Installation, Commissioning and Servicing Instructions
E.SYPRESS E1 AND E2 DIGITAL
Pressurisation Units
Note: THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE
INSTALLING, COMMISSIONING, OPERATING OR SERVICING EQUIPMENT.
THE E.SYPRESS PRESSURISATION UNITS ARE INTENDED FOR USE ONLY
IN COMMERCIAL/LIGHT INDUSTRIAL APPLICATIONS.
THESE PRESSURISATION UNITS COMPLY WITH THE ESSENTIAL REQUIREMENTS OF THE LOW
VOLTAGE DIRECTIVE 2006/95/EC AND THE ELECTROMAGNETIC COMPATIBILITY DIRECTIVE
2004/108/EC.
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INDEX
Item Page
1. General Requirements 2
2. Product Description 3
3. Technical Data 3
4. Installation 5
5. Operation of the Pressurisation Unit 7
6. Commissioning 8
7. Setting of Electronics 9
7. Error Codes 11
8. Servicing 12
1.0 GENERAL REQUIREMENTS
1.1 Related Documents
Pressure Systems and Transportable Gas Containers Regulations 1989
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 installation of the pressurisation unit and expansion vessel MUST be in accordance with the relevant
requirements of the Pressure System Regulations, Building Regulations, IEE Regulations and the bylaws of
the local water undertaking.
It should also be in accordance with any requirements of the local authority and the relevant
recommendations of the following documents: -
Applicable standards and documents are:
BS7074 Application, selection and installation of expansion vessels and ancillary
equipment for sealed water systems
BS6644 Installation of Gas Fired Hot Water Boilers 60 kW to 2MW
BS6880 Parts 1, 2 & 3 Code of Practice for low temperature hot water heating systems of output
greater than 45 kW
BS6759 Part 1 (ISO 4126): Specification for safety valves for steam and hot water
BS 3456 (CEE10 Part 1, CEE11 Part 1): Safety of Household and similar electrical appliances
HSE Guidance note PM5: Automatically controlled steam and hot water boilers.
1.2 Mains Water Connections
All connections to local water mains must comply with WRAS Regulations including any local requirements.
The System temporary fill connection must be as per water supply bylaws and must be removed
after initial filling.
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1.3 Expansion Vessels
System expansion vessels must be constructed to BS4814 or BS6144. Dab Pumps have a range of
products available on request including guidance of vessel sizing. The expansion vessel should be set
when empty at 0.1 bar below the cold fill pressure setting.
1.4 Safety Relief Valve
Must comply with BS6759 part 1, and be sized and installed in accordance with BS6644 and BS7074.
2.0 PRODUCT DESCRIPTION
The pressurisation unit is designed to maintain the minimum pressure requirement of modern low/medium
temperature, hot water sealed system. The pressurisation unit also provides replacement water for losses
from the system.
The pressurisation unit is housed in a powder coated steel cabinet with removable cover. Housed in each
cabinet is either a single or twin pumps, connecting pipe-work and pressure sensor. In the top of the
cabinet is the header tank, with a float valve. In the front of the cabinet is the systems electronic control.
The electronics have many functions including self diagnostics all of which can be found on page 9.
3.0 TECHNICAL DATA
The basic overall dimensions are shown below in Figure 1.
All screw threads used in the unit conform to ISO 7/1 or ISO 228/1 for pipe threads where applicable and
ISO 262 for all general screw threads.
Figure 1 - Basic Overall Dimensions
ELECTRONIC SINGLE AND TWIN PUMP
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Figure 2 – Electronic Single and Twin Pump Pressurisation Unit – Technical Data
General Single Pump Twin Pump
Minimum cold fill pressure bar 0.5
Maximum cold fill pressure bar 3.0
Maximum operating pressure bar 7.0
Maximum Flow Rate l/min 6
Maximum water flow rate @
Maximum cold fill pressure l/min 0.1
Weight (empty) kg 19 28
Weight (full) kg 27 36
Tank Capacity litres 7.6
Factory Preset Values
Cold fill pressure bar 1.5
System low pressure switch bar 1.0
System high pressure switch bar 2.8
To suit system conditions
Maximum water flow temp ºC 85
Maximum static height m 30
Min. system operating pressure bar 3.3
Max. system operating pressure bar 6.3
Safety relief valve setting bar 4.0
Electrical Data
Pressure switch contact rating 15A 240V AC
Electrical Supply 230V AC 50Hz 1Ph
Start current amps 9
Run current amps 2
Connection Data
Mains Inlet ½” Male BSP
Overflow 28mm Comp
Connection to System 15mm Comp
Electrical Cable Glands 4 x 10mm
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4.0 INSTALLATION
Fig 3 shows ideal layout of a typical sealed system
4.1 Location
Figure 4 - Recommended Clearance Dimensions
SINGLE AND TWIN PUMP
The unit is designed for 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. The 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 below in fig 5
below.
5 Issue 1
Figure 5 - Mounting Bracket Dimensions
SINGLE AND TWIN PUMP
4.2 Pipework Connections
1) Mains water connection - ½” Male BSP
The units have a type ‘AF’ air gap to prevent backflow in accordance with Water Supply (Water
Fittings) Regulations 1999. The water supply connection must conform to all local WRAS regulations.
2) Overflow Connection - 28mm Compression
Overflow should be piped to where it will be safe but visible so it will be noticed and corrected.
3) System Connection – 15mm Compression
The system connection is via a 15 mm compression fitting. The unit must be connected to the
system by an antigravity loop. The antigravity loop must be made in pipe-work no smaller than the
expansion vessel connection, and have a minimum height of 2 metres. It should include a lock-shield
(or lockable) valve at the system connection point for servicing and an automatic air vent fitted at the
highest point of the loop. The antigravity loop must not be lagged but can be fitted with an optional kit
to prevent freezing. The pipe-work and fittings must be pressure tested to 1.5 times the safety valve
lift pressure.
4.3 Electrical connection
All wiring to the pressurisation unit must be in accordance with the IEE regulations, and any local
regulations, which apply. Note: If in any doubt a qualified electrician should be consulted.
The Unit is supplied fitted with a 1m flying lead for connection to the mains supply. Mains connection
must be via a fused isolator rated at 13 Amps and positioned locally to the unit.
The SPDT high and low pressure switches can be incorporated into circuits to interrupt a boiler
control signal, in order to shut down the boiler in the event of a system fault condition. The boiler
control system must be designed so that manual resetting is required after a system fault condition.
The circuits are rated at 230 V ~ 50 Hz, 15 A. Note: if the factory set pressure switch levels are to be
altered, the terminals should not be connected at this stage.
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5.0 OPERATION OF THE PRESSURISATION UNIT
Figure 6 – Schematic Layout
SINGLE AND TWIN PUMP
5.1 Unit Operation
A drop in system pressure due to, for example, loss of water, will cause the pump[s] to maintain the
pressure. As the level of water in the tank reduces a ball valve allows new water into the tank. When the
pressure sensor indicates that the correct pressure has been reached the pump stops.
5.2 Safety function
The unit has three volt free relays; one for low pressure setting; one for high pressure setting; one covering
a variety of fault conditions – water level in tank too low; leak volume limit exceeded; pump drawing too
much current possibly indicating failed pump; pump not increasing pressure in allotted time possibly
indicating failed pump.
6.0 COMMISSIONING
The unit is supplied factory set and tested to suit the system parameters as specified in section 2.0. If
the application falls within these parameters the unit requires minimal commissioning checks.
6.1 Mechanical Installation
Check that the Unit and expansion vessel have been installed correctly, as detailed in section. Check
also that all lock-shield or lockable valves are correctly set.
6.2 System Flushing
Ensure that the system has been flushed and all foreign matter has been removed, including pipe-
scale.
Note: Should this material come into contact with the expansion vessel diaphragm it could result in
premature failure of the expansion vessel assembly.
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6.3 Electrical Installation
Before working on the Pressurisation unit ensure all electrical circuits connected to it are isolated.
6.4 System Expansion Vessel
To set or check the expansion vessel charge pressure the lock-shield between the Pressurisation unit
and the vessel must be closed. The charge pressure must be checked with the expansion vessel
empty.
Note: the expansion vessel charge pressure should be set at 0.1 bar less than the cold fill pressure.
A suitable gauge should be used to check the charge pressure. Generally the Schrader 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, the drain cock fitted on the base of the
expansion vessel must be open to allow any water in the vessel to escape.
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 Pressurisation unit
and the expansion vessel is open and the drain valve is closed. Ensure the air purge plug is fitted
(near the top of the expansion vessel).
6.5 Initial Setting Standard SP Pressurisation Unit
1) Check water inlet supply, it MUST have a flow greater than 8 l/min.
2) Flow Restrictors
Each standard unit comes with a selection of inserts that can be fitted into the inlet valve to
achieve the required output:
Mains inlet pressure > 4 bar - H P restrictor which is white and already fitted
Mains inlet pressure < 4 bar - L P restrictor which is red and is attached to the float arm
Figure 6 – Inlet Valve inserts
3) Connect mains water to inlet and adjust the float arm so that water level is at suitable height in the
tank – 20mm below the overflow.
4) Make sure that the Pressurisation Unit is connected to the system and has a suitable isolation
valve.
5) Make sure that the mains lead has been connected to a suitably fused switched isolator.
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6.6 Filling the Unit
1) Open isolation valve between tank and pump.
2) Undo the priming screw on pump head[s]. Prime until water drips constantly being aware that air
may still also be escaping. Close the screw and turn on the pump (keeping system isolation valve
closed). Pump should run for a few seconds until set pressure is reached.
3) Check for any leaks within the units, if OK open system isolation valve and the PU will fill the
system until it reaches the set cold fill pressure. The Pressurisation can be used to top up the
system but does have a 6 l/m flow restrictor.
4) The unit will now monitor the system and keep it at the required cold fill pressure allowing for
differential programmed into the electronics
7.0 Setting of Electronics
You need to get into the maintenance mode to be able to view all settings and make adjustments.
Switch off power to the unit, then after 10 seconds switch the power back on whilst pressing the left
hand [up arrow] button. The display should display 8888 for a few seconds then should go back to
menu settings which can be accessed by using the up and down arrow keys to take you from item to
item in the following sequence:-
ID Description Range Default
PO Current System Pressure 0.0 – 6.0 bar View Only
P2 Cold Fill Cut Out Pressure 0.7 – 6.0 bar 1.8
This can be adjusted – A1 and P1 settings will move in
line with changes made to P2, and A2 will only move
upwards when P2 is only 0.2 bar below setting.
L0 Volume of Water Introduced 0 – 9999 lts View Only
L1 Water Introduction Alarm 1 – 99 99
The alarm is in 10’s of litres, therefore setting of 23 sets
The alarm at 230 litres and when L2 setting reaches this
Threshold then the Pressurisation Unit will stop and set
off the general alarm until fault is rectified.
L2 Volume of Water Introduced since last reset 0 – 999.9 lts View
This can be reset to zero by pressing enter.
C1 Number of times pump[s] have been switched on 0 – 9999 View
This can be reset to zero by pressing enter.
H1 Pump 1 Hours Run in hours and minutes 00:00 – 99:59 View
This can be reset to zero by pressing enter.
H2 Pump 2 Hours Run in hours and minutes [Twin version] 00:00 – 99:59 View
This can be reset to zero by pressing enter.
P1 Cold Fill Cut In Pressure 0.5 – 5.8 bar 1.4
Can only be moved up to 0.2 bar below P2 setting.
If moved down A1 will move when only 0.2 bar lower.
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A1 Low Pressure Alarm Setting 0.00 – 5.6 bar 1.2
Can only be moved up to 0.2 bar below P1 setting.
When pressure goes down to this setting the Low
Alarm Relay is activated.
A2 High Pressure Alarm Setting 0.9 – 6.2 bar 3.6
Can oly be moved down to 0.2 bar above P2 setting.
When pressure goes up to this setting the High
Alarm Relay is activated.
t1 Pump Minimum Run Time 1.0 – 9.9 secs 1.0
Might be required to avoid hunting in unusual circumstances.
t2 Pump Maximum Run Time 01 – 99 mins 99
t3 Pump Minimum Cycle Time 00 – 99 mins 00
Might be required to avoid hunting in unusual circumstances.
t4 Pump Duty Cycle 00 – 99 days 30
Will cycle next pump by minimum run time.
FI Pump Selection [Twin version] 1, 2, Au Au
Can be used to manually choose just one pump if one
has failed for continued operation.
SC Password Protection Y,N N
Password can be set so that specific number has to be
entered to make changes to any setting. The number
To be entered is 21.
F2 Pump Failure Time 01 – 99 Mins 03
Self diagnostic where electronics check that pressure
is increasing by 0.005 bar within this set time. Failure
to increase the pressure activates the General Alarm
Relay.
FILL Fill function
By selecting this function, the unit will bring the system up to
P2 setting [if within 6 hours] without activating any of the
counters for – for initial filling.
NOTE to change any settings you need to press the enter button whilst on the menu entry and
then the field will either be zeroised, or you will be able to adjust the setting using the up and
down arrow keys, then setting to new figure by pressing enter when you are happy with the
setting.
It is advisable to take the unit out of maintenance menu once modifications are complete. To do this
switch off power to the unit, wait 10 seconds, then re-establish power without holding any buttons and
the standard menu will be activated only allowing changes to P2 and only displaying menu items P0
to H2.
8.0 ERROR CODES
In the event of the Pressurisation unit going into fault mode, the display will flash the following error
messages. If there is more than one fault the unit will flash between the fault codes every 3 seconds.
E:A1 The Electronics are showing that the system pressure has fallen down to the low alarm setting
and the Low Alarm Relay will have been activated.
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The error code will reset as soon as the system pressure raises above the A1 setting. If fault
persists, check for reasons why the system is at low pressure.
E:A2 The Electronics are showing that the system pressure has gone over the high alarm setting and
the High Alarm Relay will have been activated.
The error code will reset as soon as the system pressure falls below the A2 setting. If fault persists,
check for reasons why the system is at high pressure.
E:L1 The Electronics are showing that the system has introduced the volume of water as specified in
L1 Alarm setting and the General Alarm Relay will have been activated.
The error code can be reset by either increasing the L1 setting, or by zeroising the L2 reading.
Please check however why you would have lost amount of water specified
E:L3 The Electronics are showing that the water level in the tank is too low and the General Alarm
Relay will have been activated.
The error code will reset as soon as the water level in the tank is sufficient – activated by float in
water tank.
E:P1 The Electronics are showing that the power drawn by Pump 1 is above the limit set in our
electronics and the General Alarm Relay will have been activated.
This could indicate that the pump is faulty as it should only draw a large current if it cannot keep up
with requirement – e.g. if rotor seized. By pressing the enter button the fault will be cleared and you
should run pump 1 to see if it is indeed faulty.
E:P2 Twin version only and is exactly as per P1 fault but for Pump 2
E:F1 The Electronics are showing that Pump 1 has not increased the pressure in the set time and
the General Alarm Relay will have been activated.
This could indicate that the pump is faulty and is a self diagnostic. By pressing the enter button the
fault will be cleared and you should run pump 1 to see if it is indeed faulty. It could be that the F2
setting is not long enough for the size of system so increase this setting and re-check the pump.
E:F2 Twin version only and is exactly as per F1 fault but for Pump 2
9.0 SERVICING SCHEDULE
The following is a recommended servicing schedule for the Pressurisation unit and expansion vessel.
If remedial action is required;
7.1 6 Monthly
1) Check the expansion vessel charge pressure, A significant drop in charge pressure could be
due to a faulty vessel diaphragm, replacement of diaphragm should be considered.
2) Briefly run the pump to check for rotor seizure. This could occur if the pump is not run for
extended periods. This can be accomplished by slightly opening the expansion vessel drain
valve to initiate a leak.
7.2 12 Monthly
1) Check the ball float valve diaphragm for integrity and replace if necessary. Also check the
plastic float for soundness.
2) Check the expansion vessel for signs of external corrosion. If any deterioration is observed
then it is recommended that the frequency of inspection be increased.
3) Check the operation of the safety circuits it utilised on the Unit.
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DAB PUMPS Limited
Units 4&5, Stortford Hall Ind Park, Dunmow Road, Bishops Stortford, Herts. CM23 5GZ Tel: 0044 (1) 1279 652776
www.dabpumps.co.uk
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