Stuart Turner Monsoon Series Leitfaden

Installation, Operation & Maintenance

Instructions

Please leave this instruction booklet with the home owner as it contains

important guarantee, maintenance and safety information

Read this manual carefully before commencing installation.

This manual covers the following products:

Monsoon U1.5 bar Twin

Pt. No. 46505 Pt. No. 46505 ROI

Pt. No. 46505 EXP

Monsoon U2.0 bar Twin

Pt. No. 46480 Pt. No. 46480 ROI

Pt. No. 46480 EXP

Monsoon U3.0 bar Twin

Pt. No. 46410 Pt. No. 46410 ROI

Pt. No. 46410 EXP

Monsoon U4.0 bar Twin

Pt. No. 46411 Pt. No. 46411 ROI

Pt. No. 46411 EXP

Monsoon U4.5 bar Twin

Pt. No. 46412 Pt. No. 46412 ROI

Pt. No. 46412 EXP

FOR POSITIVE OR NEGATIVE HEAD APPLICATIONS

CE compliant product

- 2 -

PRODUCT DESCRIPTION

Electric motor driven twin ended peripheral pumps complete with an automatic control

system, consisting of flow switches, pressure switch and pressure vessel and electronic

controls.

APPLICATION

Monsoon Universal pumps are suitable for positive or negative head installation

conditions. The pumps are designed for whole house pressure boosting applications in

vented stored water systems. Inlet pressures to the pump and ambient temperatures

must not exceed the values given in the technical specifications.

zThis 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.

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.

zWARNING - Washer/condenser dryers and

condenser dryers. The pump must not be used in

the water supply line to a washer/condenser

drier or a condenser drier, which uses a constant

flow of cold water to aid the condenser drying

process, as damage can occur to the pump. If

in doubt or for further information contact Stuart

Turner Ltd.

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.

- 3 -

Cont ...

CONTENTS Page

Checklist ........................................................4

Pre-Installation ...................................................5

Important Facts - read before commencing installation ...................6

Location ........................................................7

Pump Connections ................................................10

Electrical Installation ...............................................13

Commissioning ...................................................16

Maintenance .....................................................18

Technical Specication .............................................20

Trouble Shooting .................................................22

Guarantee .......................................................26

- 4 -

Cont ...

CHECKLIST

Item Description Qty Item Description Qty

Pump 1 Tank & sealing washers 1

Hose & integral washer 4

Your product may vary slightly from the picture above.

REGIONAL SUITABILITY

Before commencing installation, ensure the product you have purchased is

correct for your region, to avoid invalidating the guarantee.

Check the part number:

Example:

UK product Pt. No. 46410

ROI product Pt. No. 46410 ROI

Export product Pt. No. 46410 EXP

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.

Fig. 1

Note: This image is for reference only.

- 5 -

Cont ...

The pressure vessel (Fig. 2) is factory fitted to the pump assembly.

To eliminate any risk that the vessel has lost its assembly torque and sealing ability during

transit, it must be checked prior to installation and should be hand tight.

Note: Do not overtighten pressure vessel.

PRE-INSTALLATION CHECK

zThis installation book refers to UK pipework and pumps supplied with hoses

suitable for 22 mm pipework.

zIf you have purchased a product suitable for ROI (Republic of Ireland) it will

be supplied with hoses suitable for 21 mm pipework.

zIf you have purchased a product suitable for Export it will be supplied with

hoses suitable for G ¾ connections.

Fig. 2

Pressure vessel

Note: This image is for reference only.

- 6 -

Cont ...

1 IMPORTANT FACTS: READ BEFORE COMMENCING PUMP INSTALLATION

A. Water storage capacity.

1.11 The hot and 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 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) 800 31 969 80.

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 Installation Regulations

1.24 The plumbing installation must comply with the current water and 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.

- 7 -

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 position the unit, check to

ensure the static inlet and outlet heads of water above the pump (Table 1), does

not exceed the maximum permitted limits.

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 MUST be 22 mm (21 mm in ROI).

Pipework should only reduce to 15 mm when entering terminal fitting.

2.19 Static outlet pressure: The static outlet head must not exceed the values `

shown in table 1.

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 that is

marked on the flow switch reed clamp (vertically upwards).

2.22 Flexible hoses: Only use the Stuart Turner hose set supplied with the pump.

2.23 Isolating valves: Separate system 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.

- 8 -

2.25 Non-preferred pump location: If it is necessary to position the Pump above

the secondary tapping on the hot cylinder it is fed by, the risk of introducing air

will be increased.

To avoid this risk one of the two following solutions must be adopted:

The use of a Stuart Top Entry (TE) cylinder flange.

The use of a Stuart Side Entry (SE) cylinder flange, which should have the

addition of an inverted loop (“U” bend) of 350 mm minimum drop before rising to

the pump, located as close as possible to the cylinder wall. Please note both

flange options listed above are designed to suit 22 mm pipework. If used in ROI

a suitable adaptor to 21 mm pipe must be used (not supplied). This will ensure

the pump receives an air free supply and the cylinder vents any air up the vent

pipe and not the pump feed (Fig. 3).

Table 1

Model Max.

static

inlet

pressure

Max.

static

outlet

pressure

U1.5

8 m 8 mU2.0

U3.0

U4.0 12 m 12 m

U4.5

2 PUMP LOCATION - TWIN PUMP

Fig. 3

Max. static inlet pressure (see table 1)

Min. static inlet pressure 0.5 m

hot water

services

least preferred area

200 mm

min

350 mm

Max. static

outlet pressure

(see table 1)

Negative head

Fig. 4

Max. static inlet pressure see table 1

- 9 -

Cont ...

Cold water connection:

2.26 The cold water supply: Must be a DEDICATED AIR FREE supply via a tank

connector, and must be positioned at a slightly lower level (25 mm minimum)

than the feed pipe to the hot water cylinder.

Do not connect to the mains.

Hot water connection:

2.27 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 22 mm. The U4.5 bar Twin

should have pipework of a minimum of 28 mm.

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

from the hot water cylinder or storage tank, ensuring an air free connection to the

pump. We recommend the use of either the side entry Stuart flange (SE) Part

No 27900 or the top entry Stuart flange (TE) Part No 27800 see Fig. 5 (for all

models except the U4.5 bar Twin) (U4.5 bar Twin should only use ‘a’ or ‘d’).

Please note both flange options listed above are designed to suit 22 mm

pipework. If used in ROI a suitable adaptor to 21 mm pipe must be used (not

supplied).

2.29 Expansion pipe: When the method of connection is to be made via the

expansion pipe, the BASE of the cold water storage tank MUST be at least

1 metre above the connection/take off of the hot water storage cylinder feeding

the pump.

For applications in ROI pipe sizes above should read 21 mm.

Fig. 5

Off expansion

pipe with rising

28 mm offset

reducing to

22 mm pipework

to pump and

expansion pipe.

Off expansion

pipe with rising

22 mm offset

and 22 mm

pipework to

pump.

G 1 Stuart flange

top entry (TE)

(Part No. 27800)

with 22 mm

pipework to

pump.

Factory installed G ¾

secondary tapping with

22 mm pipework to

pump.

Side mounted Stuart

flange side entry (SE)

(Part No. 27900) with

22 mm pipework to

pump

a b c d

- 10 -

Cont ...

3 PUMP CONNECTIONS

zDo not use stainless steel, chrome or nickel plated pipe with

the flexible hose push-in plumbing connections.

zDo not introduce solder flux into the joint or surrounding area

as connectors will be attacked and may fail.

zAll solder joints should be completed and flux residues removed

before final connection to push-in connections, on the flexible

hose.

zDo not allow contact with oil or cellulose based paints, paint

thinners or strippers, acid based descalents or aggressive

cleaning agents.

zNever operate pump with inlet and/or outlet isolating valves in

the closed position. Damage will occur!

3.11 Hose to pump: The pump inlet and outlet ports have factory assembled fittings

which are specifically designed for connection to the G¾ female running nuts on

the flexible hoses. The hose end is fitted with a rubber sealing washer which is

held captive within the nut assembly. Locate the hose into position and screw

the nut fully onto the fitting by hand. Finally nip tight with a spanner (4/5 Nm)

for a water tight seal (do not overtighten).

Fig. 6

Flexible hose

G ¾ running nut

assembly

Port fitting

Rubber sealing washer

(captive in nut assembly)

Reed

switch

clamp

assembly

29 mm AF

Anti-rotation flats

28 mm AF

Note: When tightening or loosening the

hose nut assembly, the anti-rotation

flats provided on the inlet and outlet

fittings should be used for placement of

a second spanner as shown. This is to

prevent complete assembly rotation.

It may be necessary to partially rotate

the reed switch clamp assembly on the

outlet fitting to avoid damage during

placement of the second spanner.

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