Stuart Turner Mainsboost Plus Guide

mainsboost
Read this manual carefully before commencing installation.
This manual covers all Mainsboost Plus vessels for vertical and horizontal units.
Mainsboost Plus
Mainsboost Plus Installation, Operation
& Maintenance Instructions
Please leave this instruction booklet with the home owner as it contains
important guarantee, maintenance and safety information
3 year guarantee on pump and ttings
CE compliant product

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PRODUCT DESCRIPTION
Mainsboost Plus consists of three key assemblies, the Mainsboost vessel, charger MJ3
pump and upstream line-in kit.
APPLICATION
Mainsboost Plus is designed to offer stored clean, potable cold water under pressure for
all domestic or small commercial applications where mains water is insufficient to offer
consistent and reliable water services.
Installation parameters must not exceed the values given in the technical
specifications.
zMainsboost Plus system must not be used for
any other application without the written consent
of Stuart Turner Limited.
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 beengiven
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.
zChildren should be supervised to ensure that they
do not play with the appliance.
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. These instructions must be left with the product.
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.

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CONTENTS Page
Checklist ................................................................4
Introduction .............................................................6
Important Facts - read before commencing installation ...........................7
Location ................................................................8
Terminology .............................................................9
Conguration ............................................................10
Installation ..............................................................12
Electrical ................................................................17
Commissioning ...........................................................19
Technical Specication .....................................................22
Trouble Shooting .........................................................24
Guarantee ...............................................................25

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CHECKLIST
Item Description Qty Item Description Qty
Package
1
1 ¼ “ BSP pressure gauge 2 Package
21 Mainsboost vessel 1
2 Lever isolating ball valve 1 Package
31 Pump 1
3Pressure vessel connector
fitting 1 2 Manifold Assy 1
46 bar pressure regulating
valve 1 3 Pressure relief valve 1
5 ¼ x ½ “ BSP Brass bush 1 4 Hose 2
6 Y pattern inline strainer 1 5 Sealing washer 2
7 Double check valve 1 6 Pump mounting bolt
assy 1 set
8 1¼ “ BSP Pressure gauge 1
Your product may vary slightly from the picture above.
Mainsboost Plus (Vertical)
IMPORTANT: Your Mainsboost Plus water performance system will be delivered
in a minimum of three boxes on one pallet. Please check the contents within
24 hours of receipt and if any component is damaged, please contact Stuart
Turner Ltd immediately.
Package 2
Mainsboost vessel
Fig. 3
1
Package 1
Upstream line-in kit
Fig. 1
61
4
8
5
2
7
3
Package 3
MJ3 pump
Fig. 2
5
4
2
1
3
6

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CHECKLIST
Mainsboost Plus (Horizontal) (available in MBP 200SH and MBP 250SH vessels only)
Mainsboost Plus horizontal is supplied with the pump assembly pre-assembled onto the
cylinder.
Your product may vary slightly from the picture above.
Item Description Qty Item Description Qty
Package
1
1 ¼ “ BSP pressure gauge 2 Package
21 Pump assembly 1
2 Lever isolating ball valve 1 2 Pump bracket 1
3Pressure vessel connector
fitting 1 3 Mainsboost vessel 1
46 bar pressure regulating
valve 1 4 Mounting cradles 1
5 ¼ x ½ “ BSP Brass bush 1 5 Hose 2
6 Y pattern inline strainer 1
7 Double check valve 1
8 1¼ “ BSP Pressure gauge 1
928 mm x 28 mm x 22 mm
Tee 1
6
Package 1
Upstream line-in kit
Fig. 4
61
4
8
5
2
7
39
Package 2
MJ3 pump
Fig. 5 4
2
1
3
5 (Hoses supplied
loose shown as such)
5

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1 INTRODUCTION
1.1 Congratulations on buying a Mainsboost Plus system, designed to offer
consistent and reliable water services throughout the property and the only
system available that is patent protected No. GB2349908.
1.2 Patents, Trademarks & Trade Names:
‘Mainsboost’ ‘Mainsboost Plus™’ and ‘Mainsboost Charger’ are
registered Trademarks of Stuart Turner Ltd.
The use of this system is patent protected and the Mainsboost Plus vessel
cannot be mixed with other accumulator systems without prior approval from
Stuart Turner Ltd.
The Mainsboost Plus vessels have special characteristics and the use of other
vessels in this application could prove to be detrimental to the design and
performance of the system and the patent.
Stuart Turner Ltd will treat any infringement of the patent very seriously and
therefore recommend that any questions regarding application be brought to the
company for consideration.
1.3 How the Mainsboost Plus System works:
The Mainsboost Plus pressure vessel stores water from the rising main in a
sealed water chamber, separated from the air space by a rubber diaphragm and
pressurised to an optimum setting. When water is drawn off by downstream
services, the water from the mains is supplemented by the water from the
Mainsboost Plus unit to provide a balanced supply at consistent pressure to
downstream services.
The Mainsboost Plus pipework manifold incorporates a unique ‘green energy’
bypass. If the incoming mains water supply delivers more than 12 l/min this
bypass should be left open to allow any additional flow rate to pass directly into
the Mainsboost pressure vessel via the integral non-return valve. If the
incoming flow rate is less that 12 l/min the bypass valve should be left closed
in order to ensure optimum efficiency of the Charger MJ3 pump.

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2 IMPORTANT FACTS READ BEFORE COMMENCING INSTALLATION
A. Commissioning
2.11 Ensure the pump is primed as described in the priming section before starting,
damage to the shaft seal will result otherwise. See Section 8.16 -
Commissioning.
B. Water temperature
This unit is designed for cold water applications only which should not exceed the
following values:
2.12 The maximum allowable water temperature is 35 oC.
2.13 The minimum allowable water temperature is 4 oC.
C. Pipework - General
2.14 Secure pipework: Ensure pipework to and from the Mainsboost Plus is
independently supported & clipped to prevent forces being transferred to inlet
and outlet branches of pump. Flexible hoses supplied must be used.
2.15 Flux: Solder joints must be completed and flux residues removed prior to pump
installation (flux damage will void any warranty).
2.16 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.
D. Plumbing Installation Regulations
2.17 The plumbing installation must comply with the current water and building
regulations.
2.18 The plumbing installation must be installed by a qualified person.
2.19 The electrical installation must be carried out in accordance with the current
national electrical regulations.
2.20 The electrical installation must be installed by a qualified person.
E. Mainsboost vessel
2.21 Ensure the Mainsboost vessel is installed correctly before operating the unit, to
avoid damage to the pumps/controls.
Do not attempt to dismantle the Mainsboost vessel
The Mainsboost vessel is pressurised to a pre-set level at the factory see
Section 8.12 - Commissioning for details.

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3 LOCATION - GENERAL
3.11 Access: For emergencies and maintenance the Mainsboost Plus
must be easily accessible.
3.12 Protection: The system must be located in a dry position, and
protected from freezing. Avoid environments which have a high
ambient temperature, high humidity or excessive condensation
and salt damage, etc.
3.13 Ventilation: Ensure an adequate air flow to cool the pump.
Separate the pump from other appliances that generate heat.
3.14 Safety: The motor casing can become very hot under normal
operating conditions. Care must be taken to ensure it cannot be
touched during operation.
3.15 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.
3.16 Static inlet pressure: Ensure the static inlet head at the pump does not
exceed the values shown in the table under point 8.14.
3.17 Incoming mains water pressure: The incoming water pressure of at least
0.1 bar is required.
3.18 Ensure that location of the unit allows adequate space to give reasonable access
to all parts to accommodate service/commissioning.
3.19 Ambient temperature: The pump must be sited in a location where the
maximum ambient temperature does not exceed 40 oC.
3.20 Pipework: Pipework should be sized to ensure optimum performance of the
system.
3.21 Direction of flow: See Fig. 6 (vertical), Fig. 7 (horizontal) to identify the suction
and discharge connections.
Vertical
Fig. 6
Suction
Discharge
Horizontal
Fig. 7
Suction
Discharge

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4 TERMINOLOGY
4.11 System Designation:
It is important to understand what upstream and downstream refers to before
starting the installation.
4.12 Upstream
The term ‘Upstream’ refers to the system configuration from the consumer’s
stopcock to the point where the supply reaches the inlet port of the Mainsboost
Plus Pump.
4.13 Downstream
The term ‘Downstream’ refers to the system configuration from the outlet tapping
on the Mainsboost Plus Pump, along the distribution header (if configured in
this way) and into the distribution pipework and outlets. This includes hot and
cold services where both are present (see Fig. 8).
Fig. 8 System designation

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5 CONFIGURATION
5.11 Mainsboost Plus is a very flexible solution, offering a patent protected packaged
system to suit any type or size of building no matter how large or small the
demand is. The following illustrations depict just some of the most typical
installations.
5.12 Single occupancy application:
Use of Mainsboost Plus in a
house offers water on
demand whilst giving
maximum flexibility. As can
be seen the upstream
line-in kit has to be fitted on to
the rising main but the vessel/
pump can be fitted wherever
there is a space, for example;
utility, kitchen, upstairs
cupboard or loft, providing
adequate provisions are taken
for the weight, frost protection
etc (see Fig 9).
Where height restrictions exist
the MPB 200SH and
MBP 250SH litre Mainsboost
Plus can be supplied for
horizontal installation.
5.13 Multiple occupancy application:
Often affected by poor water
supplies Mainsboost Plus
offers the perfect solution.
For multiple occupancy
buildings again the
upstream line-in kit is located
next to the rising main and
sized to meet the demand of
the entire building. Each
apartment then has its own
vessel and pump located
within the property, sized to
meet the apartments own
demand (see Fig. 10).
Fig. 9
Fig. 10

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5.14 High demand single occupancy application:
Where single properties have a much highter demand, it may be necessary to
use additional Mainsboost vessels connected in parallel to ensure sufficient
water is on tap to meet the much higher demand. Fig. 11 shows all vessels
being located in the same place.
5.15 Water softener:
Note: If a water softener is to be fitted it must be located between the upstream
line-in kit and pump/vessel. If high pressure is also required to the drinking tap
fit a Stuart Water Conditioner, available from Stuart Turner, rather than a water
softener.
Fig. 11
Fig. 12 Water softener

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6 INSTALLATION
Step 1:
a) Remove the Mainsboost vessel from its packaging and check to ensure it is not
damaged.
b) Carefully turn the vessel on its side using the discarded packaging to protect it.
WARNING: depending on cylinder size this may require two
people to complete safely.
c) Once on its side screw the Mainsboost vessel connector provided in the
upsteam line-in kit into the tank elbow at the base using suitable thread seal
such as PTFE tape or liquid thread lock (see Fig. 10).
d) Cut a copper tail to the following minimum length, ensuring clearance of the
base.
Pipe length:
MBP 100VS = 210 mm MBP 200VS = 270 mm MBP 300VS = 270 mm
MBP 130VS = 210 mm MBP 250VS = 270 mm MBP 450VS = 340 mm
Then re-erect the cylinder.
e) Fit the isolating valve provided to the tail now protruding from the base of the
vessel.
f) Remove the pump and mounting plate from its packaging and position it on the
Mainsboost vessel, fixing in place using the correct size screw and washers
provided (see Figs. 14 & 15).
g) Ensure the floor is sufficiently strong enough to take the total weight of the unit
when full of water (see Technical Specification section). Take care when
manoeuvring the unit so as not to damage it.
Pump mounting for 100, 130 litre vessels
Fig. 14
Fig. 13
c
Pump mounting for 200, 250, 300 & 450 litre
vessels
Fig. 15
Bolt 3/8 "
Washer
Bolt 3/8 "
Washer
Threaded insert
5/8 " - 3/8 "

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Note: Do not forget if a water softener is to be installed this has to be
included in this pipe run, and additional space must be allocated for
this.
Do not fit smaller pipework than the upstream line-in kit accepts as
this will impair performance.
i) Fix the Mainsboost vessel securely to the floor using appropriately selected and
sized fixings.
Pump manifold assembly:
a) Remove the pump manifold assembly from the packaging and connect it to the
pump assembly using the two fibre washers provided.
b) Fit the pressure relief valve to the manifold.
Fig. 16
Vertical
Fig. 17
Inlet
a
Outlet
b
Bypass valve and
integral NRV
Horizontal
Fig. 18
Inlet
a
Outlet
b
Bypass valve and
integral NRV

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Step 2:
The vessel assembly should then be positioned and checked to ensure there is
sufficient space to install the upstream line-in kit between the stopcock and
pressure vessel inlet. Refer to the chart below as a guide.
Pipe
Size
Minimum pipe length required to install the
upstream line-in kit (mm) (A)
22 mm 480 mm
28 mm 580 mm
35 mm 630 mm
40 mm 735 mm
54 mm 820 mm
Upstream line-in kit
The upstream line-in kit includes:
1 - inline strainer
2 - pressure gauge (upstream)
3 - double check valve
4 - pressure reducing valve
5 - pressure gauge (fitted to pressure reducing
valve)
6 - Mainsboost vessel connector (see step 1)
The above components must be installed in the correct order to ensure safe and
satisfactory system operation.
Fig. 19
A
5
4
3
2
1

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Step 3:
Connect the pressure relief to tundish (not supplied).
Vertical vessel
- completed installation
Fig. 20
Pressure relief valve
Tundish
Fig. 21
To waste
outside

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Horizontal vessel
- completed installation
An attenuation cover (A) is available as an option should the unit need to be installed in
a particularly noise sensitive area.
1 Inline strainer
2 Pressure gauge (upstream)
3 Double check valve
4 Pressure reducing valve
5 Pressure gauge (fitted to pressure reducing valve)
6 Mainsboost vessel connector
7 Lever isolating valve
8 28 mm x 28 mm x 22 mm tee
Vertical
Fig. 23
A
Inlet
Outlet
12 (T-piece
not supplied
4
5Flexible
hose
6
7
8
Flexible
hose
3
Fig. 22
Horizontal
Fig. 24
A

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7 ELECTRICAL
7.11 Regulations: The electrical installation must be carried out in
accordance with the current local regulations by a qualified person.
7.12 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.
7.13 Before starting work on the electrical supply ensure power supply is
isolated.
7.14 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.
7.15 Earthing: This appliance must be earthed via the supply cord, which must be
correctly connected to the earth point located in the terminal box.
7.16 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.
7.17 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:
Green and yellow coloured wire must be connected to the terminal in the
connection unit marked with the letter E or by the earth symbol: or coloured
green or green and yellow.
Blue coloured wired must be connected to the terminal marked with the letter N
or coloured black.
Brown coloured wire must be connected to the terminal marked with the letter L
or coloured red.

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7.18 Wiring diagram:
7.19 Fuse: All models should be protected by a 3 Amp fuse.
7.20 Supply cord replacement:
The internal wiring within the terminal box is 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.
7.21 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.
MAIN WINDING
THERMOTRIP
CAPACITOR
START WINDING
BLUE
BLACK
L
E
N
230 VAC/1PH/50Hz
SUPPLY
GREEN/YELLOW
BROWN
BLUE
1
2
3
4
5
6
CONTROLLER
BLUE (LINK WIRE)
BROWN
BROWN
TEMPERATURE
SENSOR PRESSURE
SENSOR
BLUE
BROWN
BROWN
BLUE
BLACK
BLUE
BLACK
BROWN
BROWN
BLUE
BROWN
BLUE
BLUE
BROWN
BLUE
BROWN
N N1 N2 L5 L4 L3 L2 L1 L
12 VAC
7
8
9
10
12 -VE
13 +VE
BLUE
BLUE (LINK WIRE)
NOT USED NOT USED
11
Fig. 25

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8 COMMISSIONING
8.11 System check: Ensure that the electrical supply to the pump is switched off
before opening the mains water supply stopcock and checking for leaks.
8.12 Check vessel pre-charge pressure:
It is important to have the correct pre-charge pressure in the vessel for your site
conditions to optimise performance. The vessel is supplied with a pre-charge
pressure of approximately 1.4 bar, and should never have a preset pressure of
less than 0.5 bar.
Checking and adjustment to the vessel pre-charge air pressure can only be
carried out when the vessel is empty (contains no water).
8.13 Check mains static pressure:
zNow close outlets and check pressure gauge after ‘Y’ strainer - for static
mains pressure and note it. This should be done at peak times of use.
zTurn stopcock off and leave outlet taps open.
8.14 Check the chart below for the correct vessel pressure against the static mains
pressure recorded.
Using a pressure gauge check the vessel and adjust to suit through the schrader
valve.
Warning: Note PRV setting must not exceed 5.0 bar.
MJ3 pump max.
set pressure
Static mains
pressure
Set vessel
pre-charge pressure
to
Differential Set PRV maximum
setting to
bar bar bar bar
3 bar 1.5 1.0 2.0 2.0
3 bar 2.0 1.0 2.0 2.0
3.5 bar 2.5 1.5 2.0 2.5
3.5 bar 3.0 1.5 2.0 2.5
Fig. 26

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8.15 Control module:
The control module has been factory pre-set to the following conditions.
Should the parameter need changing follow these steps.
zThe pump parameters are displayed in the following sequence:
Set point (SP),
Differential (DIFF),
Low pressure trip (LPR),
High pressure trip (HPR),
Pump run timer (PRT),
Pump Number (NPM),
Relay setting (CRE),
Number of alarms (NAL1/NAL2),
Hours run (HR1/HE2).
zPress and hold the set button for 5-7 seconds. (This gains access to the
pump parameters).
zPress the up/down arrows to change the selected parameter(s) to the desired
value.
zAfter changing the required parameter(s) press the set button twice in quick
succession to lock the new value into the controller memory.
zIt is possible to scroll through all the pump parameter values by simply
pressing the set button once after each parameter value has been displayed.
Settings as per factory preset:
Set point SP: 3 bar
Diff pressure DIFF: 0.5 bar
Low pressure LPR: 0.2 bar
High pressure HPR: 4.5 bar
Pump run timer PRT: 180
Pump number NPM: 2 (do not tamper)
CRE setting 0
Fig. 27
Up/down arrows
allow changes to
pump parameter
values
Alarm mute button
Set button enables
access to pump
parameter values