Stuart Turner AQUABOOST iBolt Pump Guide

AQUABOOST
Installation, Operation & Maintenance
Instructions
Please leave this instruction booklet in a safe place as it contains
important warranty, maintenance and safety information
Read this manual carefully before commencing installation.
This manual covers the following products:
Model
iBolt Pump
iBolt Single Pump Booster Set
iBolt Twin Pump Booster Set
Please note images are representative only and may not portray
your model

CONTENTS
1PRODUCT OVERVIEW............................................................................................ 1
2WARNINGS ............................................................................................................ 2
3CHECKLIST .............................................................................................................4
4IMPORTANT - READ BEFORE COMMENCING INSTALLATION ..............................7
5LOCATION - GENERAL .......................................................................................... 8
6KEY FEATURES........................................................................................................9
7INSTALLATION & CONNECTIONS......................................................................... 12
8ELECTRICAL INSTALLATION & EARTHING ........................................................... 13
9COMMISSIONING & STARTING ............................................................................ 19
10 MAINTENANCE .................................................................................................... 29
11 TROUBLE SHOOTING .......................................................................................... 30
12 PRODUCT WARRANTY ........................................................................................35
13 DECLARATION OF CONFORMITY ....................................................................... 38

1
1 PRODUCT OVERVIEW
1.1 Product Description
The iBolt range consists of a single pump unit and single and twin pump booster
sets comprising centrifugal pump(s) and electronic control.
1.2 Application
The Aquaboost iBolt range is designed to meet the demand of pressurised
systems in domestic applications where the existing mains water supply is
insufficient.
1.3 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.

2
2 WARNINGS
• This pump/pump set must not be used for any other application
without the written consent of Stuart Turner Limited.
• 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.
• This product should not be used for the supply of water to more
than one dwelling (house, apartment, flat).
• Cleaning and user maintenance shall not be made by children
without supervision.
• The motor casing can become very hot under normal operating
conditions. Care must be taken to ensure it cannot be touched
during operation.
• The electrical installation must be carried out in accordance with
the current national electrical regulations.
• The electrical installation must be undertaken by a qualified
person.
• RCDs/ELCBs are not recommended for use with variable speed
drives/motors. If an RCD is mandatory use type B RCDs.
• For single phase sets with inverter motors the earth leakage
circuit breaker must trip out when an earth fault currents with DC
content (pulsating DC) occur.
• RCD’s suitable for use with variable speed drives/motors are not
suitable for personnel protection.

3
• Before starting work on the electrical supply ensure power supply
is isolated.
• 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.
• This appliance must be earthed via the supply cord, which must
be correctly connected to the earth point located in the terminal
box.
• 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.
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.

4
3 CHECKLIST
IMPORTANT: With the appliance 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.
3.1 iBolt Pump
Item Description Qty
A iBolt pump 1
B Instruction guide 1
Your product may vary slightly from the illustration above.
A
B
Figure 1

5
3.2 iBolt Single Pump Booster Set
Item Description Qty
A iBolt booster set 1
B Instruction guide 1
Your product may vary slightly from the illustration above.
A
B
Figure 2

6
3.3 iBolt Twin Pump Booster Set
Item Description Qty
A iBolt booster set 1
B Instruction guide 1
Your product may vary slightly from the illustration above.
A
B
Figure 3

7
4 IMPORTANT - READ BEFORE COMMENCING INSTALLATION
4.1 Water Temperature
This unit is designed to pump cold water only which should not exceed the
following values:
The maximum allowable water temperature is 23 °C.
The minimum allowable water temperature is 4 °C.
4.2 Pipework - General
Do not drill holes or put fastenings into the iBolt tank, this will cause leakage.
System leaks: Ensure the system to be boosted is able to hold pressure and is leak
free before installing iBolt products. Failure to do so will cause abnormal operation
and damage to the unit.
Secure pipework: Ensure pipework to and from pump / pump set is
independently supported & clipped to prevent forces being transferred to inlet
and outlet branches of pump. Do not secure pipework to the iBolt, this will cause
damage and possible leakage.
Flux: Solder joints must be completed and flux residues removed prior to iBolt
installation (flux damage will void any warranty).
Pipework design: Care should be taken in the design of pipework runsto minimize
the risk of air locks e.g. use drawn bends rather than 90o bends.
DO NOT introduce solder flux to flexible hose, pump or any parts manufactured
from plastic.
DO NOT allow contact with oil or cellulose based paints, paint thinners or
strippers, acid based descalents or aggressive cleaning agents.
DO NOT feed other header or gravity tanks with iBolt. It is acceptable to feed
toilet cisterns provided the toilet fill valve operates correctly and is leak free.
4.3 Plumbing Installation Regulations
The plumbing installation must comply with the current water andbuilding
regulations.
The plumbing installation must be installed by a qualified person.
4.4 Pressure Vessel
The iBolt pressure vessel is pre-charged at the factory and must be set correctly
during installation see Section 10 - Maintenance for details.

8
5 LOCATION - GENERAL
• Access: For emergencies and maintenance the pump must be
easily accessible.
• Protection: The iBolt must be located in a dry, frost free area. The
iBolt must not be installed in a loft space.
• Ventilation: Ensure an adequate air flow to cool the iBolt.
Separate the iBolt from other appliances that generate heat.
• Water retention: Site the unit 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.
• Ambient temperature: The iBolt must be sited in a location where
the ambient temperature does not exceed 30 ° C.
• Isolating valves: Separate system isolating valves (non restrictive)
must be fitted to allow easy pump service. Isolating valves must
be mounted where specified to allow the system isolation and
removal of the iBolt if needed. See Section 9 for installation
details.
• Preferred iBolt location: The preferred iBolt location is on a
smooth level floor of sufficient strength to support the weight of
the iBolt close to the water source.
The iBolt must not be installed in a loft space.
It must also be considered that the noise and vibration from the
iBolt may be transmitted through the structure the iBolt is sited
on.

9
6 KEY FEATURES
6.1 iBolt Pump
ITEM
DESCRIPTION
1
iBolt Pump & Variable Speed Controller
Figure 4

10
6.2 iBolt Single Pump Booster Set
ITEM
DESCRIPTION
1
iBolt Pump & Variable Speed Controller
2
Nipple
3
Non Return Valve
4
Union Ball Valve
5
5 Way Connector
6
Isolation & Drain Valve
7
Pressure Gauge
8
M / F Union
9
8 Litre Pressure Vessel
10
Base Plate
11
Union Ball Valve
12
Pressure Transducer
13
Isolation Valve
Figure 5

11
6.3 iBolt Twin Pump Booster Set
ITEM
DESCRIPTION
ITEM
DESCRIPTION
1
Base Plate
11
Flow Through Isolating & Drain
Valve
2
iBolt Pump & Variable Speed
Controller
12
24 Litre Pressure Vessel
3
Suction Manifold
13
Isolation Valve
4
Union Ball Valve
14
Pressure Transducer
5
Nipple
15
Plug
6
Non Return Valve
16
Junction Box
7
Union Ball Valve
17
Discharge End Cap
8
Discharge Manifold
18
Suction End Cap
9
Reducing Bush
19
Drain Plug
10
Pressure Gauge
Figure 6

12
7 INSTALLATION & CONNECTIONS
7.1 Water Connection
The iBolt is to be permanently connected to a cold water storage tank using rigid
pipe or suitably sized and rated flexible hose to comply with current building and
plumbing regulations. Ensure there is a demountable joint in the pipe to allow the
removal of the iBolt if needed.
7.2 Unit Location
The iBolt is intended to be installed as a freestanding unit.
1. Slide the iBolt into position
2. Connect the services using isolation valves and demountable fittings
3. The positioning of these fittings allow the iBolt to be removed without
cutting pipes or draining the system.
7.3 Drinking Water Tap
It is recommended that at least one drinking water tap is connected into the un-
pumped water supply (typically a kitchen sink), so the water supply is maintained
in the event of a failure of the pumped supply.

13
8 ELECTRICAL INSTALLATION & EARTHING
8.1 Regulations
• The electrical installation must be carried out in accordance with
the current national electrical regulations and installed by a
qualified person.
8.2 Safety
• RCD’s/ELCB’s are not recommended for use with variable speed
drives/motors. If an RCD is mandatory use type B RCDs.
• For single phase sets with inverter motors the earth leakage
circuit breaker must trip out when an earth fault currents with DC
content (pulsating DC) occur.
• RCD’s suitable for use with variable speed drives/motors are not
suitable for personnel protection.
• Do not touch any electrical components for at least 5 minutes
after the unit has stopped to allow any discharge to occur safely.
8.3 Before Starting Work
• Before starting work on the electrical supply ensure power supply
is isolated.
8.4 Supply Cord
• 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.

14
8.5 Adjacent Pipes
• Adjacent suction and delivery pipes should be fitted with
earthing clamps in accordance with current regulations (Figure 7
Earth continuity connections).
8.6 Earthing
• This appliance must be earthed via the supply cord, which must
be correctly connected to the earth point located in the terminal
box.
8.7 Pipework
• Copper or metallic pipework must have supplementary earth
bonding where the continuity has been broken by flexible hoses
or plastic components.
8.8 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.
8.9 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 (with a minimum of 3 mm contact
separation) fused spur off the ring main and NOT connected to
the boiler or the immersion heater circuits.
• The electrical connection must be made adjacent to (not behind)
the iBolt to allow disconnection of the electrical supply should
the pump module need to be removed for service or
maintenance.
Figure 7

15
8.10 Wiring of Connection Unit
• WARNING: This appliance must be earthed.
• The wires in the mains lead (supply cord) 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.

16
8.11 Wiring Diagrams
Connection Master & Slave Communication, Pressure Transducer and
External Level Sensor
Use cables with reinforced isolation.
1. Unscrew the cover and loosen the PG located on the lateral side of
the plastic body.
2. Insert the cord through the PG.
3. Remove the connector from its housing.
4. Set up the connection following the schema.
5. Relocate the connectors on its housing. Screw the cover and the PG.
If the devices are provided with the communication cable, refer to the
following color code:
1-black, 2-brown, 3-grey, 4-yellow / blue
They will be connected by following detail A; the two central wires (brown
and grey) must be crossed.
Figure 8

17
iBolt (Twin Controller)
Figure 9

18
8.12 Fuses
The following fuse size should be used:
Model Fuse Size (AMPS)
iBolt all models 10
8.13 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 theirapproved
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.