Stuart Turner FLOMATE MBF 12 Service manual

Cont ...
INSTALLATION INSTRUCTIONS
SERVICE KIT - FLOMATE, MBF 12 (Pre-November 2017) Part No. 28457
Note: 1) Items 16, 23, 24 are pre-assemble parts, see relevant section for detailed instructions.
2) See relevant section for detailed instructions.
Fig. 1
20 (Section 3)
Capacitor (not shown)
17 (Section 5)
PCB
(not shown)
19 (Section 3 & 5)
Adhesive foam pad
(not shown)
1 (Section 1)
Woodruff key
7 (Section 1)
‘O’-ring (ID 66.4)
5 (Section 1)
Washer (OD ¾)
8 (Section 1)
Screws M6 x 35 mm
6 (Section 1)
Circlip
4 (Section 1)
Rotary seal
3 (Section 1)
Seal
counterface
18 (Section 4)
Strainer relief bush
(not shown)
21 (Section 4)
Reed switch
12 (Section 2)
Screws (M4 x 16 mm)
16 (Section 2)
Non return
valve assembly
13 (Section 2 & 4)
Reed switch tie wrap
10 (Section 2)
Clip
11 (Section 2)
Magnetic float
14 (Section 2)
Flow regulator
15 (Section 2)
‘O’-ring (ID 24.6)
12
23 (Section 2)
Inlet assembly
2 (Section 1)
Thrower
22 (Sections 3, 4 & 5)
Screws (K40 x 16 mm)
24 (Section 2)
Outlet assembly

- 2 -
Cont ...
• COMPLETE KIT CONTENTS
This kit contains parts for a range of different pump types - please ensure you correctly identify
the relevant parts for the pump being serviced before commencing. Also refer to the relevant
section for detailed instructions for the correct installation of the parts.
Fitting of incorrectly identified parts could lead to pump failure. If in doubt
contact PumpAssist on [phone].
ITEM QTY ITEM QTY
1 Woodruff Key 1 13 Reed Switch Tie Wrap 1
2 Thrower 1 14 Flow Regulator 1
3 Seal Counterface 1 15 ‘O’-ring (ID 24.6 mm) 2
4 Rotary Seal 1 16 Non-Return Valve Assembly 1
5 Washer (ID 3/8 “x OD ¾ “) 1 17 PCB (not shown) 1
6 Circlip 1 18 Strainer Relief Bush (not shown) 1
7 ‘O’-ring (ID 66.40, c/sec 1.78) 1 19 Adhesive Foam Pad (not shown) 1
8 Screws (M6 x 35 mm) 4 20 Capacitor (not shown) 1
9 Seal Applicator Tool (not shown) 1 21 Reed Switch 1
10 Clip 1 22 Screws (K40 x 16 mm) 4
11 Magnetic Float 1 23 Inlet Assembly 1
12 Screws (M4 x 16) 4 24 Outlet Assembly 1
Check to see that you have all the above items and that they are not damaged. If any damage is
found contact Stuart Turner Ltd within 24 hours of receipt.
• PUMP PREPARATION
To prepare the pump to accept the service kit parts, each pump part must be removed noting
its exact position and sequence (Fig. 1).
Now clean all the individual parts. Before fitting the new service kit parts, the pump and seal
type must be identified.
• CONTENTS PAGE
Section 1 Mechanical seal replacement .................................. 3
Section 2 Valve replacement ........................................... 5
Section 3 Capacitor replacement........................................ 8
Section 4 Reed switch replacement ..................................... 10
Section 5 Printed circuit board replacement ............................... 13

- 3 -
Cont ...
SECTION 1 - MECHANICAL SEAL REPLACEMENT
The parts required to replace the seal are:
ITEM QTY ITEM QTY
1 Woodruff Key 1 6 Circlip 1
2 Thrower 1 7 ‘O’-ring (ID 66.40, c/sec 1.78) 1
3 Seal Counterface 1 8 Screws (M6 x 35 mm) 4
4 Rotary Seal 1 9 Seal Applicator Tool (not shown) 1
5 Washer (ID 3/8 "x OD ¾ ") 1
• PUMP PREPARATION
1. Turn off and isolate power supply.
2. Isolate and drain down pump of liquid.
3. To prepare the pump to accept the service kit parts, each pump part must be removed
noting its exact position and sequence.
Difficulties may be experienced in the removal of the impeller. To overcome this, 2
screwdrivers can be used to prize the impeller from the shaft as shown; ensuring equal
pressure is applied to each side of the impeller to avoid shaft bending.
4. Clean all the components not replaced by the service kit.
• SEAL IDENTIFICATION
The seal as supplied is shown in order of assembly in Fig. 3.
A Seal seat complete with rubber cup washer.
B Rotary seal assembly.
C Stainless steel washer.
D Seal retaining clip.
Fig. 2
NOTE: DO NOT USE EXCESSIVE
FORCE, AS THIS MAY DAMAGE THE
COMPONENTS
Fig. 3
A
B
C
D

- 4 -
Cont ...
• MAINTENANCE AND CARE UPON ASSEMBLY
To allow ease of assembly along with correct functioning of
the pump, the following points on assembly are necessary.
• All pump parts must be free from debris and
assembled correctly.
• The seal must always be replaced as a complete unit
using the seal applicator tool as provided.
• The seal faces must not be handled or damaged.
• The impeller must be a slide fit on the shaft.
Side 2
Applicator Tool (Item 9)
Side 1
Fig. 4
To assemble the seal correctly, the shaft must be clean and the following steps carried out.
1 Use Side 1 of the Applicator Tool to push the seal seat (item A) firmly into the housing
ensuring it is located flat against back of housing.
2 Now use Side 2 of the Applicator Tool to push the rotary section of the seal assembly
(item B) onto the motor shaft until it is flat against the seal seat (Fig. 5). The shaft may be
lubricated with clean water to assist assembly.
Assemble the spring and location plate onto the shaft so as to complete the rotary seal
assembly (Fig. 6).
3 The washer (item C) can then be placed on the shaft and the whole assembly held into
position by locating the E clip (item D) in the groove and pushing it into position (Fig. 7).
WARNING:- Do not install E Clip onto full shaft diameter.
• INITIAL OPERATING INSTRUCTIONS
• Insert screwdriver into motor shaft slot located at fan cowl end of motor, rotate shaft by
hand to ensure free rotation of pump.
• Do not run pump dry. Allow the liquid to be pumped to enter the pump body thus ensuring
the seal is lubricated before switching the pump on. Failure to do this will damage the seal.
• Carefully check pump and pipework for leaks whilst pump running and stationary before
leaving the installation unattended.
Fig. 5 Fig. 6 Fig. 7

- 5 -
Cont ...
SECTION 2 - VALVE REPLACEMENT
The parts required to replace the valve are:
ITEM QTY ITEM QTY
10 Clip 1 16* Non Return Valve 1
11 Magnetic Float 1 16* Crossflow Pipe 1
12 Screw, M4 x 16 mm 4 23* Inlet Assembly 1
13 Reed Clamp Tie 1 24* Oulet Assembly 1
14 Flow Regulator - 12 l/min 1 23,24* ‘O’-ring, ID 13, c/sec 3 mm 2
15 ‘O’-ring, ID 24.60, c/sec 2.40 2
*Parts pre-assembled
• DISASSEMBLY (Reference Fig.1)
• Remove the existing reed switch by cutting the securing tie wrap (Item 13).
• Remove four screws (Item 12) and carefully remove manifold assembly from pump.
• Carefully dismantle the outlet assembly (Item 24), inlet assembly (Item 23), NRV assembly
(Item 16) and manifold clamps (Item A) – see Fig. 8.
Fig. 8
16
24
23
A

- 6 -
Cont ...
• REASSEMBLY
• Fit the flow regulator (Item 14) into new outlet assembly, fit the magnetic float (Item 11) into
outlet assembly (see Fig. 10) and assemble circlip (Item 10) using fine point pliers as shown in
Fig. 9.
• Reverse the disassembly instructions with the new replacement parts fitted as required.
• Parts can be lubricated with clean water to aid assembly.
• Secure manifold clamp screws, to a torque of 1.5 Nm. (Item 12).
Note – it is imperative that the new flow regulator (item 14) is fitted during this operation as
NOT to do so will infringe Regulation 5 of the Water Supply Regulations that states any pump
fitted to the mains supply pipe can only draw 12 l/min or less.
Note – Ensure the manifold clamps (item A) are placed over the outlet assembly (Item 24) and
inlet port (Item 23) BEFORE assembling them onto the NRV assembly (item 16), see Fig. 10.
Note - For the correct operation of the NRV assembly (Item 16), the ‘O’-rings must be sat into the
inlet assembly and the outlet assembly grooves before fitting the NRV assembly as shown in
Fig. 11.
Fig. 10
16
10
11
14
24
23
A
7
Fig. 9
10
Fig. 11
Outlet assembly
16
Inlet assembly
‘O’-rings

- 7 -
Cont ...
Note – For correct operation the NRV assembly (item 16) must be fitted with the orientation
groove to the left (inlet port side) as shown in Fig. 12.
For correct operation of the flow switch, the reed must be secured to the body as detailed
below.
Firstly feed the tie warp through the retainer on the reed switch, ensuring that the tie wrap
serrations are facing outwards (see Fig. 13).
Now locate the reed switch within the body groove as highlighted X-X in Fig. 14 below, and
feed the tie wrap through the second catch.
The tie wrap can now be pulled tight to secure the reed and the excess cut to length as shown
in Fig. 15.
• INITIAL OPERATING INSTRUCTIONS
• Do not run pump dry. Allow the liquid to be pumped to enter the pump body thus ensuring
the seal is lubricated before switching the pump on. Failure to do this will damage the seal.
• Carefully check pump and pipework for leaks whilst pump running and stationary before
leaving the installation unattended.
Fig. 12
16
Inlet Port
Orientation groove
to the left
Outlet Port
Fig. 13
13
21
Serrations
Catch
X
X
Fig. 14 Fig. 15

- 8 -
Cont ...
SECTION 3 - CAPACITOR REPLACEMENT
The parts required to replace the capacitor are:
ITEM QTY ITEM QTY
19 Adhesive Foam Pad 1 22 Screws (K40 x 16 mm) 4
20 Capacitor 1
• DISASSEMBLY
• Isolate electrical supply before fitting replacement part.
• Replacing the capacitor, should only be carried out by a competent
person.
• 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 reassembly to the same factory pattern is always maintained.
Reference Fig 16:
• Remove 4 screws (item 22), and carefully remove terminal box lid.
• IMPORTANT: Take note of capacitor wiring connection and colours before removal.
Disconnect and remove capacitor (item 20) and foam securing pad (item 19), make note of
pad fitted position.
Damaged components must be replaced. Contact Stuart Turner for
advice on replacements not supplied with kit.
20
19
22
Terminal box lid
Fig. 16

- 9 -
Cont ...
• REASSEMBLY
Reassembly is the reverse of the disassembly instructions, with new replacement parts fitted
as required.
Note: For correct installation the capacitor must be connected, secured and positioned as
detailed (Figs. 17 & 18).
Secure terminal box lid screws to a torque of 0.8 Nm (item 22).
IMPORTANT NOTE: For correct pump rotation, ensure both blue wires are connected to the
linked capacitor terminals as shown.
• INITIAL OPERATING INSTRUCTIONS
• Consult instruction manual for commissiong instructions.
• Do not run pump dry. Allow the water to be pumped to enter the pump body thus ensuring
the seal is lubricated before switching the pump on. Failure to do this will damage the
seal.
• Carefully check pump and pipework for leaks whilst pump running and stationary before
leaving the installation unattended.
Receptacle at 45o
(approximately)
Fig. 17 Fig. 18
20 Receptacle at 45o
(approximately)
19
Receptacle at 45o
(approximately)
Blue wires
Black
wire
Red wire

- 10 -
Cont ...
SECTION 4 - REED SWITCH REPLACEMENT
The parts required to replace the reed switch are:
ITEM QTY ITEM QTY
13 Reed Switch Tie Wrap 1 21 Reed Switch 1
18 Strain Relief Bush 1 22 Screws (K40 x 16 mm) 4
• WIRING DIAGRAMS
Fig. Pump UK Eire
19 Flomate, MBF 12 üü
• DISASSEMBLY
• Isolate electrical supply before fitting replacement part.
• Replacing the reed switch components should only be carried out by a
competent person.
• 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 reassembly to the same factory pattern is always maintained.
• Remove four screws and carefully remove terminal box lid (item 22).
• Note the cable routing within the terminal box (Fig. 19).
• Slacken the two screws retaining the reed switch wires on the PCB.
• Remove the strain relief bush and reed switch cable by gripping with pliers (Fig. 20) and
pulling downwards from the terminal box.
• Remove the existing reed switch by cutting the securing tie wrap and pulling away from
the flow switch body (Fig. 20)
Fig. 19
MAIN WINDING
THERMOTRIP CAPACITOR
START WINDING
FLOWSWITCH
REED (S3)
(BLUE)
BROWN
BLACK
GREEN/YELLOW
BLUE
BROWN L
M
N
N
S3 S3
LE
N
BLUE
LINK WIRE
MAIN WINDING
THERMOTRIP CAPACITOR
START WINDING
BLUE
BROWN
BLACK RED
GREEN/YELLOW
BLUE
BROWN L
E
N
FLOWSWITCH
REED (S3)
230 VAC/1PH/50Hz
SUPPLY 230 VAC/1PH/50Hz
SUPPLY
M
N
N
S3 S3
L
Wiring Diagram Pre-June 2016
Wiring Diagram After June 2016
S3
N
Reed Switch
S3
18

- 11 -
Cont ...
Damaged components must be replaced. Contact Stuart Turner for advice on
replacements not supplied with kit.
• REASSEMBLY
• Fit the new strain relief bush around the reed switch cable and squeeze the strain relief bush
with pliers to compress the cable.
• Push the cable and bush into the base of the terminal box ensuring the bush is fully seated
into its location.
• Connect the two reed switch wires to the PCB (Fig. 19)
• For correct operation of the flow switch, the reed must be secured to the body (Fig. 22)
• Firstly feed the tie wrap (item 13) through the retainer on the reed switch, ensuring that the tie
wrap serrations are facing outwards (Fig. 21).
• Locate the reed switch within the body groove as highlighted X-X (Fig. 22), and feed the tie
wrap through the second catch.
• The tie wrap can now be pulled tight to secure the reed and excess cut to length as shown
(Fig. 23)
22
Terminal
box lid
Bush
Pliers
Terminal box
base
Cut tie wrap
Fig. 20
Fig. 21
21
Catch
Retainer
Serrations
13

- 12 -
Cont ...
• INITIAL OPERATING INSTRUCTIONS
• Consult instruction manual for commissioning instructions.
• Do not run pump dry. Allow the water to be pumped to enter the pump body thus ensuring
the seal is lubricated before switching the pump on. Failure to do this will damage the seal.
• Carefully check pump and pipework for leaks whilst pump running and stationary before
leaving the installation unattended.
X
X
Fig. 22 Fig. 23

- 13 -
Cont ...
SECTION 5 - PRINTED CIRCUIT BOARD REPLACEMENT
The parts required to replace the printed circuit board are:
ITEM QTY ITEM QTY
17 Printed Circuit Board 1 22 Screws (K40 x 16 mm) 4
19 Adhesive Foam Pad 1
• WIRING DIAGRAM
Fig. Pump UK Eire
24 Flomate, MBF 12 üü
• DISASSEMBLY
• Isolate electrical supply before fitting replacement part.
• Replacing the PCB should only be carried out by a competent person.
• 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 reassembly to the same factory pattern is always maintained.
Fig. 24
MAIN WINDING
THERMOTRIP CAPACITOR
START WINDING
FLOWSWITCH
REED (S3)
(BLUE)
BROWN
BLACK
GREEN/YELLOW
BLUE
BROWN L
M
N
N
S3 S3
LE
N
BLUE
LINK WIRE
MAIN WINDING
THERMOTRIP CAPACITOR
START WINDING
BLUE
BROWN
BLACK RED
GREEN/YELLOW
BLUE
BROWN L
E
N
FLOWSWITCH
REED (S3)
230 VAC/1PH/50Hz
SUPPLY 230 VAC/1PH/50Hz
SUPPLY
M
N
N
S3 S3
L
Wiring Diagram Pre-June 2016
Wiring Diagram After June 2016
S3
N
Reed Switch
S3

- 14 -
Cont ...
Reference Fig 25.
• Remove four screws (Item 22) and carefully remove terminal box lid.
• IMPORTANT: Take note of capacitor wiring connection and colours before removal.
• Disconnect and remove capacitor, and foam securing pad (Item 19) make note of pad fitted
position.
• Remove M4 nut (Item A) then M4 lock washer (Item B) and plain washer (Item C), this
allows removal of earth wire and cup washer (Item D).
• Disconnect all wiring from terminal blocks on printed circuit board (PCB Item 17).
• Remove two M4 nuts (item A) and carefully lift PCB (Item 17) away from terminal box.
Damaged components must be replaced. Contact Stuart Turner for advice
on replacements not supplied with kit.
• REASSEMBLY
Reassembly is the reverse of the disassembly instructions with the new replacement parts
fitted as required.
Note: For correct installation the capacitor must be secured and positioned as detailed in
Figs. 26 & 27.
Secure PCB nuts to a torque of 1.5 Nm (item A).
Secure terminal box lid screws to a torque of 0.8 Nm (item 22).
IMPORTANT NOTE: For correct pump rotation, ensure both blue wires are connected to the
linked capacitor terminals as shown.
Fig. 25
D
Capacitor
22
19
A
C
B
A
Capacitor
17
A

- 15 -
• INITIAL OPERATING INSTRUCTIONS
• Consult instruction manual for commissioning instructions.
• Do not run pump dry. Allow the water to be pumped to enter the pump body thus ensuring
the seal is lubricated before switching the pump on. Failure to do this will damage the
seal.
• Carefully check pump and pipework for leaks whilst pump running and stationary before
leaving the installation unattended.
Stuart Turner Limited reserves the right to amend specifications without notice.
Receptacles at 45o(approximately)
19
Fig. 26
Fig. 27 Receptacles at 45o(approximately)
Receptacles at 45o(approximately)
Blue wires
Black wire
Red wire

Stuart Turner Ltd, Henley-on-Thames, Oxfordshire RG9 2AD ENGLAND
Tel: [phone], Fax: [phone]
[email protected] www.stuart-turner.co.uk
Issue No: 4817/1-02
Pt. No. 20003