Stuart Turner BOOSTAMATIC 330 User manual

BOOSTAMATIC PUMPS
OPERATING INSTRUCTIONS
Please leave this instruction booklet with the pump as it
contains maintenance and safety information.

IMPORTANT NOTES
Please read these instructions fully before starting the
installation:
The installation must comply with the relevant water supply,
electrical and building regulations and be installed by a
competent person.
If in doubt, consult Stuart Turner Ltd.
APPLICATION
The Boostamatic range is designed for pressure boosting applications in vented stored
*hot or cold, clean fresh water systems, where under gravity, no flow is available. Other
clean non aggressive, non explosive liquids with similar characteristics to water may be
pumped, consult Stuart Turner for such applications.
* Certain models only.
WARNING AGAINST MISUSE
This pump set must not be used for any other application without the
written consent of Stuart Turner Limited and, in particular, must not be
connected directly to the mains water supply or used outside the
conditions specified in the limits of application.
This appliance is not intended for use by persons (including children)
with reduced physical, sensory or mental capabilities, or lack of
experience and knowledge, unless they have been given supervision
or instruction concerning use of the appliance by a person responsible
for their safety.
Children should be supervised to ensure that they do not play with the
appliance.
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BOOSTAMATIC MODELS
INDEX . . . . . . . . . . . . . . . . . . . . . . . .Page No
Application . . . . . . . . . . . . . . . . . . . . . . . . . .2
Product Description . . . . . . . . . . . . . . . . . . .3
Limits of Application . . . . . . . . . . . . . . . . . . .4
Technical Specification . . . . . . . . . . . . . . . .5
Pump Connections . . . . . . . . . . . . . . . . . . .5/20
Pre Installation Assembly . . . . . . . . . . . . . .6
Siting of the Pump/Pipework . . . . . . . . . . . .6
Release & Connection of Push-in Fittings . .11
INDEX . . . . . . . . . . . . . . . . . . . . . . . .Page No
Electrical Installation . . . . . . . . . . . . . . . . . .13
Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Commissioning . . . . . . . . . . . . . . . . . . . . . .20
Maintenance . . . . . . . . . . . . . . . . . . . . . . . .23
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Trouble Shooting Guide . . . . . . . . . . . . . . . .25
Environment Protection . . . . . . . . . . . . . . . .26
Surface Models Submersible Models
330
500
600
Jet 40
Jet 90
Kennet KB6
Loddon LB5-4
Loddon LB6-4
Thame TB5-2
Thame TB7-2
Diver 3
Diver 4

-3-
PRODUCT DESCRIPTION
Electric motor driven pump complete with automatic control module consisting of flow
switch, pressure switch, pressure vessel and electronic control.
Motor
Diver Range: Class 'B' insulation, continuously rated and encapsulated with a (304)
stainless steel casing.
Jet Range: Class ‘B’ insulation, totally enclosed fan ventilated cooling, continuously
rated.
All Other Ranges: Class ‘F’ insulation, totally enclosed fan ventilated cooling,
continuously rated (except 600, see technical section).
General: All motors are induction type, permanent capacitor, fitted with integral auto
resetting thermal overload protection and comply with BS5000 or IEC 34-1. Enclosure
ratings are given in the technical specification section.
Pump
All models are close coupled to motor.
330, 500 and 600 are of single stage, end suction, peripheral design.
Diver 3 and 4 Submersible pumps are of three and four stage, centrifugal design.
Jet 40 and 90 are of centrifugal, end suction design.
Kennet KB6 is of single stage, end suction, centrifugal design.
Loddon LB5-4 and LB6-4 are of 4 stage, end suction, centrifugal design.
Thame TB5-2 and Thame TB7-2 are of two stage, end suction, centrifugal design.
Standard pump materials of construction of major wetted parts are as follows:-
Control Module
All models use the solid state IP65 rated pressure control module, mounted remotely in
the case of the Diver units. The wetted materials of construction are brass, rubber and
nylon 66. All control modules (except Diver) are factory fitted with a mains supply cord.
Model Body Impeller Shaft Mechanical
Seal
330, 500, 600 Brass Brass Stainless Steel Nitrile/Carbon
Ceramic/Stainless Steel
Jet 40 & 90 Polypropylene Noryl Stainless Steel Nitrile/Carbon
Ceramic/Stainless Steel
Kennet KB 6 Brass Acetal Stainless Steel Nitrile/Carbon
Ceramic/Stainless Steel
Loddon LB5-4,
LB6-4
Noryl
Stainless Steel Polycarbonate Stainless Steel Nitrile/Carbon Sil Carbide/Stainless Steel
Thame TB5-2,
TB7-2
Noryl
Stainless Steel Polycarbonate Stainless Steel Nitrile/Carbon/Silicon Carbide/Stainless Steel
Diver 3 & 4 Polypropylene Noryl Stainless Steel
& Ceramic Sleeve Lip Seal

-4-
Notes:
N/A Denotes not applicable.
Submersible pumps must be fully submerged.
Max. permitted viscosity: 9.5 centistokes (Redwood No 1 scale).
Max. permitted ambient air temp: 40°C.
* With footvalve fitted.
** Max working pressure is the maximum pressure that can be applied to the pump
internal casing under any installation conditions.
*** The supply voltage must not exceed ±10% of the above listed
voltage.
eg. 230 ±10% or 110 ±10%
Failure to adhere will damage the unit.
LIMITS OF APPLICATION
Model Supply
(Note***)
Max.
Liquid
Temp.
°C
Min.
Liquid
Temp.
°C
Max.
Suction
Lift (m)
(Note*)
Max.
Immersion
Depth
(m)
Max. No.
Starts/h
Cut In
Pressure
(bar)
Cut Out
Flow
(l/min)
Max.
Working
Pressure
kPa (bar)
(Note**)
Max.
Inlet
Head
(m)
Max.
Head
(m)
(pump
closed
valve)
330 230/1/50 65 4 4.6 N/A 60 1.4 0.5 600 (6) 14 27
330 110/1/50 65 4 4.6 N/A 60 1.4 0.5 600 (6) 14 30.5
500 230/1/50 65 4 4.6 N/A 60 1.4 0.5 600 (6) 14 39.1
500 110/1/50 65 4 4.6 N/A 60 1.4 0.5 600 (6) 14 40
500 110/1/60 65 4 4.6 N/A 60 1.4 0.5 600 (6) 14 40.5
600 230/1/50 65 4 4.6 N/A 60 1.4 0.5 700 (7) 14 49.9
Diver 3 230/1/50 35 4 N/A 7 30 1.4 0.5 600 (6) N/A 34.8
Diver 4 230/1/50 35 4 N/A 7 30 1.4 0.5 600 (6) N/A 42.2
Jet 40 230/1/50 35 4 7 N/A 30 1.4 0.5 600 (6) 5 36.5
Jet 90 230/1/50 35 4 7 N/A 30 1.4 0.5 600 (6) 5 51
KB6 230/1/50 65 4 1.0 N/A 60 0.8 0.5 600 (6) 8 13.5
LB5-4 230/1/50 65 4 4.6 N/A 60 1.4 0.5 700 (7) 14 47.5
LB6-4 230/1/50 65 4 4.6 N/A 60 1.4 0.5 700 (7) 14 49.3
TB5-2 230/1/50 65 4 4.6 N/A 60 1.4 0.5 400 (4) 10 30.4
TB7-2 230/1/50 65 4 4.6 N/A 60 1.4 0.5 400 (4) 7 33

-5-
TECHNICAL SPECIFICATION
Note: *Model 600 Boostamatic duty rating is only continuous (S1) at 7 litres/min and
above.
Note: For information on other voltages/frequencies which are not shown, consult any
supplementary instruction sheet supplied, or the rating label attached to the
pump.
Stuart Turner reserve the right to amend the specification in line with its policy of
continuous development of its products.
PUMP CONNECTIONS
Outlet
Inlet
Fig.1
Model Supply Max. Watts
consumed
Nominal
Watts
Output
(Motor)
Full
Load
Current
(AMPS)
Enc.
Rating
Duty
Rating
Dims (mm) Gross
Weight
(packed)
kg
No of
Pump
Stages
L W H
330 230/1/50 340 180 1.6 IP44 Continuous (S1) 251 199 337 7.0 1
330 110/1/50 440 370 4.3 IP44 Continuous (S1) 280 199 337 7.0 1
500 230/1/50 540 370 2.4 IP44 Continuous (S1) 280 199 337 8.5 1
500 110/1/50 555 370 5.3 IP44 Continuous (S1) 280 199 337 8.5 1
500 110/1/60 664 370 5.9 IP44 Continuous (S1) 280 199 337 8.5 1
600 230/1/50 885 550 3.9 IP44 *291 199 337 10.4 1
Diver 3 230/1/50 810 565 3.7 IP68 Continuous (S1) 149 149 376 10.6 3
Diver 4 230/1/50 960 670 4.2 IP68 Continuous (S1) 149 149 396 10.8 4
Jet 40 230/1/50 490 340 2.4 IP44 Continuous (S1) 358 209 410 9.6 1
Jet 90 230/1/50 1195 834 5.2 IP44 Continuous (S1) 400 230 419 14.0 1
KB6 230/1/50 425 250 1.9 IP55 Continuous (S1) 305 244 348 8.3 1
LB5-4 230/1/50 920 600 4.1 IP55 Continuous (S1) 401 215 405 12.2 4
LB6-4 230/1/50 1105 760 5.1 IP55 Continuous (S1) 425 215 405 13.1 4
TB5-2 230/1/50 850 530 3.7 IP55 Continuous (S1) 326 227 402 10.4 2
TB7-2 230/1/50 1150 800 5.3 IP55 Continuous (S1) 350 227 402 11.6 2
Models Inlet
(Pump)
Outlet
(Control Module)
Loddon Range G1¼ Female G1 Male
Jet 40 G1 Male G1 Male
Surface Models G1 Female G1 Male
Submersible Models G1 Female G1 Male

-6-
PRE-INSTALLATION ASSEMBLY
Assembly of pressure control module to pump
Some models are despatched with the pressure control module detached from the
pump. To assemble, the brass pipe fitting attached to the control module must be inserted
into the pump outlet connector (Fig. 2). The control module and pipe fitting must be
pushed firmly down into the outlet connector a distance of 35 mm, until the end stop
resistance is felt (Fig. 3).
SITING OF THE PUMP/PIPEWORK (Surface Models)
WARNINGS:
Pump Location
If possible site the pump in a location where in the unlikely event of a
liquid leak, any spillage is contained or routed to avoid electrics or
areas sensitive to liquid damage.
Care should be taken to protect pump from frost and freezing.
Ensure pipework to and from pump is independently supported to
prevent forces being transferred to inlet and outlet branches of pump.
Do not introduce solder flux to pumps or pump parts manufactured
from plastics. All solder joints should be completed and flux residues
removed prior to pump connection.
Do not allow plastic pump parts to come into contact with oil or
cellulose based paints, paint thinners or strippers, acid based
descalents or aggressive cleaning agents.
The motor casing can become very hot under normal operating
conditions, care should be taken to ensure it cannot be touched during
operation.
Pressure Control
Module
Pump Outlet
Connector
Brass Pipe
Fitting
Fig. 2 Fig. 3

-7-
Cont....
Do not allow scale or debris to enter pump. Fit inline strainers to
eliminate the problem in systems at risk.
Always install isolating valves to both suction and delivery pipework.
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
tanks at all time. Exceptions can be made in the case of
suction lift installations when a footvalve is required, although under
these conditions it is recommended a suitable pressure relief valve is
fitted in the discharge (outlet) pipework from the pump.
General
Locate the pump complete with pressure control module, in a frost free horizontal
position where it cannot be sprayed with water and as close to the liquid source as
possible.
The pump enclosure must be ventilated and there should be a minimum clearance of
80 mm between the pump and housing on all sides.
Care must be taken when mounting the pump that any noise is not amplified through
loose panels, pipework or other mounting medium. Noise transmission in pipework can
be reduced by fitting flexible hoses to pump inlet and outlet ports and by placing the pump
on anti-vibration mounting feet. Resilient mounting feet and flexible hoses are available
separately as optional extras, contact Stuart Turner for further details.
Ensure the liquid flow is in the direction of the arrows that are moulded onto the
pressure control module (vertically upwards).
The control module must be mounted in the vertical position in the discharge pipework
and must not be mounted in any other way (on its side for instance).
To prevent loss of pressure through pipework, use pipe size to match pump whenever
possible, minimising 90° bends.
It must be ensured that storage capacity of the liquid supply is adequate for the flow
rates required by the pump.
The pipework feeds to the storage tank should be of adequate size to ensure
replenishment rate of tanks is sufficient to meet the needs of the pump.
Isolating valves should be fitted in suction and delivery pipework to enable easy
isolation and access to the pump.
When the pump is to be installed in areas where there is a risk of debris or scale build
up within the system, it is recommended that the inlet pipework is fitted with an inline
strainer.

-8-
Pump Mounted Below Liquid Source (Flooded Suction Installation)
*Dimension ‘A’ (given above) is the
maximum distance the control module
can be repositioned when the static inlet
head is at the 1 metre minimum
requirement.
However dimension ‘A’ can be increased
to correspond with any increase in the
static inlet head eg:
Before deciding where to locate the unit, check to ensure the static inlet head (Fig. 4)
meets the minimum requirement of 1 metre and does not exceed the maximum given in
the limits of application section.
The static outlet head (Fig. 4) must also be within the maximum requirement of 8
metres for the KB6 model and 14 metres for all other models.
If the static outlet head exceeds the maximum permissible, the control module must be
re-located and consideration must be given to the maximum permitted distance the control
module can be moved (Fig. 5). No draw offs should be fitted between the control module
and the pump.
For details of removing the pressure control module from the pump and re-wiring,
consult the push-in fittings and electrical installation sections.
Diagram showing typical Boostamatic installation
with flooded suction and remote mounting of
pressure control module.
Fig. 5
Diagram showing typical Boostamatic installation
with flooded suction and pressure control module
mounted directly onto pump.
Fig. 4
Max. inlet head (consult limits of application section) Min. inlet head 1m
Negative head
Max. outlet head 14 m (except KB6)
Max. outlet head 8m (KB6 only)
Max. inlet head (consult limits of application section) Min. inlet head 1m
Negative head
Max. outlet head 14 m
(except KB6)
Max. outlet head 8m
(KB6 only)
*Dim. A (see chart)
Model Dim. ‘A’
(m) Model Dim. ‘A’
(m)
KB6 3 Jet 40 18
330 8 Jet 90 32
500 20 Loddon 29
600 31 Thame 12
Model Inlet Head
(m)
Dim. ‘A’
(m)
500 1 20
500 5 24

-9-
Pump Mounted Above Liquid Source (Suction Lift Installation)
The pumps can be used in a suction lift installation providing the height of lift is within
the limits specified in the limits of application section and the liquid to be pumped is cold
water (for applications other than cold water contact Stuart Turner).
Before deciding where to locate the unit, check to ensure the static outlet head (Fig. 6)
does not exceed the maximum requirements of 8 metres for the KB6 model and 14
metres for all other models.
If the static outlet head does exceed the maximum permissible, the control module must
be re-located and consideration must be given to the maximum permitted distance the
control module can be moved (Fig. 7). No draw offs should be fitted between the control
module and the pump.
For details of removing the pressure control module from the pump and re-wiring,
consult the push-in fittings and electrical installation sections.
A footvalve and strainer must always be used and the suction pipework size must match
the pump.
Lay the suction piping over the shortest possible distance and ensure there is a
constant rise from the liquid source to the pump. Any high spots will cause air pockets to
form, reducing system efficiency.
Ensure all joints in suction pipework are completely airtight. Failure to comply will result
in loss of prime.
The intake of the footvalve/strainer should be positioned such that it cannot be blocked
with debris or silt that are frequently found in the bottom of sumps and wells.
When a footvalve is installed in the suction pipework, it is recommended that suitable
pressure relief valve be fitted in the discharge (outlet) pipework from the pump.
Diagram showing typical Boostamatic installation
with suction lift and pressure control module
mounted directly onto pump.
Fig. 6
Max. suctiion lift (consult limits of application section)
Max. outlet head 14 m
(except KB6)
Max. outlet head 8m (KB6 only)

-10-
Jet 40/90 pumps
The Jet 40 and 90 pumps are self priming up to a suction lift of 7 metres. A discharge
hose elbow fitting and suction hose fitting, complete with hose and footvalve/strainer
suitable for this kind of installation are available as optional extras. Part Nos. as follows:-
Hose assy 7m inclusive footvalve/strainer . . . . . . . . . . 26880
G1 discharge hose elbow assy . . . . . . . . . . . . . . . . . . 26881
It is important that the optional suction hose assembly is always used on suction lift
installations.
When Jet pumps are used in a suction lift installation, delivery pipework should be a
minimum of 25 mm dia and any fittings connected directly to the pump should be plastic.
SITING OF THE PUMP/PIPEWORK (Submersible Models)
WARNINGS:
Ensure pipework from pump is independently supported to prevent
forces being transferred to outlet branch.
Do not under any circumstances use the cable fitted as a means to
carry or lower the pump into position on installation. Attach a rope
sling to the lifting eye.
Ensure the pump cannot be subjected to freezing conditions as
damage may result.
Never run pump whilst sucking air/liquid as the motor will overheat.
To prevent this from happening always install pump in the vertical
position and ensure fully submerged.
*Dimension ‘A’ (given above) is the
maximum distance the control module
can be re-positioned when the suction
lift distance is the maximum permissible
(see limits of application section).
However dimension ‘A’ can be increased
to correspond with any decrease in the
suction lift eg:
Diagram showing typical Boostamatic installation
with suction lift and remote mounting of pressure
control module.
Fig. 7
Max. suction lift (consult limits of application section)
Max. outlet head 14 m (except KB6)
Max. outlet head 8m (KB6 only)
*Dim. A (see chart)
Model Suction Lift
(m)
Dim. ‘A’
(m)
500 4.6 14
500 2.6 16
Model Dim. ‘A’
(m) Model Dim. ‘A’
(m)
KB6 0 Jet 40 9
330 2 Jet 90 23
500 14 Loddon 22
600 25 Thame 5

-11-
The pumps are supplied with a non-return valve which should be screwed directly into
the pump outlet port. The purpose of the valve is to limit back flow and pressure on the
pump and ensure discharge pipework is always primed with water. The pumps are also
supplied with an outlet adaptor which allows for a range of different pipework connections
as follows: G1 - G¾ male thread or 25/22 mm diameter bore hose. For best flow use the
largest pipe possible, small sizes will reduce performance. The pump should be installed
vertically and should be submerged at all times to avoid overheating of the motor. When
siting the pump ensure its base is raised slightly from the base of the sump reducing the
possibility of blocking the pump inlet filter with debris. The discharge pipework must be
independently supported to prevent forces being transferred to pump outlet branch.
If the pump is not to sit on the bottom of the sump or it is too deep, then it should be
suspended by a rope attached to the lifting eye located on top of the pump.
The pressure control module is supplied loose with the Diver pumps. The control
module is to be mounted remotely from the pump in a dry frost free enclosure or building
(Fig. 8). Ensure the water flow is in the direction of the arrows that are moulded onto the
pressure control module (vertically upwards).
The control module must be mounted in the vertical position and not mounted in any
other way (on its side for instance).
The pump must be wired to the control module as detailed in wiring diagram section.
RELEASE AND CONNECTION OF PUSH-IN FITTINGS (Surface Pumps only)
WARNINGS: (Push-In Connectors)
Do not use stainless steel, chrome or nickel plated pipe with Stuart
Turner push-in plumbing connections.
Do not introduce solder flux into the joint or surrounding area as
connectors will be attacked and may fail.
All solder joints should be completed and flux residues removed
before final connection to push-in connections, either on flexible hose
or pump head.
Do not allow contact with oil or cellulose based paints, paint thinners
or strippers, acid based descalents or aggressive cleaning agents.
Fig. 8
Max. 7m
Max. 14 m
Typical Submersible
Boostamatic Installation
Max. 15 m

-12-
All surface pumps use a 22 mm quick release connector to attach the pressure control
module to the pump. This is to assist in the task of relocating the control module if
required to do so.
The push-in connector allows the control module to be rotated into a position that suits
the installation whilst still remaining pressure tight.
Disconnection
To break the joint, push the control module firmly into fitting, hold collet down (Fig. 10)
and gently remove module. If the system has been filled with water care should be taken
to isolate the pump and towels used to absorb spilled liquid.
Connection
1. Stuart Turner recommend only the use of their 22 mm flexible hoses.
The hose and pump are fitted with plastic push-in connectors, which must only be
connected with the following:
a) 22 mm diameter copper pipe to BS EN 1057 - R250 (half hard) - Table 3.
b) 22 mm plastic pipe to BS 7291 part 1 and part 2 (Table 1), or part 3 (Table 1) plus
internal support sleeve*.
* The internal bore of the plastic pipe must be supported against collapse with the
pipe manufacturers recommended support sleeve (pipe insert).
c) Appropriate plumbing fittings from the John Guest 'speedfit' push-in plumbing
fitting range.
Other manufacturers fittings are not necessarily compatible and may not provide a
water tight connection.
Ensure the pipe is free from all score marks and deformities in the area of the
insertion depth (Fig. 9) and cut the pipe square removing all burrs and sharp edges to
prevent damage to the sealing 'O'-ring.
2. Prior to inserting pipe into fitting mark the insertion depth on the wall of the pipe with
a soft pencil at a distance of 35 mm from the end to be inserted.
22 mm Pipe
Pencil
mark
Insert depth
35 mm
Fig. 9

-13-
3. Check in the mouth of the fitting that 'O'-ring, nylon washer and collet are in position.
4. Push pipe firmly into the fitting, until pencil mark is level with the top of the collet and
the pipe stop resistance is felt. Pull on pipe to check it is secure and correctly fitted.
If you have any concern either about using push-in fittings or should the joint leak on
final test isolate the water supplies and contact Pump Assist on 0844 98 000 97.
ELECTRICAL INSTALLATION
WARNINGS:
The electrical installation must be carried out in accordance with the
current national electrical regulations and installed by a competent
person.
In the interests of electrical safety a 30 mA residual current device
(R.C.D.) should be installed in the supply circuit. This may be part of a
consumer unit or a separate unit. For submersible pump installations
this device MUST be installed.
Before starting work on the electrical installation ensure the power
supply is isolated.
This appliance must be earthed.
The motor and wiring must not be exposed to water.
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.
The standard pumps are suitable for a supply of 230V, 1 Phase, 50Hz. Other voltages
(110V) and frequencies (60Hz) are available on certain models and it is therefore very
important to ensure the voltage and frequency on the pump rating plate matches the
supply.
When installing a 110V, 1 phase pump, it must be in accordance with the current
electrical regulations that apply to the installation.
The pumps are rated for continuous use with the exception of the 600 Boostamatic (see
technical specification for rating details).
Fig. 10
Collet
Washer
‘O’-Ring
Outlet
Fitting
Body
Pipe Stop

-14-
Earthing
This appliance must be earthed via the supply cord.
Copper or metallic pipework must have supplementary earth bonding where the
continuity has been broken by flexible hoses or plastic components. Adjacent suction and
delivery pipes should be fitted with earthing clamps to BS 951 and connected with
earthing wire size 4 mm² (Fig. 11). A standard kit is available from Stuart Turner (Part No.
17044).
Certain installations may require additional earthing requirements such as
supplementary equipotential bonding. Reference should be made to the relevant
regulations concerning this subject to ensure compliance.
Electrical Connection (Surface models except Jet range)
The pressure control module fitted to this product range is provided with a factory fitted
supply cord. This must be permanently connected to the fixed wiring of the mains supply.
Means for disconnection must be incorporated in the fixed wiring in accordance with the
wiring rules.
A suitable method of connection would be via a double pole switched, fused connection
unit complying with BS 1363-4, protected with a fuse (see fuse section).
The connection unit should be mounted in an easily accessible position and should be
labelled if confusion is possible, to allow easy identification of the pump isolating switch.
Electrical Connection (Jet range)
The pressure control module fitted to the Jet range is provided with a factory fitted
supply cord and plug. This must be connected to the mains supply via a 13 Amp double
pole switched, socket outlet in compliance with BS 1363-2.
The socket outlet should be mounted in an easily accessible position and should be
labelled if confusion is possible, to allow easy identification of the pump isolating switch.
Electrical Connection (Submersible range)
The pressure control module provided with the submersible range is supplied loose for
remote mounting. This must be permanently connected to the fixed wiring and is provided
with a set of terminals located in the control module which allow the connection of a
flexible supply cord. Means for disconnection must be incorporated in the fixed wiring
according to the wiring rules.
A suitable method of connection would be via a double pole switched, fused connection
unit complying with BS 1363-4.
The connection unit should be mounted in an easily accessible position and should be
labelled if confusion is possible to allow easy identification of the pump isolating switch.
Diagram of earth
continuity connection.
Fig. 11

-15-
WARNINGS:
A residual current device having rated current not exceeding 30 mA
MUST be installed in the supply circuit.
Isolate power supply before putting your hands in the liquid.
The pressure control module must be protected from the elements.
Wiring (Surface models except Jet range)
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 colours of the core in the new mains lead 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 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 marked with the
letter 'N' or coloured black.
The wire which is coloured Brown must be connected to the terminal marked with the
letter 'L' or coloured red.
Wiring (Jet range)
The moulded plug fitted to this appliance is not waterproof - keep dry.
The supply cord is factory fitted with a moulded plug incorporating a fuse, the value of
which is indicated on the pin face of the plug. Should the fuse need to be replaced, an
ASTA approved BS 1362 fuse must be used of the same rating, marked thus, . If
the fuse cover is detachable, never use the plug with the cover omitted. If a replacement
fuse cover is required, ensure it is of the same colour as that visible on the pin face of the
plug (i.e. red or orange).
If the plug supplied is not suitable for your socket outlet, it should be cut off and
destroyed.
WARNING: A plug with bared flexible cords is hazardous if engaged in a
live socket outlet.
The end of the flexible cord should be suitably prepared and correct plug fitted, as
follows:
The wires in this mains lead (supply cord) are coloured in accordance with the following
code:
Green & Yellow: Earth Blue: Neutral Brown: Live
As these colours may not correspond with the coloured markings identifying the
terminals in your plug, proceed as follows:
The wire which is coloured green and yellow must be connected to the terminal in the
plug 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 or blue.
The wire which is coloured brown must be connected to the terminal which is marked
with the letter 'L' or coloured brown or red.

-16-
Wiring (Submersible range)
The supply cord that connects the remotely mounted pressure control module to the
mains supply is not provided. This cord must be sourced and provided by the installer.
Cord selection should be chosen in accordance with the current involved/surrounding
conditions and the fuse size required to protect the factory fitted pump supply cord (see
fuse section).
The pump must also be connected to the pressure control module using the factory
fitted pump supply cord which is provided with ends bared.
For information on cable fitting and connection, consult the wiring diagram and cable
gland fitting instructions for the control module.
WARNING: The supply cord of this pump cannot be replaced. If the cord
is damaged, the pump should be scrapped.
Wiring Diagrams
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 any disturbance of this internal wiring is avoided and the
factory routing and securing of all internal wiring is always maintained.
Cont....

-17-
CAPACITOR
SWITCH
MOTOR
RED
WHITE
BLACK
BLUE
BROWN
BLUE
L1 N U V
63
N1L4
L5 N2
MODULE
CONTROL
PRESSURE
E
N
L
(VIA 3 IN PLUG)
50 Hz
1 Phase
230 V
SUPPLY
WHITE BLUE BLACK BLACK BROWN
MOTOR
E
GREEN/YELLOW
MODULE
CONTROL
PRESSURE
N L1 V U
FUSE
50 Hz
1 Phase
230 V
SUPPLY
L
N
E
BLUE BROWN
MOTOR
50 Hz
1 Phase
230 V
SUPPLY
L
N
E
FUSE
V U N L1
MODULE
CONTROL
PRESSURE
E
GREEN/YELLOW
BLUE
BROWN
GREEN/YELLOW
BLACK
BLUE
50 Hz
1 Phase
230 V
SUPPLY
L
N
E
FUSE
V U N L1
MODULE
CONTROL
PRESSURE
E
RED
BLUE
BROWN
THERMOTRIP
START WINDING
MAIN WINDING
MOTOR
CAPACITOR
BROWN
FUSE
E
GREEN/YELLOW
BLUE
50 Hz
1 Phase
230 V
SUPPLY
L
N
E
FUSE
V U N L1
MODULE
CONTROL
PRESSURE
E
THERMOTRIP
START WINDING
MAIN WINDING
MOTOR
CAPACITOR
BROWN
3 4 5 6
2
1
LN TERMINAL POSTS
WHITE
WHITE
3 4 5 6
2
1
3 4 5 6
2
1
3 4 5 6 2
1
4 3 2 1 5 6
GREEN/YELLOW
CAPACITOR
50 Hz
1 Phase
110 V
SUPPLY
L
N
E
FUSE
V U N L1
MODULE
CONTROL
PRESSURE
3 4 5 6
2
1
BLUE
BROWN
L
NGREEN/YELLOW
TERMINAL
BLOCK
BLUE VIOLET
WHITE
RED BROWN
THERMOTRIP
BLACK
BLUE
CAPACITOR
MAIN WINDING MAIN WINDING
START WINDING
Fig. 12 Jet Range Fig. 13 330, 500, 600 Models (230V)
Fig. 14 330, 500 Models (110V)
Fig. 15 Kennet Range
Fig. 16 Thame & Loddon Range Fig. 17 Diver Range

-18-
Fuses
The following fuse size should be used with the appropriate pump:
Supply Cord Replacement
If the supply cord needs to be replaced, cord selection should be chosen in accordance
with the current involved, surrounding conditions and recommended fuse size. For
information on cable fitting and connection, consult the wiring diagram and cable gland
fitting instructions.
Intermediate Connecting Cord Replacement (Surface Models)
If the intermediate connecting cord between the control module and the pump 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 intermediate cords retention and routing systems and
reassemble to the same pattern.
For information on cable fitting and connection, consult the wiring diagram and cable
gland fitting instructions.
Intermediate Connecting Cord Replacement (Submersible Models)
The intermediate connecting cord (pump supply cord) which connects the pump to the
control module cannot be replaced. If the cord is damaged the pump should be
scrapped.
Cable Gland Fitting Instructions (Pressure Control Module)
The cable gland assembly (Fig. 18 items 1 & 2) provides the necessary protection
against ingress of solid objects and moisture.
The cable retention system is provided by the cable strap assembly (Fig.18 items 3 & 4)
located inside the control module terminal box.
Assembly instructions are as follows:
1. Ensure selected cable sheath diameter is within the permitted range (6 to 9 mm).
2. Strip and prepare cable sheath and insulators as shown in Fig. 19.
3. Disassemble cable gland and strap assemblies and insert cable into position as
shown (Fig. 18) ensuring rubber collar (item 2) is placed over cable before the clamp
nut (item 1) is tightened.
4. Consolidate the stranded conductor ends by twisting, insert and secure in appropriate
terminals - ensuring all conductor strands are clamped.
Model Fuse Size (Amps)
Diver range 13
Jet range 13
Thame range 13
Loddon range 13
110 Volt models 13
All other models 5

Cable Gland Fitting Instructions (Motor Terminal Box)
(Applicable to 330, 500, 600 and Kennet KB6 models)
To enable correct assembly of the cable gland, the 'O'-ring (Fig. 20 item 1) must be
placed over the cable before the clamping insert (Fig. 20 item 2) can be tightened as
shown.
Note: Cable diameter range:- 6.5 mm to 9.5 mm.
-19-
5. Assemble and secure terminal box cover.
Supply Cord Extension (Models 330, 500, 600, Kennet, Loddon and Thame
Range)
This range of pumps are fitted with a supply cord to the following specifications:-
330, 500 (230V), 600 & Kennet range:- . . . . . .HO5VV-F3 G 0.75 mm² - 6 Amp rating.
500 (110V):- . . . . . . . . . . . . . . . . . . . . . . . . . . . .HO5VV-F3 G 1.0 mm² - 10 Amp rating.
Thame and Loddon range:- . . . . . . . . . . . . . . . .HO7RN-F3 G 1.0 mm² - 10 Amp rating.
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.
Supply Cord Extension (Models Jet 40 and 90)
This range of pumps is fitted with a supply cord suitable for outdoor use. Cord
specification is as follows:-
HO7RN-F3 G 1.0 mm² - 10 Amp rating.
6
E
N
L
30
30
6
6
40
Fig. 18
Fig. 19
(Dims. in mm)
4
1
2
3
Fig. 20

-20-
If the power cord is to be extended, a cord of the same specification should be used. If
the installation is outdoors then any connectors or junction boxes must be specifically
suited for outdoor use and installed in accordance with the manufacturers instructions.
Any cable routed underground must be protected to local standards.
Intermediate Connecting Cord Extension (Models Diver 3 and 4)
The intermediate connecting cord which connects the pump to the control module is of
a type suitable for outdoor use. Cord specification is as follows:
H07RN-F3 G 1.0 mm² - 10 amp rating.
If an extension cord is necessary a cord of the proper type and rating must be used.
In general for 230 volt pumps on distances up to 40 metres (inclusive of original cord
length) the same specification cord as fitted to the pump can be used. For distances
above 40 metres a larger cord size may be required due to voltage drop and advice must
be obtained based upon installation details.
Any connectors or junction boxes must be specifically suited for outdoor use and
installed in accordance with manufacturers instructions.
Any cable routed underground must be protected to local standards.
NOISE
The equivalent continuous A-weighted sound pressure level at a distance of 1 metre
from the pumpset does not exceed 70 dB(A) for all models except Jet range.
76 dB(A) for Jet 40
81 dB(A) for Jet 90
COMMISSIONING
WARNINGS:
The motor casing can become very hot under normal operating
conditions, care should be taken to ensure it cannot be touched during
operation.
Do not run pump without guards and terminal box lids correctly fitted.
Care should be taken to protect the pump from freezing.
The pump chamber must be full of liquid at all times. Seal damage will
result if the pump runs dry.
1. System Flushing
This pump-set incorporates push-in connectors and plastic components that
must not come into contact with solder flux, acid-based descalents or
aggressive cleaning agents. The pipework system should be flushed out
prior to the pump being connected to ensure any contaminants/chemical
residues and foreign bodies are removed from elsewhere in the system.
2. Liquid Supply
Always ensure that liquid storage capacity is adequate to meet the demand.
Ensure the pump chamber is full of liquid before starting the pump. Failure
to do this could result in seal damage. To ensure dry running does not
occur the pumps must be primed as described in priming section. Do not
run pump dry.