INSTALLATION INSTRUCTIONS SERVICE KIT - MONSOON EXTRA S1.4 bar SINGLE Part No MONSOON EXTRA U1.4 bar SINGLE Part No.

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1 ISTALLATIO ISTRUCTIOS SERVICE KIT - MOSOO EXTRA S1.4 bar SIGLE Part o MOSOO EXTRA U1.4 bar SIGLE Part o Capacitor (not shown) All Models - see Sections 1 & 5 25 Adhesive foam pad (not shown) 29 PCB (not shown) 1 Thrower washer 26 Screws (3.5 x 12 mm) 4 Seal counterface 5 Rotary seal 8 M8 locknut 7 Fig. 1 Additional Parts 3 O -ring (ID mm) 2 O -ring (ID 6.07 mm) 27 Screws (M6 x 35 mm) 6 Plastic spacer 7 Stainless washer 9 O -ring (ID 8 mm) 28 Screws (M6 x 16 mm) U1.4 only - see Sections 2, 3 & 4 S1.4 only - see Sections 2 & 4 11 Reed switch tie wrap 17 Rubber washer (OD 18 mm) 13 Grub screws (M4 x 4 mm) 15 O -ring (ID 13.6 mm) 24 Reed switch 11 Reed switch tie wrap 10 or Pressure vessel (0.6 litre) 19 Pressure switch 14 O -ring (ID 29.1 mm) 24 Reed switch 20 1/8 seal OR 21 O -ring (ID 10.1 mm) 22 on-return valve assembly 10 Fibre washer (OD 38 mm) OR 16 O -ring (ID 35.1 mm) Fig or 16 Fig. 3

2 COMPLETE KIT COTETS 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 +44 (0) ITEM QTY ITEM QTY 1 Thrower Washer 1 16 O -Ring (ID 35.1 mm) 3 2 O -Ring (ID 6.07 mm) 2 17 Rubber Washer (OD 18 mm) 1 3 O -Ring (ID mm) 1 18 Pressure Vessel (0.6 litre) 1 4 Seal Counterface 1 19 Pressure Switch 1 5 Rotary Seal Assembly /8 Seal 1 6 Plastic Spacer 1 21 O -Ring (ID 10.1 mm) 1 7 Stainless Washer 2 22 on-return Valve Assembly 1 8 M8 Locknut 1 23 Capacitor 1 9 O -Ring (ID 8 mm) 1 24 Reed Switch 1 10 Fibre Washer (OD 38 mm) 3 25 Adhesive Foam Pad 1 11 Reed Switch Tie Wrap 1 26 Screws (3.5 x 12 mm) 4 12 Applicator Tool (not shown) 1 27 Screws (M6 x 35 mm) 2 13 Grub Screws (M4 x 4 mm) 3 28 Screws (M6 x 16 mm) 4 14 O -Ring (ID 29.1 mm) 1 29 PCB 1 15 O -Ring (ID 13.6 mm) 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 PREPARATIO To prepare the pump to accept the service kit parts, each pump part must be removed noting its exact position and sequence (Figs. 1, 2 & 3). ow clean all the individual parts. Before fitting the new service kit parts, the pump and seal type must be identified. COTETS PAGE Section 1 Mechanical seal replacement... 3 Section 2 on-return valve/pressure vessel replacement... 4 Section 3 Pressure switch replacement... 6 Section 4 Reed switch replacement... 8 Section 5 Capacitor replacement Section 6 Printed circuit board replacement

3 SECTIO 1 - MECHAICAL SEAL REPLACEMET The parts required to replace the seal are: ITEM QTY ITEM QTY 1 Thrower Washer 1 7 Stainless Washer 2 2 O -Ring (ID 6.07 mm) 2 8 M8 Locknut 1 3 O -Ring (ID mm) 1 9 O -Ring (ID 8 mm) 1 4 Seal Counterface 1 12 Applicator Tool (not shown) 1 5 Rotary Seal Assembly 1 27 Screws (M6 x 35 mm) 2 6 Plastic Spacer 1 28 Screws (M6 x 16 mm) 4 SEAL IDETIFICATIO For certain pump variants your seal arrangements may be different from that supplied within the service kit. The seal as supplied is an alternative and is shown in order of assembly in Fig 4. Fig. 4 A B C D A Seal seat complete with rubber cup washer. B Rotary seal assembly. C Spacer. D Stainless steel washer. MAITEACE AD CARE UPO 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. Fig. 5 Fig. 6 Applicator Tool (Item 12) Side 2 Side 1 Fig. 7 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 ow 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 seal bellows assembly (Fig. 6). 3 The spacer (item C) and washer (item D) can then be placed on the shaft and whole assembly located into position by screwing the impeller to its stop. The impeller locknut should then be secured (Fig. 7). IITIAL OPERATIG ISTRUCTIOS 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

4 SECTIO 2 - O-RETUR VALVE/PRESSURE VESSEL REPLACEMET Reed Switch Tie Wrap Flow Switch Assembly 15 Reed Switch Pressure Switch Fig or 16 The parts required to replace the non-return valve and pressure vessel are: ITEM QTY ITEM QTY 10 Fibre Washer (OD 38 mm) 1 16 O -Ring (ID 35.1 mm) 1 13 Grub Screws (M4 x 4 mm) 3 17 Rubber Washer (OD 18 mm) 1 14 O -Ring (ID 29.1 mm) 1 18 Pressure Vessel (0.6 litre) 1 15 O -Ring (ID 13.6 mm) 1 22 RV Body Assembly 1 DISASSEMBLY Remove the following parts in the order shown: 1. Reed switch and tie wrap 2. Pressure vessel and O -ring (item 15) 3. 3 Grub screws (item 13) - 2 mm allen key required. The flow switch assembly can now be removed from the RV body being careful not to place stress on the pressure switch cable. ote position of O -ring (item 14). The RV body assembly (item 22) can now be unscrewed from the pump head, noting the position of O -ring (item 10 or 16). Clean all parts that are to be re-used. Damaged components must be replaced. Contact Stuart Turner Ltd for replacements not supplied with kit

5 ASSEMBLY Assembly is the reverse of the disassembly method. Pressure vessel to be hand tightened. Grub screws torque setting m PRESSURE VESSEL REPLACEMET/CHARGE Should ever the need arise for the vessel (item 18) to be replaced or have its air charge checked or replenished, it should be carried out as follow:- a) Isolate pump electrically. b) Isolate hot and cold water supplies via the integral pump isolating valve located in the flexible hoses. c) Release system water pressure by opening a system outlet (tap). d) Check air charge at Schrader valve using a tyre pressure gauge. The pressure should be set at 0.9 bar (13 psi). e) Replenish air charge if required by injecting air into the vessel via the Schrader valve using a car or bicycle pump, ensuring a system outlet valve (tap) remains open during this procedure to allow the vessel to exhaust any excess water. f) Close all system taps, open hot and cold inlet pump isolating valves, turn on electrical power. g) After maintenance is completed prime pump before re-starting. IITIAL OPERATIG ISTRUCTIOS 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

6 SECTIO 3 - PRESSURE SWITCH REPLACEMET The parts required to replace the pressure switch are: ITEM QTY ITEM QTY 19 Pressure Switch 1 21 O -Ring (ID 10.1 mm) /8 Seal 1 DISASSEMBLY Isolate electrical supply before fitting. The supply cord and internal wiring within the terminal box are routed and secured to ensure compliance with the electrical standard E 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. To prepare the pump to accept the pressure switch, isolate and drain down the water. It may be easier at this stage to remove the pump completely from its location. ow disconnect the electrical connections from the pressure switch to the P.C.B. The pressure switch cable restraint/sealing system will vary across model types. ote the cable route, clamping and sealing method to enable re-assembly to same pattern and proceed as follows: The pump uses a rubber grommet for sealing and a cable strap for restraint. Release cable strap and gently slide cable out through sealing grommet, to avoid damage to enable re-use. Damaged components must be replaced. Contact Stuart Turner for replacements not supplied with kit. Using a suitable open ended spanner (apply to brass switch part only), rotate the pressure switch anticlockwise. MAITEACE AD CARE UPO ASSEMBLY Depending on the age of your pump it may have a sealing washer (item 20) or O -ring (item 21) always replace like for like. Ensure the sealing faces for the pressure switch are clean before using the replacement sealing washer. ow tighten the pressure switch to 7 m torque. Wiring of the switch can now be completed. The strain relief bush, as supplied will suit the new switch and must be fitted. 1 2 Fig

7 WIRIG DIAGRAM MAI WIDIG LIK WIRE () BROW THERMOTRIP START WIDIG BLACK CAPACITOR M L BROW GREE / YELLOW L 230 VAC/1PH/50Hz E SUPPLY S1 S3 S3 S1 Fig. 10 REED (S3) PRESSURE SWITCH (S1) IITIAL OPERATIG ISTRUCTIOS 1. Turn on water supply, prime and vent the pump via the vent plug. Unscrew slowly until liquid emerges, then re-tighten. ote: DO OT RU PUMP DRY. 2. Turn power supply to pump on - pump will start, pressurise the system then stop. 3. Open and close all outlets in turn associated with the pump, (including w/c systems) allowing water to flow from each outlet until all air is purged. As each outlet is opened and closed, the pump will stop and start respectively. ote: After closing the outlet there will be a small delay time before the pump stops, which is normal. 4. 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. 5. Carefully check pump and pipework for leaks whilst pump running and stationary before leaving the installation unattended

8 SECTIO 4 - REED SWITCH REPLACEMET The parts required to replace the reed switch are: ITEM QTY ITEM QTY 11 Reed Switch Tie Wrap 1 26 Screws (3.5 x 12 mm) 4 24 Reed Switch 1 WIRIG DIAGRAMS Fig. Pump UK Eire 11 Monsoon Extra S1.4 bar Single ü ü 12 Monsoon Extra U1.4 bar Single ü ü LIK WIRE BROW MOTOR M L BLACK CAPACITOR BROW GREE / YELLOW 230 VAC/1PH/50Hz SUPPLY L E S2 S2 REED (S2) REED (S2) Fig. 11 LIK WIRE () BROW MOTOR M L BLACK CAPACITOR BROW GREE / YELLOW 230 VAC/1PH/50Hz SUPPLY L E Cable clamp & screws S1 S3 S3 S1 REED (S3) PRESSURE SWITCH (S1) REED (S3) PRESSURE SWITCH (S1) Fig

9 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 E 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. 26 Terminal box lid Cut tie wrap Cable clamp screws Fig. 14 Cable clamp L M Fig. 13 Cable Grommet Remove four screws and carefully remove terminal box lid (item 26). ote the cable routing within the terminal box (Figs. 11 or 12). Identify, disconnect and remove the reed switch wiring from the terminal block (Figs. 11 or 12). IMPORTAT take note of the cable clamp orientation before removal, as reassembly in the original factory orientation is essential. Remove two screws and cable clamp, this allows any reed or pressure switch cables to be removed from the terminal box (Fig. 13). Remove the reed switch cable from the terminal box by gently sliding the cable out through the grommet, ensuring no damage to the grommet sealing area (Figs. 11 or 12). Remove the existing reed switch by cutting the securing tie wrap and pulling away from the body Fig. 14. Damaged components must be replaced. Contact Stuart Turner for advice on replacements not supplied with kit

10 REASSEMBLY Reassembly is the reverse of the disassembly instructions with the new replacement parts fitted as required. Secure cable clamp screws and terminal box lid, to a torque of 0.8 m. ote: For correct operation of the flow switch, the reed must be secured to the body as detailed below. Firstly feed the tie wrap through the retainer on the reed switch, ensuring that the tie wrap serrations are facing outward (Fig 15). ow locate the reed switch within the body groove as highlighted X-X (Fig. 16), 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 (Fig. 17). 24 Serrations 11 Catch Fig. 15 X X Fig. 16 Fig. 17 IITIAL OPERATIG ISTRUCTIOS 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

11 SECTIO 5 - CAPACITOR REPLACEMET 26 Terminal box lid 23 L M 25 Fig. 18 The parts required to replace the capacitor are: ITEM QTY ITEM QTY 23 Capacitor 1 26 Screws (3.5 x 12 mm) 4 25 Adhesive Foam Pad 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 E 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 18: Remove 4 screws (item 26), and carefully remove terminal box lid. IMPORTAT: Take note of capacitor wiring connection and colours before removal. Disconnect and remove capacitor (item 23) and foam securing pad (item 25), make note of pad fitted position. Damaged components must be replaced. Contact Stuart Turner for advice on replacements not supplied with kit

12 REASSEMBLY Reassembly is the reverse of the disassembly instructions, with new replacement parts fitted as required. ote: For correct installation the capacitor must be connected, secured and positioned as detailed (Figs. 19, 20 & 21). Secure terminal box lid screws to a torque of 0.8 m (item 26). IMPORTAT OTE: For correct pump rotation, ensure both blue wires are connected to the linked capacitor terminals as shown. 25 L M 25 Fig. 19 Receptacles upright Fig. 20 Receptacles upright Brown wire from motor connect to M terminal Protective supplementary insulation surrounding motor flying wires L M A 23 Link wire blue connect to terminal Black wire from motor Fig. 21 Linked terminal Blue wire from motor IITIAL OPERATIG ISTRUCTIOS 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

13 SECTIO 6 - PRITED CIRCUIT BOARD REPLACEMET The parts required to replace the printed circuit board are: ITEM QTY ITEM QTY 25 Adhesive Foam Pad 1 29 Printed Circuit Board 1 26 Screws, Self Tapping (3.5 x 12 mm) 4 ote: - When fitted this printed circuit board will detect the following fault conditions: Dry running caused by water starvation to the pump. If the above fault condition occurs, then the pump will stop. The fault should therefore be rectified before restarting the pump. Check that there is sufficient water supply to the pump and also ensure that all outlets are closed. 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 to re-start, then please consult Stuart Turner PumpAssist +44 (0) 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

14 To view the light the following procedure must be followed:- Isolate the mains electrical power supply from the pump. Remove the four screws (item 26) retaining the terminal box lid (Fig. 22). Lift the terminal box lid off. IMPORTAT Ensure there is no contact with any of the internal parts of the terminal box. 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 m. 26 Terminal box lid Indication light Fig. 22 Wiring removed for clarity 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 E 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. MAI WIDIG LIK WIRE () BROW M L THERMOTRIP START WIDIG BLACK CAPACITOR BROW GREE / YELLOW 230 VAC/1PH/50Hz L SUPPLY E REED (S2) S1 S2 S3 S3 S2 S1 S2 S2 REED (S2) Fig

15 MAI WIDIG LIK WIRE () BROW M L THERMOTRIP START WIDIG BLACK CAPACITOR BROW GREE / YELLOW 230 VAC/1PH/50Hz L SUPPLY E PRESSURE SWITCH (S1) REED (S3) S1 S2 S3 S3 S2 S1 S1 S3 S3 S1 REED (S3) PRESSURE SWITCH (S1) Fig A B B D C Earth wire E B Fig. 25 Capacitor (item 23) Reference Fig 25. Remove four screws (item 26) and carefully remove terminal box lid (item A). IMPORTAT: Take note of capacitor wiring connection and colours before removal. Disconnect and remove capacitor (item 23), and foam securing pad (item 25) make note of pad fitted position. Remove M4 nut (item B) then M4 lock washer (item C) and plain washer (item D), this allows removal of earth wire and cup washer (item E). Disconnect all wiring from terminal blocks on printed circuit board (PCB item 29). Remove two M4 nuts (item B) and carefully lift PCB (item 29) away from terminal box. Damaged components must be replaced. Contact Stuart Turner for advice on replacements not supplied with kit

16 REASSEMBLY The replacement PCB supplied with this kit maybe of a different design to the PCB being replaced. The new PCB is interchangeable with the existing, however, the following steps must be adhered to. Reassembly is the reverse of the disassembly instructions with the new replacement parts fitted as required. ote: For correct operation the capacitor must be secured and positioned as detailed in Figs. 26 & 27. The replacement PCB s mains supply cord must be routed and secured as shown in Figs. 23 or 24. Re-connect all internal wiring as detailed in appropriate wiring diagram and ensure the internal wiring is routed and secured to the same pattern as noted in disassembly section (except mains supply cord, see Figs. 23 or 24). Secure PCB nuts to a torque of 1.5 m (item B). Secure terminal box lid screws to a torque of 0.8 m (item 26). IMPORTAT OTE: For correct pump rotation, ensure both blue wires are connected to the linked capacitor terminals as shown. Linked Terminal L M Fig mm 9.5 mm 25 Blue Blue Black Receptacles Upright Fig Receptacles Upright IITIAL OPERATIG ISTRUCTIOS 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. Pt. o Stuart Turner Ltd, Henley-on-Thames, Oxfordshire RG9 2AD EGLAD Tel: +44 (0) , Fax: +44 (0) info@stpumps.co.uk Issue o: 1616/1-03

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