Whale SDP073R User manual

Dry-Deck 20
Installation Instructions
Model Number SDP073R Dry Deck 20
Installation guidelines for
This booklet should be read before installation

2
This Dry-Deck 20 control unit uses flow sensors to
measure the flow rate of water into the shower.
The pump speed is controlled directly by the
control unit which uses the signals sent from the
flow sensors to adjust the pump speed to match
the flow from the shower.
This minimises suction noise at the gulley. A simple
setup is required to match the pump performance
to the characteristics of the installation.
Technical Helpline: 0845 0694 253
Thank you for purchasing this Dry-Deck 20
product. Since 1995 Whale have been the leading
manufacturer of pump kits for use with shower
trays and wet floors. These kits have the reputation
of working reliably for many years without requiring
maintenance.
The front cover shows the product installation in an
apartment with the components in an adjacent
airing cupboard. Look at your installation prior to
fitting so that the pump, surge damper, control unit
and sensors are in accessible positions.
Typical installations would have these components
in an adjacent cupboard i.e. airing cupboard or in a
false wall with an access panel.
Please note: incorrect installation may invalidate
the warranty.
Principles of Operation

3
Warnings
Before installation read the instructions.
Contact the technical helpline (0845 0694 253)
if you are unsure.
• All electrical and mechanical components
(control unit, pump and flow sensors) must be
accessible after installation.
• The maximum flow rate the pump is designed
to work with is 20 ltrs/min.
• Do not plumb the pump outlet into the waste
piping that other appliances drain into as there
is a risk of induced syphoning. Use an
antisyphon trap where necessary.
• The shower floor must have a fall to the gulley.
• Plumbing installation must comply to latest
WRAS regulations.
• The electrical wiring must conform to EU wiring
regulations BS7671:2001 Amdt2: 2004.
It is advisable where the property is unattended for
an extended period that the water supply to the
shower is shut off.
If there is a reduction in pump performance after
installation please contact your installer.
Installation
User Warning
1.1 Pump Orientation 4
1.2 Rotation of Pump Head 4
1.3 Plumbing Pump Head 4
1.4 Waste Pipe Layout 5
1.5 Pump and Surge Damper 5
1.6 Tray Gulley Installation 6
1.7 Connection to Macerator Pump 7
1.8 Flow Sensor 8
1.9 Control Unit 8
1.10 Control Unit Location 8
1.11 Dry Deck Component Connections 9
1.12 Connections to Control Unit 10
1.13 Auxilary Connections to Control Unit 12
1.14 Component Connections 12
1.15 Control Panel Settings 13
1.16 Pump Head Cross Section 16
Illustrations
Pump Installation 4
Plumbing of Waste Pipe 5
Use of Dry-Deck with a Macerator Pump 7
Connect Flow Sensor to Hot & Cold
Supply of Shower 8
Control Unit 8
Schematic of Dry-Deck Components 9
Electrical Connections 10
Auxilary Functions 11
Principles of Operation 13
Setup 13
Pump Set Up Flow Chart 15
Pump Operation 16
Dry Deck 20 Status Information 18
Trouble Shooting Flow Chart 19
Dry Deck 20 Components 20
Gulley Options 21
Spares 23
Contents

1.1
1.1 Before mounting the pump refer to the
plumbing diagram opposite for maximum
pipe runs.
Mount the pump on a solid wall to prevent
vibration. Use a back board if this is not
possible.
The pump is mounted vertically (see
opposite) within 3 m of the gulley.
To aid servicing the head of the pump must
be above the floor by at least 150 mm
(maximum height of 500 mm).
Fix the pump in position through the feet with
the screws and washers provided.
1.2 Rotate the pump head if necessary to give a
straight run of pipe to the waste. Loosen the
clamping ring on the pump head and rotate
the head before retightening clamping ring.
Note: Do not remove the pump head.
1.3 Push fit fittings are provided to connect the
pump to inlet and discharge pipework.
All pipework in and out of the pump must be
in 22 mm.
Ensure fittings are locked after the pipe has
been pushed home.
4
Pump Installation
Plumbing
1.2
1.3

Maximum and minimum pipe length
Key Description Minimum Maximum
H1 in From gully to vertical lift 0.1 m 3 m
V in Vertical from floor to level of pump 0.15 m 0.5 m
H2 in Inlet distance from vertical to pump 0.1 m 1 m
H1 out From outlet to vertical rise 0.2 m 0.4 m
V out Vertical head 0 m 1 m
H2 out Horizontal to waste pipe *See notes below
*If > 1 meter use 1 1/4” or 1 1/2” waste pipe on gravity fall no maximum if on gravity fall
If < 1 m then 22 mm copper may be used to the stack.
1.4
1.4 • Only one vertical lift on the inlet to the
pump and the discharge from the pump
is allowed.
• When laying the pipe under the floor use
only slow radius bends.
• Use slow radius bends above the floor if
possible to ease the flow of water and
reduce loading on the pump.
• Use of copper pipe is recommended to
reduce risk of air leaks at connections.
• Ensure edges are burr-free. Burrs may
cause a build up of hair etc. that will
reduce flow.
• Pipework
must be secured to prevent
any vibration and noise.
• Twist lock the securing ring on the push
fit fittings (If semi rigid pipe is being used
follow the manufacturers instructions to
prevent air leaks).
5
Plumbing of Waste pipe
1.5
The surge damper prevents water hammer

1.5 Standard Plumbing Gulley: Use silicone on
top of the seal to ensure proper sealing
beneath the tray. Using the hand tool
provided to tighten the locking flange, fit the
gulley cover into the sockets and push down
with the palm of your hand to secure.
When fitting in solid floors, remove enough
concrete for the installation of the waste
water pipe and gulley. Where copper pipe
runs under the concrete it must be lined to
protect it and prevent corrosion.
Leave the hand tool in place to prevent
building debris, grout etc. falling into the
gulley. Only remove the hand tool and fit
the gulley cover when the installation is
complete.
For alternative gulley options see page 22.
6
1.6

1.6 Where the situation demands or if the pipe
run is greater than that specified for the
Whale pump a macerator pump may be
used. Contact the technical helpline
(0845 0694 253) for assistance.
The discharge from the pump must go into
the top of the macerator box and not into
lower side entries.
DO NOT USE the bottom entries.
It is preferable to have two separate
discharge lines to waste and drainage when
used in the same room as a macerator
pump.
Warning: Any failure of the macerator will not
be detected by the Whale pump.
7
Use with a Macerator Pump
1.7
From pump

1.7 Fit the Flow Sensors with the arrow in the
direction of flow to the shower, downstream
of any other connections to the water supply.
Each sensor must be protected by a filter
which is supplied in the kit.
The flow sensors must be mounted in a
straight length of unstressed pipe.
Note: Do not remove, tighten, tamper with this
device, failure to do so will invalidate warranty.
1.8 Location of Control Unit:
Locate the control unit outside the showering
area (as per BS7671: 2001 in zone 2 or 3,
refer to the drawing).
The control unit meets IP45.
Tighten all cable entry grommets, even
unused ones, to seal the Control Unit.
Connect Control Unit to 240V a.c. supply via
an unswitched 5 amp fused spur.
8
Connect Flow Sensor to Hot
and Cold Supply of Shower
Control Unit
1.9
1.10
Zone 1
Zone 0 Zone 2 Zone 3
0.6 m 2.4 m
Bathroom zones (BS7671: 2001)
1.8
R
C

9
Schematic of Dry-Deck
Components
1.11

1.10 Switch off the power to the control unit
while making connections.
Mount the control unit in a position where it
is not easily accessible to the user. The
enclosure is IP45 rated and may be
mounted in zone 2 of the bathroom.
Strip wires 10 mm and twist prior to
inserting into spring loaded contacts.
Push contact arm back with a finger or
small screwdriver before inserting wire and
then release.
Check for good connection using
gentle tug on wire.
1. Connect pump supply wires to
Pump Red and Pump Black
connections.
2. Connect flow sensor to sensor
connections using the colours as
indicated on the controller board.
For cold supply use FS1 and for hot
use FS2 connections - see diagram.
10
Electrical Connections
1.12

1.11a LED Display:
When not in programming mode the display
shows ‘- -’
Water flowing through the flow sensor is
indicated by alternately flashing 'flow rate'
for flow sensor 1 and 'flow rate' for flow
sensor 2. When no water is flowing the
display flashes ‘- -’. Flow rate is displayed
in 0.1 litre increments up to 10 ltrs and then
in 1 ltr increments.
1.11b Flow Rate Display:
When the system is not in status display
mode or configuration mode, it will display
the flow rate on the 7 segment LEDs
With no water flowing the system will
display ‘- -’ momentarily every few
seconds
With water flowing the system will display
the following:
Sensor 1 flow rate, Sensor 2 flow rate,
Combined flow rate ... repeating
Flow rates up to 9.9 ltrs/min will be
displayed to 1 decimal place.
Flow rates of 10 ltrs/min and above will
display the rate as the nearest whole
number.
For example:
3.4 ltrs/min on inlet 1
LED show “3.4”
7.5 ltrs/min on inlet 2
LED shows “7.5”
Then total flow is displayed
LED shows “11”
1.11c Solenoid Switch:
See diagrams 1.13 and 1.14.
Aux 1 is for connection to a momentary
contact switch. When the user closes the
switch Solenoid 1 and Solenoid 2 are
energized for 30 minutes. This allows water
to flow through the shower. If the switch is
closed again the 30 minute timer starts
again.
Technical specification of solenoids.
Voltage: 24V a.c.
Power Draw: 6VA
Pressure Range: 0.2 - 10 bar
Approvals: EN60730-2-8, WRAC
1.11d Pump Run Switch:
See diagrams 1.13 and 1.14.
Aux 2 is for connection to a momentary
contact switch. When pressed the pump
runs for 2 minutes and enters the over run
cycle. This may be used where the wet
room is washed down and water needs to
be pumped away.
11
Auxilary Functions

12
1.13
1.14

13
1.12a Four stages of controller operation:
1. Pump start: The pump controller
measures the volume of water released
into the shower tray. The installer sets this
volume so that there is water in the gulley
before the pump starts thus preventing
any start up sucking noise.
2. Pumping flow rate: With the shower
running at a mid flow (8 ltrs/min) setting
the installer adjusts pump speed to match
the flow of water into the tray. This is done
by watching the level of water at the gulley
and adjusting the speed up or down as
required until the water is being pumped
away slightly faster than the flow from the
shower.
3. The pump speed-narrow setting is used to
set the pump speed at 2 ltr/min
increments above 8 ltrs/min up to the
maximum flow from the shower. This is
necessary as flow characteristics from the
pump change at higher rates.
4. Pump shut down: After the pump speed
is set the shower is turned off. When the
water is drained from the tray a gurgling
noise is heard. The electric current loading
on the pump is then stored for subsequent
use in automatically turning off the pump.
How to adjust Settings:
a. Pressing the Mode button will
switch between the various mode
settings, indicated by small LEDs.
b. The Up and Down arrows are used
to adjust the value.
c. Press down the Mode button firmly
until the LED flashes which
indicates that the selected value
has been stored.
1.12b Switch power on to the control unit - the
LEDs will blink alternately. A simple setup
is all that is required for trouble-free
efficient performance of the Dry-Deck 20
system.
See flow chart on page 15
1.13
1. Inlet pipe size: Programme in the size of
pipe work from the gulley to the pump.
Select 22 mm. Ignore the 15 mm setting
as this is not used for this application. With
‘22’ illuminated on LEDs hold the Mode
button down firmly until the LED blinks.
Note: This will also reset all the factory default
settings including the pump speed.
2. Pump start up:
Start delay (ltrs)
This selects the initial amount of water in
the tray before pumping starts. This should
come above the level of the gulley.
(Factory default is the minimum setting of
0.4 ltrs). Pressing the up arrow will
increase the amount of water from 0.4 ltrs
to 5 ltrs passing through the shower head
before the pump starts.
Make adjustment to this setting during final
commissioning.
Principles of Operation
Setup
1.15

3. Pumping flow rate:
Pump speed settings
Prior to making adjustments turn the
shower on and wait till the pump runs.
Set the shower flow rate to 8 ltrs/min.
Watch the level of water within the shower
using the gulley cover as a guide. If the water
level is lowering then reduce the speed of the
pump by pressing the Down arrow. Use initial
increments of 5 until fine tuning is required.
When the water level is rising then increase
the speed of the pump by using the
Up arrow.
After making a change watch the water level.
Wait at least 30 seconds, as the system
needs to stabilise, until you see if the water is
rising or falling. When the water level is
slightly over pumping, program in the speed
setting by pressing the Mode button firmly
until the LED blinks
4. Pump speed – Narrow setting
This setting is required for higher flow rates.
a. 'Pump speed' must be set first as per
above using a mid-range flow setting.
b. Increase the flow from the shower in
increments of 2 litres and watch the
water level around the shower gulley. If
this is rising or falling over time make
adjustments until a constant level is
observed then programme in the
setting.
c. This process is repeated in 2 ltr
increments. The narrow adjustment
corrects the flow rate over a band 1
ltr/min either side of the flow rate that is
being calibrated.
5. Pump shut down:-
Over Run (Auto Sense) preferred option
To set Auto Sense Over Run (indicated by
'AS' on the LED) you must turn off the
shower when you have selected this mode.
When the pump is drawing air there will be a
gurgling noise at the gulley, press down the
Mode button so the controller stores the
loading on the pump at this point.
Over Run (Fixed)
Alternatively to set a fixed Over Run delay
use the Up and Down arrows. Each digit
represents a delay of 5 seconds
(i.e. 2 =10 seconds over run).
Hold the Mode button down to program.
Commissioning Checklist
a. All push fit fittings must have the twist
lock in the locked position.
b. Check all plumbing for leaks.
c. Check waste water plumbing for leaks
while pump is running.
d. Ensure flow sensor is unstressed.
After programming all the settings, turn the
shower on and check for correct operation.
Make final adjustment to the Start Delay if
required.
Note: 15 minutes after showering is finished, the
pump will switch on for a brief period in order to
remove any water that may have pooled.
14

15
Dry-Deck 20 Set Up
START
Exit Mode
Setup
Press MODE Button once
LED shows 22
Press and hold MODE Button firmly until
green light flashes.
Press MODE Button once.
LED shows 0.4 Start Delay is set last.
Press MODE Button once.
LED shows 50 (Pump Speed).
Turn shower on and adjust until flow rate
indicated is 8 ltrs/min
Re-enter ‘Pump Speed’ mode
Observe water level around gulley.
- If water is rising increase pump speed.
- If over pumping reduce pump speed.
When the system is slightly over pumping
Press and hold the MODE Button firmly
until green light flashes.
The pump will stop temporarily whilst the
setting is stored.
Press MODE Button once
LED shows 50 (Pump Speed Narrow)
Dry-Deck 20 Set Up
Continued
Increase flow by 2 ltrs/min as shown on the LED
Re-enter ‘Pump Speed’ Narrow
Observe water level around gulley.
- If water is rising increase pump speed.
- If over pumping reduce pump speed.
When the system is slightly over pumping
Press and hold the MODE Button firmly until
green light flashes.
The pump will stop temporarily whilst the setting
is stored.
Press MODE Button once.
LED shows AS (Auto Sense)
Turn off shower. 30 seconds after pump starts
drawing air into gulley press and hold MODE
Button firmly until green light flashes.
Press MODE Button once.
LED shows - -
Turn on Shower.
Maximum flow?
Dry-Deck 20 Set Up
Continued
Press MODE Button until orange Start Delay lights.
Turn on shower
Turn shower off. After water has drained
press up arrow to increase Start Delay.
Press and hold MODE Button firmly until orange
light flashes.
Press MODE Button until LED shows flow
rate/sensor indicator.
Turn shower off. System should shut down as
previously set.
FINISH
To Exit Mode Setup: Press and release MODE Button until MODE indicator LEDs are all blank
Does pump start before
water fills gulley?
No
No
Yes
Yes
Start delay
Set-up
Pump
Speed
Set-up
(Wide)
Dry Deck 20 Set Up Flow Chart
Exit Mode
Setup

1.14 The Whale Gulper pump uses a single
membrane to pump the water away. On the
suction stroke, water and debris are drawn in
through the inlet valve. With a chamber full of
water the pump discharges the water
through the two non-return valves on the
outlet. The two outlet valves protect the
pump against losing prime. The aggressive
flushing keeps the pump valves clear of
debris resulting in a pump which does not
require regular maintenance.
Unlike other pumps, the Whale Gulper has
the ability to run dry without causing damage
to the pump.
An additional advantage of the three
nonreturn valves in the pump head, is that no
smells can be passed back from the waste
stack into the shower area.
16
Pump Operation
1.16

17
The Dry-Deck 20 product is guaranteed for two
years from date of purchase against defects in
materials and workmanship. If the system proves
faulty, return it to your distributor with proof of
purchase and purchase date. The manufacturer
cannot be held responsible for claims arising from
incorrect installation, unauthorised modification or
misuse of the product. Incorrect installation may
invalidate the warranty.
For full warranty statement please see website.
Description of Equipment: Dry-Deck 20
Shower Drain System
Manufacturer’s Declaration
We hereby declare, under our sole responsibility,
that the above equipment complies with the
provisions of the following EC Directives.
Electromagnetic Compatibility Directive
89/336/EEC, amended by 92/31/EEC and
93/68/EEC on the approximation of the laws of the
Member States relating to electromagnetic
compatibility.
Low Voltage Directive 73/23/EEC amended by
93/68/EEC on the harmonization of the laws of the
Member States relating to electrical equipment
designed for use within certain voltage limits.
CE mark affixed: 03/06/05
Basis on which conformity is declared
The above equipment complies with the protection
requirements of the EMC Directive and the
principal elements of the safety objectives of the
Low Voltage Directive.
Standards applied
EN 60335-1:2002/A11:2004 Safety of household
and similar electrical appliances
EN 60335-2-41:2003 Particular requirements for
pumps
EN 55014-1:2000 Electromagnetic compatibility.
Requirements for household appliances, electric
tools and similar apparatus. Emission
EN 55014-2:1997 Electromagnetic compatibility.
Requirements for household appliances, electric
tools and similar apparatus. Immunity.
Signed (Authorised Person)
Please contact the Whale Technical Helpline
0845 0694 253 for help with any queries
Signed
David Cresswell
Engineering Director
Munster Simms Engineering Ltd.
277-279 Old Belfast Road
Bangor, Co. Down, BT19 1LTN
Warranty
EU Declaration of Conformity

The Dry-Deck 20 stores information on the
software version and on the usage of the pump.
This information may be accessed by pressing the
up arrow while not in any Set Up mode.
The fields are displayed on the 7-segment LEDs as
follows:
00 - Not currently used
14 - Software version / software revision
ER - (field separator) ‘Error’
01 - Error code (Object location)
02 - Error code (Object ID)
PP - (field separator) ‘Pump Powered’ time
01 - Hours powered 100,000’s, 10,000’s
02 - Hours powered 1000’s, 100’s
07 - Hours powered 10’s, 1’s
22 - Minutes powered 0 - 60
PO - (field separator) ‘Pump On’ time
02 - Hours pumping 1000’s,100’s
07 - Hours pumping 10’s, 1’s
22 - Minutes pumping 0-60
PC - (field separator) ‘Pump Cycles’
12 - Pump cycles (1000’s, 100’s)
10 - Pump cycles (10’s, 1’s)
-- - (field separator)
returns to normal display
Status display mode will be exited if the keys are
inactive for a period greater than 10 minutes
(same as configuration mode).
Status display will be exited if either the mode or
decrement key is pressed.
Status display will be exited when all the fields
have been scrolled through.
Last Error Code
Two bytes representing the last recorded is
automatically erased after it has been viewed once.
Duration Powered
This is a record for the length of time the system
has had power applied to it. It consists of hours
and minutes (see opposite).
Total Pump Run Time
This is a record for the length of time the pump has
been running. It consists of hours and minutes
(see opposite).
Total Pump Cycles
This is the total number of times the pump has
been activated (0-9999).
Currently this is set to increment every time the
pump is turned on following an off state so a purge
cycle will also trigger the count. (The software
could discriminate if required).
18
Dry-Deck 20 Status Information

19
Pump will not startPump will not stop
Set ‘Pump Speed’ and ‘Auto Sense’ settings
No further action
Repeat Set up. If pump
does not turn off replace
control unit.
Does Pump stop when water is turned off?
Has pump speed been set?
The ‘Pump Speed’ must be programmed
(by adjusting speed using up and down
arrows and programming in value by holding
down the mode key) before the Auto Sense
off delay is programmed.
When power is switched on the LED’s on the
control unit will all illuminate. The software version
will then be shown on the two digit display briefly
before two digit display will alternatively blink on
and off.
Turn shower on
Does Pump Start?
Follow
Set up
instructions
Check cable and
connections to pump.
If no voltage on pump
terminals. Replace
Control Unit
If voltage on pump
terminals check polarity
on pump.
Check connections on
sensor.
If still no indication with
water flowing replace
flow sensor.
2 Digit display should
indicate ‘1’ in first digit for a
sensor in ‘FS1’ connections
and ‘2’ in second digit for a
sensor in ‘FS2’ connections.
Is sensor shown on
2 digit display
Is there power on
control unit?
Check power is
switched on to
Control Unit.
Check power
connections on
Control Unit.
Check internal fuse
in Control Unit.
Press MODE
Button once.
LED shows AS
(Austo Sense)
No
Yes
Yes
No
No
Yes
Yes No
What is the fault?
Pump does not pump properly
Check flow rate
of shower.
The pump is
capable of
8 ltrs/min on
15mm (electric
showers only) or
12 ltrs/min on
22mm (mixer
showers only).
If the flow rate is
exceeded it must
be reduced.
Check the
tricuspid valve on
pump discharge
is closed and
undamaged.
Ensure fittings
are locked and
airtight.
Ensure inlet or
outlet pipework is
not blocked.
Remedy any
problems.
Strong
suction is felt
Low or no
suction is felt
Suction is
intermittent
Check suction at pump inlet.
Strong suction
felt
Inlet pipe is blocked
when debris, usually
a screw cap, pivots
in the pipe vertically
to block it. Once the
pump stops it falls
horizontal and allows
the pump to suck
when used next.
Rod or blow back
down the inlet pipe
until debris appears
in the gulley.
Low/ no
suction felt
Remove pump head by removing the
blue retaining clamps. Examine the
inlet and outlet flap valves for traces of
hard debris such as grout. Wash out
debris and ensure the valves are
seated correctly. Check diaphragm is
undamaged. These rubber parts are
contained in Service Kit AK1550.
Check the tricuspid valve
on pump discharge is closed
and undamaged.
Ensure fittings are locked
and airtight.
Ensure outlet pipework is
not blocked.
Remedy any problems.
Does this solve
the problem?
Yes, no further
action
Ensure that no hair or debris blocks the gulley.
Assess the suction at the waste fitting in the
tray by placing your hand over it or over the
gulley hole.
No
Dry Deck 20 Fault Diagnosis Chart

20
Control Unit - 755.176
Pump - SDS041T