Stuart Turner AQUABOOST MAB Guide

AQUABOOST
MAB & MARB Variable Speed Booster Sets
Installation, Operation & Maintenance
Instructions
Please leave this instruction booklet with the owner as it contains important warranty,
maintenance and safety information.
Read this manual carefully before commencing installation.
This manual covers the following products:
MAB Variable Speed Booster Sets
MARB Variable Speed Booster Sets
Please note images are representative only and may not portray
your model

CONTENTS
1PRODUCT OVERVIEW............................................................................................3
2WARNINGS .............................................................................................................4
3ELECTRICAL SECTION............................................................................................6
4INSTALLATION ....................................................................................................... 8
5PRIMING .................................................................................................................11
6MAINTAINANCE & SERVICE ................................................................................. 12
7PRODUCT WARRANTY TERMS & CONDITIONS .................................................. 13
8DECLARATION OF CONFORMITY ........................................................................ 16

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1 PRODUCT OVERVIEW
1.1 Product Description
The Booster sets are designed and built to ensure a constant pressure, specifically
suitable for domestic applications and small or medium systems for civil,
agricultural or industrial uses. Booster sets strengths and benefit: constant
pressure, low noise operation, low running costs, low water consumption,
protection against dry running. It’s recommended to use the sets with pressure
vessel.
1.2 Application
Cold water pressure and flow boosting in a range of domestic, commercial and
industrial applications.
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.
1.4 Environment Protection
Your appliance contains valuable materials which can be recovered or recycled.
At the end of the products’ useful life, please leave it at an appropriate local civic
waste collection point.

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2 WARNINGS
• 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.
o
Children shall not play with the appliance.
o Cleaning and user maintenance shall not be made by
children without supervision.
o 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 installed by a qualified
person.
o
Do not run the pump dry.
o System pressure must not exceed 10 bar.
o Before starting work on the electrical supply ensure
power supply is isolated.
o DO NOT allow the supply cord to contact hot surfaces,
inluding the motor shell, pump body or pupework. The
cord should be safely routed and secured by cable clips.
o This appliance must be earthed via the supply cord,
whih must be correctly connected to the earth point
loacted in the terminal box
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.
2.1 SPECIAL WARNING REGARDING FREQUENCY CONVERTER
The FREQUENCY CONVERTER should NEVER be opened or tampered with and
guards that come with it should never be removed.
The frequency converter must be installed, adjusted and maintained by qualified
personnel who understand the risks involved.
The booster set is designed to start automatically. Make hydraulic connections and
to prime the pumps before making any electrical connections.
The connection of the control panels must be performed by a qualified electrician
in accordance with the present electrical standards.

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The booster set and control panels must be connected to an efficient earthing
system in accordance with the electrical standards of the country in which it is
installed.
The connection of the earth must be performed first.
The connection of the alarms can distribute power even when the frequency
converter is turned off. Ensure that there is no residual voltage on the terminals of
the alarms. All the power terminals and other terminals must be inaccessible after
installation is completed.
The maximum output frequency must not exceed the design frequency of the
pump being controlled. Operating at a frequency higher than the allowable
frequency can cause higher current absorption and damage to the device.
If it is necessary to remove the frequency converter, remove only the covers
required in order to disconnect the electrical cables. Take care not to damage the
electronic cards.
Failure to comply with the safety regulations not only causes risk to personal
safety and damage to the equipment, but also invalidates every right to assistance
under warranty.

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3 ELECTRICAL SECTION
3.1 Warning!
The drive controller contains dangerous voltages and controls potentially
dangerous rotating mechanical parts. The installation, commissioning and
maintenance of this equipment should be performed only by qualified personnel
who are familiar with the operation. The installation, commissioning and
maintenance of this equipment should be performed only by qualified personnel
who are familiar with the operation.
Do you have particular caution if the automatic restart is activated? To avoid injury
by possibly unintentional restart of the drive controller after a power failure, turn
off the automatic restart in case of doubt. When repairing or servicing this
equipment, make sure that the system cannot be switched on by others again!
The frequency controller has DC link capacitors, which carry hazardous voltage
even after the mains supply is switched off.
Therefore, always wait after switching off the mains voltage for at least 5 minutes
before working on the machine or turn on the unit again. It is important to ensure
that no live parts are touched when power is applied or the intermediate circuit
capacitors are charged.
Do not work on the wiring and check any signals when power is applied. The
Inverter - Regulator has a leakage current. Ground the frequency controller on the
connections provided.
3.2 Caution!
All frequency controllers are tested for dielectric strength and insulation
resistance. Before the insulation measurement in the pump station, for example
within the scope of the inspection frequency controller must be disconnected! It is
strongly recommended that all electrical equipment conforms to the National
Electrical Codes and local regulations.
Factors such as high temperatures, high humidity as well as dust, dirt and
corrosive gases.
The installation should be a well-ventilated, not exposed to direct sunlight place.
Put them no mains voltage to the transducer terminals or to the control terminals.
Enter the operating signals Hand/0/Auto via the selector switch on or about the
driving of external contacts and not by switching on and off of a line or motor
contactor. Only qualified personnel should perform installation, alignment and
maintenance.
The manufacturer reserves the right to alter the technical data in order to make
improvements or update information.
The manufacturer cannot release you from the obligation to comply with the latest
safety standards the user.

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3.3 Notice!
The technical data and descriptions in this guide are correct to the best
knowledge and belief. Technical improvements have been continuously carried
out - that's why the manufacturer reserves the right, without prior notice to carry
out such changes. The manufacturer cannot be held liable for errors in the manual.
Warranty is within the incorporated statutory warranty period and applies only to
the product itself and not for any consequential loss or damage or costs
associated with the occurrence of a Warranty claim arise at other plants or plant
parts. The operator shall, in each case to ensure that a failure or defect in the
product cannot lead to further damage.
3.4 Caution Danger to life!
Incorrect installation and incorrect electrical connection can be life-threatening.
Electricity hazards must be ruled out.
•Installation and electrical connection may only be performed by qualified
personnel and in accordance with the applicable regulations (e.g. IEC, VDE,
etc.)!
•The type of current and voltage must comply with the data on the rating
plate.
•Comply with the regulations of the local power supply company!
•Comply with the accident prevention regulations!
•Never pull on the power cord
•Do not bend the cord
•Do not place any objects on the cord
•When the pump is used in systems with temperatures above 90°C, a
connection cable that is suitably resistant to high temperature must be used
•There is a risk of sharp and jaged edges during assembly.
•Never transport by holding the power cord.
•There is a risk of injury from dropping the pump.

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4 INSTALLATION
When requesting information or spare parts from our Sales Department, quote
the exact identification code of the model together with the manufacture
number.
This manual, along with any other manuals and other documents which are
delivered with the booster set, is an integral part of the operating instructions.
This manual aims to provide information and instructions essential to adequately
perform all activities related to the use of the product purchased. This manual, and
documentation, are intended to be viewed by all persons involved in the life cycle
of the booster set and therefore must be accessible to the user.
Compliance with all safety requirements is an obligation of the customer.
The following instructions and requirements relate to the standard operations; for
instructions, situations and events that are not covered in the present manual or
sales documents, contact our assistance service.
The installation must be designed and carried out only by qualified technicians;
Errors in the installation or use can cause serious damage to the equipment, the
user system and the people involved.
Do not make any action, maintenance, repairs or modifications that you do not
have specific knowledge or received detailed instructions. If doubts remain, after
consultation with the following paragraphs, surveyed Fluid Water Solutions Ltd. All
operations must be carried out while respecting the safety rules.
Remember that you respect the regulations in force in the country of
installation: if different rules are in force on the same topic, you should always
consider the more stringent requirements.
Our products have been manufactured in accordance with the applicable safety
standards in force for which it is recommended the use of all devices or notices in
order that the use does not cause injury to persons or damage to belongings.
Our products were designed for the specific use intended, THEREFORE ANY
OTHER USE THAT IS DIFFERENT AND NOT IN ACCORDANCE WITH WHAT
INDICATED, EXEMPTS STRUART TURNER LTD FROM RISKS that may occur.
The modification of both mechanical and electrical parts of the machine is strictly
prohibited. The non-compliance exempts Stuart Turner Ltd from any responsibility.
The responsibility of any operation that has not been authorised in writing shall fall
upon the executor, inasmuch that they become the manufacturer.

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READ THE INSTRUCTION MANUALS OF EVERY PUMPS, MOTORS, CONTROL
PANELS AND OTHERWISE OF ALL COMPONENTS. FOLLOW THE PROVISIONS OF
THE SAFETY AND PERFORM THE PLANNED MAINTENANCE RECOMMENDED IN THE
INSTRUCTION MANUALS!
• The set must be fitted in a well ventilated place, protected from
unfavourable weather conditions.
• When handling the set, lift it by the base.
• Do not lift the set by the delivery manifold: risk of damage to the
glued pipe work which may cause leaks when installed.
• Position the set in such a way that any maintenance jobs can be
carried out without difficulty.
• Ensure that the system pipes are independently supported and do
not weigh down on the set manifolds so as to avoid deformation or
breaking of any of its components.
It is also advisable to insert vibration-damping couplings on the system manifolds.
Make the intake section following all the precautions necessary to keep load losses
to a minimum and to avoid the formation of air pockets, for example:
• Position the set as close as possible to the power supply source.
• Consider a suction pipe diameter never smaller than that of the
manifold.
• Lay the suction pipe horizontally or sloping slightly upwards towards
the set.
• Avoid using elbows or couplings that cause sudden changes in
direction. If necessary, use bends with a wide radius.
Installation must be performed by skilled and authorised installers. During
installation, apply all safety behaviours issued by the competent bodies and
suggested by common sense. Install the unit in a dry well-ventilated place. Rest
the unit on a flat, regular and solid surface (rubber feet) or disassemble the rubber
feet and fix the unit to the base using the relevant screws. Vibrations must not
occur during functioning. The unit can only be installed in the horizontal position.
In the applications with positive suction head, the suction pipe must not be
smaller than that of the intake manifold. In the applications with negative suction
head, in particular cases there may be the necessity to replace the intake manifold
with an individual supply for each pump, in order to prevent preferential flows to
one or several pumps. Generally, in negative suction head applications, the intake
pipes must be as short and straight as possible, they must have a diameter greater
than or equal to the diameter of the pump intake (or the manifold if present). They

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must also be supplied with foot-valve and have a slight slope to the pumps, to
prevent the formation of air pockets. Functioning with leaks in intake can damage
the unit pumps. Fix carefully the piping in order not to transmit stress of any type
to the pump. Fasten the piping to the respective manifolds, without excessive
force so as not to cause damage. Booster sets can be shifted in different ways
depending on the configuration of the machine and equipment available to the
installer.
The units are delivered ready for power supply connection, which must be carried
out by a skilled, authorised installer, in compliance with the Standards in force in
the country of installation. During installation, apply all safety behaviours
suggested by law and common sense. Make sure that the electric power supply
network is protected by ground connections in compliance with Standards. Check
the correspondence between the plate data and line nominal values. Before
making the connections, make sure that the ends of the line wires are not live.
Make the connection when you are sure of the existence of an efficient ground
circuit. The ground wire must be longer than the phase wires and must be the first
to be connected during assembly and the last to be disconnected during
disassembly. The installation of a differential switch is recommended.
Before removing the inverter cover or starting interventions on
it, the system must be disconnected from the mains electricity
and you must wait 5 mins until the intermediate circuit
condensers, which can reach voltages up to 800V, have the
time to discharge via the built-in discharge resistors.
EMERGENCY STOP
An emergency stop can be performed while the inverter is
running, by turning the Hand/off/Auto switches to “0” or
turning the panel isolator off.
Before starting up, please read carefully this Manual and the instructions of MAB &
MARB Variable speed control panels.

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5 PRIMING
A pumping system must never be started dry for any reason. Dry running of the
pumps, even for very brief periods, can cause irreversible damage to mechanical
sealing and internal rotating couplings. All pumps must be primed before starting
the system by unscrewing the filler cap and filling the pump body with water (and
the intake piping connected to it). When the operation has been completed,
tighten the cap and start the pump, with the cut-off valve in flow almost
completely closed, with the system in manual functioning mode (TEST).
If, after a few tens of seconds, the pump is not primed, switch it off, check that the
intake is free, that there are no air pockets upstream from the inlet, that the body
is full of water and then repeat the operation. In the units, priming is performed for
each individual pump, turning off the other pumps and performing the operations
described above for each pump. To make priming of each pump simpler, E-SERIES
suspends the SLAVE operation if the MASTER is off (that is, the inverter returns to
being completely independent) so that each inverter can be manoeuvred
independently during the priming or test phase. Once all of the pumps are primed,
the operative parameters can be set on the MASTER inverter. These are
automatically sent to the SLAVE inverters when they are turned on.
5.1 Pressure Vessel
A minimium of one 24 ltr Pressure Wave vessel is normally fitted during
production. A vessel should always be fitted on the discharge manifold close to
the transducer to stabilize the pressure signal. Unlike conventional fixed speed
systems a large vessel reservoir is not required. The vessel air charge should be
maintained at 0.5 bar below the systems nominal operating pressure.
e.g.
Target System Pressure = 5.0 bar
Vessel Air Pressure = 4.5 bar
5.2 Inverter Settings:
See attached MAB & MARB operating & maintenance manual.
5.3 Pump Details:
See attached operating & maintenance manual.

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6 MAINTAINANCE & SERVICE
Before carrying out maintenance, cleaning and repair work, disconnect the system
from the power supply and secure it against being switched on again by
unauthorized persons.
At high water temperatures and system pressures, wait for the pump to cool
down beforehand. There is a risk of burns!
6.1 Malfunctions, causes and elimination
Maintenance work or repair attempts may only be performed by qualified
personnel. Before carrying out maintenance, cleaning and repair work, disconnect
the system from the power supply and secure it against being switched on again
by unauthorized persons. At high water temperatures and system pressures, wait
for the pump to cool down beforehand. There is a risk of burns!
6.2 Dry running protection
If the system has been stopped due to lack of water, either by an external float
switch or the automatic pressure deviation system then the inverter makes
automatic and predefined times to re-attempt starting.
In case of use under inverter and with membrane tanks, is necessary a total volume
of the tank (expressed in litres) not lower than the 10% of the maximum single
pump flow rate. The pump sets are supplied complete with installation
maintenance instructions and wiring diagram.
The present manual is aimed at giving the necessary information regarding the
installation, use and maintenance of booster sets with variable speed controls
consisting of various pumps.
It is vital that the user reads this manual prior to using the system. Improper use
may cause damage to the machine as well as the lapse of the guarantee.

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7 PRODUCT WARRANTY TERMS & CONDITIONS
Congratulations on purchasing a Stuart Turner product
We are confident this product will provide many years of trouble free service as all our
products are manufactured to the very highest standard.
All MAB booster sets are warranted to be free from defects in materials or workmanship
for up to 2 years from the date of purchase.
Within the warranty period we will repair, free of charge, any defects in the product
resulting from faults in material or workmanship, repairing or exchanging the whole unit
as we may reasonably decide.
Warranty Exclusions
Not covered by this warranty: Damage arising from incorrect installation, improper use,
unauthorized repair, normal wear and tear and defects which have a negligible effect on
the value or operation of the pump.
This warranty 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.
Warranty Claim Procedure
In the event of a claim please telephone ‘TechAssist’ on [phone]
or email us at [e-mail]
In the event of a claim within the terms of this warranty policy, your receipt or ‘proof of
purchase’ provided during registration will be reviewed.
You should obtain appropriate insurance cover for any loss or damage which is not
covered by Stuart Turner Ltd in this provision.
Please make a note for your own reference:
PRODUCT MODEL SERIAL NO. DATE PURCHASED

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8 DECLARATION OF CONFORMITY
Stuart Turner Ltd, Henley-on-Thames, Oxfordshire RG9 2AD ENGLAND
Tel: [phone] Fax: [phone]
[e-mail] | www.stuart-turner.co.uk
Issue No. 1722-01-01