INSTALLATION AND MAINTENANCE INSTRUCTIONS Zonecheck Flow Switch Tester 3825 Ohio Avenue, St. Charles, Illinois 60174 1-800-SENSOR2, FAX: 630-377-6495 www.systemsensor.com Specifications Static Pressure Rating: 175 PSI Operating Temperature Range: 32°F–120°F (0°C–49°C) Compatible Pipe (Manifold Models): Schedule 10, 2″–4″ diameter Compatible Pipe (Retrofit Models): Schedule 10 and 40, 2″–8″ diameter (50 mm through 200 mm) Service Use: Inspection, Testing and Maintenance of Water-Based Fire Protection Systems: NFPA 25; National Fire Alarm Code: NFPA 72 Manifold Assembly Length (Manifold Models): 25.6″ (65 cm) Component Connections: Manifold Models: Retrofit Models: 2 ea. - 1″ NPT/25mm 2 ea. - 1″ NPT/25mm British Standard British Standard Thread elbows Thread elbows 2 ea. - 25mm British Standard Thread elbows Valves: Red: Standard valve Green: Contains check valve Warranty: 3 years Electrical Specifications Pump Operating Voltages: Important Please Read Carefully And Save This instruction manual contains important information about the installation and operation of a Zonecheck Flow Switch Tester. Purchasers who install waterflow detectors for use by others must leave this manual or a copy of it with the user. Read all instructions carefully before beginning. Follow only those instructions that apply to the model you are installing. shall provide grooved ends for accepting the appropriate grooved connection fittings. Manifold assembly shall include no less than two drain ports with the appropriate drain plugs. Manifold Zonecheck models shall come with the pump, valves, elbows, pipe assembly, drain plugs, and System Sensor waterflow detector pre-assembled. Domestic/Canadian models: 1.63A@110 V, 60 Hz International models: .88A@220 V, 50Hz Key Switch Operating Voltage: ZCK-1 110V, 60Hz; ZCK-1E: 220V, 50Hz Key Switch Mounting Options: Includes back box for surface or flush mounting. For pre-wiring, use a 411/16″ x 411/16″ back box Key Switch Operation Modes: Self-test: Wired locally Group test: Interconnected Key Switch LED Operation: Ready state: No LED Test Initiation: Green LED Flow switch activation: Red LED Manifold Models Domestic Models with 110 V Pump ZC20, ZC25, ZC30, ZC40 Canadian Models with 110 V Pump ZC20A, ZC25A, ZC30A, ZC40A CAUTION Retrofit Models Domestic Models with 110 V Pump ZCR20 ZCR25 ZCR30 ZCR40 ZCR60 ZCR80 Use Zonecheck Flow Switch Testers in wet-pipe systems only. Do NOT use them in dry pipe, deluge, or preaction systems. Do not use in potentially explosive atmospheres. Do not allow unused wires to remain exposed. Principles Of Operation Retrofit Model Zonecheck Flow Switch Tester shall mount on any clear steel pipe span of the appropriate nominal size, either in a vertical upflow or horizontal run, between 6″ and 12″ from the flow switch. Flow Switch Tester shall consist of a recirculating pump, operating at nominal 110V or 220V as appropriate, two (2) sets of valves and elbows to facilitate the circulation of the water, a System Sensor vane-type waterflow detector, and a key switch to activate the recirculating pump. When activated, the pump shall circulate the water within the sprinkler riser around the waterflow detector vane to simulate the flow of one sprinkler head in operation. The activating key switch shall provide the means to be wired locally to one Flow Switch Tester, or interconnected with other key switches for group activation. Flow Switch Tester shall be available for manifold and retrofit installation applications. Canadian Models with 110 V Pump ZCR20A ZCR25A ZCR30A ZCR40A ZCR60A ZCR80A Replacement Parts ZCK-1 Zonecheck 110V Keyswitch ZCP-110 Zonecheck 110V Pump International Models with 220 V Pump ZCR20E ZCR25E ZCR30E ZCR40E ZCR60E ZCR80E ZCK-1E Zonecheck 220V Keyswitch ZCP-220 Zonecheck 220V Pump CAUTION Do NOT install Zonecheck on copper piping. General Installation Recommendations Before installing any waterflow-related device, be thoroughly familiar with: NFPA 72: National Fire Alarm Code NFPA 13: Installation of Sprinkler Systems, Section 3.17 NFPA 25: Inspection, Testing and Maintenance of Sprinkler Systems Manifold Model Specifications Zonecheck Flow Switch Tester manifold models shall consist of a schedule 10 pipe assembly of the appropriate nominal size. Manifold assembly D770-32-00 1 I56-0053-003R Other applicable NFPA standards, local codes, and the requirements of the authority having jurisdiction also apply. Failure to follow these directions may prevent the device from reporting the flow of water in the event the associated sprinkler system is activated by a fire. System Sensor is not responsible for devices that have been improperly installed, tested, or maintained. 1. Mount the Zonecheck Flow Switch Tester where there is adequate clearance for installation and removal and a clear view of it for inspections. 2. When installing a manifold model, locate 6 to 7 feet above the floor to protect from possible damage. When installing a retrofit model, mount between 6″ and 12″ from the flow switch. 3. On horizontal runs, orient the Zonecheck Flow Switch Tester on the side of the pipe only. Failure to do so may impair the operation of the Zonecheck pump (see Figure 1). For vertical flow applications, mount the Zonecheck Flow Switch Tester on pipe through which water flows upward. Otherwise, the unit may not operate properly. 4. Mount the Zonecheck Flow Switch Tester at least 6 inches from a fitting that changes the direction of water flow and no less than 24 inches from a valve or drain. 5. Be sure the direction-of-flow arrow shown on the saddle matches the direction of the waterflow in the pipe. 3. CAUTION Before installing a Zonecheck Flow Switch Tester: 1. Contact central monitoring station or appropriate fire safety personnel before installing the Zonecheck Flow Switch Tester. 2. Identify and close tightly the sprinkler system’s zone valve. 3. Close both (Red & Green) Zonecheck valves. 4. Drain the sprinkler zone. 4. Installation Guidelines Manifold Model 1. Remove the assembled manifold unit from the carton. 2. Prepare to install the manifold unit to the riser. If mounting the manifold unit to a vertical riser, orient the assembly with the red valve above the Zonecheck pump. If mounting the manifold to a horizontal waterflow pipe, orient the assembly with the red valve on the downstream end of the waterflow pipe (see Figure 1). Verify that the stripes on the Zonecheck pump housing will be parallel to the floor after installation. If Zonecheck will be located on a horizontal pipe, ensure that the waterflow detector, once mounted, will be located on the topside of the pipe (see Figure 1 for illustration). Ensure that the intended location does not result in the detector being mounted upside down, as water may collect in the housing and impair the operation of the detector. 3. Mount the Schedule 10 pipe (to which the Zonecheck pump and Waterflow Detector are mounted) to the riser using industry-accepted practices in conjunction with applicable NFPA standards, local codes, and the authority having jurisdiction. 4. Refer to the wiring schematic for proper electrical connections for stand-alone or multiple unit keyswitch installation. 5. 6. Retrofit Model 1. Remove contents from the carton. 2. Assemble the Zonecheck unit. If the mechanical tees used to attach the Zonecheck unit to the sprinkler pipe have a British Standard Pipe Thread (BSPT) outlet, select the elbows contained within the bag marked ‘BSPT/BSPT’. If the mechanical tees have an NPT thread outlet, select the elbows contained within the bag marked ‘NPT/BSPT’ (Note: the embossed ‘A’ on the elbow designates the NPT thread). Choose the appropriate elbows. Connect the BSPT threaded end of the 90-degree elbows to each of the Zonecheck valves, insert the gasket into the valve, and connect each valve to the correct side of the Zonecheck pump. Each valve has a female BSPT threaded end (connected to the elbow) on one side and a male union (connected to the D770-32-00 7. 8. 9. 2 Zonecheck pump) on the other. IMPORTANT: There are two Zonecheck valves enclosed with each Retrofit kit: 1.) A ‘Red’-handled valve, which is a standard valve that serves as an inlet valve; and, 2.) A ‘Green’-handled valve, which is an outlet valve that contains a check valve. The valves must be oriented properly for Zonecheck to work correctly. If mounting Zonecheck to a vertical riser, attach the Red valve so that it will be above the pump, as the assembly would appear after installion (See Figure 1 for illustration). If mounting Zonecheck to a horizontal run of pipe, attach the red valve so that it will be downstream, in relation to the sprinkler system waterflow, from the Zonecheck pump (See Figure 1 also). Attach the mechanical tees (supplied by others), ensuring that both tees are parallel to each other and perpendicular to the Zonecheck assembly. Ensure that all joints are tight and set the entire assembly aside. Place the aluminum angle template on the pipe (leg ends contacting pipe surface) locating one edge of the leg where the mechanical tee holes will be drilled. Scribe or draw a pencil line on the pipe the full length of the template. Note: Ensure that both legs of the aluminum template are in complete contact along their entire length with the pipe surface to ensure that the scribed line will run along the center line of the pipe. Failure to follow this step may cause damage to the Zonecheck product or leakage. Measure the center-to-center distance between the mechanical tees and transfer that measured distance to the scribed line on the pipe surface. IMPORTANT: Ensure that the markings on the pipe are located so that the stripes on the Zonecheck pump housing will be parallel to the floor after installation (See Figure 1 for installation). Failure to follow this step may result in pump seizure. The Waterflow detector will typically mount to the pipe 90 degrees from the location of the pump, as space permits. To determine the location of the flow switch, scribe a second line parallel to the line made in Step 3 and mark the midpoint between the mechanical tees This intersection line will locate the hole for the waterflow device. Ensure that this location will permit access to both the detector and the Zonecheck assembly. If located on horizontal pipe, ensure that the waterflow detector, once mounted, will be located on the topside of the pipe. Ensure that the intended location does not result in the detector being mounted upsidedown, as condensation may collect in the housing and impair the operation of the detector. See Figure 1 for illustration. Refer to the suggested hole size requirements from the mechanical tee manufacturer and the waterflow manufacturer and drill the three holes where marked in Steps 4 & 5. IMPORTANT: Before drilling, verify that the stripes on the Zonecheck pump housing will be parallel to the floor after installation, as noted in Step 4 (See Figure 1 for illustration). When drilling the holes with a hole saw, make certain that the center of the cut does not remain in the pipe. Clean the outside of the pipe to remove dirt, metal chips, and cutting lubricant. Mount the completed Zonecheck assembly to the sprinkler pipe. Secure the U-bolts of the mechanical tees and tighten to manufacturer’s recommended torque. Remove the waterflow detector from the carton and install on pipe. The direction-of-flow arrow shown on the saddle must match the direction of the waterflow in the pipe. Refer to the manufacturer’s instructions for mounting the waterflow detectors. Refer to the wiring diagram (see Figure 2.) for proper electrical connections for stand-alone or multiple unit keyswitch installation. I56-0053-003R Figure 1. Zonecheck Installation WATERFLOW DETECTOR ZONECHECK PUMP RED VALVE RED VALVE WATERFLOW DETECTOR GREEN VALVE ZONECHECK PUMP CORRECT Pump stripes (horizontal) Correct Horizontal Installation GREEN VALVE Correct Vertical Installation INCORRECT Pump stripes (vertical) ZONECHECK PUMP ZONECHECK PUMP Incorrect Horizontal Installation Incorrect Horizontal Installation Figure 2. Wiring Diagrams FOR INTERCONNECTING MULTIPLE ZONECHECK UNITS TO EARTH GND. OR ATTACH TO JUNCTION BOX AC GROUND GND AC AC POWER AC PUMP PUMP WIRING DIAGRAM FOR STAND ALONE APPLICATION TO EARTH GND. OR ATTACH TO JUNCTION BOX } } AC GROUND WF INPUT INTER-CONNECT GND AC WATERFLOW DETECTOR AC POWER AC PUMP PUMP PUMP } } WF INPUT INTER-CONNECT TO EARTH GND. OR ATTACH TO JUNCTION BOX WATERFLOW DETECTOR AC GROUND GND AC AC POWER AC PUMP PUMP PUMP NOTE: } } WF INPUT NOT REQUIRED FOR KEYSWITCH OPERATION IF WATERFLOW DETECTOR IS CONNECTED TO PANEL OR OTHER MONITORING DEVICE. WF INPUT INTER-CONNECT AC POWER AND PUMP WIRING MUST CONFORM TO NEC OR YOUR LOCAL CODES. WATERFLOW DETECTOR PUMP TO NEXT ZONECHECK SWITCH FOR INTERCONNECT D770-32-00 3 I56-0053-003R Zonecheck Testing: Group-Test Mode All Zonecheck systems whose ZCK-1 key switches are interconnected (refer to interconnecting wiring diagram), may be activated from any ZCK1 key switch. To initiate the group test, insert key and turn to the left. CAUTION After installing a Zonecheck Automatic Flow Switch Tester: 1. Backfill and hydraulically test the system. 2. Contact central monitoring station or appropriate fire safety personnel. 3. Open the main isolation valve slowly until fully opened. 4. Open both Zonecheck valves fully. The LEDs on the key switch from where the group test was initiated only indicate the activity for the Zonecheck connected directly to that key switch. The red and green LEDs will remain illuminated until the key is switched to the standby position. Pre-Operation Guidelines Contact central monitoring station or appropriate fire safety personnel prior to testing Zonecheck. When testing has been completed, turn the key back to the standby position. WARNING Trouble Shooting Recommendations for Zonecheck Flow Switch Tester The unit fails to activate the remote alarm signal 1. Is there power to the circulator, i.e. Zonecheck pump? 2. Is the impeller spindle turning? If not, switch off at the key switch. Turn the spindle manually with a screwdriver for several turns then switch on the keyswitch. 3. Is the circulator fitted correctly for the flow of water to move the paddle? 4. Is the green handled valve fitted on the delivery side of the circulator? 5. Are the Zonecheck valves in the “open” position? 6. Is the signal wiring operating correctly? Check the wiring. Only activate the Zonecheck ZCK-1 key switch when the valves are opened and the sprinkler system is full. Zonecheck Testing: Self-Test Mode To activate the Zonecheck wired locally to the ZCK-1 key switch (refer to stand-alone wiring diagram), insert key and turn to the right. The green LED on the ZCK-1 will illuminate to show that the pump has been activated. The red LED on the ZCK-1 will illuminate once the waterflow detector has been activated. The red and green LEDs will remain illuminated until the key is switched to the standby position. NOTE: The red LED will not illuminate if the waterflow detector is not wired to the ZCK-1 key switch. When testing has been completed, turn the key back to the standby position. Please refer to insert for the Limitations of Fire Alarm Systems WARNING The Limitations of Zonecheck Flow Switch Tester 2. All valves controlling a sprinkler water supply should be sealed or locked in the normally open position. The normally open position should be monitored by a sprinkler supervisory switch. 1. Zonecheck Flow Switch Testers may not work or operate properly if sprinkler piping being monitored is plugged with pipe scale, mud, stones or other foreign material. Sprinkler systems should be checked regularly for such blocking material, following the instructions in Chapter 5 of NFPA Standard 13A. Three-Year Limited Warranty System Sensor, Repair Department, RA #__________, 3825 Ohio Avenue, St. Charles, IL 60174. Please include a note describing the malfunction and suspected cause of failure. The Company shall not be obligated to repair or replace units which are found to be defective because of damage, unreasonable use, modifications, or alterations occurring after the date of manufacture. In no case shall the Company be liable for any consequential or incidental damages for breach of this or any other Warranty, expressed or implied whatsoever, even if the loss or damage is caused by the Company’s negligence or fault. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. This Warranty gives you specific legal rights, and you may also have other rights which vary from state to state. System Sensor warrants its enclosed Zonecheck Flow Switch Tester to be free from defects in materials and workmanship under normal use and service for a period of three years from date of manufacture. System Sensor makes no other express warranty for this Flow Switch Tester. No agent, representative, dealer, or employee of the Company has the authority to increase or alter the obligations or limitations of this Warranty. The Company’s obligation of this Warranty shall be limited to the repair or replacement of any part of the Flow Switch Tester which is found to be defective in materials or workmanship under normal use and service during the three year period commencing with the date of manufacture. After phoning System Sensor’s toll free number 800-SENSOR2 (736-7672) for a Return Authorization number, send defective units postage prepaid to: D770-32-00 4 I56-0053-003R ©2000 System Sensor