Stuart Turner Monsoon Extra U1.4 bar 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 U1.4 bar

Pt. No. 46349

Monsoon Extra U3.6 bar

Pt. No. 46594

Monsoon Extra U2.6 bar

Pt. No. 46593

Monsoon Extra U5.0 bar

Pt. No. 46595

- 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 Monsoon Extra Universal Single 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.

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).

Please read installation details carefully as they are intended to ensure this product

provides long, trouble free service. Failure to heed the warnings 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.

CONTENTS

Page

Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Important Facts - read before commencing installation . . . . . . . . . . . . . . . . . . . . 5

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Pump Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Technical Speciﬁcation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

- 3 -

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.

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.

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 & gasket 1

Anti-vibration feet 5

- 4 -

Cont ...

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 (Figs. 3 & 4) 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 (not supplied), 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

(Figs. 3 & 4).

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 Motor

Factory fitted position

U1.4 bar

Area for alternative fitting

positions

Area for alternative fitting positions

Factory fitted position U2.6 bar,

U3.6 bar, U5.0 bar

Fig. 3 Fig. 4

- 5 -

Cont ...

1 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 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 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

pump assist team at Stuart Turner Ltd.

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 & Electrical Installation Regulations

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

Regulations 1999” and “BS 6700” 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 6 - Maintenance for

details.

- 6 -

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: If possible 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 cold water level (Figs. 6 & 7) is at least

1 metre and does not exceed the max inlet head of 8 metres for the U1.4 and

10 metres for other models.

2.17 Pump position: The pump must be positioned on its anti-vibration mounting feet

and as close to the water source as possible.

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

ambient temperature does not exceed 40 oC.

2.19 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.

2.20 Static outlet pressure: The static outlet head (Figs. 6 & 7) must also be within

the maximum requirement of 8 metres for U1.4 and 13 metres for all other

models.

2.21 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.

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

on the flow switch reed clamp (vertically upwards).

2.23 Flexible hoses: Use only Stuart Turner supplied hoses.

2.24 Isolating valves: Separate isolating valves (non restrictive) must be fitted to

allow easy pump service.

2.25 Preferred pump location: The preferred pump location is at floor level next to

the hot water cylinder or a level that is below the secondary tapping that feeds

the pump. This will ensure the pump has access to an air free water supply

which is important for trouble free operation (Figs. 6 & 7).

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.

- 7 -

2.26 Non-Preferred Pump Location: The pump must be located with at least 1 metre

flooded suction at all times.

If it is not possible to locate the pump in the preferred area due to site limitations

and it is necessary to position the unit in the loft, or in a position above the

secondary tapping that feeds the pump, then there is an increased risk of air

locks. This risk must be eliminated.

The following method will help to overcome the problem:

A “U” bend or downward loop in the supply pipe to the pump of 350 mm depth

before rising to the pump should ensure the cylinder vents its air up the

expansion pipe, not up the pump feed (Fig. 5).

2 LOCATION - COLD WATER INSTALLATION

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

2.28 The cold water supply: The supply must be air free and have a dedicated

connection to the tank which should be via a tank connector, positioned at a

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

Do not connect to the mains.

Max. inlet head 10 m

( 8m for U1.4)

Min. inlet head 1m

350 mm

min.

Least preferred area

Fig. 5

Fig. 6

Cold water

pump

Static inlet pressure

Min. 1 m

Max. 10 m

Static outlet pressure

Max. 13 m

- 8 -

Cont ...

2.29 Hot water supply: The supply must be air free and have a dedicated

connection to the tank which should be via a tank connector, positioned at a

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

Do not connect to the mains.

2.30 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.

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

the hot water cylinder or storage tank.

2 LOCATION - HOT WATER INSTALLATION

Fig. 7

Fig. 8

Hot water pump

Off expansion

pipe with rising

28 mm offset

reducing to

28 mm pipework

to pump and

expansion pipe.

Factory installed

secondary tapping with

28 mm pipework to

pump.

Static inlet pressure

Min. 1 m

Max. 10 m

Static outlet pressure

Max. 13 m

- 9 -

Cont ...

3 PUMP CONNECTIONS

3.11 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).

3.12 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 -

4 ELECTRICAL INSTALLATION / EARTHING

4.11 Regulations: The electrical installation must be carried out in

accordance with the current national electrical regulations and installed

by a qualified person.

4.12 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.

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

isolated.

4.14 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.

4.15 Adjacent pipes: Adjacent suction

and delivery pipes should be

fitted with earthing clamps

to BS 951 in accordance with

current regulations (Fig. 9).

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

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

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

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

4.18 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.

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

the mains supply using the factory fitted supply cord, via a double pole switched

fused spur off the ring main and NOT connected to the boiler or the immersion

heater circuits.

4.20 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.

Diagram of

earth continuity

connections

Fig. 9

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