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Stuart Turner MIKROFILL MAXI AP 140 Installation, Operation & Maintenance Instructions Manual

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MIKROFILL MAXI AP
Installation, Operation & Maintenance Instructions
Please leave this instruction booklet with the end user as it contains important warranty, maintenance and
safety information
Read this manual carefully before commencing installation.
This manual covers the following products:
MAXI AP 140
Part No: 47721
MAXI AP 180
Part No: 47723
MAXI AP 240
Part No: 47722
MAXI AP 280
Part No: 47724
MAXI AP 140 RH
Part No: 47730
MAXI AP 180 RH
Part No: 47732
MAXI AP 240 RH
Part No: 47731
MAXI AP 280 RH
Part No: 47733

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Summary of Contents for Stuart Turner MIKROFILL MAXI AP 140

  • Page 1 MIKROFILL MAXI AP Installation, Operation & Maintenance Instructions Please leave this instruction booklet with the end user as it contains important warranty, maintenance and safety information Read this manual carefully before commencing installation. This manual covers the following products: MAXI AP 140 RH MAXI AP 140 Part No: 47730 Part No: 47721...

  • Page 2: Product Description

    PRODUCT DESCRIPTION Heating and cooling system pressurisation top up unit with integral water storage tank and electric motor driven peripheral pump(s) with an automated control system consisting of pressure transducer and water level sensors. The tank includes an AB air gap for category 5 fluid isolation (BS EN 1717). APPLICATION The Maxi AP range is designed to provide initial system fill and water top up to compensate for intermittent losses in system pressure in heating and cooling systems in commercial or industrial applications.

  • Page 3: Table Of Contents

    CONTENTS CONTENTS ..........................3 1. GENERAL SAFETY INFORMATION ..................4 WARNINGS ........................ 5 CAUTIONS FOR INSTALLATION ................6 CAUTIONS FOR OPERATION/USER ............... 8 CAUTIONS FOR MAINTENANCE ................8 INSTALLATION INSTRUCTIONS ..................9 GENERAL ........................9 PROCEDURE ......................9 USER INSTRUCTIONS ..................... 14 COMMISSIONING....................

  • Page 4: General Safety Information

    1. GENERAL SAFETY INFORMATION These instructions are intended for the installer/operator/user/maintenance of this equipment and  must be kept with the equipment, for the life of the equipment and made available to all persons. Please read GENERAL SAFETY INFORMATION before doing anything else, and then follow them carefully.

  • Page 5: Warnings

    WARNINGS 1.1.1 Do not touch any live parts for at least 5 minutes after switching off the electricity supply. Failure to observe this will constitute a severe Electric shock and/or Burns hazard and may be lethal. 1.1.2 The equipment is only suitable for earth referenced supplies and must be permanently earthed to avoid Electric shock hazard.

  • Page 6: Cautions For Installation

    CAUTIONS FOR INSTALLATION 1.2.1 READ GENERAL SAFETY INFORMATION 1, WARNINGS 1.1 and CAUTIONS 1.2, 1.3 & 1.4 1.2.2 The unit should only be installed/operated by a competent person; A competent person is someone who is technically competent and familiar with safety practices and the hazards involved. 1.2.3 Do not lift the pumpset by pipework.
  • Page 7 removed once the process is complete. Chlorination beyond these limits could seriously damage pumpset components and WILL NOT be covered by the warranty. 1.2.16 The installer/user is responsible for the installation of the correct earthing and protection according to valid national and local standards. All operations must be carried out by a suitably qualified person. 1.2.17 The equipment is only suitable for earth referenced supplies and must be permanently earthed to avoid electric shock hazard.

  • Page 8: Cautions For Operation/User

    CAUTIONS FOR OPERATION/USER 1.3.1 READ GENERAL SAFETY INFORMATION 1, WARNINGS 1.1 and CAUTIONS 1.2, 1.3 & 1.4 1.3.2 The unit should only be operated/used by a competent person; A competent person is someone who is technically competent and familiar with safety practices and the hazards involved. 1.3.3 The Owner/User of this equipment has a Legal Responsibility to ensure that it is subject to regular formal inspections.

  • Page 9: Installation Instructions

    2 INSTALLATION INSTRUCTIONS GENERAL These instructions are intended for the installer of this pressurisation unit. Please follow them carefully. The unit should only be installed by a competent person; A competent person is someone who is technically competent and familiar with safety practices and the hazards involved. It should be noted that the assembly of pressure equipment on site under the responsibility of the user (or his representative) is not subject to the Pressure Equipment Directive 2014/68/EU.
  • Page 10 2.2.4 PIPEWORK 2.2.4.1 Mains Water Supply Fit an isolating valve in the supply to enable the unit to be isolated from the supply for maintenance. Connect the supply. For Maxi AP models this is a ½" BSP male connection at the side of the cabinet.
  • Page 11 Fig 2.2a Mikrofill Maxi AP Left hand configuration Fig 2.2b Mikrofill Maxi AP Right hand configuration Page...
  • Page 12 2.2.5 EXPANSION, CONTROL and HYDRAULIC ACCUMULATOR VESSELS All vessels must be securely mounted to prevent any movement from imposing strain on the attached pipework. Vessels of 60 litres capacity or greater MUST be mounted vertically on the integral legs with water connection lowermost. Set up the vessel so the air charge filling valve and the diaphragm are accessible for future maintenance.
  • Page 13 2.2.6 ELECTRICAL 2.2.6.1 READ GENERAL SAFETY INFORMATION 1, WARNINGS 1.1 and CAUTIONS 1.2, 1.3 & 1.4 2.2.6.2 All wiring must comply with the latest edition of local wiring Regulations. 2.2.6.3 Always wear anti-static wrist strap to avoid static discharge causing problems with the built in electronic program.

  • Page 14: User Instructions

    USER INSTRUCTIONS COMMISSIONING Therefore, we strongly recommend the equipment is commissioned by our authorised agent who will prepare the equipment, make any necessary adjustments and leave the equipment in operational order. Prior to requesting an engineer to attend the site for commissioning, the client must ensure that; The equipment has been correctly installed.

  • Page 15: Operating Instructions

    OPERATING INSTRUCTIONS In normal operation, the Main Screen will show the system status as "PRESSURE CORRECT," along with the current system pressure in Bar, and the status of Pump 1 (P1) and Pump 2 (P2) (where fitted) as "AUTO" (see Fig 3.2).
  • Page 16 Back/Clear Alarms Button:   This button serves two functions: Back: Press this button to return to the previous screen or menu.  Clear Alarms: When held down during active alarms, this button clears alarms from the  dynamic message window for 30 seconds. The alarms will remain in a cleared state for 30 seconds, and if the alarm persists, they will reappear.
  • Page 17 Fig 3.6: Parameters Menu Parameters such as Duty Pressure, Low Pressure, High Pressure, Pump Differential, Duty Delay,  Support Delay, High pressure/Low-pressure lockout, High Pressure/Low-pressure Lockout Delay, User passcode, MODBUS parameters, and BMS alarms can be configured here. Upon entering the ‘PARAMETERS MENU’ screen, the first row will be highlighted in blue, indicating ...
  • Page 18 Fig 3.8: Edited Duty pressure Fig 3.9: Swiping across the Parameters After making changes, press the ‘BACK’ button to save them.  A confirmation window will appear with the options ‘Yes’, ‘No’, and ‘Cancel,’ with the cursor initially  highlighted on ‘Yes’ (see Fig 3.10). Fig 3.10: Parameters Menu Save Fi 3.11: Parameters Menu Save confirmation Use the ‘RIGHT’...
  • Page 19 Fig 3.13: Removing Commissioning Needed Alarm Scroll to the ‘LAST SERVICE DATE’ row, press the ‘ENTER’ button and enter the date the unit was  commissioned (see Fig 3.14). Fig 3.14: Resetting Last Service Date Press the ‘BACK’ button to return to the ‘MENU’ screen. ...
  • Page 20 The History Log Screen—On the ‘HISTORY LOG’ tab, press the ‘ENTER’ button to view system  logs and alarms in real-time, arranged in chronological order with the most recent entries displayed first (see Fig 3.15). Fig 3.15: History Log Use the ‘RIGHT’ and ‘LEFT’...
  • Page 21 Once a new date is set, pressing the ‘ENTER’ button will move to the ‘SET TIME’ screen, where  time can be updated (see Fig 3.17). Pressing the ‘BACK’ button will move to the date change screen and pressing the ‘ENTER’ button will save the new time.
  • Page 22 Once selected, the square box around the pump will display three mode options: ‘HAND,’ ‘OFF,’ and  ‘AUTO,’ with the cursor initially highlighting ‘HAND’ (see Fig 3.20). Fig 3.19: Pump 2 Edit Mode Fig 3.20: Pump 1 Mode Selection Use the ‘UP’ and ‘DOWN’...
  • Page 23 In ‘OFF’ mode, no circle will be displayed around the pump.  If the pump trips, an orange circle will appear around it to signal the fault.  3.3.8 Monitoring Real-time System Alarms Real-time system alarms are displayed on the ‘MAIN SCREEN’ within the dynamic message window. ...
  • Page 24 3.3.9 Muting/Clearing Real-time System Alarms Real-time system alarms displayed on the ‘MAIN SCREEN’ within the dynamic message window can  be muted or cleared during commissioning or repair. These actions should only be performed by a qualified service engineer. To mute an alarm, press and hold the ‘LEFT’ button until the buzzer stops sounding.
  • Page 25 3.3.12 System Alarms ***** Alarm ***** Cause Check Pressure vessel air charge incorrect? High pressure alarm High Pressure Insufficient expansion capacity? threshold has been reached. Pump(s) left in Hand? Pressure vessel air charge incorrect? Low pressure alarm threshold Water usage exceeds design capacity? Low Pressure has been reached.
  • Page 26 3.3.13.2 Communication Settings To establish a successful connection between the MODBUS Master and the Maxi-AP (MODBUS Slave), ensure the following communication settings are correctly configured:  Slave Device ID: 1–247 (Configurable)  Baud Rates Supported: 9600  Data Bits: 8 ...
  • Page 27 BMS Alarm 6 Discrete Input Read Only 10009 1-bit Low Water Alarm BMS Alarm 7 Discrete Input Read Only 10010 1-bit Transducer Failure BMS Alarm 8 Discrete Input Read Only 10011 1-bit Pump Failure 3.3.13.4 Step-by-Step Configuration Guide Follow these steps to connect your MODBUS Master to the Maxi-AP and read data. 1.
  • Page 28  System Run Time: Register Addresses: 30024–30025   Function Code: 04  Data Type: 32-bit Integer  Description: Reads the total run times for Pump 1, Pump 2, and the entire system. Procedure:  Initiate a MODBUS query using Function Code 04. ...

  • Page 29: Servicing

    SERVICING MAINTENANCE AND CARE OF YOUR EQUIPMENT The Mikrofill equipment that is described in this instruction booklet has been manufactured and tested to the highest standards of design and quality. It will give trouble-free operation over many years provided it is maintained regularly from when it is commissioned.

  • Page 30: Component List

    Rocker Switch 1. MX1100007 Casing, Main Body 2. MX1100008 Casing, Bottom Panel 11. MX1000038 Stuart Turner PH45TS (Maxi AP 140 & 240) 3. MX1100010 Casing, Front Panel 11. MPP-21007C Lowara PSAM70/C (Maxi AP 180 & 280) 4. MX1100009 Casing, Electrical Box 12.

  • Page 31: Technical Specifications

    TECHNICAL SPECIFICATIONS MAXI AP 140 MAXI AP 240 MAXI AP 180 MAXI AP 280 Pressurisation Unit 47721, 47730 47722, 47731 47723, 47732 47724, 47733 Warranty 2 years General Conformity Certification UKCA/CE Mounting Floor Mounted Sealed sys Capacity Up to 300,000 litres Pump Control System Features ...

  • Page 32: Maintenance Instructions

    MAINTENANCE INSTRUCTIONS PROCEDURE Pump Lubrication The pumps require no lubrication, as the pumps are self-lubricating. History Log Enter the history log and record any entries since the last service. Refer to the Systems Alarms table 3.3.12 for potential causes and rectification. Expansion Vessels Air Charge Pressure.
  • Page 33 UK DECLARATION OF CONFORMITY MIKROFILL MAXI AP RANGE Supply of Machinery Regulation - 2008 EMC Regulation – 2016 EN ISO 12100:2010, EN 809:1998+A1:2009/ AC:2010 EN IEC 55014-1: 2021 Electrical Equipment Regulation – 2006 EN IEC 55014-2: 2021 EN IEC 61000-3-2: 2019/A1:2021 EN 60335-1: 2012 +A11: 2014 +A13: 2017 + A1: 2019 + EN 61000-3-3: 2013/A2:2021 A14: 2019 +A2: 2019 + A15: 2021...

This manual is also suitable for:

Mikrofill maxi ap 240Mikrofill maxi ap 180Mikrofill maxi ap 280Mikrofill maxi ap 140 rhMikrofill maxi ap 180 rhMikrofill maxi ap 240 rh ... Show all

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