Clarke EPC1200 Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC06/22
ELECTRONIC PUMP CONTROLLER
MODEL NO: EPC1200
PART NO: 7230699

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INTRODUCTION
Thank you for purchasing this EPC1200 Electronic Pump Controller.
Before attempting to use this product, please read this manual thoroughly and
follow the instructions carefully. In doing so you will ensure the safety of yourself
and that of others around you, and you can look forward to your purchase
giving you long and satisfactory service.
Please keep these instructions in a safe place for future reference.
APPLICATIONS
This controller can be used to convert water pumps into automatic booster
sets and provides 2 main functions:
1. It provides automatic operation of your pump.
• This in-line device maintains water pressure from booster pumps by
instantly sensing water usage and automatically starting or stopping
the pump.
2. It protects the pump from running dry.
• The EPC1200 controller has a built in safety circuit which switches the
pump off when there is no water flow.
• The controller performs pump control operations automatically.
Only use the controller in conjunction with clean water which is free of mineral
particles in suspension.
DESIGN FEATURES
• Automatic and manual modes.
• In Auto mode, the pump will start without adjusting the starting
pressure. The pump will also stop automatically in case of water
shortage.
• The pump can start automatically when the power supply returns
after power failure.
• Manual mandatory startup.
• Over-pressure protection;- if the system pressure is over 10 bar, the
unit automatically stops the pump.
• Water shortage self-start. The time interval of self-start is 1 minute, 30
minutes, 1 hour and then in a 1 hour cycle.
• Built-in pressure sensor and LED display.

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• Dry mode protection can re-start the pump if no flow after 48 hours
to discourage blockages.
• The digital display can be used to test and display starting pressure.
WORKING MODES
• In Automatic mode: the controller can automatically adjust the
starting pressure according to the pressure in the pipeline and can
monitor the pipeline pressure at any time. It does not need to be set
manually so avoiding a mismatch between the starting pressure and
the head of the pump, caused by the mismatch between the faulty
set starting pressure and the head of the pump.
• In Manual mode the starting pressure can be set between 0.5 and
6.0 bar.
SPECIFICATIONS
SAFETY PRECAUTIONS
1. DO NOT attempt to modify or alter the controller in any way.
2. Observe all electrical safety precautions. DO NOT allow the controller to be
submerged. Ensure it is protected from the elements at all times.
3. Read and comply with all precautions specified in your pump manual.
4. The controller should always be installed by a suitably qualified person who
is familiar with the appropriate electrical regulations.
Power supply 230V-50-60Hz
Maximum power 1.1 kw
Max. Ambient Water Temp. 60°C
Protection Rating IP65
Maximum Operating Pressure 10 bar
Start-up pressure 0.5 - 6 bar
Water flow rate 120 L/min
Connection G1" BSP external (male) thread.

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CONNECTING THE PUMP TO THE CONTROLLER
WATER CONNECTION
The controller should be connected to a good quality water pump and a
check valve should be fitted upstream of the pump. Confirm that the pump is
operating before installing the controller.
The controller can be installed anywhere between the pump and the first tap.
No taps should be fitted between the pump and the controller.
Use a flexible hose to connect the controller to the delivery pipe and tap.
The controller can be connected directly adjacent to the pump and between
the pump and the first outlet tap.
The controller must be installed in an upright position as shown by the direction
arrows on the label.
The vertical distance between the highest taps and the controller outlet being
no more than shown in the table below.
ELECTRICAL CONNECTIONS
The EPC1200 controller is fitted with two cables.
1. One is fitted with a standard 13 amp plug.
• When connected to the mains supply, this cable carries the supply
to both the controller and the pump.
2. The other cable should be fitted to a connecting socket for the pump.
3. If the controller is to be connected to an outdoor electrical supply, make
sure that both the plug and the socket are of a BS approved waterproof
design and are protected from the elements.
Starting
Pressure (bar)
Distance of controller
and highest tap max
distance (m)
Theoretical value
of the pump min
head (m)
Suggested value
of the pump min
head (m)
1.2 12 13 17
1.5 15 16 20
2.2 22 23 27

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MECHANICAL INSTALLATION
You should always fit a non-return valve to the suction line. (A foot valve and
filter are available from your CLARKE dealer).

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WIRING CONNECTIONS
CONNECTING THE EPC1200 CONTROLLER TO DIFFERENT PUMPS

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ELECTRICAL PLUGS AND CABLES
Connect the mains lead to a standard, 230 Volt (50Hz) electrical supply
through an approved 13 amp BS 1363 plug or a suitably fused isolator switch.
If the plug has to be changed because it is not suitable for your socket, or
because of damage, it must be removed and a replacement fitted, following
the wiring instructions shown below. The old plug must be discarded safely, as
insertion into a power socket could cause an electrical hazard.
If the colours of the wires in the power cable do not agree with the markings
on the plug.
• The BLUE wire must be
connected to the
terminal which is
marked N or coloured
black.
• The BROWN wire must
be connected to the
terminal which is
marked L or coloured
red.
• The YELLOW AND
GREEN wire must be
connected to the terminal which is marked E or or coloured green.
We strongly recommend that this product is connected to the mains supply
through a Residual Current Device (RCD)
If you are in any doubt regarding electrical installation, you should consult a
qualified electrician.
EXTENSION CABLES
The maximum length of cable should not exceed 25 metres, and the size of
the conductors must be AT LEAST the same size as that on the controller.
Ensure that all connections are well clear of the water.
WARNING: READ THESE ELECTRICAL SAFETY INSTRUCTIONS
THOROUGHLY BEFORE CONNECTING THE PRODUCT TO THE MAINS
SUPPLY.
WARNING: THE WIRES IN THE POWER CABLE OF THIS PRODUCT ARE
COLOURED IN ACCORDANCE WITH THE FOLLOWING CODE:
BLUE = NEUTRAL BROWN = LIVE YELLOW AND GREEN = EARTH
Plug must be BS1363/A approved.
Always fit
Ensure that the outer sheath of
Neutral
(Blue)
Live
(Brown)
Earth
(Green and
a 13 Amp
the cable is firmly held by the clamp
fuse.
Yellow)

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CONTROLS AND DISPLAYS
No Name Description
1 FAILURE 1. Light ON = lack of water
2. Light OFF = water supply normal
3. Twinkling light means lack of water. The pump will
stop and re-start.
2 PUMP 1. Light ON = pump working
2. Light OFF = pump will stop
3 AUTO 1. Light ON shows AUTO mode running (no need to
set starting pressure
2. Light OFF = Normal Mode (starting pressure set by
the user
4 POWER Light ON = System power supply normal
5 Display 1. “000” means real time pressure
2. “L00” means the starting pressure value
3. “P” = Over-pressure protection
6 “+” button Press button to Increase the pressure setting
7 SET Change between
Automatic mode and Normal mode
8 “RUN” Press to manually re-start the pump
9 “-” button Press button to decrease the pressure setting

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SET-UP AND OPERATION
SET THE WORKING MODE
In automatic mode the AUTO light will be on. Press the SET button for 4 seconds
and the AUTO light will go off and the unit will be in normal mode.
Press the SET button for 4 seconds and the unit will return to AUTO mode.
SET THE STARTING PRESSURE
In AUTO mode, the controller will set a starting pressure according to the
pipeline pressure.
In RUN mode press the “+” or “-” button to enter the starting pressure setting.
The display will show L00. Press the SET button or wait 8 seconds to save and
exit the setting for normal operation.
• The controller has a memory function to store the chosen setting in
case of power outage.
To display the starting pressure, press RUN and SET at the same time.
If the display shows ”P- -”& blinks, it means the pump will restart in 30 minutes.
If the failure light blinks it means the pump will restart after 1 minute, 30 minutes
or 1 hour.
If the pump stops, press the RUN button to set it working again.
STARTING THE SYSTEM
1. Close all taps/valve on the discharge side of the pump.
2. After making sure that all precautions have been observed, ensure there is
power to the pump.
• The “Power” LED will light up and the “Pump” LED will indicate that
the pump has been started.
• The pump will continue to operate for a few seconds enabling the
system to fill and to reach the required pressure.
If this time is insufficient, the “FAILURE” LED lights up. If this happens, open a tap
and keep the “RUN” button pressed until the LED goes off, then release the
button and close the tap. The controller will stop the pump at its maximum
pressure.
CAUTION: ENSURE THE PUMP IS FULLY PRIMED BEFORE SWITCHING ON.
SEE YOUR PUMP INSTRUCTION MANUAL FOR DETAILS.

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RUNNING THE UNIT
• If you open the outlet valve the controller will detect a drop in
pressure and start the pump.
When operational breakdowns occur, such as water loss, obstruction of the
suction pipe, etc, the controller recognizes the problem and the red “Failure”
LED lights up at the same time as the power to the pump is cut to prevent
damage caused by dry running. If this should occur:
1. Switch off the controller at the mains.
2. Rectify the problem.
3. Switch on the controller at the mains and press the AUTO button.
The most common problems associated with water pump operation are leaks
on the SUCTION side of the pump. Even a pin hole in the inlet hose is sufficient
to seriously reduce suction.
Using the automatic mode can avoid the issue of the pump not starting if the
artificial starting pressure does not match the pump head in normal mode.
In certain conditions the pump may not start in Automatic Mode, in which
case run the unit manually before increasing the starting pressure to a suitable
value.
MAINTENANCE AND REPAIRS
Although a component diagram is included, spare parts may be obtained
from your CLARKE dealer and the work may be better left to their technicians.

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TROUBLESHOOTING
ENVIRONMENTAL RECYCLING POLICY
Through purchase of this product, the customer is taking on the
obligation to deal with the WEEE in accordance with the WEEE
regulations in relation to the treatment, recycling & recovery and
environmentally sound disposal of the WEEE.
In effect, this means that this product must not be disposed of with general
household waste. It must be disposed of according to the laws governing
Waste Electrical and Electronic Equipment (WEEE) at a recognised disposal
facility.
Problem Causes related to the controller Other possible causes
The pump
does not start
Internal PCB is broken Voltage is less than 200 v
Pump jammed
Cables incorrectly
connected
The pump
does not stop
Internal PCB is broken.
Check valve is stuck
Water contains materials in
suspension.
Pipeline leaks
Intermittent
pump
running
The internal PCB is broken.
The pump does not provide
sufficient pressure
Presence of leaks in pipeline
The pump is
jammed
Internal PCB is broken.
The pump provides a pressure
which is lower than the restarting
pressure
Water failure
Suction problems
Pump leaking internally
In normal mode the pump
head is less than starting
pressure.
Failure light
flickering
The internal PCB is broken
Air present in the pipeline
Fault with the pump such as
leaks or loss of water flow.
Code P
displayed
Internal PCB is broken
Pressure sensor is broken
Actual pipeline pressure is
greater than 9.9bar for more
than 5 seconds.
For other possible problems consult the pump instruction manual.

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ASSOCIATED CLARKE PRODUCTS
Suction/Delivery Hoses Assorted Hose Clip Set - CHT672
• Reinforced 1" diameter hose for
use with water pumps. Reinforced
hose can be used on both the
suction and delivery sides of any
surface mounted water pump or
the delivery side of a submersible
pump.
• 25mm (1") diameter 90° threaded
female hose adaptor
• An optional pump filter and
cartridge for use with the various
Clarke water pumps including the
SPP swimming pool pump range
& CBM booster pumps.
• The 1HP SPP10A 750W swimming
pool pump is a self priming pump
designed to re-circulate water to
and from the pool via a filtration
system (sold separately) allowing
for the quick and easy draining
and cleaning of pools of varying
sizes.

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DECLARATIONS OF CONFORMITY

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COMPONENT PARTS

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COMPONENT PARTS
GUARANTEE
This product is guaranteed against faulty manufacture for a period of 12
months from the date of purchase. Please keep your receipt which will be
required as proof of purchase.
This guarantee is invalid if the product is found to have been abused or
tampered with in any way, or not used for the purpose for which it was
intended.
Faulty goods should be returned to their place of purchase, no product can
be returned to us without prior permission.
This guarantee does not effect your statutory rights.
No Description No Description
1 Nameplate 20 Main housing
2 Screw 21 Check valve baffle
3 Panel 22 Inner clamp
4 Panel seal 23 Diaphragm
5 Display board 24 Outer clamp
6Screw 25Screw
7 Display board connection 26 Top cap
8 PCB with components 27 Cap spring
9 Screw 28 Top cap core
10 Pressure sensor clamp 29 Screw
11 Pressure sensor 30 Head moulding
12 Sensor O-ring 31 Compression spring
13 Screw 32 Copper float
14 Upper housing 33 Copper sleeve
15 Check valve 34 Magnet
16 Check valve O-ring 35 Sealing ring
17 Water inlet filter 36 Cable gland
18 Screw cap 37 Hex nut
19 Housing O-ring