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Summary of Contents for FLOWTECH flowpress
- Page 1 DS Pressurisation & Dosing Units OPERATION AND MAINTENANCE MANUAL First Publication Date: 01/09/2020 Revision: Revision Date:...
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Page 2: Table Of Contents
Contents General Information Safety Information Equipment Overview Principal of Operation Installation Typical Installation Diagram Electrical Power Supply Micro Controller Fault contacts Commissioning Controller Overview Controller Programming Program List Hydraulic Commissioning Balancing Valve Setting Open and Close Setting the Flow Notes Operation Fault Codes Shutdown procedure... -
Page 3: General Information
General Information These instructions are to assist in the installation of the flowpress DS Pressurisation Units please follow them carefully. If, having read this Operation & Maintenance Manual, there is any doubt about any aspect of the installation please don't hesitate to contact our technical team. -
Page 4: Safety Information
Water Solutions. This document is intended for ALL installers, operators, users and persons carrying out maintenance of this equipment and must be kept with the equipment, for the life of the equipment and made available to all persons at all times. - Page 5 Hazard of electric shock. Disconnect incoming power before working on this unit. HAND-PAP WARNING! - The inverter should be protected separately against ground fault. Observe the regional regulations for electrical installation! flowpress DS Pressurisation & Dosing Units...
- Page 6 exclamat CAUTION! - It is strongly recommended that all electrical equipment conforms to National Electrical Codes and local regulations. Only qualified personnel should perform installation, alignment and maintenance. The manufacturer reserves the right to alter the technical data in order to make improvements or update information. exclamat CAUTION! - Failure to observe these rules will render the guarantee invalid.
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Page 7: Equipment Overview
The following schematic shows the internal arrangement of a pressurisation unit: The flowpress DS unit is fitted with a break tank (1) which is filled from the mains water supply (2) via a float operated valve (3). The break tank is fitted with an overflow (4) in case the break tank overfills, and a weir overflow (5) in case the primary overflow fails. -
Page 8: 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 9 Flowpress DS Clearance and Connection Requirements Connection Size Notes Mains Water ½” BSP M An isolation valve must be installed Feed on the mains water feed for servicing. Break Tank 22mm Guidance on drainage Overflow requirements should be obtained from the local water authority.
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Page 10: 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 11: Micro Controller
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. For further information please refer to the commissioning section of this manual. flowpress DS Pressurisation & Dosing Units... -
Page 12: Commissioning
Commissioning It is highly recommended to have this equipment commissioned by a Flowtech 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 13: Controller Overview
In normal operation, the functions of the buttons are as follows: Button Function Press Hold Show Current System Pres- sure MUTE Mute Audible Reset Unit Alarm Enter Programming Menu Enter Programming Menu flowpress DS Pressurisation & Dosing Units... -
Page 14: 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 15: Program List
The cumulative run time in hours for pump 1. PUMP 1 HOURS This is a cumulative timer, the value of which cannot be modified. If using the engineer’s code, the counter can be reset to zero by holding the (MUTE) button. flowpress DS Pressurisation & Dosing Units... - Page 16 Menu Item Function Default Value The cumulative number of pump starts for pump 2. PUMP 2 COUNT This is a cumulative counter, the value of which cannot be modified. If using the engineer’s code, the counter can be reset to zero by holding the (MUTE) button.
- Page 17 Disabling this option will stop the controller from monitoring the pumps and PUMP SENSE generating <PUMP FAIL> faults. It is not recommended to disable this option. Please consult Flowtech Technical before doing so. The type of pressure sensor installed in the unit.
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Page 18: Hydraulic Commissioning
– Float Valve Setting Ensure that the break tank float valve is set to its lowest position: Flowpress DS 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 19 Failure to bleed the pumps may result in damage to the equipment, system and property. After bleeding the pumps, close the drain valve and remove the hose from the hose tail. flowpress DS Pressurisation & Dosing Units...
- Page 20 – Initial Start-up Open the internal isolation valve within the pressurisation unit by following the steps below: PressDS 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. Depending on the current system pressure, the unit will respond in one of the following ways: If the system pressure is below the low pressure alarm setting, the controller will display a “LOW PRESSURE”...
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Page 21: Balancing Valve Setting
· Clockwise to close (Red) · Anti Clockwise to open (white) · Fluid will not flow whilst red bar is showing. Note green release lever will not func- tion whilst valve is closed (red) flowpress DS Pressurisation & Dosing Units... - Page 22 The following table shows the valve settings required to achieve a given chemical concentration. Chemical Total Top-up Chemical Rate Valve Valve 6 Litres 6 Litres 6 Litres 6 Litres 8 Litres 8 Litres 8 Litres 8 Litres 8 Litres 8 Litres Chemical Control Water Control Key:...
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Page 23: Operation
There have been 4 pump starts within an 8 hour Manual Reset DEMAND period SERVICE The pressurisation unit is due an annual service Manual Reset For practical guidance on diagnosing and rectifying faults, please refer to the Troubleshooting section of this manual. flowpress DS Pressurisation & Dosing Units... -
Page 24: 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 25: Maintenance
Once the [COLD FILL] pressure is reached, the pump should stop. If the unit is a twin pump model, this test should be repeated until both pumps have run and successfully re- pressurised the system. flowpress DS Pressurisation & Dosing Units... - Page 26 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 27: Wiring Diagram
Wiring diagram flowpress DS Pressurisation & Dosing Units... - Page 28 Wiring location list...
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Page 29: Spare Parts
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 Flowtech. *Image for indication only... -
Page 30: Flowpressds Models
FlowpressDS Models *Image for indication only Description Digital Controller Power Switch Mini Float Valve Overflow Connection Midi single Break Tank (Water) Float switch ¼” Brass Locking Nut ¼”BSP M x 8mm Push-Fit Additive Break Tank (18 Litres) Float switch for Additive tank Combined Isolation &... -
Page 31: Troubleshooting
P1 and/or P2 FLOOD Bleed the pump locked and not pumping water LIMIT is displayed The unit is undersized for the Review unit selection system The FLOOD LIMIT time is too Consult Flowtech short. flowpress DS Pressurisation & Dosing Units... - Page 32 Symptom Problem Solution The PUMP TYPE option Review PUMP TYPE setting is set incorrectly. P1 and/or P2 FAIL is dis- played The relevant pump has failed Replace pump P2 FAIL is displayed but the The PUMPS NUMBER op- Set PUMPS NUMBER to 1 unit is a single pump model tion is incorrectly set to 2 The mains water supply to the...
- Page 33 The 12V transformer has failed Replace Transformer switched on The digital controller has failed Replace digital controller SERVICE is displayed The unit is due an annual ser- Contact service engineer on the screen vice flowpress DS Pressurisation & Dosing Units...
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Page 34: Warranty Details
If the unit is identified with a manufacturing defect then no charge is made for correcting the defect. The Flowtech 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 35 Unit 1 Lock Flight Buildings, Wheatlea Industrial Estate, Wigan, Greater Manchester WN3 6XP United Kingdom 9001 : 2015 REGISTERED Membership No. 700106 Certificate No. 185352020 Copyright © 2020 • All Rights Reserved • Flowtech Water Solutions Limited • Company Number: 05125479 • VAT Number: 836 8024 19...