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QT Installation Instructions

CONTENTS:

CONTENTS

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: HELPLINE NO: 01444 241310

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 supplied 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 By-Pass Kit should be fitted (see section 7).

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 USEABLE cold water storage capacity is 50 galls. for the QT45 and QT80 pumps and 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.

PUMP SPECIFICATIONS AND DIMENSIONS
  QT45 QT80 QT120
WEIGHT 4.5KG 6.0KG 8.0KG
VOLTAGE 220/240V 220/240V 220/240V
WATTS 300W 490W 740W
FUSE RATING 5A 5A 5A
SPEED 2800 RPM 2800 RPM 2800 RPM
INSULATION CLASS F F F
RATING INTERMITTENT 30 MIN. ON 30 MIN. OFF
CONNECTIONS 22 mm 'PUSH ON' FLEXIBLE HOSES
MAX. INLET PRESSURE 1.5 BAR 1.5 BAR 1.5 BAR
MAX. INLET HOT TEMP. 70° CELSIUS 70° CELSIUS 70° CELSIUS

Shower pump diagram - dimensions
DIM.
REF.
QT45 QT80 QT120
A 165 175 220
B 240 300 390
C 280 340 430
D 220 220 220
E 180 180 180
WIDTH 130 130 130
ALL DIMENSIONS ARE IN MILLIMETRES

INSTALLATION DETAILS

1. SITING

  1. The pump must, for optimum performance, be sited as close as possible to and never more than 4 metres from the HOT WATER cylinder and at least 12" (300 mm) below the bottom of the cold water storage tank (see Fig 3). A minimum gravity flow of 1 litre per minute is required on each side of the pump to activate the flow switches.
  2. The pump must be mounted horizontally on its four feet on a rigid level surface to facilitate adequate ventilation to the underside of the motor.
  3. If installed in the roof space or other unheated areas, adequate protection against frost must be provided whilst maintaining ventilation to the pump motor.

2. PIPE WORK CONNECTIONS

  1. Both HOT and COLD supplies must be dedicated / exclusive to the pump (i.e. not shared with other services).
  2. 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 is required:

    QT45 TECHFLANGE (Part No 25-002) Non-Stop Essex or WARIX (Part No 25-001)
    QT80 TECHFLANGE (Part No 25-002) Non-Stop Essex or WARIX (Part No 25-001)
    QT120 TECHFLANGE (Part No 25-002) or Non-Stop Essex


    The SURREY or YORK flange types MUST NOT be used as they can restrict flow to the pump inlet. Where a SECONDARY BOSS is fitted to the cylinder this can be converted to a non-stop fitting by using a BOSS ADAPTOR (3/4in Part No 25-010 or 1in Part No 25-009). The pipework should extend through the fitting as with an Essex Flange (See Fig 1).
  3. When the pump is sited ABOVE the HOT WATER CYLINDER only an ESSEX flange fitted with an ANTI-GRAVITY LOOP should be used. A manual finger vent should be fitted at the highest point immediately before the HOT inlet to the pump (See Fig 3).
  4. The dedicated COLD WATER connection from the cold water storage tank should be positioned at least 25mm (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.
  5. 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 22mm min. However, when the total demand from the hot water cylinder is likely to exceed 30 1/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.
  6. 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 22mm 'push on' 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.
  7. Supplies to the pump inlets and the hot expansion / vent MUST be run in 22mm (min) pipework. Downstream pipework should be 22mm wherever possible but 15mm can be sued for short runs. However, this will result in reduced performance from the pump.
  8. The flexible coupling hoses with 22mm 'push on' connectors supplied must be used in all installations. The pump should be sited in a position where the hoses are not bent or deflected by more than 30° from the vertical.
  9. 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.

    FIG 1
    Essex FLANGE
    Or Secondary Boss
    With Adaptor

    Fig 1: Essex Flange or Secondary Boss With Adaptor - Showing the flow for shower pump operation


    Fig 2
    Warix Flange

    Fig 2: Warix Flange

    Fig 3
    Essex Flange + A.G.L.

    Fig 3: Essex Flange + A.G.L.

  10. Either end of the pump can be used for hot or cold connection.
  11. Inlet filters are provided and must be fitted in every instance.
  12. 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, then end of the pipe must be thoroughly de-burred and chamfered before fitting. Also, check that the end is cut perpendicular to the length of the pipe.

3. TECHFLANGE INSTALLATION (See Fig.4)

  1. Select a position on the hot water cylinder away from any immersion heater port as water drawn from the area around the immersion heater will be aerated.
  2. Mark the centre point of the proposed hole approx. 60mm below the cylinder seam and cut a 75mm square out of the insulating material.
  3. Lower the water level in the cylinder to a point below the position of the proposed hole.
  4. Using the template supplied (see Pump box) mark out the centre-point of the hole and a circle 60mm diameter.
  5. Using the Shell Cutter supplied cut a hole (35mm dia.) using the marked centre point. Clean away any burrs from cut edge of the hole and remove any limescale deposit from the inside face of the cylinder to ensure a clean sealing face.
  6. Remove Nut and Washers from the Flange Assembly (1). Manipulate the Flange Assembly (1) through the hole cut in the cylinder by holding at an angle and rotating. Check that the flange tube does not interfere with the immersion heater coil and if necessary reduce length of tube.
  7. Open up the gap in the Split Washer (2) and slide onto the Flange Assembly (1). Feed split end through cylinder wall and rotate to position on inside of cylinder. Locate over the threaded section of the flange and pull Flange Assembly (1) up against inside wall of cylinder to close gap in washer.
  8. Now slide Sealing Washer (3) onto flange and feed through hole to position on threaded section of Flange Assembly (1).
  9. Fit second Sealing Washer (4) and Clamp Washer (5) over flange and push up against cylinder wall.
  10. Apply a bead of clear silicon sealant around inner diameter of Clamp Washer (5). Fit Nut (6) and hand tighten. DO NOT APPLY SEALANT TO SEALING WASHER (4).
  11. Ensure that the RED DOT on the Flange Assembly (1) is positioned upper-most and that the assembly is central within the circle marked on the cylinder. Lightly tighten Nut (6) to clamp up assembly. DO NOT OVER TIGHTEN.
  12. Adjust length of protruding copper tube if required and complete pipework to Pump inlet ensuring that an isolating valve is fitted. When using compression fittings ensure that the Flange Assembly (1) is gripped to prevent rotation. Close isolating valve re-fill system and check for leaks. If necessary tighten Nut (6) to achieve seal.

4. ISOLATING VALVES

  1. 22mm 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.
  2. 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.

Fig 4
Techflange Installation

Fig 3: Essex Flange + A.G.L.

5. HOT WATER TEMPERATURE

  1. The temperature of the hot supply MUST NOT exceed 70ºc at the pump inlet. A cylinder stat. MUST be fitted to provide adequate temperature control and set to a MAXIMUM temperature of 65ºc. However, other appliances and fittings installed on the domestic water system may only be rated up to 65ºc and therefore the system temperature should be reduced accordingly.

6. ELECTRICAL INSTALLATION
THIS PUMP MUST BE EARTHED

  1. The electrical installation MUST be undertaken by a competent person and MUST comply with the relevant IEE regulations.
  2. All pipework must be cross bonded and an RCCB fitted in compliance with IEE regulations.
  3. The 240 volt supply should be taken via a fused spur from the domestic ring main and fitted with a 5 amp fuse. Higher rated fuses should not be fitted.

7. COMMISSIONING

  1. The inlet pipework must be thoroughly flushed to purge the system of any swarf, traces of flux, etc. BEFORE connection to the pump.
  2. Having connected both inlet and outlet supplies, open all isolating valves.

    CHECK FOR LEAKS

  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.
  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.

8. WHOLE HOUSE PUMPING

  1. Where a twin ended pump is to be used for pumping more than three low usage single temperature supply appliances a By-Pass Kit (Part No. 25-003) must be used. 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.
  2. When in excess of 6 high usage appliances are pumped a Whole House Pack, consisting of 2 x single ended pumps and 2 x negative head switching units, should be used. These are available as a QT45 Pack, QT80 Pack or QT120 Pack.

9. 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. (See Fig. 4)
PLEASE NOTE THE REQUIREMENT FOR A MINIMUM 12" (300mm) 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.

11. 'AS' NEGATIVE HEAD SYSTEM INSTALLATION (SEE FIG.5)

The CONTROLMATIC unit activates 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 addition the By-Pass Loop will prevent damage to the pump when either hot or cold supplies are used independantly.

NOTE: Max. inlet head on QT45AS - 5 metres (0.5 bar)
Max. inlet head on QT80AS/QT120AS - 10 metres (1.0 bar)

  1. The CONTROLMATIC unit (1) MUST be fitted to the VERTICAL COLD outlet of the pump (marked with a BLUE dot and adjacent to WHITE lead).

  2. Push fit the Controlmatic assembly to the COLD OUTLET of the Pump.

  3. Push fit the Hot NRV (8) to the HOT OUTLET of the Pump.

  4. Remove the knurled screw from the by-pass connector on the outlet side of the Controlmatic (1), slide over the Blue Tube (7) fitted to the Hot NRV (8) and push-fit tubing to the by-pass connector. Re-fit screw and tighten.

  5. Screw the Swivel Hose (2) to the outlet of the Controlmatic (1) ensuring that the flat washer seal is fitted.

  6. Push fit the 3 off Standard Hoses (6) to the HOT and COLD Pump INLETS and to the outlet side of the Hot NRV (8)

  7. Remove the Control Box Cover of the CONTROLMATIC unit. Fit cable glands to unit and wire as below.
    Connect the BLACK cable leading from the top cover of the pump to the terminals marked as follows:
    Green/Yellow - Earth
    Blue - N
    Brown - L1

    Connect the WHITE cable to the terminals marked as follows:
    Green/Yellow- Earth
    Blue- V
    Brown- U

    See Wiring Diagram on CONTROLMATIC unit.

  8. Re-fit Control Box Cover.
  9. Connect the Power Cable leading from the base of the pump to a 5 amp fused spur.

    NOTE: Isolating valves MUST be fitted to Inlet and Outlet pipework otherwise site service visits will not be undertaken.


    COMMISSIONING
  10. Ensure that the power supply to the CONTROLMATIC unit is OFF.
  11. Turn on the water supply to the pump.
  12. 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.
  13. Turn on the power supply to the unit and the pump should now operate.
  14. Allow the pump to run for several minutes to purge air from the system.
  15. Close the shower valve and after a few seconds the pump will stop.


    OPERATION
  16. Opening the shower valve will automatically start the pump.
    NOTE: IF FAILURE LIGHT ILLUMINATES (QT45AS ONLY) TURN PRESSURE ADJUSTING SCREW LOCATED ON DOME OF CONTROLMATIC ANTI-CLOCKWISE UNTIL PUMP OPERATES. Rotating the adjusting screw CLOCKWISE will increase the pressure at which the pump operates.
  17. When the shower valve is closed the pump may run on for a few seconds before stopping. This is quite normal and the time will depend on the distance between the pump and the shower valve.
  18. It is also normal for the pump to run for a short while after closing the shower valve. This will occur as the pressure in the pipework between the unit and the shower valve stabilises, if this continues to occur then check for leaks in the pipework.

12. 'MSA’ NEGATIVE HEAD SYSTEM INSTALLATION

FITTING OF PUSH - BUTTON SWITCH

  1. Bore a 45mm (1 3/4 inch) hole adjacent to the shower valve to accept the push - button switch. The maximum panel thickness is 25mm.
  2. Fit the switch ensuring that an effective seal is achieved between the gasket and the mounting surface.
  3. Push - fit the air line to the rear of the switch.

    NOTE: MAX AIR LINE LENGTH IS 10M, 5M AIRLINE IS FITTED TO THE PUMP BUT EXTENSION KIT OF FURTHER 5M CAN BE SUPPLIED


    OPERATION OF PUMP IN NEGATIVE HEAD SITUATION
  4. Open the shower valve or tap.
  5. Operate the push - button switch and the pump will start.
  6. Close the shower valve or tap and the pump will stop.

13. 'MSP’ NEGATIVE HEAD SYSTEM INSTALLATION

FITTING OF PUSH - BUTTON SWITCH

  1. Fix the ceiling mounted switch in the required position.
  2. Connect the WHITE lead to the switch refering to the wiring diagram supplied with the switch.
  3. If required the WHITE lead can be connected to a junction box and then a two-core 5A reted cable run to the switch.

    OPERATION OF PUMP IN NEGATIVE HEAD SITUATION
  4. Open the shower valve or tap.
  5. Operate the pull - cord switch and the pump will start.
  6. Close the shower valve or tap and the pump will stop.

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 (AS type) activated pumps are available and where two pumps are intended to boost hot and cold supplies to a shower mixer valve the AS 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 1/min (7 Galls/min). Please contact the Helpline for further advice.

INSTALLATION

  1. Follow instructions as outlined in Sections 1-6 (above) ensuring that dedicated supplies are maintained to the pump and that the correct type of anti-aeration flange is fitted where appropriate.
  2. When the pump is fitted downstream of a shower mixer valve to boost blended flow fit as detailed in Fig. 5. Ensure that the pipe run from the shower valve to the pump is in 22mm 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.
PUMP SPECIFICATIONS AND DIMENSIONS
  QT45SE QT80SE QT120SE
WEIGHT 4.5KG 5.0KG 6.5KG
VOLTAGE 220/240V 220/240V 220/240V
WATTS 200W 300W 490W
FUSE RATING 5A 5A 5A
SPEED 2800 RPM 2800 RPM 2800 RPM
INSULATION CLASS F F F
RATING CONTINUOUS - FAN COOLED
CONNECTIONS 22 mm 'PUSH ON' FLEXIBLE HOSES
MAX. INLET PRESSURE 1.5 BAR 1.5 BAR 1.5 BAR
MAX. INLET HOT TEMP. 70° CELSIUS 70° CELSIUS 70° CELSIUS

Negative head shower pump diagram: dimensions
DIM.
REF.
QT45SE QT80SE QT120SE
A 282 305 340
B 38 60 85
C 220 220 220
       
WIDTH 130 130 130

ALL DIMENSIONS ARE IN MILLIMETRES

Fig 5
Typical Installation Pumping
Blended Outlet

Fig 5: Typical Installation Pumping Blended Outlet

TECHFLOW PRODUCTS
FAULT IDENTIFICATION TABLE

SYMPTOM PROBABLE CAUSE RECOMMENDED SOLUTION
1 Pump will not start 1.1 Insufficient gravity flow



1.2 Electrical



1.3 Pump Seized
1.1 Check flow rate minimum of 1 litre / minute required on full hot and cold

1.2 Check power supply
Check fuse
Check circuit breaker

1.3 If motor "buzzes" remove power and contact Techflow
2 Reduced/Intermittent Flow 2.1 Incorrect or no anti-aeration flange fitted


2.2 Incorrect pipe sizes


2.3 Blocked inlet filters

2.4 Air in system





2.5 Hot temp. set too high
2.1 Check that the installation complies with installation instructions. See Section 2.2

2.2 Check that 22mm pipe work is used on inlets and outlets

2.3 Clean and re-test

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 Reduce cylinder stat setting to 65°c max
3 Pump runs on with outlets closed 3.1 Debris under flow switch



3.2 Damaged reed switch
3.1 Remove outlet hoses and check that flowswitch sits in lowest position

3.2 Contact Techflow
4 Pump starts with all outlets closed 4.1 Air in system

4.2 Leak in system
4.1 See 2.4 above

4.2 Check all pipe joints and appliances for leaks
5 Flexible hose leaks 5.1 Not fitted correctly




5.2 Damaged 'O' rings
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

 

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