One of the things which is coming out of our (free!) training sessions is that it’s not always possible to install our Zone Guardian strictly in accordance with the instructions… which, funnily enough, might mean that there are problems down the line… we cover all of this in our sessions, and will be producing some videos shortly, but here are our top tips for success:
PUMP ORIENTATION: the main issue appears to be around orientation, especially when installing in a horizontal position. Our instructions state that the flow switch should be on top…but actually, the flow switch can be in any position as long as you can maintain it, and it has been tested as working with a water flow. The instruction is intended to ensure that the pump shaft is in a horizontal position, because only then can the pump run, vent and cool effectively – any other position, and the pump will not work properly and may seize, perhaps permanently. As you can’t really see the pump shaft, we can also say that the front label plate should be vertical. This is the first and main thing to ensure.
Top Tip: if you need to install the pipe assembly at a ‘strange angle’ when horizontal, then simply loosen off the large pump connector nuts slightly, rotate the pump until the label plate is vertical, and re-tighten the nuts.
PUMP VENTING: another common issue seems to be venting – either insufficiently when commissioning, or re-venting after a drain-down for instance. The Grundfos pump we use has no bleed valve, because it is self-venting – this means it will expel all air; however it can’t make air disappear, it has to have somewhere to go! In a vertical install, this is relatively easy as it shoots up the pipe; but in a horizontal install, the pump needs to be run for a few minutes with the uppermost valve open.
Top Tip: rather than trying to ‘crack’ the valve, or attaching a hose to a bucket or drain, we use an automatic air release valve (as used on a heating system or dry riser – available for under £10) in our test room – this can be attached to the valve, valve opened and any air can be released as it passes without the need to drain lots of water…every ZG toolkit should have one!
STATIC MAINTENANCE: this is often overlooked, and becomes more of a problem when commissioning and active use may be some months (or, for large projects, over a year) after the actual installation. Grundfos recommend that, after installation and prior to any attempted use, the impellor is turned by hand to ensure it’s free before turning on the pump.
Top Tip: this is easy to do, using a PH2 driver through the centre of the front label – push (it only moves 2-3mm) and turn a couple of times, and you’re good to go.
LOOK & LISTEN: when the pump is running well and full of water, you will hear a gentle hum with a background hiss, and the flow switch lever will move firmly to its operating position. If the pump is gurgling and hissing (symptom of air), or ticking every few seconds (symptom of being stuck), or the flow switch lever is wavering (usually a symptom of air) then check the other tips given here.
We’re highly confident that if the above hints and tips are following, you and your clients will enjoy trouble-free Zone Guardian remote test technology… if you’re not sure, then please do Contact Us or, even better, book onto one of our free training sessions.