Stuart Turner Stuart SPU 130 Mini Guide

Installation, Operation & Maintenance

Instructions

Please leave this instruction booklet with the end user as it contains

important guarantee, maintenance and safety information

Read this manual carefully before commencing installation.

This manual covers the following products:

SPU 130 Mini

Pt. No. 46719

SPU 230 Mini

Pt. No. 46720

STUART

CE compliant product

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Cont ...

PRODUCT DESCRIPTION

Heating and cooling system pressurisation top up unit with integral water storage tank

and electric solenoid piston pump, automated control system consisting of pressure

transducer and water level switch. The tank includes an AB air gap for category 5 fluid

isolation (BS EN 1717).

APPLICATION

The SPU Mini range is designed to provide intermittent water top up only to

compensate for intermittent losses in system pressure in heating and cooling systems

in commercial or industrial applications. These could include slight leaks, air venting,

etc. The units are not designed to deal with sudden losses of system pressure due

to major water losses over extended periods. They are also not to be used for water

boosting applications.

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 ........................................................9

Installation ..........................................................10

Electrical Installation ..................................................14

Commissioning ......................................................18

Operation ...........................................................22

Maintenance .........................................................23

Environment Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Technical Specification ................................................25

Trouble Shooting .....................................................26

Product Log .........................................................27

Guarantee ..........................................................30

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Cont ...

WARNINGS

zThis appliance must not be used for any other

application without the written consent of Stuart

Turner Limited.

zThis 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.

zChildren should be supervised to ensure that they

do not play with the appliance.

zThis product should not be used for the supply of

water to more than one heating/cooling system at

a time.

zThe electrical installation must be carried out in

accordance with the current national electrical

regulations.

zThe electrical installation must be installed by a

qualified person.

zThe motor is not accessible in normal operating

mode. The unit must only be operated with the

front cover in place.

zThe electrical installation must be carried out in

accordance with the current national electrical

regulations and installed by a qualified person.

zIn 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.

zThis appliance must be earthed via the supply

cord.

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Cont ...

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.

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Cont ...

CHECKLIST

Note:

Your product may vary slightly from the picture above.

Item Description Qty Item Description Qty

SPU 1 Fill valve flow restrictor, blue 1

Front cover 1 Rubber hose sealing washer,

to be used with item C 1

Flexible hose, G ½ 15 mm

compression 1 Cable tie 2

M6 screw 1 Instruction book 1

Wall mounting plate 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.

A D

Front cover removed for clarity

Electrical

rating plate &

serial number

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Cont ...

1 IMPORTANT FACTS: READ BEFORE COMMENCING PUMP INSTALLATION

A Water storage capacity.

1.11 The SPU Mini has a usable water volume of approximately 2 litres; the length

of time the SPU takes to pressurise a system will be dependent on:-

The pressure differential between the cold fill and set pressures and also the

refill rate of the tank

1.12 Ensure the pumps are primed as described in the priming section before

starting, to avoid causing damage to the pump. See Section 6.20 Hydraulic

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 Technical Section).

1.14 The minimum allowable water temperature is 4 oC.

C Pipework – General

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

leakage.

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 the unit. Do not secure pipework to the SPU Mini, this will cause

damage and possible leakage.

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

Mini 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 hose, tank, pump or any

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 bend the flexible hose beyond 90o. It must be installed as

detailed, DO NOT kink. See Installation Section 4.14.

D Plumbing installation regulations

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

regulations.

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

E System filling

1.24 The SPU Mini is NOT DESIGNED TO FILL THE SYSTEM FROM EMPTY.

It is only intended to top up the system after occassional water leakage.

Systems should be filled via a dedicated filling loop.

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Cont ...

2 LOCATION  GENERAL

2.11 Location: The SPU Mini must be located on a solid wall of sufficient

strength to support the filled weight of the SPU Mini, close to the

water source and a suitable overflow position (see Section 10 –

Technical Specification for filled weight). The SPU Mini must not be

installed in a loft space. It must also be considered that the noise

and vibration from the SPU Mini may be transmitted through the

structure it is sited on. Ensure the minimum clearance requirements

are followed to allow servicing of the unit.

2.12 Access and minimum clearance requirements: For emergencies

and maintenance the SPU Mini must be easily accessible and have

the minimum clearance around it as laid out in Fig. 2. Additional

access to the front of the unit will be required to operate the

keypad and view the display.

2.13 Protection: The SPU Mini must be located in a dry, frost free area.

2.14 Ventilation: Ensure an adequate air flow to cool the SPU Mini.

Separate the SPU Mini from other appliances that generate heat.

Do not block the vent holes on the front cover.

2.15 Water retention: Site the SPU Mini 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. As part of

the AB airgap (CAT 5 fluid isolation) the SPU Mini has a weir type

overflow on the front, water will be discharged from this area in the

event of the failure of the inlet valve or non-return valve.

2.16 Supply inlet pressure: The water supply inlet pressure must not exceed 7 bar.

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

ambient temperature does not drop below 4 °C or exceed 40 °C.

2.18 Pipework: For optimum performance inlet and outlet pipework must be a

minimum of 15 mm pipe.

300

500

300

150 150

Fig. 2

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Cont ...

2.19 Static outlet pressure: The static outlet head must be 3 metres below pump

maximum cold fill pressure (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 SPU Mini pump to the

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

when mounting the SPU Mini that any noise is not amplified through loose

panels or pipework.

2.21 Flexible hose: Only use the Stuart Turner hose supplied with the SPU Mini.

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

fitted to allow easy service of the SPU Mini. Isolating valves must be mounted

where specified to allow the system isolation and removal of the SPU Mini if

needed. See Section 4.14 for installation details.

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3 KEY FEATURES

3.11 The SPU Mini comprises of the following main components:-

1. Moulded tank – Main body of the SPU, comprising of an integrated water

tank with warning pipe and weir overflow and mounting the solenoid

piston pumps, manifold and controller.

2. Pump assembly – One or two piston pump units mounted into the

moulded tank with vibration isolating rubber mounts.

3. Outlet manifold – Brass manifold with pressure transducer used to monitor

system pressure and connection to the pump(s)

4. Programmable controller – Stuart Turner designed, user set controller,

allowing system set up and easy alarm connection.

5. Wall mounting plate – Robust stainless steel wall mounting plate allowing

quick, easy installation and removal if needed.

6. Moulded cover – Moulded acrylic capped ABS cover retained to the

moulded tanks with Dual LockTM fastening system for quick and easy

access

3.12 Principle of operation: The pressurisation unit consists of a break tank and

one or two piston pumps. The break tank is supplied with mains water from

the left to a float valve and includes an overflow and weir to maintain an AB air

gap in the tank. The unit is connected to the heating/chiller system

via a flexible hose which can exit the unit on either the left or right. The

pumps are connected via a flexible hose to the tank via a rubber connector.

A pressure transducer monitors system pressure and if a reduction in system

pressure is detected, the controller runs the pumps until the system is re-

pressurised to the required pre-set level. If the unit only has a single pump

connected it will run on a 30 minutes on/30 minutes off basis until this level

is reached, if the unit is a twin pump model the pumps run in duty standby

mode (the controller will alternate which pump starts first to even the

wear on the pumps). The manifold is fitted with a non-return valve to ensure

system pressure is maintained once pressurised.

1Fig. 3

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Cont ...

4 INSTALLATION

4.11 Fill valve flow restrictor guidelines: Ensure side entry fill valve is fitted

with the correct filter and flow restrictor combination (dependant on the

mains water pressure) into the G ½ threaded tail as outlined below:

Coloured insert – To be used for water pressure between 1 and 4 bar

White insert – The SPU Mini is pre fitted with the white high pressure insert.

Change if the unit is slow to fill or the water pressure is low (below 4 bar).

4.12 Cold mains feed connection: The connection to the cold water mains inlet is

made using a suitable fitting to the G ½ male thread on the left hand side of

the SPU Mini. 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. (Do not overtighten).

4.13 Wall plate fixing:

1. When installing the SPU Mini on a wall ensure suitable fixings for the wall

structure are used and are suitable to support the unit when fully

filled with water (see technical section for filled weights). The holes in the

wall plate are 6 mm in diameter, the maximum permissible screw head

height is 3 mm.

2. All holes in the wall mounting plate must have fixings used in them as per

the image below, do not leave out fastenings as this will compromise the

integrity of the wall plate.

3. Ensure you have sufficent room around the area you are mounting the SPU

Mini to allow installation, servicing and operation. See section 2.12.

4. Ensure wall plate is fixed to a flat vertical wall and the top of the plate is

horizontal.

Fig. 4

Fig. 5

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