ROTHENBERGER RP PRO III Water Pressure Testing Instruction Manual

: June 4, 2024
: Rothenberger

Table of Contents

Overview
Safety instructions
Technical data
Use
General maintenance
Repair and replacement of parts
Operating instructions
Faults, possible causes, and repairs
Documents / Resources

RP PRO III Water Pressure Testing
Instruction Manual ROTHENBERGER RP PRO III Water Pressure
Testing

Overview

ROTHENBERGER RP PRO III Water Pressure Testing -
Overview

A. Piping system or vessel to be tested
B. Master bleeder
C. High pressure hose
D. Water tank
E. Water mains
F. Feeding water connector| G. ON/OFF switch of the power pump
H. Pressure gauge
I. Cord with plug
J. Override switch
V1. Pressure adjusting valve
V2. Closing valve V2 with knob
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Please read and retain these directions for use. Do not throw them away! The warranty does not cover damage caused by incorrect use of the equipment! Subject to technical modifications!

Symbols in this document:

| Danger!
This symbol warns that the user is in danger of injury.
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| Attention!
This symbol warns that there is a danger of causing material or environmental damage.
| Action required
| Use of hearing protectors
This symbol warns that hearing protectors should be worn in order to guarantee the worker’s safety.
FMM SH-F50 Split Fiber Marking Machine - SYMBOL | Use of goggles obligatory
This symbol warns that goggles should be worn in order to guarantee the worker’s safety.
| Consult the manual or instructions book
This symbol warns that the manual should be consulted in order to avoid risks.

Safety instructions

Warning! Read all of the safety precautions, instructions, illustrations, and specifications supplied with this electrical equipment. Failure to observe all of the instructions given below may result in electric shock, fire, and/or serious injury.
Keep all of the precautions and instructions for future reference.

1.1 Safety in the work area
a) Keep the work area clean and well-lit. Untidy and dark areas can cause accidents.
b) Do not use electrical equipment in explosive atmospheres, such as in the presence of flammable liquids, gases, or dust. Electrical equipment generates sparks that could set the dust or fumes alight.
c) Keep children and onlookers at a distance when using electrical equipment. Distractions can cause a loss of control.

1.2 Electrical safety
a) The electrical equipment’s plug must be suitable for the electrical supply. Do not modify the plug under any circumstances. Do not use a plug adapter with earthed electrical
equipment. Unmodified plugs and the use of the corresponding sockets (230V or 110V) will reduce the risk of electric shock.
b) Avoid touching earthed surfaces, such as piping, radiators, chains, or coolers. The risk of electric shocks increases if the body is connected to the earth.
c) Do not expose electrical equipment to rain or moist conditions. Water getting into the equipment will increase the risk of electric shock.
d) Do not use the cord incorrectly. Never use the cord to carry, lift or unplug the electrical equipment. Keep the cord away from heat, oil, sharp edges, or moving parts. Damaged or tangled cords increase the risk of electric shock.
e) When using electrical equipment outside, use an extension cord that is suitable for outdoor use. Using an extension cord that is suitable for outdoor use reduces the risk of electric shock.
f) If using electrical equipment in moist conditions is unavoidable, use a power supply that is protected by a Residual Current Device (RCD). Using an RCD reduces the risk of electric shock.
g) If the power cord has to be replaced, it must be replaced by the manufacturer or service agent in order to avoid a safety risk.

1.3 Staff safety
a) Stay alert, check what you are doing and use common sense when handling electrical equipment. Do not use electrical equipment when you are tired or under the influence of drugs, alcohol, or medical products. One moment of distraction while handling electrical equipment can cause serious injury.
b) Use personal protective equipment. Always wear eye protection. Personal protection equipment such as dust masks, non-slip shoes, helmets or ear protection used for appropriate conditions reduce personal harm.
c) Avoid accidental start-ups. Ensure that the switch is in the “off” position before connecting to the power supply and/or battery, picking up or moving the equipment.
Transporting electrical equipment while switched on and running is very dangerous and can cause an accident.
d) Remove any keys or tools before turning the electrical equipment on. A key or a tool connected to a rotating part of electrical equipment may cause harm.
e) Keep feet firmly on the ground and maintain your balance at all times. This allows greater control of the electrical equipment in unexpected situations.
f) Dress appropriately. Do not wear loose clothing or jewellery. Keep your hair and clothing away from moving parts. Loose clothing, jewellery or long hair can get caught in
moving parts.
g) Do not allow confidence gained through frequent use of the equipment to cause you to ignore the general safety principles. One careless move can cause serious injury.

1.4 Use and care of the electrical equipment
a) Do not force the electrical equipment. Use the electrical equipment in a way that is appropriate for your application. Using the electrical equipment correctly will make work better and safer at the speed for which it was designed.
b) Do not use the electrical equipment if you are unable to move the switch from “on” to “off” and vice versa. Any electrical equipment that you are unable to control with the switch is dangerous and should be repaired.
c) Unplug the power source plug and/or remove the battery, if possible, before making an adjustment, replacing an accessory, or storing the electrical equipment. Preventative measures like this reduce the risk of starting the equipment by accident.
d) Keep inactive electrical equipment out of the reach of children and do not allow people who are not familiar with the equipment or with these instructions to handle them. Electrical equipment is dangerous in the hands of untrained users.
e) Maintain electrical equipment and accessories. Ensure that moving parts are not misaligned or blocked, and that there are no broken parts and other conditions that may affect the operation of the electrical equipment. Electrical equipment should be repaired before use when it is damaged. Many accidents are caused by poorly maintained electrical equipment.
f) Use the electrical equipment, accessories and equipment tips, etc. in accordance with these instructions, bearing in mind the work conditions and the work to be carried out. Using electrical equipment for applications different from those intended may provoke a hazardous situation.
g) Keep handles and gripping surfaces dry, clean, and free of oil and grease. Slippery handles and gripping surfaces prevent safe gripping and control of the equipment in certain situations.

1.5 Maintenance
a) Have your electrical equipment serviced by a qualified service technician and only use appropriate, genuine Rothenberger spare parts. This guarantees that the safety of the electrical equipment is maintained.

1.6 Special safety instructions
This document contains important instructions for people’s safety. It is intended for the user. Keep it in a safe place for future reference.
Read and follow these instructions closely every time that the test power pump is turned on:

Ensure that the electrical system has an appropriate RCD circuit breaker.
Always disconnect the power pump after each test and before carrying out the following operations:
a. Moving the power pump from one position to another.
b. For maintenance.
c. For accessory and part replacement.
Do not pull on the electric cord, on the supply hose, or on the high-pressure hose connected to the piping system to move the power pump.
Never pull on the electrical supply cord to unplug it.
Never let unqualified people, children, adolescents, etc., or people who are not trained in the use of power pumps use the pump.
To guarantee the safety of the power pump, follow the manufacturer’s instructions and only use original replacement parts, components, and accessories or parts that have been authorized by the manufacturer.
Water nozzles can be very dangerous if used inappropriately: never point the water jet at people, animals, electrical equipment, or the power pump itself.
Never use the water jet on yourself or other people to clean clothing or shoes.
ATTENTION: the hoses, accessories, and couplings are very important for the safety of the power pump. Only use hoses, accessories, and couplings which are recommended by the manufacturer.
Never use the power pump when the electrical supply cord or other important parts such as safety devices, high-pressure hose, etc. are damaged.
If you have to use an extension cord, the plug and connector must be waterproof.
Inappropriate extension cords can be dangerous.
The user must take all of the safety precautions mentioned in this manual into consideration. Otherwise, misuse of the equipment can cause accidents and the manufacturer assumes no responsibility if this is due to the disregard of the safety precautions mentioned here.

Do not dispose of electrical equipment with domestic waste. In compliance with the Directive 2012/19/UE of the European Parliament and its transposition to the state legislation framework in the Royal Decree 208/2005 on electrical and electronic devices and the management of their waste, the objective is to prevent the generation of this waste, to reduce its elimination and the level of danger of its components, to promote the re-use of devices and the valorization of their waste and determine a suitable way to manage this in an aim to improve the efficiency of environmental protection.

Technical data

Voltage| 230 V, 50 Hz
(110 V.), single-phase
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Nominal power of the motor| 1.3 kW
Rated current| 6 A
Protection class| IP20
Maximum pressure| 40 bar
Nominal flow: max| 6 l/min
Net weight of device:| 16 Kg
Total dimensions of device:| 380 x 290 x 300 mm
Supply water:| clean freshwater, Glycol, Tyfocor, Maximum temperature: 40ºC
High-pressure hose:| Ø int. 1/4”, 1.2 m. length
Lubricant:| oil for 4-stroke engines SAE 15W/40
Noise level:| no higher than 90 dB (A)

Use

Pressure testing of seals on piping systems and vessels used in all types of installations.
Hydraulic, heating, steam, refrigeration, oil, spraying installations, solar thermal systems, etc.
Production of boilers (verification of tightness of coils) and pressure recipients or tanks, filling of circuits.

General maintenance

Before connecting the pump to electric sockets and water supplies:
a. Carefully check the condition of the high-pressure hose and the cord of the plug. If necessary, replace them with new ones.
b. Check the water filter (No. V121M37 – C Spare Parts). Clean it and replace it if necessary.
If the device is to be stored for a long period of time, it is recommendable to empty the water remaining in the internal circuits
Avoid storing the equipment in very cold places where there is a risk of freezing
Keep the water filter clean and in good condition
If the equipment is used with antifreeze agents such as Glycol, Tyfocor, etc. use the device with clean fresh water to clean out the internal circuits

Repair and replacement of parts

There is a maintenance Kit for the most accessible set of sealing gaskets (cod. R6.1186), which enables the replacement of the most commonly worn or eroded gaskets and prologues the power pump’s lifespan.
The replacement of parts, servicing of the pump, and electrical inspection should only be carried out by official Service Centres.

Operating instructions

Open the master bleeder of the piping system or vessel to be drained (i.e. Fig B On appliance)
Connect the water inlet hose to the hose connection on side of the appliance (Fig F option A or B)
Option A: Direct from water mains (Min pressure 1 BAR)
Option B: Use Clean water from the water storage container which should be placed no more than 1-meter MAX below the pump level
Connect the high-pressure hose, threaded ½” male end to ½” female connection beside the control valve V2 on the appliance and ½” female connection on the high-pressure hose to appropriate fitting on the system to be tested
Turn control valve V2 Anticlockwise fully to OPEN
Turn control valve V1 Anticlockwise fully to –BAR
Plug appliance into mains (Fig E On appliance). Power must be 230V 50 Hz * O R on 110V
APPLIANCES USE A 3KVA TRANSFORMER ONLY!
Please note: This appliance is for testing only, NOT for filling a system. Using your RP PRO III to fill a system will damage or break the appliance! If the system is empty, use another method to fill it before pressure testing with your RP PRO III
Switch on the appliance (Fig G On appliance) and allow it to run until satisfied that the system is free of air via the bleed point. Then switch off the pump and close the bleed point immediately!
To achieve the desired test pressure:
• Turn on the pump (Making sure control valve V2 is fully OPEN)
• Slowly turn control valve V1 clockwise to +BAR, increasing pressure till desired pressure is achieved. Use V1 to increase and decrease pressure as required!
• Turn control valve V2 clockwise to CLOSE, then turn off the pump IMMEDIATELY!
If the reading on the gauge has exceeded desired pressure. Keeping the pump OFF:
• Carefully open V2 and turn V1 toward –BAR till you reach the desired pressure
• Then close V2
When testing is complete:
Turn control valve V2 Anticlockwise fully to OPEN
Turn control valve V1 Anticlockwise fully to –BAR
N.B. When storing appliances between uses and for long periods of time, open V1 & V2 fully then turn knobs back clockwise half a turn to prevent valves from sticking!

Faults, possible causes, and repairs

Despite being switched on, the motor doesn’t start

The electrical current isn’t reaching the terminal box| Check the plug/socket connection. Check the length of the cords leading to the terminal box. Reassemble the motor’s thermal protection or replace blown fuses. Return to Service Centre.
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The electrical current is reaching the terminal box, but the voltage is very low| Connect the motor to a supply of 230V, 50 Hz. For 110V, please use a 3KVA transformer.
Pump seized with ice. Motor rotor seized up| Return to an official Service Centre.

The pump is working but the pressure isn’t rising

Insufficient water supply| Check the supply hose: the inner diameter should not be less than 15 mm. Also, the water pressure at the outlet tap should not be less than 1 bar.
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A considerable amount of air in the input water| MAIN: Check fittings are tight and water supply is MIN 1 bar with sufficient flow.
TANK: Check water tank is full and that the hose is correctly submerged to draw water to the pump.
The water filter is dirty| Clean the filter.
The pump’s gaskets are in bad condition or the pump valves have seized up| Replace the sealing kit R6.1186.
V1 valve set to a minimum pressure| Open the V1 valve until the desired pressure is attained.

The discharge pressure is irregular and makes considerable noise

Air in the supply water	Check the seal at both ends of the supply hose.
Insufficient water supply	Check the supply hose: the inner diameter should

not be less than 15 mm.
Also, the water pressure at the outlet tap should not be less than 1 bar.

The piping reaches the test pressure but doesn’t maintain the desired pressure

The V2 valve isn’t working correctly| Check the operation of the V2 valve. Clean it and remove any dirt that the water may have carried inside. Return to Service Centre.
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Documents / Resources

| ROTHENBERGER RP PRO III Water Pressure Testing [pdf] Instruction Manual
RP PRO III Water Pressure Testing, RP PRO III, Water Pressure Testing, Pressure Testing
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