Stuart Turner MAINSBOOST iBOOST F200 Guide

Read this manual carefully before commencing installation.

This manual covers the following products:

iBOOST F200

Pt. No. 46668

iBOOST V200

Pt. No. 46711

Please note images are representative only and

may not portray your model

MAINSBOOST iBOOST

Installation, Operation & Maintenance

Instructions

Please leave this instruction booklet with the home owner as it

contains important warranty, maintenance and safety information

- 2 –

PRODUCT DESCRIPTION

iBOOST F200

Water pressure and flow booster set with integral water storage tank and electric

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

of flow switch, pressure switch, pressure vessel and electronic control. The design of

the tank incorporates an AF air gap for fluid isolation (BS EN 1717).

iBOOST V200

Water pressure and flow booster set with integral water storage tank and electric

motor driven centrifugal pump complete with an automatic variable speed control

system, consisting of pressure transducer and integral variable speed drive. The

design of the tank incorporates an AF air gap for fluid isolation (BS EN 1717).

APPLICATION

The Mainsboost iBoost 200 is designed to meet the demand of pressurised systems

in larger domestic applications where the existing mains water supply is insufficient.

Inlet pressures to the tank 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 . . . . . . . . . . . . . . . . . . . . . .6

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

Key Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Installation & Pump Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

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

Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Warranty Policy Terms and Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

- 3 –

WARNINGS:

This pump set must not be used for any other

application without the written consent of Stuart

Turner Limited.

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.

This product should not be used for the supply of

water to more than one dwelling (house, apartment,

flat).

Cleaning and user maintenance shall not be made by

children without supervision.

Maximum head (closed valve) 45 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.

F200: 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.

V200: RCD’s/ELCB’s are not recommended for use

with variable speed drives/motors. If an RCD is

mandatory use type B RCD’s.

For single phase sets with invertor motors

the earth leakage circuit breaker must trip out

when an earth fault currents with DC content

(pulsating DC) occur.

- 4 –

RCD’s suitable for use with variable speed

drives/motors are not suitable for personnel

protection.

Do not touch any electrical components for at

least 5 minutes after the unit has stopped to

allow any discharge to occur safely.

Before starting work on the electrical supply ensure

power supply is isolated.

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.

In order to avoid toppling over the appliance must

be placed on a smooth, level surface and the

retaining strap must be fitted.

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

Note: Item B 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

iBoost 200 1 M6 screw 1

Hose & sealing washer 1 Instruction book 1

Retaining strap 1 Installation template 1

Fig. 1

IMPORTANT: With the appliance 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.

- 6 –

1 IMPORTANT FACTS: READ BEFORE COMMENCING PUMP INSTALLATION

A Water storage capacity.

1.11 The iBoost has a usable water volume of approximately 200 litres; the length

of time the iBoost delivers water will be dependent on the usage and refill

rates.

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

starting, to avoid causing damage to the pump shaft seal. See Section 6 –

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 23 oC (see Section 7.13).

1.14 The minimum allowable water temperature is 4 oC.

C Pipework – General

1.15 Do not drill holes or put fastenings into the iBoost tank, this will cause

leakage.

1.16 System leaks: Ensure the system to be boosted is able to hold pressure and

is leak free before installing iBoost. Failure to do so will cause abnormal

operation and damage to the unit.

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

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

branches of pump. Do not secure pipework to the iBoost, this will cause

damage and possible leakage.

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

iBoost installation (flux damage will void any warranty).

1.19 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.

1.20 DO NOT introduce solder flux to flexible hose, tank, pump or any parts

manufactured from plastic.

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

or strippers, acid based descalents or aggressive cleaning agents.

1.22 DO NOT bend the flexible hose beyond 30o. It must be installed as

straight as possible.

1.23 DO NOT feed other header or gravity tanks with iBoost. It is

acceptable to feed toilet cisterns provided the toilet fill valve operates

correctly and is leak free.

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.

E Pressure vessel

1.26 The iBoost F200 pressure vessel is charged at the factory see Section 7 –

Maintenance for details.

1.27 The iBoost V200 pressure vessel pre-charge must be set correctly during

installation, see section 6.12 for details.



- 7 –

2 LOCATION  GENERAL

2.11 Access: For emergencies and maintenance the pump must be

easily accessible.

2.12 Protection: The iBoost must be located in a dry, frost free area.

The iBoost must not be installed in a loft space.

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

Separate the iBoost from other appliances that generate heat.

Do not block the vent holes on the front panel.

2.14 Safety: Motor is not accessable in normal operating mode. Unit

must only be operated with the front cover in place.

2.15 Water retention: Site the iBoost 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 Supply inlet pressure: The water supply inlet pressure must be lower than

7 bar; lower supply inlet pressures will reduce the tank fill rate and reduce the

time the iBoost will run at higher flow rates before running out of stored

water.

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

ambient temperature does not exceed 30 oC (see Section 7.13 – Water

Quality).

2.18 Pipework: For optimum performance outlet pipework must be 22 mm pipe.

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

2.19 Static outlet pressure: The static outlet head must also be within the

maximum requirement of 15 metres (vertically above the appliance).

2.20 Noise: A flexible hose is supplied as standard which will minimise the

transmission of noise and vibration from the iBoost pump to the pipework

connected to the appliance outlet. However, care must be taken when

mounting the iBoost that any noise is not amplified through loose panels or

pipework.

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 hose: Only use the Stuart Turner hose supplied with the pump.

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

fitted to allow easy pump service. Isolating valves must be mounted where

specified to allow the system isolation and removal of the iBoost if needed.

See Section 4 for installation details.

2.24 Preferred iBoost location: The preferred iBoost location is on a smooth level

floor of sufficient strength to support the filled weight of the iBoost close to

the water source and a suitable overflow position (see Section 8 – Technical

Specification for filled weight).

The iBoost must not be installed in a loft space.

It must also be considered that the noise and vibration from the iBoost may

be transmitted through the structure the iBoost is sited on.

Ensure there is sufficient room above the iBoost to allow the removal and

servicing of the internal float valve if needed, typically 350 mm.

- 8 –

3 KEY FEATURES

iBoost F200

iBoost V200

Label

Part No & Serial No

Overflow

Outlet hose

Pressure vessel

Drain valve

Tank

Tank access cover

Mains water connection

User interface

User interface cable

Pump module

Pump module retaining

screws

Pump isolation valve

(behind pump)

Fig. 2

Retaining strap

Cover retaining

screw location

Label

Part No & Serial No

Overflow

Outlet hose

Pressure vessel

Drain valve

Tank

Tank access cover

Mains water connection

User interface

Pump module

Pump module retaining

screws

Pump isolation valve

(behind pump)

Note: iBoost shown with front cover removed Fig. 3

Retaining strap

Cover retaining screw

location

- 9 –

4 INSTALLATION & PUMP CONNECTIONS

4.11 Mains water connection to iBoost: The iBoost is to be permanently

connected to the mains water supply using rigid pipe or suitably sized and

rated flexible hose to comply with current building and plumbing regulations.

The water tank fill valve has a G ½ male threaded fitting; a suitable 90oelbow

type fitting must be used. When tightening ensure the fill valve within the

tank is not rotated. If the valve is rotated it may not function correctly with

the risk of flooding.

Ensure there is a demountable joint in the pipe to allow the removal of the

iBoost if needed (see Fig. 8).

4.12 Water outlet pipework:

1. The pump has a G ¾ threaded connection to accept the supplied hose.

The hose is made water tight with a sealing washer on assembly, nip tight

to 4 to 5 Nm for water tight seal. (Do not overtighten). The supplied hose

must only be connected to 22 mm pipework.

Ensure the pipe is free from all score marks and deformities in the area of

the insertion depth (Fig. 4) and cut the pipe square removing all burrs and

sharp edges to prevent damage to the sealing ‘O’-ring.

2. Prior to inserting the pipe into the fitting mark the insertion depth on the

wall of the pipe with a soft pencil at a distance of 33 mm from the end to

be inserted.

3. Check in the mouth of the fitting that the ‘O’-ring, nylon washer and collet

are in position.

Fig. 4

Pencil mark

Insert depth

33 mm

Pipe

Fig. 5

Collet

Body

Washer

‘O’-ring

Pipe stop

Hose

- 10 –

4. Push pipe firmly into fitting, until pencil mark is level with the top of the

collet and the pipe stop resistance is felt. Pull on the pipe to check it is

secure and correctly fitted.

5. To break the joint, push pipe firmly into fitting, hold collet down and

gently remove pipe. If the system has been fitted with water care should

be taken to isolate pump and towels used to absorb spilled water.

4.13 Connection to overflow/warning pipe: The overflow fitting is designed to

use G 1 ¼ (35 mm OD) plastic waste pipe. Ensure there is a demountable

joint in the pipe to allow the removal of the iBoost if needed (see Fig. 8). The

overflow must be free to vent to atmosphere either via a tundish or a

dedicated external pipe.

4.14 The iBoost is intended to be either installed as a freestanding unit with its

back to a wall or into a 600 mm tall kitchen cupboard. If installed into a

600 mm kitchen cupboard the floor and back panel will need to be removed.

The carcass of the cupboard will need to be screwed to the adjacent units

and the wall for support.

All the services are connected to the iBoost via a plumbing access window at

the back of the unit, the installation is conducted in 4 simple steps.

Prior to installation remove the screw on the top of the unit and pull the

corner of the front cover to remove it and retain them in a safe place.

Step 1

Position the paper installation template on the wall where the iBoost is to be

installed, ensuring the ‘floor level’ of the template is level and resting on the

surface the iBoost is to be mounted on (Fig. 6).

InstallationTemplate

140

100

480

320

600

100

Fig. 6

Mains water

supply

Non-pumped

water supply

Overflow

Floor

(see 2.24)

All dimensions in mm

Pumped water

supply

Tundish

External

overflow

Template

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