Dutypoint ScubaTANK WX.A User manual

ScubaTANK WX.A
Operation and Maintenance Manual
DOC-WXAOM2308

About us.
Applied knowledge.
Shared know-how.
Fearless innovation.
Together, we are Dutypoint. Since 1976, we’ve been building up industry-defining expertise in fluid
technology.
This knowledge means we solve complex challenges with straightforward solutions that are built
around meeting and exceeding our clients’ needs. We approach everything with the same
philosophy: how will we go above and beyond?
Our commitment to collaboration and sharing knowledge galvanises and cements robust
relationships. Relationships that are built to last, because our clients are our partners.
Our focus for the future? Innovation. We want to be the future of our industry, globally. Where we
benchmark thought leadership, expertise and customer care.
We set the bar.
Contact details.
T: [phone]
E: [email protected]
Registered Office:
Dutypoint Ltd
Unit A, Quedgleley West Business Park,
Hardwicke,
Gloucester
GL2 4PA
United Kingdom

Table of Contents
© 2018 Dutypoint Limited
Dutypoint is a trading name of Dutypoint Limited, a company registered in England and Wales No 9045694
Important Safety Information.........................................................................................................4
Specifications....................................................................................................................................................10
Installation Sequence.................................................................................................................................15
Commissioning................................................................................................................................................21
Operating the Pump Set........................................................................................................................... 25
Pressure Vessel................................................................................................................................................27
System User Maintenance.............................................................................................................. 31
Pump Maintenance .............................................................................................................................33
Pressure Set Point Adjustment............................................................................................................ 35
Frequently Asked Questions .................................................................................................................38
Troubleshooting .............................................................................................................................................39
Control Panel Wiring Diagrams...........................................................................................................45
VASCO V209 and V214 Pump Controllers.............................................................................49
Declaration of Conformity......................................................................................................................67
Dutypoint Standard Warranty......................................................................................................68
Tank level Control Parameters.............................................................................................................36

1. Important Safety Information
4
1. Important Safety Information
1.1 Health & Safety at Work Act 1974
Section 6(a) of this Act requires manufacturers to advise their customers on the safety and the handling precautions
to be observed when installing, operating, maintaining and servicing their products. The user’s attention is therefore
drawn to the following:
• The appropriate sections of this manual must be read before working on the equipment.
• Installation, operating and maintenance must only be carried out by suitably trained/qualified personnel.
• Normal safety precautions must be taken and appropriate procedures observed to avoid accidents.
Refer to Dutypoint for any technical advice or product information. It is the responsibility of the customer and/or the
contractor:
• To ensure that anyone working on the equipment is wearing all necessary protective gear/clothing;
• Is aware of appropriate health & safety warnings and to read the information in this manual.
1.2 Safety Messages and Hazard Statement
Table 1.1: Hazard Notice Definitions
1.3 Qualified Personnel
WARNING
This product is intended for operation by qualified personnel only
• Only qualified personnel are allowed to install or operate this equipment
• Qualified personnel are defined as trained staff, who are authorised to install, commission and maintain
equipment, systems and circuits in accordance with relevant laws and regulations. Personnel must be
familiar with the instructions and safety procedures described in this document.
• This product should not be used by anyone with mental disabilities, or anyone without the relevant
experience and knowledge, unless they have received instructions on using the equipment and on the
associated risks, or are supervised by a responsible person.
• Children must be supervised to ensure they do not play on or around the equipment.
1.4 Environmental Protection
All local regulations and codes regarding emissions and waste disposal must be followed. This may include:
• Reporting of emissions to appropriate authorities
Message Level Definition
DANGER A hazardous situation which, if not avoided, will result in death or serious injury
WARNING A hazardous situation which, if not avoided, could result in death or serious injury
CAUTION A hazardous situation which, if not avoided, could result in minor injury or
moderate injury
ELECTRICAL HAZARD Risks associated with electricity will cause hazards if not properly avoided
Note A situation which may arise resulting in undesirable conditions and/or will not
cause direct hazards to persons

1. Important Safety Information
5
• Sorting, recycling and disposal of solid or liquid waste
• Clean-up of spills
• Separate disposal of electrical components from domestic waste
1.5 Mechanical Device Servicing
• Familiarise yourself with the relevant contents of this manual
• Installation, maintenance and repair work must only be carried out by trained, skilled and suitably qualified
personnel.
• Disconnect or lock-out the power source to ensure that the item(s) will remain inoperative. Locking out the
equipment by switching off the release mechanism or set value WILL NOT prevent accidental starting.
• Allow the item(s) to cool if over-heated.
• CLOSE the isolating valves on the suction and discharge connections of the affected item(s).
• If working on pump, VENT slowly and cautiously – Refer to the relevant section of this manual.
• DRAIN the pump(s).
1.6 Pump Hand Control Mode (Where Fitted)
In the 'HAND' position the pump(s) controlled by the switch will normally run at full speed and completely
independently of any control devices, and can result in pump(s) running against a closed valve head if there is no
draw. This can cause the system to be maintained at the maximum pressure produced by the pump plus any
incoming pressure and additional pressure caused by water surge and can potentially damage the pump and other
parts of the system.
The 'HAND' option should only be used with a competent operator in attendance, or when there is a continued
demand sufficient to provide constant flow through the pumps to maintain the running pressure of the system to an
acceptable level.
1.7 Personal Protective Equipment
Use personal safety equipment according to the site conditions and employer regulations. This may include, but may
not be limited to:
• Hard hat
• Safety goggles with side shields
• Protective footwear
• Protective gloves
• Respirator
• Ear protection
• First aid kit
• Safety devices
1.8 Precautions Before Commencing Work
Ensure that the following safety precautions are complied with before commencing work:
• Provide a suitable barrier around the work area
• Ensure all safety guards and in place and secure
• Ensure you have a clear path of exit
• Ensure that the product cannot roll or fall over and cause damage to persons or property
• Ensure all lifting equipment is in good condition and rated for the intended task
• Use a lifting harness, safety line and respirator as required
• Allow hot components to cool before handling them
• Ensure that product has been thoroughly cleaned
• Disconnect and lock out power supply, ensuring that it cannot be accidentally re-connected

1. Important Safety Information
6
• Check for any risk of explosion before using hand tools
1.9 Precautions During Work
• Never work alone
• Always wear protective clothing and hand protection
• Stay clear of suspended loads
• Always use appropriate lifting devices
• Beware of risks of sudden starts of any automated equipment such as level control
• Beware of starting jerks of electric motors - these can be powerful
• Do not exceed the stated operating limits of equipment
• Do not remove vent plugs from a pressurised system - ensure pressurised components are relieved of
pressure before disassembly
• Ensure guards are in place during operation
1.10 Hazardous Fluids and Chemicals
If hazardous chemicals come into contact with skin or eyes, use the following procedures:
1.11 Electrical Safety - High Voltages
This information is especially applicable when Variable Speed Controllers (Inverters) are fitted to pumps.
When the inverter variable speed drive head is connected to the power supply the components of the power unit as
well as certain components of the master control unit – are also connected to the power supply.
DANGER!
Touching these components can seriously endanger life!
• Before removing the frequency inverter cover, the system must be disconnected from the power supply
• After switching off the power supply wait at least 5 minutes before starting work on or in the inverter drive
head - the capacitors in the intermediate circuit must be given time to discharge completely via the discharge
restors.
ELECTRICAL HAZARD
Up to 800V can be present - if there are faults this can be higher
• All work carried out when the frequency inverter is open must be performed only by suitably qualified and
properly authorised personnel.
Condition Action
Chemicals or
hazardous fluids in
eyes
1) Hold your eyelids apart forcibly with your fingers
2) Rinse the eyes with eyewash or running water for at least 15 minutes
3) Seek medical attention
Chemicals or
hazardous fluids on
skin
1) Remove contaminated clothing
2) Wash the skin with soap and water for at least 1 minute
3) Seek medical attention

1. Important Safety Information
7
ELECTRICAL HAZARD
THE SYSTEM MUST ONLY BE OPERATED WHEN IT HAS BEEN CORRECTLY EARTHED AND PIPES
BONDED TO EARTH IN ACCORDANCE WITH IEE REGULATIONS
• When connecting external control wires care must be taken not to short circuit adjacent components. Bare
cable ends which are not in use must be insulated.
1.12 Electronic Safety Devices
• Inverter drives contain electronic safety devices which switch off the control element in the event of a fault
developing.
• A motor can also be stopped by ‘mechanical blocking’
• If it is switched off electronically, the motor is disconnected from the mains voltage supply via the electronics
in the inverter drive.
• Voltage fluctuation and power failures (temporary outages) can cause the motor to switch itself off.
WARNING
A motor will have zero current but will remain energised as it stops
• Take necessary precautions - the motor is not voltage-free in the circuit itself
WARNING
Repair of faults can cause items to start up again unexpectedly
• Ensure the motor is isolated before commencing any work
WARNING
High voltage tests of inverters may damage the electrical components.
• Bridge before the incoming/outgoing terminals L-L2-L3 and U-V-W.
• To avoid incorrect metering by capacitors incorporated in the electronic circuits, isolate the motor from the
inverter drive head.
1.13 Spare Parts
WARNING
Use of non-genuine spare parts may cause damage to equipment, damage to property and voiding of
warranty
• Use genuine, Dutypoint-approved spare parts only
• If in doubt, contact Dutypoint Service on 01452 300590.

1. Important Safety Information
8
1.14 Transportation and Lifting
WARNING: LIFTING HAZARDS
• Stay clear of suspended loads
• Observe accident prevention regulations in force
• Do not damage the cables during transports; so not squeeze, bend or dray the cable
• Always keeps the cable ends dry
• Secure the unit against tipping over and slipping until it is mounted and fixed in its final location
• Lift and handle the product carefully, using suitable lifting equipment (stacker, crane, crane mounting device,
lifting blocks, sling ropes, etc.)
• Always lift the unit by its lifting handle
WARNING: ASSEMBLED SYSTEMS ARE HEAVY
• Failure to properly lift and support this equipment can result in serious physical injury and/or equipment
damage,
• Lift equipment only at the specifically identified lifting points.
• Lifting devices such as eye bolts, slings and spreaders must be rated, selected and used for the entire load
being lifted
• Select the appropriate lifting points
1) Inspect the package
a) Inspect the package for damage or missing items upon delivery
b) Note any damaged or missing items on the shipping paperwork and contact Dutypoint immediately
c) File a claim with the shipping company if anything is out of order
d) If the product has been picked up at a distributor, file a claim with the distributor
2) Inspect the unit
a) Remove packing materials from the product
b) Dispose of all packing materials in accordance with local regulations
c) Inspect the product to determine if any parts have been damaged or are missing
d) If applicable, unfasten the product by removing any screw, bolts or straps. For your personal safety, be
careful when you handle nails and straps.
e) Contact Dutypoint if you have any issues.
1.15 Storage
The product must be stored in a covered and dry location free from heat, dirt and vibrations.
NOTE: Protect the product against humidity, heat sources and mechanical damage
NOTE: Do not place heavy weights on the packed product
NOTE: See section on storage limits
1.16 Disposal
At the end of its working life, this product should not be disposed of with standard household waste, but rather
dropped off at a collection point for the disposal of Waste Electrical and Electronic Equipment (WEEE) for recycling.

1. Important Safety Information
9
Figure 1.1: Waste Symbol
This is confirmed by the Waste Symbol found on the product, user manual or packaging.
Defending on their characteristics the materials may be recycled. Through recycling and other forms of processing
Waste Electrical and Electronic Equipment, you can make a significant contribution towards helping to protect the
environment.
Please contact your local authorities for information on the collection point nearest you.

2. Specifications
10
2. Specifications
Table 2.2: ScubaTANK WX Standard Range Specifications
2.1 Identifying ScubaTANK Models
Figure 2.2: ScubaTANK Model Codes
Applications Water with no gas or aggressive substances
Flow Range 0.8 - 3.1 litres/sec
Pressure Range 2.0 - 7.0 bar
Liquid Temperature 1°C - 23°C
Ambient
Temperature
+5°C - +40°C for indoor installations
Humidity Max 50%
Controller Type Modus VASCO as standard - other types available
Protection Low water level via hydrostatic sensor
Tank Construction GRP construction
25mm insulation (HCFC and CFC free)
Tank Capacity 175 - 2,250 litres
Inlet Valve 3/4" or 1" ultra high flow failsafe motorised ball valve
Discharge WX1 models: 1¼” BSP
WX2 models: 1½” BSP
Pressure Vessel 12 litre stainless steel
WX2-5040-0490-AB-HS-RM/2.A
Product Prefix
Number of Pumps
Pump Model
Tank Actual Capacity (litres)
Options:
AB = Category 5 AB air gap
HS = Horizontally split tank
RM = Control panel supplied loose for remote mounting
/2 = Twin Tank System

2. Specifications
11
Table 2.3: Pump Ratings
Figure 2.3: ScubaTANK Components
Pump Model
Motor kW
Rating
Power Supply to
Control Panel
(V/Ph/Hz)
Power Output from
Inverter to Pump
(V/Ph/Hz)
Per pump
Current @
Full Load (A)
3040-T230 0.55 230/1/50 230/3/50 4.1
3040-T230 0.75 5.2
3080-T230 1.1 7.4
3100-T230 1.5 5.5
5040-T230 0.75 5.0
5060-T230 1.1 7.4
5080-T230 1.5 10.5
5100-T230 2.2 9.0
9040-T230 1.5 10.5
9060-T230 2.2 11.9
9070-T 3 400/3/50 400/3/50 5.9
9090-T 3 6.8
Electrical cabinet
Pressure
Vessel
Flexible Connector
(supplied loose, do not
bend excessively)
Outlet
Motorised inlet valve
Incoming Main
(¾” or 1” BSP)
Inverter
Drives
Pressure
Transducers
Non-Return
Valves
Submersible
Pumps
Level Control
Sensor

2. Specifications
12
2.2 Pump Curves (Single Pump)
Figure 2.4: WXx-3000 Series Pump Curves

2. Specifications
13
Figure 2.5: WXx-5000 Series Pump Curves

2. Specifications
14
Figure 2.6: WXx-9000 Series Pump Curves

3. Installation Sequence
NOTE: An additional 250mm minimum clearance is required above the overall height
NOTE: Inlet centre: 62mm below the open tank top height
• The area should be dry, frost-free and well ventilated, away from extremes of temperature. All pipework must
be adequately protected from freezing.
• Adequate provision should be made for drainage, leakage damage protection and service access.
• The tank is free-standing, and should be installed on a level and structurally sound surface.
• Suitable measures must be taken to prevent ingress of liquids into the tank, such as protection from drips.
Tank Size (l) Footprint (mm)
Overall Height
(mm)
Height to Top of
Open Tank (mm)
Weight When
Empty (kg)
Weight When
Full (kg)
375 600 × 900 1678 1200 117 492
440 600 × 900 1978 1200 127 492
490 750 × 950 1678 1200 117 492
575 750 × 950 1978 1200 127 492
650 750 × 1200 1678 1200 150 800
750 750 × 1200 1978 1200 160 800
800 1160 × 1160 1462 1000 165 965
1050* 800 × 1500 1978 1500 170 1,220
1250* 1160 × 1160 1978 1500 194 1,444
1650* 1160 × 1500 1978 1500 211 1,861
2250* 1160 × 2000 1978 1500 218 2,468
*Additional overflow warning pipe: ¾” push fit
** Dimensions relate to 9040, 9060, 9070 & 9090 series pumps only.
1) Connect all hydraulic connections - see Section 3.3 Hydraulic Connection (p. 16)
2) Connect the electrical supply cable from a fused supply with correct rating - see Section 3.4 Electrical Supply
(p. 16)
3) Remove level sensor cable tie and carefully lower the sensor to it's correct position (bottom of sensor to be
suspended no higher than 50mm from the bottom of the tank).
CAUTION: If this step is not correctly completed before powering the system on, the tank may overflow.
4) Connect the inlet valve quick connector (supplied disconnected), ensuring the plug and socket are fully
engaged and latched
5) Fill the system and vent the pump(s)
6) Test and commission - see Section 4. Commissioning (p. 21).
NOTE: The ScubaTANK must be installed on a stable, level surface or plinth capable of supporting the tank and liquid.
Table 3.5: ScubaTANK Dimensions and Weights for WX2
1762**
2062**
1762**
2062**
1762*
2062**
1549**
2062**
2062**
2062**
2062**
3. Installation Sequence
3.1 Position and Secure the Tank
note: For installation of ScubaTANK models with a horizontal split tank (model has designation -HS), first follow the
instructions in Section 3.4 Horizontal Split Tank Installation (Applicable to -HS Models) (p. 18) before returning t
this section.

3. Installation Sequence
3.2 Hydraulic Connection
NOTE:
• The discharge pipework must be sized according to the system demand.
• All pipework must be in accordance with local Water Authority regulations.
• All pipework must be securely supported and not over-stressed.
• The overflow and the warning pipe (if fitted) must be piped to a suitable location.
• Strainer to be installed upstream of ScubaTANK inlet (BY OTHERS)
1) Connect the inlet water supply via an isolation valve;
2) Connect the overflow system to a suitable drain;
3) Connect the warning pipe (where fitted) and pipe to a suitable location;
4) Connect the outlet pipe;
3.3 Electrical Supply
WARNING: ALL ELECTRICAL WORK MUST BE CARRIED OUR BY A
SUITABLY QUALIFIED PERSON FOLLOWING THE LATEST IEE
REGULATIONS
• The system must only be operated when it has been correctly earthed and pipes bonded to earth in
accordance with the latest IEE regulations
WARNING: CONTROLLER ELECTRIC SHOCK DANGER. THE
CONTROLLER CONTAINS HIGH VOLTAGE
• Never open the controller or work with any electrical connections within it unless the electrical supply to the
unit is isolated.
• Wait a further 2 minutes after isolation for the internal circuitry to discharge.
• The electrical supply feed to the ScubaTANK should be a dedicated line to minimise electromagnetic
interference.
• The electrical supply rating must be at least double the FLC, assuming all pumps operate together (see Table
3.5: ScubaTANK Breaker Ratings (p. 17).) and are protected by a suitably rated external MCB
• The power supply cable to the ScubaTANK should be connected via an isolator switch located within 2m of
the ScubaTANK and suitable accessible for maintenance purposes.
16

3. Installation Sequence
Table 3.5: ScubaTANK Breaker Ratings
Figure 3.8: Common Fault Volt Free Contact Wiring Details
WX1 (Single pump) models:
Pump
Model
Pump
FLC
Single Pump
ScubaTANK
Model
Twin Pump
ScubaTANK
Model
WX1 (Single
Pump) Breaker
Rating
WX2 (Twin
Pump)
Breaker
Rating
3040 4.1 WX1-3040-xxx WX2-3040-xxx 10 (1~) 20 (1~)
3060 5.2 WX1-3060-xxx WX2-3060-xxx 10 (1~) 20 (1~)
3080 7.4 WX1-3080-xxx WX2-3080-xxx 10 (1~) 20 (1~)
3100 5.5 WX1-3100-xxx WX2-3100-xxx 10 (1~) 20 (1~)
5040 5.0 WX1-5040-xxx WX2-5040-xxx 10 (1~) 20 (1~)
5060 7.4 WX1-5060-xxx WX2-5060-xxx 10 (1~) 20 (1~)
5080 10.5 WX1-5080-xxx WX2-5080-xxx 10 (1~) 20 (1~)
5100 9.0 WX1-5100-xxx WX2-5100-xxx 16 (1~) 32 (1~)
9040 10.5 WX1-9040-xxx WX2-9040-xxx 10 (1~) 20 (1~)
9060 11.9 WX1-9060-xxx WX2-9060-xxx 16 (1~) 32 (1~)
9070 5.9 WX1-9070-xxx WX2-9070-xxx 16 (3~) 32 (3~)
9090 6.8 WX1-9090-xxx WX2-9090-xxx 16 (3~) 32 (3~)
WX2 (Twin pump) models:
17

3. Installation Sequence
NOTE: Ensure you follow the procedure according the images and instructions below.
3.5 Horizontal Split Tank Assembly
WARNING
The flange sealant is very adhesive
• Ensure it is aligned correctly before applying it to the flange.
• Remove paper backing as you progress along the flanges
• Check that you have the correct number of fixing components, i.e. nut, bolt, washers and arboseal.
• Ensure the flanges are free from grease and grit or other substances which may damage or prevent the
flange sealant from sticking,
• Ensure the flange sealant black strip is applied approx 5mm from the inner edge of the flange, water side.
3.4 Horizontal Split Tank Installation (Applicable to -HS Models)
NOTE: This section applies only to ScubaTANK WX models with horizontal split tanks. These have the -HS
designation.
1) Disassemble system
a) De-wire pump(s) from control panel
b) Remove pump(s) by opening lid and loosening union
c) Disconnect inlet valve power connector
d) Remove tank lid
e) Loosen bolts along horizontal split to allow the tank sections to be separated
2) Position all sections at location of final installation
3) Reassemble system
a) Replace lid
b) Place tank sections together, following instructions in 3.5 Horizontal Split Tank Assembly (p. 19).
c) Replace tank lid assembly and screw down
d) Reconnect inlet valve power connector
e) Connect pump(s) to union and tighten
f) Re-wire pump(s) to control panel
Figure 3.9: Remote on/off Signal Wiring Details
WX1 (Single pump) models: WX2 (Twin pump) models:
18

3. Installation Sequence
Figure 3.10: Applying split tank sealant
When the flange seals have been applied to the bottom section, the top section of the tank is carefully lifted onto it.
A podger/screwdriver may be used to align the bolt holes by pushing it through the top flange hole, through the flange
seal and through the lower flange hole. A bolt may be pushed through to hold it in place while the other holes are
located. It is recommended that all bolts are pushed through before tightening begins. Recommended torque: 40Nm
(30lb/ft)
After all the nuts have been spun onto the bolts by hand, you may begin tightening sequentially from the first bolt to
its diagonal opposite and continue in a clockwise or anticlockwise direction.
1) First time around, just pinch the nuts with a spanner;
2) Second time around, apply 30% recommended torque;
3) Third time around, apply 60% recommended torque;
4) Fourth time around, apply 100% recommended torque.
3.6 Bolt Tightening Sequence for Split Tank Flange Assembly
Nut and bolt arrangement. Ensure flanges are clean
and free from grease, grit
etc.
Apply flange sealant
ensuring the black strip is
water side.
When applying sealant to
the next flange, ensure a
overlap.
Flange sealant overlaps like
this.
DO NOT LEAVE A GAP
BETWEEN SEALS
✓×
Note: some sealant may
squeeze out from between
the flanges. This is normal.
19

3. Installation Sequence
3.7 Tank Level Sensor
The ScubaTANK water level is monitored via a hydrostatic analogue (4-20ma) level transducer. This is
connected to the pump controller (s) (via the control box) which use the input signal for low level pump
protection, inlet valve control and high level alarm.
For WX1 (single pump) models, the green core from the level sensor connects to terminal 6 in the control
box, and the brown core connects to terminal 7 (for full wiring schematics see page 46)
For WX2 (twin pump) models, the level sensor analogue signal is sent to both inverters via a relay (4). These
relays control which inverter the signal is transferred to. On twin pump systems using the Combo function,
only the master inverter (INV 0) receives the level signal and performs the tank level control functions. In
event of failure of the master inverter, the standby inverter automatically resumes role of master and takes
over the level control functions.
For WX2 (twin pump) models, the green core from the level sensor connects to terminal 7 in the control box,
and the brown core connects to terminal 8 (for full wiring schematics see page 48)
20