GL0131P Domestic Sensor Gamma Gravity Rainwater Harvesting Systems Installation & Operation Guidelines. Service Contact Numbers:

Transcription

1 GL0131P Domestic Sensor Gamma Gravity Rainwater Harvesting Systems Installation & Operation Guidelines Service Contact Numbers: GB: Tel: +44 (0) NI: Tel: +44 (0) IRL: Tel: +44 (0) Issue Description Date 06 CC1320 October 2016

2 CONTENTS: SITE DELIVERY CHECKLIST ADDITIONAL ITEMS REQUIRED FOR INSTALLATION INSTALLATION INSTRUCTIONS... 5 INSTALLATION... 6 TANK INSTALLATION... 7 SYSTEM INSTALLATION... 9 GRAVITY SYSTEM GUIDE SHEET SET UP AND COMISSIONING.... Error! Bookmark not defined. CONTROLLER MENU DESCRIPTIONS TECHNICAL SPECIFICATION AND BOX DIMENSIONS TROUBLESHOOTING REGULATIONS - GENERAL HEALTH & SAFETY MAINTENANCE MAINTENANCE LOG These instructions cover the installation of the Mechanical and Electrical components of the system as supplied by ourselves. The installation of the Storage Tank and Rain Water Filter are covered by separate installation instructions. The installation of ancillary equipment is covered by the manufacturer s own installation instructions. Please ensure that the installation is carried out in accordance with the relevant regulations for that part of the procedure (Building Regulations, Planning Requirements, Electrical Regulations, and Water Regulations etc.) For assistance or further information, please visit Thank you for purchasing your Gamma RWH system. The following instructions will help you to install your chosen system with ease. It is important that you read and understand all of the installation procedure within these instructions. Please call us should you wish to discuss any part of the procedure in more detail. Page 2

3 SITE DELIVERY CHECKLIST. Page 3

4 ADDITIONAL ITEMS REQUIRED FOR INSTALLATION. NB: All of the above items are a requirement for a complete installation but these items will NOT be included in your delivery. Every care is taken to ensure that all components are correctly fitted and no debris is left in the bottom of the unit prior to leaving the factory. However, subsequent handling during transportation and installation may result in debris collecting in the unit. Your installation contractor should have thoroughly checked the unit, on inspection if there is any debris or building contamination, please remove prior to starting the unit. All rain feeding pipework and rain collection surfaces should also be flushed clear of debris. Page 4

5 INSTALLATION INSTRUCTIONS General: 1. The Storage tank requires the installation of a duct, of minimum diameter 100mm to carry the pump cable and the Depth Sensor cable. The duct should run from the Storage Tank to the Control Panel and should be suitable for drawing the cables freely. 2. The Storage tank requires an MDPE (Medium Density Poly-Ethylene) pump feed pipe from the tank back to the Control Panel of MINIMUM 25mm diameter (see the tank connector). To comply with current regulations this pipe should be Black with green stripes (see section on Water Regulations). 3. The Storage tank requires an Inlet feed from the rainwater Collection pipe work (usually via the Rainwater Filter or pre-tank collection manhole) and an Outlet to a suitable waste water discharge point (Surface Water Drain, Ditch, Stream or Soak away). This pipe work should preferably be Solvent Jointed rather than ringseal jointed. 4. The Display Unit requires a four core alarm type cable back to the Control Panel. The Display Unit should be mounted in a frost free, highly visible location and not in an area which is rarely used. 5. The location of the Control Panel should be in a frost free, well lit place, with good access and mounted at a convenient height above the top water level of the rainwater storage tank (1.5 to 2 metres). If the Control Panel is mounted any higher than 2.0m above the rainwater storage tank (on a higher floor / in an attic etc.), please contact technical sales to discuss the implications. The height difference between the bottom of the external Storage tank and the Control Panel, or the difference in height between the Control Panel and the appliances, may affect the set up procedure. 6. As in any plumbing system, a correctly sized Pressure Vessel (Expansion Vessel) should be installed. The vessel (supplied by others) should be installed between the Control Panel and the header tank. Pressure vessel sizes will vary site by site, however a 12L pressure vessel will cover 95% of domestic installations, it is your responsibility to ensure your vessel is sized to suit your specific site. Incorrect sizing of the pressure vessel will lead to system issues at a later date.. 7. Once you have fully understood these general points, you should be confident in the type of system you intend installing and in the layout and location of the parts. You should now be able to begin installation. Be aware of the following advisory points. a) Before carrying out any work of the system isolate the electrical supply. b) The display unit should be mounted in a visible location. c) The control panel must be fitted the correct way up, i.e. with the cable entries at the bottom. d) If using an external Rain Water Filter it should only be installed when all levels and pipe falls have been decided. The Filters have different falls across, depending on which model is used and generally have two outlets. One outlet of clean Rainwater to the Storage Tank and one outlet to waste. e) All serviced appliances and external taps must be connected on the plumbing line after the header tank. Page 5

6 INSTALLATION These guidelines represent Best Practice for the installation of Kingspan RWH (Rainwater Harvesting) Units. Many years of specialist experience has led to the successful installation of thousands of units it must be noted, however, that these Guidelines are of a general nature. It is the responsibility of others to verify that they are appropriate for the specific ground conditions and the in-service loads of each installation. Similarly, a qualified specialist (e.g. Civil engineering consultant) must verify any information or advice given by employees or agents of Kingspan regarding the design of an installation. 1.0 Handling & Storage 1.1 Care must be taken to ensure that units are not damaged during delivery and handling on site. 1.2 The design requirements of Kingspan products will frequently mean that the centre of gravity of the unit is offset. Care must therefore be taken to ensure that the unit is stable when lifting. Rainwater may also collect inside units, particularly if they have been stored on site prior to installation, adding weight and increasing instability. Check units before lifting and pump out any excess water. 1.3 When lifting units, use webbing slings of a suitable specification. DO NOT USE CHAINS. 1.4 A suitable spreader bar should be used to ensure that units are stable and that loads are evenly distributed during lifting. When lifting units, a spreader bar should be used where the slings would otherwise be at an angle > 30 degrees to the vertical. 1.5 Lifting equipment should be selected by taking into account the unit weight, length and the distance of lift required on site. 1.6 Kingspan accept no responsibility for the selection of lifting equipment. 1.7 Whenever Kingspan units are stored or moved on site, ensure that the storage location is free of rock, debris and any sharp objects, which may damage the unit. The units must be placed on ground which is flat and level to evenly support the base of the unit. Do not roll units. 2.0 Site Planning The following points should be considered before installation of the equipment: 2.1 Position the unit at a minimum distance of 5 metres from the face of the building, so as not to affect either the structural integrity of the building or the tank. 2.2 Ground conditions and water table level should be assessed. If the water table will be above the base of the unit at any time of the year, adequate concrete backfill must be provided to avoid flotation. In poorly draining ground, consideration should also be given to the likelihood of flotation due to surface water collecting in the backfill, and an appropriate installation method devised to avoid this. 2.3 The unit must be installed at a level that will allow connection to the incoming down pipe and a free discharge at the system overflows. 2.4 Do not install the unit deeper than necessary; ensure that you purchase any necessary neck extension shafts at the same time as the unit purchased. The minimum invert depth of the unit is shown on the relevant equipment drawing. Units installed with an invert greater than 2.0m will require a civil design specific to the installation. The greater the invert the more difficult servicing & maintenance of the unit becomes. The pump rope will need to be extended, mount a hook 300mm down from ground level, to attach the extended pump rope. Fit a chain to the leaf filter to aid access. 2.5 Adequate access to the unit must be provided for routine maintenance. Vehicles should not be permitted within a distance equal to the depth of the unit, unless suitable structural protection is provided to the installation. 2.6 There must be at least 1 metre of clear, level ground all around the access covers to allow for routine maintenance. 2.7 Suitably qualified and experienced contractors, in accordance with current Health and Safety Regulations should only carry out installation. A qualified electrician, working to the latest edition of IEE should carry out electrical work. Page 6

7 TANK INSTALLATION 3.0 DRY GROUND CONDITIONS. 3.1 Excavate the site, allowing for a minimum clearance on all sides and base of the unit of 200mm and level the base. 3.2 Ensure that the hole is kept dry. Should any rain or surface water collect in the hole, this should be pumped out. 3.3 A base of at least 200mm of lean mix concrete should be provided. 3.4 Lower the tank into the hole: GRW KSW:- use a rope sling through the lifting points provided on the tank (under no circumstances should the sling be attached to the inlet pipe or the outlet pipe). 3.5 Position the inlet pipe in line with the incoming drain. Note that the inlet and the outlet pipes are clearly labelled on the tank. The unique profile of the base will help to level the tank, but make sure the tank is in the truly upright position. 3.6 After any concrete in the base has taken up its initial set (usually after one day), ballast the tank by putting approximately 0.5m depth of water into it. 3.7 Backfill the space around the tank with pea gravel or similar material. The backfill should be free from organic material, large stones, bricks or sharp objects. 3.8 Continue to ballast/backfill the tank in 300mm stages up to the level of your connections. It is most important that the installer progressively fills the tank with water to the level above the backfill in order to stabilize pressures on the tank. 3.9 See SYSTEM INSTALLATION for pipe work connection details 3.10 Backfilling can now proceed up to ground level in 300mm stages ensuring tank is ballasted in all chambers as you go A galvanized lockable manhole cover and frame is to be fitted to suit specific site loadings, THE TANK MUST NOT BE LOAD BEARING. The top of the manhole should not be sat below the local ground level. If necessary you should use brick work above the tank to bring the cover up to ground level Venting is provided on all tanks and must be used, ventilation to be run above ground level and finished with necessary rodent protection screen. 4.0 WET GROUND CONDITIONS: 4.1 Excavate a hole to appropriate depth allowing at least 300mm for lean mix concrete and hard-core base. Allow for tank width plus at least 400mm with additional allowance for any necessary shuttering. 4.2 De-water the excavation using suitable pumping equipment. Ensure that the pump discharge does not saturate the ground in the immediate vicinity. In wet ground conditions the installer should ensure that the base is adequate to support the weight of the tank and its contents. If the base of the excavation is unstable, i.e. running sand or similar, excavate an additional mm below concrete levels and fill up with compacted hard-core. Place a sheet of polythene over the hard-core and up the sides of the excavation before putting in the concrete cradle. 4.3 Lay a bed of concrete (minimum 150mm thick) on top of the polythene at the base of the excavation. Dewatering is to continue until you are satisfied that the concrete has cured. 4.4 Lower the tank onto the concrete bed, ensuring that the inlet and outlet are in the correct position. Ensure the tank is upright and then ballast it with water to a maximum of 500mm deep. 4.5 Haunch up the concrete bed at least 450mm all round the base, ensuring that all voids in the concrete are eliminated and at least 150mm of concrete is left below the tank base. 4.6 Backfill to the invert depth with concrete. Ensure that the water level inside the tank is maintained no more than mm above concrete backfill level. It is most important that the installer progressively fills the tank with water to a level above the backfill in order to stabilize pressure on the tank. Page 7

8 4.7 Backfill evenly all round the tank, consolidating in layers. The backfilling should start before the base has hardened and be a single continuous operation so that the tank has a full concrete jacket without joins. 4.8 DO NOT use vibrating pokers to consolidate concrete. DO NOT discharge concrete directly on to tank. Ensure that the concrete is not too wet and that is tamped in around the tank. 4.9 See SYSTEM INSTALLATION for pipe work connection details Build up a shell of concrete around neck of tank to mm thickness before completing the backfill with a suitable material. Necks must be suitably braced whilst backfilling around this nonballasted area Fit cover and frame. Apply surface finish e.g. turf Do not empty tank until the concrete backfill has cured. Tanks may be left filled with water. The Concrete Specification is a general specification. It is not a site specific installation design. TYPE OF MIX PERMITTED TYPE OF CEMENT PERMITTED TYPE OF AGGREGATE (coarse & fine) NOMINAL MAXIMUM SIZE OF AGGREGATE GRADES: C25 /30 MINIMUM CEMENT CONTENT SLUMP CLASS RATE OF SAMPLING C25 /30 C16 /20 C30 C20 GENERAL CONCRETE SPECIFICATION IN ACCORDANCE WITH BS EN ( BS ) (DC) DESIGN BS 12 (OPC): BS 12 (RHPC): BS 4027 (SRPC) BS mm REINFORCED & ABOVE GROUND WITH STORAGE DOWN BOLTS REINFORCED (EG. FOR HIGH WATER TABLE) UNREINFORCED (NORMAL CONDITIONS) Kg/M Kg/M 3 S1 (25mm) READY MIX CONCRETE SHOULD BE SUPPLIED COMPLETE WITH APPROPRIATE DELIVERY TICKET IN ACCORDANCE WITH BS EN NOTE: STANDARD MIXES SHOULD NOT BE USED WHERE SULPHATES OR OTHER AGGRESSIVE CHEMICALS EXIST IN GROUND WATER Page 8

9 SYSTEM INSTALLATION Please refer to the GRAVITY SYSTEM Guide Sheet (at the end of this section) throughout these instructions. As you are installing a GRAVITY system it is assumed that you have MAINS WATER SUPPLY available and you wish to use MAINS water in this scheme by the installation of a header tank. In all cases, this equipment should be installed by competent, qualified personnel and should comply fully with all the relevant regulations, particularly the current Water Regulations and the current edition of the IEE regulations concerning the safe installation of such equipment. Be safe. It is assumed that you have read and understood the tank Installation Instructions, the Tank is IN SITU but not backfilled, and you must now consider the installation of the pipe work and cable runs. Please be aware that there are connections to the pump and depth sensor, located in the tank, which must exit via the turret. If you intend using extension rings on the tank turret please bear this in mind. If there is any doubt regarding the ability to carry out these connections due to such extensions, you may need to consider an access chamber. Consult with a qualified civil engineer in this circumstance, particularly regarding the surface loading. Study the GRAVITY Guide Sheet and decide on the following: 1) The route by which you will take the surface drain pipes (minimum 110mm) back to the tank from the gullies and whether you are fitting an external rainwater leaf filter or not. 2) The route of your tank overflow pipe If you are not using the overflow it MUST be blanked off with a good seal. (NOTE. IF YOU ARE FITTING A PUMPED OVERFLOW you should refer to the separate document on NON-STANDARD SYSTEMS before proceeding.) 3) The route and inverts for pipe work from any manifold chamber collection points or Rain Water Filters. 4) Choose the location of the Control Panel. Note that this unit should be mounted under cover, protected from frost, and be located at a convenient height of between 1.5 metres and 2 metres above top water level in the storage tank. If you wish to mount the unit in any other location please contact Kingspan for further advice. NOTE. Do not install the pump until you are ready to electrically connect it in to the CONTROL PANEL. See step 13. 5) Refer to the Guide Sheet DIAGRAM A. The pump outlet tank connector is supplied with the tank. Make certain that it is securely tightened in to the tank turret. Cut the MDPE 25mm (black) pipe squarely and clean off rough edges. Use an insert in the end of the pipe as recommended by the supplier. Make sure that the pipe and tank connector are clean and free from grit and soil etc. Ensure the section to be inserted is not badly scratched. With the collet loose on the tank connector, insert the pipe fully home then tighten the collet. Check the fitting nut, tank side, for tightness. (Do not over tighten.) 6) Refer to the Guide Sheet DIAGRAM A. Lay in the MDPE pump outlet pipe; ensure that bending radii are kept as large as possible to avoid kinking. Before terminating the pipe in the building, flush it through to clear any grit or small stones. Fix and secure to a stop-cock convenient for connection to the Control Panel, leaving adequate space for the inline filter. 7) Refer to the Guide Sheet DIAGRAM A. The Electrical Duct should be 110mm PVC and should be suitable for the purpose. The duct should enter the tank turret through the pre-drilled hole. If this hole is not present or conveniently located a hole may be drilled using a proprietary hole-cutter. Do not drill this hole at less than 300mm below ground level. The duct should be sealed into the tank using a quality waterproof sealant. Also seal any unused hole. Run the duct in its trench with as straight a route as possible, using the minimum number of bends with sweep-bend joints of 45 degrees maximum only if absolutely necessary. Feed the draw wire (or rope) as the duct is laid. Use accessible joint boxes if there is a need for an acute bend on entry into the building. Terminate the duct at a point close to, or convenient for connection to, the CONTROL UNIT. 8) Refer to the Guide Sheet DIAGRAM B. If you are using an external Rain Water Leaf Filter take particular care to note the invert levels of the pipe work. The entry points are the TOP spigot of the filter, the clean water outlet is the MIDDLE spigot and the waste water outlet is the bottom. The surface water pipe work from the collection area should be jointed prior to the inlet. If a Rain Water Leaf Filter is not required, a manhole chamber should still be installed if only for roding purposes. Page 9

10 Once all the collection pipe work is in place, the joints should be inspected. Most drainage pipe work is tested to withstand a specified internal pressure. In RWH systems it is important that surface water cannot seep into the pipe work under the external ground water pressure. 9) Refer to the Guide Sheet DIAGRAM B. You are installing a GRAVITY system and so it is necessary to take a mains water supply feed to the HEADER TANK and to connect in (as illustrated below). NOTE. The illustration below does not show the weir or overflow arrangement which regulations require. The RWH float shown is the FLUIDMASTER type 747. It is recommended to use that type of float valve. In opposition to old ball cocks the fluidmaster 747 is non leaking which prevents pressure drops and reduces the number of pump start times. As you can see on the picture above the Mains ball cock OFF level should be below the RWH float valve OFF level as shown. It is very important to keep that levels as shown on the picture. The mains ball cock Shut Off Level should be a tank water depth of 275mm and the RWH Shut Off Level should be a level of 350mm. The Mains should only fill the header tank when the Gamma RWH storage tank run out of rainwater and pump stop to pumping. In normal operation when the RWH pump is pumping rainwater to the header tank the Mains ball cock should be close. 10) Refer to the Guide Sheet DIAGRAM B. Install the in-line filter between the stop-cock and control panel. Fit the filter as shown on the Guide Sheet ensuring the direction of flow is correct, arrow towards the control unit, and complete the connection to the RWH inlet using a compression fitting or push fit. Do not tighten against the spigot. Use two spanners in contra-rotation to compress the olive and make a seal. Do not use soldered joints under any circumstances. Note. It is permissible to install a service valve within 0.5 metres of the outlet from the control unit. 11) Refer to the Guide Sheet DIAGRAM C. The electrical installation must be carried out by a competent person to the relevant standards as laid down in the current Building & IEE Regulations. 12) Refer to the Guide Sheet DIAGRAM C. The display unit is an important part of your system. Locate in a visual position in an area which is often occupied. The unit is designed to be surface mounted in a dry location. The display unit is wired back to the control unit (up to 300m). This cable should be four cores at 1 amp per core rating. In installations where the cable is exposed to harsh conditions or spans of over 50 metres, a 4 core armoured (7/0.2 mm each core) cable should be used. The cable should be connected between the DISPLAY terminal block on the DISPLAY unit to the DISPLAY terminal block on the CONTROLLER unit. The terminal blocks at both ends are marked GND - BLACK core, RED core, A - BLUE core and B -YELLOW core. Page 10

11 13) Refer to the Guide Sheet DIAGRAM C. To install the pump you should take great care. It is a heavy item. Two people will make the job much easier. Take the pump to the tank turret. Release the ties on the mains electric cable. Uncoil the HOSE and attach to the pump. Attach the suction filter to the pump. Draw the mains electric cable through the duct along with another draw-wire (or rope) to pull through the sensor cable later. When the electric cable is fully in place, with the waterproof connector accessible, connect the waterproof pump cable connector to the mains electric waterproof connector and twist to effect the seal. The pump can be lowered carefully, on its rope, into the tank. Do not lower the pump by the electrical cable or by the hose. One person should hold on to the pump hose free end and should guide the other person, not allowing the cable to be trapped by the descending pump. When the pump is sitting on the tank bottom, the rope should be tied off to the turret bracket, just sufficiently taught to keep the pump upright but not enough to suspend it. The pump hose should now be connected to the tank connector, ensure the seal is in place. Do not over tighten. Run the pump electrical cable from the duct to the control unit and wire it in to the terminals marked L brown core, N blue core and E green/yellow core, designated, MASTER PUMP. Pump is capable of lifting water to a head of 30 metres and creating a maximum pressure of about 68psi (4.7bar). NOTE. If you have extended the pump cables and have used oversized, armoured or solid conductors to achieve this you must convert to 1.5mm 2 flexible TRS using a joint box before entering the control unit. A suitable pump isolator switch is a convenient joint box. Page 11

12 14) Refer to the Guide Sheet DIAGRAM C. Connect the level sensor. There are several level sensors you can connect to the rainwater panel. Check the dip switches settings located in the middle of the controller s printed circuit board to see what sensor is used in your system see picture below. Gamma RWH systems are supplied with a Wave Guide. Remember that only one dip switch should be in the ON position. a. Dip Switch mA unvented: it is a depth sensor without atmospheric pressure compensation. 4-20mA sensor should be connected to the 4-20mA LEVEL socket on the controller unit as shown on the picture below. Usually 4-20mA sensor has only 2 core cable. The wires should be connected to the + and - pins in the socket. If there is a cable screen it should be connected to the GND pin. The depth sensor should lie flat on the bottom of the tank. Page 12

13 b. Dip Switch mA vented: it is a depth sensor with atmospheric pressure compensation. The difference between vented and unvented 4-20mA sensor is that vented sensor has a small plastic pipe inside the cable. 4-20mA sensor should be connected to the 4-20mA LEVEL socket on the controller unit as shown on the picture above. The depth sensor should lie flat on the bottom of the tank. c. Dip Switch 3 Differential: it is a depth sensor with a differential voltage output. Differential sensor should be connected to the DIFFERENTIAL socket on the controller unit as shown on the picture below. The depth sensor should lie flat on the bottom of the tank. Differential sensor has a 4 core cable: - red (5V) connected to pin 1 - green (GND) connected to pin 2 - yellow (+Out) connected to pin 3 - blue (-Out) connected to pin4. Dip Switch mA Wave Guide unit: this sensor should be mounted on top of the tank. It provides 4-20mA analogue signal and should be connected to the 4-20mA LEVEL socket on the controller unit as shown on the picture below. The wires should be connected to the + and - pins in the socket. When using wave guide sensor it is very important to set correct tank height in the controller. The tank height should be measured from the bottom of the tank to the base of the sensor. Setting the incorrect tank height can damage the pump. Page 13

14 NOTES a) The sensor cable is of a pre-ordered length (20m, 50m or 100m). b) Extension cable not supplied by Kingspan must be of a similar specification. The specification is 16/0.2mm per core, screened by braid or SWA. The outer insulation must be rated at 240v rms. c) The screen or SWA must be earthed at the control unit end only and must be electrically continuous with the screen on the sensor cable supplied. d) Any connectors must be suitable for the environment in which they are located To install the Wave Guide sensor, uncoil the cable and draw all the cable through the duct, along with another draw-wire (or rope) for future use. The level sensor is mounted in the tank neck. To install all other depth sensors, uncoil the cable fully and straighten out on the ground. Do not cut the cable to length at this stage. It is important that this cable is not unduly stretched so lubricate if necessary. Draw all the cable through the duct, along with another draw-wire (or rope) for future use, until there is enough cable in the tank turret to enable the depth sensor to lie flat on the floor of the tank. Carefully lower the sensor into the tank until it lays flat on the bottom. Page 14

15 15) Refer to the Guide Sheet DIAGRAM C. The main electrical supply should come from the Distribution Board, fused or with MCB Type C rated 16 amps, with a separate Residual Current Detector (RCD) to an isolated switch local to the control unit, or from a 16 amp switched fused spur with integral RCD. Remove the control unit lid and identify the terminals within. The mains supply terminal block is marked POWER connect accordingly to L brown core, N blue core and E green/yellow core. Whatever cable is run to the local switch arrangement, the maximum cable size to enter the CONTROL UNIT should be 1.5mm 2 flexible TRS. Use a suitable joint box to convert if necessary. 2) You have now completed the installation of your GRAVITY system. Before proceeding to the final stage, Set-up and Commissioning, you should check the following. a) Are all the pipe work joints secure? c) Is the pump submerged in clean water, free from installation detritus? If not fill tank with a hose pipe from the mains until the pump is submerged. d) Are you aware of the location of all items of equipment, particularly the DISPLAY unit? e) Have you completed the plumbing to all appliances to be served by the system? Page 15

16 GRAVITY SYSTEM GUIDE SHEET Page 16

17 SET UP AND COMMISSIONING Step 1: Apply power to the system and observe the display unit. The system identifies that this is the first install and enters the setup wizard. If not go to MAIN MENU, SETUP,WIZARD. Tank Model Depth (cms) GRW080KSW (2350 Lt) 108 GRW110KSW (3100 Lt) 157 GRW160KSW (4600 Lt) 157 Step 2: The system now asks for the tank height. Manually enter the height of the tank in centimetres ref to the table. Press ENTER See sticker on top of wave guide assembly to identify your tank model. Step 3: The controller now enters learning mode. The system will learn the maximum system operating pressure. The display will show an hour glass timer prompting the installer to wait until the system has fully pressurised. This will take a minimum of 4 minutes and, depending on the type of system, may take considerably longer. When max pressure has been learned the hour glass will disappear and the main screen will revert to normal mode. If hourglass doesn t go off after 15 mins this indicates a leak in the system. This will need rectified and the system recommissioned. When fully pressurised the system will show 5 bars. Step 4: To check that the system is pressurised go to MAIN MENU, go to SETUP, select PRESSURE TEST The pressure in indicated both by a readout expressing the system in PSI as well an arrow indicating the inclination of the pressure at that given moment. Ideally the system will show a steady pressure indicating that system has no leaks. If the system pressure is falling then there is an output open or there is a pressure leak. Typical system pressures will be between psi. If higher check your pressure vessel is charged. You have now completed set-up and commissioning. Test all appliances and check to ensure that the STATUS indicator light (ORANGE), which may have illuminated during set-up, has now extinguished. If the STATUS indicator light fails to extinguish within five minutes, switch off the system and go to the Troubleshooting section in Full manual. Page 17

18 CONTROLLER MENU DESCRIPTIONS Main screen 20 Main Screen indicators 20 Main Menu 22 Advanced Menu 22 Display Options 24 Restore Default Settings. 24 Setup 25 Pump Menu 27 PIN Settings 29 Page 18 Page

19 A. Main Screen After power up the main screen will be displayed on the remote unit. Picture1. Main screen. On the right side of the display there is a storage tank indicator showing the level of water in the tank. In the bottom left corner of the display there is a value of the height of the water in the tank displaying in the [cm] and [%] of the tank height. In the top left corner of the display there is an in-line pressure bar-graph indicator showing the actual pressure in the pipes. Five displaying bars mean that the system is fully pressurised. If the pressure starts to drop the pressure bars will disappear and the pump will start. This is indicated by a moving doted line on the storage tank indicator (see picture below). Picture2. Main screen with pump on. B. Main Screen indicators There are some additional options and alarms that can be indicated on the main screen: Water temperature: can be displayed if there is a temperature sensor fitted. Picture3. Temperature measurement. To activate this option go to Display Options in the Main Menu. If the temperature sensor is disconnected or out of range the temperature disconnection icon will appear on the screen. Picture4. Temperature sensor disconnection. Page 19

20 Level sensor disconnection alarm: will appear on the screen if the 4-20mA level sensor breaks or loses connection. Picture5. Level sensor disconnection alarm. Communication alarm: will appear if the remote unit does not receive any data from the controller. The red LED on the display board will illuminate if the condition occurs. Picture6. Communication alarm. Learning mode: an hour-glass icon will appear if system is in learning mode (learning the maximum pressure). Picture7. Learning mode. Pump lock out: if the system is in lock out mode, when the status light comes on the pump will switch off and the padlock icon will appear on the display. C. Main Menu. Picture8. Pump lock out. Click the Enter/Menu button to enter the Main Menu: Page 20

21 Picture9. Main Menu. In the Main Menu choose one of 6 options: Advanced menu, Display options, Restore default settings, Setup, Pump menu and PIN settings. Using the Up and Down buttons choose the menu option (active option is highlighted in yellow) clicking the Enter/Menu button enters the highlighted option. D. Advanced Menu. The advanced menu can change the tank height, pump disable level, top up level and pump overflow level and set temperature to cut the pump off. Picture10. Advanced Menu. Tank Full Level: change the tank height by entering the value manually or auto detect height if the tank is full. Picture11. Tank Full Level. o Auto Detect Height: the system will detect the actual height of the water in the tank, and if OK choosen the system will store this value as a Tank Height. (Do not confuse tank height with water height) Picture12. Auto Detect Height. Install Height Tank Height stored in the memory. Current Height measured height (level of the water in the tank) Page 21

22 o Enter Tank Height: manually enter the Tank Height using the Up and Down buttons, confirm by pressing Enter/Menu button. Picture13. Enter Tank Height. Pump Overflow Level: is the level above which the additional overflow solenoid valve opens, preventing storage tank from overflowing. Picture14. Pump Overflow Level. As a default this level is set to 95% of the Tank Height. To set this level use Up and Down buttons. To store the level click the Enter/Menu button. Top Up Level: is the level below which the solenoid valve opens to top up the storage tank with mains water. This is used in a direct system. Picture15. Top Up Level. The default value is set to 38 cm. To set this level use Up and Down buttons. To store the level click the Enter/Menu button. Pump Disable Level: this is level below which the pump is disabled. At the same time solenoid valve for gravity system opens to fill the header tank with mains water. Picture16. Pump Disable Level. As a default this value is set to 25 cm. The minimum value you can set is 18 cm. Make sure that this level is not below the pump inlet. Run dry can damage the pump. To set this level use Up and Down buttons. To store the level click the Enter/Menu button. Page 22

23 Cut off temperature: the pump will cut off when water temperature in the tank excess Temperature cut off point. The default value is set to 40 C. This option is working only when the thermistor is installed in the system. Temperature value on the main screen is blinking to indicate that the pump has been cut off. Refer to the Non Standard Systems documentation for more information. Picture17. Temperature cut off point. To set this value use Up and Down buttons. To store the value click Enter/Menu button. E. Display Options. In this menu choose what option will or will not be displayed on the main screen. Picture18. Display Options. Pressure enables the system to display the pressure bar graph in the top left corner of the main screen. Temperature enables the system to display the water temperature. The default display setting is pressure only. To choose the option use the Up and Down buttons. To confirm click the Enter/Menu button. F. Restore Default Settings. Having selected this option the system will reinstate default factory settings which are: Pump Disable Level: 25 cm. Top Up Level: 38 cm. Pressure Switch Point: 30%. Pressure Max Point: 5% Overrun Time: 35 sec. Lock Out Mode: OFF Auto Standby Mode: OFF. Maximum Learned Pressure: 0. Status Time: 3 minutes Cut Off Temperature: 40 C. The system will re boot and start the installation wizard. Refer to system installation. Picture19. Restore Default Settings. Page 23

24 G. Setup. In this menu activate the Wizard, change the Pressure Points, carry out a Pressure Test and set the direct flush option. Picture20. Setup Menu. Depth Sensor: PIN protected option, used to calibrate the submersible depth sensor. This procedure should only be carried out by a trained installer. A Pin number must be attained to carry out this procedure. Contact the manufacturer for details Wizard: this option activates the installation wizard and auto system pressure learning process. Picture21. Activate Wizard. At the beginning wizard asks to drop the sensor into the storage tank. If the tank is full we click Yes and a system will automatically detect the Tank Height and store it in the memory. By clicking No enter the Tank Height manually as in the Advanced Menu. Picture22. Setting up the Tank Height. Having set the tank height the wizard starts the pump and begins to pressurise the system. This is called learning mode. Learning mode will automatically learn the Maximum Pressure of any given system. It will take at least 5 minutes. During that time the hour glass icon will be displayed on the main screen. Pressure Switch Point: this is a pressure difference between Pump Switch Off Point and Pump Switch On Point. The larger is the difference the longer pump stays off during normal operation. Care must be taken while setting these parameters because if the pressure difference is too big, the pump could not switch on at all. By observing the main screen we can identify if the pump switch on frequency is too fast. Ideally it should not switch on at all on a closed system. Page 24

25 Picture23. Pressure Switch Point. As a default this value is set to 30%. To change this value use Up and Down buttons. To store this value click the Enter/Menu button. This parameter can be set from 5% to 40%. Pressure Max Point: this is a pressure difference between Maximum Learnt Pressure (learnt during the learning mode) and Pump Switch Off Point. It sets the level at which the pump goes off. Picture24. Pressure Max Point. As a default this value is set to 5%. It means that the Pump Off Point is 5% lower than the Maximum Learnt Pressure. To change this value use Up and Down buttons. To store this value click the Enter/Menu button. This parameter can be set from 2.5% to 10%. Pressure Test: is an integrated tool to assist the installer/user in determining if the system is closed or not. It indicates the in-line pressure. Picture25. Pressure Test. Value it s an actual value of the pressure in [psi] Max P it s a Maximum Learned Pressure above which pump will go off. Pressure is steady Pressure is rising Pressure is falling Direct Flush: if this option is switched on the system will open the direct solenoid valve to flush the standing water in the pipes. System opens solenoid valve for 10 seconds once a week. Page 25

26 H. Pump Menu. Picture26. Direct Flush. In this menu activate Duty Assist Mode, Auto Standby Mode, Lock Out Mode, reset Pump Lock Out, change the Pump Overrun Time and Status Time. Picture27. Pump Menu. Status Time: this option allows the time to be changed after which the status light comes on. As a default the status light comes on after 3 minutes of pump running time. This time can be changed from 1 minute to 60 minutes. Picture28. Status Time. Lock Out Mode: this option will switch the pump off if the pump has been running for more than specified Status Time and the system has failed to pressurise (status light goes on). Picture29. Lock Out Mode. To activate this option highlight ON and click Enter/Menu button. When pump lock out occurs the padlock icon will appear on the screen (see Picture8). To activate the pump again go to Pump Menu and choose Reset Lock Out, or switch the mains power off and on. The Padlock will disappear but Lock Out Mode remains on. After another cycle of pump on time the system will switch the pump off again if the pump working time exceed the Status Time. As a default the Lock Out Mode is OFF. Reset Lock Out: if the pump is locked out this option will reset the pump and allow it to start again. Pump Overrun Time: set the maximum pump running time against a high pressure (outlet closed, no flow). When the pump reaches the Maximum Learned Pressure the pump will run for the specified Pump Overrun Time and then it will go off. Page 26

27 Picture30. Pump Overrun Time. As a default Pump Overrun Time is set to 35 seconds. Auto Standby Mode: this option enables a second pump (Slave Pump). After a specified Status Time (indicated by status light) of the Master Pump running the Slave Pump will be turned on, and the Master Pump will then go off. Refer to the separate Non-standard systems instruction if you want to use that option. Picture31. Auto Standby Mode. As a default this parameter is OFF. Duty Assist Mode: this option enables a second pump (Slave Pump). Slave Pump switches on together with the Master Pump but with the 5 seconds delay. Refer to the non-standard systems instruction if you want to use that option. Picture32. Duty Assist Mode. I. PIN Settings. In this menu activate, deactivate and change the PIN number which can lock access to the Main Menu. The Default PIN number is Picture33. PIN Settings. Page 27

28 Activate PIN number: to activate the PIN number enter the PIN number (which as a default is 1111). Picture34. Enter PIN number. To enter a PIN number use the Up and Down buttons to change a value on the highlighted position and click Enter/Menu to jump to the next position. Deactivate PIN number: To deactivate a PIN number enter the pre programmed number first. Change PIN number:. To change we have to first enter the existing PIN number (old PIN number), and enter a new PIN number and again re-enter the new PIN number. Page 28

29 TECHNICAL SPECIFICATION AND BOX DIMENSIONS. Dimensions Ambient temperature Altitude Range IP rating Class of protection Overvoltage category Rated impulse voltage Type of automatic action Supply voltage Electrical connections, Controller unit Electrical connections, Display unit Display LEDs Operation Height: 180mm, Width: 365mm, Depth: 90mm 0C to +40C <2000m above sea level IP40 I II 2500V 1B V AC, 50-60Hz, 2.3kVA Master Pump: 3 pin terminal 5.08mm pitch, output for single phase pump, 230V AC, max 5A Slave Pump: 3 pin terminal 5.08mm pitch, output for single phase pump, 230V AC, max 5A Direct: 3 pin terminal 5.08mm pitch, output for solenoid valve, 230V AC, max 5A Overflow: 3 pin terminal 5.08mm pitch, output for solenoid valve, 230V AC, max 5A Gravity: 3 pin terminal 5.08mm pitch, output for solenoid valve, 230V AC, max 5A BMS: 3 pin terminal 5.08mm pitch, relay output for alarm indication, max 230V AC, max 4A Display: 4 pin terminal 5.08mm pitch, supply and communication with display unit, 12V DC, max 0.5A 4-20mA level: 3 pin terminal 3.5mm pitch, input for 4-20mA depth sensor with range 15psi Differential: 4 pin terminal 3.5mm pitch, input for optional differential depth sensor with range 5psi, 5V DC Cascade: 3 pin terminal 3.5mm pitch, input/output for connecting controller units together in cascade mode, 5V DC Economy float switch: 3 pin terminal 3.5mm pitch, input for float switch in economy mode, 5V DC Temp.: 2 pin terminal 3.5mm pitch, input for temperature sensor, 10k thermistor, 5V DC Pressure: 4 pin terminal 3.5mm pitch, input for in-line pressure transducer with range 100psi, 5V DC Ultrasonic: 3 pin terminal 3.5mm pitch, input for optional ultrasonic level measurement device, 3V DC LEDs: 4 pin terminal 3.5mm pitch, output for front lid LEDs, 5V DC Display: 4 pin terminal 5.08mm pitch, supply and communication with controller unit, 12V DC 128x64 graphic LCD, blue Green power Orange status Red alarm 3 buttons on the display unit Page 29

30 Note: Risk of electric shock. Isolate supply before opening the controller lid. Terminals for external earth conductors are indicated on the printed circuit board by this symbol and letter E. Protective Earth must be connected to the controller unit as the safety of peripheral components may be dependant on it. If the equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired. Maintenance F1 (Fuse) - 1A Slow Blow Fuse The equipment contains no other user serviceable parts and all maintenance and repair must be carried out by the manufacturer. Controller box dimensions: Page 30

31 All dimensions in mm. Page 31

32 Display box dimensions: All dimensions in mm. Page 32

33 TROUBLESHOOTING. PROBLEM LIKELY CAUSE SOLUTION WARNING: Isolate supply before opening cover of the controller unit. Controller unit power down. Power LED (green) is off. Controller is tripping main circuit breaker in the building electrical box. Display unit power down. Communication alarm. Display unit ERROR LED on. Level sensor connection alarm. ERROR LED on. Supply cable is connected incorrect. Fuse on the printed circuit board is blown. Power supply cable, pump cable or solenoid valve cable are connected incorrect. Pump is broken. Solenoid valve is broken. Cable connection between Controller unit and a Display unit is broken or the wires are mixed. Communication error between Controller unit and a Display unit. Cable connecting display to the controller is broken or wires are mixed. All dip switches are in off position. Level sensor is disconnected, incorrectly connected or Page 33 Check if the supply cable is connected to the POWER terminal on the printed circuit board and the wires are connected to the correct pins: E yellow/green, N blue, L brown. Isolate the supply and open the box. Fuse is located in the top left corner of the circuit board. It is 20mm glass fuse, slow blow, 1A, 250V. If the fuse is good you will see the wire inside the glass tube, otherwise if the wire is blown the fuse is broken. You can also check the fuse using continuity test on the multimeter. If the fuse is blown then replace it, close the lid and switch the power on. If the fuse blown again that means there is a short circuit on the board. Check if the pressure transducer, depth sensor and display unit are connected correctly. If yes that means there is a short circuit on the printed circuit board and the board should be replaced. Check if the cables are connected to the proper sockets, and the wires are connected to the proper pins in the socket. L brown, N blue, E yellow/green Broken pump or solenoid valve can trip the circuit breaker. Unplug the pump from the board, switch the power on and check if it tripped again, if no that means the pump is broken. Repeat the procedure for solenoid valve as well. Check the continuity and colour coding between the controller and display unit (GND, +12V, A, B). If this is unsuccessful replace the cable between both units and re test. (ensure max length is <300m). Check the DISPLAY terminals on the Controller unit and on the Display unit. Ensure the unit is wired correctly and the wires are connected to their matching counterparts? Check that the one and only one of the dip switches is in on position. Dip switch choose which level sensor is used in the system. Make sure that the dip switch in the on position match the level sensor you are using. Check if the cable is connected to the proper socket and the wires are connected to the

34 broken. proper pins in the socket. Check if there are no short circuits between the wires. Connection to the temperature Check if the sensor is connected to the sensor is broken. TEMP socket in the controller board. The polarisation does not affect the temperature sensor. Temperature sensor disconnection alarm. ERROR LED blinking. STATUS LED on. System Depressurisation Alarm. NOTE. Under high discharge rate conditions and with pressure adjustment control set slightly high it is possible that a temporary alarm indication will occur. This is normal and is an indication that water has been discharging at a high rate for an extended period. The alarm condition will cancel when the discharge reduces or stops. The alarm condition referred to is a permanent alarm when the system is not supplying water. This alarm is sensitive and indicates many possible conditions. Pump is not switching off when the system is fully pressurised. Pump is working all the time. STATUS LED on. Temperature sensor is not present in the system but the option appears on the screen. Pump has been starting more than 40 times per hour. 40 starts per hour is a pump factory maximum starting frequency. Storage tank delivery pipe blocked/ ruptured/ kinked/ collapsed/ disconnected/ frozen/ compressed. Stop-cock(s) turned off/ jammed shut/ faulty. In-line filter blocked. Pump jammed or seized. Pressure transducer is broken or the connection from transducer to controller is broken. Page 34 To switch the temperature display off go to the DISPLAY OPTIONS in the screen menu. Check for the leaks in the system. Investigate to determine if the pump is operating by checking the line pressure. This is most easily done at an external tap. Choose a Reset Default Settings from the main menu. System starts to learn the maximum pressure from the beginning. Check the cable from the transducer. Check if it s connected to the PRESSURE terminal in the controller. Wires colours: 1 red, 2 green, 3 yellow, 4 blue. Go to the Pressure test in the SETUP menu. When the system is fully pressurised the value should be bigger than Max P. (maximum learnt pressure) and the pump should go off. If the value is slightly smaller than Max P. you can go to the SETUP menu and choose Pressure Max Point. By increasing this percentage value you can bring the Max P. point lower and allow pump to switch off. Another solution is go to Setup menu and choose Wizard. That will start the learning procedure. In the learning mode system will learn the maximum pressure automatically. If the value is much smaller than Max P. or is zero that means the pressure transducer is broken or the connection is broken. NOTE: If you replaced the pressure transducer you must start Wizard from the setup menu or Reset default settings from the main menu.