklist 14
Controller Overview 15
Controller Programming 16
Program List 17
Hydraulic Commissioning 19
1 – Float Valve Seing 19
2 – Bleeding Pumps 19
Forcing Pumps to Run 21
3 – Initial Start-up 21
4 – Testing 22
Operation 22
Fault Codes 23
Shutdown procedure 23
Start-up Procedure 23
Maintenance 23
Visual Inspection 24
Interrogate Controller 24
Test Unit Operation 24
Check Float Valve Operation 24
Check Float Switch Operation 24
Check Break Tank Water Condition 24
Check Expansion Vessel Pre-Charge 25
Wiring diagram 26
Wiring location list 27
Wiring diagram – 3 Phase 27
Spare Parts 29
Troubleshooting 31
Warranty Details 33
Warranty - What Is Not Covered? 33
Site Visit 33
Commissioning 33
Liability 33
Service Record 33
2

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 WMDA 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 WMDA Pressurisation Units
3

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.
4

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.
WARNING! - Install an emergency stop key separately from the isolator. Rotating
shas can be hazardous.
WARNING! - This equipment has a high leakage current and must be permanently
fixed to earth.
WARNING! - Do not aach or remove wiring or connectors when the power is applied.
Do not check signals during operation. When the power is turned on and the running
command is on, the motor will start rotating. The stop key is only eective when the
function is set. If there is a power failure and an operation instruction is given the unit
may start automatically when the power is reinstated.
WARNING! - Make sure that the input voltage is correct. Be sure to install the unit in
a room that is not exposed to direct sunlight and is well ventilated.
Avoid environments which have a high ambient temperature, high humidity or
excessive condensation. Avoid dust. Corrosive gas, explosive gas, inflammable gas,
grinding-fluid mist and salt damage, etc.
WARNING! - Do not connect the power source to any terminals except power
connectors.
WARNING! - Motor control equipment and electronic controllers are connected to
hazardous line voltages. When servicing drives and electronic controllers, you may be
exposed to components at or above the line potential. Extreme care should he taken
to protect against shock. Dangerous voltage may exist aer the power light is o.
Wait more than 5 minutes aer turning o the power supply before performing
maintenance or inspection. Hazard of electric shock. Disconnect incoming power
before working on this unit.
WARNING! - The inverter should be protected separately against ground fault.
Observe the regional regulations for electrical installation!
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flowpress WMDA Pressurisation Units
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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.
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Note - It is highly recommended to have this equipment commissioned by a Flowtech approved engineer.
Any damage or loss incurred through incorrect commissioning by an unapproved engineer will not be
covered by the warranty.
If you wish for Flowtech to arrange this please contact us.
Please see the warranty section for details.
Remember to fill in details for future use for re-commission unit.
Remember – When installing a expansion vessel with the pressurisation unit make sure the cold pressure is
the same in order for the system to work eectively.
Flowpress WMDA 1-1 and Flowpress WMDA 1-2 - Under no circumstances must be used to fill a
system of any size.
flowpress WMDA Pressurisation Units
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Equipment Overview
The function of this pressurisation unit is to provide a means of automated water 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.).
This equipment is not designed to cope with sudden 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
applications.
Principal of Operation
The following schematic shows the internal arrangement of a pressurisation unit:
The pressurisation unit is fied with a break tank (1) which is filled from the mains water supply (2) via a float
operated valve (3). The break tank is fied with an overflow (4) in case the break tank overfills, and a weir
overflow (5) in case the primary overflow fails.
The pressurisation unit is connected into the heating system (6) via an isolation valve (7). The pressure sensor
(8) monitors the system pressure.
If the pressure sensor detects a drop in pressure, the pump (9a) will pump water from the break tank into the
system. Once the required pressure has been reached, the pump will stop.
On twin pump models, a second pump (9b) is provided. The two pumps will run in a duty/standby
configuration (i.e. the active pump will alternate with each pump start).
The pump(s) are fied with non-return valves (10a, 10b) to prevent backflow.
A drain valve (11) is provided for draining down the unit and for commissioning purposes.
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Installation
This pressurisation unit is not designed to be installed in an outdoor environment. The unit must be installed
in a frost free environment, away from precipitation and water sprays/jets. If there is a risk of flooding, the unit
must be installed on a raised plinth.
Please 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.
Pipe Connections
To avoid damaging the float valve, the mains water supply pipe must be flushed before connection to the
pressurisation unit.
All pipe connections must be made with appropriate jointing compound/PTFE tape. If PTFE tape is used, care
must be taken to ensure that the tape does not obstruct the orifice of the fiing.
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.
The pressurisation unit and expansion vessel should be connected to the system at the same point, to
provide a neutral pressure reading. This point of connection should be in the system return, on the suction
side of the circulation pump.
Typical Installation Diagram
Flow Restrictors (ECO & WMDA Models Only)
Pressurisation equipment fied with a plastic, side-entry torbeck valve must be fied with a filter and –
depending on the mains water pressure – a flow restrictor. Failure to do this may result in damage to the
equipment.
Two dierent flow restrictors are supplied with the equipment, both of which include an integral filter. The
selection of the appropriate flow restrictor is based on the maximum mains water pressure at the point of
installation. Please refer to the following table for selection.
flowpress WMDA Pressurisation Units
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Mains Water
Pressure
Requirement
Below 1 Bar No Restrictor. Install Filter Only
1 – 4 Bar Low Pressure Restrictor (coloured)
Above 4 Bar High Pressure Restrictor (white)
If no restrictor is required, the filter must be removed from one of the restrictors and installed on its own. The
following diagram shows how to remove the filter:
To install the flow restrictor/filter, hold it by the tab and push it into the opening of the float valve connection,
as shown in the diagram below:
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WMDA Clearance and Connection Requirements
Connection Size Notes
Mains
Water Feed
½” BSP M An isolation valve must be installed on the
mains water feed for servicing.
Break Tank
Overflow
22mm Guidance on drainage requirements should
be obtained from the local water authority.
System
Connection
½” BSP M / 15mm The pressurisation unit andexpansion vessel
should be connected to the system at the
same point.
The point of connection should be in the
system return, on the suction side of the
circulation pump.
Non-return valves, pressure reducing valves
and RPZ valves must not be used.
flowpress WMDA Pressurisation Units
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Electrical Power Supply
This equipment must be electrically isolated before removing the covers. Cables connected to the volt free
contacts may be supplied from another source and may remain live aer the unit is isolated. These must be
isolated elsewhere.
All electrical connections must be carried out by a suitably qualified and competent person.
The mains power supply to the pressurisation unit must be connected into the fused terminal block as
shown below:
On some larger models, the fused terminal block is replaced by a fused spur. If this is the case, the power
supply must be connected into the fused spur, as shown below:
It is recommended to supply power to the pressurisation unit via a lockable isolator. This should be installed
within 2m of the equipment.
This equipment can be damaged by the high voltages produced by electrical installation testing equipment.
When performing electrical installation tests, the equipment must be isolated from the supply.
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Micro Controller
Fault contacts
There are 6 volt free fault contacts which can be used for connection to a BMS system, or as a boiler
interlock. These are terminals 1-12, located on the digital controller:
With the exception of the Common Alarm, it is possible to convert all other fault contacts to normally closed.
For further information please refer to the commissioning section of this manual.
The other volt free contacts you can connect to the BMS and when the alarm is triggered this is shown on
the Pressurisation unit and the BMS. So you can indication if something is in fault with the unit.
flowpress WMDA Pressurisation Units
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Commissioning
It is highly recommended to have this equipment commissioned by a Flowtech approved engineer. Any
damage or loss incurred through incorrect commissioning by an unapproved engineer will not be covered by
the warranty.
Pre-Commissioning Checklist
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 property.
Equipment is sited in a frost free area, away from precipitation and water sprays/jets
All necessary pipe/electrical connections have been made to a satisfactory standard
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
The following conditions must be met for the pressurisation unit and heating/cooling system to function
correctly. If these conditions have not been met, it is not advisable to proceed with the commissioning
process.
The system connection has been made into the system return header/pump suction
There are no non-return valves, pressure reducing valves or RPZ valves installed between the pressurisation
unit and the heating/cooling system
The expansion vessel is pre-charged to the correct pressure (equal to fill pressure)
It is advisable to fill the heating/cooling system prior to commissioning. If this is not possible, the
pressurisation unit 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.
The heating/cooling system is filled and pressurised to the required cold fill pressure, with the water at
ambient temperature (approximately).
14

Controller Overview
The following image shows the front of the pressurisation unit digital controller. 4 buons are provided for
programming, and an LED display which shows scrolling messages.
When the controller is first powered up, it will display the controller version number. This manual relates to
controller version >8.0. If the controller is of a dierent version, there may be dierences in the menu items
available.
When in normal operation, the controller will display the current system pressure. If a fault occurs, the
controller will display a fault code and produce an audible alarm.
In normal operation, the functions of the buons are as follows:
Buon Function
Press Hold
SET -Show Current System Pressure
MUTE Mute Audible Alarm Reset Unit
+ - Enter Programming Menu
- - Enter Programming Menu
flowpress WMDA Pressurisation Units
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Controller Programming
Do not alter any seings without first understanding the implications of doing so. Incorrect seings may cause
damage to the equipment, system or property.
To enter the programming menu, hold the (+) buon until “enter code” appears on the screen, followed by
“0000” with a flashing cursor aer the first digit.
To gain access to the programming menu, one of the following codes must be entered:
Customer Code Standard set of options 2601
To enter the code, change the first digit with the (+) and (-) buons, then press (SET) to move onto the
next digit. Repeat for all digits, then once the correct code is shown on the display, press (SET) to enter the
programming menu.
Once a correct code has been entered, the first option [COLD FILL] will appear on the screen.
Once in the menu, the value of the current menu item can be changed using the (+) and (-) buons. Once
the current value has been set, pressing the (SET) buon will move on to the next option.
It is not possible to navigate backwards through the menu. To return to a previous seing in the menu, press
the (SET) buon repeatedly to scroll through to the end of the menu, and then re-enter the appropriate code.
If the controller looses power while in the programming menu, all changes made will be erased. To confirm all
changes, the end of the menu must be reached, and the “SAVING...” message must be displayed.
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Program List
The table below gives details of all menu items, in the order that they will appear:
#Menu Item Function Default
Value
1 COLD FILL
The required fill pressure, i.e. pump ‘cut-out’ pressure.
The recommended seing is 0.3 BAR above the static pressure of the system
(0.1 Bar per meter of static height).
For example, a 14m high installation will have a static pressure of 1.4 Bar, making the
recommended cold fill pressure 1.7 Bar.
It is not possible to enter a value higher than the current [HIGH SET] or lower than
the current [LOW SET] values.
1.0 Bar
2HIGH SET
The high pressure alarm seing.
If the pressure in the system reaches this value, the <HIGH PRESSURE> alarm and
common alarm will be activated.
The recommended seing is 10% below the safety valve rating.
For example, if the safety valve rating is 3 Bar, the recommended seing is 2.7Bar. It
is not possible to enter a value lower than the current [COLD FILL] value.
2.7 Bar
3LOW SET
The low pressure alarm seing.
If the pressure in the system falls below this value, the <LOW PRESSURE> alarm and
common alarm will be activated, and the pressurisation pumps will not run.
The recommended seing is 0.5 Bar below the [COLD FILL] pressure.
It is not possible to enter a value higher than the current [COLD FILL] value.
0.5 Bar
4 DIFFERENTIAL
The dierential between the ‘cut-in’ and ‘cut-out’ pressures of the pressurisation
pumps.
The cut-in pressure will be equal to the [COLD FILL] pressure, minus the dierential
pressure.
For example, if the [COLD FILL] pressure is set to 1.5 bar, and the dierential set to 0.2
Bar, the pump ‘cut-in’ pressure will be 1.3 Bar (1.5 – 0.2 = 1.3)
0.2 Bar
5 FLOOD LIMIT
The maximum continuous run time for each of the pressurisation pumps.
If a pump runs continuously for longer than this period, the pump will stop and a
<FLOOD LIMIT> alarm will be activated.
This is to prevent the unit from pumping large amounts of water in the event of a
large leak/burst pipe.
For very large systems, this may need to be increased.
The value can be changed in increments of 10 minutes, to a maximum of 990.
10 MINS
6PUMP 1
COUNT
The cumulative number of pump starts for pump 1.
This is a cumulative counter, the value of which cannot be modified. If using the
engineer’s code, the counter can be reset to zero by holding the (MUTE) buon. -
7PUMP 1 HOURS
The cumulative run time in hours for pump 1.
This is a cumulative timer, the value of which cannot be modified. If using the
engineer’s code, the counter can be reset to zero by holding the (MUTE) buon.
-
8PUMP 2
COUNT
The cumulative number of pump starts for pump 2.
This is a cumulative counter, the value of which cannot be modified. If using the
engineer’s code, the counter can be reset to zero by holding the (MUTE) buon.
-
9PUMP 2
HOURS
The cumulative run time in hours for pump 2.
This is a cumulative timer, the value of which cannot be modified. If using the
engineer’s code, the counter can be reset to zero by holding the (MUTE) buon.
-
10 ALARM
COUNT
The cumulative number of all alarm incidents.
This is a cumulative counter, the value of which cannot be modified. If using the
engineer’s code, the counter can be reset to zero by holding the (MUTE) buon.
-
flowpress WMDA Pressurisation Units
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11 POWER
INTERRUPTED
The cumulative number of power interruptions (i.e. controller turned o/power cut).
This is a cumulative counter, the value of which cannot be modified. If using the
engineer’s code, the counter can be reset to zero by holding the (MUTE) buon.
-
12 PULSE When enabled, if a pump has been inactive for 60 days, it will start and run for
2 seconds. This is to prevent the pumps from seizing. YES
13 EXCESSIVE
STA RT
When enabled, if there are more than 3 individual pump runs within an 8 hour
period, the unit will register an <EXCESSIVE DEMAND> alarm. Enabling this option
may cause false alarms on some systems.
NO
14 SERVICE
When enabled, a service reminder will be displayed aer 12 months from when the
option was enabled.
To reset the service reminder, set the value to ‘NO’ and exit the menu. Then, re-enter
the menu and set the value to ‘YES’ again.
NO
15 FILL SYSTEM
When enabled, the <LOW PRESSURE> and <FLOOD LIMIT> alarms will be disabled,
and pump 1 will run continuously for up to 24 hours until the cold fill pressure has
been reached.
Once the cold fill pressure has been reached, this option will automatically be
deactivated, and the low pressure alarm and flood limit will be reactivated. This
function is used to fill a system that is empty or at low pressure.
Care must be taken using this option as the flood limit alarm is disabled, increasing
the risk of flooding.
This option cannot be enabled on Mini pressurisation units.
NO
If using the customer code, the menu will end at this point. Aer pressing (SET) once more, the controller will
display “SAVING...” and return to normal operating mode. If using the engineer’s code, additional menu items
will be displayed.
The following seings are all pre-programmed in the factory and should not need to be modified on site. If
these seings appear to have been reset, the most likely cause is a power spike. If this problem persists, a
power filter may be required.
The following seings are for experienced engineers only. Incorrect configuration of these seings can cause
the equipment not to function correctly, and may cause damage to the equipment, system or property.
#Menu Item Function Default
Value
16 PUMPS NUMBER The number of pumps installed in the pressurisation unit.This can be set to either
1 or 2.
2
17 PUMP TYPE The type of pump installed in the pressurisation unit.
There are two options, which are as follows:
0 – Centrifugal Pump
1 – Piston Pump
0
18 PUMP SENSE Disabling this option will stop the controller from monitoring the pumps and
generating <PUMP FAIL> faults.
It is not recommended to disable this option.
YES
19 SENSOR TYPE The type of pressure sensor installed in the unit.
There are two options which are as follows:
1 – 1-6V Output, 0-10 Bar Range
2 – 1-6V Output, 0-16 Bar Range
1
20 SPC
CONTROLLER
Not required on standard Pressurisation unit NO
21 ADDITIVE Not required on standard Pressurisation unit NO
18

22 ID NUMBER A user configurable identification number.
This option does not serve any functional purpose.
01
23 RELAY
INVERSION
When enabled, all normally open fault contacts (i.e. all except the common alarm)
are converted to normally closed.
NO
24 OVERRUN Allows the pump to continue running for a set period of time aer the required
pressure has been reached.
This will prevent the pumps from ‘hunting’.
The value can be set from 0 – 10 seconds.
5
25 PRESSURE
ALARM AUTO
RESET
When enabled, the <HIGH PRESSURE> and <LOW PRESSURE> alarms will be
cleared automatically if and when the pressure returns to normal. If disabled, the
alarms must be manually reset.
YES
26 BOOST When enabled, the controller will allowing the pumps to run even if the system
pressure is zero.
NO
27 CASCADE Allows the pumps to operate in duty/assist mode.
Aer either pump starts, the other pump will start aer a set period of time. This
option can be set to OFF, or 5 – 30 seconds.
OFF
28 SOLENOID
CONTROLLER
When enabled, the “high water” input is used to trigger a top up solenoid valve
connected to the “sensor healthy” volt free contact.
This option should only be enabled on units which utilize a solenoid valve as the
means of top-up.
NO
Hydraulic Commissioning
1 – Float Valve Seing
Ensure that the break tank float valve is set to its lowest position:
If a drain valve is fied to the break tank, ensure that it is closed. Then, turn on the mains water supply and
allow the break tank to fill.
When the float valve operates for the first time, it may not close immediately, causing the break tank to overfill.
Once the internals of the valve have been fully weed this should not occur again.
2 – Bleeding Pumps
This step is only necessary for FSDA and WMDA units.
Make sure that the internal isolation valve within the pressurisation unit is closed by following the steps below.
Failure to do this may cause injury or damage to the equipment, system or property.
flowpress WMDA Pressurisation Units
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Un-screw cap turn cap push cap on socket Twist cap
Aach a length of hose to the hose tail on the drain valve and put the other end to drain. Then, using the cap
o the isolation valve, open the drain valve:
Locate the bleed screw on the pump. The following diagrams show examples of typical bleed screw
locations for most pumps:
Do not use excessive force when tightening the bleed screw as this may damage the pump casing.
If the pump has a plastic bleed screw like the one shown below, do not use excessive force or aempt to use
any tools to turn it as this may damage the pump casing.
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