Brio 2000 / Brio 2000-M Service Manual Rev. 0.0 SAFETY INFORMATION The operations described in the present document must be performed only by technicians who are instructed about the risks becoming from high voltage electricity. HOME · PROBLEM SOLVING PROCEDURE · REPLACING ELECTRONIC BOARD · ADJUSTING CUT-IN PRESSURE · FLOW SENSOR CALIBRATION · CLEANING THE CHECK-VALVE Is the device powered on (green LED on) ? YES NO - Check power supply cable and plug - Check incoming voltage - Check electronic board for possible damages (if necessary replace the board following the procedure ) Which is the problem ? The pump doesn’t start! The pump doesn’t stop! Others… Pump doesn’t start: does the device show a FAILURE (red LED on) ? YES NO Pump doesn’t start and FAILURE light is ON: - Starting pressure is set too high. Carry-out pressure adjustment - Check the motor of the pump for possible failures (i.e. starting capacitor, locked rotor, thermal protection, etc.) - Check the cable between Brio and the pump - If a float switch has been installed between the Brio and the pump please remove it. - If the device is installed on a submersible pump and the problem appears when the system is inactive for several hours, arrange a small bypass - Check electronic board for possible damages (if necessary replace the board following the procedure ) Pump doesn’t start and FAILURE light is OFF: - Starting pressure is set too low. Carry-out pressure adjustment - If a non return valve has been installed directly before or directly after the Brio, please remove it. Check this example. - Check electronic board for possible damages (if necessary replace the board following the procedure ) INSTALLATION OF NON-RETURN VALVES 1) Never install a non return-valve between the pump and the Brio. 2) Never install a non return valve at the outlet of Brio. 3) When the Brio is installed with a submersible pump, it’s allowed to install a non return valve at a distance > 3mt from the Brio. ADJUSTING STARTING PRESSURE The cut-in pressure must be adjusted according to the height of the water column at the exit of Brio. Each 1 mt. of water column of water corresponds to 0.1 Bar. The factory setting is 1.5 Bar and allows the Brio to operate up to 15 mt. To make an optimal setting of the starting pressure: 1) unscrew completely the setting screw ( “-” direction) 2) open the highest tap on the system and wait for complete water discharge (pump should not start) 3) turn the screw progressively clockwise ( “+” ) until the pump will start. 4) turn the setting screw clockwise (“+”) for 2-3 turns more to grant a constant functioning along the time. CREATING A BY-PASS When the Brio is installed on a submersible pump and the non return valve incorporated on the pump has a leakage and cannot grant a perfect seal, it can happen that the pipe between the pump and the Brio gets empty during long periods of inactivity (i.e. during the night). When the pump is re-started, the user can get an error for “dry running” because the water needs to much time to be lifted from the ground. The problem can be solved by installing a small by-pass (max.Ø 6.0mm) over the Brio in order to grant communication between the pipes before and after the Brio. In case of leakages from the non-return valve incorporated on the pump, the pressure drop will be detected by the Brio that will automatically re-start the pump and will keep the pipe full of water. REPLACING THE ELECTRONIC BOARD Open the unit cover, unplug the electrical cables and remove the electric board internal protection cover by means of the 2 fastening screws. Unplug the pressure switch connector and remove the electronic board releasing the fastening screws. Place the new electronic board and fasten it by means of the two proper screws, then plug again the pressure switch connector. Put on back the board protection cover and the RESET button extension. Connect again the electric cables and close the unit cover. VERY IMPORTANT !! CARRY OUT FLOW SENSOR CALIBRATION! FLOW SENSOR CALIBRATION Keep the RESET button pressed and reconnect the power supply. When the green and red light are both on, release the RESET button. Make sure the check valve is closed (absence of flow) and press the RESET button in order to automatically reset the flow sensor to zero. Check the device correct functioning closing all the taps and waiting the pump stop. If this does not happen, then repeat again previous steps. Pump doesn’t stop - Flow sensor is not calibrated. Carry out automatic calibration. - The check-valve is dirty or is stuck. Please clean it! - There’s a serious leakage somewhere in the system, please check. - If a non return valve has been installed directly before or directly after the Brio please remove it. Check this example - Please check if the RESET button is stuck. - Check electronic board for possible damages (if necessary replace the board following the procedure ) Other conditions: 1) THE PUMP CONTINUOUSLY STOPS AND IMMEDIATELY RE-STARTS or 2) SOMETIMES THE PUMP STARTS EVEN IN ABSENCE OF WATER CONSUMPTION: - check for possible leakages in the system. - install a small pressure tank after the Brio CLEANING THE CHECK VALVE If there’s some dirt inside the inlet hub and the check-valve cannot close completely, it could happen that the pump doesn’t stop. In that case the check-valve can be cleaned by means of the following actions: 1) Try to move the check valve with a finger, push and release the valve in order to remove stones or similar objects. 2) Try to clean the valve using compressed air, from the inlet to the outlet. 3) If the previous actions don’t solve the problem, proceed with disassembling the check-valve. DISASSEMBLING CHECK VALVE The check-valve can be fully inspected by removing the inlet hub. The inlet hub can be unscrewed taking care do not damage the plastic parts of Brio. MAGNET When re-assembling the check-valve and the inlet hub, take care of the correct alignment of the magnet. The magnet must be displaced toward the electronic board.