Please do not hesitate to contact us with any enquiries.

Transcription

1 PRIMARILY DESIGNED TO BE FITTED INTO ANY CARAVAN WITH AN ONBOARD WATER PUMP SUCH AS THE WHALE, SHURFLO OR FIAMMA PUMPS, WHICH MOST CARAVAN MANUFACTURERS FIT AS STANDARD. IDEAL FOR WINTER CARAVANING. THE WATER WIZARD CAN BE ADAPTED TO WORK WITH OTHER MAKES OF ONBOARD WATER PUMP SYSTEMS. EASY TO INSTALL MICROPROCESSOR CONTROLLED ONBOARD FRESH WATER SYSTEM USING LOW VOLTAGE (12VDC) SUPPLY AND PUSH FIT PIPE FITTINGS. TWO MODES OF AUTOMATIC OPERATION:- AUTO REFILL ONBOARD TANK FROM AQUAROLL (external water carrier) OR CHANGE OVER TO AQUAROLL WHEN ONBOARD TANK RUNS LOW. NO MANUAL CHANGE OVER VALVES. CAN BE USED WITH EXISTING SYSTEMS THAT ALREADY HAVE ONBOARD TANK TO REPLACE MANUAL CHANGE OVER VALVES. BUILT IN WATER LEVEL INDICATOR WITH LOW LEVEL WARNING. BUILT IN LOW LEISURE BATTERY VOLTAGE WARNING. CONTROLLER IS SURFACE MOUNTED, AVAILABLE IN BLACK OR LIGHT GREY. NO WIRING OR HOLES TO DRILL TO INSTALL. NO HOLES IN TANK. ALL FITTINGS ARE MOUNTED IN THE INSPECTION HATCH (ABOVE WATER LEVEL). TANK FILLS TO 40 LITRES. OPERATES WITH MAINS WATER ADAPTOR WITH OPTIONAL NON RETURN VALVE KIT. PUMP AND SURGE DAMPER NOT SUPPLIED. Capricorn Controls Ltd, Thorpe Close, Banbury, OX16 4SW. England Pump not supplied with kit. Tel: +44 (0) Fax: +44 (0) sales@capricorn-controls.com Web: Please do not hesitate to contact us with any enquiries. ISSUE 6

2 INSTALLATION OVERVIEW. CHECK ALL PARTS ARE CORRECT AS ORDERED. SITE TANK. DISCONNECT EXISTING PUMP PUSH FITTINGS. CONNECT SOLENOID ASSEMBLY PUSH FITTINGS TO PUMP. RECONNECT AQUAROLL INLET AND OUTLET TO TAPS TO SOLENOID ASSEMBLY CONNECT FILL AND OVERFLOW PIPES TO TANK. CONNECT FILL PIPE TO SOLENOID ASSEMBLY. CONNECT OVERFLOW PIPE TO EXISTING OVERFLOW. DISCONNECT ELECTRICAL PUMP CONNECTOR AND FIT ADAPTOR. CONNECT ELECTRICAL PUMP ADAPTOR TO RELAY UNIT (OTC200) MOUNT RELAY UNIT AND CONNECT TO SOLENOID ASSEMBLY. MOUNT MAIN CONTROL UNIT AND CONNECT TO RELAY UNIT. CONNECT TANK LEVEL PROBES TO RELAY UNIT. ENSURE INSPECTION HATCH IS FIRMLY TIGHTENED. FILL TANK AND REFILL AQUAROLL. DO NOT TRAVEL WITH WATER IN EITHER TANK. DRAIN THE SYSTEM COMPLETELY. WHILST EVERY EFFORT HAS BEEN PUT INTO THE DESIGN OF THIS ONBOARD FRESH WATER SYSTEM IT IS IMPOSSIBLE TO CATER FOR ALL MAKES AND MODELS OF CARAVANS. WITH A SMALL AMOUNT OF KNOWLEDGE OF WIRING AND PUSH FIT PLUMBING THE SYSTEM IS FLEXIBLE ENOUGH TO BE MODIFIED TO SUIT A WIDE VARIETY OF CARAVANS. OUR TEAM WILL BE ON HAND FOR ANY HELP AND ADVICE YOU MAY NEED. PLEASE FEEL FREE TO CONTACT US AT CAPRICORN CONTROLS AND WE WILL GIVE YOU ALL THE HELP THAT WE CAN. WE ARE ALSO INTERESTED TO RECEIVE FEEDBACK INCLUDING IDEAS TO IMPROVE AND EASE INSTALLATION FOR VARIOUS CARAVANS. SPECIFIC NOTES WILL BE ADDED ON FOLLOWING PAGES IN DUE COURSE. FITTING INSTRUCTIONS. (skip to next page if solenoid assembly is pre-assembled). Decide which is the best layout for the solenoid assembly, see figure 2-4. Use P.T.F.E tape on all threaded joints. Screw the appropriate fittings into the solenoids as required. Follow example layout drawings. Note the direction of flow on solenoids. Fit blue rigid pipes, push firmly all the way into fittings. See drawings for lengths. (Approximately 25mm into Fitting. Connect the wires to the solenoids (note the colours of wire to the correct solenoid, see figure 2-4 ). Follow installation instructions to install tank system. Ensure all pipes are pushed fully into fittings and threaded fittings are tightened into solenoids and check for leaks on first filling / test of system. 2

3 FITTING INSTRUCTIONS. Decide where tank will fit underneath one of the front benches and position using the non slip mat provided to stand tank on. The tank can be fitted under the opposite side bench to where the pump and hot tank is fitted, (you will need to have a longer pipe and level sensor extension wire from solenoid and the OTC200 relay assembly). You may need to remove and refit a small amount of the framework to aid fitting of the tank. Ensure any bits from inside the tank are cleaned out with a vacuum cleaner, any foreign bodies will be drawn into the system and may prevent the solenoids from operating correctly. Please ensure the hot tank and pump are completely drained before disconnecting any water pipe fittings. Disconnect the battery supply to the pump before continuing (switch pump switch off) Disconnect the pump push fittings from the Aquaroll inlet and outlet to hot tank and taps by pushing the collar back towards the pump and withdrawing the pipes. Catch any water that may drip from pump with a cloth. Position the SOLENOID assembly to the pump and push the fittings into the inlet and outlet of the pump. The solenoid assembly will be marked as to which is inlet and outlet. Ensure all push in fittings are pushed fully home. The solenoid assembly and fittings can be rotated to suit different layouts. Push the Aquaroll inlet and tap outlet pipes into the solenoid assembly as marked. Connect the tank fill pipe to the solenoid assembly as marked, and connect the other end to the tank. Cut this pipe to length as required, push fitting into pipe and fit hose clip, push fitting into tank connector. Mark the overflow pipe where it passes through the caravan floor, Remove the existing overflow pipe and cut in two at the point marked, fit the Y piece. Connect the clear plastic overflow pipe to the tank and connect the other end to the Y piece, cut to length if required,fit hose clip. Push overflow pipe back through caravan floor, ensure it passes all the way through. The overflow pipe can be passed through the floor without Y piece if there is room.. Decide where to position the Relay unit close to the pump and fit using the supplied screws. Connect the green 4 pole connector from the solenoids. Disconnect the 3 pole electrical connector to the pump by pressing the locking tab and pulling apart, reconnect the pump using the supplied adaptor. Connect green connector on the adaptor to the relay unit. Please check that the pump adaptor red wire corresponds with the red wire and the white pump running wire corresponds with the white wire on the pump connector. If it does not please contact Capricorn Controls for help or a modified adaptor. Connect the 6 pole tank level connector to the relay unit and the other end to the tank level probes fitted in the inspection hatch on the tank. Decide where you would like the main controller unit. The controller is surface mounted. Use the supplied template to mark the position of the fixing screws, fit with the supplied screws so as to allow the box to snugly fit onto the keyhole slots on the rear of the box, (alternatively you can use a removable adhesive supplied). Use the supplied trunking to house the wires to controller. Connect the 10 pole connector to the relay unit. You are now ready to fill and test the system. Please contact Capricorn Controls for any assistance. We are happy to help. Please take care if it is ever necessary to remove any of the connectors. Do not pull the wires, always grip the body of the connector. (press the release catch on the 6 and 10 way connectors) 3

4 4 Inspection Hatch Assembly (Figure 1)

5 5 SAMPLES OF PIPE WORK LAYOUT (Figure 2)

6 6 SAMPLES OF PIPE WORK LAYOUT (Figure 3)

7 SAMPLES OF PIPE WORK LAYOUT (Figure 4) 7

8 POWERING UP (SWITCHING PUMP ON AT MAIN SWITCH) If water in the tank is LOW / EMPTY the system will select to run from the aquaroll. Fill the hot tank in the usual way by opening the hot water tap until the hot water tank is full. Open the cold water tap at this point to purge any remaining air in the system If water in the onboard tank is above 1/4 the system will select to run from the onboard tank. OPERATING INSTRUCTIONS. Tank will not fill if the level sensor is not connected to the relay unit. As described in caravan manufactures hand book it is advisable to switch off pump at main switch when leaving caravan for any length of time For optimum performance please ensure that the aquaroll or external water carrier is kept full. TANK LEVEL IS DISPLAYED WHEN PUMP IS RUNNING, or by pressing CHECK LEVEL. When tank level is below 1/4, the low level red LED flashes. Press AUTO. If tank level is below 1/4, FILL ONBOARD TANK is automatically selected. If water in the tank is above 1/4 RUN FROM ONBOARD TANK is automatically selected. Two modes of AUTO are selectable via an internal DIP switch at rear of control box. See figure 6. In AUTO mode 1. Switch 1 off. when tank level reaches low you have approximatly10 litres of water. After 75 seconds the controller will automatically select run from aquaroll, maintaining the water flow to the taps/shower (subject to aquaroll containing water). In AUTO mode 2. Switch 1 on. when tank level reaches low you have approximatly10 litres of water. After 75 seconds the controller will automatically attempt to refill the onboard tank from the aquaroll. Please note while tank is filling flow to taps/shower will be substantially reduced. After 15 minutes if tank does not reach full (because the aquaroll is empty) the system assumes there is some water in the tank so automatically selects RUN FROM ONBOARD TANK. Press RUN FROM ONBOARD TANK after filling, the system will draw water from onboard tank. Use this mode to pump out tank through hot tank drain or through taps. Press RUN FROM AQUAROLL the system will draw water from aquaroll. Use this mode if mains water adaptor is connected Press FILL ONBOARD TANK the tank will fill from aquaroll (subject to sufficient water in the aquaroll), if filling a drained system from a standard 40 litre aquaroll you will have to refill aquaroll part way through, this will complete the filling of the tank and give you a reserve. When tank is full or after 15 minutes trying to fill the onboard tank the controller will automatically change over to RUN FROM ONBOARD TANK The LOW LEISURE BATTERY light flashes when the voltage drops to approximately 10.5 volts. This could indicate charger failure or mains supply off. Modes of operation can be changed at any time by pressing the appropriate button. To drain the onboard tank run the water level low towards the end of your stay, drain hot tank in the normal way, leave drain tap open, then select RUN FROM ONBOARD TANK,the pump will empty tank through the hot tank drain outlet. PREPARING FOR WINTER STORAGE. Drain the system as previously described. Disconnect the aquaroll. To ensure there is no water left in the system open taps and drain outlet, then run in RUN FROM ONBOARD TANK and RUN FROM AQUAROLL modes several times until no more water flows. Follow caravan manufactures instructions for complete winterising. FLUSHING OUT AND CLEANING. Follow caravan manufactures instructions. The inspection hatch can be unscrewed to enable tank to be cleaned if required. Take care when removing pipes and electrical 8

9 CONTROLLER LAYOUT (Figure 5) SHOWN ACTUAL SIZE REAR VIEW SHOWING DIP SWITCH 1, FOR AUTO SELECTION (Figure 6) Switch main pump switch off before operating switch. 9

10 USER NOTES:- PLEASE LEAVE THIS DOCUMENT IN CARAVAN FOR FUTURE OWNERS 10

11 TROUBLE SHOOTING. Pump does not run when tap is opened. Master switch not on. Switch master switch on Master switch is on but system does not operate. (no lights on) Fuse blown Fuse blown in relay unit. Check caravan hand book,replace with correct rating. Check fuse, replace with a 3 amp automotive fuse. Pump runs but no water to tank or taps Air being drawn into system Check there is water in Aquaroll Tank will not fill from Aquaroll when Fill Onboard Tank is selected. Pump runs occasionally for a very short time (2-3 seconds) without a tap being opened Foreign body in a solenoid valve Tank level probe connector is not Connected to tank. Remove solenoid coil, check valve seat for particles. Check diaphragm for holes. Check that that both connectors are plugged into the tank and relay unit. Inspect connectors for damaged wires. Slight leak from water connector / hose Carefully check all connections and hoses as described in caravan manufactured hand book. 11

12 SPECIFICATION. Tank size W500*D400*H275mm(With fittings) with 150mm sealed inspection hatch fitted with tank level probes, fill and overflow connections. Overall weight of system Approx 4.5 Kg. Microprocessor controller Selects mode of operation, controls relays, solenoid assembly, tank level monitor and checks leisure battery voltage. Choice Grey or Black control box. Operating voltage 12 volts DC Battery burden in Auto 45mA WARRANTY. Our warranty applies only if the equipment has been located, installed and maintained strictly in accordance with good engineering practice, our data sheets, operating and installation instructions and drawings. Terms and conditions of sale available upon request. LIABILITY / DISCLAIMER Capricorn Controls LTD will accept no responsibility for incorrect fitting or installation of this equipment that may cause any loss or damage whatsoever arising from any failure, use or misuse of the equipment, nor for any consequential loss arising there from. All equipment supplied has been checked by our engineers to ensure it is in full working order when it leaves our premises. We are available via phone or and will always endeavour to offer the correct advice to assist installation and overcome any problems that may arise. Any sale is subject to our standard terms and conditions which are available on request. Capricorn Controls Ltd, Thorpe Close, Banbury, OX16 4SW. England Tel: +44 (0) Fax: +44 (0) sales@capricorn-controls.com Web: Please do not hesitate to contact us with any enquiries. E&OE 12 ISSUE 6