Stuart Turner CH 4-30 FL 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 suitable for 230/1/50 supply.
CH 4–30 FL
Pt. No. 46578
Pt. No. 46578 EXP
CH 4–40 FL
Pt. No. 46596
Pt. No. 46596 EXP
CH 4–50 FL
Pt. No. 46605
CH 4–60 FL
Pt. No. 46606
FOR POSITIVE HEAD APPLICATIONS ONLY
50 Hz CE compliant product
2
STUART

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Cont ...
Arabic Installation Operation & Maintenance Instructions ................... 31
English (GB) Installation Operation & Maintenance Instructions .............. 2
PRODUCT DESCRIPTION
Electric motor driven centrifugal pump complete with an automatic control system,
consisting of flow switch, and electronic control.
APPLICATION
The Stuart CH FL range is designed for pressure boosting applications in vented
stored, hot, cold or blended clean water systems, where under gravity, a flow is
available of at least 1 l/min. If you wish to boost both hot and cold services, then CH
Boostamatic models must be used, for further details contact ‘TechAssist’.
Inlet pressures to the pump and ambient temperatures must not exceed the values
given in the technical specifications.
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 ...........................................................5
Important Facts – read before commencing installation ......................7
Location ............................................................8
Electrical Installation ..................................................9
Plumbing ...........................................................11
Technical Specification ................................................13
Trouble Shooting .....................................................14
Guarantee ..........................................................16

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Cont ...
WARNINGS:
zThis pump set must not be used for any other
application without the written consent of Stuart
Turner Limited.
zDo not connect this pump to the mains water supply.
zThis 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.
zChildren shall not play with the appliance.
zCleaning and user maintenance shall not be made by
children without supervision.
zMaximum head (closed valve) CH 4–30 FL-25 metres,
CH 4–40 FL-36 metres, CH 4–50 FL-50 metres,
CH 4–60 FL-62 metres.
zThe motor casing can become very hot under normal
operating conditions. Care must be taken to ensure it
cannot be touched during operation.
zThe electrical installation must be carried out
in accordance with the current national electrical
regulations.
zThe electrical installation must be installed by a
qualified person.
zIn 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.
zBefore starting work on the electrical supply ensure
power supply is isolated.

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Cont ...
zDo 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.
zThis appliance must be earthed via the supply cord,
which must be correctly connected to the earth
point located in the terminal box.
zThe supply cord and internal wiring within the
terminal box are routed and secured to ensure
compliance with the electrical standard
IEC 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.
zIf 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.

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CHECKLIST
Your product may vary slightly from the picture above.
Fig. 1
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.
Outlet port
Inlet port

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Cont ...
ASSEMBLY
To protect the unit during tansit the pump is supplied with the flow switch removed.
Follow the instructions below to complete assembly.
zEnsure all components are clean and free from debris.
zScrew complete flow switch body assembly into pump body, ensuring ‘O’-ring is
fitted (Fig. 2).
zTighten to 7 – 10 Nm (5 – 7 lb ft).
zCare should be taken when handling the reed switch not to damage the reed or
cable.
zFor correct operation of the flow switch, the reed must be secured to the body
(Fig. 2).
zFirstly feed the tie wrap through the retainer on the reed switch, ensuring that the
tie wrap serrations are facing outwards (Fig. 3).
zLocate the reed switch within the body groove as highlighted X-X (Fig. 2), and feed
the tie wrap through the second catch. Note the arrow on the reed switch should
be pointing up, towards the outlet connection.
zThe tie wrap can now be pulled tight to secure the reed and the excess cut to
length as shown (Fig. 4).
X
X
Torque rotation
Flow switch body
Reed switch tie wrap
‘O’-ring
Pump
Fig. 2
reed switch
(pre-wired)
Reed switch
Catch
Serrations
Trim off
Tie wrap
Retainer
Fig. 3 Fig. 4

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Cont ...
1 IMPORTANT FACTS: READ BEFORE COMMENCING PUMP INSTALLATION
A Water storage capacity.
1.11 The 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 4 –
Plumbing.
B Water temperature
The water entering the pump must be controlled as follows:
1.13 The maximum allowable water temperature is 65 oC.
1.14 The minimum allowable water temperature is 4 oC.
1.15 Ambient temperature: The pump must be sited in a location where the
maximum ambient temperature should not exceed 50 oC.
1.16 DO NOT fit a pump if the hot water is heated via a method whereby the water
temperature cannot be controlled, such as solar or solid fuel you must consult
the TechAssist team on [phone].
C Water flow
1.17 For this pump to operate correctly there must be a minimum gravity flow of at
least 1 l/min through all outlets to be pumped.
D Pipework – general
1.18 Secure pipework: Ensure pipework to and from pump is independently
supported & clipped to prevent forces being transferred to inlet and outlet
branches of pump.
1.19 Flux: Solder joints must be completed and flux residues removed prior to
pump installation (flux damage will void any warranty).
1.20 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.
1.21 DO NOT introduce solder flux to pump parts manufactured from
plastic.
1.22 DO NOT allow contact with oil or cellulose based paints, paint thinners
or strippers, acid based descalents or aggressive cleaning agents.
1.23 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.
E Plumbing installation regulations
1.24 The plumbing installation must be installed by a qualified person and in
accordance with local regulations.
F Electrical/installation regulations
1.25 Check the mains voltage and frequency corresponds to the values on the
pump rating plate.

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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 Mounting foot securing: This pump is fitted with cast feet. If there is a
requirement to secure the pump via the feet, the following points should be
noted.
The pump should be mounted only in the horizontal position.
The mounting bolts used to secure the pump must be fitted with a plain
washer to distribute clamping load evenly across load bearing face of foot
(not supplied).
Fig. 5
PLAIN
WASHER
MOUNTING
FOOT
BOLT
Fig. 6

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Cont ...
3 ELECTRICAL INSTALLATION  EARTHING
3.11 Regulations: The electrical installation must be carried out in
accordance with the current local regulations by a qualified person.
3.12 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.
3.13 Before starting work on the electrical supply ensure power supply is
isolated.
3.14 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.
3.15 Earthing: This appliance must be earthed via the supply cord, which must be
correctly connected to the earth point located in the terminal box.
3.16 Connections: The pump must be permanently connected to the fixed wiring
of the mains supply using the factory fitted supply cord, via a dedicated
double pole switched fused spur off the ring main.
3.17 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:
zThe 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.
zThe wire which is coloured blue must be connected to the terminal which
is marked with the letter N or coloured black.
zThe wire which is coloured brown must be connected to the terminal
which is marked with the letter L or coloured red.

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3.18 Wiring diagram:
3.19 Fuse: All models should use 13 Amp fuse.
3.20 Supply cord replacement:
The supply cord and internal wiring within the terminal box are
routed and secured to ensure compliance with the electrical
standard IEC 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.
3.21 If the supply cord is to be changed or damaged, it must be replaced by a
special cord available from Stuart Turner or one of its approved repairers.
GREEN / YELLOW
BLUE
BROWN L
E
N220 VAC/1PH/60Hz
SUPPLY
RED
CAPACITOR
MOTOR
GREEN / YELLOW (LINK WIRE)
RED
YELLOW
RED
BLACK
BLACK
FLOWSWITCH
REED (S2)
S2 S2
M
N
NL
Fig. 7

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Cont ...
Hot water installation
4.18 Must have a dedicated air free supply.
4.19 Pump must be sited as close to the water
source as possible and never more than
4 metres away.
4.20 The preferred pump location is below the
hot water take off.
4.21 However if the pump can not be located
below the hot stored water take off the
following must be adhered too:
zThe pump must be located 0.5 metre
below the cold water tank.
zFrom a hot dedicated air free
connection a downward loop of
350 mm depth must be fitted before
rising directly to the pump.
4 PLUMBING
4.11 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.
4.12 Isolating valves: Separate isolating valves (non restrictive) must be fitted to
allow easy pump service.
4.13 Inline strainer: When pump is to be installed in areas where there is risk of
debris or scale build up within the system, you MUST ensure the inlet
pipework is fitted with an inline strainer.
4.14 The pump must be located with at least 0.5 metres flooded suction at all
times.
Cold water installation
4.15 Must have a dedicated air free supply.
4.16 Pump must be sited as close to the
water source as possible and never
more than 4 metres away.
4.17 Do not connect this pump to the
mains supply.
Fig. 8 Cold water
pump
Static inlet pressure Min. 0.5 m Max. 10 m
Max. static outlet pressure 12 m
Fig. 9
Hot water
pump
Static inlet pressure Min. 0.5 m Max. 10 m
Max. static outlet pressure 12 m

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Cont ...
4.22 System flushing: 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.
4.23 Priming:
Never operate pump with inlet and/or outlet isolating valves in the
closed position. Damage will occur!
The pump must be primed (filled with water) before starting.
Turn on the service valves and vent/prime pump head.
(a) Loosen priming plug and allow an even flow of water this may take a
few seconds.
(b) Re-seal vent plug, nipping tight. The pump is now ready to start.
4.24 Starting:
a) Switch on power and open terminal fitting.
b) Open and close all outlets in turn associated with the pump, allowing
water to flow from each outlet until all air is purged. As each outlet is
opened and closed, the pump will start and stop respectively.
c) Any tap or control valve within the system when opened and closed will
now turn the pump on/off.
4.25 Maintenance:
This product is maintenance free for its life, however it is a mechanical
product and will eventually show signs of wear. Spare parts are available, for
more information phone the Stuart Turner TechAssist team on
[phone].
Fig. 10
Vent
Plug
Drain
Plug
Outlet
Inlet

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5 TECHNICAL SPECIFICATION
Stuart Turner reserve the right to amend the specification in line with its policy of
continuous development of its products.
*Note: The maximum pressure that can be applied to the pump under any installation
conditions.
**Note: A stored water temperature of 60 oC is considered sufficient to meet all normal
requirements and will minimise deposition of scale in hard water areas.
5.11 Noise: The equivalent continuous A-weighted sound pressure level at a
distance of 1 metre from the pump does not exceed 70 dB(A).
Pump Model
CH 4–30 FL
50 Hz
46578
CH 4–40 FL
50 Hz
46596
CH 4–50 FL
50 Hz
46605
CH 4–60 FL
50 Hz
46606
General Guarantee 2 years
WRAS approval 1601035
Approvals WRAS, CE
Features Pump type Centrifugal multistage
Pump control Flow switch
Mechanical seal EPDM / Carbon / Ceramic
Dry run protection ü ü ü ü
Priming vent plug ü ü ü ü
Noise 67 dB(A) 68 dB(A) 69 dB(A) 70 dB(A)
Materials Pump Body Brass / stainless steel
Impeller Stainless steel
Performance Maximum head (closed valve) 25 metres 36 metres 50 metres 62 metres
Performance @ 50 l/min 21 metres 30 metres 45 metres 56 metres
Performance @ 100 l/min 13 metres 17 metres 31 metres 41 metres
Maximum flow 134 l/min 141 l/min 145 l/min 148 l/min
Minimum static inlet pressure 0.05 bar (0.5 metre)
Maximum static inlet pressure 1.0 bar (10 metres)
Maximum static outlet pressure 1.2 bar (12 metres)
Maximum working pressure* 600 kPa (6 bar) 900 kPa (9 bar)
Max. ambient air temperature 50 oC
Min / Max water temperature** Min 4 oC / Max 65 oC
Flow switch sensitivity (approx) 1 l/min
Connections Pump connections G 1¼ female (inlet), G 1 female (outlet)
Motor Type Induction, auto-reset thermal trip
Duty rating Continuous (S1)
Electrical Power supply / phase / frequency 230 V a.c. / 1 / 50 Hz
Current (full load) 3.6 Amps 5.4 Amps 7.3 Amps 8.8 Amps
Power consumption 805 Watts 1210 Watts 1640 Watts 1980 Watts
Fuse rating 13 Amps
Power cable (pre-wired) 0.75 metres
Physical Enclosure protection IPX5
Length 360 mm 384 mm 431 mm 456 mm
Width 155 mm 187 mm
Height (excluding hoses) 228 mm 247 mm
Weight (including fittings) 10.2 Kg 12.0 Kg 15.5 Kg 18.0 Kg

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6 TROUBLE SHOOTING GUIDE
Symptoms Probable Cause Recommended Action
Pump will not start. Electrical supply. Check power supply.
Check fuse (see fuse section).
Check circuit breaker is set.
Check wiring connections.
Pump Jammed. If motor ‘Buzzes’ switch off power and contact Stuart
Turner.
Recommended static inlet/
outlet heads exceeded.
Re-position pump (see pump location section).
No flow. Insufficient gravity flow to start the pump (must be at least
1 l/min.
Internal motor thermotrip
activated.
Wait for thermotrip to auto-reset and check that duty
point and run time is within specification (see technical
specification).
Reduced/intermittent flow. Incorrect or no anti-aeration
flange fitted
Check that the installation complies with installation
instructions.
Incorrect pipe sizes. Check for correct pipe sizing, see Page 11 – Section 4.11.
Blocked inlet filters. Clean inline strainer.
Hot water temperature set
too high.
Reduce cylinder stat setting to 60 oC max.
Blocked shower head spray
plate
Clean in accordance with manufacturers instructions.
No hot water. Air locked water feed. Vent hot water pump of air.
Check cold feed to hot water cylinder.
Check water level in cold water tank and that all stopcocks
and isolating valves are open.
Heat source not operating. Check boiler is switched ‘on’.
Check cylinder thermostat.
Check immersion heater.
Check cylinder contains hot water.
All hot water has been used. Check tank volume is adequate.
Faulty thermostatic mixer
valve.
Consult makers instructions.
Pump runs on with outlets
closed.
Leak in system. Check tap washers, w/c valve washers, pipe joints.
Damaged reed switch, P.C.B. Check visually reed seated in groove on flow switch body.
Position a magnet directly in front of the reed, slowly move
the magnet up and down to a position that exceeds the
extent of the reed clamp. If the pump does not start a
possible reed switch or P.C.B fault is indicated.
Contact Stuart Turner.
Jammed flow switch. Remove outlet hoses and check that flow switch sits in
lowest position. Check float for free movement.
Flexible hose leaks Not fitted correctly. Check that the hose is pushed firmly onto the pump inlet/
outlet connections and pipework.
Damaged ‘O’-rings. Check copper pipe ends are cleanly cut and deburred.

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Cont ...
6.11 Fault Finding: The PCB is also fitted with a “power on” indicator light. This will
remain illuminated when mains power is supplied to the board.
The indicator light is located on the PCB within the terminal box.
This operation should only be carried out by a competent
person
To view the light the following procedure must be followed:-
zIsolate the mains electrical power supply from the pump.
zRemove the four screws retaining the terminal box lid (Fig. 11).
zLift the terminal box lid off.
zIMPORTANT – Ensure there is no contact with any of the internal parts of
the terminal box.
zBriefly reconnect the mains power supply to the pump – the ‘power on
light should illuminate if the pump has been correctly wired.
zIsolate the mains electrical power supply from the pump.
zRe fit the terminal box lid ensuring no cables are trapped.
zRe fit the four terminal box lid retaining screws, tighten to 0.8 Nm.
6.12 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.
‘Power on’ light
Terminal box lid
Retaining screws x 4
Fig. 11 Wiring removed for clarity
Note: This image is for
reference only.

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7 YOUR 2 YEAR GUARANTEE
Congratulations on purchasing a Stuart Turner pump.
We are confident this pump will provide many years of trouble free service as all
our products are manufactured to the very highest standard.
All Stuart Pumps are guaranteed to be free from defects in materials or
workmanship for 2 years from the date of purchase.
Within the guarantee period we will repair, free of charge, any defects in the pump
resulting from faults in material or workmanship, repairing or exchanging the whole
unit as we may reasonably decide.
Not covered by this guarantee: Damage arising from incorrect installation,
improper use, unauthorised repair, normal wear and tear and defects which have a
negligible effect on the value or operation of the pump.
Reasonable evidence must be supplied that the product has been purchased within
the guarantee term prior to the date of claim (such as proof of purchase or the
pump serial number).
This guarantee 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.
In the event of a claim please telephone ‘TechAssist’ or return the pump and
flexible hoses with the accessories removed e.g pipes etc. If you have any doubt
about removing a pump, please consult a professional.
[phone]
Proof of purchase should accompany the returned unit to avoid delay in
investigation and dealing with your claim.
You should obtain appropriate insurance cover for any loss or damage which is not
covered by Stuart Turner Ltd in this provision.
Please record here for your records
TYPE NO. SERIAL NO. DATE PURCHASED

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      )             
.( 
          .      
.    
        «(TechAssist)  »        
.            .   
[phone]
.               
.Stuart Turner Ltd               
.    

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عبتُي
   
 
. 
.           
.      .
     
.  
        
       . 
         
         . 
.      
.    
.           
.     
  

.   /         
.   
«»            
. 
   .6
    .« «         :   611
.          .     
••      
. 
-:     
••       
.
••        
.(9)
••.     ••         – 
.  
••      
     –    
.        « »
••.         ••.            ••.. 08           
       .          :  6.12
.         
  
   4
 9.    
: 
 
.
 “ ”

- 19 –
عبتُي
   
  
.
.   .    
.(  )   
.     
.   
.     « »    
.  
    

.(   )    
.    )       
.(    
   
. 
        
         
.(  ) 
 /
.
    
.     
.       
.          
.4.11  – 22
.  .   
.    .        
.        
    
.  
 60        
. 
    
.
.    
.   .    .      
         
.
          
.  
.   .«»      
.    
.   
.       
.    .       
.    .   
   .6

- 20 –
  .5
.            Stuart Turner  
.                   : *
   60      .   65            : **
.              
     ()           : 5.11
.)(  70   1
 
CH 4–30 FL
50 Hz
46578
CH 4–40 FL
50 Hz
46596
CH 4–50 FL
50 Hz
46605
CH 4–60 FL
50 Hz
46606


(WRAS)       
1601035

WRAS, CE

     
  
 
   /  /     
    
üüüü
   
üüüü

)  67
(A  
)  68
(A  
)  69
(A  
)  70
(A  

 /  
  

( )  
 25 36 50 62
   50   21 30 45 56
   100   13 17 31 41
 
   134   141   145   148
   
( 0.5)  0.05
   
( 10)  1.0
   
( 12)  1.2
*  
( 6)   600( 9)   900
   
  50
**    / 
  65  /   4
()   
   1
 
(() 1   ()  ¼ 1   

      
 Continuous(S)
 
// 
 50 / 1/  230  
( ) 
 3.6 5.4 7.3 8.8
 
 805 1210 1640 1980
 
 13
(  )  
 0.75
 
 
IPX5

 360 384 431 456

 155 187
( ) 
 228 247
( ) 
 10.2 12.0 15.5 18.0