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| PLEASE READ THESE INSTRUCTIONS
CAREFULLY BEFORE PROCEEDING WITH THE INSTALLATION.
FAILURE TO COMPLY
COULD INVALIDATE YOUR
WARRANTY AND ADVERSELY AFFECT THE IF YOU REQUIRE ANY
FURTHER INFORMATION |
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| The TECHFLOW TURBO range of regenerative 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. A comprehensive range of twin, single and negative head pumps
is available. Please contact the HELPLINE for full details.
It is essential to ensure that the MINIMUM
USABLE cold water storage
capacity of The installer / end user must ensure that the product is suitable for the application for which it is intended. 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.
1 SITING 1.1 For optimum performance the pump should be sited at the base of the hot water cylinder and never more than 4 metres from the HOT WATER cylinder. It must also be at least 12" (300 mm ) below the bottom of the cold water storage tank (see Fig 5). A minimum gravity flow of 1 litre per minute is required on each side of the pump to activate the flow switches. 1.2 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. 1.3 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 2.1 Figs. 1-5 show typical installations with Fig.1 being the recommended method for all pump types. Figs. 2-5 can be used for some pump types and these are detailed below in order of preference:
2.2 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.) 2.3 When the pump is sited ABOVE the HOT WATER CYLINDER only a TECHFLANGE or Non-Stop 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 5). 2.4 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. 2.5 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 l/min, a 28mm down service MUST be used. Typically, this will occur when two or more bathrooms are supplied from a single hot water cylinder. 2.6 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 22 mm ‘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. 2.7 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 used for short runs. However, this will result in reduced performance from the pump. 2.8 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 these hoses are not bent or deflected by more than 30º from the vertical. 2.9 Before fitting the hoses ensure that the Float Stop and Inlet Filter are correctly located in the recess provided. 2.10 To remove
the hoses from the pump or pipework hold the grey collet towards
the fitting and pull off the hose.
FIG
2
FIG
3
FIG
4
2.11 Either end of the pump can be used for hot or cold connection. 2.12 Ensure that the OUTLET connections are made to the ports marked with the ‘arrow’. 2.13 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. 3. TECHFLANGE INSTALLATION (SEE FIG 6) 3.1 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. 3.2
Mark the centre point of the proposed hole approx. 60mm below the
cylinder seam and cut a 3.3 Lower the water level in the cylinder to a point below the position of the proposed hole. 3.4 Using the template
supplied (see Pump box) mark out the centre-point of the hole and
a circle 3.5 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. 3.6 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. 3.7 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. 3.8 Now slide Sealing Washer (3) onto flange and feed through hole to position on threaded section of Flange Assembly (1). 3.9 Fit second Sealing Washer (4) and Clamp Washer (5) over flange and push up against cylinder wall. 3.10 Apply a bead
of clear silicon sealant around inner diameter of Clamp Washer (5).
Fit 3.11 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. 3.12
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) 4. ISOLATING VALVES 4.1 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. 4.2 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 6 5. HOT WATER TEMPERATURE 5.1 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. 6. ELECTRICAL INSTALLATION 6.2 All pipework must be cross bonded and an RCCB fitted in compliance with IEE regulations. 6.3
The 240 volt supply should be taken via a fused spur from the ring
main and fitted with the 7. COMMISSIONING 7.1. The inlet pipework must be thoroughly flushed to purge the system of any swarf, traces of flux etc. BEFORE connection to the pump. 7.2 Having connected
both inlet and outlet supplies open all isolating valves. 7.3. Open the shower
valve or terminal fitting and allow water to flow through the system
on 7.4 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. 8. WHOLE HOUSE PUMPING 8.1 When in excess of 6 high usage appliances with separate hot and cold outlets are pumped a Whole House Pack, consisting of 2 x single ended SE/NH pumps should be fitted. Contact the HELPLINE for further advice. 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) 10. SERVICING TECHFLOW PUMPS ARE FACTORY SEALED UNITS AND THEREFORE SERVICING OR DISMANTLING THE PRODUCT WILL INVALIDATE YOUR WARRANTY. 11. ‘NH’ NEGATIVE HEAD SYSTEM INSTALLATION (SEE FIG.7) The ‘NH’ Control Units 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. inlet head on Turbo 1NH - 5 metres (0.5 bar) IF THIS INLET HEAD IS EXCEEDED THE PUMP WILL FAIL TO OPERATE 11.3 Push-fit the
Stem Hoses (2) to the INLET ports and the 22mm Hoses (3) to the OUTLET 11.4 Complete the pipework to the Inlet side of the Pump and Outlet side of the ‘NH’ Control Units. Isolating Valves (4) MUST be fitted to both inlet and outlet pipework. 11.5 Connect the Pump Power Lead to a fused spur ensuring that the correct rated fuse is fitted. COMMISSIONING 11.6 Ensure that the power supply to the Pump is OFF. 11.7 Turn on the water supply to the pump. 11.8 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. 11.9 Turn on the power supply and the pump should now operate. 11.10 Allow the pump to run for several minutes to purge air from the system. 11.11 Close the shower valve and after a few seconds the pump will stop. OPERATION 11.12 Opening the shower valve will automatically start the pump. 11.13 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. 11.14 If the pump continues to stop/start with all outlets closed then check for leaks in the pipework. 11.15 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, 12. SINGLE ENDED PUMPS The TECHFLOW TURBO range of SE (single ended) pumps have been designed
to boost For further information or advice please contact our HELPLINE. FIG 7 INSTALLATION 12.1
Follow instructions as outlined in Sections 1– 6 ensuring
that the appropriate hot or cold 12.2 When the pump is fitted downstream of a shower mixer valve to boost blended flow install as shown in Fig. 8 below. The pipe run from the mixer valve to the pump should be 22mm min. and for best results the pump should be sited as close as possible to the mixer valve. NOTE: The NH (negative head) Pump types cannot be fitted in this type of installation. 12. SINGLE ENDED PUMPS Both flow-switch and pressure switch operated (NH type) pumps are available and these can be used to pump separate hot or cold supplies or alternatively fitted downstream of a mixer valve to pump a blended supply (SEE FIG.8) For further information or advice please contact our HELPLINE. INSTALLATION 12.1
Follow instructions as outlined in Sections 1– 6 ensuring
that the appropriate hot or cold 12.2
When the pump is fitted downstream of a shower mixer valve to boost
blended flow install as shown in Fig. 8 below. The pipe run from
the mixer valve to the pump should be 22mm min. and for best results
the pump should be sited as close as possible to the mixer valve. NOTE: The NH (negative head) Pump types cannot be fitted in this type of installation.
FIG.8 TYPICAL INSTALLATION PUMPING BLENDED SUPPLY
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