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Ultraflow Macerator

Instruction Manual

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Please keep this instruction manual for future reference.

C>Grafton Group PLC Page 1 of20

UL TRAFLOW MACERATOR

INDEX

1. Declaration of Conformity

2. Specification

3. Safety Instructions

4. Product Description

5. Operating Principle

6. Parts Listing

7. Installation

8. Troubleshooting

9. Clearing Blockages

10. Clearing a Pressure Tap Chamber Blockage

11. Replacing the Air Switch

12. Appliance Disposal

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1. DECLARATION OF CONFORMITY

We www.plumbworld.co.uk declare that the Ultraflow Macerator product is in conformity with the following directives to specification under which conformity is declared.

The Low Voltage Directive (Directive 2006/95/EC)

EMC Directive (Directive 89/336/EEC)

CE Marking Directive (Directive 98/37/EC)

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2. SPECIFICATION

Water temperature 1 degree centigrade (minimum) / 90 degrees centigrade (maximum)

Voltage 220v-240v

Amperage 3Amps

Motor Power 600Watts

Thennal Safety Device 135 degrees centigrade

Discharge head 6mws

Capacitor 10uF/450 Volts

Water Ingress Protection IPX4

Flow rate at pump output 270 litres/ minute

Maximum discharge height 5.5 metrest

Maximum discharge horizontal length 60 metrest

*Product compliant with standard EN 12050-3

j ~

tAllow a reduction of 0.5m per bend introduced, see Fig A for example.

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.., @, :§, ..c

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.., E 0 ..c

l w ~ E m E "? N E "' ' E "? "? .,, "' II 1,

Fig A

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3. SAFETY INSTRUCTIONS

Prior to installation

• Ensure the entire contents of this instruction manual are read.

• Ensure the package contains all component parts listed in this instruction manual. • Ensure the two check valves stored inside the rubber chamber of the appliance are removed.

• Ensure all packaging material is removed and disposed of correctly.

Installation

• Electrical installation of the appliance must only be carried out by a qualified person.

• The appliance must be installed in accordance with the installation instructions specified in this document.

• Always ensure the macerator is connected to mains power before water enters the unit.

Prior to use

• Before using the macerator, clean water must be flushed through the appliance several times. This will ensure the macerator is correctly installed.

Daily use

• The appliance is suitable for domestic, indoor use only.

• The appliance is suitable for the discharge of domestic faecal matter, waste water and toilet paper only. Failure to comply with this will invalidate the warranty.

• Products not to be discharged using the appliance include but are not exclusive to: kitchen towels, wet wipes, cotton wool, condoms and sanitary towels.

Servicing and maintenance

• Before servicing the appliance, always ensure the electrical supply is fully disconnected.

• Troubleshooting, maintenance and servicing of the appliance must only be carried out by a person who is competent to do so.

• To maintain optimum performance, it is recommended that the appliance is serviced and cleaned at least once every 6 months.

• For hygiene reasons, rubber gloves should be worn at all times when servicing the appliance.

WARNING: This appliance must only be used with a 32mm or 40mm waste pipe from the outlet to the soil stack. It is not suitable for use with 22mm or 25mm pipework. Using the macerator with an incorrectly sized waste may result in a leaking unit.

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INVALIDATION OF WARRANTY

Please note that any one of the following situations will invalidate the product warranty:

• Failure to install the appliance in accordance with the installation instructions contained in this document.

• Electrical installation of the appliance by an unqualified person. • Discharge of materials other than faecal matter, waste water and toilet paper through the

appliance. • Failure to carry out regular maintenance and servicing of the appliance as detailed in these

instructions.

4. PRODUCT DESCRIPTION

The Ultraflow Macerator is designed for the purposes of discharging normal domestic faecal waste, waste water and toilet paper in accordance with the relevant regulations.

It is compatible for use with a maximum of three bathroom items, including:

• 1 x basin

• 1 x shower

• 1 x toilet

OR it can be used to discharge waste from any one of the following:

• 1 X bath

• 1 x kitchen sink

• 1 x washing machine

• 1 x dishwasher

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5. OPERATING PRINCIPLE

The macerator comprises a tank that holds waste before it is discharged, and an electric pump. The pump is controlled by an automatic pressure switch. As with a conventional toilet, the discharge action is triggered when the flushing system is actuated.

• Domestic waste is collected in the tank (A). • The air chamber (B) records the air pressure flowing through the outlet pipe (C) to the

pressure switch (D). • The pressure switch (D) trips the motor (E). The motor drives the turbine (F). • Domestic waste is discharged through the outlet (G).

CONTROL COMPONENTS: D - Pressure Switch

MECHANISM COMPONENTS: E - Electric Motor F-Turbine

CONTROL COMPONENTS AND SAFETY DEVICES: G - Check Valve H - Manual Override Switch

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6. PARTS LISTING

The Ultraflow Macerator includes the following component parts:

1 - Case 2- Tank 3- Air Switch 4- Motor Assembled Part 5- Locknut 6- Flange 7- Gasket The appliance is also supplied

8- Mechanical Seal with the following spare parts:

9 - Open Impeller 10 - Injector 3 x clamping ring

11 - Outlet Pipe 3 x blanking caps

12 - Cable and Plug 2 x check valve

13- Cable Gland 14- Case Cover 15- Unilateralism Valve 16- Manual Override Button 17 - Clamping Ring

Case Cover

Tank I \

Impeller Motor Assembled Part

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7. INSTALLATION

ELECTRICS: Do not connect the macerator to a conventional plug and socket. The appliance must be wired to a wall-mounted fused connection unit, positioned close by.

The cable is connected to the load terminals of the fused connection unit as follows:

1) 2) 3)

Brown - Live Blue - Neutral Green/Yellow- Earth.

4) Fit a 5 Amp fuse to the fused connection unit.

5) THIS APPLIANCE MUST BE EARTHED

HYDRAULICS: The macerator is only compatible for use with a toilet with a horizontal outlet. It must also have a tank or flushing tap.

Please note: In accordance with European standards, the centre of the horizontal outlet must be 18cm above floor level. See image below.

NB. DISCHARGE PIPEWORK

Discharge pipe length to the first elbow MUST be a minimum of 0.6 metres.

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CONFIGURATION WITH TOILET ONLY

Clamp with jubilee clip supplied

Discharge pipe mustbe32mm or40mmonly

NOTE DIRECTION OF ARROW ON CHECKVALVE­POINTING UPWARDS

Secure macerator to pan with large jubilee clip, ensuring it is fully tightened

1) Place the horizontal toilet outlet inside the rubber sleeve of the macerator. Clamp the outlet and sleeve using one of the jubilee clips supplied.

2) Place the discharge pipe inside the rubber outlet. The discharge pipe must be 32mm or 40mm in diameter. Clamp the discharge pipe and rubber outlet using one of the jubilee clips supplied.

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CHECK VALVE

In all situations, the check valve must be fitted as closely to the macerator as possible. Please note: the pipe length from the check valve to the macerator must never exceed 30cm. This 30cm must include the total length of pipework when fully seated in the centre ridge of the check valve. Once in position, seal the connection with two of the jubilee clips supplied.

Please see the diagram below.

30

l Macerator

Check Valve

pipe work is fully seated into both the Macerator and the check valve

An arrow on the side of each check valve indicates the correct direction of frtment.

If fitted vertically, the direction of the arrow should point upwards - away from the macerator. If fitted horizontally, the direction of the arrow should point away from the macerator (excluding showers - please refer to 'Configuration with toilet and other appliances').

The surface labelled with the arrow must always face upwards to prevent backflow. Please see below.

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CONFIGURATION WITH TOILET AND OTHER APPLIANCES

Bathroom Basin

Washing Machine, Dishwasher, Utility Sink

Bath, Shower, Bidet

Discharoe Pioe

Toilet

Connect the discharge pipes of each appliance to the rubber connectors provided. Now clamp with jubilee clips.

For use with a bath or shower, there must be a sufficient slope from the bottom of the shower tray or bath outlet to the macerator. This gradient must be 1cm per metre or greater. Failure to install the appliance with the correct gradient will prevent waste from being discharged.

If used with a shower, the second check valve must also be used. This must be fitted between the shower tray and the macerator. It is essential that the arrow displayed on the check valve points away from the shower tray, towards the macerator.

When connecting other appliances along the discharge line, check valves must be installed on each discharge pipe. This is important to prevent waste return. The horizontal slope along the discharge line must also be installed with a gradient of at least 1cm per metre.

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8. TROUBLESHOOTING

The Ultraflow Macerator is designed to discharge faecal matter, waste water and toilet paper only. Using the appliance to discharge any other materials may cause the unit to fail. This is the main cause of breakdowns.

The majority of problems that may arise during usage can be resolved with the help of the Troubleshooting guide below.

WARNING: Troubleshooting, maintenance and servicing of the appliance must only be carried out by a person who is competent to do so. If you are in any doubt, please seek professional assistance.

TROUBLESHOOTING GUIDE

Sl!!!!l!toms Causes Remedies

The macerator has The motor has Leave the unit to cool down for at least 30

switched itself off. overheated. This has minutes. Switch it back on. Press and activated the thermal hold the override switch for at least 30 cut out switch. seconds. This will reset the machine.

Check the machine for any internal blockages.

The electrical power supply has been Check the fuse and power supply. interrupted.

Water is back-flowing There is an insufficient Ensure a gradient of at least 1 cm per into the shower/ bath. gradient between the metre between the shower tray / bath

shower tray / bath outlet outlet and the macerator. and the macerator.

The unit is leaking. The check valve is not Ensure the check valve is fitted in fitted. accordance with installation instructions.

Jubilee clips or blanking Ensure that all jubilee clips and blanking caps a re fitted caps are fitted correctly. incorrectly.

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The macerator is non- The macerator is Reconnect to a 32mm or 40mm waste operational. It has connected to an pipe. never operated. incorrectly sized waste

pipe. Ensure the unit is installed by a qualified person.

The electrical installation of the appliance Is Incorrect.

Ensure the arrow on the check valve is facing the correct direction.

The check valve is Press and hold the override switch for 30 facing the wrong seconds to reset the unit. direction.

Check the pressure switch and replace if The pressure switch is necessary. partially blocked.

The pressure switch has developed a fault.

The macerator is not The discharge pipes are Check pipework. If necessary, refit powerful enough or is too long or too high. discharge pipes. discharging waste too slowly. The discharge pipe Check pipework. If necessary, refit

diameter is too small. discharge pipes.

The unit is partially Actuate the pump by using the manual blocked. override switch. If the problem continues,

the pump could be blocked. Check the pump and clean if necessary.

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The macerator emits a The pump is blocked. Check the pump. humming noise but does not discharge the The check valve is Reinstall the check valve the correct way waste. installed the wrong way round.

round.

The macerator starts There is a defect with Examine check valve and replace if running and the check valve. necessary. discharging waste without demand. A leak in the flushing Repair the leak from the flushing tank.

tank is causing water to flow into the macerator. This is causing it to run intermittently. Clear the blockage.

A partial blockage in the pressure valve tube is causing the macerator Check the pressure switch. Replace if to think water is inside necessary. the unit.

There is a pressure switch defect.

The macerator is not The macerator is not Check the macerator's electrical emitting a humming property connected to connection. noise. the electrical supply.

Press the manual override switch several The pressure switch is times. If the appliance starts to run, check not properly connected the connection of the pressure switch and to the electrical supply. pressure switch line.

The motor is non- If pressing the manual override switch has operational. no effect, check the motor and replace if

necessary.

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The macerator is The vertical discharge is Install a check valve to the vertical running continually. fitted without a check discharge.

valve. Ensure the check valve is fitted within

The check valve is fitted 30cms of the macerator. too far away from the macerator. Check that 'floppy paddle' inside check

valve is connected and moving freely. There is a defect with Replace if necessary. the check valve.

Check the pressure switch and replace if necessary.

There is a defect with Check the vertical tube inside the sealed the pressure switch. rubber chamber. Ensure this is not

blocked. The pressure switch pipe is blocked.

PRESSURE SWITCH INSPECTION

To fully inspect the pressure switch, locate the pressure tap chamber in the rubber tank. Press it down to create pressure and listen for a clicking sound. This indicates that the motor has switched on.

If there is no click, inspect the air chamber and pressure switch pipe nozzle for any leaks or blockages.

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9. CLEARING BLOCKAGES

WARNING: Always ensure the electrical supply is fully disconnected before attempting to clear a blockage.

IMPORTANT: Only a competent person should attempt this operation. If you are in any doubt, please seek professional assistance.

To successfully clear blockages without damaging the macerator, carefully follow the step-by-step guide below. This operation requires the following tools:

• Pliers • Flat blade screwdriver • Cross head screwdriver • Rubber gloves

• Siphon or 'wet' vacuum cleaner • A bucket

1) Fully disconnect the unit from the electrical supply. 2) Drain the unit using the siphon or "wet' vacuum cleaner. 3) Loosen the hose clips with pliers. Disconnect the inlet and outlet connections. 4) Loosen the large hose clip securing the unit to the pan. Detach the appliance. 5) Remove the lid from the appliance by undoing the fixing screws. 6) Remove the black rubber tank and motor as a complete unit. 7) Once removed, separate the black rubber tank from the motor. 8) Thoroughly clean the black rubber tank. 9) Remove the turbine casing. 10) Clear all debris from around and behind the turbine. 11) Ensure the turbine moves freely by turning it carefully. Note: the electrical motor will offer

some resistance. 12) Reassemble the motor unit. 13) Temporarily reconnect to the electrical supply. Check that the motor operates by pressing the

manual override button. This can be found on the lid. 14) Reassemble the unit fully and reinstall.

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10. CLEARING A PRESSURE TAP CHAMBER BLOCKAGE

WARNING: Always ensure the electrical supply is fully disconnected before attempting to clear a blockage.

IMPORTANT: Only a competent person should attempt this operation. If you are in any doubt, please seek professional assistance.

To successfully clear a pressure tap chamber blockage without damaging the macerator, carefully follow the step-by-step guide below. This operation requires the following tools:

• Pliers • Rubber gloves

• Rod

1) Remove the macerator lid by undoing the fixing screws. Locate the plug on the top of the main tank (Fig. 1).

2) Loosen the hose clip with pliers. At the same time, remove the plug from the top of the pressure tap chamber (Fig. 2).

3) Examine the end of the plug to ensure it does not contain debris (Fig. 3). 4) Rod out any debris inside the pressure tap chamber, (Fig. 4). 5) Reassemble the unit. Loosen the hose clip once more, using pliers. Whilst doing so, push the

plug back into the top of the pressure tap chamber and ensure it is fully in place. Release the pliers, allowing the hose clip to clamp the plug in the top of the chamber. This is essential as the appliance will not function without an airtight seal.

6) Replace the lid and fixing screws. Now test the appliance.

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11. REPLACING ntE AIR SWITCH

NOTE: If clearing the Pressure Tap Chamber does not rectify the problem, the appliance will require a new air switch.

WARNING: Always ensure the electrical supply is fully disconnected before attempting to clear a blockage.

IMPORTANT: Only a competent person should attempt this operation. If you are in any doubt, please seek professional assistance.

To successfully replace the air switch without damaging the macerator, carefully follow the step­by-step guide below. This operation requires the following tools:

• Pliers • Rubber gloves

1) Remove the lid by undoing the fixing screws (Fig. I). Locate the rubber air switch chamber. 2) Now find the clear air pipe. Using pliers, loosen the hose clip at the point where the hose

enters the air switch chamber (Fig. II). Slide the hose clip back down the clear hose. 3) Peel back the edge of the rubber air switch chamber. Remove the white plastic plate to

expose the air switch (Fig. Ill). 4) Pull the electrical connections off the terminals on the air switch. 5) Peel the rubber air switch chamber back and remove the air switch from inside (Fig. IV). 6) Remove the replacement air switch from its packaging and locate the spigot. This will project

from the main body of the switch. 7) Insert the spigot into the end of the clear hose where it projects through the wall of the rubber

air switch chamber. Ensure the spigot is securely in place. This is essential as the new switch will not function without an airtight seal.

8) Ensure the new switch sits in the bottom of the rubber air switch chamber. The two electrical terminals should point towards you. Now reconnect the electrical connections to the corresponding terminals.

9) Insert the white plastic plate into the top of the rubber chamber. Ensure the edges of the chamber completely trap the edge of the plate.

10) Loosen the hose clip, using pliers, and slide it back up the hose into position over the spigot. Release the pliers, allowing the hose clip to clamp the air switch chamber and clear hose together. This is essential as the appliance will not function without an airtight seal.

11) Complete reassembly of the appliance by replacing the lid and fixing screws. The macerator can now be tested.

Please refer to the following page for a visual guide to replacing the air switch.

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12. APPLIANCE DISPOSAL

When the product reaches the end of its service life, it cannot be treated as an ordinary item of household waste. It must be taken to a waste recovery centre for disposal.

The symbol on the appliance indicates that it meets the new directive 2002/95/EC 2002/96/EC 2003/108/EC and must be handled in accordance with these standards at the end of its service life.

Customer Care Helpline

Our customer care centre can be contacted during normal working hours. For spare parts and after sales service, proof of purchase must be provided.

The terms and conditions of our after sales service are available upon request. Please contact our customer care line for further information.

Tel: 0844 03766 0111

Email: customerservices@plumbwortd.co.uk

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