Wallgate WDC400 ELECTRONIC CONTROL User manual

WDC400 ELECTRONIC CONTROL
for
Basins Showers WC and Lighting
Product Manual
Wallgate Ltd. tel: [phone]
Crow Lane, Wilton, fax: [phone]
Salisbury, Wiltshire, email: [e-mail]
SP2 0HB, England web: www.wallgate.com
Wallgate®
PRODUCT MANUAL
Issue 3
ORIGINAL
INSTRUCTIONS
© 2014Wallgate Ltd.

Product Manual WDC400
Wallgate
2014
2
|Revision 3.0
For technical advice, or further information on Wallgate products, contact our Customer Services
Department.
Tel: [phone]
Fax: [phone]/742933 (Service)
Email: [e-mail]
[e-mail]
www.wallgate.com
Crow Lane, Wilton, Salisbury, Wiltshire, SP2 OHB, England.

Product Manual WDC400
Wallgate
2014
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|Revision 3.0
Table of Contents
1. Disclaimer..............................................................................................................................................5
2. Conventions ..........................................................................................................................................6
2.1 Warning.........................................................................................................................................6
2.2 Note ..............................................................................................................................................6
2.3 Numbered procedures..................................................................................................................6
2.4 Bullet lists......................................................................................................................................6
2.5 Menu items...................................................................................................................................6
3. Glossary................................................................................................................................................. 7
4. System Overview...................................................................................................................................9
5. Installation and Commissioning..........................................................................................................11
5.1 Package Contents........................................................................................................................11
5.2 Site Preparation ..........................................................................................................................11
5.2.1 Mounting guidelines ...........................................................................................................11
5.3 Mounting the Controller Unit .....................................................................................................15
5.4 Cable Connections ......................................................................................................................16
5.4.1 Connecting the 3pin connector ..........................................................................................18
5.4.2 Connecting the 3.5 mm connector .....................................................................................18
5.5 Electrical Supply Connection.......................................................................................................18
5.5.1 Electrical connections mains voltage..................................................................................18
5.6 Commissioning for use................................................................................................................20
5.6.1 Purge Cycle function ...........................................................................................................21
5.6.2 Lockout function .................................................................................................................22
5.6.3 Piezo pushbutton and infra red sensor controls.................................................................23
5.6.4 System Test function...........................................................................................................24
5.7 Optional features ........................................................................................................................26
5.7.1 Remote Lockouts.................................................................................................................26
5.7.2 Ethernet Communications ..................................................................................................26

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5.8 Technical Specifications ..............................................................................................................27
6. User and Maintenance Instructions....................................................................................................28
6.1 Operation....................................................................................................................................28
7. Maintenance .......................................................................................................................................31
8. WDC400 Menu Settings......................................................................................................................32

Product Manual WDC400
Wallgate
2014
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1.Disclaimer
The specifications of Wallgate products can change without notice because of
developments in design and manufacturing.

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2.Conventions
Certain conventions are used in this manual to make it easier to read and understand. They
are given in the sections below.
2.1 Warning
A warning with white text on a red background is used to give information about hazards
that can cause injury or death. Read and understand these warnings before you install and
commission the WDC400. Failure to heed these warnings can have serious consequences.
WARNING! This is a warning!
2.2 Note
A note with black text on a yellow background is used to draw your attention to important
and useful information.
NOTE: This is a note.
2.3 Numbered procedures
Steps in procedures are numbered, starting from 1.
1. This is step 1.
2. This is step 2 etc.
2.4 Bullet lists
A bullet list is used to give information that is not sequential.
2.5 Menu items
Menu items, submenu items and settings, where available, are given in bold.

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3.Glossary
The glossary lists all words, abbreviations and technical terminology used in this manual, along with a
short description of these terms.
Term
Description
Building Management
System
BMS
WDCMS
A Building Management System is a computer-based control
system installed in buildings that controls and monitors the
building’s mechanical and electrical equipment such as
ventilation, lighting, power systems, fire systems, and
security systems.
The WDCMS Wallgate system is used for standalone
networking of the WDC control units to a dedicated PC or
laptop computer. You can manage the WDC units through
the network. You can also adjust time cycle settings, lockout
settings, remote water isolation on individual units or groups,
RTC settings, etc. You can also view the unit status in real
time and log the data.
Dual Flush
This option is used when both full and half flush options must
be provided, using either one or two pushbuttons.
Exclusivity
This feature prevents more than one water outlet from being
operated at a time.
Full Flush
This feature uses a 6 or 4.5 litre flush.
Half Flush
This feature uses half the quantity of water delivered by a full
flush.
Hygiene Purge
This feature operates services unused for a specified number
of days. This avoids water stagnation when the services are
unused for longer periods.
Latching
A latching switch is a switch that maintains its state after
being activated.
Lockout
The term Lockout refers to regulating services by restricting
the number of usage cycles.
Momentary
A momentary switch returns to its normal OFF position when
released.
Piezo Pushbutton
A piezoelectric pushbutton converts the force applied to the
face of the pushbutton into an electrical signal.
Power Rating
The power rating of a device is a guideline set by the
manufacturer as the maximum power to be supplied to that
device.

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Term
Description
Purge Cycle
This feature is used to help remove air trapped in the
plumbing system.
Remote Lockouts
The term Remote Lockout refers to isolating water services
from a remote location.
RJ45 connection
The RJ-45 connector is used for connecting the WDC unit to a
PC or laptop.
RTC
Real Time Clock. This is a 24 hour 7 day clock used by the
WDC400 for program features such as Time Slots and
Hygiene Purge.
System Test
The System Test is a feature that allows you to operate
switches and pushbuttons and make sure that these operate
the necessary outputs such as lights or valve solenoids.
Time Slots
Usage of services such as basins, showers and WC pans can
be controlled using preset time slots. For example, this
feature can be used to prevent all the showers in a facility
being operated simultaneously during peak periods, which
can lead to lack of water shortage. The day is divided into 4
time slots, normally set at 00:00 to 06:00, 06:00 to 12:00,
12:00 to 18:00 and 18:00 to 00.00.
Toggle type switch
A toggle switch is a class of electrical switches that are
actuated by a mechanical lever, handle, or rocking
mechanism.
Water Lockouts
The term Water Lockout refers to regulating water services
by restricting the number of usage cycles.

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4.System Overview
The WDC400 series control unit consists of a sheet steel enclosure that houses the
electronic control circuitry behind a hinged, lockable door. The circuitry contains relays and
mains power connection terminals.
You can safely operate the electrical isolator and circuit breakers from outside the housing.
The following devices are also located outside the enclosure:
User interface.
Visual display.
Low voltage control inputs.
Outputs at 12 V DC.
The control unit requires 230 V AC single phase electrical supply and is designed for wall
mounting. Refer to Table 3 for the technical specifications of the WDC400 control unit.
The control unit manages the delivery of water in 2 cells/rooms to:
Warm and cold water feeds for hand wash basins.
Premixed warm water for showers.
Cold water feed for WC full or half flush.
The control unit can:
Control the electrical supply to the sockets in each individual cell or room.
Switch the cell/room lighting on or off.
Switch the cell/room lighting on or off individually to vary the lighting levels.
Control the cell/room lighting using timers to conserve energy.
Remotely control the water services.
Control the services that the occupant of the cell or room can use.

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The standard unit is preset at the factory with default settings. You can change these
settings as necessary to deliver customised cell or room services. All the programming is
done through the keypad on the front panel, or through a PC workstation over the network
link.
As all the settings are retained in non volatile memory, the settings are not lost if the power
supply to the unit is disconnected. Customised settings from one unit can be easily copied to
other units using a PC workstation over the network link.
The electronic water management and Lockout features are designed to conserve water
and prevent misuse of the water services. The user interface is structured to ensure each
control valve has independent control and can be easily adjusted and viewed on the
illuminated display.
The user operates Piezo pushbuttons or infra red hand sensors to open and shut the water
supply to various services such as the basin, shower and WC. The cell/room lights are
controlled by either momentary or latching toggle/rocker switches. You can manage the
control unit in real time through a PC connected to the network (Comms) sockets.

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5.Installation and Commissioning
5.1 Package Contents
Before you begin the installation, make sure that you have the following items:
1 WDC400 electronic control unit.
1 Top mounting bracket.
1 Bottom mounting bracket.
4 Bracket attachment screws.
1 Control unit door key.
1 Product manual.
Cable assemblies necessary to connect the control unit to the valve solenoids and
pushbuttons are sold separately. When ordering, please specify the quantity and lengths of
cable required.
5.2 Site Preparation
5.2.1 Mounting guidelines
The unit must be attached to a vertical surface that can support the weight of the
unit. See Table 3 on page 27 for the unit weight.
The unit must be positioned in dry surroundings above pipes carrying water, so that
water from leaks in the plumbing does not drip on the unit.
The electronic control unit should be mounted in a location that allows easy access.
Mount the unit such that the, breaker switches, keypad and display on the unit are
readily visible and accessible. See Figure 1 for a typical 2 cell or room installation
using WDC400.
When the mounting positions of the control and the peripheral components are
marked out, the required length of the various cables to and from the unit can be
determined.

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The control box housing has 4 mounting holes located externally, 2 at the top and 2 at the
bottom. Refer to Figure 2 for an illustration showing the location of these holes. Screws of a
suitable size are necessary for securely attaching the unit to the wall.
Figure 1 Typical 2 cell or room installation with WDC400

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Figure 2 WDC400 mounting holes & general arrangement

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Figure 3 Front panel WDC400
AUXILIARY INPUT 1 AUXILIARY INPUT 1
MAIN LIGHT EXTERNAL SWITCH
SHOWER LIGHT EXTERNAL SWITCH
MAIN LIGHT EXTERNAL SWITCH
SHOWER LIGHT EXTERNAL SWITCH
Model Number: WDC400
Network address:
COMport:
Voltage
210-260V AC @ 50/60Hz
(230VAC ±10%)
MAIN LIGHT INTERNAL SWITCHMAIN LIGHT INTERNAL SWITCH
SHOWER LIGHT INTERNAL SWITCH
SHOWER BUTTON
WC FLUSH BUTTON
BASIN HOT BUTTON
BASIN COLD BUTTON
SHOWER VALVE
SHOWER LIGHT INTERNAL SWITCH
AUXILIARY INPUT 2
AUXILIARY INPUT 3
CHECK LIGHT SWITCHCHECK LIGHT SWITCH
AUXILIARY INPUT 2
AUXILIARY INPUT 3
NOT IN USE
NOT IN USE
NOT IN USE
NOT IN USE
WC FLUSH VALVE
BASIN COLD WATER VALVE
BASIN HOT WATER VALVE
WC FLUSH VALVE
SHOWER VALVE
NOT IN USE
NOT IN USE
NOT IN USE
NOT IN USE
BASIN COLD WATER VALVE
BASIN HOT WATER VALVE
WC FLUSH BUTTON
SHOWER BUTTON
BASIN COLD BUTTON
BASIN HOT BUTTON
Insulation Voltage
600V
This product must
be earthed
Impulse Withstand Voltage
1.5kV
Current of each Circuit
Incoming circuit
Outgoing circuits
•
32Amp Max
•
2 x Sockets 10Amp
2 x Lighting6 Amp
1 x SELVoutputs 1Amp
32Amp Total
Short Circuit Withstand Strength
• Socket Outputs (10A)
150Amp for 20mS (1Cycle)
• Lighting Outputs (6A)
100Amp for 20mS (1Cycle)
ElectricShockProtection
•
Indoor useonly!
Remove power andisolate beforeopening!
All external connectors areSELV.
• A special tool is required to open the enclosure.
• Socket & lighting circuits are protected by RCBO devices.
• All incoming and outgoing LV circuits must have the
earth conductorcorrectly connected.
• All wiredconnections are LV.
Makesure theEarth Terminal is connected
before applyingpower tothis assembly
Dimensions
410mm(H)x280mm(W)x110mm(D)
Weight
~ 8Kg
Internal Separation
Form 2a
Environment
Residential/Light Industrial
(Equipment Class B (IEC 61000-6-3)
Standard
IEC 60439-1
WDC400 SERIES
CONTROL SYSTEM
EnclosureRating
IP 53
LIGHT
LOCK OUT LIGHT
LOCK OUT
S1 = ROOM LOCKOUT FOR WATER SYSTEM.
S2 = ROOM LOCKOUT FOR SOCKETS.
S1+S2 = ROOM LOCKOUT LIGHTS.

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A single phase AC electrical supply of 210-260v ac 50Hz must be provided from a sub
main distribution board. To determine the necessary cross section of the feed cable,
see Table 3 for the power rating.
A water supply must be provided, with a pressure rating suitable for appliances
fitted in the installation. Locally-fitted isolating taps are necessary for the hot and
cold water feeds to the basins, showers and WC cisterns.
WARNING! Always mount the control unit with the cable glands facing upwards.
5.3 Mounting the Controller Unit
To mount the WDC400 control unit to the wall:
1. Attach the mounting brackets to the rear of unit housing using the provided screws.
WARNING! The weight of the control unit is approximately 8.0 Kg. Use safe lifting
procedures when lifting the unit.
2. Place the control unit in the necessary location on the wall.
NOTE: The cable glands must face upwards when mounting. Allow sufficient room to run
the cables through the top cable glands and for plugging the cables in at the
bottom of the unit. Make sure there is enough space for the door to open fully.
3. Mark the fixing points for the control unit on the wall. Make sure the cables from
the solenoid valves and pushbuttons are of sufficient length to reach the control
unit.
4. Mark the 4 mounting holes on the wall.
5. Drill the four mounting holes using a suitable drill bit. Use suitable wall plugs if
necessary.
NOTE: The diameter and depth of the mounting holes vary according to the type of fixture
necessary.
6. Attach the unit to the wall using four round head screws.
NOTE: When mounting the unit, make sure the cable sockets at the bottom of the unit
point downwards and are unobstructed.

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5.4 Cable Connections
The input and output sockets are located in the lower panel of the box. Refer to Figure 4 on
Page 16 for an illustration of the lower panel.
Figure 4. Connectors in the WDC400 control unit
Table 1. Legend for Figure 4
Item number
Description
Function
CON1
Output to Cell Call Light
External Cell Call Light
CON 2
Output to Cell Call Light
Internal Cell Call Light
CON 3
Output to Valve
Basin Cold water Valve
CON 4
Output to Valve
Basin Hot water Valve
CON 5
Output to Valve
WC Flush valve
CON 6
Output to Valve
Shower Valve
SKT1
Input from control
External Cell Call RST Button
SKT2
Input from control
Internal Cell Call Button
SKT3
Input from control
Basin Cold Button
SKT4
Input from control
Basin Hot Button
SKT5
Input from control
WC Full Flush Button
SKT6
Input from control
Shower Button
SKT13
Input from control
Main Light Internal Switch
SKT14
Input from control
Shower Light Internal Switch
SKT15
Input from control
Main Light External Switch
SKT16
Input from control
Shower Light External Switch
SKT17
Optional input
Auxillary1
SKT18
Optional input
Auxillary2
SKT19
Optional input
Auxillary3
SKT20
Input from control
Check Light External Switch

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Item number
Description
Function
CON 7
Output to Valve
WC Flush Valve
CON 8
Output to Valve
Shower valve
CON 9
Output to Valve
Basin Cold Water Valve
CON 10
Output to Lighting
Basin Hot Water Valve
CON 11
Output to Lighting
External Cell Call Light
CON 12
Input from control
Internal Cell Call Button
SKT21
Input from control
Main Light Internal Switch
SKT22
Input from control
Shower Light Internal Switch
SKT23
Input from control
Main Light External Switch
SKT24
Input from control
Shower Light External Switch
SKT25
Optional input
Auxillary14
SKT26
Optional input
Auxillary15
SKT27
Optional input
Auxillary16
SKT28
Input from control
Check Light External Switch
Comms IN
Left RJ45 Socket
Ethernet Input.
The input and output RJ45 connectors are
used to manage the WDC400 through an
existing Building Management System (BMS)
or stand alone system (WDCMS).
You can control and monitor:
Individual cell/room isolation for water
and electrical power.
Remote, individual and group operation
and settings, RTC settings.
Real time status feedback from cell/room
Control Units.
Comms OUT
Right RJ45 Socket
Ethernet Output
There are three types of sockets in the WDC400 control unit:
Twelve 3 pin female sockets, to connect the unit to 8 solenoid valves and 4 cell call
lights. The 8 sockets are used to connect the water valve solenoids, two sockets for
the WC flush valves, four for the wash basin valves and two for the shower control
valves.
Twenty eight 3.5 mm female sockets, to connect the unit to the pushbuttons,
optional remote controls and lighting switches.
Two RJ45 connectors, to connect the control unit to an Ethernet network.

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The socket assignments are given on the front of the unit. Refer to the label on the front of
the unit. Also see Figure 4 on page 16 and Table 1 for the socket assignments.
The connectors for each cell/room are grouped together, with connectors for cell/room 1 at
the left of the panel and those for cell/room 2 at the right side. See sections 5.4.1 and 5.4.2
for instructions on how to insert the plugs correctly into the sockets.
You can order the control cables once you have determined the required lengths. The cable
assemblies have the necessary connectors at both ends and are available in various
standard lengths.
You must connect each cable into the correct connector in the WDC400 unit. Label the
cables so that you can identify them easily when plugging them into the WDC400 unit.
5.4.1 Connecting the 3pin connector
To connect the 3 pin type connector to the socket in the unit:
1. The cable plug has a raised key that must be aligned with the slot in the socket, for it
to fit correctly. Push the connector fully into the socket and pull it back out slightly to
check the latch on the front of the plug has engaged the socket. To remove the plug,
press the latch button down firmly with your thumb and pull out the plug.
5.4.2 Connecting the 3.5 mm connector
To connect the 3.5 mm type connector to the socket in the unit:
1. Push the plug firmly into the socket until the black plastic casing of the plug firmly
contacts the unit. Make sure the plug is fully inserted into the socket.
5.5 Electrical Supply Connection
5.5.1 Electrical connections mains voltage
WARNING! Risk of electric shock, serious injury and death. Before you make the electrical
connections, make sure you isolate the mains power to the unit. All the circuit
breakers and isolators in the control unit must be set in the OFF position.
NOTE: Position all electrical fittings such that water does not drip on the electrical fittings
if a leak occurs, or a pipe bursts.
WARNING! The controller unit must be earthed using the earth lead in the power supply.

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WARNING! The electrical connections must be made by a qualified electrical engineer in
accordance with present nationally approved IEE Regulations.
To connect the WDC400 to the electrical supply and sub circuits:
1. Fit suitably sized cable glands into the holes in the top face of the cabinet, for the
cables entering the unit.
NOTE: Use one gland per cable.
The electrical supply cable glands are not supplied by Wallgate.
The supply cable gland fits into the 25mm hole.
The glands for the lighting and power sockets fit into the 20 mm holes.
2. Pass the power cables for mains input and switched mains outputs through the cable
glands in the top of the unit. Refer to the wiring diagram given in Figure 5. Working
in order from left to right or right to left, insert each cable through the gland closest
to where the cable is connected to the terminal block.
3. Fit hole blanks to any unused cable gland positions.
4. Connect the power supply cable to the main isolator switch and earth bar inside the
control unit.
5. Complete earth bonding to the tap head water supply pipes and shower nozzles.
6. Make sure that the pushbutton leads from the basin, shower and WC are plugged
into the correct sockets on the base of the control unit. Refer to section 5.4 or the
label on the front of the box.
7. Complete electrical testing of the installation.

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Figure 5. Electrical wiring diagram WDC400
5.6 Commissioning for use
To commission the WDC400 unit:
1. Fully open the water supply isolating taps. Check the plumbing system carefully for
water leaks.
2. Switch on the power supply to the WDC400 at the sub main distribution board.
3. Set the mains isolator to the ON position.
Red Line is the cutout line
Socket Cell 1 ShowerLight Cell 1 Night Light Cell 1 Main Light 1Cell1 Main Light 2Cell1 NOTUSED NOTUSED Main Light 2Cell2 Main ShowerLi
Light 1Cell2
Night Light Cell2
ght Cell 2
Socket Cell 2
10A 10A 6A
6A