Grundfos IMpress User manual

IMpressPressurisation Sets
comprising of
Basic, Advanced, Glycol and H/C.
Installation, Operation and
Maintenance Manual

DECLARATION OF CONFORMITY
We,Grundfos,declareunderoursoleresponsibilitythattheImpress andImpress
Advanced, Glycol and Twin Circuit pressurisationunitsreferencedinthese installation
instructions, to which thisdeclarationrelates,areinconformitywiththe:
Machinery (89/392/EEC), EN292
Electromagnetic Compatibility (89/336/EEC), EN50 081-1 & EN50 082-2
Electrical equipment designed for use within certain voltage limits
(73/29/EEC), EN60 335-1 & EN60 335-2-51
Iffurtherdetailsarerequired,pleasecontactoneoftheGrundfosofficeslistedonthe
back page of these instructions.
1st August 2007
Grundfos Pumps Ltd.
Grovebury Road
Leighton Buzzard
Beds.
LU74TL
GENERAL DATA
These installation, operation and maintenance instructions are given as a guide to
good practice in the installation, putting into service, operation and maintenance of
theGrundfosIMpress andIMpress Advanced, Glycol and H/C units.Theydonot contain
full service instructions,proceduresforthecontinualservice andoperationof the unit.
The servicesofaqualifiedengineershouldbeemployedtomaintainandrepairthe module.
ThisI.O.M.manualmayrefertocomponents/functionsnotfittedtoallunits.
DELIVERY AND HANDLING
Onarrival,inspect theunit(s) forsignsofdamagebeforesigningthedeliverynoteand
report any damage to the supplier within 7 days. The unit is supplied from the factory
onawoodenpalletsuitableforhandlingwith forkliftequipment.
The weight and the size of the module may require the use of proprietary lifting
equipment in order to be handled safely.
WARRANTY
1. The Grundfos warranty covers all defects within the unit originating from faulty
workmanship and/or materials for a period of one year from the date of installation or
eighteenmonthsfromthedateofdespatch fromthefactory,whicheverissooner.
The warranty covers the replacement of any faulty parts and our labour cost to
replace the faulty parts. It does not cover the cost of removing, returning and refitting
the unit or any secondary losses arising from the failure.
2. Under no circumstances should faulty equipment be dismantled. Failure to comply
with this instruction could invalidate the warranty.
3. Defects arising from the incorrect installation, water containing debris, or harmful
chemicals, inadequate electrical protection, faulty ancillary equipment, lighting or
othercircumstancesbeyondourcontrolisnotcoveredbythis warranty.
Peter Reynolds, General Manager
Grundfos Pumps Ltd

SITE STORAGE
It is strongly recommended once the unit has been delivered to site, that it be placed
immediatelyintoadust,moistureandfrost-freeareathathasbeensecuredto prevent
unauthorisedinterference.Ifthisisnotpossibletheunitshouldbestoredin an area
thatisasneartotheidealstorageconditionsdescribedabove.
APPLICATIONS
TheGrundfosrangeofIMpress unitshavebeendesignedto be compact, reliable
andsimpletouse and to provide manyyearsofefficientand effective service.
The main application of the unit(s) is:
Pressurisation of sealed heating systems
Pressurisation of sealed chilled water systems
MAXIMUM OPERATING CONDITIONS
TheGrundfosrangeofIMpress unitshavebeendesignedto
Liquid temperature range : 3 to +90°C
Ambient temperature : up to +40°C
Relative Humidity : up to 95 %
Maximum operating pressure : 6 Bar
Recommended maximum start-stops per hour : 20 - 30
NOISE LEVEL
The noise level of the pressurisation units referenced in these installation
instructions is lower than the limiting values stated in the EEC machinery
directive.
If pressurisation units are installed close to living accommodation, it is
advisable to fit anti-vibration mountings on the unit and a flexible pipe
coupling on the outlet pipework from the unit to prevent vibration being
transmitted through the system pipework. This applies especially to units installed in
concrete buildings.

INSTALLATION
Do not attempt to start the pump even to check the direction of rotation until
the system has been filled with water and both the pump and the system
have been primed/vented.
All electrical connections should be carried out by a qualified and authorised
electrician in accordance with the latest issue of the I.E.E. regulations.
Do not remove motor terminal box covers, electrical cables or any other
electrical protective covering without first ensuring that the electrical supply
is suitably isolated and cannot be switched on.
Do not attempt to supply electricity to the unit without ensuring that all
electrical fittings, cables and enclosures are intact and suitably electrically
isolated from human touch during operation.
Electrical motors will have hot external surfaces during operation and care
must be taken to ensure that persons cannot come into contact with the
surfaces of the electric motor.
LOCATION
1. The unit should be sited in a dry, well ventilated but frost-free position where it will
not be subjected to extremes of temperature.
2. The environment should be non-aggressive and the atmosphere non-explosive.
3. Ensure that there is sufficient clearance around the unit to allow maintenance
operations to take place without obstruction
4. To enable maintenance and service of the unit to be carried out satisfactorily the
area should have adequate lighting for this work to be carried out safely.
5. The pipe work installation of the unit should be in accordance with local water
authority regulations.
FOUNDATION
The pressurisation unit should be installed on a concrete base, which is both
horizontal and flat to avoid distortion of the base plate.
Please allow a minimum clearance of 500mm above the unit for servicing float valve
and tank, and 750mm in front for servicing pumps and controls).
PRESSURE VESSEL(S)
On heating systems it is vitally important that the expansion vessel(s) has
more than sufficient capacity for the expansion of the liquid in the system. It
isbettertooversize ratherthanundersizefor safety reasons. Itis equally
importanttohavethecorrect pre-chargepressureintheexpansionvessel(s) set in
accordance withthemanufacturersinstructionsandtherequirementsofthe system.

SERVICE CONNECTIONS
Do not open electrical panel enclosures, panel components, pressure
switch covers, motor terminal box covers or any other electrical protective
covering without first ensuring that the electrical supply is suitably isolated
and cannot be switched on.
Do not attempt to supply electricity to the control panel and run the pump
electric motors without ensuring that all electrical fittings, cables and
enclosures are intact and suitably electrically isolated from human touch
during operation.
REMOVAL OF CABINET COVERS
ThetopandthefrontcoverscanberemovedfromtheIMpress cabinetstoallow
access for making electrical and pipe work connections.
Remove the four screws from the top cover, and remove the cover/lid.
Remove the two screws on the front panel. Remove the front panel by lifting it off the
locating pins in the base.
PIPEWORK CONNECTIONS
The service connections to the pressurisation unit should be made as follows.
1. Connect the mains cold water supply to the ball valve ½" BSP male connection on
the side of the pressurisation unit.
2. An isolating valve must be fitted to the mains cold water supply pipework supplying
the pressurisation unit.
3. Connect the discharge pipe (15mm compression) from the pressurisation unit to
an appropriate position on the heating/chilled water system.
4. Connect the over flow pipe (¾" bsp male) from the pressurisation unit break tank
to a suitable drain.
5. The electrical supply connections to the pressurisation unit should be made in
accordance with the wiring diagrams supplied with the unit.
6. If applicable, connect the freestanding expansion tank(s) to the heating/chilled
water system.
7. Ensure the pressurisation unit is not stressed by the pipework connections and
that the pipework is properly supported.

Feeder Water Tank
Microprocessor
Controller
PCB
Transducer
Tank overflow
Mains water in
Pressurised water out (15mm)
NRV
Pumps
Mains supply in
5m of cable
Elecrical connection
Water connection
Transducer
Pump B
Pump A
Low Water
DIMENSIONS, WEIGHTS AND CONNECTION DETAILS
PIPEWORK CONNECTIONS
Water supply connection: ½" BSP Male
Overflow pipe: ¾" BSP Male
System connection: 15mm Compression

Module enclosure
5m of cable
Mains supply
230−240v 45−60 Hz
Pumps (2 off)
NRV (2 off)
Dosed Pressurised
water out (22mm)
Mains water in
Tank overflow
5 Bar
Transducer
Controller
Feeder Water Tank
Transducer
Pump
Pump
Low Water
Dosing pump
Pulsing
Water Meter
Isolation
Valve
(MIpress Glycol Duo system shown)
DIMENSIONS, WEIGHTS AND CONNECTION DETAILS
PIPEWORK CONNECTIONS
Water supply connection: ½" BSP Male
Overflow pipe: ¾" BSP Male
System Connections: 22mm Compression

Cold circuit
Hot circuit
Isolation
Valves
Low Water
Pump
Pump
Transducer
Feeder Water Tank
Controller
5 Bar
Transducers
Tank overflow
Mains water in
Pressurised
water out (22mm)
NRV
(2 off)
Pumps (2 off)
Mains supply
230−240v 45−60 Hz
5m of cable
Module enclosure
Pressurised
water out (22mm)
Transducer
(1 pump per circuit shown)
DIMENSIONS, WEIGHTS AND CONNECTION DETAILS
PIPEWORK CONNECTIONS
Water supply connection: ½" BSP Male
Overflow pipe: ¾" BSP Male
System Connections: 22mm Compression

ELECTRICAL CONNECTIONS
In the interest of electrical safety a local means of isolating the electrical
supplyshouldbelocatedasclose as is practicaltotheunit.
The electrical supply should be connected to a 240 volt single phase 13
amp supply only.
All cables must be of an adequate size to prevent excessive voltage drop in
the supply to the unit. The electrical installation should be in accordance
with the latest issue I.E.E. regulations.
TheIMpress unitsaresuppliedwithapproximately4mmainssupplycablefor
connection into a local isolator switch adjacent to the unit.

Volt Free Contact
Low Water
Pump B
Pump A
240V 1Ph 13A Mains Supply
Microprocessor Controller PCB
Pressure Transducer

Pump A
Pump B
240V 1Ph 13A Mains Supply

VOLT FREE CONTACTS CONNECTIONS
IMpress (Standard)Unit
If a connection to the volt free contact (VFC) is required, it is necessary to remove the
cover from the control box within the cabinet as follows.
Afterremovalofthecabinettopandfrontpanels, removethefourscrewsfromthe
control box front cover. The display is connected to the back circuit board by a cable.
If required, the display can be detached by unplugging from the cable from the main
circuit board. Push back the locking tabs at each end of the connector and remove
theconnector,donotpullonthecable.Donotattempttodetachedfromthedisplay
boardonthefrontcover. The VFC changeover terminals are marked 'STOP'.
Nootherconnectionsare required or should be made into the control box.
IMpress Advanced, IMpress Glycol and IMpress H/C
If a connection to the volt free contacts (VFC) is required, it is only necessary to
remove the cover of the VFC connection box on the side of the cabinet. There is no
need to remove the cover from the control box within the cabinet.
CABLE GLANDS
A single M12 cable gland is included, which can be fitted once the M12 knockout has
been carefully removed.
The VOLT FREE Contacts are marked C=Common, NC=Normally Closed,
NO=Normally Open. The maximum contact rating is 240V AC 10A (Resistive).

COMMISSIONING GUIDE
Do not attempt to start the pump(s) even to check the direction of rotation
until the system has been filled with water and both the pump and the
system have been primed/vented.
Arrangements should be made for an engineer to commission the pressurisation unit.
Please contact the GRUNDFOS service company EUROPUMP SERVICES LTD by
telephoning 08450 508100 where arrangements can be made for an engineer to
commissiontheunit.
FILLING
The system should be initially filled via a filling loop. Turn on the water supply and
ensure the tank fills properly and stops. Ensure there are no leaks. DO NOT ALLOW
the tanktoempty,andthepumpstorundry,asthiscouldinvalidatethepump
warranty. This is especially important after initial installation and during the fill cycle.
OPERATION
Do not attempt to supply electricity to the control panel and run the pump
electric motors without ensuring that all electrical fittings, cables and
enclosures are intact and suitably electrically isolated from human touch
during operation.
Pump electric motors will have hot external surfaces during operation and
caremust betakentoensurethatpeople cannotcomeintocontact with
the surfaces of the electric motors.
When all electrical covers are in place, and the pumps have been vented, and the
cabinetcoversreplaced,thentheelectricalsupplyto the unit can be switched on.
The pressurisation unit will start two seconds after electrical supply has been
applied.

CONTROL
THE PANEL BUTTONS & INDICATORS
Digital Display
The Liquid Crystal Display (LCD) shows the current operational status
along with any error conditions.
DOWN Button
When in Set-Up/Menu Mode, this button is used to decrease (where
permitted) any displayed value.
UP (Mute) Button
When in Normal (Operational) Mode, pressing this button will cause the
controller to toggle the Alarm Beeper On or Off. When in Set-Up/Menu
Mode, this button increases (where permitted) any displayed value.
STATUS LED
This indicator will display GREEN when all systems are operating within
normal parameters, and will flash RED if an Alarm Condition exists.
SET (Set-Up/Menu) Button
When in Normal (Operational) Mode, pressing this button will cause the
controller to jump into the Set-Up (Menu) Mode. When in Set-Up Mode,
this button will cause any displayed value to be saved, and will
progress to the next item.
SET-UP/MENU MODE
To enter the Set-Up/Menu Mode, press the SET Button whilst the unit is in
its Normal (Operational) Mode. The Display will change prompting the user
with Enter PIN: You now need to enter a valid PIN. The Factory PIN is
0000 (4 Zero’s).
Use the UP and DOWN Buttons to scroll through selecting the
individual character for each of the four possible characters
making up the PIN.
Press SET to advance from one character to the next. For security, the
previously entered character changes to a star ‘
*’ , press set again after the
fourthcharacter.

Access is gained to the Set-Up menu, after a correct PIN entry (0000). An incorrect
PIN entry will cause “INVALID PIN” to be displayed. If you need to reset the PIN (to
all blanks), press and hold the set button, whilst powering up the pressurisation unit.
Thisbuttonmustbeheldforatleast FIVEseconds.
SET UP MENU
Set Pressure:
Enter the pressure the required cold fill cut out pressure, the cut in pressure is set
underdifferential (see below).Settingrange0.5to16bars, defaultsetting:1.5bars.
Pump A/B Control:
Select betweenOFF-Pumpisdisabled,Auto-Pumpisavailableforoperation,or
ON-PumpisswitchedmanualON.ManualON,causesthepumptorunfor
approximately30seconds. UsetheUPorDOWNKeystoswitch pumpoffbefore
the 30 seconds has elapsed time if required. Default setting: Auto
Pump Lettering. Pump A is designated as the first (or only) pump in the unit. Pump B
isthesecondpump (where fitted).SomeSet-Up/Menuoptionsarerepeatedfora
multiple-pumpinstallation.These optionswillnotappearifasinglepumpinstallationis
enabled.
Differential
This is the pressure at which a pump engages below the Set Pressure. The pump
will switch off when the Set Pressure is reached. Setting range 0 to 16 bars, default
setting 0.3 bars. Note, the setting for Differential B can be ignored.
Pump Test
Thisfeaturepreventspumpsseizing up throughinactivity,bybrieflyrunningapumpifit
has not been run after a set number of hours. Setting range 0 to 250 hours, if set to
0,thefeatureisdisabled.This is notrecommendedforsmallsystems, asitcangradually
raise thesystempressureover aperiodoftime,iftherearenoleaks.
P- Low Alarm On, and P- Low Alarm Off
The pressures at which the low pressure alarm comes on and goes off at. Setting
range 0 to 25 bar, default setting: On = 1 bar, Off = 1.3 bar.
P-High Alarm On, and P- High Alarm Off
The pressures at which the high pressure alarm comes on and goes off at. Setting
range 0 to 25 bar, default setting: On = 2.5 bar, Off = 2.2 bar.
Water- Low Alarm
This should be set to Alarm on Make.
Water- Low Reset
The time until the pumps can operate again following a Water-Low Alarm. Setting
range 0-255 seconds, default 120 seconds. This prevents pumps from continually
switching on and off of the tank float switch.
Leak Alarm
An alarm is caused if pumps have run for equal to or more than the total cumulative
preset time in any hour (excludes Manual-On). If set to 0 seconds this feature is
disabled. Setting range 0 to 59 minutes, default setting: 0 seconds.

Volt Free Relay
Sets all the conditions that operate the volt free relay. The Failsafe option reverses
theoperationoftherelay,i.e.itisde-energisedonfault.Failsafeallowsforthe
provision of an Alarm on Power-Failure to be programmed. The operation of the
NC/NO contacts are reversed if the Failsafe setting option is used.
Beeper / Alarm LED
Sets all the conditions that will enable the audible Beeper and Alarm LED.
The Beeper Key Press setting enables or disables the audible ‘plip’ every time a
panel control button is pressed.
LED Constrast : LCD Backlight
Changes the LCD display contrast ratio, setting range 0 to 6, default setting 2.
LCD backlight level adjust to suit lighting conditions, setting range 0 to 5, default
setting 2.
Standby Mode
When set to ‘Yes’, causes the unit to enter Standby Mode following Power-On. The
SETbutton will need to be pressed for at least five seconds to start the
pressurisation unit. When set to ‘NO’ causes the unit to start as soon as power is applied.
User PIN
Sets the PIN (Password) to enter the Set-Up mode. The default setting is 0000
Passwords: Four characters need to be entered. The PIN is case sensitive, so ‘abcd’
is NOT the same as ‘ABCD’. A setting of ‘all spaces’ (blanks), disables the PIN.
Whilst itisrecommendedthataPINbealways programmed topreventunauthorised
tampering, the User Set-Up Menu is factory shipped without a PIN to facilitate initial
configuration.Please record and retain anyPINcodes thatyouset.
MAINTENANCE
IMPORTANT: There are NO User Serviceable parts inside this equipment.
Please Refer Servicing to Qualified Personnel. !
Grundfospressurisationunitshavebeendesignedto require theminimumof
maintenance. While the unit requires minimal maintenance it should be inspected on
a regular basis, as failure of the unit could potentially cause personal injury and
considerable damage. It is therefore recommended that a Grundfos maintenance
contract be taken out to cover maintenance of the unit. Please contact Grundfos
Europump Service department on 0845 508 100 for further details.
However, it is the customer’s responsibility to inspect the unit in addition to any
maintenance contract to ensure the safety and correct operation of the unit during the
interimperiodsbetweenservice visits. It is recommended that the following checks be
carriedoutatregularintervals.
1. Check there are no leaks on pipe work both in and around the unit.
2.Check theunitison,theunitmustbeswitchedonallthetime.
3. Check for any corrosion.
4. Check unit operates quietly and smoothly.
5. Check that the electrical mains lead to unit is not damaged.

IMpress GLYCOL
Overview.
The IMPRESS GLYCOL model is an enhanced version of the IMPRESS ADVANCED
with some additional Hardware and Software.
At-a-Glance
The noticeable differences are that the
GLYCOL version has a SNOWFLAKE on
the face of the Control Panel Decal, and
two additional grey M16 Cable-Glands
fitted to the enclosure. On Power-Up the
display identifies with the word GLYCOL.
Cable-Entry
Facilities for Cable Entry have been much expanded to keep abreast of additional Alarm,
BMS/Telemetry and Communications features. The Bottom of the Control Box is provided
with two additional grey M16 Cable Glands and FOUR additional knock-outs for M12
Control Panel (Base View) GLYCOL Version
M12 Cable-Gland
(Water-Low Sensor)
2 x M12 Knock-Outs
2 x M16 Knock-Outs
Available for use as desired
M12 Cable-Gland
(Pressure Transducer)
M16 Cable Gland
Power Entry M16 Cable Gland
Pump-B Supply
M16 Cable Gland
Pump-A Supply M16 Cable Gland
Pump-C Supply
(Dosing Pump)
M16 Cable Gland
Pump-C Alarm
(Dosing Pump Alarm Cable)
é
é
é
and M16 Cable Glands.

Terminal Connections
The GLYCOL Main Board has the same connector arrangement as the standard
IMPRESS ADVANCED Board with two noticeable differences;
Main PCB (Internal Front View)
Terminal Connections
GLYCOL Version
PUMP-A
RUN
J110
PUMP-B
RUN
J111
PRESS
LOW
J101
PRESS
HIGH
J102
WATER
LOW
J103
WATER
LEAK
J104
PUMP-A
FAULT
J105
PUMP-B
FAULT
J106
SERVCE
DUE
J107
SYSTEM
FAULT
J108
TELEMETRY VOLT-FREE CONTACTS - 250mA/100vDC MAX COMMS
RS232
RXD GND TXD
J109
WATER
LOW
J5
AUX
ALARM
WH BN BL
J16
REMOTE
NO C NC
J2
STOP
NO C NC
J3
VOLT-FREE CONTACTS
DOSING
PUMP
E L N
J14
Dosing Pump Supply AUX Alarm Sensor Input