Stuart Turner Monsoon Extra S1.4 bar Leitfaden

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 S1.4 bar

Pt. No. 46387

FOR POSITIVE HEAD APPLICATIONS ONLY

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Cont ...

PRODUCT DESCRIPTION

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

consisting of flow switches and electronic controls.

APPLICATION

The Monsoon Extra Standard Single range is designed for pressure boosting applications

in vented stored, hot or cold, clean water systems, where under gravity, a flow of at least

1 l/min is available.

Inlet pressures to the pump and ambient temperatures must not exceed the

values given in the technical specifications.

Monsoon Extra pumps are not suitable for boosting a single side of a dual flow mixer

valve or tap. Consult Stuart Turner for alternative pump.

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 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.

Children should be supervised to ensure that they do not play with

the appliance.

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.

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

Pump Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Technical Speciﬁcation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

- 3 -

CHECKLIST

Your product may vary slightly from the picture above.

Item Description Qty Item Description Qty

Pump 1 Anti-vibration feet 3

Hose & sealing washer 2 Inline strainer 1

Inlet/outlet connectors &

gaskets 2

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.

IMPORTANT: With the pump

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.

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Cont ...

1 READ BEFORE COMMENCING PUMP INSTALLATION

A. Water storage capacity.

1.11 The stored water storage capacity to be pumped, 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 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 PumpAssist team on +44 (0) 844 98 000 97.

C. Water flow

1.16 For this pump to operate correctly there must be a minimum gravity flow of at

least 1 l/min through all outlets to be pumped.

D. Pipework - General

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.

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

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 hoses, pumps or pump 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 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.

1.23 DO NOT bend the flexible hoses beyond 30o. They must be installed as

straight as possible.

1.24 DO NOT connect this pump to the mains water supply.

E. Plumbing & Electrical Installation Regulations

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

Regulations 1999” and “BS 6700” building regulations.

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

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

national electrical regulations.

1.28 The electrical installation must be installed by a qualified person.

- 5 -

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: 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. 2 & 3) is at least

1 metre and does not exceed the max inlet head of 14 metres for the S1.4.

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

maximum ambient temperature does not exceed 40 oC.

2.18 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.

2.19 Static outlet pressure: The static outlet head (Figs. 2 & 3) must also be within

the maximum requirement of 14 metres for S1.4.

2.20 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.

2.21 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 hoses: Use only Stuart Turner supplied hoses.

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

allow easy pump service.

2.24 Preferred pump location: The pump must, for optimum performance, be sited

as close as possible to and never more than 4 metres from the HOT WATER

cylinder. The pump should always be sited BELOW the HOT WATER take-off

from the cylinder. The 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.

- 6 -

Cont ...

2 LOCATION - BLENDED WATER INSTALLATION

2 LOCATION - COLD WATER INSTALLATION

2.25 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.

Outlet head must be

below bottom of cold

water tank and able

to pass a minimum of

1 l/min of gravity flow

Fig. 2

Static inlet pressure

10 metres max

1metre min

Fig. 3

Outlet head must be

below bottom of cold

water tank and able

to pass a minimum of

1 l/min of gravity flow

Static inlet pressure

10 metres max

1metre min

- 7 -

Cont ...

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

from the hot water cylinder or storage tank which should be via a secondary

dedicated tapping (see Fig. 5).

Do not connect to the mains.

2 LOCATION - HOT WATER INSTALLATION

Fig. 4

Static inlet pressure

10 metres max

1metre min

preferred

area

Outlet head must be

below bottom of cold

water tank and able

to pass a minimum of

1 l/min of gravity flow

Fig. 5

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.

- 8 -

Cont ...

2.27 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:

In this application only use an Essex or Techflow side entry flange, then fit 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. 6).

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.

Max. inlet head 10 m

Min. inlet head 1m

350 mm

min.

200 mm

min.

Least preferred area

Fig. 6

hot water

services

- 9 -

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

in accordance with

current regulations (Fig. 7).

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. 7

- 10 -

4.21 Wiring Diagrams:

Model Fuse Size (AMPS)

Monsoon Extra S1.4 bar 5

4.22 Fuses: The following fuse size should be used with the appropriate pump:

4.23 Supply Cord Replacement:

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.

On disassembly note the cord retention and routing system. Re-assemble to the

same pattern.

For information on cable connection consult the wiring diagram and cable gland

fitting instructions.

4.24 Cable Gland Fitting Instructions:

To enable correct assembly of the cable gland the

‘O’-ring (Fig. 9 item 1) must be placed over the cable

before the clamping insert (Fig. 9 item 2) can be

tightened.

Note: Cable diameter range:- 6.5 mm to 9.5 mm.

4.25 Supply Cord Extension:

The pumps are fitted with a supply cord to the

following specification:-

All models . . . . . . . . . . . . . . . . . HO5VV-F3 G 0.75 mm² - 6 Amp rated cable.

If the supply cord is to be extended, a cord of the same specification should be

used. Any connections or junction boxes used should be specifically suited for

the application and installed in accordance with the manufacturers instructions.

Fig. 9

MAIN WINDING

THERMOTRIP CAPACITOR

START WINDING

LINK WIRE (BLUE)

BROWN

BLACK

GREEN/

YELLOW

BLUE

BROWN L

S2 S3 S3 S2

FLOWSWITCH

REED (S3)

S1S1

BLUE

Monsoon Extra S1.4 bar Single

Fig. 8

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