Xylem Lowara Presfix Beta MK2 Manual

PRESFIX Beta MK2
Dual System Pressurisation set
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Operating and Maintenance Instructions
EC Declaration of conformity
Xylem Water Solutions UK Limited declare that the Presfix pressurisation set conforms to the requirements of
the Machinery Safety Directive 2006/42/EC.
Electromagnetic Compatibility (EMC) Directive 2014/30/EU
Conforming to the UK Health & Safety Requirements 2008 No.1597
Water supply (Water fittings) regulations 1999
Code of practice for heating and chilled water systems BS7074 (parts 1, 2 & 3)
Signed: Position: Engineering manager Date: 20-04-2016 Revision B
Clive Willmott
Introduction
This leaflet contains information to enable the safe installation and operation of the products mentioned above.
The following instructions must be read and understood by all persons responsible for the installation, operation
and maintenance of this product.
Warning Symbols
Safety instructions where noncompliance would affect safety.
Safety instruction where electrical hazard is involved.
Safety instruction where noncompliance could cause damage to the equipment.
Instruction for safe use
This product has been designed for the pressurisation of sealed heating, chilled water and closed-
condenser water systems to the operating conditions shown.
This product should not be installed until this leaflet has been studied carefully.
Handling, transportation and installation of this equipment should only take place with the proper
use of lifting equipment.
This product must be stored in a frost-free dry environment.
Noise Emissions
This equipment operates at a noise level lower than 70dBA.
Protection degree IP54
Ambient temperature 4-30°C
Maximum system operating pressure: 2.8 & 5.5 units (10 bar) 8.0 units (13 bar)

Installation
The Presfix Beta unit is despatched mounted on a wooden pallet and covered in a protective film, it is recom-
mended that the unit be retained in the protective packaging until the product is to be installed. The unit will
arrive pre-packaged and wired ready for installation.
This product has been fully run tested at our works under simulated site conditions. The unit
should be thoroughly checked for physical damage that may have been caused during transit.
If the unit is found to have damage it must be reported immediately and should not be installed.
The unit must be sited in a dry clean well-ventilated area with good all round access, mounting
can be either wall or floor. The unit is despatched with bottom fixing brackets turned inward suitable for wall
mounting, for floor mounting turn brackets to face outward which will give access to mounting holes.
Electrical connections
The cable used for the incoming supply must be of adequate size to carry the motor full load
current. This is shown on the duty plate. All non-power cabling should be limited to 2.5mm².
All connections must be made using the appropriate wiring drawings for the equipment being
installed, with particular attention being paid to the supply voltages.
The supply voltage is shown on the set duty plate.
Never operate this product with the control panel door in the open position.
It is essential that this equipment is earthed to the building earth system.
Pumps operate at 230v 50Hz
The base frame must be earth bonded directly to the building earth system.
All wiring should be arranged such that it enters the control section through the appropriate
cable glands.
Water supply and system connection
Connect the Presfix Beta set ½”BSP ball valve (left side of cabinet) to a suitable water supply, incorporating
an approved stop cock. If the pressure available at the ball valve is below 0.3 bar, a low pressure orifice must
be obtained and fitted. Extend the 22mm plastic overflow pipe from the Presfix Beta break tank
to a position where an overflow will be noticed and rectified. Ensure the warning pipe is able to
handle the incoming water volume, if this is not the case then a pressure reducing valve should
be fitted to the incoming water supply. System 1:connect the pressurisation port ½” BSPF (left
hand side of cabinet) to the expansion vessel pipeline which in turn should be connected to the
suction side of the system circulating pump. Quick fill and isolating valves must also be fitted to this line (see
connection sketch Fig 1)
System 2:connect the pressurisation port ½” BSPF (right hand side of cabinet) to the expansion vessel
pipeline which in turn should be connected to the suction side of the system circulating pump. Quick fill and
isolating valves must also be fitted to this line (see connection sketch Fig 1)
The Break tank is constructed to have a weir slot as required by the water bylaws to prevent back flow con-
tamination, if the inlet ball valve or NRV suffered a catastrophic failure the overflow may not be able to keep
up with the inflow in which case excess water will be ejected through the weir slot and onto the plant room
floor, if this is not acceptable then consideration should be given to fitting the pressurisation set onto a try with
overflow to drain.
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Commissioning
1. Fill the system with water via the quick fill filling loop to the system fill pressure, this filling loop must comply
with local water authority bylaws and contain double check valves. The filling loop must be
completely removed after the system has been filled.
The pressurisation unit must never be used to fill the system.
The maximum running time for pumps fitted to this product must not exceed 4 hours in any 24
hour period.
It is essential that all air is allowed to escape freely via air vents and radiator vents etc.
All air must be evacuated from the system for this product to operate correctly.
2. Turn on the water supply feeding the product break tank.
Water treatment crystals/chemicals must never be introduced to the system via the break tank.
3. Check that pumps have been fully evacuated of all air by removing the bleed screw of each pump where
fitted and allow water to escape until no air is present. Replace bleed screws.
4. Before the unit is opened up to the main system pressure check the pre-charge in the internal vessel. The
pre-charge should be set to approximately 0.35bar below the system fill pressure. Charge as necessary with
Nitrogen or dry air. Open system valve to Presfix Beta unit.
System set points
System set points are entered via the front panel interface.
To stop unauthorised adjustment of set points a lock switch is positioned on the back of the display PCB this
will need to be switched to the unlocked position to enable set points to be changed.
Switch the selector switch to the appropriate set point and the display will show the value of that
particular set point, if the value is blinking on/off the value is able to be modified, if the value is
not blinking it means that the lock is active and the value will not be able to be changed.
To increase or decrease the value press the up/down buttons. The longer you press the button
the quicker the change rate.
Once you have selected the correct value move the selector switch to next set point that you
wish to change,
the values in the previous set point will be automatically saved.
Once you have entered data into all relevant set point parameters the selector switch should be set to the
Auto position. If the data is to be locked then switch the lock switch on the rear of display PCB to the locked
position.
Set point description
Delay Start
This set point is adjustable between 0-10 seconds and is used to delay starting the pressurisation pump for
the set period. This can be useful especially on chilled water system where it can be very difficult to remove
all air.
Low pressure set point
This set point is typically set approximately 0.4 bar below the fill point.
High pressure set point
This set point is typically set approximately 0.2 bar above the final working pressure.
Duty pump cut in
This should be set to the static height of the building + 0.35 bar. The standby set points are automatically
set from the duty pump set points. The system set point must be set to the same pressure on both
system displays.

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Auto
Each system should be set to Auto once all the set points have been entered. This is the normal operating
position for the set and each display will show the system pressure for that system.
Off
The off position performs two functions, if the main pump has failed and the duty standby pump has been
activated, the duty pump will be locked out until the system is reset by switching the selector to the off
position and then back to auto. If the selector switch is left in the off position no pumps will be able to run
but the system will still be monitored for all other conditions I.E. low/high pressure.
P1/P2 hand positions
If either pump one or pump two is selected that pump will run continuously regardless of system pressure.
This function is primarily intended to check pump rotation and pumps should not be left to run excessively.
If a pump is left to run in this position it will automatically be locked out after 18 minutes.
Exercise
This set point is adjustable between 0-30 days and is used to run the pumps for a short period after the set
time has elapsed, running the pumps at regular intervals helps prevent pumps from seizing due to inactivity.
V/Free contacts
See appropriate drawing for Volt free contact availability. Rating 1A 50v maximum.
Features
Hours Run
With the selector switch in the off position press the up button to view pump1 run time press up button again
to enter reset mode, hold down both up & down buttons for 8 seconds and the display will zero. Repeat for
pump 2 using down button.
Note: Each display will show the hours that the pump has run for that system, this will need to be added to
the hours run of the opposite system to ascertain the total pump running time.
Commissioning valves
Commissioning valves have been provided to aid fault finding and checking that the system operates at the
correct values. The internal system isolation valve fitted on the unit discharge pipe can be turned off so the
unit is isolated from the system pressure. The small isolation valve can then be used to manipulate the
pressure within the unit to check that the pump cuts in and out as required. This valves can also be used to
dump water/pressure back to the break tank to enable the internal vessel pre-charge to be checked.
Remote inhibit
If the remote inhibit contacts have been activated then the display will show set inhibited, during this
condition no pumps are allowed to run irrespective of system pressure, however the system will still be
monitored for all conditions.
Run limit exceeded
If a pump is called to operate for periods in excess of 18 minutes or a combination of frequent starts both
pumps will be locked out and prevented from further operation. To reset the timer circuit switch the selector
switch to the off position and back to Auto again.
Transducer failure
If the transducer fails the display will read Sensor error and prevent pump operation, the high low pressure
contacts will simultaneously operate to indicate that a failure has occurred and switch off the boiler circuit.
Break tank low water level
The break tank contains a low level float switch which will stop all pumps from operating whilst the water
level is low. Once the water level rises to the reset position the pumps will be released to operate as normal.

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Boiler/chiller interlock
A volt free normally closed circuit is provided as a boiler/chiller interlock. The circuit has 1 high pressure
contact and 1 low pressure contact either of which, when operating, will open the boiler/chiller circuit. If the
high pressure contact is not required with chiller applications it can be omitted. See product wiring drawing.
Operation
Ensure MCBs in the electrical section are at the on position, switch selector switch on front panel to Auto.
Switch main isolator on front door to the on position. The digital display will now go through the starting
check sequence, after about 8 seconds the display will show system pressure.
If the system pressure is lower than the fill pressure then a pump will run and start to raise the
system pressure. Once the system pressure is restored the pump will stop.
If the pressure in the system falls to the duty pump cut in point the duty pump will start, once the system
pressure has been restored the duty pump will stop. Each time the pressure falls the alternate pump (on two
pump units) will start and restore system pressure. If the duty pump after running for 2 seconds
has not succeeded in raising the pressure and it continues to fall by 0.2 bar it will be deemed
that the duty pump has failed. The failed pump will then be locked out and the standby pump
will run and take the place of the duty pump.
If a pump trips for any reason it will be locked out and the standby pump will operate in its place.
Once the reason for pump failure has been ascertained and rectified the selector switch can be switched to
the off position and back to auto to reset the controls.
Maintenance
Routine check (3 monthly intervals)
1. Check that the pump seal is not leaking.
2. Check the pump is not seized and develops the correct pressure.
3. Check that the pump operates without undue noise or vibration.
4. Check that the motor runs without overheating.
Routine check (6 monthly intervals)
1. Check the break tank is clean and that the correct water level has been maintained.
2. Check that all screws are tight on electrical components.
3. Check that the earth connections are tight and making good contact.
4. Check that the gas pre charge is at the correct pressure, this should be done by isolating the unit from the
System and draining water back into the break tank by opening one of the 4mm ball valves (see drawing
for location) once the unit pressure has been discharged, a tyre gauge can be connected to the pre
charge valve to display the vessel pre charge pressure. Recharge as necessary with Nitrogen or dry air.
All other expansion vessels connected to the system can be checked in the same manner.

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Typical Heating + chilled water sealed systems Intermediate vessel only required on MTHW systems
Fig 1

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Fault finding guide
Fault Possible Cause Remedy
Pump fails to start
Power supply failure
Control panel fuse blown,
MCB tripped
Remote inhibit active
Low water level
Reinstate incoming power supply
Replace power supply fuse
Reset MCB
Turn remote inhibit off
Reinstate water supply
Pump fails to stop
Set point set too high
Manual operation selected
System pressure low due
to large leak
Lower set point
Select Auto operation
Switch unit off until leak is repaired
Pump switches on and off
quickly
Air in system
Vessel pre-charge
incorrect
Purge air from pumps and pipework
Check vessel pre-charge and Charge as
necessary with Nitrogen or dry air
Pump runs but will not
make pressure
Pump air locked
Commissioning valve left
open
Incorrect rotation
Passing too much water
Open pump bleed screw and vent pump
Check commissioning valves are in
correct position.
Check pump internal connections.
Check system for leaks
Pump overheating Pump partially seized. Remove pump and check for sediment
build up or foreign objects
Pump set frequently
starting. (pressure falls
to cut in point)
Newly installed system
with large amount of air in
pipe work
Leaks in system pipe work
Vessel pre-charge
incorrectin open position
Bleed system to remove air
Repair leaks
Isolate vessel and pre-charge with
Nitrogen as appropriate
Break tank overflowing
Leaking ball valve
Non-return valve letting by
Commissioning valve left
in open position
Replace ball valve seal
Replace/clean non-return valve
Close commissioning valve
Pump stops and
pressure drops
immediately
Non-return valve letting by
Vessel pre-charge incorrect
Replace non-return valve
Check vessel pre-charge and Charge as
necessary with Nitrogen or dry air

Xylem Water Solutions UK Limited
Millwey Rise Industrial Estate
Axminster, Devon EX13 5HU - UK
Tel: [phone]
Fax: [phone]
[email protected]
www.lowara.co.uk
www.xyleminc.com
Lowara is a trademark of Xylem Inc. or one of its subsidiaries.
© 2016 Xylem, Inc.
Lowara reserve the right to make modifications without prior notice.
Code UKLIT0123 P04/16
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