Stuart Turner CH 4-30 B 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

CH 4-30 B

Pt. No. 46593

CH 4-40 B

Pt. No. 46594

CH 4-50 B

Pt. No. 46595

CH 4-60 B

Pt. No. 46610

FOR POSITIVE OR NEGATIVE HEAD APPLICATIONS

50 Hz

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Cont ...

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 Stuart CH Boostamatic range is designed for pressure boosting applications in

vented stored, hot or cold, clean water systems, where under gravity, no flow is available

and can be used in systems where either a positive or negative head exists.

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

values given in the technical specifications.

zThis pump set must not be used for any other

application without the written consent of Stuart

Turner Limited.

zThis pump MUST NOT be connected directly to

the mains water supply.

zThis 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.

zChildren should be supervised to ensure that they

do not play with the appliance

zThis 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.

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CONTENTS Page

Checklist ............................................................4

Pre-Installation .......................................................5

Important Facts - read before commencing installation .......................6

Location ............................................................7

Pump Connections ....................................................12

Electrical Installation ...................................................13

Commissioning .......................................................15

Maintenance .........................................................16

Technical Specication .................................................18

Trouble Shooting .....................................................20

Guarantee ...........................................................23

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Cont ...

CHECKLIST

Note: Item C & G are supplied loose and will require fitting to the pump inlet/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 & ‘O’-ring 1

Anti-vibration feet 5

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.

Note: This image is for reference only.

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Fig. 2

Grub Screws

(3 off)

Outlet Tower can be swivelled at

this joint line after loosening the

3 equi-spaced grub screws

PRE-INSTALLATION ASSEMBLY

Re-positioning of Pressure Vessel

The pressure vessel can be rotated to alternative positions (Fig. 3) in the event of the

factory fitted position being unsuitable for a specific installation.

a) Remove pressure vessel by unscrewing anti-clockwise.

b) Using a 2 mm allen key, carefully loosen all three retaining grub screws by two

turns (Fig. 2).

c) Warning - Care must be taken when re-positioning the pressure vessel to

ensure no strain is placed upon the pressure

switch or reed switch cables.

The flow switch assembly can now be carefully

rotated to an alternative position

(Fig. 3).

d) Ensure all three grub screws

are re-tightened securely to

a torque of 2.2 Nm (1.62 ft lbf).

e) Re-fit the pressure vessel

ensuring the ‘O’-ring seal

is in place.

Motor

Area for alternative fitting positions

Factory fitted position all models

Fig. 3

Note: These images are for

reference only

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Cont ...

1 IMPORTANT FACTS: READ BEFORE COMMENCING PUMP INSTALLATION

A. Water storage capacity.

1.11 The hot and cold water storage capacity (must be a minimum of 230 litres) and

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

The water entering the pump must be controlled as follows:

1.13 The maximum allowable water temperature is 65 oC.

1.14 The minimum allowable water temperature is 4 oC.

1.15 DO NOT fit a pump if the hot water is heated via a method whereby the water

temperature cannot be controlled, such as solar or solid fuel you must consult

the PumpAssist team on +44 (0) 800 31 969 80.

C. Pipework - General

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

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

branches of pump.

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

installation (flux damage will void any warranty).

1.18 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.

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

manufactured from plastic.

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

strippers, acid based descalents or aggressive cleaning agents.

1.21 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.

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

straight as possible.

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

D. Plumbing Installation Regulations

1.24 The plumbing installation must comply with the current water and building

regulations.

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

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

national electrical regulations.

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

E. Pressure vessel

1.28 Pressure vessel is charged at the factory see Section 5 - Maintenance for

details.

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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 water tank

(Figs. 4 & 5) is at least 1 metre and does not exceed the max inlet head of

10 metres.

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

maximum ambient temperature does not exceed 40 oC continuous or 50 oC

intermittent.

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

used but will result in reduced pump performance. Note: Inlet pipework must

always be greater than or equal to the outlet pipework diameter.

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

2.19 Static outlet pressure: The static outlet head (Figs. 4 & 5) must also be within

the maximum requirement of 13 metres.

2.20 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.

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

on the flow switch reed clamp (vertically upwards).

2.22 Flexible hoses: Only use the Stuart Turner hose set supplied with the pump.

2.23 Isolating valves: Separate system isolating valves (non restrictive) must be

fitted to allow easy pump service.

2.24 Preferred pump location: The pump must, for optimum performance, be sited

as close as possible to and never more than 4 metres from the HOT WATER

cylinder. The pump should always be sited BELOW the HOT WATER take-off

from the cylinder. 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 for hot or cold

water installation.

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Cont ...

2 LOCATION - COLD WATER INSTALLATION

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

connector, and must be positioned at a slightly lower level (25 mm minimum)

than the feed pipe to the hot water cylinder.

Do not connect to the mains.

Fig. 4

Cold water

pump

Static inlet pressure

Min. 1m

Max. 10 m

Static outlet pressure

Max. 13 m

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Cont ...

2.26 Hot water cylinder or storage tank: When a hot water cylinder or storage

tank is used, ensure the pipework size from the cold water storage to the hot

water storage is of adequate size and a minimum of 28 mm.

2.27 Hot water supply: The pump must be supplied with a dedicated feed direct

from the hot water cylinder or storage tank which should be via a secondary

dedicated tapping (see Fig. 6).

Do not connect to the mains.

2LOCATION - HOT WATER INSTALLATION

Fig. 5

Hot water

pump

Static inlet pressure

Min. 1m

Max. 10 m

Static outlet pressure

Max. 13 m

Fig. 6

with rising

28 mm offset

expansion pipe

and pump.

Factory installed

secondary tapping with

28 mm pipework to

pump.

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Cont ...

2.28 Pump Mounted Above Liquid Source (Suction Lift Installation):

2.29 The pumps can be used in a suction lift installation providing the height of lift is

within the limits specified in the limits of application section and the liquid to be

pumped is cold water (for applications other than cold water contact Stuart

Turner).

2.30 Before deciding where to locate the unit, check to ensure the static outlet head

(Fig. 7) does not exceed the maximum requirements 13 metres.

2.31 A footvalve and strainer may be used and the suction pipework size must match

the pump.

2.32 Lay the suction piping over the shortest possible distance and ensure there is a

constant rise from the liquid source to the pump. Any high spots will cause air

pockets to form, reducing system efficiency.

2.33 Ensure all joints in suction pipework are completely airtight. Failure to comply

will result in loss of prime.

2.34 The intake of the footvalve/strainer should be positioned such that it cannot be

blocked with debris or silt that are frequently found in the bottom of sumps and

wells.

2.35 When a footvalve is installed in the suction pipework, it is recommended that

suitable pressure relief valve be fitted in the discharge (outlet) pipework from the

pump.

Fig. 7

Diagram showing typical Pressure Control

installation with suction lift.

Max. suction lift 4.6 m

Max. static outlet pressure 13 m

Note: This image is for

reference only

This manual suits for next models

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