Stuart Turner 46601 Guide

Installation, Operation & Maintenance

Instructions

Please leave this instruction booklet with the owner as

it contains important guarantee, maintenance and safety

information

Read this manual carefully before commencing installation.

This manual covers the following products:

CE compliant product

Monsoon Extra 2.6 bar PS

Pt. No. 46601 Monsoon Extra 3.6 bar PS

Pt. No. 46602

FOR POSITIVE OR NEGATIVE HEAD APPLICATIONS

- 2 -

PRODUCT DESCRIPTION

Electric motor driven centrifugal pump complete with an automatic control system,

consisting of flow switch, pressure switch, pressure vessel and electronic control.

APPLICATION

The Monsoon Extra Pressure Set (PS) range is designed for pressure boosting

applications in vented, stored, cold clean water systems, where under gravity, no flow is

available and can be used in systems where a negative head exists.

Inlet pressures to the pump and ambient temperatures must not exceed the values

given in the technical specifications.

This pump set must not be used for any other application without the

written consent of Stuart Turner Limited.

This pump MUST NOT be connected directly to the mains water supply.

This appliance can be used by children aged from 8 years and above

and persons with reduced physical, sensory or mental capabilities or

lack of experience and knowledge if they have been given

supervision or instruction concerning use of the appliance in a safe

way and understand the hazards involved. Children shall not play

with the appliance. Cleaning and user maintenance shall not be made

by children without supervision.

Children should be supervised to ensure that they do not play with the

appliance.

This product should not be used for the supply of water to more than

one dwelling (house, apartment, flat).

Please read installation details carefully as they are intended to ensure this product

provides long, trouble free service. Failure to install the unit in accordance with the

installation instructions will lead to invalidation of the warranty.

STORAGE

If this product is not to be installed immediately on receipt, ensure that it is stored in a dry,

frost and vibration free location in its original packaging.

CONTENTS Page

Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Important Facts - read before commencing installation . . . . . . . . . . . . . . . . . . . . 4

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Pump Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Technical Speciﬁcation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

- 3 -

CHECKLIST

Note: Item G supplied loose - this will require fitting to the pump outlet. Tighten to torque

4/5 Nm.

Your product may vary slightly from the picture above.

Item Description Qty Item Description Qty

Pump 1 Inline strainer 1

Hose & sealing washer 2 Pressure vessel 1

Inlet connector & ‘o’-ring 1 Outlet connector & gasket 1

Anti-vibration feet 4

Fig. 1

28 mm copper

inlet pipework

(suction).

28 mm isolating valve

(non restrictive) and

fittings (not supplied)

must be fitted to allow

easy pump service.

28 mm copper outlet pipework (discharge).

Short 28 mm copper pipe

tails to connect between

isolating valve and flexible

pipes.

28 mm isolating valve

(non restrictive) and

fittings (not supplied)

to allow easy pump

service.

28 mm - G 1 connector

(not supplied) must

be fitted

28 mm flexible

pipes. These

hoses are fitted

with G 1 female

connector suitable

for connection to a G 1 (1 “ BSP)

adaptor or fitting.

IMPORTANT: With the pump

removed from its packaging check

for any damage prior to installation.

If any damage is found contact Stuart

Turner Ltd within 24 hours of receipt.

- 4 -

Cont ...

1 READ BEFORE COMMENCING PUMP INSTALLATION

A. Water storage capacity.

1.11 The cold water storage capacity must be sufficient to meet the flow rates

required by the pumped equipment and any other water using fittings and

appliances, which may be operated simultaneously.

1.12 Ensure the pump is primed as described in the priming section before starting,

damage to the shaft seal will result otherwise. See Section 5 - Commissioning.

B. Water temperature

This unit is designed to pump cold water only which should not exceed the following

values:

1.13 The maximum allowable water temperature is 35 oC.

1.14 The minimum allowable water temperature is 4 oC.

C. Pipework - General

1.15 Secure pipework: Ensure pipework to and from pump is independently

supported & clipped to prevent forces being transferred to inlet and outlet

branches of pump.

1.16 Flux: Solder joints must be completed and flux residues removed prior to pump

installation (flux damage will void any warranty).

1.17 Pipework design: Care should be taken in the design of pipework runs to

minimize the risk of air locks e.g. use drawn bends rather than 90obends.

1.18 DO NOT introduce solder flux to flexible hoses, pumps or pump parts

manufactured from plastic.

1.19 DO NOT allow contact with oil or cellulose based paints, paint thinners or

strippers, acid based descalents or aggressive cleaning agents.

1.20 DO NOT install a non-return valve, or devices which contain non-return

valves, in the suction (inlet) pipework to the pump. The pump must be free

to vent to the supply tank at all times.

1.21 DO NOT bend the flexible hoses beyond 30o. They must be installed as

straight as possible.

1.22 DO NOT connect this pump to the mains water supply.

D. Plumbing & Electrical Installation Regulations

1.23 The plumbing installation must comply with “The Water Supply (Water Fittings)

Regulations 1999” and “BS 6700” building regulations.

1.24 The plumbing installation must be installed by a qualified person.

1.25 The electrical installation must be carried out in accordance with the current

national electrical regulations.

1.26 The electrical installation must be installed by a qualified person.

E. Pressure vessel

1.27 Pressure vessel is charged at the factory see Section 6 - Maintenance for

details.

- 5 -

Cont ...

2 LOCATION - GENERAL

2.11 Access: For emergencies and maintenance the pump must be

easily accessible.

2.12 Protection: The pump must be located in a dry position, frost free and

protected from freezing, particularly when installed in a loft (not

recommended).

2.13 Ventilation: Ensure an adequate air flow to cool the pump. Separate

the pump from other appliances that generate heat. An 80 mm (3 “) air

gap must be maintained around the pump.

2.14 Safety: The motor casing can become very hot under normal

operating conditions. Care must be taken to ensure it cannot be

touched during operation.

2.15 Water retention: Site the pump in a location where in the unlikely

event of a water leak, any spillage is contained or routed to avoid

electrics or areas sensitive to water damage.

2.16 Static inlet pressure: Before deciding where to locate the unit check to ensure

the static inlet head between pump and the bottom of the cold tank (Fig. 2) is at

least 1 metre and does not exceed the max inlet head of 10 metres.

2.17 Pump position: The pump must be positioned on its anti-vibration mounting feet

and as close to the water source as possible.

2.18 Ambient temperature: The pump must be sited in a location where the maximum

ambient temperature does not exceed 40 oC.

2.19 Pipework: For optimum performance pipework use 28 mm dia., 22 mm can be

used but will result in reduced pump performance.

Pipework should only reduce to 15 mm when entering terminal fitting.

2.20 Static outlet pressure: The static outlet head (Fig. 2) must also be within the

maximum requirement of 13 metres.

2.21 Noise: The anti-vibration mounting feet and flexible hoses which are supplied

as standard, and a precaution to reduce noise transmission, however care must

be taken when mounting the pump that any noise is not amplified through loose

panels or pipework. Do not screw down the pump.

2.22 Direction of flow: Ensure the water flow is in the direction of the arrow marked

on the flow switch reed clamp (vertically upwards).

2.23 Flexible hoses: Use only Stuart Turner supplied hoses.

2.24 Isolating valves: Separate isolating valves (non restrictive) must be fitted to

allow easy pump service.

2.25 Preferred pump location: The preferred pump location is at floor level next to

the water source or a level that is below the tapping that feeds the pump.

The Pump location is also dependent on limitations of the static inlet and

outlet heads of the installation. For guidance on limitations and recommended

location, consult the following relevant section.

- 6 -

Cont ...

2 LOCATION

2.26 The cold water supply: Must be a DEDICATED AIR FREE supply via a tank

connector.

Do not connect to the mains.

Fig. 2

Cold

water Hot water

Unvented hot

water cylinder

Static inlet pressure

Min. 1 m

Max. 10 m

Static outlet pressure

Max. 13 m

- 7 -

Cont ...

3 PUMP CONNECTIONS

3.11 Hose to pump: These pumps have G 1 threaded connections to accept the

hoses supplied. The hose end is made water tight with a sealing washer on

assembly, nip tight to 4/5 Nm for water tight seal (Do not overtighten).

3.12 Hose to pipework: Hoses terminating in G 1 threaded connections are supplied

and when securing the male end to a suitable pipe fitting, seal with PTFE tape or

other suitable sealant.

- 8 -

4 ELECTRICAL INSTALLATION / EARTHING

4.11 Regulations: The electrical installation must be carried out in

accordance with the current national electrical regulations and installed

by a qualified person.

4.12 Safety: In the interests of electrical safety a 30 mA residual current

device (R.C.D. not supplied) should be installed in the supply circuit.

This may be part of a consumer unit or a separate unit.

4.13 Before starting work on the electrical supply ensure power supply is

isolated.

4.14 DO NOT allow the supply cord to contact hot surfaces, including the

motor shell, pump body or pipework. The cord should be safely routed

and secured by cable clips.

4.15 Supplementary Bonding: The pressure set is factory fitted with a

supplementary earthing wire to ensure continuity throughout the assembly

(Fig. 3). It must be ensured throughout the product life that this electrical

connection remains in place.

4.17 Earthing: This appliance must be earthed via the supply cord, which must be

correctly connected to the earth point located in the terminal box.

4.18 Pipework: Copper or metallic pipework must have supplementary earth bonding

where the continuity has been broken by flexible hoses or plastic components.

4.16 Adjacent pipes: Adjacent suction and delivery pipes should be fitted with

earthing clamps to BS 951 in accordance with current regulations (Fig. 4).

Diagram of

earth continuity

connections

Fig. 4

Fig. 3

Warning Tag

- 9 -

Cont ...

4.19 Additional earthing: Certain installations may require additional earthing

arrangements such as equipotential bonding. Reference should be made to the

relevant regulations concerning this subject to ensure compliance.

4.20 Connections: The pump must be permanently connected to the fixed wiring of

the mains supply using the factory fitted supply cord, via a double pole switched

fused spur off the ring main and NOT connected to the boiler or the immersion

heater circuits.

4.21 Wiring of connection unit:

WARNING: This appliance must be earthed.

The wires in the mains lead are coloured in accordance with the following code:

Green and Yellow: Earth Blue: Neutral Brown: Live

As the colours of the wires in the mains lead of this appliance may not correspond

with the coloured markings identifying the terminals in your connection unit

proceed as follows:

The wire which is coloured green and yellow must be connected to the terminal

in the connection unit which is marked with the letter E or by the earth symbol:

or coloured green or green and yellow.

The wire which is coloured blue must be connected to the terminal which is

marked with the letter N or coloured black.

The wire which is coloured brown must be connected to the terminal which is

marked with the letter L or coloured red.

4.22 Wiring Diagram:

Model Fuse Size (AMPS)

All Models 13

4.23 Fuses: The following fuse size should be used with the appropriate pump:

GREEN / YELLOW

BLUE

BROWN L

NLE

N230 VAC/1PH/50Hz

SUPPLY

RED

CAPACITOR

MOTOR

GREEN / YELLOW (LINK WIRE)

RED

YELLOW

RED

BLACK

FLOWSWITCH

REED (S3)

S3 S3 S2S2S1 S1

PRESSURE

SWITCH (S1)

Monsoon Extra 2.6, 3.6 bar PS

Fig. 5

- 10 -

Cont ...

4.24 Supply Cord Replacement:

The supply cord and internal wiring within the terminal box are

routed and secured to ensure compliance with the electrical

standard EN 60335-1. It is essential that prior to any disturbance

of this internal wiring, all cable routing and securing details are

carefully noted to ensure re-assembly to the same factory pattern

is always maintained.

If the supply cord is to be changed or is damaged, it must be replaced with a

special cord assembly available from Stuart Turner or one of their approved

repairers.

On disassembly note the cord retention and routing system. Re-assemble to the

same pattern.

For information on cable connection consult the wiring diagram and cable gland

fitting instructions.

4.25 Cable Gland Fitting Instructions:

To enable correct assembly of the cable gland the ‘O’-ring (Fig. 6 item 1) must

be placed over the cable before the clamping insert (Fig. 6 item 2) can

be tightened.

Note: Cable diameter range:- 6.5 mm to 9.5 mm.

4.26 Supply Cord Extension:

The pumps are fitted with a supply cord to the following specification:-

All models. . . . . . . . . . . . . . . . .HO5VV-F3 G 0.75 mm² - 6 Amp rated cable.

If the supply cord is to be extended, a cord of the same specification should be

used. Any connections or junction boxes used should be specifically suited for

the application and installed in accordance with the manufacturers instructions.

Fig. 6

This manual suits for next models

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