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Operation &
Maintenance Manual
BOSS Digital Pressurisation Equipment
AX Models (AX1-2.5E, AX2-2.5E, AX1-5E, AX2-5E)
PF Models (PF1-2.5E, PF2-2.5E, PF1-5E, PF2-5E)
Midi Models (MD1-2.5E, MD2-2.5E, MD1-5E, MD2-5E)
Digifiller (Digifiller 0.5, Digifiller 1.0, Digifiller 1.5, Digifiller 2.0)
Mini Models (MX1-3E, MX2-3E)
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Summary of Contents for Boss AX1-2.5E
- Page 1 Operation & Maintenance Manual BOSS Digital Pressurisation Equipment AX Models (AX1-2.5E, AX2-2.5E, AX1-5E, AX2-5E) PF Models (PF1-2.5E, PF2-2.5E, PF1-5E, PF2-5E) Midi Models (MD1-2.5E, MD2-2.5E, MD1-5E, MD2-5E) Digifiller (Digifiller 0.5, Digifiller 1.0, Digifiller 1.5, Digifiller 2.0) Mini Models (MX1-3E, MX2-3E)
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Page 2: Table Of Contents
Wiring Diagram Service Log Spares Electrical Items (All Models) AX Models (AX1-2.5E, AX2-2.5E, AX1-5E, AX2-5E) PF Models (PF1-2.5E, PF2-2.5E, PF1-5E, PF2-5E) Midi Models (MDE1-2.5, MDE2-2.5, MDE1-5, MDE2-5) Digifiller Models (Digifiller 0.5, Digifiller 1.0, Digifiller 1.5, Digifiller 2.0) Mini Models (MX1-3E, MX2-3E) -
Page 3: About This Manual
About this Manual This Operation and Maintenance Manual contains all the necessary information to install, commission, operate and maintain pressurisation equipment. It is recommended to read all parts of this manual before undertaking any work on the equipment. Conventions used in this Manual This manual makes use of symbols to identify key pieces of information. -
Page 4: Equipment Overview
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. -
Page 5: Installation
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. -
Page 6: Flow Restrictors (Midi & Mini Models Only)
Flow Restrictors (Mini, Midi & Digifiller models only) Pressurisation equipment fitted with a plastic, side-entry torbeck valve must be fitted 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 different flow restrictors are supplied with the equipment, both of which include an integral filter. -
Page 7: Ax Skid Clearance And Connection Requirements
AX Skid Clearance and Connection Requirements Connection Size Notes An isolation valve must Mains ½” BSP M be installed on the mains Water Feed water feed for servicing. Guidance on drainage Break Tank requirements should be 22mm Overflow obtained from the local water authority. -
Page 8: Pressfill (Pf) Clearance And Connection Requirements
Pressfill (PF) Clearance and Connection Requirements Connection Size Notes An isolation valve must Mains ½” BSP M be installed on the mains Water Feed water feed for servicing. Guidance on drainage Break Tank requirements should be 22mm Overflow obtained from the local water authority. -
Page 9: Midi (Md) Clearance And Connection Requirements
Digifiller & Midi (MD) Clearance and Connection Requirements Connection Size Notes An isolation valve must Mains ½” BSP M be installed on the mains Water Feed water feed for servicing. Guidance on drainage Break Tank requirements should be 22mm Overflow obtained from the local water authority. -
Page 10: Mini (Mx) Clearance And Connection Requirements
Mini (MX) Clearance and Connection Requirements Connection Size Notes An isolation valve must Mains ½” BSP M be installed on the mains Water Feed water feed for servicing. Guidance on drainage Break Tank requirements should be 22mm Overflow obtained from the local water authority. -
Page 11: Electrical Power Supply
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 after the unit is isolated. These must be isolated elsewhere. All electrical connections must be carried out by a suitably qualified and competent person. -
Page 12: Fault Contacts
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. -
Page 13: Power Filter
Power Filter The digital controller can be adversely affected by EMI and power spikes. A power filter may be required if the supply to the equipment is unstable (e.g. frequent power cuts), shared by equipment which generates high levels of EMI (e.g. inverters, IT equipment etc.) or is fitted with a backup generator. -
Page 14: Commissioning
Commissioning It is highly recommended to have this equipment commissioned by an AMS (BSS Service Team on 0870 850 3886) 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. -
Page 15: Controller Overview
Controller Overview The following image shows the front of the pressurisation unit digital controller. 4 buttons 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 6.3. -
Page 16: Controller Programming
Controller Programming Do not alter any settings without first understanding the implications of doing so. Incorrect settings may cause damage to the equipment, system or property. To enter the programming menu, hold the (+) button until “enter code” appears on the screen, followed by “0000”... - Page 17 The table below gives details of all menu items, in the order that they will appear: Default Menu Item Function Value The required fill pressure, i.e. pump ‘cut-out’ pressure. The recommended setting is 0.3 BAR above the static pressure of the system (0.1 Bar per meter of static height). COLD FILL For example, a 14m high installation will have a static pressure 1.0 Bar...
- Page 18 Default Menu Item Function Value The cumulative number of pump starts for pump 2. This is a cumulative counter, the value of which cannot be PUMP 2 COUNT modified. If using the engineer’s code, the counter can be reset to zero by holding the (MUTE) button. The cumulative run time in hours for pump 2.
- Page 19 The following settings are for experienced engineers only. Incorrect configuration of these settings can cause the equipment not to function correctly, and may cause damage to the equipment, system or property. Default Menu Item Function Value The number of pumps installed in the pressurisation unit. 16 PUMPS NUMBER This can be set to either 1 or 2.
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Page 20: Hydraulic Commissioning
Hydraulic Commissioning 1 – Float Valve Setting Ensure that the break tank float valve is set to its lowest position: AX & PF Units Min,i Midi & Digifiller Units If a drain valve is fitted to the break tank, ensure that it is closed. Then, turn on the mains water supply and allow the break tank to fill. - Page 21 Attach a length of hose to the hose tail on the drain valve and put the other end to drain. Then, using the cap off 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.
- Page 22 If the pump has a plastic bleed screw like the one shown below, do not use excessive force or attempt to use any tools to turn it as this may damage the pump casing. Forcing Pumps to Run Turn on the power supply to the digital controller and wait for the system pressure to appear on the display.
- Page 23 3 – Initial Start-up Open the internal isolation valve within the pressurisation unit by following the steps below: AX, PF, Digifiller & Midi Units MX Units Once the isolation valve is open, the pressure sensor will be able to read the system pressure. Turn on the power supply to the pressurisation unit.
- Page 24 4 – Testing To test the operation of the pressurisation unit while connected to the system, the system pressure must be lowered slowly to simulate a minor leak. This can be achieved by using a drain point on the system, the drain point on the pressurisation unit, or by manually opening the safety relief valve.
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Page 25: Commissioning Record
Commissioning Record Site Reference: PU Reference: Date Commissioned: Site Contact Name: Contact No.: YES / NO Engineer Name: AMS Accredited: Delete as appropriate Company: Contact No.: YES / NO COLD FILL: FILL SYSTEM: Delete as appropriate 1 / 2 HIGH SET: PUMPS NUMBER: Delete as appropriate 0 / 1... -
Page 26: Operation
Operation Once commissioned, the pressurisation unit should operate without any user intervention. Under normal operating conditions, the display will show the current system pressure in Bar. While the unit is filling, the display will show <PUMP 1 RUN> or <PUMP 2 RUN> depending on which pump is currently running. -
Page 27: Shutdown Procedure
Shutdown Procedure The pressurisation unit must be shut-down during any of the following scenarios: Work is being carried out on the system. Work is being carried out on the pressurisation unit The heating/cooling system is being flushed To shut down the pressurisation unit, please follow the steps below: 1. -
Page 28: Troubleshooting
Troubleshooting BSS Technical (Leicester) AMS Wigan AMS Spares & Service (Nottingham) Tel: 0116 262 3232 Tel: 0870 609 2101 Tel: 0870 850 3886 Email: enquires@bssgroup.com Email: amspumps@bssgroup.com Email: amsse@bssgroup.com If the pressurisation unit is showing a fault code on the display, holding down the [SET] button will cause the current system pressure to be temporarily shown on the display. - Page 29 Symptom Problem Solution The PUMP TYPE option is set Review PUMP TYPE setting incorrectly. P1 and/or P2 FAIL is displayed The relevant pump has failed Replace pump P2 FAIL is displayed but the unit The PUMPS NUMBER option is Set PUMPS NUMBER to 1 is a single pump model incorrectly set to 2 The mains water supply to the...
- Page 30 Symptom Problem Solution The wrong/no flow restrictor is Check float valve flow restrictor installed in the float valve (MX, selection (MX, Digifiller and Digifiller and midi units only) midi units only) The break tank is overfilling and The float valve position is set Set the float valve to its lowest discharging water to drain or incorrectly...
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Page 31: Maintenance
Maintenance Due to variations in operating conditions, and the varying loads placed on pressurisation units, it is not feasible to provide accurate predictions of component lifespan. The most effective method of maintenance is to inspect the pressurisation unit for early signs of component failure and take action accordingly. - Page 32 Check Float Valve Operation To test the operation of the break tank float valve, first ensure that the break tank overflow has a suitable path to drain. Gently push down on the arm of the float valve until it starts to discharge water, then release the float valve arm.
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Page 33: Wiring Diagram
Wiring Diagram... -
Page 34: Service Log
Service Log This service log should be completed by the service engineer after each annual service. -
Page 36: Spares
Spares The drawings on the following pages show the internal components for a range of pressurisation equipment. Due to continuing development and minor design changes, some components may be changed without notice. Therefore, the drawings may not accurately reflect the current production design. If in any doubt about the compatibility of replacement parts, please contact AMS. -
Page 37: Ax Models (Ax1-2.5E, Ax2-2.5E, Ax1-5E, Ax2-5E)
AX Models (AX1-2.5E, AX2-2.5E, AX1-5E, AX2-5E) *Image for indication only Description Part Code Pump See Datasheet ½” Non-Return Valve FC SC1 Pressure Transducer (0-10 Bar, 1-6V) 1-6V TRANSDUCER Combined Isolation & Drain Valve FCCG NO Float Valve BSS P33 Overflow Connection... -
Page 38: Pf Models (Pf1-2.5E, Pf2-2.5E, Pf1-5E, Pf2-5E)
PF Models (PF1-2.5E, PF2-2.5E, PF1-5E, PF2-5E) *Image for indication only Description Part Code Pump See Datasheet ½” Non-Return Valve FC SC1 Braided Hose BSS FLEXHOSE Pressure Transducer (0-10 Bar, 1-6V) 1-6V TRANSDUCER Combined Isolation & Drain Valve FCCG NO Float Valve BSS P33 Overflow Connection BSS M021... -
Page 39: Midi Models (Mde1-2.5, Mde2-2.5, Mde1-5, Mde2-5)
Digifiller & Midi Models (MD1-2.5E, MD2-2.5E, MD1-5E, MD2-5E) *Image for indication only Description Part Code Pump See Datasheet ½” Non-Return Valve FC SC1 Braided Hose BSS FLEXHOSE Pressure Transducer (0-10 Bar, 1-6V) 1-6V TRANSDUCER Mini Float Valve BSS M003 Combined Isolation & Drain Valve FCCG NO Overflow Connection BSS M021... -
Page 40: Mini Models (Mx1-3E, Mx2-3E)
MX/Mini Models (MX1-3E, MX2-3E) *Image for indication only Description Part Code Pump See Datasheet Pressure Transducer (0-10 Bar, 1-6V) 1-6V TRANSDUCER ¼” Ball Valve BSS M005 Overflow Connection BSS M021 Mini Float Valve BSS M003 Float Switch BSS R012 8mm Poly-tube BSS M015 ¼”BSP M x 8mm Push-Fit BSS M007... - Page 41 Notes...
- Page 42 Notes...
- Page 43 Notes...
- Page 44 Notes BOSS Pressurisation O&M Manual – Version 8 – February 2014...
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