Stuart Turner CH 4-30 PS Guide

STUART

CH PRESSURE SETS

Installation, Operation & Maintenance

Instructions

Please leave this instruction booklet with the home owner as it contains important

warranty, maintenance and safety information.

Read this manual carefully before commencing installation.

This manual covers the following products:

CH 4-30 PS

Pt. No. 46601

CH 4-50 PS

Pt. No. 44622

CH 4-40 PS

Pt. No. 46602

CH 4-60 PS

Pt. No. 44624

Please note images are representative only and may not portray your mode

- 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 CH 4 Pressure Set 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.

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

1WARNINGS......................................................................................................3

2CHECKLIST ......................................................................................................5

3IMPORTANT FACTS .........................................................................................6

4LOCATION - GENERAL ....................................................................................7

5PUMP CONNECTIONS .....................................................................................9

6ELECTRICAL INSTALLATION / EARTHING .................................................... 10

7COMMISSIONING / SYSTEM FLUSHING/ PRIMING / STARTING.................. 13

8MAINTENANCE .............................................................................................. 14

9TECHNICAL SPECIFICATION ......................................................................... 16

10 TROUBLE SHOOTING GUIDE......................................................................... 18

11 PRODUCT WARRANTY TERMS & CONDITIONS............................................ 21

Cont ...

- 3

1WARNINGS



This pump set must not be used for any other

application without the written consent of Stuart

Turner Limited and in particular, 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.



This product should not be used for the supply of

water to more than one dwelling (house, apartment,

flat).



Maximum head (closed valve) CH 4-30 PS-25 metres,

CH 4-40 PS-37 metres, CH 4-50 PS-51 metres,

CH 4-60 PS-64 metres.



The motor casing can become very hot under normal

operating conditions. Care must be taken to ensure it

cannot be touched during operation.



The electrical installation must be carried out in

accordance with the current national electrical

regulations.



The electrical installation must be installed by a

qualified person.



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.



Before starting work on the electrical supply ensure

power supply is isolated.

Cont ...

- 4



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.



This appliance must be earthed via the supply cord,

which must be correctly connected to the earth point

located in the terminal box.



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.

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.

Cont ...

- 5

2CHECKLIST

Note: Item E 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

APump 1DPressure vessel 1

BHose & sealing washer 2EMounting feet & fittings 4

CInline strainer 1

28 mm copper outlet pipework (discharge).

Short 28 mm copper

pipe tails to connect

between isolating valve

and ﬂexible pipes.

28 mm copper

inlet pipework

(suction).

28 mm isolating valve

(non restrictive) and

ﬁttings (not supplied)

to allow ea sy 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

suitab le for connection to a

G 1 (1 “ BSP) adap tor or ﬁtting.

28 mm isolating valve

(non restrictive) and

ﬁttings (not supplied)

must be ﬁtted to allow

easy pump service.

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.

Cont ...

- 6

3IMPORTANT FACTS

READ BEFORE COMMENCING PUMP INSTALLATION

AWater storage capacity.

3.11 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.

3.12 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.

BWater temperature

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

following values:

3.13 The maximum allowable water temperature is 23 oC.

3.14 The minimum allowable water temperature is 4 oC.

Pipework - General

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

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

branches of pump.

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

pump installation (flux damage will void any warranty).

3.17 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 90o bends.

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

manufactured from plastic.

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

or strippers, acid based descalents or aggressive cleaning agents.

3.20 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.

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

straight as possible.

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

DPlumbing Installation Regulations

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

regulations.

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

Pressure

vessel

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

details.

Cont ...

- 7

4LOCATION - GENERAL

4.11 Access: For emergencies and maintenance the pump must be easily

accessible.

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

and protected from freezing, particularly when installed in a loft

(not recommended).

4.13 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.

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

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

touched during operation.

4.15 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.

4.16 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.

4.17 Pump position: The pump must be positioned on its mounting feet and as

close to the water source as possible.

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

maximum ambient temperature does not exceed 40 oC.

4.19 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.

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

maximum requirement of 13 metres.

4.21 Noise: 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.

4.22 Direction of flow: Ensure the water flow is in the direction of the arrow

marked on the flow switch reed clamp (vertically upwards).

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

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

fitted to allow easy pump service.

4.25 Preferred pump location: The preferred pump location is at floor level next

to the water source or a level that is below the secondary tapping that feeds

the pump. Ensure the pump is mounted in a position that allows easy access

to the terminal box if required. The pump location is also dependent on

limitations of the static inlet and outlet heads of the installation.

Cont ...

- 8

Unvented hot

water cylinder

Cold

water

Hot water

Fig. 2

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

connector.

Do not connect to the mains.

Static

inlet pressure

Min. 1 m

Max. 10 m

Static

outlet pressure

Max. 13 m

Cont ...

- 9

5PUMP CONNECTIONS

5.11 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).

5.12 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.

- 10 -

6ELECTRICAL INSTALLATION / EARTHING

6.11 Regulations: The electrical installation must be carried out in

accordance with the current national electrical regulations and

installed by a qualified person.

6.12 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.

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

isolated.

6.14 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.

6.15 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.

Warning Tag

Fig. 3

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

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

Diagram

of earth

continuity

connections

Fig. 4

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

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

6.18 Pipework: Copper or metallic pipework must have supplementary earth

bonding where the continuity has been broken by flexible hoses or plastic

components.

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