Stuart Turner Monsoon U1.5 bar Twin Manual de usuario

Installation Instructions

For Monsoon Universal

Twin Pump

Medium Pressure U1.5 bar High Pressure U3.0 bar

Medium Pressure U2.0 bar High Pressure U4.0 bar

High Pressure U4.5 bar

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.

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.

WARNING - 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 leave this instruction booklet with the pump as it contains

maintenance and safety information (Original Instructions)

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

Product Description . . . . . . . . . . . . . . . . . . . .1

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

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

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

Pre-Installation Check . . . . . . . . . . . . . . . . . .2

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

Pipework . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Pump Connections . . . . . . . . . . . . . . . . . . . . .6

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

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

Commissioning . . . . . . . . . . . . . . . . . . . . . . . .13

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .15

Technical Specification . . . . . . . . . . . . . . . . . .18

Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Trouble Shooting Guide . . . . . . . . . . . . . . . . .19

Environment Protection . . . . . . . . . . . . . . . . .20

- 2 -

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.

TYPICAL INSTALLATION

(Universal Twin Pump System)

This diagram should be used for

schematic reference only

Item 1 = System service valves (not

supplied) should be fitted.

Item 2 = Flexible hoses complete with

integral pump isolating valves

(supplied).

Positive Head 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 consult Stuart Turner Ltd.

STEP 1: PRE-INSTALLATION CHECK

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.

Tighten the vessel as shown to confirm a secure hand tight connection.

Note: Do not overtighten pressure vessel.

Pressure vessel

Fig. 2

- 3 -

STEP 2: PUMP LOCATION

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 a loft installation.

The motor casing can become hot under normal operating conditions,

care should be taken to ensure it cannot be touched during operation.

The pump must not be located where the static pressure on the inlet

or outlet to the pump is greater than permitted. Should the

installation exceed these limits, contact Stuart Turner for further

advice.

The pump must be installed so that the following conditions are met:

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 0.5 metres at all times.

The pump has a side mounted terminal box. Ensure the pump is mounted in a position

that allows easy access to the box if required.

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

reed clamp (vertically upwards).

Before deciding where to position the unit, check to ensure the static inlet and outlet

heads of water above the pump (Figs 3 & 4), do not exceed the maximum permitted

limits.

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

purpose build 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 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 (Fig. 3).

Either end of the pump is suitable for hot or cold water.

Cont....

- 4 -

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 measures are suggestions that may overcome the problem:

1) 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. 4).

2) An alternative to the above would be the installation of an automatic air vent situated

at the top of a vertical pipe run directly connected to the pump discharge. This will

ensure any air collecting in the pump is automatically vented.

Note: If installed in loft

there must be a height of

200 mm from water surface

to the highest point of the

hot or cold inlet pipework at

all times to prevent air

locks.

Least Preferred Pump

Location (shaded area).

Pump located above the hot

cylinder can increase the

risk of air locks.

Preferred Pump Location

(shaded area). Pump at a level

below draw off tapping in

cylinder.

Negative head

Max. inlet head (see table 1)

Min. inlet head 0.5 m

least preferred area

Max. outlet head

(see table 1)

Fig. 4

200 mm

min

350 mm

hot water

services

Negative

head

Max. inlet head (see table 1)

Min. inlet head 0.5 m

Preferred

area

Max. outlet head (see table 1)

Fig. 3

hot water

services

Model Max. inlet

head

Max. outlet

head

U1.5

8 m 8 m

U2.0

U3.0

U4.0

12 m 12 m

U4.5

Table 1

- 5 -

STEP 3: PIPEWORK (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, pump parts or hoses

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.

Never operate pump with inlet and/or outlet isolating valves in the

closed position. Damage will occur!

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.

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).

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

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

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

The pump should be supplied with balanced pressure hot and cold supplies.

To prevent loss of water pressure through pipework use 22 mm pipework throughout.

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

appropriate bend fittings. All pipework should be securely clipped.

The flexible hoses supplied incorporate integral isolating valves. These hoses should

be fitted in the suction and delivery pipework to enable easy access to the pump when

required.

Pipework Connections (Cold)

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

storage tank.

The supply must be air free and connection 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.

- 6 -

Pipework Connections (Connection between pump and system outlet)

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

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

WARNINGS:

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

flexible hose 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, on the flexible hose.

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

or strippers, acid based descalents or aggressive cleaning agents.

Never operate pump with inlet and/or outlet isolating valves in the

closed position. Damage will occur!

The pump is supplied with flexible hoses for connection to inlet and outlet pipework. It

is recommended that only the Stuart Turner hoses supplied are used for making these

connections.

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 22 mm.

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

cylinder or storage tank.

The supply must be air free and connection to the cylinder can be made by one of the

methods shown in Fig. 5.

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

storage cistern should be at least 1 metre above the top of the hot water cylinder.

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.

Off vertical

expansion pipe

with 22 mm

pipework to

pump.

Factory installed G ¾

secondary tapping

with 22 mm pipework

to pump.

Site installed G ¾

Essex Flange with

22 mm pipework to

pump.

Warix Flange with

22 mm pipework to

pump.

Fig. 5

- 7 -

Hose to pipework

1. The hoses 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 that are compatible and will provide a water tight

connection.

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

insertion depth (Fig. 7) and cut the pipe square removing all burrs and sharp

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

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).

Cont....

Rubber sealing washer

(captive in nut assembly)

Fig. 6

Flexible hose

G¾ running nut

assembly

Port fitting

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.

Reed

switch

clamp

assembly

Anti-rotation flats

28 mm AF

29 mm AF

- 8 -

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 33 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.

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 pipe to check it is secure and correctly fitted.

5. To break the joint, push pipe firmly into fitting, hold collet down and gently

remove pipe. If the system has been filled with water care should be taken to isolate

pump and towels used to absorb spilled water.

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 Pump Assist on 0844 98 000 97.

Fig. 8

Body

Collet

Washer

‘O’-Ring

Pipe Stop

Isolating Valve

22 mm Pipe

Pencil

mark

Insert depth

33 mm

Fig. 7

- 9 -

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

are used.

Never operate pump with inlet and/or outlet isolating valves in the closed

position. Damage will occur!

Pump Connections (General)

Pump body.

Flow switch.

Anti-vibration foot. Fig. 9

Vent plug.

Isolating valve.

Delivery supply to shower/bathroom

fitted with G¾ male threaded pump

connection.

G¾ running nut with captive sealing

washer.

Flexible hose.

22 mm copper outlet

pipework.

22 mm flexible pipes

with push-in

connections, ensure

that connection is fully

pushed home into hose

end fitting and that hoses are kept as

straight as possible.

In the case of horizontal feeds use a

22 mm compatible stem elbow (not

supplied). Do not bend the hose

more than 30° as they may become

damaged, transmit noise or leak.

22 mm copper inlet

pipework

Suction supply

from tank with

push-in plumbing

connection.

Integral pump isolating

valve shown in ‘OFF’

position.

Integral pump isolating valve

shown in ‘ON’ position.

Flexible hose.

Inlet strainer housed

in this location (see

maintenance section).

Suction supply from tank

with G¾ male threaded

pump connection.

G¾ running nut with captive

sealing washer.

30°

Max.

permitted

flexible

hose

bend. Pressure switch.

Do not kink or twist

the hose.

- 10 -

Typical Low Level Installation

In certain installations it may be necessary to install a 90° bend on the inlet or outlet

connections of the pump before the flexible hose to accommodate a low level installation.

Below are some preferred connection options. All connections seal on the pump body

using a fibre or rubber sealing washer. Tap connector fittings should be used which must

be of an appropriate pressure and temperature rating.

It is essential when using any of the fittings shown below, that a correct water tight seal

is obtained between the pump body and selected fitting and also the flexible hose and

selected fitting. If in doubt contact the fitting manufacturer and confirm compatibility with

the connection to be sealed.

Carefully check connections and pipework for leaks whilst pump running and stationary

before leaving the installation unattended.

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.

G¾ female x 22 mm

elbow tap connector.

22 mm compression to

G¾ male. G¾ female flexible hose

(supplied in kit).

Fibre washer.

22 mm copper pipe.

22 mm

copper

pipe

G¾ female x 22 mm

swivel tap connector

with rubber sealing

washer.

G¾ female x 22 mm

tap connector with

rubber sealing washer.

22 mm stem elbow.

G¾ female flexible hose

(supplied in kit).

22 mm compression to

G¾ male.

G¾ female x 22 mm

tap connector.

Fibre washer.

G¾ female

flexible hose

(supplied in

kit).

22 mm to G¾

male.

Fig. 10

Sealing washer

(sometimes captured in

fitting)

22 mm

elbow.

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