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: Monsoon Extra U1.4 bar Monsoon Extra U2.6 bar Pt. No. 46349 Pt. No. 46593 Monsoon Extra U3.6 bar Monsoon Extra U5.0 bar Pt. No. 46594 Pt. No.
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.
CHECKLIST 28 mm copper outlet pipework (discharge). 28 mm isolating valve (non restrictive) and fittings (not supplied) to allow easy pump service. Short 28 mm copper pipe tails to connect between isolating valve and flexible pipes. 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.
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).
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.
2 LOCATION - GENERAL 2.16 2.17 2.18 2.19 2.20 2.21 2.22 2.23 2.24 2.25 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.
350 mm min. Least preferred area Max. inlet head 10 m ( 8 m for U1.4) Min. inlet head 1 m 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.
Static outlet pressure Max. 13 m Static inlet pressure Min. 1 m Max. 10 m 2 LOCATION - HOT WATER INSTALLATION Hot water pump Fig. 7 Hot water connection: 2.29 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.
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. Cont ...
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.
4.21 Wiring Diagrams: GREEN / YELLOW (LINK WIRE) BLUE CAPACITOR CAPACITOR BLACK BLACK THERMOTRIP BROWN LINK WIRE (BLUE) MAIN WINDING START WINDING A M N L GREEN/ YELLOW N N S1 S2 S3 S3 S2 S1 A M N L BLUE BROWN GREEN / YELLOW N 230 VAC/1PH/50Hz L SUPPLY E RED YELLOW RED N L E BLACK RED BLUE BROWN MOTOR FLOWSWITCH REED (S3) FLOWSWITCH REED (S3) S1 S2 S3 S3 S2 S1 PRESSURE SWITCH (S1) Monsoon Extra U1.4 bar Single Fig. 10 PRESSURE SWITCH (S1) Monsoon Extra U2.6, U3.6 & U5.
5 COMMISSIONING / SYSTEM FLUSHING/ PRIMING / STARTING 5.11 System Flushing: The pipework system should be flushed out prior to the pump being connected to ensure any contaminants/ chemical residues and foreign bodies are removed from elsewhere in the system. 5.12 Water Supply: Always ensure that water storage capacity is adequate to meet the demand. Ensure the pump chamber is full of water before starting the pump. Failure to do this could result in seal damage.
6 MAINTENANCE 6.11 Turn off water supplies to the pump and release pressure by opening water outlets before attempting maintenance. 6.12 Inlet strainer: Incorporated in the strainer is a removable gauze filter which may require periodic cleaning. The frequency of this operation is dependent upon installation conditions. The strainer is located in the inlet pipework to the pump (Fig. 15). The gauze filter is removed as follows:a) Isolate pump electrically. b) Release all system pressure.
Model ‘O’-Ring Air Charge bar (psi) U1.4 0.9 (13) All other models 2.1 (30) Schrader valve (under cap) Pressure vessel Detail view of ‘O’-Ring groove in fitting point ‘O’-Ring Fitting point Fig. 16 NOTE: Do not over tighten pressure vessel. 6.14 Water scale: As water is heated scale deposits are released in areas of hard water, scale can cause the mechanical seal to stick if left without use for long periods.
7 TECHNICAL SPECIFICATION Pump Dimensions Mechanical Electrical Model U1.4 bar U2.6 bar U3.6 bar U5.0 bar Power supply Volts/phase frequency 230/1/50 230/1/50 230/1/50 230/1/50 Enclosure IPX4 IPX5 IPX5 IPX5 Type of motor Induction Induction Induction Induction Power consumption 415 Watts 775 Watts 1136 Watts 1630 Watts Full load current 1.8 Amps 3.5 Amps 5.1 Amps 7.3 Amps Rating Continuous (S1) Continuous (S1) Continuous (S1) Continuous (S1) Max.
8 TROUBLE SHOOTING GUIDE Symptoms Probable Cause Recommended Action Pump will not start. Electrical supply. Check power supply. Check fuse (see fuse section). Check circuit breaker is set. Check wiring connections. Pump Jammed. If motor ‘Buzzes’ switch off power and contact Stuart Turner. Damaged pressure switch. Turn off power. Release system water pressure. Turn on power, pump should start. If NOT contact Stuart Turner. Recommended static inlet/outlet heads exceeded.
8.11 Dry Run Protection: This pump is fitted with a safety control circuit, which will detect the following fault condition: Dry running caused by water starvation to the pump. Should the pump run out of water it will stop as part of a “protective logic sequence”, detailed below. The fault should be rectified before re-starting the pump. Check that there is sufficient water supply to the pump and also ensure that all terminal fitting outlets are closed. 8.
Briefly reconnect the mains power supply to the pump – the ‘power on’ light should illuminate if the pump has been correctly wired. Isolate the mains electrical power supply from the pump. Re fit the terminal box lid ensuring no cables are trapped. Re fit the four terminal box lid retaining screws, tighten to 0.8 Nm. Terminal box lid Retaining screws x 4 ‘Power on’ light Fig. 17 Wiring removed for clarity 8.
9 THE MONSOON EXTRA GUARANTEE Congratulations on purchasing a Stuart Turner pump. We are confident this pump will provide many years of trouble free service as all our products are manufactured to the very highest standard. All Monsoon Extra pumps are guaranteed to be free from defects in materials or workmanship for 2 years from the date of purchase.
DECLARATION OF CONFORMITY 2006/42/EC BS EN ISO 12100-1, BS EN ISO 12100-2, BS EN 809 2006/95/EC BS EN 60335-1, BS EN 60335-2-41 2004/108/EC BS EN 55014-1, BS EN 55014-2, BS EN 55022, BS EN 61000-3-2, BS EN 61000-3-3, BS EN 61000-4-2, BS EN 61000-4-3, BS EN 61000-4-4, BS EN 61000-4-5, BS EN 61000-4-6, BS EN 61000-4-11 1999/519/EC BS EN 62233 2011/65/EU IT IS HEREBY CERTIFIED THAT THE STUART ELECTRIC MOTOR DRIVEN PUMP AS SERIAL NUMBER BELOW, COMPLIES WITH THE ESSENTIAL REQUIREMENTS OF THE ABOVE E.E.C.
