Cold Water Booster Sets
Easymat & IMAT
OPERATING INSTRUCTIONS Page 2 English
GB
Page 2 / 12 BS...IMAT Rev2 - Operating Instructions
THIS INSTRUCTION MANUAL IS THE PROPERTY
OF CALPEDA S.P.A. ANY REPRODUCTION,
EVEN IF PARTIAL, IS FORBIDDEN
1. GENERAL INFORMATION
Before using the product carefully read the
information contained in this instruction manual, the
manual should be kept for future reference. English
is the original language of this instruction manual,
this language is the reference language in case of
discrepancies in the translations.
This manual is part of the essential safety
requirement and must be retained until the product
is nally decommissioned. The customer, in case
of loss, can request a copy of the manual by
contacting Calpeda Ltd or their agent, specifying
the type of product data shown on the label of
the machine (see 2.3 Marking) Any changes,
alterations or modications made to the product or
part of it, not authorized by the manufacturer, will
revoke the “CE declaration” and warranty.
This appliance should not be operated
by children younger than 8 years,
people with reduced physical, sensory
or mental capacities, or inexperienced
people who are not familiar with the
product, unless they are given close
supervision or instructions on how to
use it safely and are made aware by a
responsible person of the dangers its
use might entail.
Children must not play with the
appliance.
It is the user's responsibility to clean
and maintain the appliance. Children
should never clean or maintain it
unless they are given supervision.
Do not use in ponds, tanks or
swimming pools or where people may
enter or come into contact with the
water.
Read carefully the installation
section which sets forth:
- The maximum permissible
structural working pressure
(chapter 3.1).
- The type and section of the
power cable (chapter 6.5).
- The type of electrical protection
to be installed (chapter 6.5).
1.1. Symbols
To improve the understanding of the manual, below
are indicated the symbols used with the related
meaning.
Information and warnings that must be
observed, otherwise there is a risk that the
machine could damage or compromise
personnel safety.
The failure to observe electrical information
and warnings, could damage the machine or
compromise personnel safety.
i
Notes and warnings for the correct
management of the machine and its parts.
Operations that could be performed by
the nal user. After carefully reading of the
instructions, is responsible for maintenance
under normal conditions. They are
authorized to affect standard maintenance
operations.
Operations that must be performed by a
qualied electrician. Specialized technician
authorised to affect all electrical operations
including maintenance. They are able
to operate with in the presence of high
voltages.
Operations that must be done performed by a
qualied technician. Specialized technician
able to install the device, under normal
conditions, working during “maintenance”,
and allowed to do electrical and mechanical
interventions for maintenance. They must
be capable of executing simple electrical
and mechanical operations related to the
maintenance of the device.
Indicates that it is mandatory to use
individual protection devices.
OFF
Operations that must be done with the
device switched off and disconnected from
the power supply.
ON
Operations that must be done with the
device switched on.
SUMMARY
1. GENERAL INFORMATION ........................2
2. TECHNICAL DESCRIPTION ......................3
3. TECHNICAL CHARACTERISTICS ............3
4. SAFETY......................................................4
5. TRANSPORT AND HANDLING .................4
6. INSTALLATION ..........................................4
7. STARTUP AND OPERATION ..................... 6
8. MAINTENANCE .........................................7
9. DISPOSAL ..................................................7
ELECTRICAL DIAGRAM ....................................8
Declaration of conformity .................................. 12
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BS...IMAT Rev2 - Operating Instructions Page 3 / 12
1.2. Manufacturer name and address
Manufacturer’s name: Calpeda Ltd
Address: 6-8 Wedgwood Rd Ind Est
Bicester OX26 4UL, UK
www.calpeda.co.uk
1.3. Authorized operators
The product is for qualied operators upon nal
users and specialized technicians. (see above).
i
It’s forbidden for the nal user to do any
operation reserved only for the authorized
technicians. The manufacturer isn’t
responsible for the related damage done by
missing this prohibition.
1.4. Warranty
Warranty covers all defects within the booster set
resulting from faulty workmanship and/or materials
for a period of two years from the date of installation
or 30 months from the date of dispatch from our
production centre, whichever is the shorter.
i
The warranty covers the replacement or
repair of the faulty parts and labour to do so.
It does not cover any secondary loss, costs
associated with the removal, returning or
retting of the set.
Under no circumstances should the faulty
equipment be dismantled. Failure to comply could
invalidate the warranty.
The warranty may be lost in these cases:
- Whenever the use of this product is different from
its intended use described in this manual.
- Defects arising from incorrect installation and/or
operation.
- In case of modications or customizations made
without the authorization of the manufacturer.
- In case of technical assistance operations made
by non-authorized personnel.
- In case of missing maintenance (described in this
manual).
1.5. Technical assistance
Any further information on documents, service
assistance, and device parts, please contact:
Calpeda Ltd
6-8 Wedgwood Rd Ind Est,
Bicester OX26 4UL, UK
T:+44 1869 241441 F: +44 1869 240681
E: pumps@calpeda.co.uk
W: www.calpeda.co.uk
2. TECHNICAL DESCRIPTION
Constant pressure booster sets with built-in
frequency converter made with multiple pumps,
ball valve, non-return valve and pressure gauge on
discharge side, ball valve on suction side.
EASYMAT – Domestic and Commercial use
I-MAT – Domestic, commercial and industrial
2.1. Intended use
For clean liquids: non-explosive and non-ammable,
non-hazardous for health or the environment, non
aggressive for booster set materials, not containing
abrasives, solid or brous particles.
Liquid temperature from 0 °C to + 40 °C in line with
the regulation.
2.2. Expected improper use
The device is designed and manufactured
exclusively for the purpose described in sec. 2.1.
Improper use of the device is forbidden, as
is use under conditions other than those
indicated in these instructions.
Booster sets must not be used in hazardous
areas as they could cause an explosion if
there is the danger of ignition by a ame
path.
It will be not accepted liability for the use of our
sets with liquids which could be construed as being
hazardous to health either by touch, ingestion, or
inhalation of fumes or gases given off by the liquid.
Calpeda cannot be held responsible for failures
or injuries related to the inobservance of the
restrictions described.
2.3. Marking
The following picture is a copy of the name-plate.
1) Type
2) Working pressure
3) Total power
4) Control panel
5) Weight
6) Certications
7) Serial number
3. TECHNICAL CHARACTERISTICS
Dimensions and weight (see technical catalogue).
Protection IP54 (depending on pump model)
Supply voltage / Frequency:
EASYMAT 230 V1~50 Hz
I-MAT 400V3~50 Hz
Sound pressure: refer to individual pump data
Maximum permissible pressure: up to 10 bar
depending on model.
3.1. Operating conditions
The product works properly only if the followings
conditions are respected.
Floating voltage rate: +/-10% max
Floating frequency rate: +/- 4% max
Ambient temperature: up to 40°C
Relative Humidity: up to 90% without condensing
Altitude: Below 1000 m inside a building.
i
Booster sets must be used in conjunction
with a cold water storage tank and must not
be connected direct to mains in-line with
water byelaw regulations.
3.2. Product overview
The booster set is generally made of:
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Page 4 / 12 BS...IMAT Rev2 - Operating Instructions
1 or more pumps
suction manifold (from 2 pumps)
interception valve on suction for each pump
no-return valve on suction for each pump
interception valve on delivery 1 for each pump
delivery manifold (from 2 pumps).
frequency converters (according with the model)
electrical panel
one or more pressure vessels with relevant
accessories.
4. SAFETY
4.1. General behavior standards
Before using the product it is necessary
to acknowledge all the information about
safety.
Carefully read all operating instructions and the
indications dened for the different steps: from
transportation to disposal.
The specialized technicians must carefully comply
with all applicable standards and laws, including
local regulations of the country where the pump is
sold. The device has been built in conformity with
the current safety laws. The improper use could
damage people, animals and objects.
The manufacturer declines any liability in the event
of damage due to improper use or use under
conditions other than those indicated on the nameplate and in these instructions.
i
Follow the routine maintenance schedules
and the promptly replace damaged parts,
this will allows the device to work in the
best conditions. Use only original spare
parts provided from Calpeda or from an
authorized distributor.
Don’t remove or change the labels placed
on the device. Do not start the device in
case of defects or damaged parts.
Maintenance operations, requiring full or
partial disassembly of the device, must
be done only after disconnection from the
supply.
All the power terminals and other terminals
must be inaccessible after installation is
completed.
4.2. Residual risks
The device, for its design and designation (in
accordance to intended use and safety standard),
has no residual risks.
4.3. Safety icons and information
Please refer to all product manuals supplied in the
pack.
5. TRANSPORT AND HANDLING
During transport do not stack heavy objects on it.
Make sure that during transport the vehicle that is
used, is big enough for the total dimension of the
package.
The vehicles used must be suited for the dimensions
and weights of the chosen device.
5.1. Handling
The booster sets are supplied from factory
mounted on a pallet base suitable for
handling with forklift equipment.
The weight of the booster set may require the use
of specialist lifting equipment in order that it can
be handled safely. During lift or manoeuvre of the
equipment never use the set pipe-work, vessels or
ttings as a lifting point.
5.2. Site storage
It is advised that once the set has been delivered
it must be placed immediately in a dry, frost and
dust free
area and secured from interference.
6. INSTALLATION
6.1. Ambient requirements and installation site
dimensions
The customer has to prepare the installation site in
order to guarantee the right installation and in order
to
fulll the device requirements (electrical supply,
etc...).
The place where the device will be installed must
fulll
the requirements in the paragraph 3.2. It's
absolutely forbidden to install the machine in an
environment with potentially explosive atmosphere.
6.2. Unpacking
i
Inspect the device in order to check any
damages which may have occurred during
transportation.
Package material, once removed, must be
discarded/recycled according to local laws of the
destination country.
6.3. Installation
The booster set should not be installed in roof
spaces as the small level of vibration associated
with rotating equipment will cause disturbance, and
considerable damage could occur in the event of
water leakage or loss during commissioning and/
or service.
The booster sets should be installed in a wellventilated, dry frost free position.
External installation should make use of a rodent
proof enclosure with adequate ventilation and
protected from freezing.
A space around the set of approximately 750 mm
should be provided for access and servicing.
GB
BS...IMAT Rev2 - Operating Instructions Page 5 / 12
Adequate drainage should be provided with
protection from water damage in the immediate
vicinity should a leak or spillage occur.
Adequate lighting should be provided for service,
inspection and commissioning.
6.3.1. General arrangement
It is important that the following items are installed
over and above those supplied with the standard
booster set:
1. Storage tank.
2. Ball/Float valve.
3. Mains Water inlet.
4. Mains Water by-pass
5. Suction Isolating valve.
6. Discharge Isolating valve.
7. Booster set.
Installation must be in accordance with local
regulations and Water bye-laws.
6.3.2. Foundation
The set should be installed with anti-vibration
mounting pads and anti-vibration pipe coupling
especially
in noise sensitive areas. Otherwise install the set
on a level concrete plinth which will not distort or
twist
the base-plate, use shims if required. Always install
in a horizontal position and use adequate xings.
Do
not install on a wooden substructure or any
potentially exible substructure.
6.3.3. Storage tank and bypass
The booster sets must be used in conjunction with
an adequately sized water storage tank, supplied
and installed in accordance with the water byelaws.
The set must not be directly connected to a mains
water
supply. In the event of a failure of the booster set
it is advised that a cold water mains bypass should
be tted to allow for a continued supply even at a
reduced pressure. The bypass should be installed
in-line with water byelaws.
6.4. Pipes
Ensure the insides of pipes are clean and
unobstructed before connection.
ATTENTION: The pipes connected to the booster
set should be secured to rest clamps so that they
do not transmit stress, strain or vibrations to the
booster set.
The pipe diameters must not be smaller than the
booster set connections.
Isolation valves should be tted before the set
suction manifold and on the discharge manifold
after the set to allow the set to be removed without
a major loss of water in the system.
6.4.1. Suction pipe
The suction pipe must be perfectly airtight and be
led
upwards in order to avoid air pockets.
With a booster set located above the water level
(suction lift operation) t a foot valve with strainer
which must always remain immersed.
With the liquid level on the suction side above the
pump (inow under positive suction head) t an
inlet gate valve.
For suction from a storage tank t an anti-backow
valve.
Follow local specications if increasing network
pressure.
6.4.2. Delivery pipe
Fit a gate valve in the delivery pipe.
6.5. Electrical connection
OFF
Electrical connection must be carried out
only by a qualied electrician in accordance
with local regulations.
Follow all safety standards.
The unit must be properly earthed (grounded).
Connect the earthing (grounding) conductor to the
terminal with the
marking.
Compare the frequency and mains voltage with
the plate data and connect the in accordance with
the diagrams.
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The set is supplied with a separate control
box which allows control and monitoring
features to be connected without accessing
either the motor terminal box or the inverter
terminals. Please follow carefully the wiring
diagrams supplied.
6.6. Power supply connection
Electrical supply must comply with the description
in section 3.
If the electric control box is connected to an
electric plant with a differential switch (ELCB) or
a Ground Fault Circuit Interrupter (GFCI) as a
further protection, these devices must comply the
GB
Page 6 / 12 BS...IMAT Rev2 - Operating Instructions
following characteristics:
Suitable to control leakage current and, in case of
short pulsed leakage current.
Must operate in case of a fault alternating current,
and in case of fault current with DC content, such
as fault pulse DC current and at DC current
The electric control box must have installed a
B-type differential switch or GFCI.
These protections must be signed with the
followings symbol.
7. STARTUP AND OPERATION
7.1. Commissionig
It is strongly advised that commissions of
the set must be done using an approved
agent or one of our Engineers.
Correct commissioning will guarantee the longevity
of the set and ensure that is operates at optimum
efciency.
water supply and all electrical connections made.
Most of the basic functions are pre-programmed at
the time of production but the most basic settings
must be checked. If modications on the settings
are required refer to the Easymat or I-Mat manual
in this pack
7.2. Vessel pressure
OFF
Before installation, check the status of the air
cushion load in the vessel.
Air preloaded pressure of the vessel must be of 0,2
bar lower than the restart pressure value.
7.3. First starting
OFF
After completing hydraulic and electrical connection
and checked the preloaded pressure (for booster
set with membrane tank), start the plant as
indicated below:
Prime the pumps (see the pumps’ instructions).
Pump with suction lift:
- Fill the suction pipe and the pump body by means
of the plug hole located close to the delivery port
of the pump.
- Fill the suction tube by pouring water through the
plug hole on the suction manifold of the pump.
Pump with positive suction head:
- Open the gate-valve in the suction pipeline.
With sufcient head, the water will overcome the
resistance of the non-return valve tted in the
suction side of the pump and will ll the pump
body. Otherwise, prime the pump with the plug
hole near the delivery port.
Never run the pump for more than ve
minutes with a closed gate valve
Starting pumps
Press the button
(play) in all the frequency
converter, to change the pump status from STOP to
run. The pump starts up with the acceleration ramp
set to reach the wished set-point.
When the motor start turning, check the
direction of rotation.
If the booster set has been primed correctly, after
a few seconds the pressure will begin to increase
on the display.
If, after a few seconds of operation the pressure
remains at 0.0 bar, stop the booster set by selecting
(stop) in each frequency converter as priming
has not been carried out correctly and the pump is
idling. Re-prime the pumps and repeat the starting
up procedure.
7.4. Inversion of the direction of rotation
OFF
To change the direction of rotation of the motor push
the button
(menu) and then with the button
(plus) or
(minus) move up to the programming
parameter UP. Conrm with
(enter) and with
the button
(plus) or (minus) move up to
the parameter UP04, conrm with (enter) and by
pushing of the button
(plus) change the value,
conrm with
(enter). To exit the program, push
(menu) until you arrive on the basic display,
when you are out from the setup mode the icon
disappear.
7.5. Quick set-point modication
ON
It is possible to change the set point pressure
without enter on the user parameter (UP menu).
Pushing the button
(enter) for more than 5
seconds, in any of the frequency converter, you
will enter directly to the set point pressure (UP05
parameter).
By pushing of the buttons
(plus) or (minus)
change the pressure value and conrm with
(enter).
By pushing of the button (menu)
the system
will return to the basic display (see paragraph 9.1.).
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BS...IMAT Rev2 - Operating Instructions Page 7 / 12
7.6. Switch off of the pump
ON
The appliance must be switch off every time
there are faults.
The product is designed for a continuous duty, the
switch off is performed by disconnecting the power
supply by means the expected disconnecting
devices (see paragraph “6.5 Electrical connection”).
8. MAINTENANCE
Before any operations it's necessary to disconnect
the power supply.
If required ask to an electrician or to an expert
technician.
Every maintenance operations, cleaning
or reparation executed with the electrical
system under voltage, it could cause serious
injuries to people.
In case of extraordinary maintenance, or
maintenance operations that require part-removing,
the operator must be a qualied technician able to
read schemes and drawings.
It is suggest to register all maintenance operation
executed.
i
During maintenance keep particular
attention in order to avoid the introduction of
small external parts, that could compromise
the device safety.
It is forbidden to execute any operations with
the direct use of hands. Use water-resistant,
anti-cut gloves to disassemble and clean the
booster set.
i
During maintenance operations external
personnel is not allowed.
Maintenance operations that are not described
in this manual must be made only by special
personnel authorized by Calpeda.
For further technical information regarding the use
or the maintenance of the device, contact Calpeda.
8.1. Routine maintenance and inspection
OFF
Before every maintenance operations
disconnect the power supply and make
sure that the device could not accidentally
operate.
Close the suction and delivery gate valves
and before attempting any maintenance
activity.
It is suggested to make an inspections at least
every 6 months. The inspection must include:
1. Check that there are no leaks especially around
the area of the pump seals.
2. Check for any corrosion or signs of wear.
3. Check that the pump rotate freely.
4. Check that there is no sign of water at the vessel
air valve by quickly depressing the air valve
needle.
5. Check that the pump/s are operating correctly
and quietly without excessive vibration.
6. Check that the system operates smoothly and
comes to rest when there is no demand and the
set pressure has been reached.
7. Check all electrical cables and ttings for signs of
damage or wear.
8. Check the vessel pre-charge.
9. Check the operation of any oat switches or
safety or protection devices.
i
We advise that for a reliable and constant
supply of water that you take out a
maintenance contract. These are especially
devised for the set you have and the work is
carried out by fully qualied and experienced
staff.
8.2. Dismantling the system
OFF
Close the suction and delivery gate valves and
drain
the booster set before dismantling.
9. DISPOSAL
OFF
The nal disposal of the device must be done by
specialized company.
Make sure the specialized company follows the
classication of the material parts for the separation.
Observe the local regulations and dispose the
device accordingly with the international rules for
environment protection.
Changes reserved.
8 / 12 BS...IMAT Rev2
10 ELECTRICAL DIAGRAM
EASYMAT1-2= Frequency converter
EASYMAT 1
Supply
50/60Hz
8 9
10 11
8 9
10 11
8 9
10 11
EAS
MCB2
ISL
MCB1
YMAT 2
2
Panel Type
QTE2 -10M
QTE2 -16M
QTE2 -20M
MCB (1,2)
10A
16A
20A
BS...IMAT Rev2 9 / 12
ELECTRICAL DIAGRAM
EASYMAT1-3= Frequency converter
EASYMAT 1
1 2 3
Supply
50/60Hz
8 9
10 11
8 9
10 11
8 9
10 11
8 9
10 11
EASYMAT 2 EASYMAT 3
Panel Type
QTE3 -10M
QTE3 -16M
QTE3 -20M
MCB (1,2,3)
10A
16A
20A
MCB2 MCB3MCB1
ISL
10 / 12 BS...IMAT Rev2
ELECTRICAL DIAGRAM
I-MAT 1 I-MAT 2
Supply
400V 3ph 50Hz
I-MAT1-2 = Frequency converter
C C C C C C 1A 1A 1A 2A 2A 2A 1A 1A 1A 2A 2A 2A E U V W E U V W
1 2 1 3 9 10 7 8 9 7 8 9 2 3 4 2 3 4
Float 1 Float 2
Remote
ON/OFF
Common
N/O N/C
Common
N/O N/C
Common
N/O N/C
Common
N/O N/C Pump 1 Pump 2
Pump 1
Alarm 2
Pump 2
Alarm 2
Pump 1
Alarm 1
Pump 2
Alarm 1
Panel Type
QTI2-10T
QTI2-16T
QTI2-32T
MCB (1,2)
10A
16A
32A
MCB2
ISL
MCB1
BS...IMAT Rev2 11 / 12
ELECTRICAL DIAGRAM
I-MAT 1 I-MAT 3
Supply
I-MAT1-3 = Frequency converter
I-MAT 2
CCC
C C C 1A 1A 1A 2A 2A 2A 3A 3A 3A 1A 1A 1A 2A 2A 2A 3A 3A 3A E U V W E U V W E U V W
1 2 1 3 9 10 7 8 9789789 2342342 3 4
Float 1 Float 2
Remote
ON/OFF
Common
N/O N/C
Common
N/O N/C
Common
N/O N/C
Common
N/O N/C
Common
N/O N/C
Common
N/O N/C Pump 1 Pump 2 Pump 3
Pump 1
Alarm 2
Pump 2
Alarm 2
Pump 3
Alarm 2
Pump 1
Alarm 1
Pump 2
Alarm 1
Pump 3
Alarm 1
Panel Type
QTI3-10T
QTI3-16T
QTI3-32T
MCB (1,2,3)
10A
16A
32A
400V 3ph 50Hz
MCB2 MCB3
ISL
MCB1
GB DECLARATION OF CONFORMITY
We CALPEDA Ltd declare that our booster sets with type and serial number as shown below, are
constructed in accordance with Directives 2006/42/EC and 2014/30/EU, and assume full responsibility
for conformity with the standards laid down therein.
The manufacturer also declares that the following harmonised international standards have been
applied:
- EN ISO 12100:2010
- EN 809:1998+A1:2009
- EN 60204-1:2006/A1:2009
- EN 61800-3:2004
Bicester 01.2018
Managing Director
Calpeda Ltd
Ken Hall
Calpeda Limited - 6-8 Wedgwood Road, Ind. Estate, BICESTER, Oxon OX26 4UL
Tel. +44 1869 241441 - Fax +44 1869 240681 - E.mail: pumps@calpeda.co.uk www.calpeda.co.uk
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