Installation, Commissioning & Servicing Instructions
Intended For Commercial / Light Industrial Applications
www.elco.co.uk Doc No. L372 / rev A
Minifill – E
Compact Wall Mounted Electronic Pressurisation Unit
IMPORTANT NOTE:
THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD
BEFORE INSTALLING, COMMISSIONING, OPERATING OR
SERVICING THE EQUIPMENT
2
THIS PRESSURISATION UNIT COMPLIES WITH THE ESSENTIAL REQUIREMENTS OF THE
MACHINERY DIRECTIVE 2006/42/EC, THE LOW VOLTAGE DIRECTIVE 2014/35/EC AND
THE ELECTROMAGNETIC COMPATIBILITY DIRECTIVE 2004/108/EC.
COUNTRY OF DESTINATION : UNITED KINGDOM & REPUBLIC OF IRELAND
Section
1.0 General 3
2.0 Product description 4
3.0 Technical data and dimensions 5
4.0 Delivery and packaging 6
5.0 Location 6
6.0 Installation clearances 6
7.0 Wall mounting 6
8.0 Water connections 7
9.0 Electrical connections 9
10.0 Determining cold fill pressure 10
11.0 Filling the system 11
12.0 Maintenance & Commissioning 12
13.0 Fault Finding 15
14.0 Internal components and short parts list 16
15.0 Commissioning form 17
Figures
3 Dimensions 5
6 Clearances 6
7 Wall mounting 6
8.1 Flow restrictors 7
8.2 Changing restrictor inserts 7
8.3 Water connections 8
8.4 System connections 8
9.1 Wiring diagram 9
11.1.1 Filling a domestic system 11
11.1.2 Filling a commercial system 11
12.1 Control panel 12
12 Controls schematic 15
14 Internal components 16
15 Commissioning form 17
Contents
3
These instructions are intended to
assist the installer, commissioning
engineer, maintenance engineer
and the end user with the usage of
the equipment.
Please read this manual fully before
commencing the installation of the
unit. The pressurisation unit should
only be installed by persons deemed
to be competent. This manual shall
be handed to the user following
completion of the installation.
The unit shall not be left to operate
without being correctly commissioned.
Installation Requirements
The installation of the pressurisation
unit shall be in accordance with the
relevant requirements of all current
Regulations, such as;
• Pressure Systems & Transportable
Gas Containers Regulations 1989.
• Water Supply (Water Fittings)
Regulations 1999 (Amended
Dec 2000).
• Water Byelaws 2000-Scotland.
• Local Water Authority Byelaws.
• IEE Electrical Regulations.
• Health & Safety at Work Act.
• Building Regulations.
• Construction (Design &
Management) Regulations 1994.
• National Fire Regulations.
• Insurance Company requirements.
It is the law that pressure system
appliances are installed by competent
persons in accordance with the
above regulations. Failure to install
appliances correctly could lead to
prosecution. It is in your own interest
and that of safety, to ensure that this
law is complied with.
The following British Standards /
Codes of Practice are also applicable:
• BS 6644: (As amended)
Specification for gas fired hot water
pressurisation units of rated inputs
between 60kW and 2MW.
• BS 6880: (As amended) Code of
Practice for low temperature hot
water heating systems of output
greater than 45kW. Parts 1, 2 & 3.
• BS 7074: Application, selection and
installation of expansion vessels
and ancillary equipment for sealed
water systems.
• BS 7593: 1 (As amended) Code of
Practice for treatment of water in
domestic hot water central heating
systems.
• BS 7671: (As amended)
Requirements for electrical
installations. IEE Wiring Regulations.
• BS EN 60335-1: Safety of household
and similar electrical appliances.
• BS EN 41236-1: Specification for
safety valves for steam and hot
water.
• ICOM Water treatment and
Conditioning of Commercial
Heating Systems.
1.0 General Notes
General
4
The pressurisation unit is housed in
a powder coated steel cabinet with
a removable cover and is suitable for
filling and maintaining the cold fill
pressure in sealed heating, cooling,
or chilled water systems.
The wall mounted unit has been
designed to meet the needs of
the commercial/large domestic
installations, where plant room space
may be restricted and is fitted with a
single pump.
At 600mm High, 382mm Wide, and
280mm Deep, the pressurisation unit
allows for site installation where space
is of a premium, without compromising
serviceability.
The unit incorporates the following
features:-
• Micro-processor controller
• Non-return valve
• Pressure transducer
• LCD display screen & User
interface keypad
• Isolating Valve (between tank
and pump)
All screw threads used in the
pressurisation unit conform to ISO 7/1
or ISO 228/1 for pipe threads where
applicable & ISO 262 for all general
screw threads.
Versatility of Use
The pressurisation unit can be
configured to achieve and maintain a
system Cold Fill Pressure from as low
as 0.8bar up to 3.0bar.
The unit detailed in this manual utilises
a Type AF Air Gap, and is therefore
compatible for use with both Fluid
Category 3 (C-3) In-House, and Fluid
Category 4 (C-4) Other Than In-House
systems.
Building Management System
(BMS) Compatible
The pressurisation unit is supplied
as standard with Volt Free Relay
Outputs to provide the following
alarms; General Alarm, High
Pressure Alarm & Low Pressure
Alarm. These switches are rated to
accept 230Volts AC 50 Hz 1Ph, with
a maximum current of 0.5 Amps.
Self Diagnostic
The micro-processor is fully
diagnostic. Should a problem occur
with the operational function of the
appliance, the micro-processor will
operate the Low or High Pressure
relay or for other faults, the General
Fault relay, and a Flashing Error Code
will be displayed on the LCD Display
indicating the identified fault.
Guarantee
The warranties available on the
pressurisation unit are as follows;
Supply and Commissioned (By the
manufacturer) – Parts and Labour
Warranty, against manufacturing or
material defects for a period of up to
15 months from the date of delivery.
Supply Only - Parts Only Warranty,
against manufacturing or material
defects for a period of 12 months from
the date of delivery.
2.0 Product Description
Product description
5
3.0 Technical Data & Dimensions
Technical Data & Dimensions
278
Mains water
inlet ½“ BSP
Overflow plastic pipe
32mm dia. bore
Wall fixing
bracket
Cable entry
- alarms
Cable entry
- mains
Outlet 15mm
compression
Side View (Left Hand side) Front View
70
382
151 80
6.6dia
75
40
40
150
180
210
240
486
557
600
125
Figure 3 - Dimensions
Technical Data
Cold Fill Pressure Min 0.8 bar / Max 3.0 bar
Minimum MCW supply
8 l/min
Power supply (230V 50Hz)
10.0 Amps
Start current
9.0 Amps
Run current
2.8 Amps
Air gap type
AF
Break tank capacity
7.6 litres
Weight - empty
22.0 kg
Weight - full
30.0 kg
Connections
MCW inlet 1/2” BSP Male
Waste water overflow 32mm plastic
System Water outlet 15mm comp
Mains electrical gland 1*10mm
Electrical cable glands 3*10mm
Noise level @1m 58 dBA
Temperature rating 4-65°C
Housing classification IP65
6
The pressurisation unit is delivered
as a single carton containing:
• Assembled and factory tested
pressurisation unit.
• Wall mounting bracket.
(Supplied attached to the
front of the water tank.)
5.0 Location
The pressurisation unit is not suitable
for installation external to a building.
The position chosen for the appliance
shall be a structurally sound wall
capable of supporting the filled
weight of the appliance and all
associated ancillary equipment.
The wall shall be plumb vertical
to ensure correct operation.
6.0 Installation
For ease of installation, commissioning,
servicing and maintenance the following
clearances should be observed.
NOTE: These distances are
MINIMUM and MUST NOT be
reduced. Failure to observe
these clearances could result in
the warranties on the appliance
becoming VOID.
7.0 Wall Mounting
A mounting bracket is supplied inside
the unit taped to the front of the tank.
It is intended that this bracket should
be fixed to the wall and the unit hung
from it.
Each wall mounted unit also has two
holes in the back of the chassis for
extra security.
The corresponding holes in the wall
should be drilled to suit once the unit
is mounted on its bracket. The bracket
dimensions are shown in Fig 7 below.
Note: The wall shall be plumb vertical
to ensure correct operation.
4.0 Delivery and Packaging
Delivery and Packaging
PLAN VIEW
100
150
450
Figure 6 0 – Clearances
Rear View
382
600
151 80
6.6dia
125
Figure 7 0 – Wall mounting
7
The Mains Cold Water (MCW) supply
connection (A) shall be able to supply
at least 8 litres per minute of clean
water; otherwise the operation of the
appliance may empty the break tank
of water.
The appliance is fitted with a low water
level switch in the break tank to prevent
operation of the unit when there is
insufficient water available. This is to
protect the pump assembly from air
locks and subsequent damage.
The Waste Water Outlet/Overflow (B)
shall be routed to a safe discharge
location that will not cause harm
to persons, nor property, but shall
be clearly visible, so that any water
discharge will be identified and
remedial action taken, ensuring that
any wasted water is kept to a minimum.
The Waste Water Outlet/Overflow
shall not be connected directly to any
foul water system without a suitable
warning method being incorporated,
as above.
After the warning method, and before
connection to the foul water system
a suitable trap shall be incorporated
to prevent the release of any vapour/
effluent from the foul water system.
The Waste Water Outlet/Overflow
shall be routed in such a way to
minimise the risk of blockage
through freezing. If any part of the
Waste Water Outlet/Overflow is to
be run external to the building or
is at risk of freezing, then the pipe
shall be suitably insulated to protect
against freezing.
The System Connection (C) shall be
connected to the system pipework
in such a manner so that the suction/
discharge pressure of any circulation
pumps shall not influence the
appliance. It is recommended that
the System Connection be routed in
such a manner to include/incorporate
the supply connection to any system
expansion vessels. See Fig 8.2
Each unit comes with a selection of
inserts that can be fitted into the inlet
valve to achieve the required output:
Mains inlet pressure > 3 bar H.P.
restrictor (white see fig 8.1) Mains inlet
pressure < 3 bar L.P. restrictor (red see
fig 8.1)
The HP restrictor is fitted in the inlet
side of the float valve assembly.
This should be unscrewed in order to
change the restrictor (see fig 8.2).
The LP Restrictor is clipped to the
side of the valve assembly.
8.0 Water Connection
Water Connections
Figure 8.1 – Flow restrictors
Figure 8.2 – Changing
restrictor inserts
8
8.1 Water Connection
Water Connections
To set or check the expansion vessel
charge pressure the lock-shield valve
between the unit and the vessel must
be closed. The drain cock fitted on the
base of the expansion vessel must be
open to allow any water in the vessel
to escape.
A suitable gauge should be used to
check the charge pressure. Generally
a Schrader ‘car type’ valve is fitted near
the top of the expansion vessel.
If the charge pressure is too high
it can be reduced by depressing
the centre of the Schrader valve or
by using a pressure gauge with an
integral air release valve. If the charge
pressure is too low a small increase
can be provided using a car foot pump
otherwise an oil free compressor or
nitrogen bottle is recommended.
Note! The expansion vessel charge
pressure should be set to 0.1 bar less
than the cold fill pressure. When the
correct pressure is set the Schrader
valve protective cap must be replaced.
Check the integrity of the pipe-work.
Ensure the lock-shield valve between
the unit and the expansion vessel is
open and the drain valve is closed.
Lockshield
valve
Lockshield
valve
Drain
valve
Anti-gravity loop
drain valve
Pressurisation
unit
Lockshield
valve
Lockshield
valve
Lockshield
valve
Automatic
air vent
System expansion
vessel
(External to
pressurisation unit)
Mains water
supply
Strainer
System
return
header
RPZ
valve
Figure 8.3 – Water connections
Figure 8.4 – System connections – clarity
15mm Mains cold
water supply (A)
32mm Plastic waste
outlet/overflow (B)
15mm System
connection (C)
9
The pressurisation unit is supplied
with a flying lead for the Mains Power
Connection; this cable should not
be replaced.
Mains connection must be via a
fused isolator rated at 13 Amps and
positioned locally to the unit. and
within 1 metre of the unit. The cable
size serving the unit shall be sized
in accordance with the IEE
Electrical Regulation.
After the outer casing has been
removed, the Electrical Terminal
Connection rail can be located
on the front-hinged inner door.
See Fig 9.1 for connection details.
9.1 Wiring details
The High & Low alarm switches have
been wired to allow volt free indication
of faults. If the power interruption of
the associated Boiler/Chiller plant is
required, the 230V 50Hz power supply
for the associated Boiler / Chiller plant
should be connected as follows:
Interlock circuit In Term 2
Link wire Terms 3 & 5
Interlock circuit Out Term 6
If a general alarm is required Link
Terminal 6 to Terminal 8. Then the
Interlock Circuit Out is Terminal 9.
In this manner, if one of the alarm
switches are activated, the power
supply to the associated Boiler /Chiller
plant will be interrupted.
9.0 Electrical Connection
Electrical Connection
Figure 9.1 – wiring diagram
MAINS SUPPLY
240V/50HZ
10AMPS
GENERAL
FAULT ALARM
VOLT FREE
(MAX 240V 0.5A)
HIGH
PRESSURE
ALARM VOLT
FREE(MAX 240V
0.5A)
LOW PRESSURE
ALARM VOLT
FREE (MAX 240V
0.5A)
1
2
3
4
5
6
7
8
9
10
11
12
EARTH
NEUTRAL
LIVE
NORMALLY OPEN
NORMALLY CLOSED
COMMON
COMMON
LOW ALARM NO (PU POWERED)
LOW ALARM NC (PU POWERED)
LOW ALARM COMMON
HIGH ALARM NC (PU POWERED)
HIGH ALARM NO (PU POWERED)
HIGH ALARM COMMON
GENERAL ALARM NO (PU POWERED)
GENERAL ALARM NC (PU POWERED)
GENERAL ALARM COMMON
PUMP 1 LIVE
PUMP 1 NEUTRAL
MAINS NEUTRAL
MAINS LIVE
GREY
BLACK
BROWN
BROWN
BROWN
BLUE
BLUE
GREY
GREY
GREY
BROWN
BROWN
BROWN
BROWN
BLACK
BLACK
BLACK
BLUE
G/Y
YELLOW
BLUE
GREEN
RED
RED
YELLOW
BLUE
GREEN
PRESSURE TRANSPONDER CABLE
TANK LEVEL SWITCH
MAIN CONTROLLER PCB
USER TERMINAL
240/50Hz
SENSOR
CONNECTOR
BOX
CONNECTOR
RED TERMINAL
YELLOW TERMINAL
BLUE TERMINAL
GREEN TERMINAL
1
4
Not Connected
2
3
4
5
6
7
8
9
10
11
12
13
14
15
1
2
WATER LEVEL SWITCH
BLACK
GREY
BROWN
GREY
BLACK
BROWN
PUMP
NORMALLY CLOSED
NORMALLY OPEN
NORMALLY CLOSED
COMMON
NORMALLY OPEN
DISPLAY PCB
10
10.0 Determining the Cold Fill Pressure
Determining the Cold Fill Pressure
The cold fill pressure is critical to the
correct operation of any pressurisation
unit and associated system. This
pressure needs to be calculated from
the static pressure of the system
(measured height in metres from the
base of pressurisation unit to the top
of the highest part of the heating
system, divided by 10 to convert to bar
pressure), and an allowance for venting
and vapour pressure. Therefore, the
cold fill pressure for a system with a
maximum operating temperature up
to 90°C, can be calculated as per the
example below:
Static Pressure 0.8 bar
(Height of 8.0m
divided by 10)
Venting Allowance 0.3 bar
(Allowance from
table below)
Vapour Pressure 0.0 bar
(Allowance from
table below)
Cold Fill Pressure 1.1 bar
(Sum of the above)
Venting and Vapour Pressure Allowances
Venting Allowance 0.3
Allowance to ensure system can be correctly vented
Vapour Pressure
Allowance
0.0
Max operating temperature up to 90°C
0.2
Max operating temperature 90°C to 95°C
0.5
Max operating temperature 95°C to 100°C
0.8
Max operating temperature 100°C to 105°C
1.2
Max operating temperature 105°C to 110°C
1.6
Max operating temperature 110°C to 115°C
2.0
Max operating temperature 115°C to 120°C
11
11.0 Filling the System
Filling the System
The pressurisation unit may be used
to fill the system as the unit has a Fill
Function suitable for small systems to
a maximum of 200 litres. Where this
fill function is used it is not necessary
to have a quick fill loop using an RPZ
valve. Before commissioning the
pressurisation unit, the entire Heating
/ Cooling / Chilled Water system
shall be filled, vented and completely
flooded by a method approved by the
Water Regulation Advisory Scheme
(WRAS) for the type of heating system
installed. The use of an RPZ (Reduced
Pressure Zone) valve with integral Type
BA air gap is recommended for filling
a larger system. Information regarding
the application, use and maintenance
requirements for RPZ valves with Type
BA air gap is available from WRAS.
It is also advisable to contact the
local water utility company to verify
notification requirements for the use of
these valves. i.e. Domestic (In-House)
Fluid Category 3 (C-3) Non Domestic
(Other than In-House) Fluid Category
4 (C-4 )
11.1 For Category 3 systems, the
approved method of filling must
comprise of the following
components in the arrangement
shown in Fig 11.1.1
• Control Valve incorporating a
Double Check Valve on the MCW
supply.
• Temporary connecting hose, which
must be disconnected after use.
• Control valve, on the heating
system.
11.2 For Category 4 systems, the
approved method of filling must
comprise of the following components
in the arrangement shown in Fig 11.1.2
• Control Valve.
• Strainer.
• Verifiable Backflow Device with
ReducedPressure Zone (RPZ Valve)
• Incorporating a ‘Type BA’ Air Gap.
• Tundish.
• Control Valve.
11.3 Introduction of Water
Treatment
The MCW Supply pipework shall
be thoroughly cleaned and flushed
to remove debris, flux residues, etc.
before opening the isolation valve
and flooding the pressurisation unit.
Reference should be made to “ICOM
Water treatment and Conditioning
of Commercial Heating Systems” for
guidance.
After the Heating / Chilled Water
system has been filled, flushed,
and cleaned in accordance with BS
7593:1992, the system will need to
be treated with a suitable Water
Treatment for the prevention of
corrosion, scale formation and
micro- biological growth.
Some water treatments are supplied in
a concentrated liquid form; following
the successful commissioning of the
appliance as detailed below in Section
12, and in the absence of a suitable
dosing pot, the Water Treatment
Chemicals may be added to the water
in the break tank in small doses.
Drain an amount of water from the
system (at a position some distance
from the pressurisation unit), so that
the system pressure drops and the
treated water in the break tank is
introduced into the system.
As the break tank is replenished with
fresh water, gradually add the water
treatment chemical (at the correct
concentration) until the appliance
turns off.
Repeat this process until the entire
water treatment chemical has been
fully introduced. Let the system
circulate for a minimum of 1 hour,
and then undertake a water analysis
to ensure the correct dosage level
has been obtained. See Section 12.0
Commissioning.
Note: Care should be observed when
using the FILL function to ensure that
all water joints etc are sound and leak-
free. The manufacturer cannot be held
responsible for any damage that may
result from water leaks.
To terminate the FILL function turn
OFF the Power Supply.
MCWS
CV DCV HOSE CV
Heating
System
MCWS
CV
Strainer
Tundish
RPZ
CV
Heating
System
Figure 11.1.1 - Filling a Domestic System Figure 11.1.2 - Filling a Commercial System
12
12.0 Maintenance & Commissioning Menu
Maintenance & Commissioning Menu
The maintenance & commissioning of
the pressurisation unit shall only be
undertaken by a competent person,
as various safety items associated
with the safe operation of the heating
cooling / chilled water system need
to be checked and confirmed. It
is therefore recommended that a
qualified Gas Safe registered engineer
undertake these works.
12.1 Control Panel
The Control Panel can be accessed
with the case On or Off, and has
two access levels, Standard &
Maintenance. These levels can be
accessed using the UP, DOWN and
ENTER buttons.
Standard Menu – For the End User.
Maintenance Menu – For the
Commissioning / Service Engineer.
12.2 Standard Menu
When the POWER supply has been
turned ON to the appliance, the LCD
will display the STANDARD MENU, as
detailed below. Review of the ID Lines
is done by using the UP or DOWN
buttons.
Please note, COLDFILLPRES is the
only ID line that can be altered at this
level, all other data displayed is
READ ONLY.
Note*: the pump fitted to the unit
is capable of a maximum Cold Fill
pressure of 3.0 bar
The procedures detailed in Sections
10 & 11 above shall be completed
prior to commissioning and to ensure
safe operation of the equipment prior
to hand over.
The appliance is factory set, and
should not require many adjustments,
other than those required to suit the
particular requirements of the system,
such as COLD FILL PRESSURE, and
HIGH / LOW WATER PRESSURE
ALARMS.
To review / alter the operational
settings, the MAINTENANCE MENU
of the micro-processor needs to
be accessed, by undertaking the
following procedure:
1) Turn ON the Mains Power Supply;
2) Press and
& Program Buttons
simultaneously for 5 seconds. The
screen will display USER MENU ON
or USER MENU OFF depending on
the previous menu setting.
Using the
& buttons, parameters
can be reviewed or adjusted as
appropriate.
To amend a Parameter, select the
ID Line required, Press the ENTER
button, to select that parameter, then
use the UP or DOWN buttons to
change the value, and then Press the
ENTER button to confirm the change.
To return to normal operation, turn
OFF the Mains Power supply, wait 30
seconds, then turn ON
the Mains Power supply.
Figure 12.1 – Fascia Panel
ID line Description Range Factory Default Comments
SYSTEM PRES Current System Pressure
0-6.0bar ** Actual value - Review only
COLDFILLPRES
Cold Fill Pressure (pump cut-out)
0.7-3.4bar 1.8bar
Can be altered
MAKE-UP V0
Volume of Water Introduced
0-9999 L *** Actual value - Review only
MAKE-UP ALARM
Water Introduction Alarm
00-99L 99
Review only. Review only
Actual volume=XX*10 L
MAKE-UP V2
Volume of Water Introduced
(since last rest)
0-999.9 L *** Actual value - Review only
PUMP OPS
Number of pump cycles
0-9999 *** Actual value - Review only
PUMP1 HRS
Hours operation of pump1
0-99.59 **:** Actual value - Review only
PUMP2 HRS
Hours operation of pump2
0-99.59 **:** Actual value - Review only
13
12.3 Maintenance menu
Maintenance & Commissioning Menu
ID line Description Range Factory Default Comments
SYSTEM PRES Current System Pressure
0-6.0bar ** Actual value - Review only
COLDFILLPRES
Cold Fill Pressure (pump cut-out) P2
0.7-3.4bar 1.8bar
Can be altered
MAKE-UP V0
Volume of Water Introduced
0-9999 L *** Actual value - Review only
MAKE-UP ALARM
Water Introduction Alarm
00-99L 99
Can be altered
and can
be disabled by setting to 00.
Actual volume=XX*10 L
MAKE-UP V2
Volume of Water Introduced
(since last rest)
0-999.9 L ***
Actual value - Reset
PUMP OPS
Number of pump cycles
0-9999 ***
Actual value - Reset
PUMP1 HRS
Hours operation of pump1
0-99.59 **:**
Actual value - Reset
PUMP2 HRS
Hours operation of pump2
0-99.59 **:**
Actual value - Reset
CUT IN PRES Pump cut-in Pressure P1 0.5-3.2bar 1.4bar Recommended value - P1=P2-0.4
L PRES ALARM Low Pressure Alarm 0-3.0bar 1.2bar
Recommended value -
Safety valve setting +0.3 bar
H PRES ALARM High Pressure Alarm 0.9-6.2bar 3.6bar
Recommended value-
Safety valve setting -0.3 bar
PUMP MIN RUN Pump minimum run time 1-9.9 secs 1.0sec Minimum operating time for pump
PUMP MAX RUN Pump maximum run time 01-99 min 99min Maximum operating time for pump
PUMP DELAY Pump minimum cycle time 0-99 min 00min
Minimum off time for pump
to stop hunting ON/OFF
PUMP KICK Pump duty cycle time 0-99 days 30days
Number of days pump is
idle then operated for 1 sec
PUMP Pump selection
PUMP1
PUMP2
ALTERNATE
ALTERNATE
Pump 1 only
Pump 2 only
Auto rotation
PASSCODE Password ON / OFF OFF Pass code =21
PUMP TIMEOUT Pump failure time 1-99 min 03min
Self diagnostic check that the
pressure is increasing by 0.005 bar
within the selected tim
FILL FUNCTION Automatic filling function - -
Press
on this menu to
operate function
Detailed below are the parameters which should only be accessed by a competent person.
Note: These Settings will affect the operational function of
the appliance, hence, alterations should only be undertaken
by a competent person.
Once the settings are complete, press and
& Program
Buttons simultaneously for 5 seconds and the screen will
revert to USER MENU OFF.
* The pump fitted within this unit
is capable of a maximum Cold Fill Pressure of 3.0Bar
14
12.4 Alarms
Maintenance & Commissioning Menu
There are a number of alarms and the unit will always
default to alarm display when one is in activation.
The unit will flash when in alarm mode to indicate
that there is a problem. If more than one alarm is tripped
then the system will display all alarms currently affecting
the unit - the unit will flash each alarm for a couple
of seconds before showing the next one, and will
continue to scroll through the list. When any condition
has been rectified the unit will continue to display any
other current alarms that still affect the system. Only
when all alarm faults have been rectified, will the unit
go back to Auto mode.
Note: There are volt free relays on the unit to give audible,
visual or BMS signals that the unit has gone into alarm mode.
The Low and High Pressure Alarms have their own circuits,
with all other conditions setting off General Alarm relay.
The alarms are as follows:
ID line Description Comments
ALARM – LO PRES Low pressure alarm activated
The unit will continue to operate under this alarm function, but invariably
the alarm will be caused by some other problem
ALARM – HI PRESS
High pressure alarm activated
The pump control will be discontinued until the alarm fault has
been rectified
ALARM – LEAK LIMIT
Volume of Water Introduced
The leakage limit volume has been exceeded. The pump control will
not operate until the alarm fault has been rectified. This can be done by
resetting Leakage Volume to 0, or by increasing make-up alarm above
make-up V2.
ALARM – TANK LEVEL
Water level in tank is too low
The pump control will be discontinued until the alarm fault has been
rectified. Investigate the cause.
FAULT PUMP1
Pump1 current draw is excessive
Press when this is displayed and the pump will start if it is working.
Run pump1 to ascertain the fault!
FAULT PUMP2
Pump2 current draw is excessive
As with pump1
PUMP1 TIMED OUT
Set point pressure not achieved
within the limit setting
Press when this is displayed and the pump will start if it is working. Run
pump1 to ascertain the fault! If this problem persists and the pump is still
working, then pump timeout setting should be increased.
PUMP1 TIMED OUT
Set point pressure not achieved
within the limit setting
As with pump1
15
13.0 Fault Finding
Fault Finding
Fault Possible Cause Action
Pump will not run • Unit up to pressure
• No power to unit
• Isolator fuse blown
• Cut in pressure set incorrectly
• Pump seized or faulty
• None
• Check at source
• Replace fuse. Note – investigate the cause of the blown fuse
• Adjust cut in pressure
• Service or replace pump
Pump runs but will
not build up
pressure
• Pump isolating valve closed
• Pump not primed
• Float switch faulty
• Pump non return valve jammed
• Blocked flow restrictor
• Open valve
• Prime pump
• Check water level and replace float switch
• Check valve
• Check flow restrictor for blockage
Pump cuts in & out
rapidly
• Value of cut in and cold fill pressure set
incorrectly
• Non return valve not sealing correctly
• System leak
• Adjust values
• Clean valve seat or replace valve if necessary
• Trace leak and ensure system is sound
Pump runs
continuously
• Value of cold fill pressure set incorrectly
• Pump relay faulty
• System leak
• Adjust value
• Replace faulty relay pcb in grey box
• Trace leak and ensure system is sound
Pump cuts out at
wrong pressure
• Pressure gauge is inaccurate
• Internal pressure sensor faulty
• Replace pressure gauge
• Replace pressure sensor
Maximum system
working pressure is
too high
• Cold fill pressure set incorrectly
• Internal pressure sensor faulty
• Adjust value
• Replace pressure sensor
Boiler switches off
unexpectedly
• Hi or Lo pressure alarms set incorrectly
• Safety circuit is wired incorrectly
• Adjust values
• Check wiring against wiring diagram
System pressure
runs consistently at
cold fill pressure
• Small system leak
• Trace leak and ensure system is sound
Figure 12 – Controls Schematic
COLD WATER
INLET
OVERFLOW
BALL VALVE
LOW LEVEL ALARM
ISOLATING VALVE
NON
RETURN
VALVE
PUMP
0.7HP
2.8A
PRESSURE
SENSOR
PRESSURISATION UNIT
TO SYSTEM
16
14.0 Internal Components & Short Parts List
Internal Components & Short Parts List
Note: The pump assembly (item 4) is
mounted onto a removable tray.
To remove the assembly, disconnect
all of the water connections, remove
the two M10 bolts, slightly lift the front
of the pump tray and slide the tray
forward, this will dis-engage the three
location posts at the top of the tray.
The tray and pump assembly can then
be removed from the appliance.
10
9
8
7
2
11
3
5 & 6
2x M10 Bolts4 1
Item No. Description Part No
1 Pressure transducer Z870012422
2 Pump assembly complete (incl fittings) Z870005665
3 Pump inlet isolation valve & flexible pipe assembly Z870020995
4 Drain valve Z870020990
5 Pump outlet isolation valve & flexible pipe assembly Z870020991
6 Outlet pipe assembly Z870016132
7 Control Panel (complete) Z870008316
- Main control pcb Z870006913
- LCD display pcbs Z870006914
8 Water level switch Z870011722
9 Water tank Z870073261
10 Ball float valve Z870020988
11 Pump non-return valve cartridge Z870071455
- Casing cover Z870058689
17
15.0 Commissioning Form
Commissioning Form
The commissioning engineer should complete this section on the day of Setting Up the appliance; so that a record is kept
of the settings made for future reference.
Engineer: Company:
Date:
Serial No:
Results Setting
System Static Hight metres
Cold Fill Pressure bar
System Vessel Size litres
System Vessel Air Charge bar
Maximum System Operating Temperature ºC
System Safety Valve Setting bar
Final Working Pressure of System (Hot) bar
High Pressure Alarm Switch Setting bar
Low Pressure Alarm Switch Setting bar
High Pressure Fault Test Yes/No
Low Pressure Fault Test Yes/No
Hour Run Meter Reading Hours
Comments:
Service Department: 01268 546770
Spares Department: 01268 546771
Technical Department: 01268 546772
Contracts Department: 01268 546730
ELCO Heating Solutions
3 Juniper West, Fenton Way,
Basildon, Essex, SS15 6SJ.
Tel: 01268 546700
www.elco.co.uk
Service
This publication is issued subject to alteration or withdrawal without notice. The illustrations and specifications are not
binding in detail. All offers and sales are subject to the Company’s current terms and condition of sale.
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