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WPL Installation Manual for Rainwater Harvester Packages Home System INSTALLATION MANUAL FOR... Rainwater Harvesting Home Packages 1. HEALTH AND SAFETY 1.1. United Kingdom Health and Safety at Work Act 1974 Section 6a of this act requires manufacturers to advise their customers on the safety and the handling precautions to be observed when operating, maintaining and servicing their products. The user's attention is drawn to the following: All the sections of this manual must be read before working on the equipment. Suitably trained and qualified personnel must carry out installation. Normal safety precautions must be taken and appropriate procedures observed to avoid accidents. Refer to WPL Ltd for any further technical advice or product information. 2. PRE INSTALLATION CONSIDERATIONS This section of the manual is intended as a guide and as such does not cater for every situation that may be experienced during installation. WPL Ltd assumes that the installer/end user has ensured that all necessary permissions have been sought and granted and that the installation procedures will be carried out observing the requirements of the Health & Safety at Work Act and will involve good building and sound civil engineering practice. Please ensure that due consideration has been given to and appropriate action taken with regard to the following: • Planning permissions & Building Regulations and other regulating or interested parties. • Environmental regulator’s consent to discharge. • The legal responsibility for the plant as far as operation and maintenance and ongoing discharge is concerned. • Costs, legal implications and siting in consideration to shared systems. • The whereabouts of other services, pipes, cables, ducts, etc. • Local ground conditions. Is specialist knowledge of civil engineering required to cater for unusual soil conditions such as underground rivers, running sand, chemicals in the soil, etc? • The water table at the time of installation. Specialist knowledge is required when installing in an excavation that allows water to enter. • The water table in winter. Special consideration should be given to installations that will be subject to high water table pressure or flood conditions. The Rainwater Harvesting system will need to be installed so that it cannot “float” out of the ground. IMPORTANT NOTE – In areas with high water tables the correct type of tank is required. If you are unsure please contact WPL Ltd prior to proceeding. • Siting. Advice from building control should be sought. IMPORTANT NOTE – When using a suction pump the maximum distance from the tank should not exceed 8 METERS • Electrical supply. Only a qualified electrician should undertake electrical installation. A safe and reliable power supply is required at all times. DO NOT REMOVE ANY SUPPLIED PLUGS OR FITTINGS. • See manuals supplied for specific components • Before carrying out any work, electrical equipment must be securely isolated • Temporary barriers and warning signs should be erected around any excavations, open covers or manholes, in particular warning of deep water in the tanks. • Any visiting personnel must report to site office or householder on arrival and fully acquaint themselves with safety regulations applicable. 3. INTRODUCTION Rainwater Harvesting Systems: Home Package: The home package consists of 3 main components:- 1. The tank: This is a polyethylene tank pre-sized based on the customers information and come complete unless pre-specified. The turret and lid should be assembled as per tank installation instruction. 2. The filter: the filter system is supplied as components with assembly instructions on the side of the box. 3. The pump and control module is made up of a 20 lt mains water tank with AB air gap, a pressure sensor, pump with integrated 3 way valve and float switch. This unit is supplied with 10mts of suction hose an allowance of 2 mts should be given allowing for tank depth. 4. DELIVERY 4.1 Off-loading Off-loading will only be at the nearest roadway to site that is suitable for heavy goods vehicles. If there are electrical cables overhead, ensure that there is adequate clearance or that the power is turned off. For off-loading from a lorry mounted with a crane, there needs to be a firm area for the stabilisers, the total width being a minimum of 4.6m (15 feet). If the nearest road access for a heavy goods vehicle is not adjacent to the site, it is the responsibility of the purchaser to arrange transport from the road to the site. If in doubt, contact WPL as soon as possible with any queries. Inspect the unit for any damage before placing on the ground. The unit should only be placed on level ground with no sharp stones, bricks, etc as they may damage the unit. All electrical equipment must be stored in dry, condensation free conditions until required. 4.2 Extent of supply a. See the delivery note for full details Ensure all components are free of damage before accepting delivery 4.3 Lifting and moving a. DO NOT attempt to lift the unit if it contains water. b. When moving across rough ground, great care should be taken to avoid increased loads due to sudden movement of the unit. 5 INSTALLATION 5.1 Introduction All installation procedures should be carried out observing the requirements of the Health and Safety at Work Act and involve good building practice. Tank and Filter Installation instructions Appendix 1. Pump and control installation instructions Appendix 2. General arrangement Appendix 3. APPENDIX 1  1. General Notes 1.1 Safety The relevant accident prevention regulations must be observed during all work. Particularly when walking on the tanks, a 2nd person is required to secure the tank. The relevant regulations and standards must additionally be taken into consideration during installation, assembly, servicing, repair, etc. The system or individual parts of the system must be installed by qualified specialists. During all work on the system or parts of the system, the entire system must always be rendered inoperable and secured to prevent unauthorised reactivation. Except in the event of work carried out in the tank, the cover of the tank must always be kept sealed, as this otherwise constitutes a maximum risk of accident. Only original GRAF covers or covers approved in writing by GRAF must be used. GRAF offers an extensive range of accessories, all of which are designed to match each other and which can be extended to form complete systems. The use of other accessories may lead to impediments to the system's functional capability, therefore invalidating liability for resulting damage. 1.2 Identification obligation All service water pipes and outlets must be identified in writing with the words "Not drinking water" or in the form of images in order to avoid inadvertent connection with the drinking water mains even after a number of years. Mix-ups, e.g. by children, may still occur even in the case of correct identification. All service water extraction points must therefore be installed with valves with child-proof locks.        Instruction for installation and maintenance Optimax-Pro Filter internal  1. General Advice      Appendix 2 Installation and Maintenance Instructions for the House and Garden GRAF Eco-Plus House and Garden System.  1. General 1.1 Safety All current standard safety regulations for the prevention of accidents must be observed at all times when any work is being carried out on the rain harvesting system. This work includes any assembly, maintenance, inspections and repair that may be required on the system. In particular, a second person must always be present as a safety precaution when inspecting or installing the underground tanks. Only competent and trained personnel must carry out the installation of this Eco- Plus House and Garden System and its individual system components. The rainwater harvesting system operates automatically. In order to prevent the rainwater harvesting system from automatically “starting up” while work is being carried out, it must be electrically isolated from the mains supply by suitably qualified electricians. All electrical cables fittings and connections must be installed to the current regulations and standards. GRAF offers an extensive range of accessories that are designed to interconnect with each other and can be used to expand existing systems. The use of accessory equipment supplied by others may result in damage to the GRAF Rainwater System and as a consequence the warranty on the whole system may be revoked. As it’s possible for water to leak from this system, we recommend that a drain be installed in the floor in the vicinity of the Eco-Plus Controller. It is imperative that the Eco-Plus wall bracket be adequately fixed so that the system remains securely mounted on the wall. 1.2 Duty to label The rainwater is not suitable for human consumption or physical hygiene. All lines and tapping points containing rainwater must bear written or image labels with the words "Not drinking water" (DIN 1988 part 2, sect. 3.3.2.). This is required to avoid cross connecting the rainwater supply to the mains serviced drinking water. These labels must be maintained for as long as the rainwater system is in service. Even with the correct labelling, errors can still occur (e.g. by children) and all service water taps connected with rain harvested water must be installed with childproof locks. 2. Applications A float level switch inside the rainwater underground tank controls the GRAF automatic changeover system to the mains water. The mains water is connected to a break tank that forms part of the Eco-Plus controller assembly. A float valve situated inside the break tank maintains the level of water within the break tank. This automatic system guarantees a continuation of supply with mains water should the underground rainwater tank ever become empty. Rainwater can be used to water the garden, to flush the toilet, for the laundry and for general cleaning. The GRAF In- House Eco-Plus system is intended for installation in frost protected areas and rooms that have built in drains to deal with any potential water leaks so as to prevent these rooms from flooding. Please find further details on the system layout, assembly and operation in the following document.  3.2 Control Control takes place via a float valve installed in the break tank. 3.3 Float valve
3.4 3-way reversing valve
3.5 Pressure and flow control "Controlmatic"
3. Specifications The pump may be restarted after a dry run by pressing the “RESET” button. Please consult WPL Ltd if there are problems with the water “hammering” due to the action of quick acting valves or other fittings. 3.6 Pump Drive: Single phase A.C. IP 44, insulation class F motor 220-240 V / 50 Hz with integrated overload protection. 3.6.1 Additional drinking water feed console 15/4
3.6.2 Additional drinking water feed console 25/4
 4. Installation and Assembly Remove all the components for the Eco-Plus House and Garden System from the packaging. Immediately check all the components for any possible damage. Any damage has to be reported prior to assembly and installation. 4.1 Wall-mounted assembly The Eco-Plus House and Garden Controller is designed to be suspended from a wall or any other suitable structure. It must be installed in an area that is free from frost and that has a means of controlling the emergency overflow. When selecting a location, a clear area of approximately 500 mm must be left all around the unit to facilitate any maintenance works. The chosen wall or other structure has to be suitable to carry the controller weight when the break tank is full of water (40 kg approx.)  Use the Eco-Plus controller support bracket as a template when marking the mounting holes at your chosen location on the wall where it is to be fixed. Drill the holes with a 12 drill to a depth of approximately 60 mm. Insert the enclosed plugs and locate the supporting bracket before inserting the screws. It is important that the support bracket be mounted horizontally. The controller is then hung onto the supporting bracket and the lower fixing point is marked on the wall. Remove the controller again and drill the marked location with a 10 drill and insert the relevant plug. Glue the 4 self-adhesive rubber buffers onto the outer corners on the back of the controller before hanging it permanently onto the support bracket.  4.2 Connection of the emergency overflow The emergency overflow consists of a standard DN 70 pipe. In a room that is fitted with a floor drain, it is sufficient to let the water from the emergency overflow onto the floor as it will then drain away from the room. If there is no floor drain fitted in the room, then the emergency overflow pipe should be connected to a similar sized pipe that is routed to an outside drain. In this case the emergency overflow pipe should remain open-ended so that there is never any danger of it becoming blocked.  Drinking water connection The 3/4" reinforced hose is installed between the float valve in the break tank and the mains water supply. It is imperative that the float valve is not twisted in any way when tightening the inlet pipe as this will cause problems with the water levels inside the break tank. We recommend the inclusion of an additional stop valve on the inlet pipe as this will facilitate easy access to the tank and float valve during future maintenance. The mains water pipe must be rinsed out well prior to the installation. A fine filter prior to the float valve would also assist the long term function of the float valve and the 3-way reversing valve.  4.3 Connection of the suction pipe The 1” suction pipe is lead through the services duct from the Diamant Tank up to the Eco-Plus controller. The 1” suction pipe is then connected above the red 3-way reversing valve. We recommend the inclusion of an additional stop valve on the inlet suction pipe as this will facilitate easy access to the tank and 3-way reversing valve during future maintenance.  4.4 Connection of pressure pipe The outlet pressure pipe (supplied by client) is connected to the pressure and flow controller. Standard polypropylene pressure pipe is adequate (do not use copper pipes) for this connection. We recommend the inclusion of an additional stop valve on the outlet pipe as this will facilitate easy access to the tank and controller during future maintenance.  4.0 Installation and Assembly 4.5 Connection of the float switch The float switch cable is lead through the services duct from the buried Diamant Tank to the Eco-Plus Controller. The special double plug is plugged into a standard 230 V socket. The 3-way valve is then connected to this double plug. The float switch and cable are attached in the tank so that float head is suspended approximately 100 to 150 mm above the tank floor. The yellow counter weight is positioned approximately 200 mm above the float head.  5.0 Initial Operation The inlet and outlet pipes must be rinsed out with clean water prior to the start up of the system. Any Particles > 0.2 mm can lead to serious damage to the pump and the other components. Never start the pump dry! Unscrew the filling stud on the pump case and fill the pump body with water.  The suction pipe must also be filled with water prior to start-up. This can be achieved by undoing the suction pipe at the top of the red 3-way valve. Ensure that the 3 way valve is set to automatic [A]. Fill the entire system by opening the inlet valve on the filling hose until water exits from the opened outlet and free of any air bubbles. This procedure is a reliable means of removing any air from the pipework. The mains plug of the Controller can now be plugged into a socket (230 V / fuse protection 16 A slow fuse) and the system will start up automatically once an outlet has been opened downstream from the pump and controller. If the pump does not start or cuts out after a short period, press the “RESET” on the controller. This procedure may need to be repeated a number of times until all the air in the system is removed. Once all the air is removed and the pump is running smoothly, the outlet point can be closed. This will allow the pressure to build up in the pipework and once its reaches the required level the pump will switch off automatically. 6.0 Maintenance and Care 6.1 Maintenance The entire system has to be maintained at regular intervals (every 3 - 4 months). All screwed connections should be checked for tightness and for leaks. The function of the float valve should also be checked during these regular checks. If the system is not used over a long period of time or if there is a danger of frost, the system should be drained of all water. 6.2 Care The Eco-Plus system can be wiped clean with damp cloth. If there is a lot of dirt on the unit, a damp cloth can be used with a mild cleaner. Never clean the unit with solvents or cleaners containing solvents. 7.0 Faults and Remedies Any electrical repairs that may be required must be completed by a qualified electrician.
 Appendix 3 
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