The SMT 400 is a high specification integrated solar heating controller, compact,
robust and easy to use. This controller has evolved as a result of research and
development and years of experience in the solar industry. It forms a valuable
information system for the modern-day user and provides the necessary details,
revealing the performance of the solar system. The large graphics display ensures
that the unit communicates with the user with the greatest of ease and friendliness.
THE SMT 400 FEATURES
•Precise digital differential controller for efficient heat collection
•Digital display of collector (manifold) temperature
•Digital display of return (system) temperature
•Digital display of Tank 1 and Tank 2 temperatures
•Digital display of daily collected energy in kilo-calories
•Bargraph display of collector (manifold) temperature
•Bargraph display of instantaneous power collected in kW, with auto-adjusting
scale
•50 Year clock & calendar
•Two presettable divert temperatures providing a three-user zone system
•Pump control matrix providing total user versatility
•‘Smart’ Mode providing automatic heat diversion
•Adjustable Delta T () differential from 4-10
•Adjustable ‘Smart’ Mode Delta T (S)differential from 6-12°C
•Anti-frost thermostat for system protection
•Maximum system temperature thermostat
•Daily maximum / minimum temperature recorder for all its sensors
•Three independent time-thermostats for heat boosting
•Graphical display of collector and tank temperatures as well as the energy
gain for the current and previous days, based on an average reading taken
every 10 minutes
•Graphical display of collector daily maximum temperatures, tank1 daily
maximum temperatures and total daily energy gain for the last 8 weeks
•Bar graph display of monthly accumulated energy gain for the last 6 months
•Status screen for indication of the current state of inputs and outputs of the
collector
•Manual override of outputs for system testing
•Alarm indicator for warning in case of sensor failure or over-temperature
•Plug-removable controller for ease of installation
•Plug-in sensors for ease of installation
o
C
Note: The information supplied in this manual is for guidance only - no part of this
may be used for any agreement, whether express or implied, or to form any contract.
Thermomax reserves the right to change specifications without prior notice.
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SECTION 2 - INSTALLATION
Note: This installation procedure is for guidance only, and its suitability
should be verified by the installer.
2.1SMT 400 UNIT
NOTES: For viewing comfort, the SMT 400 unit should be positioned at eye
level. It is always good practice to keep electronic equipment away from
cold, and heat, as extremes of temperature may reduce the lifetime of the
device. It is also good practice to keep electronic equipment away from
heavy electrical loads, switches, relays or contactors as these may cause
electrical and electromagnetic interference when switched on or off.
1Remove the two side restraining screws as per diagram below, then separate
the TOP controller from the connector BASE.
TOP
SCREWSCREW
BASE
2If your cables are to enter the enclosure from behind the unit, then knock out
the appropriate entries in the BASE of the SMT 400.
3Use the BASE of the enclosure to mark the four corner mounting holes.
Remove the base and drill all necessary holes in the wall or mounting panel.
4Assemble any grommets or conduit adapters if used, replace the base and
fasten using the four corner screws.
2.2SENSORS
The SMT 400 is supplied with three sensors (Collector, Return, Tank 1). If
longer cables are needed, sensors are available with extended cable lengths.
Alternatively, sensor extenders are available in a variety of lengths. If the
sensors need to be extended, but factory-made extenders are not available,
they can be extended using a suitable 4 core or 3 core cable, according to
the diagram shown below.
(Note: The SMT 400 is supplied with Tank 2 sensor disabled. A Tank 2 sensor
may ordered separately if required. See section 3.4 for details).
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2.3POWER CONNECTIONS AND WIRING DIAGRAM
NOTES: This device should be properly earthed. Flexible wires simplify
connection to the terminals. All connections should be secure and
adequately tightened. It is good practice to keep mains cables away from
sensor cables and other low voltage signal cables.
Connect the mains supply to the unit, as per diagram below:
P1 - Hot Water Pump 1P2 - Hot Water Pump 2P3 - Hot Water Pump 3
A1 - Auxiliary Heater 1A2 - Auxiliary Heater 2
AUX1 + AUX2 :MAX 3.5A (800W)
PUMP1 + PUMP2 + PUMP3 :MAX 2.0A (450W)
TOT AL LOAD :5.5A(1250W)
If the Auxiliary outputs are being used to drive a water heater which has a
greater rating than 800W, then a mains contactor (Relay) should be used as
illustrated below:
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2.4BATTER Y
The battery supplied is a PP3 nickel metal hydride rechargeable battery and
is contained in the battery compartment inside the unit, but not connected.
This should be connected after installation. A battery is not essential for the
system operation, but is used in the case of power failure, thereby
maintaining the system clock for 1 - 2 hours. It is recommended for the
battery to be changed every 6 - 12 months, in order to maintain good mains
failure operation. When replacing, ensure that the same type of battery is
used as specified.
2.5ENERGY COLLECTED CALCULATIONS & SETTINGS
The Flow rate of the system is used to calculate the Energy Collected. A flow
meter is used to determine the actual value of flow rate in Litres per Minute.
This value must then be entered into SMT 400 control unit (see section
3.4 “System presets”) for further information on setting the flow rate and
setting the % of Anti-freeze (Glycol) used in your system. The diagram below
shows the location of the flow meter on the SMT 400 Pump control Unit.
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SECTION 3 - OPERATION
In order to understand the simplicity of operation SMT 400, the description below
should be read carefully.
3.1DESCRIPTION
12
5
4
3
1Graphics LCD Display:
Displays all the information. The contrast is adjustable to suit the user.
(See MAIN SCREEN Digital Temperature Display, Section 3.2).
2Function Keys:
There are six function keys on the SMT 400 controller:
MAIN SCREEN 1 Temperature and Energy Display
CLOCK SCREEN Setting the System Clock
SET SCREEN 1 - Main System parameters
SET SCREEN 2 - The SMT 400 Pump control matrix
SET SCREEN 3 - System Presets.
SET SCREEN 4 - Energy calculation configuration
TIMER SCREEN - Auxiliary heat Boost.
SOLAR HISTORY - Collector, Tank and Energy Collected
STATUS SCREEN - System Diagnostics.
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3Select Keys
Within each function, there are a few parameters that can be selected for
setting or display purposes. The select keys allow the different parameters to
be chosen, without changing the value of any of the parameters.
4Set Keys
Once any parameter is chosen, in order to set the value, the and keys
increase / decrease the value respectively. In most of the functions
described later, the
hold the key in order to advance quickly.
Note that the
keys may be pressed to view or select any of the parameters without
affecting any change in the system.
5Indicators
and keys have an auto-repeat facility: press and
and keys are the only ‘ destructive ’ keys. The other
PUMP 1
PUMP 2
PUMP 3
The System Alarm can be triggered by a high temperature alarm or by a
sensor fault.
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3.2MAIN SCREEN 1 - TEMPERA TURE AND ENERGY DISPLAY
2
3
45
DISPLAY CONTRAST:
1
The display contrast may be adjusted in this screen. Press the
increase and the
and hold for auto-repeat.
1MAIN SCREEN Function selector
Pressing this button once reveals Main Screen 1. This screen may display
either the Collector temperature or the “Energy Collected” for the current day.
Pressing this key a second time reveals Main Screen 2 which is a digital
display of all four temperature sensors.
2Collector temperature bar graph
Displays the current collector temperature in bargraph form.
3Energy Collected bar graph
Displays the instantaneous power being collected in kW with automatically
adjusting scale.
4Current Time display
5Informati on Window
key to decrease the contrast. To adjust quickly, press
key to
Use the
current Collector temperature or the Energy Collected for the current day.
keys to change the “Information Window” to display either the
This window will display the current collector temperature
when the “C” option 1 is selected.
This window will display the Energy Collected for the current
day when the “E” option is selected.
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3.3CLOCK / CALENDAR SCREEN - SETTING THE SYSTEM CLOCK AND DA TE
2
3
1CLOCK/CALENDAR SCREEN Function selector
The datalogging system uses the calendar to file the logged data.
2Selection indicator
The highlighted parameter is adjusted by pressing the
(The selections are: ‘year’, ‘month’, ‘day’, ‘↑’, ‘hour’ and ‘minutes’)
The ‘↑’ indicates that the day on the calendar above is being set.
The clock is in 24-hour format.
1
1
keys.
To advance quickly press and hold the
3Calendar
This is the calendar of the month selected, with the day of the week
indication.
SETTING THE DATE AND TIME
Step 1:Use the
Step 2:Use the
Step 3:Repeat step 2 to set the current ‘date’ and ‘time’ (‘minutes’
keys to set the current ‘Year’ .
key to move to the ‘Month’ option and then
use the
keys to set the current month.
and ‘hours’) in turn.
keys for auto repeat.
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3.4SET SCREEN 1 - MAIN SYSTEM PARAMETERS
2
1
TC
309060
3
2
1
TT1TT2
***
T
S
T
6
6
TF
5
TM
24
78
2
4
3
1
1
90
9
1Set Screen function selector
Pressing this key once reveals Set Screen 1. The main system parameters
are set using this screen.
2TC is the minimum collector temperature which will activate the pumps
o
(recommended set value: 30
C).
3TT1 is the State 1 to State 2 divert temperature; (In normal/default operation
this is the Tank1 to Tank2 divert temperature). The default value is set to
90°C for a one pump system. In an application that has more than one
pump, this value must be adjusted to the required divert temperature, (i.e. a
temperature of 40°C is recommended).
4TT2
In the default state (as shipped from the factory), the Tank 2
sensor input is disabled. This is denoted by an X in the TT2
window. If your system has two tank 2 sensors, then you will
need to follow step (a) as follows:
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(a)TO ENABLE THE T ANK 2 SENSOR
Use the
seconds to remove the X. The
keys to move to the TT2 window. Then press the key for 5
/ keys may now be used to set TT2
(state 2 to state 3 divert temperature).
(b)TO DISABLE THE T ANK 2 SENSOR
If your system does not have a Tank 2 sensor, this input must be disabled to
ensure correct operation of the controller. This is done as follows :
Use the
the TT2 parameter reaches 90
keys to move to the TT2 window. Then press the key until
0
C, continue to press the key for 5 seconds
(until an X appears in this window). This sensor has now been disabled.
5
is the required temperature difference between the collector and return
temperature to activate the pump (recommended set value: 4).
6S
is the required temperature difference between the collector and return
temperature to satisfy the ‘Smart’ condition, (Section 4, page 13).
7TF is the anti-frost temperature (recommended set value with no anti-freeze:
+2°C).
8This is the alarm mute selector, press
to enable piezo alarm or to
disable it.
9TM is the maximum system temperature alarm.
If the temperature of either Tank 1 or Tank 2 sensor exceeds TM, then all
Pump relays are switched OFF as a protection feature.
To set any parameter use the
then use the
keys to adjust this parameter.
keys to move to the appropriate window,
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SET SCREEN 2 - THE SMT 400 PUMP CONTROL MATRIX
2
P3
P2P2
COL > TCTNK2>TT2TNK1>TT 1
3
1Set Screen function selector
Pressing this key a second time reveals Set Screen 2. The Screen allows the
user to program the output status of each pump when the SMT is in one of
three states. (It is assumed that the collector temperature is greater than the
return temperature by
).
4
1
1
2State 1 - When the COLL > TC, the controller is in State 1. Therefore any
pump which has been selected in Column 1 will be “ON”.
3State 2 - When the TNK1 > TT1 and COLL > TC, the controller is in State 2.
Therefore any pump which has been selected in Column 2 will be “ON”. The
conditions for State 2 are overridden when the ‘Smart’ mode is
selected. Please refer to “Smart Mode Select” on page 13. If the ‘Smart’
mode is selected ‘S’ will appear at the bottom right hand corner of this
window.
4State 3 - When the TNK2 > TT2 and TNK1 > TT1 and COLL > TC, the
controller is in State 3. Therefore any pump which has been
selected in Column 3 will be “ON”.
Note:This indicates that Pump1 will be “ON” for this State.
This indicates that Pump1 will be “OFF” for this State. To
change the status of any pump simply use the
move the selection window, then use the
pump to “ON”, and the
key to switch the pump to “OFF”
key to switch the
12
keys to
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SET SCREEN 3 - SYSTEM PRESETS
2
1Set Screen function selector
Pressing this key a third time reveals Set Screen 3. The system presets are
set using this screen.
3
4
1
5
6
2Flow Rate
Use the
minute, (0-100) or 10l per minute (100-1000).
This value is used with Delta T (
section 2.5
“Energy Collected Calculations” and section 3.4 note 2.
3System Anti-freeze (Glycol) Percentage
Use the
percentage anti-freeze.
4‘Smart’ mode select
Principle of Smart Mode Operation:
The SMT 400 offers the facility to maximise the energy gain from the solar
sysyem. When the energy gain from the system is low during some periods
of the day, the heat output from the system may be diverted to a swimming
pool. When the energy gain increases the heat output from the system is
diverted to the hot water tank. A new Smart Mode Delta T “S
govern this operation. The diagram on the following page illustrates
operation in this mode.
keys to set the system flow rate in steps of 1 Litre per
) to calculate the Energy Collected. See
key to select this window then use the keys to set
” is used to
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Use the
disable ‘Smart’ mode. (Press and hold for 3 seconds). When the Smart
option is enabled, the unit switches to Pump status 2, as long as COLL -
RET >
option is activated, S
Please note that the controller will operate as normal if the conditions for
State 1 , State 2 and State 3 are met.
key to select this window then use the keys to enable or
and COLL - RET < S, (see diagram below). When the Smart
appears on the display to the left of .
A = SWIMMING POOL, B = HOT W ATER TANK
5Energy units
Use the
seconds to change the energy units from kWh to calories or vice versa.
6Communication Language
Use the
communication language.
key to select this window then press and hold the key for 5
key to select this window then use the keys to select the
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SET SCREEN 4 - ENERGY CALCULATION CONFIGURA TION
1SET SCREEN function selector
Pressing this key a fourth time reveals the energy calculation configuration
screen. This screen lets you choose which pump outputs will be used for the
1
energy calculation. Use the
disable for calculation.
Use the
NOTE 1: For correct energy calculation, outputs NOT powering pumps should
NOT be enabled for calculation.
NOTE 2: The accuracy of the solar energy gain calculations are dependent
upon the accuracy of the flow meter. As this is a mechanical device and it’s
accuracy will fluctuate over time, the flow rate in set screen 3 should be set
as follows:
When the sun is vertical to the collector, the solar intensity (instantaneous
collected power) should be approximately 700W per square meter. The flow
rate value in set screen 3 should be adjusted to obtain this reading.
keys to make setting.
keys to select which outputs to able or
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3.5TIMER SCREEN - AUXILIARY HEA T BOOST
65432
3.5.1
1Timer Screen function selector
Pressing this key once reveals the timer screen as shown above. The SMT
400 offers three independent timers with associated thermostats. Each
timer can be linked to any of the two tank sensors and two relays.
1
2Auxiliary output selection
This allows you to select which relay will be controlled by the selected
output.
‘OFF’: This selection indicates that the selected timer will not affect any of
the relays.
‘A1’:This selection indicates that the selected timer will control auxiliary
output 1 relay.
‘A2’:This selection indicates that the selected timer will control auxiliary
output 2 relay.
Use the
3,4,5Timer start, timer end and temperature settings
Use the
settings of the timer.
6Sensor selection
This allows you to select which sensor will be used for the selected timer.
This selection indicates that Tank sensor 1 will be used.
keys to adjust the start time, end time and temperature
keys to make the selection.
This selection indicates that Tank sensor 2 will be used.
Use the
Use the
keys to make the selection.
keys to select the required parameter.
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3.5.2 BOOST OPTION
1
1Pressing and holding the key for 4 seconds will select the boost
option.
2Pressing the
3Pressing the
Note: This option will only operate if the timer temperature parameters have
been programmed for A1, (auxiliary output 1). The unit will choose the
maximum temperature which has been programmed for A1, [i.e. 45°C in
this example, as 45°C (timer 1) > 40°C (timer 3)].
The auxiliary output will remain switched on until:
(a)the appropriate tank sensor (
(b)a one hour period has elapsed.
If no times have been set when the
display the message: “BOOST UNA VAILABLE PLEASE REFER T O
MANUAL”
If this screen is displayed, then any one of the following reasons will prevent
the boost function from being activated:
(1)AUX 1 Relay has been manually switched off (see section 3.7, page 20).
(2)AUX 1 Relay has been manually switched on (see section 3.7, page 20).
(3)A1 timer temperature has not been set.
(4)A1 Relay has not been selected.
(5)A1 timer is already running.
key allows you to activate the boost function.
key allows you to cancel the boost function.
in this example) has reached 45°C, or
key has been pressed, the unit will
17
TIMER 1
TIMER 2
TIMER 3
Page 19
3.6SOLAR HISTORY - COLLECTOR, T ANK AND ENERGY COLLECTED
2
3
1
1SOLAR HISTORY Function selector
Pressing this key once reveals the solar history screen. The SMT 400 records
the collector and tank temperature of each day as well as the energy
collected. The storage capacity of the SMT 400 is approximately 2 years.
When the memory is full the oldest data in the databank will be overwritten. A
sample is taken every 10 minutes from each of these readings. These are
then displayed in graphical form, thereby representing the system
performance for the user with clarity. A calendar allows the user to choose
the day of which data will be plotted. The unit also records daily readings
from the last 8 weeks, which is also plotted and can be viewed by pressing
this key twice. Pressing this key three times will display the directory of the
memory bank. The highlighted months on the screen are the months for
which the databank contains data. To view the plot of a particular day, select
the required month from the calendar using the
key to accept the selection. A second screen appears for the selection of
the day after which the logged data of the required day is displayed for
inspection.
2Collector, Tank & Energy Selector
Use the
graph.
C - Collector sensor temperature.
T - Tank sensor temperature.
E - Energy collected.
keys to select which parameter is to be displayed on the
keys, followed by the
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3Monthly T otal Collected Energy / Previous Log Selector (MCAL or
KWHR)
(a)The screen on the previous page is shown by pressing the
(b)By pressing the
(c)By pressing the
shown below.
key, the current day’s plot can be selected.
key, this data can be viewed in graphical form, as
key.
(d)By pressing the key, this data can also be viewed in tabular form, as
shown below.
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3.7STA TUS SCREEN - SYSTEM DIAGNOSTICS
SMT 400 2.000 18 F2
COL SEN:
RET SEN:
TNK1 SEN:
TNK2 SEN:
PMP 1 PMP 2PMP 3ZUS 1ZUS 2
AUTO
0
36 C0 00
38 C0 00
29 C0 00
38 C0 00
AUTO AUTO AUTO AUTO
0000
1111
1
33.5 °C
23.5 °C
74.0 °C
54.0 °C
7
1
8
1
2
3
4
1Status Screen function selector
Pressing this key reveals the Status Screen as shown above.
2Pump 1 Relay Status.
The output status of the Pump 1 relay may be viewed here, or altered by
pressing the
or key when the RELAY window is selected.
“0” = Relay Manually OFFa frame around ‘0’ indicates Relay OFF
“AUTO” = For normal operation
“1” = Relay Manually ONa frame around ‘1’ indicates Relay ON
3Pump 2 Relay Status.
The output status of the Pump 2 relay may be viewed or changed here (as
above).
4Pump 3 Relay Status.
The output status of the Pump 3 relay may be viewed or changed here (as
above).
5
6
5Auxiliary Output 1 Relay Status.
The output status of the Auxiliary Output 1 relay may be viewed or changed
here (as above).
6Auxiliary Output 2 Relay Status.
The output status of the Auxiliary Output 2 relay may be viewed or changed
here (as above).
7Electronic Signature.
Each SMT 400 has its own Electronic Signature which is used in the factory
for date of manufacture information.
8Sensor Calibration and Status Windows.
These windows display sensor calibration data and also the temperature
reading for all sensors.
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3.8CALIBRATION TRIMMING SCREEN
3
2
1
1Pressing and holding the key for 10 seconds, reveals the calibration
trimming screen.
2Use the
trim.
3To alter the value of trimming, simply press the
temperature reading will change accordingly.
keys to select which sensor temperature value you want to
or key and the
SECTION 4 - FAULT FINDING
Problem:Nothing happens when the unit is powered-up.
Cause/Remedy:One of the fuses could be blown - check and replace if
necessary (refer to specifications for values). If the fuses blow
again, contact the agency where the unit was purchased.
Problem:The temperature display is fluctuating.
Cause/Remedy:One of the sensor connectors may be loose, or a sensor may
be too close to a mains cable. Check sensor connectors and
re-route cables as necessary.
Problem:The display screen is too dark or faint.
Cause/Remedy:Adjust the display contrast to suit - see ‘Display Contrast’
(Section 3.2).
Problem:The System Alarm light is flashing.
Cause/Remedy:This indicates a system alarm warning, which may be caused
by a sensor fault or if the TM setting is exceeded (see Section
3.4 SET SCREEN 1). A sensor will show fault if it measures a
temperature above +99°C or below -15°C, this will not
damage the sensor and the fault condition will clear when the
sensor is operated within this range.
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Problem:The controller does not function correctly and all the LEDs are
on.
Cause/Remedy:The unit may have been subjected to mains fluctuations or
failures beyond it’s specifications. To resolve this problem the
controller must be reset as follows:
(1) Switch off the mains supply to the unit.
(2) Remove the two restraining screws from the sides of the
controller (see section 2.1) then separate the
TOP controller from the BASE.
(3) Disconnect the PP3 battery from the controller.
(4) Now plug the TOP controller back onto the BASE and
switch on the mains supply to the unit.
(5) The Unit should now restart and display the THERMOMAX
opening screen. If the unit does not work at this stage, it
must be returned to your distributor.
(6) If the unit is now functional you must switch off the mains
supply to the unit, then disconnect the TOP from the BASE
and reconnect the PP3 battery.
(7) Replace the TOP controller onto the BASE and then
replace the two restraining screws.
Please note that this operation should be carried out by
qualified personnel only !
Switch on the mains supply to the SMT 400. The Unit should
now restart and display the THERMOMAX opening screen.
The clock should now be set.
Problem:The Auxiliary timer does not appear to function correctly.
Cause/Remedy:The SMT 400 can be programmed to use either Tank sensor 1
and / or Tank sensor 2 to control Auxiliary outputs 1&2 (see
Section 3.5 “Timer Screen”), therefore both Tank 1 and Tank 2
sensor must be connected to the unit.
Problem:The Auxiliary heater or water Pumps do not switch on when
they should.
Cause/Remedy:The user can check the five relay’s status by entering the
system diagnostics screen (see Section 3.7 “STATUS SCREEN
- System Diagnostics”). The relays may be switched to
manually OFF, AUTO normal operation, or manually ON. If the
external heaters or water pumps do not operate when the
relays are switched to “manually ON” then check the system
wiring (this should be carried out by qualified personnel only).
Check all “neutral” connections. Check that the relay current
specifications have not been exceeded. If your system is using
an external Mains Relay (contactor) as per wiring diagram in
section 2.3, then you should check connections to ensure they
have not loosened.
NOTE: Please disconnect the PP3 battery when the unit is
not in use.
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SECTION 5 SPECIFICATIONS
ELECTRICAL:
Supply Voltage:220-240V AC Single Phase
Fuses:1 X 6.3A Slow Blow, 1 X 1A Quick Blow.
Relay Outputs:Pump 1 Relay:2A single pole - output live
when energized (max. 400W).
Pump 3 Relay:2A single pole - output live
when energized (max. 400W).
Pump 3 Relay:2A single pole - output live
when energized (max. 400W).
A1 Relay:2A changeover 3 pin isolated (volt free
contacts) can be used for mains voltage
only. (max. 400W).