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ELECTRONIC PUMP CONTROLLER
MODEL NO: EPC2200
PART NO: 7230701
OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC05/24
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INTRODUCTION
Thank you for purchasing this EPC2200 Electronic Pump Controller.
Before attempting to use this product, please read this manual thoroughly and follow
the instructions carefully. In doing so you will ensure the safety of yourself and that of
others around you, and you can look forward to your purchase giving you long and
satisfactory service.
Please keep these instructions in a safe place for future reference.
APPLICATIONS
This controller can be used to convert water pumps into automatic booster sets and
provides 2 main functions:
1. It provides automatic operation of your pump.
• This in-line device maintains water pressure from booster pumps by
instantly sensing water usage and automatically starting or stopping the
pump.
2. It protects the pump from running dry.
• The EPC2200 controller has a built in safety circuit which switches the
pump off when there is no water flow.
• The controller performs pump control operations automatically.
Only use the controller in conjunction with clean water which is free of mineral
particles in suspension.
DESIGN FEATURES
• Automatic and manual modes.
• In Auto mode, the pump will start without adjusting the starting pressure.
The pump will also stop automatically in case of water shortage.
• The pump can start automatically when the power supply returns after
power failure.
• Manual mandatory startup.
• Over-pressure protection;- if the system pressure is over 10 bar, the unit
automatically stops the pump.
• Water shortage self-start. The time interval of self-start is 1 minute, 30
minutes, 1 hour and then in a 1 hour cycle.
• Built-in pressure sensor and LED display.
• Dry mode protection can re-start the pump if no flow after 48 hours to
discourage blockages.
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• The digital display can be used to test and display starting pressure.
WORKING MODES
• In Automatic mode: the controller can automatically adjust the starting
pressure according to the pressure in the pipeline and can monitor the
pipeline pressure at any time. It does not need to be set manually so
avoiding a mismatch between the starting pressure and the head of the
pump, caused by the mismatch between the faulty set starting pressure
and the head of the pump.
• In Manual mode the starting pressure can be set between 0.5 and 6.0 bar.
SPECIFICATIONS
Power supply 230V-50-60Hz
Maximum power 2200 W
Max. Ambient Water Temp. 60°C
Protection Rating IP65
Maximum Operating Pressure 10 bar
Start-up pressure 0.5 - 6 bar
Cut-off pressure 0.8-9.8 Bar
Water flow rate 120 L/min
Connection sizes G1" BSP external (male) thread.
SAFETY PRECAUTIONS
1. DO NOT attempt to modify or alter the controller in any way.
2. Observe all electrical safety precautions. DO NOT allow the controller to be
submerged. Ensure it is protected from the elements at all times.
3. Read and follow all precautions specified in your pump manual.
4. The controller should always be installed by a suitably qualified person who is
familiar with the appropriate electrical regulations.
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CONNECTING THE PUMP TO THE CONTROLLER
WATER CONNECTION
The controller should be connected to a good quality water pump and a check valve
should be fitted upstream of the pump. Confirm that the pump is operating before
installing the controller.
The controller can be installed anywhere between the pump and the first tap.
No taps should be fitted between the pump and the controller.
Use a flexible hose to connect the controller to the delivery pipe and tap.
The controller can be connected directly adjacent to the pump and between the pump
and the first outlet tap.
The controller must be installed in an upright position as shown by the direction
arrows on the label.
The vertical distance between the highest taps and the controller outlet being no
more than shown in the table below.
Starting
Pressure (bar)
1.2 12 13 17
1.5 15 16 20
2.2 22 23 27
Distance of controller
and highest tap max dis-
tance (m)
Theoretical value of
the pump min head
(m)
Suggested value of
the pump min head
(m)
ELECTRICAL CONNECTIONS
The controller is fitted with two cables.
1. One is fitted with a standard 13 amp plug.
• When connected to the mains supply, this cable carries the supply to both
the controller and the pump.
2. The other cable should be fitted to a connecting socket for the pump.
3. If the controller is to be connected to an outdoor electrical supply, make sure that
both the plug and the socket are of a BS approved waterproof design and are
protected from the elements.
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ELECTRICAL PLUGS AND CABLES
WARNING: READ THESE ELECTRICAL SAFETY INSTRUCTIONS
THOROUGHLY BEFORE CONNECTING THE PRODUCT TO THE
MAINS SUPPLY.
Connect the mains lead to a standard, 230 Volt (50Hz) electrical supply through an
approved 13 amp BS 1363 plug or a suitably fused isolator switch.
If the plug has to be changed because it is not suitable for your socket, or because of
damage, it must be removed and a replacement fitted, following the wiring
instructions shown below. The old plug must be discarded safely, as insertion into a
power socket could cause an electrical hazard.
WARNING: THE WIRES IN THE POWER CABLE OF THIS PRODUCT
ARE COLOURED IN ACCORDANCE WITH THE FOLLOWING
CODE:
BLUE = NEUTRAL BROWN = LIVE YELLOW AND GREEN =
EARTH
If the colours of the wires in the cable do not agree with the markings on the plug.
• The BLUE wire must be
connected to the
terminal marked N or
coloured black.
• The BROWN wire must
be connected to the
terminal marked L or
coloured red.
• The YELLOW AND
GREEN wire must be
connected to the
terminal marked E or
or coloured green.
We strongly recommend that this product is connected to the mains supply through a
Residual Current Device (RCD)
If you are in any doubt regarding electrical installation, you should consult a qualified
electrician.
(Green and
Yellow)
Plug must be BS1363/A approved.
Earth
Neutral
(Blue)
Ensure that the outer sheath of
the cable is firmly held by the clamp
Always fit
a 13 Amp
fuse.
Live
(Brown)
EXTENSION CABLES
The maximum length of cable should not exceed 25 metres, and the size of the
conductors must be AT LEAST the same size as that on the controller.
Ensure that all connections are well clear of the water.
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WIRING CONNECTIONS
CONNECTING THE CONTROLLER TO DIFFERENT PUMPS
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MECHANICAL INSTALLATION
You should always fit a non-return valve to the suction line. (A foot valve and filter are
available from your CLARKE dealer).
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CONTROLS AND DISPLAYS
No Name Description
1 FAILURE 1. Light ON = lack of water
2. Light OFF = water supply normal
3. Twinkling light means lack of water. The pump will
stop and re-start.
2 PUMP 1. Light ON = pump working
2. Light OFF = pump will stop
3 AUTO 1. Light ON shows AUTO mode running (no need to
set starting pressure
2. Light OFF = Normal Mode (starting pressure set by
the user
4 POWER Light ON = System power supply normal
5 Display 1. “000” means real time pressure
2. “L00” means the starting pressure value
3. “P” = Over-pressure protection
6 “+” button Press button to Increase the pressure setting
7 SET Change between
Automatic mode and Normal mode
8 “RUN” Press to manually re-start the pump
9 “-” button Press button to decrease the pressure setting
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SET-UP AND OPERATION
SET THE WORKING MODE
In automatic mode the AUTO light will be on. Press the SET button for 4 seconds and
the AUTO light will go off and the unit will be in normal mode.
Press the SET button for 4 seconds and the unit will return to AUTO mode.
SET THE STARTING PRESSURE
In AUTO mode, the controller will set a starting pressure according to the pipeline
pressure.
In RUN mode press the “+” or “-” button to enter the starting pressure setting. The
display will show L00. Press the SET button or wait 8 seconds to save and exit the
setting for normal operation.
• The controller has a memory function to store the chosen setting in case of
power outage.
To display the starting pressure, press RUN and SET at the same time.
If the display shows ”P- -”& blinks, it means the pump will restart in 30 minutes.
If the failure light blinks it means the pump will restart after 1 minute, 30 minutes or
1 hour.
If the pump stops, press the RUN button to set it working again.
STARTING THE SYSTEM
CAUTION: ENSURE THE PUMP IS FULLY PRIMED BEFORE SWITCHING
ON. SEE YOUR PUMP INSTRUCTION MANUAL FOR DETAILS.
1. Close all taps/valve on the discharge side of the pump.
2. After making sure that all precautions have been observed, ensure there is power
to the pump.
• The “Power” LED will light up and the “Pump” LED will indicate that the
pump has been started.
• The pump will continue to operate for a few seconds enabling the system
to fill and to reach the required pressure.
If this time is insufficient, the “FAILURE” LED lights up. If this happens, open a tap
and keep the “RUN” button pressed until the LED goes off, then release the button
and close the tap. The controller will stop the pump at its maximum pressure.
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RUNNING THE UNIT
• If you open the outlet valve the controller will detect a drop in pressure
and start the pump.
When operational breakdowns occur, such as water loss, obstruction of the suction
pipe, etc, the controller recognizes the problem and the red “Failure” LED lights up at
the same time as the power to the pump is cut to prevent damage caused by dry
running. If this should occur:
1. Switch off the controller at the mains outlet.
2. Rectify the problem.
3. Switch on the controller at the mains and press the AUTO button.
The most common problems associated with water pump operation are leaks on the
SUCTION side of the pump. Even a pin hole in the inlet hose is sufficient to seriously
reduce suction.
Using the automatic mode can avoid the issue of the pump not starting if the artificial
starting pressure does not match the pump head in normal mode.
In certain conditions the pump may not start in Automatic Mode, in which case run
the unit manually before increasing the starting pressure to a suitable value.
MAINTENANCE AND REPAIRS
Although a component diagram is included, spare parts may be obtained from your
CLARKE dealer and the work may be better left to their technicians.
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TROUBLESHOOTING
Problem Causes related to the controller Other possible causes
The pump
does not start
The pump
does not stop
Intermittent
pump running
The pump is
jammed
Failure light
flickering
Internal PCB is broken Voltage is less than 200 v
Pump jammed
Cables incorrectly connected
Internal PCB is broken.
Check valve is stuck
Water contains materials in
suspension.
The internal PCB is broken.
The pump does not provide sufficient
pressure
Internal PCB is broken.
The pump provides a pressure which
is lower than the restarting pressure
The internal PCB is broken
Air present in the pipeline
Pipeline leaks
Presence of leaks in pipeline
Water failure
Suction problems
Pump leaking internally
In normal mode the pump
head is less than starting pressure.
Fault with the pump such as
leaks or loss of water flow.
Code P displayed
For other possible problems consult the pump instruction manual.
Internal PCB is broken
Pressure sensor is broken
Actual pipeline pressure is
greater than 9.9bar for more
than 5 seconds.
ENVIRONMENTAL RECYCLING POLICY
Through purchase of this product, the customer is taking on the obligation
to deal with the WEEE in accordance with the WEEE regulations in relation
to the treatment, recycling & recovery and environmentally sound disposal
of the WEEE.
In effect, this means that this product must not be disposed of with general
household waste. It must be disposed of according to the laws governing Waste
Electrical and Electronic Equipment (WEEE) at a recognised disposal facility.
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COMPONENT PARTS
No Description No Description
1 Nameplate 20 Main housing
2 Screw 21 Check valve baffle
3 Panel 22 Inner clamp
4 Panel seal 23 Diaphragm
5 Display board 24 Outer clamp
6 Screw 25 Screw
7 Display board connection 26 Top cap
8 PCB with components 27 Cap spring
9 Screw 28 Top cap core
10 Pressure sensor clamp 29 Screw
11 Pressure sensor 30 Head moulding
12 Sensor O-ring 31 Compression spring
13 Screw 32 Copper float
14 Upper housing 33 Copper sleeve
15 Check valve 34 Magnet
16 Check valve O-ring 35 Sealing ring
17 Water inlet filter 36 Cable gland
18 Screw cap 37 Hex nut
19 Housing O-ring
GUARANTEE
This product is guaranteed against faulty manufacture for a period of 12 months from
the date of purchase. Please keep your receipt which will be required as proof of
purchase.
This guarantee is invalid if the product is found to have been abused or tampered
with in any way, or not used for the purpose for which it was intended.
Faulty goods should be returned to their place of purchase, no product can be
returned to us without prior permission.
This guarantee does not effect your statutory rights.
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DECLARATIONS OF CONFORMITY
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ASSOCIATED CLARKE PRODUCTS
Suction/Delivery Hoses Hose Adaptors
• Reinforced 1" diameter hose for use
with water pumps. Reinforced hose
can be used on both the suction and
delivery sides of any surface
mounted water pump or the delivery
side of a submersible pump.
Pipeline Filters Pool and Booster Pumps
• An optional pump filter and cartridge for use with the various Clarke
water pumps including the SPP swimming pool pump range & CBM
booster pumps.
• 25mm (1") diameter 90° threaded
female hose adaptor
• The 1HP SPP10A 750W swimming
pool pump is a self priming pump
designed to re-circulate water to and
from the pool via a filtration system
(sold separately) allowing for the
quick and easy draining and cleaning
of pools of varying sizes.
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