Stuart Turner Monsoon Extra 2.6 bar PS 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:
CE compliant product
Monsoon Extra 2.6 bar PS
Pt. No. 46601 Monsoon Extra 3.6 bar PS Pt. No. 46602

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PRODUCT DESCRIPTION
Electric motor driven centrifugal pump complete with an automatic control system,
consisting of flow switch, pressure switch, pressure vessel and electronic control.
APPLICATION
The Monsoon Extra Pressure Set (PS) range is designed for pressure boosting
applications in vented stored, cold clean water systems, where under gravity, no flow is
available and can be used in systems where a negative head exists.
Inlet pressures to the pump and ambient temperatures must not exceed the values
given in the technical specifications.
This pump set must not be used for any other application without the
written consent of Stuart Turner Limited.
This pump MUST NOT be connected directly to the mains water supply.
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.
This product should not be used for the supply of water to more than
one dwelling (house, apartment, flat).
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Important Facts - read before commencing installation . . . . . . . . . . . . . . . . . . . . 4
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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CHECKLIST
Item Description Qty Item Description Qty
Pump 1 Anti-vibration feet 4
Hose & sealing washer 2 Inline strainer & sealing washer 1
Inlet connector & ‘o’-ring 1 Pressure vessel 1
Fig. 1
28 mm copper
inlet pipework
(suction).
28 mm isolating valve
(non restrictive) and
fittings (not supplied)
must be fitted to allow
easy pump service.
28 mm copper outlet pipework (discharge).
Short 28 mm copper pipe
tails to connect between
isolating valve and flexible
pipes.
28 mm isolating valve
(non restrictive) and
fittings (not supplied)
to allow easy pump
service.
28 mm - G 1 connector
(not supplied) must
be fitted
28 mm flexible
pipes. These
hoses are fitted
with G 1 female
connector suitable
for connection to a G 1 (1 “ BSP)
adaptor or fitting.

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1 READ BEFORE COMMENCING PUMP INSTALLATION
A. Water storage capacity.
1.11 The cold 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 DO NOT allow the pump to run dry as damage to the shaft seal will result. To
ensure dry running does not occur the pump must be primed as described in
priming section. See Section 4 - Commissioning.
B. Water temperature
This unit is designed to pump cold water only which should not exceed the following
values:
1.13 The maximum allowable water temperature is 35 oC.
1.14 The minimum allowable water temperature is 4 oC.
C. Pipework - General
1.15 Ensure pipework to and from pump is independently supported & clipped to
prevent forces being transferred to inlet and outlet branches of pump.
1.16 Solder joints must be completed and flux residues removed prior to pump
installation.
1.17 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.
1.18 DO NOT introduce solder flux to flexible hoses, pumps or pump parts
manufactured from plastic.
1.19 DO NOT allow contact with oil or cellulose based paints, paint thinners or
strippers, acid based descalents or aggressive cleaning agents.
1.20 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.
1.21 DO NOT bend the flexible hoses beyond 30o.
D. Plumbing & Electrical Installation Regulations
1.22 The plumbing installation must comply with “The Water Supply (Water Fittings)
Regulations 1999” and “BS 6700” building regulations.
1.23 The plumbing installation must be installed by a competent person.
1.24 The electrical installation must be carried out in accordance with the current
national electrical regulations.
1.25 The electrical installation must be installed by a qualified electrician.
E. Pressure vessel
1.26 Pressure vessel is pre-charged at the factory see Section 5 - Maintenance for
details.

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2 LOCATION - GENERAL
2.11 Access: For emergencies and maintenance the pump must be
easily accessible.
2.12 Protection: The pump must be protected from frost and freezing
particularly when located in a loft installation (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 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 Protection: The pump must be located in a dry position where it cannot be
sprayed with water and protected from the weather.
2.17 Static inlet pressure: Before deciding where to locate the unit check to ensure
the static inlet head between pump and cold water level (Fig. 2) is at least 1 metre
and does not exceed the max inlet head of 10 metres.
2.18 Pump position: The pump must be positioned horizontally on its anti-vibration
mounting feet and as close to the water source as possible.
2.19 Ambient temperature: The pump must be sited in a location where the maximum
ambient temperature does not exceed 40 oC.
2.20 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.
2.21 Static outlet pressure: The static outlet head (Fig. 2) must also be within the
maximum requirement of 13 metres.
2.22 Noise: Care must be taken when mounting the pump that any noise is not
amplified through loose panels or pipework.
2.23 Direction of flow: Ensure the water flow is in the direction of the arrow marked
on the flow switch reed clamp (vertically upwards).
2.24 Flexible hoses: Use only the Stuart Turner supplied hoses to connect the pump.
2.25 The hoses must be used and kept straight with a maximum allowable bend of 30o.
2.26 NRV’s: DO NOT install non-return valves, 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 times.
2.27 Preferred Pump Location: The preferred location of the pump is on the floor
1 metre below the base of the water tank.

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2 LOCATION
2.28 Cold water mains: DO NOT connect the pump to the cold water mains.
2.29 Cold water supply: The pump must be supplied with a dedicated air free supply
direct from the cold water storage tank in 28 mm pipework.
2.30 The cold pump feed: MUST NOT be shared with any other outlets.
2.31 The cold water supply: Must be via a tank connector positioned at a slightly
lower level (25 mm minimum) than the feed pipe to the hot water cylinder and
on the opposite side to the cold mains inlet.
Fig. 2
Cold
water Hot water
Unvented hot
water cylinder
Static inlet pressure Min. 1 m Max. 10 m
Static outlet pressure Max. 13 m

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3 ELECTRICAL INSTALLATION / EARTHING
3.11 Regulations: The electrical installation must be carried out in
accordance with the current national electrical regulations and installed
by a qualified electrician.
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 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.
3.14 Supplementary Bonding: The pressure set is factory fitted with a
supplementary earthing wire to ensure continuity throughout the assembly
(Fig. 3). It must be ensured throughout the product life that this electrical
connection remains in place.
3.16 Earthing: This appliance must be earthed via the supply cord, which must be
correctly connected to the earth point located in the terminal box.
3.17 Pipework: Copper or metallic pipework must have supplementary earth bonding
where the continuity has been broken by flexible hoses or plastic components.
3.18 Additional earthing: Certain installations may require additional earthing
arrangements such as equipotential bonding. Reference should be made to the
relevant regulations concerning this subject to ensure compliance.
3.15 Adjacent pipes: Adjacent suction and delivery pipes should be fitted with
earthing clamps to BS 951 in accordance with current regulations (Fig. 4).
Diagram of
earth continuity
connections
Fig. 4
Fig. 3
Warning Tag

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3.19 Connections: The pump must be permanently connected to the fixed wiring of
the mains supply using the factory fitted supply cord, this must be a fused spur off
the ring main and NOT connected to the boiler or the immersion heater circuits.
3.20 Wiring of connection unit:
WARNING: This appliance must be earthed.
The wires in the mains lead are coloured in accordance with the following code:
Green and Yellow: Earth Blue: Neutral Brown: Live
As the colours of the wires in the mains lead of this appliance may not correspond
with the coloured markings identifying the terminals in your connection unit
proceed as follows:
The wire which is coloured green and yellow must be connected to the terminal
in the connection unit which is marked with the letter E or by the earth symbol:
or coloured green or green and yellow.
The wire which is coloured blue must be connected to the terminal which is
marked with the letter N or coloured black.
The wire which is coloured brown must be connected to the terminal which is
marked with the letter L or coloured red.
3.21 Wiring Diagram:
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.
Model Fuse Size (AMPS)
All Models 13
3.22 Fuses: The following fuse size should be used with the appropriate pump:
GREEN / YELLOW
BLUE
BROWN L
MA
N
NLE
N230 VAC/1PH/50Hz
SUPPLY
RED
CAPACITOR
MOTOR
GREEN / YELLOW (LINK WIRE)
RED
YELLOW
RED
BLACK
BLACK
FLOWSWITCH
REED (S3)
S3 S3 S2S2S1 S1
PRESSURE
SWITCH (S1)
Monsoon Extra 2.6, 3.6 bar PS
Fig. 5

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4.13 Air purge: Open and close all pumped outlets in turn allowing water to flow from
each outlet until all air is purged.
4.14 Switch on the pump: Open and close all pumped outlets in turn. The pump will
start and stop upon demand. Note: After closing the outlet there will be a small
delay time before the pump stops, which is normal.
Any tap or control valve within the system when opened and closed will now turn
the pump on/off. Providing this is the case the system is now operating correctly.
Carefully check pump and pipework for leaks whilst pump running and stationary
before leaving the installation unattended.
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 lid correctly
fitted.
The pump chamber must be full of water at all times. Seal
damage will result if the pump runs dry.
4.15 For Further Technical Support: Phone the Stuart Turner Pump Assist team
on 0844 98 000 97. Our staff are trained to help and advise you over the phone.
4 COMMISSIONING / SYSTEM FLUSHING/ PRIMING / STARTING
4.11 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.
4.12 Priming: Prior to switching the pump on and connecting the outlet hoses to
the system pipework the pump chamber must be primed. The pump must be
primed (filled with water) before starting. Turn on water supply, prime and vent
the pump by unscrewing the priming plug (Fig. 6) slowly until all air escapes and
water emerges. Re-tighten the plug.
2.6, 3.6 bar PS Fig. 6
Priming/
vent Plug
Drain
Plug

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5 MAINTENANCE
5.11 Inlet strainer: Incorporated in the strainer is a removable gauze filter which
may require periodic cleaning. The frequency of this operation is dependent upon
installation conditions.
The strainer is located in the inlet pipework to the pump (Fig. 1). The gauze filter
is removed as follows:-
a) Isolate pump electrically.
b) Release all system pressure.
c) Isolate water supply.
d) Remove screwed hexagonal plug from strainer body taking care to collect or
absorb any residual water (Fig. 7).
e) Remove and clean stainless steel gauze filter.
f) Reassemble gauze and secure plug tightly.
g) Turn on water supplies, connect power supply and test.
5.12 Pressure vessel: The pressure vessel should be checked once every 6 months
to have its air pre-charge checked or replenished, this should be carried out
as follows:-
a) Isolate pump electrically.
b) Isolate the water supply by closing the appropriate isolating valves.
c) Release system water pressure by opening an outlet on the system.
d) Disconnect hose fitted to pressure vessel.
e) Check air pre-charge at Schrader valve (Fig. 8) using a tyre pressure gauge.
f) Replenish air charge by injecting air into the vessel via the Schrader valve
using a car or bicycle pump (Fig. 8).
g) Re-connect hose to pressure vessel to achieve a water tight connection.
Ensure fibre washer seal is in place.
h) Close all system outlets, open inlet and outlet isolating valves.
i) After maintenance is completed refer to Section 4 - Commissioning for
instructions on re-starting pump.
Strainer
Gauze
Gasket
Hex plug
Fig. 7

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5.13 Water scale: Deposits of scale are released in areas of hard water (usually south
of a line between the Wash and Bristol Channel), scale can cause the mechanical
seal to stick if left without use for long periods.
The pump must run for at least 5 minutes every four weeks to “exercise” all
working parts.
This particularly applies to guest bathrooms used infrequently.
5.14 Cleaners, Disinfectants and Descalents:
Acid based descalents and aggressive cleaning agents must not
come into contact with the pump. The pump must be removed from
the system prior to the use of these products. The system should be
flushed to remove all chemicals before the pump is re-connected.
If in any doubt as to the suitability of the chemical solutions, please
contact our Pump Assist helpline on 0844 98 000 97.
Fig. 8
Schrader valve
(under cap)
Cap
Pressure vessel
Model Air Precharge
bar (psi)
All other
models 2.1 (30)

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6 TECHNICAL SPECIFICATION
Stuart Turner reserve the right to amend the specification in line with its policy of
continuous development of its products.
*Note: Max working pressure is the maximum pressure that can be applied to
the pump internal casing under any installation conditions.
6.11 Noise: The equivalent continuous A-weighted sound pressure level at a distance
of 1 metre from the pump does not exceed 70 dB(A).
Model 2.6 bar PS 3.6 bar PS
Electrical
Power supply
Volts/phase frequency 230/1/50 230/1/50
Enclosure IPX5 IPX5
Type of motor Induction Induction
Power consumption 775 Watts 1136 Watts
Full load current 3.5 Amps 5.1 Amps
Rating Continuous (S1) Continuous (S1)
Max. No Starts per hour 60 60
Mechanical
Min inlet head 1 metres 1 metres
Max inlet head 10 metres 10 metres
Max head (closed valve) 26 metres 36 metres
Max working pressure* 600 kPa (6.0 bar) 900 kPa (9.0 bar)
Max ambient air temperature 40 oC 40 oC
Max water temperature 35 oC 35 oC
Min water temperature 4 oC4
oC
Cut out flow 1 l/min (approx) 1 l/min (approx)
Cut in pressure 180 kPa (1.8 bar) 180 kPa (1.8 bar)
Vessel pre-charge 210 kPa (2.1 bar) 210 kPa (2.1 bar)
Pump
Dimensions
Length (max) 541 mm 541 mm
Width (max) 300 mm 300 mm
Height (excluding flexible hoses) 602 mm 602 mm
Gross Weight (including accessories) 17 Kg 18.5 Kg

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7 TROUBLE SHOOTING GUIDE
Symptoms Probable Cause Recommended Action
Pump will not start. Electrical supply. Check wiring connections.
Check all switches are ‘on’.
Check fuse (see fuse section).
Check circuit breaker is set.
Failed reed switch/PCB. Contact Pump Assist.
Recommended static inlet/outlet
heads exceeded. Re-position pump (see Section 2 - Location).
Internal motor thermotrip
activated. Wait for thermotrip to cool and auto-reset and investigate cause of problem before re-starting.
Water starvation to pump. Refer to ‘dry running’ section.
Pump starts when outlets are off. Leak in system. Check tap washers, w/c valve washers, pipe joints.
or
Pump cycles (hunts) on/off
frequently.
Low pre-charge pressure in
pressure vessel. Check pre-charge pressure in pressure vessel (see Section 5 - Maintenance).
Debris under non-return valve
sealing face. Run at full flow to try and flush away debris or remove, clean or replace non-return valve.
Pump runs on when all terminal
outlets are closed. Leak in system. Check tap washers, w/c valve washers, pipe joints.
Reed clamp out of position. Ensure reed clamp is fitted correctly in location groove.
Failed reed switch or P.C.B. If pump continues to run, this indicates a closed circuit in
either the flow switch reed or P.C.B. in the terminal box, these
should be checked electrically.
Jammed flow switch. Isolate the pump electrically and hydraulically and remove
brass housing that contains the float. Check float for free
movement.
Reduced flow/performance. Blocked inlet strainers. Clean inlet strainers (see Section 5 - Maintenance).
Blocked shower head spray
plate. Clean in accordance with manufacturers instructions.
Blocked pipework or pump. Isolate pump electrically and hydraulically, locate blockage
and remove.

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7.11 Dry Run Protection:
This pump is fitted with a safety control circuit, which will detect the following fault
condition:
Dry running caused by water starvation to the pump.
Should the pump run out of water it will stop as part of a “protective logic
sequence”, detailed below.
The fault should be rectified before re-starting the pump. Check that there is
sufficient water supply to the pump and also ensure that all terminal fitting outlets
are closed.
7.12 Protective Logic Sequence:
If water starvation occurs and the power supply to the pump remains
uninterrupted, the pump controller will perform the following protective sequence.
1. If the pump detects water starvation, it will stop operation after a 1 minute
period.
2. The pump will remain in the off condition for a period of 5 minutes.
3. The pump will then re-start and if the water starvation condition remains
present, the pump will then stop operation after a 1 minute period.
4. The pump will remain in the off condition for a period of 5 minutes.
5. The pump will then re-start and if the water starvation condition remains
present, the pump will then stop operation after a 1 minute period.
6. The pump will remain in the off condition for a period of 5 minutes.
7. The pump will then re-start and if the water starvation condition remains
present, the pump will then stop operation after a 1 minute period.
8. After three consecutive resets are performed the pump will remain in the off
condition indefinitely.
9. To restart the pump, the power supply should be first isolated for a period of at
least 10 seconds before switching on again.
If the pump fails to operate normally after three attempts, then please consult
the Pump Assist team on 0844 98 000 97.
7.13 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:-
ISOLATE THE MAINS ELECTRICAL POWER SUPPLY FROM THE PUMP.
Remove the four screws retaining the terminal box lid (Fig. 9).
Lift the terminal box lid off.
IMPORTANT – Ensure there is no contact with any of the internal parts of the
terminal box.

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Briefly reconnect the mains power supply to the pump – the indicator light
should illuminate if the pump has been correctly wired.
Isolate the mains electrical power supply from the pump.
Re fit the terminal box lid ensuring no cables are trapped.
Re fit the four terminal box lid retaining screws, tighten to 0.8 Nm.
7.14 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.
Indication
light
Terminal box lid
Retaining screws x 4
Fig. 9 Wiring removed for clarity

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8 YOUR 2 YEAR GUARANTEE
Monsoon Extra Pressure Sets are guaranteed by Stuart Turner Limited to be free from
defects in materials or workmanship and the guarantee period starts from the date
of purchase or date of manufacture. Within the guarantee period we will repair, free
of charge, any defects in the pump resulting from faults in material or workmanship,
repairing, exchanging parts 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 pump has been purchased within the
applicable guarantee period 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 or
Citizen’s Advice Bureau.
In the event of a claim please telephone Stuart Turner Limited on 0844 980 0097
before taking any further action. If you have any doubt about removing a pump, please
consult a professional.
Proof of purchase should accompany the returned pump to avoid delay in investigation
and dealing with your claim.
Please record here for your records.
TYPE NO. SERIAL NO. DATE PURCHASED

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Stuart Turner Ltd, Henley-on-Thames, Oxfordshire RG9 2AD ENGLAND
Tel: [phone], Fax: [phone]
email: [e-mail] web: www.stuart-turner.co.uk
V.A.T. REG. No. 199 0987 92. Registered in England No. 88368. Registered Office: Market Place, Henley-on-Thames
DECLARATION OF CONFORMITY
2006/42/EC
BS EN ISO 12100-1, BS EN ISO 12100-2, BS EN 809
2006/95/EC
BS EN 60335-1, BS EN 60335-2-41
2004/108/EC
BS EN 55014-1, BS EN 55014-2, BS EN 55022, BS EN 61000-3-2, BS EN 61000-3-3,
BS EN 61000-4-2, BS EN 61000-4-3, BS EN 61000-4-4, BS EN 61000-4-5, BS EN 61000-4-6,
BS EN 61000-4-11
1999/519/EC
BS EN 62233
2011/65/EU
IT IS HEREBY CERTIFIED THAT THE STUART ELECTRIC MOTOR DRIVEN PUMPAS
SERIAL NUMBER BELOW, COMPLIES WITH THE ESSENTIAL REQUIREMENTS OF THE
ABOVE E.E.C. DIRECTIVES.
RESPONSIBLE PERSON
AND MANUFACTURER STUART TURNER LIMITED
HENLEY-ON-THAMES, OXFORDSHIRE
RG9 2AD ENGLAND.
Signed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Business Development Director
Stuart Turner are an approved company to BS EN ISO 9001:2000
Issue No. 1912/1-01 Pt. No. 19703