KERAFLO TANKTRONIC User manual

Specification
Max working pressure: 10 bar
Min working pressure: 0.5 bar
Power requirements: 6VDC, 1.4W
Valve
Ingress protection: IP68 (sensor) IP66 (vent box)
Operating temp range: 0 to 40oC
Sensor Assembly
Control classication: Multi purpose control
Mains supply: 230V ± 10%, 50/60HZ, Max load 0.85A
Environmental: 0 to 40oC, Max 85% RHI
Main Control Unit
Keraflo Ltd, Unit 1, Woodley Park Estate,
59-69 Reading Road, Woodley, Reading, Berkshire, RG5 3AN
0118 921 9920
info@keraflo.co.uk
www.keraflo.co.uk
TANKTRONIC®
INSTALLATION
GUIDE
TT/21B-01
WARNING
Mains voltage inside panel
Mains supply: 3 core up to 2.5 mm2, switched fused spur
Control valve: 2 core 1mm2, 50m max length
Vent box: 2 core 1mm2, 100m max length
Repeater Panel: 5 core 1mm2, 100m max length
Cable specication

TANKTRONIC
CONTENTS
2CONTENTS 3CONTENTS
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INTRODUCTION
1. Parts supplied P4
2. Unit dimensions P5
INSTALLATION
1. Assessing system layout P6
2. Installing the sensor in the tank P8
3. Installing the valve assembly P10
4. Mounting Main Control and Repeater Units P12
5. Mounting S-Module and Battery Modules P13
6. Wiring P14
a. Standard set-up P15
b. Optional devices P16
7. Connecting to mains power P17
COMMISSIONING
1. Initial start up P20
2. Standard set-up P21
3. Advanced set-up P25
a. Additional tanks P26
b. Sensor set-up P26
c. Pilot and control valves P28
d. Devices P29
e. Level offset P33
f. Holiday mode set-up P35
4. Connecting to building management systems (BMS) P37
5. System maintenance P38
USER GUIDE
1. Checking tank and system status P42
2. Alarms P43
3. Tank Lock P44
4. Override holiday time P45
MENU MAP P46

INTRODUCTION
Main Control Unit (MCU)
The primary monitoring and control
hardware for the Tanktronic system.
The unit can manage up to 4 x individual
tank sensors and 2 x Keraflo control
valves plus additional third party
devices.
S-Module
An expansion module that increases
Tanktronic’s operational capacity. Each
S-Module will allow 2 x control valves
to be added, plus additional third party
devices. Up to two S-Modules can be
joined to a single MCU.
Repeater Unit
Works as an interface extension to the
MCU, allowing the user to monitor and
control the Tanktronic system from
another location. The Repeater Unit
can be located up to 100m from the
water tank(s) and does not require a
separate power supply.
Battery Module
Provides a back-up power source to
the mains supply, providing up to two
days of normal operation before power
is expended. We strongly recommend
tting this module if the building
application is particularly dependant
on Tanktronic’s ‘Holiday Schedule’
function.
Dimensions
4INTRODUCTION 5INTRODUCTION
Parts supplied as standard
1. Main Control Unit including power supply
2. Vent box, sensor and bung
a. Single sensor (3m or 5m cable)
or
b. Twin sensor (3m or 5m cable)
3. Fixings
a. 4 x #6 screws for mounting main
control unit
b. 4 x #4 screws for mounting vent box
c. 4 x Wall xing plugs
d. 4 x Self-adhesive pads
e. 4 x oating washers
Optional parts
1. Control valve assembly
a. PVC tting (3/4” to 1 1/2” valve)
b. Flanged tting (2” to 6” valve)
2. Battery Module
3. S-Module
4. Repeater Unit
1.
3.
a. b. c. d. e.
b.a.
1.
batterybackup
2.
batterybackup
3.
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4.
Main Control Unit
Repeater Unit
143.51mm 203.51mm 85.40mm
193.69mm
2a. 2b.
Battery Module
S-Module
or
4 x

1. ASSESSING SYSTEM LAYOUT
INSTALLATION
6INSTALLATION 7INSTALLATION
Main
Control Unit
Sensor
assembly
Vent box
Valve
assembly
Twin tank (common valve)
Main
Control Unit
Sensor
assembly
Sensor
assembly
Vent box
Control
Valve
Multiple tanks Main
Control Unit
Vent box Vent box
Sensor
assembly
Sensor
assembly
Control
Valve
Control
Valve
Control
Valve
Twin tank (separate valves)
Main
Control Unit
Sensor
assembly
Sensor
assembly
Vent box
Control
Valve
Control
Valve
Before installing your Tanktronic system,
make sure you understand the system
layout you require. It is suggested
that you assess the tank environment
to establish the best position for the
equipment. This assessment also
ensures that you have adequate cable
and fixings to complete the installation
before starting.
Single tank
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NOTE: For monitoring only, omit valve assembly.
S-Module
Before commencing
installation, isolate
mains power and
water supply.

8INSTALLATION 9INSTALLATION
2. INSTALLING THE
SENSOR IN THE TANK
Allocate one sensor to
each tank. It is advisable
to label each sensor
(Sensor 1 for example)
and its corresponding
tank (Tank 1 for example)
prior to lowering the
sensor into the tank.
1. A 25mm hole should
be drilled in the top of
the tank, preferably
away from the water
inlet pipe.
2. Lower the sensor
into the tank so it is
suspended with the tip
of the sensor touching
the bottom of the tank.
Take care not to allow
debris to enter the
tank. It is suggested
that the tank is drained
down and chlorinated
before refilling.
3. A tapered rubber
bung is fitted to the
sensor cable to hold
the sensor in place
in the tank; slide this
bung down the cable
and force into the
hole through which
the sensor has been
lowered, securing the
cable in place.
Tip of sensor to
touch tank oor
Tank
oor
Tank
lid
Rubber
bung
To vent
box
25mm
a. MOUNTING VENT BOX
The vent box is supplied with self-adhesive
pads to fix it to the top of the tank being
used. Alternatively, the vent box can be
secured with the four screws supplied.
Four clearance holes are located in the
corners of the box to facilitate such fixing.
Notes on positioning
To reduce the effects of turbulence, do
not position the sensor close to the inlet.
Do not cut the sensor
cable and take care not
the damage the clear
plastic tube at the centre
of the cable.
To Main Control
Unit (cable not
supplied)
To sensor/s
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10 INSTALLATION 11INSTALLATION
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Main
Control Unit
Sensor
assembly
Vent box
Control
Valve
Isolation
valve
Water feed
Typical Twin Tank Installation
(common valve)
Sensor
assembly
Twin tank (separate valves)
Vent box
Control
Valve
Control
Valve
Isolation valve
Isolation valve
Sensor
assembly
Sensor
assembly
Water feed
Main
Control Unit
The valve assembly consists of a pilot
and control valve. Installation of valves
should be in accordance with The Water
Supply (Water Fittings) Regulations 1999
and BS6700:1997 Para. 2.2.4
•The control valve can be positioned
either horizontally or vertically .
•An isolation valve must be fitted
upstream of the control valve.
•Prior to installation, all pipework
should be flushed through to remove
debris.
3. INSTALLING VALVE ASSEMBLY
(WHEN SUPPLIED)
Maintenance
One tank/compartment may be isolated
for cleaning, chlorinating or for any other
reason. For further details see page 38.
1 2
Control
Valve
Typical Single Tank Installation
Isolation
valve
Main
Control Unit
Control
Valve
1
2
Note:
The preferred orientation of the
control valve is vertical. If fitted
horizontally fit a coarse y-strainer
upstream of the control valve.

12 INSTALLATION 13INSTALLATION
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5. MOUNTING S-MODULE AND
BATTERY BACK-UP MODULES
If the installation involves multiple tanks
or a battery back-up is required, please
follow the instructions below.
1. Slide tabs with a screwdriver as
shown below.
NOTE: These tabs are not load-
bearing and any extra units should
be supported during tting.
2. Align the subsidiary module to the
main control unit using the tabs.
3. Mark the position of the mounting
holes. A drilling template is included
in the packaging; this can be used to
mark the drilling points. Push out and
use the central part of the template
to mark the position of the battery
back-up box. Pay particular attention
to ensure that the cable glands are
free from obstruction. NOTE: Remove
the unit prior to drilling.
4. Drill 8mm diameter holes and insert
wall fixing plugs.
5. Screw unit in position using floating
washers and #6 screws provided.
6. Repeat for additional modules or the
Battery Module.
Mounting additonal modules
•Additional modules can be
mounted on either side of the Main
Control Unit.
•Up to two S-Modules can be
connected to the Main Control Unit.
4. MOUNTING MAIN CONTROL
AND REPEATER UNITS
The units should be mounted to a solid
surface, such as a wall, within easy reach
of the tanks being monitored.
1. Open the cover and offer the unit to
the wall.
2. Ensure the Unit can be opened fully,
with no obstructions below the unit
that could limit access.
3. A drilling template is included in the
packaging and this can be used
to mark the drilling points. Use the
complete template to mark the
position of the unit.
4. Mark the position of the mounting
holes as per the drilling template. Pay
particular attention to ensure that the
cable glands are free from obstruction.
NOTE: Remove the unit prior to drilling.
5. Drill 8mm diameter holes and insert
wall fixing plugs.
6. Screw unit in position using floating
washers and #6 screws provided.
Take care not to trap the ribbon cable
when closing the unit.
It is also possible to mount the units on
a DIN Rail.
Snap-o tabs
on MCU and
S-Module

14 INSTALLATION 15INSTALLATION
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Pilot valve
For single tank or twin tanks with a
common valve:
• Connect Pilot Valve to SOL1,
observing polarity
For 2 x single tanks or twin tanks with
separate valves:
• Connect first Pilot Valve to SOL1
and second Pilot Valve to SOL2,
observing polarity
For more additional pilot valves, an
S-Module will be required.
24V
6V
0V
A
B
LNE
Mains
power in Volt free contact
output for devices
Pre-tted
at factory
24V PSU
Battery, S-Module &
Repeater Unit connection (if tted)
To
pilot
valve
1
To
pilot
valve
2
To vent box /sensor
SOL1 SOL2 VFCI1 3800
Input
a. STANDARD SET-UP
VFCO1 VFCO2
Outputs
Outputs
Volt free
contact input
for adding
devices Input The Battery,
S-Module &
Repeater Unit
can also be
connected here
VFCI2
Input
Connecting subsidiary
S-Module and Battery Module
The subsidiary S-Module and the Battery
Module are each supplied with a 5-way
connector.
Interfacing with Main Control Unit
The Main Control Unit will need to be
configured to recognise the S-Module(s)
when connected. Refer to Advanced
Set-up section for details (see page 25).
Battery Back-up
The Battery Module will provide
approximately 2 days of normal operation
before power is expended.
Connecting Repeater Panel
The Repeater Panel is supplied with
connection plugs, the connection wire of
required length will need to be sourced.
The Repeater Panel is connected using
the multipin connector to the power ports
as illustrated (see page 16).
Interfacing with Main Control Unit
The Main Control Unit will automatically
recognise the Repeater Panel and
operate accordingly.
6. WIRING
For cable
specication refer
to back page.
Ensure mains power
is isolated

16 INSTALLATION 17INSTALLATION
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7. CONNECTING TO MAINS POWER
Tanktronic requires a 230v/50Hz single
phase supply from a switched fused
3A supply.
1. Connect with a suitable spec power
cable, first slide the cable through
the safety sleeve, then attach it to
the connector.
2. Slide the safety sleeve back over
the connector before pushing the
assembly firmly into the required
socket. See diagram on page 16.
3. Ensure cables are fed through the
cable glands.
4. Replace Main Control Unit cover.
Safety sleeve Cable Connector
Isolate water
supply when setup
is complete.
For cable
specication refer
to back page.
Do not power up
unit until all previous
installation stages are
completed and wiring
carried out to BS7671 IEE
regulations.
Sensor
The sensor is supplied pre-wired to the
vent box. The ‘net’ connector in the
vent box will need to be wired (over the
required length) to the ‘3800’ connector in
the Main Control Unit. 2 x electrical plugs
are supplied for this purpose but wire
must be sourced as required.
Please note polarity.
b. OPTIONAL DEVICES
Additional connections
using the S-Module
Adding the optional S-Module unit
will allow 2 x control valves to be
added, plus additional third party
devices*. Up to two S-Modules can
be joined to a single MCU.
Please proceed to the
commissioning section page 29
for details on adding devices.
Adding devices
Tanktronic uses volt-free contacts to
carry both inputs and output devices.
Inputs
Devices could include
• Leak detection
• Override button
Outputs
Devices could include
• Additional filling valves
• Low level alarm
• Dump valve
• Secondary shut-off valve
• Immersion heater
• Pump override
For cable
specication refer
to back page.
* Third party devices not supplied by Keraflo

The various monitoring criteria shown
below must be set up for each tank.
Alarm Level High
Alarm Level Low
Open Level
Close Level
Fill Delay
Override Level Low
Override Level High
D
E
F
C
B
A
C
B
A
E
18 COMMISSIONING 19COMMISSIONING
Standard set-up wizard
Tanktronic features a set-up wizard that
allows standard set-ups to be configured
quickly and easily. The wizard proceeds
through a series of configuration steps
using default settings intended to satisfy
most simple systems.
Advanced set-up
For more complicated set-ups the wizard
can still be used, but where more specific
settings are required the settings can be
changed manually.
Tank layout set-up reference
TANK LAYOUT SET-UP NOTE
1 x Single WIZ –
2 x Single WIZ –
3 x Single ADV S-Module
required
4 x Single ADV S-Module
required
1 x Twin
separate valve WIZ –
1 x Twin
common valve WIZ –
2 x Twin S-Module
separate valve ADV required
2 x Twin S-Module
common valve ADV required
Quick reference checklist
Prior to commissioning Tanktronic,
it is recommended to list the settings
required, as applicable, below.
(Default settings as indicated).
NOTE:
WIZ Program via set-up wizard
ADV Additional programming via
advanced set-up function
Tank set-up criteria
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COMMISSIONING
D
F
DEFAULT SET UP ENTER
REQUIRED
SETTING
Area (10.0m) WIZ .................
Close Level (1.2m) WIZ .................
Fill Delay (0.2m) WIZ .................
Alarm Level
High (0.2m) WIZ .................
Override Level
High (0.3m) WIZ .................
Alarm Level Low (0.2m) WIZ .................
Override Level
Low (0.3m) ADV .................
Alarm Temp
High (20°c) WIZ .................
Override Temp
High (22°C) ADV .................
Alarm Temp Low (5°C) WIZ .................
Override Temp
Low (3°C) ADV .................
Note:
Levels A, B & D are relative to level C.
Levels E & F are relative to level D.
Before powering up
unit ensure all water
connections and wiring
are completed.