Global Water Solutions SuperFlow Series User manual

SuperFlow™ Series
Global Water Solutions Ltd.
INSTALLATION AND OPERATING MANUAL
EN
Installed on __________ by ________________
PLEASE READ ALL INSTRUCTIONS BEFORE INSTALLING YOUR NEW
GLOBAL WATER SOLUTIONS (GWS) TANK
CAUTIONS AND WARNINGS
⚠CAUTION: To prevent personal injury, ensure all water pressure is released from the pressure
system prior to work being performed.Ensure pumps are disconnected and/or electrically isolated.
⚠WARNING: It is strongly recommended that the system is protected by a suitable pressure relief
valve set at or below the maximum tank pressure rating. Failure to install a relief valve may result
in tank explosion in the event of a system malfunction or over pressurization,resulting in property
damage, serious personal injury or death.
⚠WARNING: If the pressure tank leaks or shows signs of corrosion or damage do not use it.
⚠WARNING: If the expansion tank is heavier than 30 kgs, proper equipment such as lifting crane
etc. should be used in order to avoid damage to the tank and personnel.
These instructions have been prepared to acquaint you with the correct method of installing and
operating your GWS pressure tank. We urge you to study this document carefully and follow all of
the recommendations. In the event of installation difculties or the need for further advice, you should
contact the dealer from whom you purchased the system or the nearest GWS sales ofce.
• SuperFlow™ Series tanks are designed for use in well water, potable water booster systems (Refer
to Sec. 1 for installation details) and for use in non-potable closed loop hydronic or solar water
heating systems (Refer to Sec. 2 for installation details) as well as for use in open loop potable water
heating applications. (Refer to Sec. 2 for installation details.)
• See tank data label for maximum working pressure and maximum temperature.
• Be sure to protect tank, piping and all system components from freezing temperatures.
• The manufacturer is not responsible for any water damage in connection with this pressure tank.
INSTALLATION MUST BE IN ACCORDANCE WITH LOCAL AND STATE PLUMBING CODES.
www.globalwatersolutions.com
Revision: M-BT3-2021-r1.00

1. Well Water and Booster System Tank Installation
1.1 Proper GWS Tank Location
In order to ensure your tank provides its maximum service life it should always be installed in a
covered, dry position. The tank should not be allowed to rub against any surrounding hard surfaces,
such as walls etc.
1.2 System Connection
1. Place the GWS tank in its nal desired location.
2. Level as necessary. All vertical and horizontal model tanks should be placed on a rm base. If
vibration is likely to occur in the vicinity the tank should be mounted on a resilient mounting.
3. Connect the tank to the pump supply line with a short pipe to eliminate unnecessary friction loss.
4. All piping should be in accordance with prevailing local codes and standards.
5. Tanks mounted on booster sets should be strapped down for shipment.
1.3 Adjusting Precharge Pressure
Correct precharge is required for proper tank performance.
1. For tanks installed with a pressure switch controlled pump with a differential pressure set up to 2
bar (30 psi), the precharge should be set to 0.2 bar (2 psi) below the cut-in pressure.
2. For tanks installed with a pump controlled by a pressure switch with a pressure differential greater
than 2 bar (30 psi), electronic controls or variable speed controls, the precharge should be set to
65% of the cut-out or maximum system pressure.
3. For tanks installed on mains’ pressure, the tank precharge should be set equal to the mains’
pressure. For mains’ pressure exceeding 6 bar (88 psi), a suitable pressure regulator should be
installed.
4. Precharge of SuperFlow™ tanks should be checked every 3 months.
For correct operation, pressure tanks should be precharged as follows:
1. Turn off the pump, disconnect the tank from the system and completely drain all water inside the
tank to avoid water pressure affecting precharge readings.
2. Using a suitable pressure gauge, check the precharge pressure of the tank.
3. Release or add air as necessary to adjust to the required precharge pressure.
4. Replace protective air valve cap and seal with the air valve label, if provided.This will enable you to
determine if the valve has been tampered with in case of future service calls.
⚠CAUTION: Never over-charge the tank and precharge the tank with air at ambient temperature
only!
If the tank is to be precharged over 4 bar (58 psi):
1. Adjust the precharge of the tank to 4 bar (58 psi).
2. Install the tank into the system.
3. Fill the system with water to equalise the system and precharge pressure at 4 bar (58 psi).
4. Increase precharge pressure in maximum 3 bar (44 psi) steps and afterwards adjust the system
pressure to the new precharge pressure by lling water into the system.
5. Repeat steps 3 and 4 until the required precharge is reached.
Emptying a tank that has a precharge over 4 bar (58 psi):
1. Make sure there is some water in the tank.
2. Isolate the tank from the system (close isolation valve).
3. Make sure no additional water can get into the tank (shut off the pump and/or any water supply).
4. Release air from tank until 3 bar (44 psi) tank/air pressure is remaining.
5. Open a drain valve and afterwards the isolation valve to drain the tank.
⚠CAUTION: Make sure that the system pressure is never lower than 4 bar (58 psi) below
precharge. If system pressure needs to be lowered, the tank should be isolated or emptied as
previously described.
1.4 Pump Run Control Operating Principles
Without a pressure tank,a water system’s pump would cycle (turn on) every time there was a demand
for water. This frequent and potentially short cycling would shorten the life of the pump. Pressure
tanks are designed to store water when the pump is running and then deliver pressurized water back
to the system when the pump is shut off (Fig 1.4).A properly sized tank will store at least one liter of
water for every liter per minute (LPM) of pump capacity. This allows for fewer pump starts and longer
run times which should maximize the life of the pump.
1. Before drawdown 2. During
drawdown
3. Pump comes on
and begins to ll
the tank
Fig. 1.4

1.5 Multiple Tank Installation
All tanks must have the same precharge for the system to function properly.Tanks should be installed
on a header to ensure all tanks receive equal and balanced pressure.Adjust each tank precharge as
detailed in section 1.3.The system pressure switch or control should be centrally located (see Fig 1.5)
in order for the tanks to function properly.
2. Thermal Expansion Tank Installation
Thermal expansion tanks are designed to accommodate the natural expansion of water as it is
heated. Thermal expansion tanks may be used in several different applications including closed loop
hydronic heating systems, direct and indirect solar heating systems, and open loop potable water
heating systems. GWS has developed three different series of tanks to be used for each application:
HeatWave™ for closed loop hydronic heating systems, SolarWave™ for indirect closed loop solar
heating systems, and ThermoWave™ for direct solar heating and open loop potable water heating
systems. For high volume thermal expansion applications Challenger™ and SuperFlow™ Series tanks
may be used.
⚠CAUTION: Check tank data label for maximum operating pressure and temperature prior to
installing.
⚠CAUTION: Additives (such as glycol) can affect the thermal expansion and expansion tank
operation. Check with your GWS dealer or nearest GWS sales ofce for more details.
2.1 Precharge
Using a suitable pressure gauge, check the tank precharge pressure prior to installation. Refer to
the tank data label for factory precharge pressure. Tanks in closed loop heating circuits should be
precharged to system ll pressure. Tanks in open loop heating storage systems should be precharged
to mains’ pressure.For tanks in closed loop solar systems precharge should be set at minimum system
operating pressure and/or ll pressure. Release or add air by the tank air valve accordingly. Make
sure the tank is completely drained of water and there is no system pressure affecting the precharge
pressure reading when adjusting tank precharge.
2.2 Thermal Expansion Tank Location
As tanks, pipes and connections can leak even when installed correctly; make sure to install the tank
at a location where any leak will not cause water damage. The thermal expansion tank should be
installed on the cold or supply side of any heating system. The tank should be installed indoors and
protected from freezing temperatures.
2.3 System Connection
SuperFlow™ tanks are designed to be self-supporting and should be connected to the system with
additional piping (See Fig. 2.3).
Fig. 1.5 Multi-tank Installation
NOTE:All tanks must have
equal precharge
Relief
Valve Pressure
Switch
Header to be sized
for maximum velocity of
1.8m/sec (6ft/sec)
Water Flow
Fig. 2.3
Hot
Relief
Valve
Water Heater
BackFlow Preventer or
Check Valve
Vertical
Tank
w/ Feet
Cold

2.4 Solar Heating System
Connections
SuperFlow™ tanks can be used in the solar
liquid loop of indirect thermal transfer systems
and may be mounted either on the suction
or pressure side of the circulation pump.
If a condenser is employed to cool
evaporated solar liquid it must be in the
location between the solar liquid loop and
the expansion tank. A relief valve should
be employed and maximum operating
parameters must not be exceeded. If the
temperature of the solar system has the
potential to rise above the evaporation point
of the solar liquid, a condenser chamber or
coil is required between the solar collector
and the expansion tank (See Fig. 2.4).
2.5 Thermal Expansion Operating Principles
As water is heated it expands. A thermal expansion tank is used to accommodate for this natural
water expansion, which otherwise may lead to increased system pressure and cause damage to piping,
ttings and other system components. A thermal expansion tank uses a membrane sealed inside
the vessel to create a barrier between water and air chambers. The air chamber acts as a cushion
which compresses as heated water expands.The thermal expansion tank absorbs the expanded water
volume and ensures constant system pressure is maintained. Using a thermal expansion tank also
conserves water and energy. This is accomplished by eliminating the need to rell and reheat water
lost due to venting from the relief valve during heating cycles.
3. Maintenance
SuperFlow™ pressure tanks should be checked by an authorized service professional,every 3 months.
To check precharge, shut off power to the pump, isolate and drain the tank. Check precharge using a
pressure gauge. If needed, top up air to appropriate precharge level using an air pump or compressor.
Open isolation gate valve allowing the pump to ll the tank with water.
Always release all water and air from tank before disassembling the parts exposed to pressure such
as anges, air valve, pressure gauge etc. Make sure that the system is switched off and no electricity
or electrical devices are running.
If the pump short cycles or the heating system relief valve constantly opens, check the air valve
mounted on the tank. If water bleeds from the valve the membrane has burst. Please call an authorized
service provider to replace the membrane with a factory replacement, following the instructions for
membrane replacement in this manual.
Check the quality of the water by draining water from the tank using the drain valve. If the water is
rusted, calcied, or has solid deposits, then either the membrane has failed which can be veried by
above mentioned process or the tank is blocked.
4. Membrane Replacement Instructions
1. Turn off the water and/or disconnect the power to the pump.
2. Release the air and drain all water from tank.
3. Unbolt and remove the ange (water connection) from the tank.
4. Remove the nut and the washer on the top of the tank which is attached to the membrane hanger
that is anchoring the top of the membrane (g. 4.1, g. 4.4).
5. Pull and remove the membrane through the bottom opening to which the ange was attached.
6. Remove the top connection membrane hanger from the damaged membrane, this can be reused
and should be cleaned.
7. Take the membrane hanger and attach it to a rod, a cable or alike, as seen in g. 4.2.
8. Pull the rod and hanger up through the membrane until the top of the hanger is protruding from
the top of the membrane (g. 4.3).
9. Feed the rod from the bottom of the tank up through the opening at the top of the tank until the
hanger is protruding from the top of the tank and the threads are visible.
10. Slip the washer and then the hanger nut over the end of the rod/cable and tighten onto the
exposed connector (g. 4.4).
Hot
Cold
Pump
Pump
Solar Collector
Condenser
Solar
Tank
Storage
Tank
Heat
Exchanger
Fig. 2.4
Fig. 4.2
rod
cable
membrane hanger
Fig. 4.1

11. After tightening the hanger nut onto the exposed connector, disconnect and remove the rod.
12. If applicable; use silicon tape to thoroughly wrap and seal the hanger connector sealing bolt (g.
4.5). For hanger connector sealing bolts equiped with an o-ring or gasket, silicone tape is not
needed.
13. If applicable;insert the sealing bolt into the open connector,ensure it is properly seated and tighten it.
Do NOT over-tighten (g. 4.6).
14. Fill 2 bar (30 psi) of precharge air or nitrogen and using a soap solution check for leaks all around
the air valve, pressure gauge, top nut and bottom ange.
15. Lift tank upright and attach to pressure system as described earlier in this manual.
16. Open gate valve and allow some water into tank and then pump more air/nitrogen to set tank to
appropriate precharge as described in section 1.3.
17. Now open isolation gate valve to allow full functionality of tank.
Note: For tanks with a ange instead of a hanger on top of the tank, rst mount the membrane to
the top ange.
5. Disposal
Check with local authorities for proper disposal and recycling. Do not dispose of the manual - keep
it for further reference.
6. Warranty
Global Water Solutions Ltd. (GWS) warrants its SuperFlow™ tanks
for a period of 1 years from the date of manufacture for manufacturing defects on the steel shell.
Warranty applies to GWS products only when used for their intended purpose, and does not
apply if a defect is due to improper use of the product, result of accident, misuse, or abuse. If the
product was improperly installed or altered in any way, not specically authorized by the factory,
the warranty is void.The warranty set forth in this paragraph is made expressly in lieu of all other
warranties expressed, or implied, including but not limited to merchantability or tness for a
particular purpose.
For replacement of the membrane, provided the tank is installed by an authorized installer and
pre-charge is set properly as per instruction manual and the pre-charge is checked as per the same
manual at a time interval of every 3 months, warranty is granted for a period of 3 months from date
of manufacture on membrane defects.
In no event shall GWS be liable for cost of processing, lost prots, goodwill or any other
consequential or incidental damage of any kind resulting from the order or use of its products
whether arriving from breach of warranty, nonconformity to ordered specications, delay in delivery,
or any loss sustained by the buyer nor will GWS be liable for labor and expenses necessary to
remove and reinstall replacement product.
To obtain service under this warranty, consumer must deliver alleged defective product, freight
prepaid, to an authorized GWS distributor or OEM partner. GWS will either issue credit or at its
option, repair or replace defective product freight prepaid to the distributor. GWS reserves the right
to make changes in construction, which, in its judgment, constitutes a product improvement.
All warranty is subject to veriable proper installation, adjustment of pre-charge as per our
engineering bulletins and installation of a pressure relief valve as recommended in the installation
manual.
Standard manufacturer’s warranty as dened in the standard GWS warranty terms and conditions.
Fig. 4.3
membrane
rod or cable
Fig. 4.5
hanger connector
sealing bolt
silicone tape
Fig. 4.6
hanger connector
sealing bolt washer
hanger nut
Fig. 4.4
rod or cable
hanger nut washer
tank

*Air valve versions:
Version 1:
Internally mounted air valve with external nut Version 2:
Externally screwed in air valve
DECLARATION OF CONFORMITY
Pressure Vessels Types MCPA / MCMA / MCUA
7. Torque values
Part Size 10/16bar 25bar
Flange Bolts ≤150L 31 Nm
200L~850L 45 Nm 65 Nm
1000L~3000L 65 Nm 76 Nm
Hanger Nut 95 Nm
M5 Bolt In Hanger 4 Nm
Air Valve Version 1*5 Nm
Version 2*7 Nm
EN - Declarations of conformity for EU and UK can be found on our website.
ES - Las declaraciones de conformidad para la UE y el Reino Unido se pueden encontrar en nuestro
sitio web.
PT - As declarações de conformidade para a UE e o Reino Unido podem ser encontradas no nosso
sítio web.
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site web.
DE - Die Konformitätserklärungen für EU und UK nden Sie auf unserer Website.
IT - Le dichiarazioni di conformità per l’UE e il Regno Unito sono disponibili sul nostro sito web.
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