Stuart Turner Monsoon Extra 2.6 bar PS 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

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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 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 is not intended for use by persons (including children)

with reduced physical, sensory or mental capabilities, or lack of

experience and knowledge, unless they have been given supervision

or instruction concerning use of the appliance by a person responsible

for their safety.

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).

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

Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Technical Speciﬁcation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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

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CHECKLIST

Item Description Qty Item Description Qty

Pump 1 Anti-vibration feet 4

Hose & sealing washer 2 Inline strainer & sealing washer 1

Inlet connector & ‘o’-ring 1 Pressure vessel 1

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.

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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 DO NOT allow the pump to run dry as damage to the shaft seal will result. To

ensure dry running does not occur the pump must be primed as described in

priming section. See Section 4 - 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 Ensure pipework to and from pump is independently supported & clipped to

prevent forces being transferred to inlet and outlet branches of pump.

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

installation.

1.17 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.

D. Plumbing & Electrical Installation Regulations

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

Regulations 1999” and “BS 6700” building regulations.

1.23 The plumbing installation must be installed by a competent person.

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

national electrical regulations.

1.25 The electrical installation must be installed by a qualified electrician.

E. Pressure vessel

1.26 Pressure vessel is pre-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 protected from frost and freezing

particularly when located in a loft installation (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 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 Protection: The pump must be located in a dry position where it cannot be

sprayed with water and protected from the weather.

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

the static inlet head between pump and cold water level (Fig. 2) is at least 1 metre

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

2.18 Pump position: The pump must be positioned horizontally on its anti-vibration

mounting feet and as close to the water source as possible.

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

ambient temperature does not exceed 40 oC.

2.20 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.

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

maximum requirement of 13 metres.

2.22 Noise: Care must be taken when mounting the pump that any noise is not

amplified through loose panels or pipework.

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

on the flow switch reed clamp (vertically upwards).

2.24 Flexible hoses: Use only the Stuart Turner supplied hoses to connect the pump.

2.25 The hoses must be used and kept straight with a maximum allowable bend of 30o.

2.26 NRV’s: DO NOT install non-return valves, 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 tanks at all times.

2.27 Preferred Pump Location: The preferred location of the pump is on the floor

1 metre below the base of the water tank.

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Cont ...

2 LOCATION

2.28 Cold water mains: DO NOT connect the pump to the cold water mains.

2.29 Cold water supply: The pump must be supplied with a dedicated air free supply

direct from the cold water storage tank in 28 mm pipework.

2.30 The cold pump feed: MUST NOT be shared with any other outlets.

2.31 The cold water supply: Must be via a tank connector positioned at a slightly

lower level (25 mm minimum) than the feed pipe to the hot water cylinder and

on the opposite side to the cold mains inlet.

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

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3 ELECTRICAL INSTALLATION / EARTHING

3.11 Regulations: The electrical installation must be carried out in

accordance with the current national electrical regulations and installed

by a qualified electrician.

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 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.

3.14 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.

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

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

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

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

3.18 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.

3.15 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

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Cont ...

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

the mains supply using the factory fitted supply cord, this must be a fused spur off

the ring main and NOT connected to the boiler or the immersion heater circuits.

3.20 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.

3.21 Wiring Diagram:

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 any disturbance of this

internal wiring is avoided and the factory routing and securing of

all internal wiring is always maintained.

Model Fuse Size (AMPS)

All Models 13

3.22 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

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Cont ...

4.13 Air purge: Open and close all pumped outlets in turn allowing water to flow from

each outlet until all air is purged.

4.14 Switch on the pump: Open and close all pumped outlets in turn. The pump will

start and stop upon demand. Note: After closing the outlet there will be a small

delay time before the pump stops, which is normal.

Any tap or control valve within the system when opened and closed will now turn

the pump on/off. Providing this is the case the system is now operating correctly.

Carefully check pump and pipework for leaks whilst pump running and stationary

before leaving the installation unattended.

The motor casing can become very hot under normal operating

conditions, care should be taken to ensure it cannot be

touched during operation.

Do not run pump without guards and terminal box lid correctly

fitted.

The pump chamber must be full of water at all times. Seal

damage will result if the pump runs dry.

4.15 For Further Technical Support: Phone the Stuart Turner Pump Assist team

on 0844 98 000 97. Our staff are trained to help and advise you over the phone.

4 COMMISSIONING / SYSTEM FLUSHING/ PRIMING / STARTING

4.11 System Flushing

The pipework system should be flushed out prior to the pump

being connected to ensure any contaminants/chemical residues

and foreign bodies are removed from elsewhere in the system.

4.12 Priming: Prior to switching the pump on and connecting the outlet hoses to

the system pipework the pump chamber must be primed. The pump must be

primed (filled with water) before starting. Turn on water supply, prime and vent

the pump by unscrewing the priming plug (Fig. 6) slowly until all air escapes and

water emerges. Re-tighten the plug.

2.6, 3.6 bar PS Fig. 6

Priming/

vent Plug

Drain

Plug

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Cont ...

5 MAINTENANCE

5.11 Inlet strainer: Incorporated in the strainer is a removable gauze filter which

may require periodic cleaning. The frequency of this operation is dependent upon

installation conditions.

The strainer is located in the inlet pipework to the pump (Fig. 1). The gauze filter

is removed as follows:-

a) Isolate pump electrically.

b) Release all system pressure.

c) Isolate water supply.

d) Remove screwed hexagonal plug from strainer body taking care to collect or

absorb any residual water (Fig. 7).

e) Remove and clean stainless steel gauze filter.

f) Reassemble gauze and secure plug tightly.

g) Turn on water supplies, connect power supply and test.

5.12 Pressure vessel: The pressure vessel should be checked once every 6 months

to have its air pre-charge checked or replenished, this should be carried out

as follows:-

a) Isolate pump electrically.

b) Isolate the water supply by closing the appropriate isolating valves.

c) Release system water pressure by opening an outlet on the system.

d) Disconnect hose fitted to pressure vessel.

e) Check air pre-charge at Schrader valve (Fig. 8) using a tyre pressure gauge.

f) Replenish air charge by injecting air into the vessel via the Schrader valve

using a car or bicycle pump (Fig. 8).

g) Re-connect hose to pressure vessel to achieve a water tight connection.

Ensure fibre washer seal is in place.

h) Close all system outlets, open inlet and outlet isolating valves.

i) After maintenance is completed refer to Section 4 - Commissioning for

instructions on re-starting pump.

Strainer

Gauze

Gasket

Hex plug

Fig. 7

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