Techflo... - Installation Instructions

Techflo... - Installation Instructions
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QT PUMP RANGE
INSTALLATION INSTRUCTIONS
PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE
PROCEEDING WITH THE INSTALLATION
FAILURE TO COMPLY COULD INVALIDATE YOUR WARRANTY AND
ADVERSELY AFFECT THE PERFORMANCE OF THE PUMP
IF YOU REQUIRE ANY FURTHER INFORMATION PLEASE CALL
THE TECHNICAL HELPLINE 01444 258017
Tel: 01444 258003 (Sales & Enquiries) Fax: 01444 258004
E-mail:info@techflow.co.uk
www.techflow.co.uk
e
PRODUCTS
The TECHFLOW ‘QT’ range of TWIN centrifugal pumps with integral flow
switches have been designed to boost pressure and flow from normal domestic
tank fed supplies to mixing type shower valves and/or to other suitable terminal
appliances / outlets in the house. Where baths, washing machines, dish washers
and toilet cisterns need to be pumped using a twin ended pump a bypass kit
(27902) should also be fitted, available separately (See Section 8). For
further information on Whole House Pumping see our Technical Data Sheet
No.4.
Twin ended pumps are designed to boost both hot and cold supplies to shower
and /or other terminal appliances. It is essential to ensure that the MINIMUM
USABLE cold water storage capacity is 225L (50 galls.) for the QT50 and
QT80 pumps and 300L (70 galls.) for the QT120 and that the hot water capacity
is adequate.
Techflow pumps are designed to comply with the United Kingdom
water fitting bye laws scheme and all installations should be carried
out by a competent person in accordance with the relevant Water
Bye Laws and requirements of the Institute of Electrical Engineers.
This appliance is not intended for use by persons (including children) with
reduced physical, sensory or mental capabilities, or lack of experience and
knowledge, unless they have been given supervision or instruction concerning
use of the appliance by a person responsible for their safety. Children should be
supervised to ensure that they do not play with the appliance.
QT PUMP RANGE SPECIFICATIONS
MODEL
WEIGHT
VOLTAGE
WATTS
FUSE RATING
IP RATING
SPEED
INSULATION CLASS
RATING
CONNECTIONS
MAX. INLET PRESSURE
MAX TOTAL HEAD
MAX. INLET HOT TEMP.
QT50
QT80
4.5 KG
6.0 KG
220/240 V
220/240 V
300 W
490 W
5A
5A
IPx4
IPx4
2800 RPM
2800 RPM
F
F
30MIN ON
30MIN ON
30MIN OFF
30MIN OFF
22 mm ‘PUSH-IN’ FLEXIBLE HOSES
1.5 BAR (150 Pa)
1.5 BAR (150 Pa)
27m
37m
65ºc
65ºc
-2-
QT120
8.0 KG
220/240 V
740 W
5A
IPx4
2800 RPM
F
60MIN ON
30MIN OFF
1.5 BAR (150 Pa)
48m
65ºc
QT PUMP RANGE SPECIFICATIONS
#
"
!
$
1 SITING
1.1
1.2
1.3
1.4
%
QT50
QT80
QT120
A
165 mm
175 mm
220 mm
B
240 mm
300 mm
390 mm
C
280 mm
340 mm
430 mm
D
220 mm
220 mm
220 mm
E
180 mm
180 mm
180 mm
WIDTH
130 mm
130 mm
130 mm
INSTALLATION DETAILS
The pump must, for optimum performance, be sited as close as possible to and never
more than 4 metres from the HOT WATER cylinder. The pump should always be sited
BELOW the HOT WATER take-off from the cylinder. Where it is a requirement of the
installation to sight a pump ABOVE the hot water take-off then we recommend either
the TP or TURBO range of pumps.
A minimum gravity flow of 1 litre per minute is required on each side of the pump to
activate the flow switches.
The pump must be mounted horizontally on it’s four feet on a rigid level surface to
facilitate adequate ventilation to the underside of the motor.
If installed in an unheated area, adequate protection against frost must be provided whilst
maintaining ventilation to the pump motor.
2 PIPE WORK CONNECTIONS
2.1
2.2
2.3
2.4
Both HOT and COLD supplies must be dedicated / exclusive to the pump (i.e. not shared
with other services ).
The dedicated HOT WATER connection to the cylinder MUST be via a ¾ ” anti - aeration
flange. Only the following flange types should be used. These can be supplied by Techflow if
required:
QT50 side entry Techflange (Part No 27900) or top entry Techflange (Part No 27901)
QT80 side entry Techflange (Part No 27900) or top entry Techflange (Part No 27901)
QT120 side entry Techflange (Part No 27900)
The SURREY or YORK flange types MUST NOT be used as they can restrict flow to the
pump inlet.
The dedicated COLD WATER connection from the cold water storage tank should
be positioned at least 25 mm (1 ”) below the cold water supply pipe to the hot water
cylinder. NEVER CONNECT COLD WATER MAINS SUPPLIES DIRECTLY TO
THE PUMP OR PLACE IT IN THE SAME LINE AS ANOTHER PRESSURE
PUMP.
The DOWN SERVICE from the cold water storage tank to the hot water cylinder
should be made on the opposite side of the tank from the cold mains inlet (to minimise
aeration to the pump) and run in 22 mm min. However, when the total demand from the
hot water cylinder is likely to exceed 30 l/min, a 28 mm down service MUST be used.
Typically, this will occur when two or more bathrooms are supplied from a common hot
water cylinder.
-3-
2.5
2.6
2.7
Only PLASTIC TUBE or COPPER PIPE to relevant B.S. specification should be used NEVER use stainless steel tube as this is not compatible with the 22 mm ‘push-in’ type
fittings on the inlet/outlet flexible hoses. Wherever possible it is recommended that
plastic tube is used as this will reduce even further any resonance or noise levels but
adequate support should be provided.
Supplies to the pump inlets and the hot expansion / vent MUST be run in 22 mm (min)
pipework. Downstream pipework should be 22 mm wherever possible but 15 mm can be
used for short runs. However, this will result in reduced performance from the pump.
The flexible coupling hoses with 22 mm ‘push-in’ connectors supplied must be used in all
installations. The pump should be sited in a position where these hoses are not bent or
deflected by more than 30º from the vertical.
1)
Hoses incorporating integral isolating valves should be applied to the inlet side of
pump to satisfy servicing requirements.
2)
Standard hoses with no integral isolating valve should be applied to the outlet side
of pump.
3)
Use correct tool for opening and closing integrated isolating valve to prevent
damage. Please note these valves are of quarter turn design, rotate clockwise to
close and anti-clockwise to open. Failure to comply to these instructions could lead to
valve damage.
4) WARNING - pump must not run with valve closed.
Open
Close
-4-
2.8
To remove the hoses from the pump or pipework hold the grey collet towards the fitting
and pull off the hose.
NEVER MAKE DIRECT CONNECTIONS TO THE PLASTIC INLETS/
OUTLETS OF THESE PUMPS WITH COMPRESSION TYPE FITTINGS.
DO NOT install non return valves or devices which contain non-return valves,
in the suction (inlet) pipework to the pump. The supply must be free to vent
to the supply tank at all times.
SIDE ENTRY TECHFLANGE
WITH ADAPTER
SUITABLE FOR ALL MODELS
Part No. 27900
TOP MOUNT TECH FLANGE
QT50 & QT80 ONLY
Part No. 27901
FIG. 2
FIG. 1
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2.9
2.10
2.11
Either end of the pump can be used for hot or cold connection.
Inlet filters are provided and must be fitted in every instance.
All connecting pipes should be cut with a standard pipe cutter so that the pipe end is
correctly finished prior to insertion into the flexible hose coupling . If any other tool is
used to cut the pipe, the end of the pipe must be thoroughly deburred and chamfered
before fitting. Also, check that the end is cut perpendicular to the length of the pipe.
-5-
#/,$
).
A typical alternative outlet
installation
In the case of horizontal feeds use a 22 mm
compatible elbow (not supplied). Do not bend the
hose more than 30° as they may become damaged,
transmit noise or leak.
Inlet
Outlet
Outlet
Inlet
22 mm Inlet
pipework fed from
water storage
system.
Outlet
22 mm Outlet pipework.
22 mm Copper pipe
Integral pump
isolating valve shown
in ‘ON’ position.
Flexible hose
Open
30°
Max.
permitted
flexible hose
bend.
Close
22 mm Flexible pipe with push-in
connections, always ensure
connection is fully pushed home
and that hoses are kept as straight
as possible. Do not kink or twist
the hose.
Do not bend hose more than 30°
as they may become damaged,
transmit noise or leak.
Do not kink or twist
the hose.
The pump should not be screwed down, ensure anti-vibration feet and flexible
hoses are used.
3 ISOLATING VALVES
3.1
3.2
22 mm GATE TYPE or FULL - BORE LEVER OPERATED BALL TYPE isolating valves
MUST be fitted to all inlets and outlets in an accessible position and as close to the pump
as possible. SERVICE CALLS WILL NOT BE UNDERTAKEN BY TECHFLOW
PERSONNEL WHERE ISOLATING VALVES ARE NOT FITTED.
Ballofix and other types of isolating valves MUST NOT be fitted as they can be
restrictive resulting in starvation at the pump inlet and subsequent damage to the pump.
4 HOT WATER TEMPERATURE
4.1
4.2
The temperature of the hot supply MUST NOT exceed 65ºC at the pump inlet. A
cylinder stat. MUST be fitted to provide adequate temperature control and set to a
MAXIMUM temperature of 60ºC.
If a cylinder stat is not fitted and the temparature is to be controlled using a blending
valve then either a TP or Turbo pump should be fitted.
-6-
5 ELECTRICAL INSTALLATION
THIS PUMP MUST BE EARTHED
5.1
The electrical installation MUST be undertaken by a competent person and MUST
comply with the relevant IEE regulations.
5.2
All pipework must be cross bonded and an RCCB fitted in compliance with IEE
regulations.
Copper or metallic pipework must have supplementary earth bonding where the
continuity has been broken by flexible hoses or plastic components. Adjacent suction
and delivery pipes should be fitted with earthing clamps to BS 951 and connected with
earthing wire size 4 mm² as shown.
Diagram of
earth continuity
connections
5.3
5.4
5.5
Certain installations may require additional earthing arrangements such as equipotential
bonding. Reference should be made to the relevant regulations concerning this subject to
ensure compliance.
The 240v supply should be taken via. a fused spur from the ring main which must
incorporate a switch to ensure that the pump can be disconnected from the supply.
Ensure that the correct fuse is fitted as shown in the specification table.
HIGHER RATED FUSES SHOULD NOT BE FITTED.
If the supply cord is damaged, it must be replaced by the manufacturer, its service agent
or similarly qualified persons in order to avoid a hazard.
6 COMMISSIONING
6.1.
The inlet pipework must be thoroughly flushed to purge the system of any swarf, traces
of flux etc. BEFORE connection to the pump.
6.2
Having connected both inlet and outlet supplies open all isolating valves.
CHECK FOR LEAKS.
6.3. Open the shower valve or terminal fitting and allow water to flow through the system on
GRAVITY for 2/3 minutes. With the shower valve still open switch on the power supply
to the pump for 5/10 seconds and then switch off again. Allow a further 30 seconds of
GRAVITY flow before switching the pump on to run for 10 seconds. Repeat this cycling until
all air is purged from the system. Use the fitted manual finger vents to assist in purging the
system.
NOTE: If a flexible hose and handset shower system is installed remove the handset
from the shower hose and lay the hose in the shower tray when purging the
system.This ensures maximum gravity flow and will reduce the purging time.
6.4
After initial commissioning of the system the isolating valves should be closed in order
that the pump inlet filters can be removed, inspected and if necessary cleaned. Once
reassembled the valves can be opened again.
NEVER ATTEMPT TO OPERATE A DRY PUMP AS THIS WILL CAUSE
IRREPARABLE DAMAGE TO CRITICAL INTERNAL SEALS ETC.
-7-
7 WHOLE HOUSE PUMPING
Where a twin ended pump is to be used for pumping more than three low usage single
temperature supply appliances a bypass kit part no. 27902 must be fitted to a standard
QT Pump and this ensures that when one supply only is being pumped the opposite end
of the pump, running against a closed outlet, maintains a low flow of water ensuring that
the pump will not overheat and preventing subsequent damage.
8 NEGATIVE HEAD INSTALLATIONS
A Negative Head situation occurs when the level of cold water in the storage tank falls
below the shower head outlet or other taps or appliances resulting in no gravity flow
through the system or insufficient flow to operate the integral flow switches fitted in the
standard QT pumps. PLEASE NOTE THE REQUIREMENT FOR A MINIMUM
300 mm (12 ”) GAP BETWEEN THE BOTTOM OF THE COLD WATER
TANK AND THE PUMP INLETS STILL APPLIES.
See Sections 11-13 for installation of Negative Head Pumps.
9 SERVICING
TECHFLOW PUMPS ARE FACTORY SEALED UNITS AND THEREFORE
SERVICING OR REPAIRS SHOULD ONLY BE CARRIED OUT BY TECHFLOW OR
ITS AUTHORISED SERVICE AGENTS.
DISMANTLING THE PRODUCT WILL INVALIDATE YOUR WARRANTY.
10 ‘NHE’ NEGATIVE HEAD SYSTEM INSTALLATION (SEE FIG.3)
The ‘NHE’ Pressure Switch Assemblies activate the pump when the pressure in the
system drops. This will occur when the shower valve or other outlet is opened. The unit
will also prevent the pump from running dry in the event of water supply failure.
NOTE: Max. system head on QT50 NHE - 5 metres (0.5 bar)
Max. system head on QT80 NHE & QT120 NHE - 10 metres (1.0 bar)
IF THIS HEAD IS EXCEEDED THE PUMP WILL FAIL TO OPERATE
10.1 Push-in the two Pressure Switch Assemblies (1) to the OUTLET ports.
10.2 Ensure that the sealing washer is correctly located in the Manifold (5) and screw
the Expansion Vessel (6) to the Manifold (5). HAND TIGHTEN ONLY, IT IS
ADVISABLE TO GRIP THE MANIFOLD WHILST TIGHTENING.
10.3 Connect the blue tubing (7) to both the Manifold (5) and the Pressure Switch Assembly
(1). Push the tubing over the fitting tail and tighten the knurled screw.
10.4 Push-in the Hoses (2) to the pump INLET ports and to the OUTLET connectors of the
NHE Pressure Switch Assembly(1).
10.5 Thoroughly flush through the pipework and connect to complete the connections to the
pump hoses. Isolating Valves (3) MUST be fitted to both inlet and outlet pipework.
NOTE: If Isolating Valves are NOT fitted to BOTH inlets and outlets then site
visits will not be undertaken.
10.6 Connect the Pump Power Lead (4) to a fused spur ensuring that the correct rated fuse is
fitted.
COMMISSIONING
10.7
10.8
10.9
Ensure that the power supply to the Pump is OFF.
Turn on the water supply to the pump.
Open the shower valve and allow 2 or 3 minutes for the water to reach the pump and for
air to vent out of the system.
10.10 Turn on the power supply and the pump should now operate.
-8-
10.11 Allow the pump to run for several minutes to purge air from the system.
10.12 Close the shower valve and after a few seconds the pump will stop.
OPERATION
10.13 Opening the shower valve will automatically start the pump.
10.14 When the shower valve is closed the pump will run on for a few seconds before stopping.
This is quite normal as the pressure in the pipework is being re-charged.
10.15 If the pump continues to stop/start with all outlets closed then check for leaks in the
pipework.
NOTE: On long pipe-runs it is possible that the pump will run for a short time
every few hour to re-charge the system. This is quite normal.
10.16 In the event of water supply failure or excessive aeration of the supply the pump will
shut-down. Once the water supply is restored switch off the mains electrical supply to
the pump, leave for a few seconds and then switch on again. This will re-set the pump
which can then be operated normally.
‘NHE’ NEGATIVE HEAD SYSTEM
FIG. 3
Inlet
Outlet
Outlet
Inlet
3
2
Open
Close
6
1
5
7
4
-9-
11 SINGLE ENDED PUMPS
The TECHFLOW ‘QT’ range of SINGLE ENDED centrifugal pumps have been
designed to boost pressure and flow from normal domestic tank fed supplies to suitable
terminal appliances / outlets in the house. Both flow-switch and pressure-switch (NH
type) activated pumps are available and where two pumps are intended to boost hot and
cold supplies to a shower mixer valve the NH range is recommended.
All pumps in the range are continuously rated and are designed to boost either hot or
cold supplies. It is essential to ensure that both the hot and cold water storage capacity is
adequate for the intended application. Each pump is capable of delivering up to 30 l/min
(7 Galls/min). Please contact the Helpline for further advice.
INSTALLATION
11.1
11.2
Follow instructions as outlined in Sections 1-6 ensuring that dedicated supplies are
maintained to the pump and that the correct type of anti-aeration flange is fitted where
appropriate.
When the pump is fitted downstream of a shower mixer valve to boost blended flow fit
as detailed in Fig.4. Ensure that the pipe run from the shower valve to the pump is in
22 mm and as short as possible.
Restrictive valves and systems can result in starvation to the pump inlet resulting in loss
in performance. If in doubt consult the TECHFLOW Helpline.
QTSE PUMP RANGE SPECIFICATIONS
MODEL
WEIGHT
VOLTAGE
WATTS
FUSE RATING
SPEED
INSULATION CLASS
RATING
CONNECTIONS
MAX. INLET PRESSURE
MAX. INLET HOT TEMP.
QT50SE
4.5 KG
220/240 V
200 W
5A
2800 RPM
F
1.5 BAR
65ºC
QT80SE
QT120SE
5.0 KG
6.5 KG
220/240 V
220/240 V
300 W
490 W
5A
5A
2800 RPM
2800 RPM
F
F
CONTINUOUS - FAN COOLED
22 mm ‘PUSH-IN’ FLEXIBLE HOSES
1.5 BAR
1.5 BAR
65ºC
65ºC
QTSE PUMP RANGE SPECIFICATIONS
QT50SE QT80SE QT120SE
#
"
!
$
%
- 10 -
A
165 mm
175 mm
220 mm
B
240 mm
300 mm
390 mm
C
280 mm
340 mm
430 mm
D
220 mm
220 mm
220 mm
E
180 mm
180 mm
180 mm
WIDTH
130 mm
130 mm
130 mm
SIDE MOUNTED TECHFLANGE
FIG. 4
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QT RANGE TWIN ENDED PUMP PERFORMANCE
COMPARISONS
QT Twin Performance Curves
(Positive & Negative Head)
3.50
Pressure (BAR)
3.00
QT1
20
2.50
QT80
2.00
1.50
QT50
1.00
0.50
0.00
0
5
10
15
20
25
30
35
40
45
50
55
60
65
FLOW litres per minute
QT Single Performance Curves
(Positive & Negative Head)
3.50
QT
Pressure (BAR)
3.00
120
2.50
QT80
2.00
1.50
QT50
1.00
0.50
0.00
0
5
10
15
20
FLOW litres per minute
- 11 -
25
30
35
FAULT IDENTIFICATION TABLE
SYMPTOM
1
2
3
4
5
PUMP WILL NOT START
REDUCED/
INTERMITTENT FLOW
PUMP RUNS ON WITH
OUTLETS CLOSED
PROBABLE CAUSE
1.1 INSUFFICIENT GRAVITY
FLOW
1.1 CHECK FLOW RATE MINIMUM
OF 1 LITRE / MINUTE REQUIRED
ON FULL HOT AND COLD
1.2 ELECTRICAL
1.2 CHECK POWER SUPPLY
CHECK FUSE
CHECK CIRCUIT BREAKER
1.3 PUMP SEIZED
1.3 IF MOTOR “BUZZES”REMOVE
POWER AND CONTACT
TECHFLOW
2.1 CHECK THAT THE
INSTALLATION COMPLIES WITH
INSTALLATION INSTRUCTIONS.
SEE SECTION 2.2
2.1 INCORRECT OR NO ANTIAERATION FLANGE FITTED
2.2 INCORRECT PIPE SIZES
2.2 CHECK THAT 22 mm PIPE
WORK IS USED ON INLETS
AND OUTLETS
2.3 BLOCKED INLET FILTERS
2.3 CLEAN AND RE-TEST
2.4 AIR IN SYSTEM
2.4 RUN SYSTEM ON FULL HOT
WITH PUMP SWITCHED OFF
(I.E. GRAVITY ONLY) FOR
SEVERAL MINUTES.
CHECK THAT VENTS ARE
FITTED AS DETAILED IN
INSTRUCTIONS
2.5 HOT TEMP. SET TOO HIGH
2.5 REDUCE CYLINDER STAT
SETTING TO 65oc MAX
3.1 REMOVE OUTLET HOSES AND
CHECK THAT FLOWSWITCH
SITS IN LOWEST POSITION.
3.1 DEBRIS UNDER FLOW
SWITCH
3.2 DAMAGED REED SWITCH
PUMP STARTS WITH ALL 4.1 AIR IN SYSTEM
OUTLETS CLOSED
4.2 LEAK IN SYSTEM
FLEXIBLE HOSE LEAKS
RECOMMENDED SOLUTION
5.1 NOT FITTED CORRECTLY
5.2 DAMAGED ‘O’ RINGS
3.2 CONTACT TECHFLO
4.1 SEE 2.4 ABOVE
4.2 CHECK ALL PIPE JOINTS AND
APPLIANCES FOR LEAKS
5.1 CHECK THAT THE HOSE
IS PUSHED FIRMLY ONTO
THE PUMP INLET/OUTLET
CONNECTORS AND PIPE
WORK
5.2 CHECK COPPER PIPE ENDS ARE
CLEANLY CUT AND DEBURRED
IF YOU REQUIRE ANY FURTHER INFORMATION
PLEASE CALL THE TECHNICAL HELPLINE:
01444 258017
- 12 -
TECHFLOW PRODUCTS LTD.
WARRANTY STATEMENT
Thank you for buying one of our ‘QT’ range of pumps.
We are confident that the superior design and operating performance of our
pump, combined with very high standards of manufacturing quality, will offer
long operational life and product satisfaction.
The TERMS and CONDITIONS of the WARRANTY are:
1. The Scope of the Warranty
TECHFLOW PRODUCTS LTD. (‘The Company’ ) will, subject to the terms and conditions
below and for the warranty period specified in paragraph 3, repair or replace free of charge
any of its products that, in the opinion of the company, are defective because of faulty
materials or workmanship. This warranty will not apply to any of the Company’s product(s)
that in the opinion of the company have been modified altered or misused in any way or
where the products have been incorrectly installed or operated other than as described in
the Company’s ‘Installation Instructions, or if any servicing or repair of the product(s) has
been carried out by anyone other than our authorised Company Service Engineer or Dealer.
2. TERMS AND CONDITIONS
This Warranty is available to you on the following terms and conditions.
2.1
You are the original purchaser of the product(s) from an authorise dealer of the company
(‘The Dealer’) and not an assignee or subsequent purchaser of the product(s).
2.2
You must provide evidence of the date of purchase of the product(s) by retaining the
original invoice or receipt from the Dealer. Without such evidence the to Company
reserves the right to reject any claim under the terms of the Warranty.
2.3
Any alleged defect of the Company’s product(s) giving rise to liability as stated in
paragraph 1 must be advised to the Company within 30 days of discovery
3. THE WARRANTY PERIOD
3.1
This warranty will run for a period of 2 years from the date of purchase.
If the pump is installed in compliance with Fig. 1 of these instructions using a side mounted
Techflange the Warranty will be extended by one year to three years from the date of
purchase.
3.2
The Warranty period in respect of any product(s) repaired or replaced under the terms of
the Warranty shall be that part of the above 2 year period which remains unexpired.
4.
In the event of a claim for repairs or replacement being made under the terms of the
Warranty where, in the opinion of the Company, the defect has not been caused by the
Companies materials or workmanship then the company reserves the right to charge the
claimant at the hourly rates and list prices prevailing in respect of any service engineer’s
time and any replacement parts.
5.
This Warranty is given in addition to and does not alter your statutory rights.
6.
This Warranty is applicable only to products(s) purchased and used exclusively in the
U.K.
For other territories refer to your Distributor for details of Warranty cover.
7.
Where the company makes a replacement the product(s) replaced shall be returned to
the Company immediately and shall become the property of the Company.
8.
No authority has been given to any person, company or any other party to waive the
terms of this Warranty.
- 13 -
NOTES
- 14 -
NOTES
- 15 -
Techflow Products
Service Department
Greys Road
Henley-on-Thames
Oxfordshire
RG9 1RY
Issue No: 4510/1-02
Pt. No. 19420
Pdf Supplied By http://www.plumbworld.co.uk/
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