Table of Contents
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JET Digital Pressurisation Equipment
MAXI Models (D125, D225, D150, D250)
MD Models (125, 225, 150, 250)
Mini Models (130D, 230D)
Operation & Maintenance
Manual
Rev 8.1
.
Rev 8.1 Oct-15
Page 1 / 42
We reserve the right to change designs and technical specifications of our products
www.wolseley.co.uk
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Table of Contents
Summary of Contents for Jet MAXI D125
- Page 1 JET Digital Pressurisation Equipment MAXI Models (D125, D225, D150, D250) MD Models (125, 225, 150, 250) Mini Models (130D, 230D) Operation & Maintenance Manual Rev 8.1 Rev 8.1 Oct-15 Page 1 / 42 We reserve the right to change designs and technical specifications of our products...
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Page 2: Customer & Equipment Details
Customer Details Please fill in information future reference: Company: Contact: Address: Tel No: Fax No: Post Code: E-mail: Equipment Details Details of model and serial number may be found on the label Model: Serial No: Purchase date: Purchase From: Note: It is highly recommended to have this equipment commissioned by a Wolseley approved engineer. -
Page 3: Commission Record
Commissioning Record FILL IN RECORD TO VALIDATE WARRANTY OF PRESSURISATION UNIT Site Reference: PU Reference: Date Commissioned: Engineer Name: Company: COLD FILL: FILL SYSTEM: YES / NO Delete as appropriate HIGH SET: PUMPS NUMBER: 1 / 2 Delete as appropriate LOW SET: PUMP TYPE: 0 / 1... -
Page 4: Table Of Contents
Contents Customer & Equipment details Commission Record About this Manual Where to find more Information Equipment Overview Principal of Operation Installation Pipe Connections Typical Installation Diagram Flow Restrictors (MD & Mini models only) MAXI Clearance and Connection Requirements MD Clearance and Connection Requirements Mini Clearance and Connection Requirements Electrical Power Supply Fault Contacts... -
Page 5: About This Manual
About this Manual This Operation and Maintenance Manual contains all the necessary information to install, commission, operate and maintain Flexfiller 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 6: 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 7: 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 8: Flow Restrictors (Md & Mini Models Only)
Flow Restrictors (Mini & Midi 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. -
Page 9: Maxi Clearance And Connection Requirements
MAXI Clearance and Connection Requirements Connection Size Notes An isolation valve must be Mains ½” BSP M installed on the mains water feed Water Feed for servicing. Guidance on drainage Break Tank 22mm requirements should be obtained Overflow from the local water authority. The pressurisation unit and expansion vessel should be connected to the system at the... -
Page 10: Md Clearance And Connection Requirements
MD Clearance and Connection Requirements Connection Size Notes An isolation valve must be Mains ½” BSP M installed on the mains water Water Feed feed for servicing. Guidance on drainage Break Tank requirements should be 22mm Overflow obtained from the local water authority. -
Page 11: Mini Clearance And Connection Requirements
Mini Clearance and Connection Requirements Connection Size Notes An isolation valve must be Mains ½” BSP M installed on the mains water Water Feed feed for servicing. Guidance on drainage Break Tank requirements should be 22mm Overflow obtained from the local water authority. -
Page 12: 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 13: Fault Contacts
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. -
Page 14: Commissioning
Commissioning It is highly recommended to have this equipment commissioned by a Flamco 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. -
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 >8.0. -
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: Program List
Program List 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). - 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 modified. If using the PUMP 2 COUNT engineer’s code, the counter can be reset to zero by holding the (MUTE) button.
- 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: MAXI Units Mini & MD 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: MAXI & MD Units Mini 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: 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 26: 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 27: 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. The following maintenance procedures should be performed at least once a year: Visual Inspection A basic visual inspection will highlight the majority of potential faults on a pressurisation unit. - Page 28 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 29: Wiring Diagram
Wiring diagram Rev 8.1 Oct-15 Page 29 / 42 We reserve the right to change designs and technical specifications of our products www.wolseley.co.uk... -
Page 30: Wiring Location
Wiring location list Rev 8.1 Oct-15 Page 30 / 42 We reserve the right to change designs and technical specifications of our products www.wolseley.co.uk... -
Page 31: Electrical Items (All Models)
Spare Parts 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. -
Page 32: Maxi Models (D125, D225, D150, D250)
MAXI Models (D125, D250, D150, D250) *Image for indication only Description Part Code Pump – Model 125D & 225D (Pedrollo PQA60) BSS PQA 60 Pump – Model 150D & 250D (Pedrollo PQ81B) BSS PQ81b Pump – Model 280DS (Pedrollo PQA90) FC039 ½”... -
Page 33: Md Models (125, 225, 150, 250)
MD Models (125, 250, 150, 250) *Image for indication only Description Part Code Pump – Model 125D & 225D (Pedrollo PQA60) BSS PQA 60 Pump – Model 120D & 250D (Pedrollo PQ81B) BSS PQ81b ½” Non-Return Valve FC SC1 Braided Hose BSS FLEXHOSE Pressure Transducer (0-10 Bar, 1-6V) 1-6V TRANSDUCER... -
Page 34: Mini Models (130D, 230D)
Mini Models (130D, 230D) *Image for indication only Description Part Code Pump – All Models (Model E EP77) BSS M024 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... -
Page 35: Troubleshooting
Troubleshooting If for any reason the pressurisation unit does not seem to be functioning correctly, please refer to the table below for a list of solutions to known problems. 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 36 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 unit has...
- Page 37 Symptom Problem Solution The wrong/no flow restrictor is Check float valve flow restrictor installed in the float valve (mini and selection (mini 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 38: Service Log
Service Logs This service log should be completed by the service engineer after each annual service. Rev 8.1 Oct-15 Page 38 / 42 We reserve the right to change designs and technical specifications of our products www.wolseley.co.uk... - Page 39 Rev 8.1 Oct-15 Page 39 / 42 We reserve the right to change designs and technical specifications of our products www.wolseley.co.uk...
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Page 40: Warranty Information
If the unit is identified with a manufacturing defect then no charge is made for correcting the defect. The JET equipment is manufactured to order and is clearly marked, where applicable, with a unique serial number, allowing traceability to both individual model configuration and the engineer or site responsible for the build and test. - Page 41 Notes Rev 8.1 Oct-15 Page 41 / 42 We reserve the right to change designs and technical specifications of our products www.wolseley.co.uk...
- Page 42 Wolseley Centre Harrison Way Leamington Spa Warwickshire CV31 3HH United Kingdom T +44 0870 8506538 W www.jetrange.co.uk Rev 8.1 Oct-15 Page 42 / 42 We reserve the right to change designs and technical specifications of our products www.wolseley.co.uk...