Watermill BP65S User manual

HEAVY DUTY
BRASS SHOWER PUMPS
Performance Shower Products
SERVICE HELPLINE TEL:
01883 730339
YOUR GUARANTEE IS AT RISK
IF PUMP NOT INSTALLED CORRECTLY.
SEE SECTION 2 IMPORTANT INSTRUCTIONS

1. GENERAL
Your Watermill Shower Pump has been designed, manufactured and carefully tested, in
England.
If correctly installed and not misused, it will give many years of reliable service.
To ensure satisfactory operation, we ask that you read the instructions before commencing
installation. Then carry out, in sequence, each step as described.
The important instructions MUST be followed, otherwise the pump may be damaged and
your guarantee invalidated.
2. IMPORTANT INSTRUCTIONS
1. When unpacking and installing pump, ensure that no
foreign particles (such as solder or dust, etc) are allowed
to enter the outlets; these will cause the flowswitch to
malfunction and the destruction of the pump impeller.
2. Do not connect pump to water mains pressure.
The pump cannot normally be used with combination boilers.
3. A supply head of at least 2 metres is recommended.
However the pump will function
with a supply head as low as
600mm (2’) providing; the water make up system has
unrestrictive pipework; and provision is made to avoid air
locks.
Note: The pump cannot operate if the level of the
water in the cold water storage tank is below the
level of the pump
IMPORTANT
Select a position for installing the pump which affords easy access for
subsequent servicing and maintenance.
This shower pump is fitted with carbon/silicon carbide mechanical long
life seals which, in some circumstances, can leak. Although this is very
unlikely, when locating the pump, position to mitigate against possible
water damage.
4. Do not fit non-return valves in the inlet line to the
pump. The pump must be able to vent back to the
supply tank.
5. Complete all pipework before making electrical
connections.
Do not let any water into the
electric terminal box
5. Push Fit Connections. The pump inlets and outlets are fitted
with “push fit” connections. The hoses supplied with the pump
must be used.
Make sure each hose connection is fully inserted to the red “insert
guide line”. Pipes must be inserted to a minimum depth of 33mm.
1

6. Disconnecting hose. To disconnect “push fit” hose, firmly push down white retaining
ring, whilst pulling out the hose.
7. NO SOLDER FLUX.
Do not allow any solder flux to come into contact with any of the plastic parts of the
pump especially the “push fit” retaining rings.
8. Do not let the pump run dry.
Purge with water thoroughly for 5 minutes before running
pump. Then check that each connection is water tight and
not leaking.
9. After completing installation, the
whole system must be thoroughly
tested – operating both hot and cold
at full flow.
10. Maximum hot water temperature must not exceed 60°C
(140°F) in accordance with BS6700 1997.
The hot water supply to the pump inlet should be connected
from the first outlet from the hot water cylinder expansion
pipe, i.e use a Surrey Flange.
3. POSITIONING PUMP
Pumps are designed to push water, not suck. For this reason, keep the pump as close as
possible to the source of hot and cold water. Keep the pump as low, and the input head of
water as high as possible.
For optimum performance ensure a good water flow to the pump from the tank. This is
achieved by having a sufficient head, unrestrictive pipework and provision to prevent air
locks.
Suggested location for the pump, if space allows, is on the floor of the airing cupboard.
The area around the pump must be well ventilated – the pump must not be covered by
boxes, clothes etc, otherwise the motor will overheat.
If the pump is to be installed in the loft, see note 3 of section 2 (important instructions),
there may not be sufficient head to feed the pump. Protect from frost damage.
The pump must be mounted horizontally with outlets vertically upwards to ensure correct
operation of the flow switches.
To reduce noise caused by vibration we recommend the pump be mounted on a small
concrete paving slab approximately 225 x 225mm and 40-50mm thick.
Connect pump and shower system as shown in Fig. 1.
To achieve 0.5 l/min to turn the flowswitches on, there must be a minimum height
between the water level in the cold water storage cistern and the shower outlet of
approximately 250mm –- see Fig 1.
The pump must be installed in accordance with the Water Supply (Water Fittings)
Regulations 1999.
2

Negative Head
If the water level of the cold water storage cistern is below the level of the shower outlet,
this is called a negative head system. To enable the pump to operate it must be a Negative
Head pump from the Watermill Automatic Negative Head range.
Note. If the pump is positioned above the outlet from the hot water cylinder; ensure the
pipework to the pump from the cylinder has a downward loop. This will help prevent air locks.
4. HOT WATER CYLINDER CONNECTIONS
DO NOT USE ANY JOINTING COMPOUNDS
The use of a Surrey Flange (see Fig 1) is recommended to ensure a free flowing supply of
“air free” hot water.
The hot water feed may be taken directly from the top of the hot water cylinder – but
entrapped air may cause problems.
22mm Copper pipe must be used to ensure an adequate flow to the pump. Where high
flows are expected 28mm is recommended.
3

5. COLD WATER SUPPLY
DO NOT CONNECT DIRECTLY TO WATER MAINS SUPPLY
DO NOT USE ANY JOINTING COMPOUNDS
The cold water supply to the pump must be connected using 22mm pipe, to the cold water
tank (do not connect to the central heating header tank!) see Fig 1. The tank connector
should be positioned at least 25mm (1”) lower than the cold water feed to the hot water
cylinder, to prevent the supply of hot water only.
6. CONNECTING PUMP
DO NOT USE ANY JOINTING COMPOUNDS
For ease of installation, future servicing and cleaning of filters, full bore isolating gate
valves should be fitted in both hot and cold inlets and outlets.
Isolating valves greatly assist draining down,
filter cleaning and refilling, which will result in
much lower service costs.
The flexible hoses supplied with the pump, or
authorised replacements from Watermill, must
be used for connecting this pump to the
pipework. Use of these hoses will ensure strain
and vibration-free watertight connections.
Make sure each hose connection is fully
inserted to the red “insert guide line”. When
connecting to the pump hoses, make sure
connecting pipe is fully inserted to a minimum
depth of 33mm (11/4”). Failure to fully insert
connections will cause leaks
The inlets to the pump are fitted with strainers
to prevent damage to the pump from abrasive
debris in the water supply.
After initial installation, run the pump for a few
minutes, switch off, drain down and clean the
strainers.
If Y strainers are fitted (as fig. 2) access is via the angled plug on the inlet port. If internal
strainers are used remove the inlet hose from the pump and the strainer basket can be
removed by hand or with long nosed pliers.
Position pump level (see section 3 positioning pump) ensuring that the outlets are vertical
for correct operation of the flow switches.
Line up pipework and fit hoses to pump before connecting to pipes. Position pipework
accurately sop that the pump is not subject to mechanical strain, such as supporting
weight of pipes.
Do not bend hoses as this will cause restriction of flow.
Figure 2
4

7. ELECTRICAL CONNECTIONS
WARNING - THIS PUMP MUST BE EARTHED
Electrical hazard will result if the pump is not correctly earthed.
If in doubt - consult a qualified electrician or call your local electricity board engineer.
The pump must be connected to a 230 volt 50Hz supply with a switched spur fused of
5A (10A on model BP130D). The switch must have a double pole disconnection with a
separation gap of at least 3mm. See Fig 1. Connect as the following colour code:
Connect BROWN to terminal L (Live)
Connect YELLOW/GREEN to terminal E (Earth)
Connect BLUE to terminal N (Neutral)
Insert wire fully into terminal connector and screw down firmly – ensure connection is
secure. Be sure to tighten cable restraint.
Ensure compliance with I.E.E. regulations. In the interests of safety it is recommended that
a residual current device (RCD) be installed in the supply circuit.
To avoid electrical hazard do not operate pump without terminal cover in place.
The mains on indicator light (where fitted) must not be relied on as a disconnect safety
check. The light may be faulty. Always switch off before removing terminal box cover.
For normal operation of the system the pump switch should be left on at all times.
Copper pipes should have supplementary earth bonding. Where the earth continuity has
been broken by flexible pipes the pump discharge and suction pipework should be
connected with earthing clamps to BS951 and 4mm earthing wire.
Power Cord Replacement
This operation should be carried out by a competent person.
If the power cord needs replacement, it is important to use the correct cable and fit it in
the correct manner.
The cable should be 3 core 0.75mm2. H05V V-F.
The pump connection end should be made as the diagram below.
NB. The power cord is available complete from Watermill Products. Part number WS137.
To fit:
Disconnect the power supply.
Remove the terminal box lid and existing damaged
cable taking care not to lose any fixings.
Loosen the knurled nut on the cable gland.
Pass the new cable through the cable gland and its
rubber insert.
Connect the cable as follows:
Brown to the terminal marked L
Blue to the terminal marked N
Yellow/Green (ring terminal) to E or
After inserting the L & N cables into their terminals tighten the screws and ensure that the
cables are secure.
Fit the ring terminal with a lock washer and nut and tighten with a suitable M4 spanner or
nut runner. 5
HO5 V-F
0.75mm BLACK
3-CORECABLE
M4 Ring
Terminal
(Earth)
PT.NO. WS137 - Cable Termination

Tighten the cable gland. Ensure the cable is secure within the gland.
Replace the terminal box.
8. BEFORE USING
WARNING - Do not run pump dry. Purge water thoroughly through system before
switching on pump electrical supply.
DO NOT TURN ON THE ELECTRICITY SUPPLY
1. Turn on water supply. Allow system to fill.
2. Immediately inspect for any leaks.
3. With pump not running, allow maximum water flow, for example remove handset from
shower hose, letting the shower hose hang into the shower tray or bath; operate
maximum hot and cold flow for at least 2 minutes, to flush out all debris and ensure
air is thoroughly purged from system.
4. SWITCH ON ELECTRICITY SUPPLY TO PUMP.
Again operate pump in both full hot and cold modes for about 2 minutes.
5. With the pump operating carefully inspect again for any leaks from all connections on
both hot and cold feed pipes to the pump and to the system.
After hot water has been run for several minutes check all hot water connections and
make sure “push fit” connectors are fully inserted.
6. The first few times the pump is used, the insulating varnish used on the pump motor
may give off an odour – this is perfectly normal and will diminish with use.
9. SERVICING
1. If the flow from the shower drops below its normal performance it may be necessary
to clean the pump filters. Blocked filters are common on initial installation of
pumps, or in new buildings where the use of jointing compounds, tapes, flux and other
debris can be flushed through the system.
In this event turn off service valves, remove and clean strainers (see 6 Connecting
Pump).
2. A common cause of poor shower performance is a clogged shower head/handset, so
regular cleaning and descaling is important – this applies particularly to hard water
areas.
10. FAULT FINDING
AIf pump fails to start, check the following:
1. Electricity supply and fuse (5A rating or 10A on BP130D).
2. Are isolating valves turned on?
3. Are the pump filters blocked, causing insufficient flow to the pump? Turn off service
valves or isolating valve; clean the strainers; replace, and turn on water supply.
4. Is pump correctly installed with outlets (flow switches) vertical?
5. Is there sufficient water flow to operate the flow switches 0.5 litres per minute?
6. If, for any reason, the motor overheats, the built-in thermal protection will turn off the
motor. It will automatically reset once the motor has cooled sufficiently.
6

B. If the pump won’t turn off:
1. Ensure that the hot water outlet from the pump cannot flow back to the hot water
system.
2. Is the flow through the pump completely stopped?
3. Is air entrapped in the system, causing pulsing?
4. Is flow switch jammed in the up (on) position by dirt or debris?
C. Pump Pulses:
Use of other water supplies in the house can cause the pump to start momentarily. If this
is a problem contact the Watermill Helpline.
DO NOT OVERTIGHTEN RETAINING SCREWS.
D. Unstable water temperature/noisy pump.
A common cause of poor shower performance and control is air entering the pump, most
commonly from the hot water cylinder.
1. If problem persists, fit a Surrey Flange.
2. Reduce hot water temperature. The maximum recommended hot water temperature is
60°C (140°F).
3. Study the pipework layout. There should be no high points where air can collect.
4. Is debris caught in the impeller casing?
Model BP65S BP100S BP50D BP65D BP100D BP130D
ELECTRICAL
Volts/Phase/Frequency 230/1/50 230/1/50 230/1/50 230/1/50 230/1/50 230/1/50
Power Consumption (W) 400 435 525 640 850 920
Full Load Current (A) 1.7 1.9 2.3 2.8 4.0 4.3
Rating* Continuous Continuous Continuous Continuous Continuous Continuous
Enclosure IPX2 IPX2 IPX2 IPX2 IPX2 IPX2
Motor Induction Induction Induction Induction Induction Induction
MECHANICAL
Inlet Head (min-max) 1-20m 1-20m 1-20m 1-20m 1-20m 1-15m
Max Developed Pump Head 23m 31m 21m 24m 34m 41m
Max Working Pressure 6 bar 6 bar 6 bar 6 bar 6 bar 6 bar
Min starting flow rate 0.5lpm 0.5lpm 0.5lpm 0.5lpm 0.5lpm 0.5lpm
DIMENSIONS
Length (mm) a178 178 243 243 266 296
Width (mm) 145 145 145 145 145 145
Height (mm) 225 225 225 225 225 225
Weight (Kg) 6.1 6.1 7.5 7.5 9.5 13.7
*Recommended minimum flow rate 5lpm.
aFor pumps fitted with Y strainers add 8mm to a single ended pump and 16mm to a twin.
NOISE
The sound pressure level 1m from the pump is less than 70dbA.
TECHNICAL DATA
7
SERVICE HELPLINE Tel: [phone]
WATERMILL PRODUCTS LTD
WATERMILL HOUSE, FAIRVIEW INDUSTRIAL ESTATE, HOLLAND ROAD, HURST GREEN, OXTED, SURREY, ENGLAND RH8 9BD
TEL: [phone] FAX: [phone]
e-mail: [email protected] website: www.watermillshowers.co.uk
ML 752/A 7/04 Made in England

Watermill Products Ltd Guarantee Registration Card
Product serial number
Name
Address
Post Code
Telephone number E-mail
Date of purchase Product type
Purchased from
Installed by
A COPY OF THE ORIGINAL PURCHASE INVOICE MUST BE ATTACHED
WATERMILL PRODUCTS LTD GUARANTEE JANUARY 2004
Watermill Products Ltd. guarantee the parts and workmanship of this product for a period of
two years from the date of initial purchase, provided that:
The product is installed and operated in accordance with our instructions and has not
been damaged or abused.
The guarantee registration card is completed and returned within ten days of purchase
accompanied by a copy of the original invoice (proof of purchase). We will acknowledge
receipt of the guarantee registration card within ten days. It is this guarantee
acknowledgement that acts as your two year guarantee and must be kept in a safe
place and produced in the event of a claim under the terms of this guarantee. If this
acknowledgement cannot be produced, the guarantee reverts to two years from date of
manufacture.
The information on the guarantee registration card is purely for the use of Watermill Products
Ltd. in connection with the guarantee of the product. The information will not be divulged to
third parties or used by Watermill for any other marketing activities.
The guarantee is limited to product repair or replacement only.
This guarantee does not affect your statutory rights.

GUARANTEE CLAIM PROCEDURE
If you believe the product is not operating correctly, phone the helpline number 01883
730339. Most problems with pumps can be eradicated by adjustments to the pump or
installation. Please have to hand your:- Guarantee acknowledgement. If the product has not
as yet been registered, or the acknowledgement has been mislaid please have to hand your:-
Proof of purchase, Pump type (to be found on top label), Pump serial number (to be found
on top label).
DO NOT REMOVE THE PUMP FROM ITS INSTALLATION AS THIS WILL INVALIDATE THE
GUARANTEE.
A large percentage of pumps removed from site and returned to us work perfectly when
tested in our laboratory. This makes it very difficult for us to help you solve the problem long
term. Sometimes the product is just not suitable for the application. It helps us to help you
if we can obtain details of the application.
It is also very useful to have digital photographs of the installation e--mailed to
[e-mail] prior to contacting us. These photographs should show as
much of the installation as possible, in particular:- The pump and hoses, the connection to
the cylinder, the connection to the cold water tank, the top label on the pump, the proof of
purchase.
If an engineer’s site visit call is required there must be an adult on site during the visit.
Site visits to products malfunctioning that are covered by the terms of this guarantee will
be provided free of charge. Site visits to products outside the terms of this guarantee will
be on a chargeable basis for parts and labour and must be paid for at the time of the site
visit.
Watermill Products Limited
Watermill House
Fairview Industrial Estate
Holland Road
Hurst Green
Oxted
Surrey RH8 9BD
Affix
Stamp
Here