Stuart Turner 31778 User manual

Cont ...
INSTALLATION INSTRUCTIONS
SERVICE KIT  FLOW SWITCH MANIFOLD REPLACEMENT KIT.
Part Nos. 31778, 31784
 Monsoon Universal Twin Pumps
 KIT CONTENTS
ITEM QTY ITEM QTY
1 Flow Switch Manifold Assembly 1 5 ‘O’-Ring (ID 15.0 mm x 3.5 mm sec) 2
2 ‘O’-Ring (ID 10.1 mm x 1.6 mm sec) 1 6 Screw Self Tapping M4 × 16 4
3 Tie Wrap 1 7 ½ “ BSP Rubber Washer 1
4 ‘O’-Ring (ID 24.6 mm x 2.4 mm sec) 2 8 Screw Self Tapping 3.5 × 12 4
 WIRING DIAGRAM
Before the removal of the flow switch manifold assembly can be achieved, the pressure
switch must be disconnected electrically and removed as shown:
Fig. Pump UK Eire
1 Monsoon Universal N2.5 bar Twin ü–
Monsoon Universal N3.5 bar Twin ü–
Monsoon Universal N4.1 bar Twin ü–
Monsoon Universal N1.5 bar Twin – ü
Monsoon Universal N2.5 bar Twin – ü
Monsoon Universal N3.5 bar Twin – ü
Monsoon Universal N4.1 bar Twin – ü
Monsoon U1.5 bar Twin üü
Monsoon U2.0 bar Twin üü
Monsoon U3.0 bar Twin üü
Monsoon U4.0 bar Twin üü
Monsoon U4.5 bar Twin üü
2 Monsoon Universal N1.5 bar Twin – ü
Monsoon Universal N2.5 bar Twin – ü
Monsoon Universal N3.5 bar Twin – ü
Monsoon Universal N4.1 bar Twin – ü
Manufactured from
November 2008
Manufactured from
October 2009
Manufactured up to
October 2008

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Cont ...
FLOWSWITCH
REED (S3)
LINK WIRE (BLUE)
BROWN
GREEN / YELLOW
BLUE
BROWN L
S2 S3 S3 S2
E
N
230 VAC/1PH/50Hz
SUPPLY
NM
NL
S1 S1
FLOWSWITCH
REED (S2)
PRESSURE
SWITCH (S1)
MOTOR CAPACITOR
BLACK
BLUE
 DISASSEMBLY
• Isolate electrical supply before fitting replacement part.
• Replacing the terminal box part components should only be carried out
by a competent person.
• 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 reassembly to the same factory pattern is always maintained.
FLOWSWITCH
REED (S3)
LINK WIRE (BLUE)
BROWN
GREEN / YELLOW
BLUE
BROWN L
S2 S3 S3 S2
E
N
230 VAC/1PH/50Hz
SUPPLY
NMNL
S1 S1
FLOWSWITCH
REED (S2)
PRESSURE
SWITCH (S1)
MOTOR CAPACITOR
BLACK
BLUE
Fig. 2
Pressure Switch S1
Reed Switch S3
Reed Switch S2
Fig. 1
Pressure Switch S1
Reed Switch S3
Reed Switch S2

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• Remove four screws and carefully remove terminal box lid (Fig. 3).
• Note the cable routing within the terminal box (Figs. 1 or 2).
• Identify and remove the pressure switch wiring from the terminal block (Figs. 1 or 2).
• IMPORTANT – take note of the cable clamp position before removal, as reassembly in
the original factory orientation is essential – Remove two screws and cable clamp (Fig. 3).
• Remove the pressure switch cable from the terminal box by gently sliding the cable out
through the sealing grommet, ensuring no damage to the seal area (Figs. 1, 2 & 3).
LN
MN
Fig. 3
4 Terminal
box lid screws
(item 8)
Terminal box lid Cable clamp screws
Cable clamp
Sealing Grommet
Pressure Switch Removal.
• Unscrew the pressure switch
and remove with ‘O’-ring from
the flow switch manifold (Fig 4).
Reed Switch Removal.
• Remove the reed switch by
cutting the securing tie wrap
and pulling away from flow
switch body (Fig 5).
Fig. 4 Fig. 5
‘O’-ring
Pressure switch
Reed
switch
Cut tie wrap

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Cont ...
Pressure Vessel Removal.
• Unscrew and remove the pressure vessel as shown in Fig. 6.
• Note rubber washer location in manifold body (Fig. 7).
Flow Switch Assemblies Removal.
To remove the flow switch manifold, body and transfer pipe assembly.
• Remove four manifold clamp screws (A) and lift complete assembly away from pump
assembly (Fig. 8).
Fig. 6 Fig. 7
Pressure vessel Manifold body
Rubber
washer
Fig. 8
A

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Cont ...
Disassembly of the flow switch manifold, body and transfer pipe assembly.
• Remove the transfer pipe from the flow switch manifold (Fig. 9).
• Remove the 15 mm ‘O’-ring from the flow switch manifold ensuring no damage to the
manifold parts, using ‘non-metallic’ tools (no sharp objects) (Fig. 8).
Fig. 9
Flow switch body
‘O’-ring
Transfer pipe
Flow switch
manifold
Damaged components must be replaced. Contact Stuart Turner for advice on
replacements not supplied with kit.

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Cont ...
 REASSEMBLY
Reassembly is the reverse of the disassembly instructions with the new replacement parts
fitted as required.
Care should be taken when inserting the transfer pipe into the flow switch ‘O’-rings.
Lubricate with water and gently insert whilst rotating to avoid damage to the ‘O’-rings.
• Secure flow switch manifold clamp screws (A), to a torque of 1.5 Nm.
• Secure cable clamp screws and terminal box lid screws, to a torque of 0.8 Nm.
• Pressure switch to be tightened to a torque of 7–8 Nm.
• Pressure vessel to be fitted by engaging the thread and rotating the vessel as shown to
confirm a secure hand tight connection (Fig 10).
Fig. 10

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Note: For correct operation of the flow switch, the reed must be secured to the body as
detailed below.
• Firstly feed the tie wrap through the retainer on the reed switch, ensuring that the tie
wrap serrations are facing outwards (Fig 11).
• Now locate the reed switch within the body groove as highlighted X-X (Fig. 12), and
feed the tie wrap through the second catch.
• The tie wrap can now be pulled tight to secure the reed and the excess cut to length as
shown in Fig. 13
Fig. 11 Fig. 12 Fig. 13
 INITIAL OPERATING INSTRUCTIONS
• Consult instruction manual for commissioning instructions.
• Do not run pump dry. Allow the water to be pumped to enter the pump body thus
ensuring the seal is lubricated before switching the pump on. Failure to do this will
damage the seal.
• Carefully check pump and pipework for leaks whilst pump running and stationary before
leaving the installation unattended.
Stuart Turner Limited reserves the right to amend specifications without notice.
X
X
Catch
Reed switch
Tie wrap
Serrations

Stuart Turner Ltd, Henley-on-Thames, Oxfordshire RG9 2AD ENGLAND
Tel: [phone], Fax: [phone]
[e-mail] www.stuart-turner.co.uk
Issue No: 0520/2–02
Pt. No. 19082