Stuart Turner S2.0 bar Twin Guide

MONSOON
Installation, Operation & Maintenance
Instructions
Please leave this instruction booklet with the home owner as it contains important
warranty, maintenance and safety information.
Read this manual carefully before commencing installation.
This manual covers the following products:
Monsoon S2.0 bar Single
Monsoon S1.5 bar Twin
Pt. No. 46497 Pt. No. 46497 ROI
Pt. No. 46506 Pt. No. 46506 ROI
Pt. No. 46497 EXP
Pt. No. 46506 EXP
Monsoon S3.0 bar Single
Monsoon S2.0 bar Twin
Pt. No. 46419 Pt. No. 46419 ROI
Pt. No. 46415 Pt. No. 46415 ROI
Pt. No. 46419 EXP
Pt. No. 46415 EXP
Monsoon S4.5 bar Single
Monsoon S3.0 bar Twin
Pt. No. 46420 Pt. No. 46420ROI
Pt. No. 46416 Pt. No. 46416 ROI
Pt. No. 46420EXP
Pt. No. 46416 EXP
Monsoon S4.0 bar Twin
Pt. No. 46417 Pt. No. 46417 ROI
Pt. No. 46417 EXP
Monsoon S4.5 bar Twin
Pt. No. 46418 Pt. No. 46418 ROI
Pt. No. 46418 EXP
FOR POSITIVE HEAD APPLICATIONS
Please note images are representative only and may not portray
your model

CONTENTS
1PRODUCT OV ERVIEW .....................................................................................1
2WARNINGS .................................................................................................... 2
3CHECKLIST .................................................................................................... 4
4REGIONAL SU ITABILITY .................................................................................. 5
5IMPORTANT FACTS - READ BEFORE COMMENCING PUMP INSTALLATION....... 6
6LOCATION - G ENERAL ................................................................................... 8
7PUMP CONNECTIONS ................................................................................... 14
8ELECTRICAL INSTALLATION .......................................................................... 19
9COMMISSIONING ..........................................................................................24
10 MAINT ENANCE..............................................................................................25
11 TECHNICAL SPECIFICATION ..........................................................................27
12 TROUBLE SHOOTING GU IDE .........................................................................32
13 THE MONSOON WARRANTY – 5 YEA RS.........................................................36
14 DECLARATION OF CONFORMITY.................................................................. 38

1
1PRODUCT OVERVIEW
1.1 Product Description
Electric motor driven single or twin ended peripheral pump, complete with an
automatic control system, consisting of flow switches and electronic controls.
1.2 Application
Monsoon Standard pumps are suitable for positive head installation conditions.
The pumps are designed for pressure boosting applications in vented stored hot
or cold, clean fresh water systems, where under gravity, some flow (approx.
0.6 l/min) is available. Inlet pressures to the pump and ambient temperatures must
not exceed the values given in the technical specifications.
Monsoon Standard Single pumps are not suitable for boosting a single side of a
dual flow mixer valve or tap. Consult Stuart Turner for alternative pump.
1.3 Storage
If this product is not to be installed immediately on receipt, ensure that it is stored
in a dry, frost and vibration free location in its original packaging.
1.4 Environment Protection
Your appliance contains valuable materials which can be recovered or recycled.
At the end of the products’ useful life, please leave it at an appropriate local civic
waste collection point.

2
2WARNINGS
•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.
•This appliance can be used by children aged from 8 years and
above and persons with reduced physical, sensory or mental
capabilities or lack of experience and knowledge if they have
been given supervision or instruction concerning use of the
appliance in a safe way and understand the hazards involved.
•Children shall not play with the appliance.
•Cleaning and user maintenance shall not be made by children
without supervision.
•The motor casing can become very hot under normal operating
conditions. Care must be taken to ensure it cannot be touched
during operation.
•The electrical installation must be carried out in accordance
with the current national electrical regulations.
•The electrical installation must be installed by a qualified
person.
•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.
•Maximum head (closed valve) S1.5 bar twin-15 metres, S2.0 bar
twin-20 metres, S3.0 bar twin-30 metres, S4.0 bar twin-
40 metres, S4.5 bar twin-45 metres. S2.0 bar single-20 metres,
S3.0 bar single-30 metres, S4.5 bar single-45 metres.
•Before starting work on the electrical supply ensure power
supply is isolated.
•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.
•This appliance must be earthed via the supply cord, which
must be correctly connected to the earth point located in the
terminal box.

3
•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 re-assembly to
the same factory pattern is always maintained.
•If 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.

4
3CHECKLIST
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.
Figure 1
Item Description Qty
A Pump 1
B Hose & integral washer 4 (2)
Your product may vary slightly from the illustration above.
The quantitiesshown above are for twin pumps, (single pumps are shown in
brackets).
A
B

5
4REGIONA L SUITABILITY
Before commencing installation, ensure the product you have purchased is
correct for your region, to avoid invalidating the warranty.
Check the part number:
Example:
UK product Pt. No. 46416
ROI product Pt. No. 46416 ROI
Export product Pt. No. 46416 EXP
•This installation book refers to UK pipework and pumps supplied
with hoses suitable for 22 mm pipework.
•If you have purchased a product suitable for ROI (Republic of Ireland)
it will be supplied with hoses suitable for 21 mm pipework.
•If you have purchased a product suitable for Export it will be
supplied with hoses suitable for G ¾ connections.

6
5IMPORTANT FACTS - READ BEFORE COMMENCIN G PUMP INSTALLA TION
5.1 Water Storage Capacity
The hot and cold water storage capacitymust be sufficient to meet the flow rates
required by the pumped equipment and any other water using fittingsand
appliances, which may be operated simultaneously.
Ensure the pump is primed as described in the priming section before starting,
damage to the shaft seal will result otherwise. See Section 9- Commissioning.
5.2 Water Temperature
The water entering the pump must be controlled as follows:
•The maximum allowable water temperature is 65 °C.
•The minimum allowable water temperature is 4 °C.
•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].
5.3 Minimum Flow
For this pump to operate correctly there must be a minimum gravity flow of at
least 0.6 l/min through all outlets to be pumped.
5.4 Pipework
– General
Secure pipework: Ensure pipework to and from pump is independentlysupported
& clipped to prevent forces being transferred to inlet and outlet branches of
pump.
Flux: Solder joints must be completed and flux residues removed prior to pump
installation (flux damage will void any warranty).
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 90° bends.
•DO NOT introduce solder flux to flexible hoses, pumps or pump
parts manufactured from plastic.
•DO NOT allow contact with oil or cellulose based paints, paint
thinners or strippers, acid based descalents or aggressive
cleaning agents.
•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.
•DO NOT bend the flexible hoses beyond 30°. They must be
installed as straight as possible.
•DO NOT connect this pump to the mains water supply.

7
5.5 Plumbing Installation Regulations
The plumbing installation must comply with the current water and building
regulations.
The plumbing installation must be installed by a qualified person.

8
6LOCATION
- GENERAL
•Access: For emergencies and maintenance the pump must be
easily accessible.
•Protection: The pump must be located in a dry position, frost
free and protected from freezing, particularly when installed in a
loft (not recommended).
•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.
•Safety: The motor casing can become very hot under normal
operating conditions. Care must be taken to ensure it cannot be
touched during operation.
•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.
•Static inlet pressure: Before deciding where to locate the unit,
check to ensure the static inlet head between pump and the
bottom of the cold water tank (Figure 2 and Figure 3), is at least
0.5 metres and does not exceed the max inlet head of 14 metres.
•Ambient temperature: The pump must be sited in a location
where the maximum ambient temperature does not exceed
40 °C.
•Pipework: For optimum performance pipework MUST be 22 mm
(21 mm in ROI). Pipework should only reduce to 15 mm when
entering terminal fitting.
•Noise: The anti-vibration mounting feet and flexible hoses which
are supplied as standard, and a precaution to reduce noise
transmission, however care must be taken when mounting the
pump that any noise is not amplified through loose panels or
pipework. Do not screw down the pump.
•Direction of flow: Ensure the water flow is in the direction of the
arrow that is marked on the flow switch reed clamp (vertically
upwards).
•Flexible hoses: Only use the Stuart Turner hose set supplied with
the pump.
•Isolating valves: Separate system isolating valves (non
restrictive) must be fitted to allow easy pump service.

9
6.1 Preferred Pump Location
The pump must, for optimum performance, be sited as close as possible to and
never more than 4 metres from the HOT WATER cylinder. The pump should always
be sited BELOW the HOT WATER take-off from the cylinder. The pump location is
also dependent on limitations of the static inlet and outlet heads of the installation.
For guidance on limitations and recommended location, consult the following
relevant section for hot or cold water installation.
Location – Single Pump
Figure 2
Max static inlet pressure 14m
Outlet head must be below
bottom of cold water tank
and be able to pass a
minimum of 0.6 litre/min
gravity flow

10
Location – Twin Pump
Figure 3
Max static inlet pressure 14m
Outlet head must be below
bottom of cold water tank
and be able to pass a
minimum of 0.6 litre/min
gravity flow
Either end of a twin pump
may be used to pump the
hot or cold supply

11
6.2 Non-Preferred Pump Location
The pump must be located with at least 0.5 metres flooded suction at all times.
If it is necessary to position the pump above the secondary tapping on the hot
cylinder it is fed by, the risk of introducing air will be increased.
To avoid this risk one of the two following solutions must be adopted:
a. The use of a Top Entry cylinder flange.
b. The use of a Side Entry (SE) cylinder flange, which should have the addition
of an inverted loop (“U” bend) of 350 mm minimum drop before rising to
the pump, located as close as possible to the cylinder wall.
Please note both flange options listed above are designed to suit 22 mm
pipework.
If used in ROI a suitable adaptor to 21 mm pipe must be used (not supplied).
This will ensure the pump receives an air free supply and the cylinder vents any air
up the vent pipe and not the pump feed (Fig 4 and Fig 5).
200mm min
Least preferred
area
350mm
min
Max static inlet pressure 14m
Min static inlet pressure 0.5m
Figure 4
Standard Single Pump

12
200mm min
Least preferred
area
350mm
min
Max static inlet pressure 14m
Min static inlet pressure 0.5m
Figure 5
Standard Twin Pump

13
6.4 Cold Water Connection
The cold water supply: Must be a DEDICATED AIR FREE supply via a tank
connector, and must be positioned at a slightly lower level (25 mm minimum) than
the feed pipe to the hot water cylinder.
Ensure that the pipework size from the cold water tank is 22mm minimum.
Do not connect to the mains.
6.5 Hot Water Connection
Hot water cylinder or storage tank: When a hot water cylinder or storage tank is
used, ensure the pipework size from the cold water storage to the hot water
storage is of adequate size and a minimum of 22 mm for all model except the
S4.5 bar twin which should be a minimum of 28 mm.
Hot water supply: The pump must be supplied with a dedicated feed direct from
the hot water cylinder or storage tank, ensuring an air free connection to the
pump. We recommend the use of either the Side Entry Flange (SE) Part No 27900
or a Top Entry Flange (TE) Part No 27800 (for all models except the S4.5 bar Twin;
S4.5 bar Twin should only use ‘A’ or ‘D’). Please note both flange options listed
above are designed to suit 22 mm pipework. If used in ROI a suitable adaptor to 21
mm pipe must be used (not supplied).
Expansion pipe: When the method of connection is to be made via the expansion
pipe, the BASE of the cold water storage tank MUST be at least 1 metre above the
connection/take off of the hot water storage cylinder feeding the pump.
Figure 6
Off expansion
pipe with rising
28mm offset
reducing to
22mm pipework
to pump and
expansion pipe.
Off expansion
pipe with rising
22mm offset
and 22mm
pipework to
pump.
Top Entry
F
lange (Part No
27800) with
22mm pipework
to pump.
Factory installed G
¾
secondary tapping with
22mm pipework to
pump.
Or
Side Entry F
lange (Part
No 27900) with 22mm
pipework to pump.
30°- 45° 30°- 45°
For applications in
ROI pipe sizes above
should read 21 mm.
A B C D

14
7PUMP CONNECTIONS
•Do not use stainless steel, chrome or nickel plated pipe with
the flexible hose push-in plumbing connections.
•Do not introduce solder flux into the joint or surrounding area
as connectors will be attacked and will fail.
•All solder joints should be completed and flux residues
removed before final connection to push-in connections, on the
flexible hose.
•Do not allow contact with oil or cellulose based paints, paint
thinners or strippers, acid based descalents or aggressive
cleaning agents.
•Never operate pump with inlet and/or outlet isolating valves in
the closed position. Damage will occur!
7.1 Flexible Inlet and Outlet Hoses
The pump inlet and outlet ports are threaded G ¾ M. These ports are provided
with a flat sealing face suitable for use with an appropriately sized flat faced fitting
and fibre or rubber washer. Ensure a water tight seal is achieved when the pump is
both stationary and running.
Figure 7
Use correct tool for opening and closing integrated isolating valve to prevent
damage.
Please note these valves are of quarter turn design, rotate clockwise to close and
anti-clockwise to open. Failure to comply with these instructions could lead to
valve damage.
WARNING: Pump must not run with valve closed.
Flexible hoses with integral isolating valves do not replace system isolation valves
which must be installed.
Open
Close

15
7.2 Hose to Pump
The pump inlet and outlet ports have factory assembled fittings which are
specifically designed for connection to the G ¾ F running nuts on the flexible
hoses.
The hose end is fitted with a rubber sealing washer which is held captive within
the nut assembly.
Locate the hose into position and screw the nut fully onto the fitting by hand.
Finally nip tight with a spanner (4/5 Nm) for a water tight seal (do not
overtighten).
Figure 8
Note:When tightening or loosening the hose nut assembly, it is not necessary to
use an additional spanner. Place the spanner as shown, do not over tighten the
hose assembly.
After tightening ensure the reed switch clamp assembly has not been displaced
and is correctly located in the machined groove, see Figure 17 for reference.
Flexible hose
Port fitting
G
¾running
nut assembly
Rubber sealing
washer
Reed switch clamp
assembly

16
7.3 Hose to Pipework
The hoses are fitted with plastic push-in connectors, which must only be
connected to the following:
22 mm dia. pipework in the UK.
21 mm dia pipework in the ROI.
1. Ensure the pipe is free from all score marks and deformities in the area of
the insertion depth (Figure 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 insert depth on the wall of the
pipe with a soft pencil at a distance of 33 mm from the end to be inserted.
Insert depth = 33mm
Pencil mark
22mm pipe
Figure 9

17
3. Check in the mouth of the fitting that the ‘O’-ring, nylon washer and collet
are in position as shown in Figure 10.
4. Push the 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 the pipe to check it is
secure and correctly fitted.
5. To release the joint, push pipe firmly into fitting, hold collet down and
gently remove pipe. If the system has been filled with water care should be
taken to isolate pump and towels used to absorb spilled water.
7.4 Typical Low Level Installation
In certain installations it may be necessary to install a 90° bend on the inlet or
outlet connections of the pump before the flexible hose to accommodate a low
level installation.
Below are some preferred connection options. All connections seal on the pump
body using a fibre or rubber sealing washer. Tap connectorfittingsshould be used
which must be of an appropriate pressure and temperature rating.
It is essential when using any of the fittingsshown below, that a correct water
tight seal is obtained between the pump body and selected fitting and also the
flexible hose and selected fitting. If in doubt contact the fitting manufacturer and
confirm compatibility with the connection to be sealed.
Carefully check connectionsand pipework for leaks whilst pump running and
stationary before leaving the installation unattended.
Collet
Washer
O
-ring
Flexible hose
Pipe stop
Figure 10

18
Figure 11
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 TechAssist on
[phone].
Fibre washer 22mm copper pipe
G ¾F x 22mm elbow
tap connector
22mm compression
to G ¾M
G ¾F flexible hose
(supplied)
Fibre washer
22mm elbow
22mm copper pipe
G ¾F flexible hose
(supplied)
22mm compression
to G ¾M
G ¾F x 22mm
tap connector
22mm stem
elbow
22mm to G ¾M
G ¾F flexible hose
(supplied)
G ¾F x 22mm tap connector with flush central
spigot and rubber sealing washer fitted directly
to the pump terminals
G ¾F x 22mm swivel tap connector with flush
central spigot and rubber sealing washer fitted
directly to the pump terminals
Sealing washer (sometimes captured in fitting)
For applications in
ROI pipe sizes above
should read 21 mm.