Transcript
DFKIT03 WC DIRECT FLUSH
Product Manual
Product Manual DFKIT03
Wallgate 2014
For technical advice, or further information on Wallgate products, contact our Customer Services Department. Tel: (01722) 744594 Fax: (01722) 742096/742933 (Service) Email:
[email protected] [email protected] www.wallgate.com
Crow Lane, Wilton, Salisbury, Wiltshire, SP2 OHB, England. 2
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Table of Contents 1.
Disclaimer...................................................................................................................................4
2.
Conventions................................................................................................................................5 2.1
Warning ..............................................................................................................................5
2.2
Note....................................................................................................................................5
2.3
Numbered procedures .........................................................................................................5
2.4
Bullet lists............................................................................................................................5
2.5
Menu items.........................................................................................................................5
3.
Glossary......................................................................................................................................6
4.
Overview ....................................................................................................................................7
5.
Installation and Commissioning....................................................................................................8
6.
7.
5.1
Package Contents ................................................................................................................8
5.2
Site Preparation...................................................................................................................8
5.3
Preparing the DFKIT03 .......................................................................................................10
5.4
Installing the DFKIT03.........................................................................................................11
5.5
Electrical connection to solenoid valve. ...............................................................................13
5.6
Commissioning for use .......................................................................................................13
5.7
Flow rate & dynamic pressure information ..........................................................................15
5.8
Technical Specifications......................................................................................................17
User and Maintenance Instructions ............................................................................................18 6.1
Operation..........................................................................................................................18
6.2
Maintenance .....................................................................................................................19
Related Documentation.............................................................................................................20
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1. Disclaimer The specifications of Wallgate products can change without notice because of developments in design and manufacturing.
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2. Conventions Certain conventions are used in this manual to make it easier to read and understand. They are given in the sections below.
2.1 Warning A warning with white text on a red background is used to give information about hazards that can cause injury or death. Read and understand these warnings before you install and commission this product. Failure to heed these warnings can have serious consequences. WARNING! This is a warning!
2.2 Note A note with black text on a yellow background is used to draw your attention to important and useful information. NOTE: This is a note.
2.3 Numbered procedures Steps in procedures are numbered, starting from 1. 1. This is step 1. 2. This is step 2 etc.
2.4 Bullet lists
A bullet list is used to give information that is not sequential.
2.5 Menu items Menu items, submenu items and settings, where available, are given in bold.
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3. Glossary The glossary lists all words, abbreviations and technical terminology used in this manual, along with a short description of these terms.
Term
Description
Solenoid flush valve
This is an electro mechanical valve for opening & closing the water supply flow to flush the wc pan.
DC Device (Pipe Interrupter)
This is an inline pipe fitting with an integral air gap that prevents contamination of the cold water supply in the event of dirty water back flowing from the wc pan. The flush pipe is a plastic pipe that links between the DC Device and the inlet to the water closet (WC).
Flush pipe Flush pipe wc seal
The wc seal is a plastic or rubber connector that is inserted into the inlet of the wc pan for the flush pipe to seal into.
Water Dynamic pressure
This is the water pressure when the outlet is open and water is flowing.
Water Static pressure
This is the water supply pressure is water is not flowing.
Water Flow rate
This is the rate of flow of water from an outlet measured as either liters per minute (lpm) or liters per second (lps).
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4. Overview The DFKIT03 is a water control for the intended purpose of flushing a water closet (WC) direct from a suitably rated mains cold water supply. Flushing directly from the mains cold water supply: Flushing a WC from a mains cold water supply requires a suitable category 5 protection method or device to comply with water regulations. In the case of WC’s compliance can be achieved in three ways: a) The use of a dedicated supply for flushing use only, supplied from a break tank that protects the mains water supply with a type AA, AB or AD air gap. b) The use of a specific type WC bowl which has been tested and shown to incorporate the equivalent of a type AB air gap. c) The use of a DC pipe interrupter located between the cold water mains supply and the inlet to the WC. About DC pipe interrupters: These devices have an integral air gap; it is therefore important that pipe work design and water supply capacity are appropriate to ensure sufficient flow to flush the WC while preventing water flowing back up and out of the air gap. Key design & installation notes:
Install the DFKIT03 as high as possible above the WC bowl.
Install a free flowing, low restriction pipe between the DFKIT03 and the WC inlet. A suitable pipe of this type is supplied with the product.
Make use of the flow regulators provided, and be aware that the mains supply may require either further flow restriction devices or a pressure reducing device further upstream of the DFKIT03.
The DFKIT03 is not suited to systems using grey water/rain harvesting.
For chemical water treatment, if the water system had been treated with chemical dosing, ensure the system is thoroughly flushed before fitting the DFKIT03 product. Concentrated chemicals in dead legs can damge the product and result in failure if the water is treated with Chlorine Dioxide (ClO₂), ensure concentration levels are maintained below 5ppm.
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5. Installation and Commissioning 5.1 Package Contents Before you begin the installation, make sure that you have the following items:
1 Product manual 1 DFKIT03 (comprising of) Solenoid water valve + Pipe interrupter + flow regulator (100 lpm) Flow regulators (90 & 125lpm) Rubber seal for water valve inlet Flush pipe Flush pipe WC seal NOTE: An electronic control unit, water valve cable, flush activation button or sensor, are supplied separately as an option. Contact the Wallgate sales desk for more information.
5.2 Site Preparation
The DFKIT03 must be mounted vertically and it is recommended that a suitable pipe bracket is used to support and secure the assembly to the wall.
A mains cold water supply is required that is suitably rated for the overall demand to flush one or multiple WC outlets. This is critically important to ensure the correct product performance. A 28mm copper pipe terminated with a 1”BSP female fitting is required for the DFKIT03 water valve that has a 1” BSP male thread.
You must drill a hole in the wall for the WC flush pipe to connect to the WC pan inlet connection. Note that additional holes are likely to be also required for fixing other associated products such as the WC pan, flush activation button or IR sensor and electronic control unit. Refer to the instructions supplied with those products for wall holing details.
NOTE: Ensure holes are inserted into the wall accurately and hole diameters allow for a degree of clearance to ease installation assembly of the products.
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An electrical supply of 230V 50Hz with a 1 Amp rating is required for the optional electronic control units. |Revision 3.0
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Figure 1 DFKIT03 WC flush kit
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Figure 2 DFKIT03 typical installation layout
5.3 Preparing the DFKIT03 The mounting height of the flush valve & pipe interrupter assembly must be established prior to: 1. Cutting the flush pipe for the vertical height to connect it to the pipe interrupter. Note that it is preferable to mount the pipe interrupter and water valve at the max height possible to suit the pipe length but if not then a minimum height of 300mm must be maintained as shown on fig 2 above. 2. Provide a suitable pipe bracket to support the vertical section of the pipe to the wall allowing sufficient spacing away from the wall to give clearance for the water valve and pipe interrupter. 3. Cutting the horizontal section of the flush pipe to pass through the wall thickness and allowing a minimum of 50mm length to pass into the WC pan inlet seal. NOTE: If the flush pipe is cut to suit the installation, ensure the cuts are straight at both ends to avoid incorrect fitting and a poor seal that may result in water leakage.
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5.4 Installing the DFKIT03 To mount the water flush valve & pipe interrupter: NOTE: Flush out the supply pipes to remove any debris that could cause failure of the DFKIT03 prior to its installation. As a precautionary measure, a filter installed on the supply pipe can help to avoid product failure due to water supply contamination. 1. The 28mm water supply pipe should be terminated to a isolator tap such as a lever ball valve or gate valve and then terminated with a 1” BSP female fitting for the DFKIT03 to connect to. Assemble the 1” female fitting onto the water valve on the DFKIT03 using the rubber seal provided. Insert the seal into the female 1” fitting and screw the fitting onto the water flush valve. Ensure the seal is correctly seated (not twisted or crumpled) before tightening the fitting to the valve. Refer to fig 2. 2. Ensure the water flush valve is fully tightened into the pipe interrupter & the 100 lpm flow regulator is located within the inlet to the pipe interrupter as shown on fig 2. 3. Connect the female fitting to the 28mm supply pipe along with the attached water valve & pipe interrupter. Position the water valve so that the electric coil terminals are directed either to the left or right before tightening the fitting to the supply pipe. NOTE: Do not use pipe sealant compounds on the water flush valve inlet connection & if used on the supply pipe fittings ensure that excessive amounts are avoided as this could potentially pass through into the DFKIT03, causing failure of the product. 4. Fit the flush pipe to the pipe interrupter using the nut washer and seal provided. Refer to fig 2 to ensure correct assembly of the parts. It is advisable to connect the pipe also into the WC pan inlet with the seal provided prior to tightening the pipe fittings on the pipe interrupter. 5. The pipe must be secured onto the wall bracket (Not supplied). NOTE: Ensure flush pipe inserts into the WC pan seal by 50mm.
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Rubber seal for water valve inlet.
Water flush valve.
Rubber seal for water valve outlet. Flow regulator. 100 lpm regulator fitted as standard.
Pipe interrupter (DC Device).
Flush pipe cap nut seal.
Flush pipe cap nut washer.
Flush pipe cap nut.
Fig 2: DFKIT03 Water valve and pipe interrupter parts assembly (Flush pipe not shown).
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5.5 Electrical connection to solenoid valve. 1. The DFKIT03 solenoid valve requires a 12VDC electrical supply to control its ON/OFF operation. The Wallgate electronic control units are specifically designed to operate this product and also other wash room products such as basins and showers . A flush valve cable link from the control unit to the solenoid valve is required fitted with the appropriate connector plugs & are available from Wallgate in 2 & 4m standard lengths. Activation of the control unit output to the solenoid valve requires an input device such as a piezo touch button or infra red sensor, both are available from Wallgate. 2. To complete the electrical connection to the solenoid valve, terminate the flush valve cable push on receptacles onto the coil blade terminals and fit the rubber boot over the coil & terminals. Note that the cable wires can be fitted to either terminal, there is no polarity requirement. 3. Complete the installation of the control unit in accordance with the product instructions provided with it. Connect the flush valve cable to the control unit ensuring it is plugged into the correct output socket. 4. Complete the installation of the touch button or sensor & connect it to the control unit ensuring it is plugged into the correct input socket.
5.6 Commissioning for use NOTE: Before you do the following steps, ensure that as stated on section 5.4 of these instructions that the water supply pipes have been flushed to remove any debris and trapped air. 1. Pre-commissioning checks: All plumbing connections are complete & tightened to the DFKIT03. DFKIT03 flush pipe connection to WC pan inlet is correctly fitted. WC pan waste outlet connection is correctly fitted. Cable connection to flush solenoid valve & control unit is correctly fitted. Input device (Touch button or sensor) is correctly fitted and connected to control unit.
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Water supply dynamic pressure is set for 1.5Bar (150kPa) for initial flush commissioning. Electrical power to control unit is ON. Water supply is ON. Check plumbing system for any leaks. 2. Activate the flush using the touch piezo button or sensor. Note that at the completion of a flush there is a 30 second delay before the flush can be repeated. This delay is primarily intended for prevention of product misuse and for cistern flush installations to allow cisterns time to refill. The delay can be adjusted if required. Wallgate control units include a PURGE function to assist in commissioning products, refer to the control unit instruction booklet for full details. 3. Repeat the wc flush a few times to allow the system to release any trapped air and for the flush to stabilize. If required make adjustments to the flow rate or dynamic water supply pressure if water splashes out from the WC pan or if the flow is insufficient. 4. Flow rate & dynamic pressure adjustments are made by: Using a different size flow regulator fitted into the pipe interrupter inlet as shown on fig 2. A 100 lpm regulator is fitted as standard, and additional regulators rated at 90 lpm & 125 lpm are included to use if required. The solenoid valve has a flow adjustment screw that can also be used to make adjustments, see fig 2. Adjusting the screw clockwise will reduce the flow, the screw should be fully open (counter clockwise) normally and only adjusted if required. The dynamic water supply pressure should be adjusted if the flow performance is too low or too high for flow regulation methods to have positive result. The ideal dynamic pressure would normally be between 1.5 – 1.75 Bar (150 – 175 kPa). Note that the flush cycle time of the solenoid valve being in the open state can be adjusted on the Wallgate electronic control units to give a longer flush if required. NOTE: Ensure that installations consisting of multiple WC outlets are tested & balanced to give the best possible flush performance at each product.
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5.7 Flow rate & dynamic pressure information NOTE: Water flow requirement! To achieve an effective & efficient flush, the water system needs to deliver at least 90 lpm. Typically this would require that the dynamic pressure, measured before the valve is at least 1.5Bar (150kPa). If 90 lpm cannot be achieved, the flush will be less effective and a longer flush duration or multiple flushes may be required. This can result in water wastage. Water splashing over the pan can be due to an excessive flow rate and/or to water turbulence caused by air being pulled into the water flow from the pipe interrupter. Controlling the flow and dynamic pressure will help to reduce any splash. The pipe interrupter is fitted with a flow regulator that will limit the flow to 100 lpm. Additional flow regulators for 90 lpm and 125 lpm are included to adjust the flow rate. The flow regulators are colour code:
Dark blue:
90 lpm.
Black:
100 lpm (fitted as standard).
White:
125 lpm.
Note the flow regulator can also be removed to maximize the flush volume. Flow regulator.
DC Pipe interrupter.
Approximate flow rate with flow regulators fitted 15
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The flush volume is determined by the flush duration & the flow rate of the water supply. Use of the flow regulators and adjustment of the flush duration time on the control unit will set the flush volume as required. Consideration to multiple WC pans flushing simultaneously on the installation may reduce the flow rate at each outlet. Note that the flow rate can also be reduced by turning the adjuster screw in the middle of the solenoid valve or by fitting a third party reducing valve above the DFKIT03 inlet connection. Note that the water dynamic pressure should be measured while the solenoid valve is open & the water is running.
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5.8 Technical Specifications Table 1. Technical specifications
Weight Dimensions Water solenoid valve:
Back siphonage protection Water Supply
0.8 Kg 126mm (W) x 163mm (H) x 67mm (D) Input voltage 12VDC Coil rating 5.4W Terminal connections 6.35 x 0.8mm blades. Water inlet size 1” BSP male. Class 5, type DC. Maximum static pressure 10 Bar (1) Minimum dynamic working pressure 1.5 Bar (2) Maximum dynamic working pressure 1.75 Bar (2) Supply pipe size 28mm copper Valve inlet connection size 1”BSP male (1)
(2)
The maximum static pressure stated, refers to the maximum rating that the product components can withstand & not to the recommended working pressure for the correct performance of the product in its application. A facility to adjust the system dynamic pressure is recommended to have the facility to balance the performance of the products flush performance should that be required.
Optional Control Unit Specifications Power supply
230V AC 50/60Hz 1 Amp for models WDC100 & WDC200.
Power rating
Maximum power rating 50 W
Weight Dimensions Enclosure IP Rating Regulatory compliance
1.7 Kg 200mm (W) x 150mm (H) x 80mm (D) IP55 (Models WDC100 & WDC200)
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Complies with RoHS, LVD 2006/95/EC and EMC 2004/108/EC directives.
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6. User and Maintenance Instructions The DFKIT03 when, installed, operated and maintained according to the instructions given in this manual, will give reliable, efficient service. If you need any further information or advice, please contact Wallgate customer services. Wallgate offers a comprehensive service package, details of which can be obtained from our customer service department. A spare parts service is also available. Any service or repair work must be done by a qualified engineer. During the warranty period, the service or repair must only be done by a Wallgate engineer or appointed service agent. Refer to the Wallgate terms and conditions for warranty information.
6.1 Operation 1. The unit associated control unit option is switched ON and OFF using the main isolation switch provided by the installer, located in the maintenance duct near the electronic control box. NOTE: If a fault occurs with the unit you must set the isolator to the OFF position until the fault is repaired by a qualified engineer. WARNING! Risk of electric shock, serious injury and death. Only trained and qualified personnel should remove the cover of the electronic control box. 2. The activation device for the WC flush will usually be either a piezo touch button or an infra red sensor. The piezo touch button does not have any moving parts and is operated by lightly pressing it with your finger tip. If an infra red sensor is fitted then bring your hand (palm) to within 50mm of the sensor face. Activating the touch button or (IR) sensor signals the input to the control unit to switch ON the output to the DFKIT03 solenoid valve which opens the water for the WC flush to start. The control unit maintains the output for a preset duration that is adjustable. Typically a full flush duration is 3 seconds and a reduced flush is 1.7 seconds. The durations to achieve the required flush volume may require adjustment to suit the flow performance of the system. Refer to the product manual for the control unit for instructions on how to make the adjustments.
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6.2 Maintenance General wear mainly affects the components in contact with water. As with all water containing products lime scale in hard water areas can affect the products performance. This can result in maintenance to remove the lime scale when required. Table 2 Spare Parts List
Part Number WS3841 RW9650 AIR_BK03 CIFP24 PS0100
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Description. Water solenoid valve 12VDC. Rubber seal to solenoid inlet. DC Pipe interrupter assembly. Flush pipe. Flush pipe WC inlet seal.
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7. Related Documentation The DFKIT03 can be used with any of the following control units:
WDC100. For more information on this control unit, refer to the WDC100 product manual.
WDC200. For more information on this control unit, refer to the WDC200 product manual.
WDC400. For more information on this control unit, refer to the WDC400 product manual.
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