Mainsboost Charger MBC 100SV Guide

mainsboost
Read this manual carefully before commencing installation.
This manual covers all Mainsboost Charger units.
Mainsboost Charger
Mainsboost Charger Installation,
Operation & Maintenance Instructions
Please leave this instruction booklet with the home owner as it contains
important guarantee, maintenance and safety information
CE compliant product

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PRODUCT DESCRIPTION
Mainsboost Charger pump assembly, consists of case, pump and connecting hoses.
APPLICATION
Mainsboost Charger is designed to offer stored clean, potable cold water under pressure
for all domestic or small commercial applications where mains water is insufficient to offer
consistent and reliable water services.
Installation parameters must not exceed the values given in the technical
specifications.
zMainsboost Charger 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.
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. These instructions must be left with the product.
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.

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CONTENTS Page
Checklist ................................................................4
Introduction .............................................................5
Important Facts - read before commencing installation ...........................6
Location ................................................................7
Terminology .............................................................8
Installation ..............................................................9
Electrical ................................................................11
Commissioning ...........................................................13
Technical Specication .....................................................16
Trouble Shooting .........................................................17
Guarantee ...............................................................18

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CHECKLIST
Item Description Qty Item Description Qty
Package
1
1 Mounting tray 1
Package
1 cont..
7 Bolt 4
2 Pump assembly 1 7 Rubber grommets 4
3 Pressure reducing valve 1 7 Rubber grommets 4
4 Hoses 2 7 Hose washers 4
5 Ball valve 1 7 Fixing screws 4
6 Single check valve 1 7 Wall plugs 4
Your product may vary slightly from the picture above.
IMPORTANT: Your Mainsboost Charger water performance system will be
delivered in one box. Please check the contents within 24 hours of receipt and
if any component is damaged, please contact Stuart Turner Ltd immediately.
Package 1
Fig. 1
5
4
2
1
3
6
7

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1 INTRODUCTION
1.1 Congratulations on buying a Mainsboost Charger system, designed to offer
consistent and reliable water services throughout the property and the only
system available that is patent protected No. GB2349908.
1.2 Patents, Trademarks & Trade Names:
‘Mainsboost’ ‘Mainsboost Plus™’ and ‘Mainsboost Charger’ are
registered Trademarks of Stuart Turner Ltd.
Stuart Turner Ltd will treat any infringement of the patent very seriously and
therefore recommend that any questions regarding application be brought to the
company for consideration.
1.3 How the Mainsboost Charger System works:
The Mainsboost pressure vessel stores water from the rising main in a sealed
water chamber, separated from the air space by a rubber diaphragm and
pressurised to an optimum setting. When water is drawn off by downstream
services, the water from the mains is supplemented by the water from the
Mainsboost unit to provide a balanced supply at consistent pressure to
downstream services.
On occasions where the static pressure is less than 2 bar, a charger pump unit
can be used to ensure sufficient pressure is available for the Mainsboost system
to continue to function correctly.
The Mainsboost Charger pipework manifold incorporates a unique ‘green energy’
bypass. If the incoming mains water supply delivers more than 12 l/min this
bypass should be left open to allow any additional flow rate to pass directly into
the Mainsboost pressure vessel via the integral non-return valve. If the
incoming flow rate is less that 12 l/min the bypass valve should be left closed
in order to ensure optimum efficiency of the Charger pump.

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2 IMPORTANT FACTS READ BEFORE COMMENCING INSTALLATION
A. Commissioning
2.11 Ensure the pump is primed as described in the priming section before starting,
damage to the shaft seal will result otherwise. See Section 8.16 -
Commissioning.
B. Water temperature
This unit is designed for cold water applications only which should not exceed the
following values:
2.12 The maximum allowable water temperature is 35 oC.
2.13 The minimum allowable water temperature is 4 oC.
C. Pipework - General
2.14 Secure pipework: Ensure pipework to and from the Mainsboost Charger is
independently supported & clipped to prevent forces being transferred to inlet
and outlet branches of pump. Flexible hoses supplied must be used.
2.15 Flux: Solder joints must be completed and flux residues removed prior to pump
installation (flux damage will void any warranty).
2.16 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.
D. Plumbing Installation Regulations
2.17 The plumbing installation must comply with the current water and building
regulations.
2.18 The plumbing installation must be installed by a qualified person.
2.19 The electrical installation must be carried out in accordance with the current
national electrical regulations.
2.20 The electrical installation must be installed by a qualified person.

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3 LOCATION - GENERAL
3.11 Access: For emergencies and maintenance the Mainsboost Charger
must be easily accessible.
3.12 Protection: The system must be located in a dry position, and
protected from freezing. Avoid environments which have a high
ambient temperature, high humidity or excessive condensation
and salt damage, etc.
3.13 Ventilation: Ensure an adequate air flow to cool the pump.
Separate the pump from other appliances that generate heat.
3.14 Safety: The motor casing can become very hot under normal
operating conditions. Care must be taken to ensure it cannot be
touched during operation.
3.15 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.
3.16 Static inlet pressure: Ensure the static inlet head at the pump does not
exceed the values shown in the table under point 7.13.
3.17 Incoming mains water pressure: The incoming water pressure of at least
0.1 bar is required.
3.18 Ensure that location of the unit allows adequate space to give reasonable access
to all parts to accommodate service/commissioning.
3.19 Ambient temperature: The pump must be sited in a location where the
maximum ambient temperature does not exceed 40 oC.
3.20 Pipework: Pipework should be sized to ensure optimum performance of the
system.
3.21 Direction of flow: See Fig. 2 to identify the suction and discharge connections.
Fig. 2
Inlet
Outlet

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4 TERMINOLOGY
4.11 System Designation:
It is important to understand what upstream and downstream refers to before
starting the installation.
4.12 Upstream
The term ‘Upstream’ refers to the system configuration from the consumer’s
stopcock to the point where the supply reaches the inlet port of the Mainsboost
Charger Pump.
4.13 Downstream
The term ‘Downstream’ refers to the system configuration from the outlet tapping
on the Mainsboost Charger Pump, along the distribution header (if configured in
this way) and into the distribution pipework and outlets. This includes hot and
cold services where both are present (see Fig. 3).
Fig. 3 System designation

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5 INSTALLATION
Select best position to mount Charger pump unit (Fig. 4).
1) Fit mounting plate onto wall ensuring level (Fig. 5).
2) Hook pump assembly onto mounting plate and secure in place using M6 set
screw (Fig. 5).
Fig. 5
Fig. 4
Mounting plate
Pump assembly
M6 set screw
Selected position

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3) Your charger will have been supplied with either a green energy lever valve
and check valve to suit the main water supply size of (22, 28 or 35 mm).
Having ensured the stopcock is turned off and (if installing on an existing
Mainsboost system) drained it, remove a section of pipe to allow fitting
of 2 tee pieces (not supplied), the lever valve and check valve (Fig. 6).
4) The Charger unit has been designed to allow pipework connections to be
made in the most convenient way, select the best route.
5) Ensure the PRV is securely fitted and connect the flexible hoses provided,
routing them to the desired case exit points (Fig. 6).
6) Care should be taken not to kink the hoses or bend them through an angle
greater than 30o.
7) Route 15 mm feed and return from the tees inserted in the main, passing
through the isolating valves supplied and the check valve (fitted in the feed
line only) (Fig. 6).
8) Ensure grommets are fitted correctly in all case appetures to ensure the
pipework does not vibrate against the case (Fig. 6).
Fig. 6
PRV
Isolating valve
Check valve
Isolating
valve
Isolating valve
Pressure reducing
valve (PRV)
Stopcock
Stainer
Pressure
gauge
Check valve

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6 ELECTRICAL
6.11 Regulations: The electrical installation must be carried out in
accordance with the current local regulations by a qualified person.
6.12 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.
6.13 Before starting work on the electrical supply ensure power supply is
isolated.
6.14 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.
6.15 Earthing: This appliance must be earthed via the supply cord, which must be
correctly connected to the earth point located in the terminal box.
6.16 Connections: The pump must be permanently connected to the fixed wiring of
the mains supply using the factory fitted supply cord, via a dedicated double
pole switched fused spur off the ring main.
6.17 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:
Green and yellow coloured wire must be connected to the terminal in the
connection unit marked with the letter E or by the earth symbol: or coloured
green or green and yellow.
Blue coloured wired must be connected to the terminal marked with the letter N
or coloured black.
Brown coloured wire must be connected to the terminal marked with the letter L
or coloured red.

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6.18 Wiring diagram:
6.19 Fuse: All models should be protected by a 3 Amp fuse.
6.20 Supply cord replacement:
The internal wiring within the terminal box is 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.
6.21 If the supply cord is to be changed or damaged, it must be replaced by a special
cord available from Stuart Turner or one of its approved repairers.
MAIN WINDING
THERMOTRIP
CAPACITOR
START WINDING
BLUE
BLACK
L
E
N
230 VAC/1PH/50Hz
SUPPLY
GREEN/YELLOW
BROWN
BLUE
1
2
3
4
5
6
CONTROLLER
BLUE (LINK WIRE)
BROWN
BROWN
TEMPERATURE
SENSOR PRESSURE
SENSOR
BLUE
BROWN
BROWN
BLUE
BLACK
BLUE
BLACK
BROWN
BROWN
BLUE
BROWN
BLUE
BLUE
BROWN
BLUE
BROWN
N N1 N2 L5 L4 L3 L2 L1 L
12 VAC
7
8
9
10
12 -VE
13 +VE
BLUE
BLUE (LINK WIRE)
NOT USED NOT USED
11
Fig. 7

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7 COMMISSIONING
7.11 System check: Ensure that the electrical supply to the pump is switched off
before opening the mains water supply stopcock and checking for leaks.
7.12 Check mains static pressure:
zNow close outlets and check pressure gauge after ‘Y’ strainer - for static
mains pressure and note it.
zTurn stopcock off and leave outlet taps open.
7.13 Check the chart below for the correct pump pressure setting against the static
mains pressure recorded.
Warning: Note PRV setting must not exceed 5.0 bar.
Refer to the Mainsboost instruction manual for the correct commissioning of the
vessels.
MJ3 pump max.
set pressure
Static mains
pressure
Set vessel
pre-charge pressure
to
Differential Set PRV maximum
setting to
bar bar bar bar
3 bar 1.5 1.0 2.0 2.0
3 bar 2.0 1.0 2.0 2.0
3.5 bar 2.5 1.5 2.0 2.5
3.5 bar 3.0 1.5 2.0 2.5

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7.14 Control module:
The control module (Fig. 8) has been factory pre-set to the following conditions.
Should the parameter need changing follow these steps.
zThe pump parameters are displayed in the following sequence:
Set point (SP),
Differential (DIFF),
Low pressure trip (LPR),
High pressure trip (HPR),
Pump run timer (PRT),
Pump Number (NPM),
Relay setting (CRE),
Number of alarms (NAL1/NAL2),
Hours run (HR1/HE2).
zPress and hold the set button for 5-7 seconds. (This gains access to the
pump parameters).
zPress the up/down arrows to change the selected parameter(s) to the desired
value.
zAfter changing the required parameter(s) press the set button twice in quick
succession to lock the new value into the controller memory.
zIt is possible to scroll through all the pump parameter values by simply
pressing the set button once after each parameter value has been displayed.
Settings as per factory preset:
Set point SP: 3 bar
Diff pressure DIFF: 0.5 bar
Low pressure LPR: 0.2 bar
High pressure HPR: 4.5 bar
Pump run timer PRT: 180
Pump number NPM: 2 (do not tamper)
CRE setting 0
Fig. 8
Up/down arrows
allow changes to
pump parameter
values
Alarm mute button
Set button enables
access to pump
parameter values

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7.15 On completion of the installation, follow the commissioning process below.
zLeave pump power switched off.
zLeave all outlet valves closed.
zTurn on stopcock and open inlet ballvalve, both pressure gauges on inlet
and PRV will start to show movement as the mains pressure fills the system.
zCheck for leaks on all joints made.
zDependant on the incoming mains pressure the vessel will start to fill with
water.
zSwitch on the power to the pump, it will sense the pressure in the system
and if less than 3 bar will start to assist filling of the system.
zClose Mainsboost vessel isolation valve
zAllow the pump to continue running until air has been completely purged
from the system, all outlets will have to be opened and closed.
zAll outlets have been closed, open the Mainsboost vessel isolation valve.
zThe pump will continue to run to charge the system, this may take some
time dependant on size and number of Mainsboost vessels fitted.
Once the system is completely full the pump will stop and only start again if the
Mainsboost vessel pressure drops below set point minus the differential
of the pump control.
Green Energy
- Bypass
If the flowrate is greater than 12 l/min leave the isolation valve open.
If the flowrate is less than 12 l/min close the isolation valve.

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8 TECHNICAL SPECIFICATION
Pump Mainsboost Charger
General Guarantee 3 years
WRAS approval 1611336
System patent no. 2349908
Features Pump type Peripheral
Mechanical seal EPDM / PTFE / Al. Oxide
Flexible hoses 2
Dry run protection ü
Materials Pump body Brass
Impeller Brass
Performance Maximum head (closed valve) 4.3 bar
Maximum working pressure* 600 kPa (6 bar)
Maximum ambient air temperature 40 oC
Min / Max water temperature Min 4 oC / Max 35 oC
Connections Pump connections G ¾ male
Flexible hoses Connections 22 mm push-in x 22 mm push-in x 240 mm long
Motor Type Induction, auto-reset thermal trip
Duty rating Continuous
Electrical Power supply / phase / frequency 230 V a.c. / 1 / 50 Hz
Current (full load) 1.8 Amps
Power consumption 398 Watts
Fuse rating 3 Amps
Power cable (pre-wired) 1.5 metres
Physical Enclosure protection IPX4
Length 180 mm
Width 290 mm
Height (excluding hoses) 465 mm
Stuart Turner reserve the right to amend the specification in line with its policy of
continuous development of its products.
*Note: The maximum pressure that can be applied to the pump under any installation
conditions.
8.11 Noise: The equivalent continuous A-weighted sound pressure level at a
distance of 1 metre from the pump does not exceed 70 dB(A).

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9 TROUBLE SHOOTING GUIDE
9.11 Alarm
The ChargerTM controller has an internal alarm buzzer.
When the alarm is triggered the buzzer will sound and a related failure
message will appear on the display.
The alarm will sound when the following conditions occur:- when alarm sounds
investigate and rectify cause.
Then press alarm mute button, alarm will stop.
Remote alarm option
A remote alarm option is available, the ChargerTM unit would need to be
ordered in advance pre-wired for this option. Please consult Stuart Turner.
Attempting to change the ChargerTM MJ wiring will invalidate the guarantee.
9.12 Alarm fault codes
All alarms automatically reset except Prt, pf1.
Displayed message Fault description Action
AHnt
high temp cut out
Pump head overheating - head
temperature has exceeded the set
Hnt value
Allow pump to cool. Ensure the
pump inlet check valve and by
pass are clear of debris.
BHpr
Hi pressure cut out
The current pressure rises above
the Hpr value
Investigate the cause, then turn
power off and on to reset or allow
self reset.
CLpr
Low pressure cut out
The current pressure falls below
the set Lpr value
Investigate the cause, then turn
power off and on to reset or allow
self reset.
DPrt
pump run time
The pump has run longer than the
set Prt value
Investigate cause, then turn power
off and on. Contact Stuart Turner if
problem persists
EPF1 Pump failure Contact Stuart Turner.

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10 YOUR GUARANTEE
Congratulations on purchasing a Stuart Turner Mainsboost Charger Pump.
We are confident this product will give you many years of trouble free service as all
our products are manufactured to the very highest standard.
The Mainsboost Charger pump is covered by the three year guarantee.
Within the guarantee period we will repair, free of charge, any defects in the
Mainsboost Charger resulting from faults in material or workmanship, repairing or
exchanging the part affected or whole unit as we may reasonably decide.
Not covered by this guarantee: Damage arising from incorrect installation, improper
use, unauthorised repair, normal wear and tear and defects which have a negligible
effect on the value or operation of the unit.
Reasonable evidence must be supplied that the product has been purchased within
the guarantee term prior to the date of claim (such as proof of purchase or the
product serial number).
This guarantee is in addition to your statutory rights as a consumer. If you are in any
doubt as to these rights, please contact your local Trading Standards Department.
In the event of a claim please telephone ‘PumpAssist’ customer support.
[phone]
You should obtain appropriate insurance cover for any loss or damage which is not
covered by Stuart Turner Ltd in this provision.
Please record here for your records.
TYPE NO. SERIAL NO. DATE PURCHASED

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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.
DIRECTIVES.
RESPONSIBLE PERSON
AND MANUFACTURER STUART TURNER LIMITED
HENLEY-ON-THAMES, OXFORDSHIRE
RG9 2AD ENGLAND.
Signed................................................ Technical Director
Stuart Turner are an approved company to BS EN ISO 9001:2000
Stuart Turner Ltd, Henley-on-Thames, Oxfordshire RG9 2AD ENGLAND
Tel: [phone], Fax: [phone]
[email protected] www.stuart-turner.co.uk
Issue No. 2218/1-01 Pt. No. 20537