Stuart Turner 46601 Guide

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:
CE compliant product
Monsoon Extra 2.6 bar PS
Pt. No. 46601 Monsoon Extra 3.6 bar PS Pt. No. 46602
FOR POSITIVE OR NEGATIVE HEAD APPLICATIONS

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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 Pressure Set (PS) range is designed for pressure boosting
applications in vented, stored, cold clean water systems, where under gravity, no flow is
available and can be used in systems where a negative head exists.
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.
This pump MUST NOT be connected directly to the mains water supply.
This 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.
Children should be supervised to ensure that they do not play with the
appliance.
This product should not be used for the supply of water to more than
one dwelling (house, apartment, flat).
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.
CONTENTS Page
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Important Facts - read before commencing installation . . . . . . . . . . . . . . . . . . . . 4
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pump Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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CHECKLIST
Note: Item G supplied loose - this will require fitting to the pump outlet. Tighten to torque
4/5 Nm.
Your product may vary slightly from the picture above.
Item Description Qty Item Description Qty
Pump 1 Inline strainer 1
Hose & sealing washer 2 Pressure vessel 1
Inlet connector & ‘o’-ring 1 Outlet connector & gasket 1
Anti-vibration feet 4
Fig. 1
28 mm copper
inlet pipework
(suction).
28 mm isolating valve
(non restrictive) and
fittings (not supplied)
must be fitted to allow
easy pump service.
28 mm copper outlet pipework (discharge).
Short 28 mm copper pipe
tails to connect between
isolating valve and flexible
pipes.
28 mm isolating valve
(non restrictive) and
fittings (not supplied)
to allow easy pump
service.
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.
A
A
F
F
G
G
C
C
E
E
B
B
D
D
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.

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Cont ...
1 READ BEFORE COMMENCING PUMP INSTALLATION
A. Water storage capacity.
1.11 The 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
This unit is designed to pump cold water only which should not exceed the following
values:
1.13 The maximum allowable water temperature is 35 oC.
1.14 The minimum allowable water temperature is 4 oC.
C. Pipework - General
1.15 Secure pipework: Ensure pipework to and from pump is independently
supported & clipped to prevent forces being transferred to inlet and outlet
branches of pump.
1.16 Flux: Solder joints must be completed and flux residues removed prior to pump
installation (flux damage will void any warranty).
1.17 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.
1.18 DO NOT introduce solder flux to flexible hoses, pumps or pump parts
manufactured from plastic.
1.19 DO NOT allow contact with oil or cellulose based paints, paint thinners or
strippers, acid based descalents or aggressive cleaning agents.
1.20 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.
1.21 DO NOT bend the flexible hoses beyond 30o. They must be installed as
straight as possible.
1.22 DO NOT connect this pump to the mains water supply.
D. Plumbing & Electrical Installation Regulations
1.23 The plumbing installation must comply with “The Water Supply (Water Fittings)
Regulations 1999” and “BS 6700” building regulations.
1.24 The plumbing installation must be installed by a qualified person.
1.25 The electrical installation must be carried out in accordance with the current
national electrical regulations.
1.26 The electrical installation must be installed by a qualified person.
E. Pressure vessel
1.27 Pressure vessel is charged at the factory see Section 6 - Maintenance for
details.

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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 locate the unit check to ensure
the static inlet head between pump and the bottom of the cold tank (Fig. 2) is at
least 1 metre and does not exceed the max inlet head of 10 metres.
2.17 Pump position: The pump must be positioned on its anti-vibration mounting feet
and as close to the water source as possible.
2.18 Ambient temperature: The pump must be sited in a location where the maximum
ambient temperature does not exceed 40 oC.
2.19 Pipework: For optimum performance pipework use 28 mm dia., 22 mm can be
used but will result in reduced pump performance.
Pipework should only reduce to 15 mm when entering terminal fitting.
2.20 Static outlet pressure: The static outlet head (Fig. 2) must also be within the
maximum requirement of 13 metres.
2.21 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.
2.22 Direction of flow: Ensure the water flow is in the direction of the arrow marked
on the flow switch reed clamp (vertically upwards).
2.23 Flexible hoses: Use only Stuart Turner supplied hoses.
2.24 Isolating valves: Separate isolating valves (non restrictive) must be fitted to
allow easy pump service.
2.25 Preferred pump location: The preferred pump location is at floor level next to
the water source or a level that is below the tapping that feeds the pump.
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.

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Cont ...
2 LOCATION
2.26 The cold water supply: Must be a DEDICATED AIR FREE supply via a tank
connector.
Do not connect to the mains.
Fig. 2
Cold
water Hot water
Unvented hot
water cylinder
Static inlet pressure Min. 1 m Max. 10 m
Static outlet pressure Max. 13 m

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Cont ...
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.

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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.
4.14 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.
4.15 Supplementary Bonding: The pressure set is factory fitted with a
supplementary earthing wire to ensure continuity throughout the assembly
(Fig. 3). It must be ensured throughout the product life that this electrical
connection remains in place.
4.17 Earthing: This appliance must be earthed via the supply cord, which must be
correctly connected to the earth point located in the terminal box.
4.18 Pipework: Copper or metallic pipework must have supplementary earth bonding
where the continuity has been broken by flexible hoses or plastic components.
4.16 Adjacent pipes: Adjacent suction and delivery pipes should be fitted with
earthing clamps to BS 951 in accordance with current regulations (Fig. 4).
Diagram of
earth continuity
connections
Fig. 4
Fig. 3
Warning Tag

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Cont ...
4.19 Additional earthing: Certain installations may require additional earthing
arrangements such as equipotential bonding. Reference should be made to the
relevant regulations concerning this subject to ensure compliance.
4.20 Connections: The pump must be permanently connected to the fixed wiring of
the mains supply using the factory fitted supply cord, via a double pole switched
fused spur off the ring main and NOT connected to the boiler or the immersion
heater circuits.
4.21 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:
The wire which is coloured green and yellow must be connected to the terminal
in the connection unit which is marked with the letter E or by the earth symbol:
or coloured green or green and yellow.
The wire which is coloured blue must be connected to the terminal which is
marked with the letter N or coloured black.
The wire which is coloured brown must be connected to the terminal which is
marked with the letter L or coloured red.
4.22 Wiring Diagram:
Model Fuse Size (AMPS)
All Models 13
4.23 Fuses: The following fuse size should be used with the appropriate pump:
GREEN / YELLOW
BLUE
BROWN L
MA
N
NLE
N230 VAC/1PH/50Hz
SUPPLY
RED
CAPACITOR
MOTOR
GREEN / YELLOW (LINK WIRE)
RED
YELLOW
RED
BLACK
BLACK
FLOWSWITCH
REED (S3)
S3 S3 S2S2S1 S1
PRESSURE
SWITCH (S1)
Monsoon Extra 2.6, 3.6 bar PS
Fig. 5

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Cont ...
4.24 Supply Cord Replacement:
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 re-assembly to the same factory pattern
is always maintained.
If the supply cord is to be changed or is damaged, it must be replaced with a
special cord assembly available from Stuart Turner or one of their approved
repairers.
On disassembly note the cord retention and routing system. Re-assemble to the
same pattern.
For information on cable connection consult the wiring diagram and cable gland
fitting instructions.
4.25 Cable Gland Fitting Instructions:
To enable correct assembly of the cable gland the ‘O’-ring (Fig. 6 item 1) must
be placed over the cable before the clamping insert (Fig. 6 item 2) can
be tightened.
Note: Cable diameter range:- 6.5 mm to 9.5 mm.
4.26 Supply Cord Extension:
The pumps are fitted with a supply cord to the following specification:-
All models. . . . . . . . . . . . . . . . .HO5VV-F3 G 0.75 mm² - 6 Amp rated cable.
If the supply cord is to be extended, a cord of the same specification should be
used. Any connections or junction boxes used should be specifically suited for
the application and installed in accordance with the manufacturers instructions.
Fig. 6
2
1