Stuart Turner Monsoon extra User manual

INDEX ............................................... Page No

Application . . . . . . . . . . . . . . . . . . . . . . . . 1

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Typical Installation . . . . . . . . . . . . . . . . . . 2

Pre-Installation Assembly . . . . . . . . . . . . 2

Pump Location . . . . . . . . . . . . . . . . . . . . . 3

Pipework Connections . . . . . . . . . . . . . . . 5

Pump Connections . . . . . . . . . . . . . . . . . 7

INDEX ............................................... Page No

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

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

Maintenance . . . . . . . . . . . . . . . . . . . . . . 14

Technical Specification . . . . . . . . . . . . . . 16

Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Trouble Shooting Guide . . . . . . . . . . . . . . 17

Environment Protection . . . . . . . . . . . . . . 19

Please leave this instruction booklet with the pump as it

contains maintenance and safety information.

Installation Instructions

For Monsoon Extra

Negative Single Duty Pump

Medium Pressure N1.3 bar High Pressure N2.4 bar

High Pressure N2.9 bar High Pressure N3.7 bar

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 Single Negative Monsoon Extra range is designed for pressure boosting

applications in vented stored, hot or cold, clean water systems, where under gravity, no

flow is available. 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 and in particular, 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.

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.

- 2 -

TYPICAL INSTALLATION (Cold Water, Negative Duty Single Pump System)

STEP 1: PRE-INSTALLATION ASSEMBLY

Pressure Check and Assembly of Pressure Vessel

a) Your pump is supplied in two parts, the main pump and pressure vessel. The

pressure vessel is pre-charged with air at the factory (see table below). This

pressure should be checked at the schrader valve using a tyre pressure gauge and

adjusted if necessary using a car or bicycle pump prior to installation.

b) To assemble, remove protective plastic cap from pressure vessel thread. Ensure that

the fibre washer is present at the bottom of the fitting point. Screw the pressure

vessel clockwise until hand tight to achieve a water tight connection.

This diagram should be used for

schematic reference only

1: Isolating valve

2: Inlet strainer

3: Flexible hose

Negative

Head

Fig. 1

The plumbing installation

must comply with the

following:

The Water Supply (Water Fittings)

Regulations 1999.

BS6700 and building regulations.

Be installed by a competent person.

• If in doubt contact Stuart Turner Ltd

Schrader valve

Pressure vessel

Fibre washer

Fig. 2

Fitting point

NOTE: Do not over tighten pressure vessel.

Model Air Precharge

bar (psi)

All models 0.9 (13)

- 3 -

STEP 2 PUMP LOCATION (General)

WARNINGS:

Pump Location

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.

Care should be taken to protect pump from frost and freezing,

particularly when located in loft position.

The motor casing can become very hot under normal operating

conditions, care should be taken to ensure it cannot be touched

during operation.

Locate the pump in a dry, frost free position where it cannot be sprayed with water. It

should be positioned horizontally on its anti-vibration mounting feet and should not be

screwed down. It should be positioned as close to the water source as possible having a

minimum flooded suction head of 1 metre at all times.

Ensure the water flow is in the direction of the arrow that is marked on the flow switch

reed clamp (vertically upwards).

Typical pump locations are in an airing cupboard, or inside a vanity unit with a small

purpose built dry and ventilated enclosure. The enclosure should have a minimum

clearance of 80 mm (3 ”) between the pump and housing on all sides. The enclosure

should be secure and access should only be available by the use of tools.

The resilient anti-vibration mounting feet and flexible hoses which are supplied as

standard, are a precaution to reduce noise transmission, however care must be taken

when mounting the pump that any noise is not amplified through loose panels, pipework

or other mounting medium.

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. 3 & 4).

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.

Cont....

- 4 -

Cold Water Installations

Preferred Pump Location

(shaded area). Pump at a

level below the cylinder

draw off tapping.

Fig. 3

Max. inlet head 10 m ( 8m for N1.3)

Min. inlet head 1m

Negative

head

Fig. 4

Max. inlet head 10 m ( 8m for N1.3)

Min. inlet head 1m

Max. outlet head 13 m ( 8m for N1.3)

Negative

head

Preferred

area

Before deciding where to locate the unit, check to ensure the static inlet head (Fig. 3)

meets the minimum requirement of 1 metre and does not exceed the maximum

requirement of 8 metres for N1.3 and 10 metres for other models.

The static outlet head (Fig. 3) must also be within the maximum requirement of

8 metres for N1.3 and 13 metres for other models.

Hot Water Installations

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 (Fig. 4).

Before deciding where to locate the unit, check to ensure the static inlet head (Fig. 4)

meets the minimum requirement of 1 metre and does not exceed the maximum

requirement of 8 metres for N1.3 and 10 metres for other models.

The static outlet head (Fig. 4) must also be within the maximum requirement of

8 metres for N1.3 and 13 metres for other models.

Max. outlet head 13 m ( 8m for N1.3)

- 5 -

STEP 3 PIPEWORK CONNECTIONS (General)

WARNINGS

Ensure pipework to and from pump is independently supported to

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

Do not introduce solder flux to pumps or pump parts manufactured

from plastic. All solder joints should be completed and flux residues

removed prior to pump connection.

Do not allow contact with oil or cellulose based paints, paint thinners

or strippers, acid based descalents or aggressive cleaning agents.

Always install isolating valves to both suction and delivery pipework.

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

tanks at all times.

Hot Water Installations

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 measure is a suggestion that may 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).

Least Preferred Pump

Location (shaded area).

Pump located above the

hot cylinder can increase

the risk of air locks.

Fig. 5

Max. inlet head 10 m ( 8m for N1.3)

Min. inlet head 1m

Max. outlet head 13 m ( 8m for N1.3)

Negative

head

Least preferred area

350 mm

min.

- 6 -

Outlet

Inlet

Fig. 6

N2.4 Single shown.

It must be ensured that the water storage capacity is sufficient to meet the flow rates

required by the pump and any other water using fittings and appliances, which may be

operated simultaneously.

As a rule of thumb: assuming a cold water temperature of 10°C and a hot water

temperature of 65°C.

A 6-minute shower using 10 litres/min will consume 40 litres of hot water and 20 litres

of cold. This means the total quantity of water used from the cold water storage tank

will be 60 litres (40 + 20).

A 10-minute shower using 15 litres/min will consume 100 litres of hot water and 50

litres of cold. This means the total quantity of water used from the cold water storage

tank will be 150 litres (100 + 50).

On installations where there are high flow requirements e.g. multiple showers or body

jets.

A 10-minute shower using 45 litres/min will consume 300 litres of hot water and 150

litres of cold. This means the total quantity of water used from the cold water storage

tank will be 450 litres (300 + 150).

The pipework feeds to the storage tank should be of adequate size to ensure

replenishment rate of tanks is sufficient to meet the needs of the pump.

Care should be taken in the design of pipework runs, to minimize the risk of airlocks.

To prevent loss of water pressure through pipework use 28 mm suction pipework to the

pump.

Any bend requirements should be achieved by hand drawing the tube or by use of the

appropriate bend fittings. All pipework should be securely clipped.

Isolating valves (not supplied) should be fitted on the suction and delivery pipework to

enable easy isolation and access to the pump.

The 1 " inline strainer as supplied should be fitted in the suction line to the pump

between the isolating valve and the pump. This will eliminate the risk of debris or scale

entering the pump.

Pipework Connections (Cold)

The pump must be supplied with a dedicated feed direct from the cold water

storage tank.

Ensure the pipework size from the cold water storage tank to the pump is of adequate

size and a minimum of 28 mm.

The supply must be air free and connections of the feed pipe to the tank should be via

a tank connector, positioned at a slightly lower level (25 mm minimum) than the feed pipe

to the hot water cylinder.

- 7 -

Pipework Connections (Hot)

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.

The pump must be supplied with a dedicated feed direct from the hot water

cylinder or storage tank.

Ensure the pipework size from the hot water storage tank to the pump is of adequate

size and a minimum of 28 mm. The supply must be air free and connection to the

cylinder can be via an Essex flange, or by one of the methods shown in Fig. 7.

When the method of connection is to be made via the expansion pipe, the cold water

cistern should be at least 1.5 metres above the top of the hot water cylinder.

(As close to the cylinder as possible)

Existing

secondary

tappings

22 mm

Essex

flange

28 mm

Surrey

flange

22 mm outlet

Off expansion

pipe, off-set 45°,

28 mm pipework

Off vertical

expansion

pipe 28 mm

pipework

Most preferred Fig. 7 Least

preferred

NOT RECC

45°

Pipework Connections (Connection between pump and system outlets)

This should run as far as possible in 22 mm copper tube. Any bend requirements

should be achieved by hand drawing the tube or by use of the appropriate bend fittings.

Pipework should only be reduced to 15 mm copper if necessary when entering the

terminal fittings. By this method the maximum performance of the pump will be

maintained. All pipework should be securely clipped.

STEP 4 PUMP CONNECTIONS (Release and connection of push-in connectors)

WARNINGS:

Do not use stainless steel, chrome or nickel plated pipe with Stuart

Turner push-in plumbing connections.

Do not introduce solder flux into the joint or surrounding area as

connectors will be attacked and may fail.

All solder joints should be completed and flux residues removed

before final connection to push in connections, either on flexible hose

or pump head.

Do not allow contact with oil or cellulose based paints, paint thinners

or strippers, acid based descalents or aggressive cleaning agents.

- 8 -

Disconnection

To break the joint, push the pipe into fitting, hold collet down and gently remove pipe by

pulling out of collet. If the system has been filled with water, care should be taken to

isolate the pump and towels used to absorb spilled water.

Connection

1. Stuart Turner recommend only the use of their 22 mm flexible hoses.

The hose and pump are fitted with plastic push-in connectors, which must only be

connected with the following:

a) 22 mm diameter copper pipe to BS EN 1057 - R250 (half hard) - Table 3.

b) 22 mm plastic pipe to BS 7291 part 1 and part 2 (Table 1), or part 3 (Table 1) plus

internal support sleeve*.

* The internal bore of the plastic pipe must be supported against collapse with the

pipe manufacturers recommended support sleeve (pipe insert).

c) Appropriate plumbing fittings from the John Guest 'speedfit' push-in plumbing

fitting range.

Other manufacturers fittings are not necessarily compatible and may not provide a

water tight connection.

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

insertion depth (Fig. 8) and cut the pipe square removing all burrs and sharp

edges to prevent damage to the sealing 'O'-ring.

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

a soft pencil at a distance of 35 mm from the end to be inserted.

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

position.

Pencil

mark

22 mm Pipe

Insert depth

35 mm

Fig. 8

Collet

Washer

‘O’-Ring

Fig. 9

Outlet

Fitting

Body

- 9 -

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.

If you have any concern either about using push-in fittings or should the joint leak on

final test isolate the water supplies and contact Stuart Turner Service Dept. on 01491

572655.

Pump Connections (General)

The pump should not be screwed down, ensure anti-vibration feet and flexible

hoses are used.

Fig. 10

22 mm copper outlet pipework (discharge).

22 mm isolating valve and

fittings (not supplied).

To allow easy pump service.

22 mm flexible

pipes with push-in

connections.

Ensure that

connections are

fully pushed home into pump

head and that hoses are kept as

straight as possible (Do not kink

or twist the hose).

In the case of horizontal feeds

use a 22 mm John Guest stem

elbow (not supplied). Do not

bend the hose more than 30° as

they may become damaged,

transmit noise or leak.

Sealing washer.

Anti-vibration foot/pad

22 mm x 1 ” male

push-in fitting.

(Note on N3.7 bar

pump this fitting

cannot be

removed.)

22 mm tailend x 1 ”

male adaptor.

1 ” Inlet 'Y' type

strainer.

28 mm isolating

valve and fittings

(not supplied).

28 mm copper

inlet pipework

(suction).

Filter plug

(removal of this plug

enables internal gauze

filter to be cleaned).

Sealing washer.

‘O’-Ring/sealing

washer.

Priming plug.

22 mm x 1 ”

male push-in

fitting.

Short 22 mm copper pipe

tails to connect between

isolating valve and flexible

pipes. Ensure all burrs

are removed prior to

installation into push-in

connectors. Tube must

be fully pushed home into

the flexible push-in

connector.

- 10 -

STEP 5 ELECTRICAL INSTALLATION

WARNINGS:

The electrical installation must be carried out in accordance with the

current national electrical regulations and installed by a competent

person.

In the interests of electrical safety a 30 mA residual current device

(R.C.D.) 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.

This appliance must be earthed.

The motor and wiring must not be exposed to water.

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.

The motor fitted to this pump is suitable for a 230/1/50Hz supply. It is thermally

protected by an integral auto resetting thermotrip for your safety and rated for the duty

listed in the technical specification section.

Electrical Connection

The motor is provided with a factory fitted supply cord. This must be permanently

connected to the fixed wiring of the mains supply. Means for disconnection must be

incorporated in the fixed wiring in accordance with the wiring rules.

A suitable method of connection would be via a double pole switched, fused connection

unit complying with BS 1363-4, protected with a fuse (see fuse section).

The connection unit should be mounted in an easily accessible position and should be

labelled if confusion is possible, to allow easy identification of the pump isolating switch.

Earthing

This appliance must be earthed via the supply cord, which must be correctly connected

to the earth point located in the terminal box.

Copper or metallic pipework must have supplementary earth bonding where the

continuity has been broken by flexible hoses or plastic components. Adjacent suction and

delivery pipes should be fitted with earthing clamps to BS 951 and connected with

earthing wire size 4 mm² (Fig. 11). A standard kit is available from Stuart Turner (Part No.

17044).

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.

Diagram of

earth continuity

connections

Fig.11

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