matrix installation guide
Matrix pressurisation units These installation, commissioning and servicing instructions are intend for use with the matrix compact and standard pressurisation units. efore commencing installation, commissioning or servicing these instructions must be read and understood. Matrix pressurisation units are intended for use only in the heating system of small commercial or light industrial buildings. Note! These pressurisation units are not intended to be used for the initial filling of the system. Introduction Dimensions The matrix standard and compact pressurisation sets are fully packaged units designed to maintain the minimum design pressure in LTHW sealed heating systems. The pressurisation units also provide top-up water for losses from the system. 1 2 D F The units are supplied in a high quality zinc coated steel casing, finished in a textured white stove enamelled epoxy powder coating 3 E H G The compact and standard pressurisation units consist of pump header tank with float valve pump control pressure switch, Matrix ompact D high and low pressure switches (standard unit only) 0 to 6 bar pressure gauge, which is visible from the front of the cabinet 1 2 non-return valve J isolating valve between the header tank and pump (standard unit only) G E connecting pipework ll pipe connection threads conform to S EN 10226 or S EN ISO 228-1 and general purpose screw threads to S ISO 262. Product ode Description MI-100001 matrix standard pressurisation unit - wall mounted and floor standing MI-100002 matrix compact pressurisation unit - wall mounted 3 Unit D E F G H J ompact 430 345 140 40 369 90 334 81 180 Standard 550 382 280 70 507-442 - 150 onnections Matrix Standard J onnection Thread Function 1 - ompact ½ SP male brass - G½ Water supply inlet 1 - Standard ½ SP male plastic - G½ Water supply inlet 2 22mm female plastic - solvent Tank over flow 3 15mm compression Outlet to system 1
Technical Specification Schematic of Matrix Pressurisation Units Model ompact Standard Min. cold fill pressure bar 0.7 0.7 Max. cold fill pressure bar 3.4 3.4 Max. operating pressure bar 7.0 7.0 Max. flow rate l/m 6 6 old water flow rate@ Maximum cold fill pressure l/m 0.1 0.1 Weight - empty kg 13 19 Weight - full kg 16 27 Tank capacity litres 2.6 7.6 Factory Preset Values old fill pressure bar 1.8 1.8 Low pressure switch setting bar - 1.3 High pressure switch setting bar - 3.65 System onditions Max. water flow temperature 82 82 Safety relief valve setting bar 4.0 4.0 Nom. pressure differential bar 0.4 0.4 Electrical onditions Pressure switch contact rating 15 240V 15 240V Electrical supply Operation 230V 50Hz 1ph 230V 50Hz 1ph Start current amp 9 9 Run current amp 2.8 2.8 drop in system pressure below the cold fill pressure due to, for example, loss of water, will cause the pressure switch (E) to switch on the pump and pump water from the tank into the main system thus restoring system pressure. s the level of water in the tank reduces the ball float valve opens and allows water to flow into the tank until the water level returns its original level. 1 2 J 3 D E G H F Item omponent Item omponent all float valve F Pressure gauge 0-6 bar reak tank G High alarm switch Pump H Low alarm switch D Single check valve J Isolating valve E old fill pressure switch onnection Thread Function 1 - ompact ½ SP male brass - G½ Water supply inlet 1 - Standard ½ SP male plastic - G½ Water supply inlet 2 22mm female plastic - solvent Tank over flow 3 15mm compression Outlet to system Note: The ltecnic matrix pressurisation units comply with the essential requirements of the Machinery Directive 2006/42/E Low Voltage Directive 2014/35/E Electromagnetic ompatibility Directive 2004/108/E Safety Function The Standard unit is fitted with a high pressure and low pressure switches. pressure above the set pressure of SPDT high pressure switch or a pressure below the set pressure of the SPDT low pressure switch will interrupt the circuit, which can sound an alarm, if wired into the circuit. 2
Sealed System Function pplication Diagram The diagram shows a typical sealed system incorporating a Matrix pressurisation unit and an expansion vessel. Mains Water Supply Return Header V Expansion Vessel 2 m minimum LSV LSV D D LSV Matrix Unit Expansion Vessel Operation ir / Nitrogen 1 2 3 4 1 Diaphragm position at the cold fill / charge pressure. The vessel is empty of system fluid. 2 Diaphragm position at the hot working pressure. The system volume has expanded due to the temperature rise. The gas in the vessel is compressed. cceptance factor = 0.35 maximum (recommended). 3 Diaphragm position at high system pressure. The boiler system is shut down by the system pressure switch. 4 Diaphragm at the safety valve lift pressure. This could be caused by failure of the boiler temperature limiter for example. cceptance factor = 0.5 maximum (recommended). 3
Sealed System Function Terminology Expansion vessel charge pressure The air pressure in the expansion vessel with the water connection open to atmosphere. System cold fill pressure The water pressure in the system the pressurisation unit is set to maintain. Expansion Vessel Operation The system expansion vessel charge pressure is set 0.1 bar below the cold fill pressure. efore operation of the boiler, with the system at cold fill pressure the expansion vessel is empty. s the system heats up, the expanded volume is absorbed by the expansion vessel. small pressure rise occurs which is accommodated by the vessel. When the system cools the volume of water reduces and the pressure drops. If there has been some fluid loss the pressurisation unit provides replacement. General Requirements Related Documents Pressure Systems Safety Regulations 2000 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, uilding 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: S 7074 pplication, selection and installation of expansion vessels and ancillary equipment for sealed water systems. S 6644 Specification for installation of gas fired hot water boilers of rated input between 70 kw (net) and 1.8 mw (net)(2 nd and 3 rd family gases). Related Documents S 6880 Parts 1, 2 & 3: ode of Practice for low temperature hot water heating systems of output greater than 45 kw. S EN ISO 4126 Part 1: Safety devices for protection against excessive pressure. Safety valves. S 3456 (EE10 Part 1, EE11 Part 1) Specification for safety of household and similar electrical appliances. HSE Guidance note PM5: utomatically controlled steam and hot water boilers. Mains Water onnection ll connections to local water mains must comply with the Water Supply (Water Fittings) Regulations 1999 and the Scottish Water ylaws 2004 including any local requirements. Expansion Vessel System expansion vessels must be manufactured to meet the requirements of PED 97/23/E Directive and S EN 13831:2007 losed expansion vessels with built in diaphragm for installation in water. Expansion vessels must be sized correctly for the size of system. ltecnic are able to offer a full range of expansion vessels. Safety Relief Valve Safety relief valves must comply with S EN ISO 4126-1:2004, and be sized and installed in accordance with S 6644 and S 7074. 4
Installation The units are supplied inside a strong cardboard box with padding and should be left in this packaging until they arrive on site and are installed. Location Recommended clearance dimensions Mounting racket Dimensions D E F ØG Plan View Matrix ompact D ØG Matrix ompact E F Plan View Matrix Standard * Matrix Standard Unit ompact 10 450 100 Standard 150 450 100 oth units are designed for wall mounting but the standard unit can also be floor mounted if required. mounting bracket is supplied inside each 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 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 the diagram. 5 * When the standard unit is used floor standing the two holes in the back of the chassis should still be used for additional security. Unit D E F G ompact 430 345 75 120 180 210 6.6 Standard 550 382 75 120 180 210 6.6
Pipework onnections Matrix ompact 1 2 3 Matrix Standard onnection Thread Function 1 - ompact ½ SP male brass - G½ Water supply inlet 1 - Standard ½ SP male plastic - G½ Water supply inlet 2 22mm female plastic - solvent Tank over flow 3 15mm compression Outlet to system The units have a type F air gap to prevent backflow in accordance with Water Supply (Water Fittings) Regulations 1999. The water supply connection must conform to all local WRS regulations. Overflow should be piped to where it will be safe but visible so it will be noticed and corrected. 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 - see pplication Diagram 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. Electrical onnection ll 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. Mains onnection oth the Standard and ompact are supplied fitted with a 1m flying lead for connection to the mains supply. Mains connection must be via a fused isolator rated at 13 mps, positioned locally to the unit (not supplied). Safety Switches 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. Note: if the factory set pressure switch levels are to be altered, the terminals should not be connected at this stage. ommissioning Matrix units are supplied factory set and tested to suit the system parameters as specified. If the application falls within these parameters the unit requires minimal commissioning checks. Mechanical Installation heck that the Matrix unit and expansion vessel have been installed correctly, as illustrated in the pplication Diagram. Pipe-work connections. heck also that all lock-shield or lockable valves are correctly set. 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. Electrical Installation efore working on a Matrix unit ensure all electrical circuits connected to it are isolated. 6
ommissioning Expansion Vessel To set or check the expansion vessel charge pressure the lock-shield between the Matrix unit and the vessel must be closed. Note: The expansion vessel charge pressure should be set 0.1 bar less than the cold fill pressure. suitable gauge should be used to check the charge pressure. Generally a 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 to escape. When the correct pressure is set the Schrader valve protective cap must be replaced. heck the integrity of the pipe-work. Ensure the lock-shield valve between the Matrix 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). Flow Restrictors - see Location photographs ompact Unit - if the mains pressure is above 1 bar fit the low pressure flow restrictor provided into the inlet connection from the mains. Standard Unit - is supplied with the high pressure already fitted. If the mains pressure is below 3 bar the flow restrictor needs changing to the low pressure restrictor. Initial Settings heck water inlet supply, it MUST have a flow greater than 8 l/m. Filling the Unit heck all connections and pressures. Open inlet isolation valve and fill the tank (standard unit only) Undo the priming screw on pump head. Prime until water appears. lose the screw and turn on the pump (keeping system isolation valve closed). Pump should run for a few seconds until set pressure is reached. Filling the Unit Matrix ompact Matrix Standard heck for any leaks within the unit, if no leakage open system isolation valve and fill system via a temporary filling loop. The unit will now monitor the system and keep it at the required pressure. 7
ommissioning Pressure Switch djustment The pressure switches are fitted with a scale to indicate the pressure at which they are set. This scale is to be used for indication only. s all the pressure switches and the pressure gauge take readings from the same place, the unit s pressure gauge can be used to give an accurate reading when setting switching levels. The switches should be set last, after all the other commissioning tasks are complete. ll the pressure switches have a nominal differential (Hysteresis) of 0.4 bar. This means that there will be 0.4 bar between the pressure at which the switch changes state during a pressure rise and the pressure at which it will change when the pressure is falling again or vice versa. For example, if the cold fill pressure switch is set to 3.4 bar then the switch will operate when the pressure rises to 3.4 bar causing the pump to stop. The switch will not change over and start the pump until the pressure has fallen back to 3.0 bar. Pressure Switch djustment Equipment When adjusting the pressure switches the unit must be set up with the apparatus similar to that shown, connected to the outlet. Pressure / Leak Source D LSV Matrix Unit Pressure Switch djustment old Fill Pressure Switch Designed to stop the pump when pressure reaches a preset level. Setting procedure as follows: Ensure the system pressure is lower than the pressure the switch is to be set to. Switch the unit on. Introduce a small leak at the outlet. djust the cold fill pressure switch until the pump cuts out at the desired working pressure. Low Pressure Switch (Standard unit only) Designed to prevent the boiler operating if the pressure falls below the preset level. fter setting the cold fill pressure switch, allow the system to run to pressure. Isolate the Matrix unit from the mains electrical supply and from the boiler circuits. The low pressure switch is lowest on the panel which pivots around corner for easy access. Set the Low pressure switch to its lowest position, this ensures that the terminals at either end of the switch form a closed circuit. Introduce a small leak until the unit s pressure gauge reading equals the required Low pressure setting. Stop the leak. djust the switch until the circuit is open. meter across the two terminals will signal the change. Re-connect all the electrical supplies, ensure that the pump switches on and the pressure increases and that the low pressure switch operates to open circuit and that the unit reaches the desired cold fill pressure High Pressure Switch (Standard unit only) Designed to prevent the boiler operating if the pressure exceeds the preset level. Isolate the Matrix unit from the mains electrical supply and boiler circuits. Set the High pressure switch to its highest position. Use a pressure source to increase the system pressure until the gauge reads the required high level pressure. djust the switch down until the circuit is closed. meter across the two terminals will signal the change. 8
Problem Solving The following details are supplied for on site queries, if the Matrix unit still does not operate correctly, contact ltecnic for assistance. Fault Possible ause Solution Pump will not run Pump runs but pressure will not increase Pump cuts in and out frequently (hunting) Pump runs continuously Pump cuts out at incorrect pressure Maximum system pressure too high oiler switches off unexpectedly System pressure runs consistently at the cold fill pressure Unit up to pressure No power to the unit Isolator fuse blow old fill pressure switch set incorrectly Pump jammed Pump seized or defective Pump isolating valve closed Pump not primed No water in break tank Pump non return valve jammed Flow restrictor blocked Pressure switches set incorrectly Non return valve not sealing correctly Leakage from system old fill pressure switch set incorrectly old fill switch defective Leakage from system old fill pressure switch set incorrectly old fill pressure switch defective old fill pressure switch set incorrectly old fill pressure switch defective High or low pressure switch set incorrectly High or low pressure switches and the circuits wired incorrectly Small system leak None heck at source Replace fuse in isolator. Note investigate cause of blown fuse before starting the unit heck wiring and / or adjust the pressure switch setting There is access on both units to rotate the impellor by screw drive which may free the pump Service or replace the pump Open valve Prime pump heck water level and investigate if necessary heck the valve is operating correctly Remove flow restrictor and flush with clean water djust pressure switches lean valve seat or replace valve if necessary Trace source of leakage, rectify cause and check all system to ensure no other leaks. djust pressure switch Replace switch Trace source of leakage, rectify cause and check all system to ensure no other leaks. djust pressure switch Replace defective switch djust pressure switch Replace defective switch djust pressure switches heck electrical wiring and connections Trace source of leakage, rectify cause and check all system to ensure no other leaks. Note: Please check the appropriate section in this manual when making adjustments. 9
Servicing Schedule The following is a recommended servicing schedule for the Matrix unit and expansion vessel. If remedial action is required; 6 Monthly heck the expansion vessel charge pressure, significant drop in charge pressure could be due to a faulty vessel diaphragm, replacement of diaphragm should be considered. riefly 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. 12 Monthly heck the ball float valve diaphragm for integrity and replace if necessary. lso check the plastic float for soundness. heck the expansion vessel for signs of external corrosion. If any deterioration is observed then it is recommended that the frequency of inspection be increased. heck the operation of the safety circuits it utilises Flow Restrictor Location Matrix ompact Matrix Standard E & O.E ltecnic Ltd Mustang Drive, Stafford, Staffordshire ST16 1GW T: +44 (0)1785 218200 E: sales@altecnic.co.uk Registered in England No: 2095101 altecnic.co.uk IOM 006 08-06-16