Stuart Turner CH 4-30 FL 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 suitable for 230/1/50 supply.

CH 4–30 FL

Pt. No. 46578

Pt. No. 46578 EXP

CH 4–40 FL

Pt. No. 46596

Pt. No. 46596 EXP

CH 4–50 FL

Pt. No. 46605

CH 4–60 FL

Pt. No. 46606

FOR POSITIVE HEAD APPLICATIONS ONLY

50 Hz CE compliant product

STUART

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Cont ...

Arabic Installation Operation & Maintenance Instructions ................... 31

English (GB) Installation Operation & Maintenance Instructions .............. 2

PRODUCT DESCRIPTION

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

consisting of flow switch, and electronic control.

APPLICATION

The Stuart CH FL range is designed for pressure boosting applications in vented

stored, hot, cold or blended clean water systems, where under gravity, a flow is

available of at least 1 l/min. If you wish to boost both hot and cold services, then CH

Boostamatic models must be used, for further details contact ‘TechAssist’.

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

given in the technical specifications.

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 ...........................................................5

Important Facts – read before commencing installation ......................7

Location ............................................................8

Electrical Installation ..................................................9

Plumbing ...........................................................11

Technical Specification ................................................13

Trouble Shooting .....................................................14

Guarantee ..........................................................16

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Cont ...

WARNINGS:

zThis pump set must not be used for any other

application without the written consent of Stuart

Turner Limited.

zDo not connect this pump 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.

zChildren shall not play with the appliance.

zCleaning and user maintenance shall not be made by

children without supervision.

zMaximum head (closed valve) CH 4–30 FL-25 metres,

CH 4–40 FL-36 metres, CH 4–50 FL-50 metres,

CH 4–60 FL-62 metres.

zThe motor casing can become very hot under normal

operating conditions. Care must be taken to ensure it

cannot be touched during operation.

zThe electrical installation must be carried out

in accordance with the current national electrical

regulations.

zThe electrical installation must be installed by a

qualified person.

zIn 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.

zBefore starting work on the electrical supply ensure

power supply is isolated.

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Cont ...

zDo 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.

zThis appliance must be earthed via the supply cord,

which must be correctly connected to the earth

point located in the terminal box.

zThe supply cord and internal wiring within the

terminal box are routed and secured to ensure

compliance with the electrical standard

IEC 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.

zIf 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.

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.

- 5 –

CHECKLIST

Your product may vary slightly from the picture above.

Fig. 1

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.

Outlet port

Inlet port

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Cont ...

ASSEMBLY

To protect the unit during tansit the pump is supplied with the flow switch removed.

Follow the instructions below to complete assembly.

zEnsure all components are clean and free from debris.

zScrew complete flow switch body assembly into pump body, ensuring ‘O’-ring is

fitted (Fig. 2).

zTighten to 7 – 10 Nm (5 – 7 lb ft).

zCare should be taken when handling the reed switch not to damage the reed or

cable.

zFor correct operation of the flow switch, the reed must be secured to the body

(Fig. 2).

zFirstly feed the tie wrap through the retainer on the reed switch, ensuring that the

tie wrap serrations are facing outwards (Fig. 3).

zLocate the reed switch within the body groove as highlighted X-X (Fig. 2), and feed

the tie wrap through the second catch. Note the arrow on the reed switch should

be pointing up, towards the outlet connection.

zThe tie wrap can now be pulled tight to secure the reed and the excess cut to

length as shown (Fig. 4).

Torque rotation

Flow switch body

Reed switch tie wrap

‘O’-ring

Pump

Fig. 2

reed switch

(pre-wired)

Reed switch

Catch

Serrations

Trim off

Tie wrap

Retainer

Fig. 3 Fig. 4

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Cont ...

1 IMPORTANT FACTS: READ BEFORE COMMENCING PUMP INSTALLATION

A Water storage capacity.

1.11 The 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 4 –

Plumbing.

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

maximum ambient temperature should not exceed 50 oC.

1.16 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 TechAssist team on +44 (0) 800 31 969 80.

C Water flow

1.17 For this pump to operate correctly there must be a minimum gravity flow of at

least 1 l/min through all outlets to be pumped.

D Pipework – general

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

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

branches of pump.

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

pump installation (flux damage will void any warranty).

1.20 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.

1.21 DO NOT introduce solder flux to pump parts manufactured from

plastic.

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

or strippers, acid based descalents or aggressive cleaning agents.

1.23 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.

E Plumbing installation regulations

1.24 The plumbing installation must be installed by a qualified person and in

accordance with local regulations.

F Electrical/installation regulations

1.25 Check the mains voltage and frequency corresponds to the values on the

pump rating plate.

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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 Mounting foot securing: This pump is fitted with cast feet. If there is a

requirement to secure the pump via the feet, the following points should be

noted.

The pump should be mounted only in the horizontal position.

The mounting bolts used to secure the pump must be fitted with a plain

washer to distribute clamping load evenly across load bearing face of foot

(not supplied).

Fig. 5

PLAIN

WASHER

MOUNTING

FOOT

BOLT

Fig. 6

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Cont ...

3 ELECTRICAL INSTALLATION  EARTHING

3.11 Regulations: The electrical installation must be carried out in

accordance with the current local regulations by a qualified person.

3.12 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.

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

isolated.

3.14 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.

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

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

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

of the mains supply using the factory fitted supply cord, via a dedicated

double pole switched fused spur off the ring main.

3.17 Wiring of connection unit:

WARNING: This appliance must be earthed.

The wires in the mains lead (supply cord) 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:

zThe 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.

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

is marked with the letter N or coloured black.

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

which is marked with the letter L or coloured red.

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3.18 Wiring diagram:

3.19 Fuse: All models should use 13 Amp fuse.

3.20 Supply cord replacement:

The supply cord and internal wiring within the terminal box are

routed and secured to ensure compliance with the electrical

standard IEC 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.

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

special cord available from Stuart Turner or one of its approved repairers.

GREEN / YELLOW

BLUE

BROWN L

N220 VAC/1PH/60Hz

SUPPLY

RED

CAPACITOR

MOTOR

GREEN / YELLOW (LINK WIRE)

RED

YELLOW

RED

BLACK

FLOWSWITCH

REED (S2)

S2 S2

Fig. 7

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