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:

Jet 55-45 PS

Pt. No. 46617

Jet 80-45 PS

Pt. No. 46618

CE compliant product

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 Jet Pressure Set (PS) range is designed for pressure boosting applications in vented stored, cold clean water systems, where under gravity, no flow is available.

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 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.



Children should be supervised to ensure that they do not play with



This product should not be used for the supply of water to more than one dwelling (house, apartment, flat).

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.

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 Specifi cation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Cont ...

- 2 -

CHECKLIST

A

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.

C

Fig. 1

Item Description

A

Pump

B

Anti-vibration feet

B

Qty Item Description

1

4

C

Pressure vessel

Your product may vary slightly from the picture above.

- 3 -

Qty

1

Cont ...

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 Ensure the pump is primed as described in the priming section before starting, damage to the shaft seal will result otherwise. 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 o

C.

1.14 The minimum allowable water temperature is 4 o

C.

C. Pipework - General

1.15 Secure pipework: Ensure pipework to and from pump is independently supported & clipped to prevent forces being transferred to inlet and outlet branches of pump.

1.16 Flux: Solder joints must be completed and flux residues removed prior to pump

1.17 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 o

bends.

1.18 DO strippers, acid based descalents or aggressive cleaning agents.

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 connect this pump to the mains water supply.

D. Plumbing 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 qualified 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 person.

E. Pressure vessel

1.26 Pressure vessel is charged at the factory see Section 5 - Maintenance for details.

Cont ...

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2 LOCATION - GENERAL

2.11 Access: For emergencies and maintenance the pump must be

2.12 Protection: The pump must be located in a dry position, frost free and protected from freezing, particularly when installed in a loft (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 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.

2.16 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 5 metres.

2.17 Ambient temperature: The pump must be sited in a location where the maximum ambient temperature does not exceed 40 o

C.

2.18 Pipework: For optimum performance pipework 28 mm should be used. 22 mm is acceptable, however, any pipe size reduction will reduce the pumps

performance.

2.19 Static outlet pressure: The static outlet head (Fig. 2) must also be within the maximum requirement of 13 metres.

2.20 Noise: The anti-vibration mounting feet and flexible hoses have been 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.

2.21 Direction of flow: Ensure the water flow is in the direction of the arrow marked on the flow switch reed clamp (vertically upwards).

2.22 Isolating valves: If permanently installed, isolating valves should be fitted in suction and delivery pipework to enable easy isolation and access to the pump.

2.23 Inline stainer: When pump is to be installed in areas where there is risk of debris or scale build up within the system, you MUST ensure the inlet pipework is fitted with an inline strainer.

2.24 Preferred pump location: The preferred pump location is at floor level next to the water source or a level that is below the secondary tapping that feeds the pump. The pump has a side mounted terminal box. Ensure the pump is mounted in a position that allows easy access to the box if required. The pump location is also dependent on limitations of the static inlet and outlet heads of

Cont ...

- 5 -

2 LOCATION - PUMP MOUNTED BELOW WATER SOURCE

Unvented hot water cylinder

Cold water

Hot water

Fig. 2

2.25 Water supply: Must be made via a tank connector offering a dedicated supply direct to the pump.

- 6 -

Cont ...

3 ELECTRICAL INSTALLATION / EARTHING

3.11 Regulations: The electrical installation must be carried out in

3.12 Safety: In the interests of electrical safety a 30 mA residual current accordance with the current national electrical regulations and installed by a qualified person.

This may be part of a consumer unit or a separate unit.

3.13 Before starting work on the electrical supply ensure power supply is

isolated.

3.14 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.

3.15 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.

Warning Tag

Fig. 3

3.16 Adjacent pipes: Adjacent suction and delivery pipes should be fitted with earthing clamps in accordance with current regulations (Fig. 4).

Diagram of earth continuity connections

Fig. 4

3.17 Earthing: This appliance must be earthed via the supply cord, which must be correctly connected to the earth point located in the terminal box.

3.18 Pipework: Copper or metallic pipework must have supplementary earth bonding where the continuity has been broken by flexible hoses or plastic

components.

3.19 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.

- 7 -

3.20 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.

3.21 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

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.

3.22 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.

GREEN / YELLOW (LINK WIRE)

CAPACITOR

BLACK

RED

N

A M

N

L

BLUE

BROWN

GREEN / YELLOW

E

L

N 230 VAC/1PH/50Hz

SUPPLY

MOTOR

FLOWSWITCH

REED (S3)

S1 S2 S3 S3 S2

S1

PRESSURE

SWITCH (S1)

Jet 55-45 PS, Jet 80-45 PS

Fig. 5

3.23 Fuses: The following fuse size should be used with the appropriate pump:

Model

All Models

Fuse Size (AMPS)

13

Cont ...

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4 COMMISSIONING

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 Water Supply: Always ensure that water storage capacity is adequate to meet the demand. Ensure the pump chamber is full of water before starting the pump.

Failure to do this could result in seal damage. To ensure dry running does not occur the pump must be primed as described in priming section below.

Do not run pump dry.

4.13 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

Priming/ vent Plug

Drain

Plug

Jet 55-45 PS, Jet 80-45 PS Fig. 6

4.14 Starting the pump: a) Ensure all outlets are closed, turn power supply ‘on’ - pump will start, pressurise the system then stop.

b) Open and close all outlets in turn associated with the pump, allowing water to flow from each outlet until all air is purged. As each outlet is opened and closed, the pump will start and stop respectively.

Note: After closing the outlet there will be a small time delay before the pump stops, which is normal.

c) 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.

d) Carefully check pump and pipework for leaks whilst pump running and stationary before leaving the installation unattended.



Do not run pump without guards and terminal box lid



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 PumpAssist team on +44 (0) 844 98 000 97. Our staff are trained to help and advise you over the

phone.

- 9 -

5 MAINTENANCE

5.11 Pressure vessel: The pressure vessel should be checked once every 6 months to have its air charge checked or replenished, this should be carried out 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 charge at Schrader valve (Fig. 7) 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. 7).

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.

Schrader valve

(under cap)

Model

All models

Air Precharge bar (psi)

2.0 (29)

Cap

Pressure vessel

Fig. 7

5.12 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 PumpAssist helpline on +44 (0) 844 98 000 97.

Cont ...

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Pump Model

Jet 55-45 PS

46617

Jet 80-45 PS

46618

General

Features

Guarantee

Pump type

Mechanical seal

Fully automatic control

24 litre diaphragm tank

Built in ‘no water’ cut out

Positive and negative head application

Quiet operation

Performance

Maximum head (closed valve)

Performance @ 9 l/min

Performance @ 18 l/min

Maximum flow

Manimum static inlet pressure

Maximum static inlet pressure

Maximum static outlet pressure

Maximum working pressure*

Maximum ambient air temperature

Min / Max water temperature

Maximum suction lift

Cut out flow

Cut in pressure

Pressure vessel air pre-charge

Connections Pump connections

Motor Type

Electrical

Duty rating

Power supply / phase / frequency

Current (full load)

Power consumption

Fuse rating

Power cable (pre-wired)

Physical

Enclosure protection

Length

Width

Height (excluding hoses)

Weight (including fittings)

1 year

Centrifugal

EPDM / Carbon / Ceramic





















4.5 bar 4.2 bar

3.1 bar

1.2 bar

3.2 bar

2.2 bar

53 l/min 75 l/min

0.1 bar (1 metre)

0.5 bar (5 metres)

1.3 bar (13 metres)

500 kPa (5 bar) 470 kPa (4.7 bar)

40 o C

Min 4 o

C / Max 35 o

C

5 metres

1 l/min (approx)

180 kPa (1.8 bar)

2.0 bar (29 psi)

G 1 female

Induction, auto-reset thermal trip

Continuous (S1)

230 V a.c. / 1 / 50 Hz

2.9 Amps

640 Watts

13 Amps

1.5 metres

5.2 Amps

925 Watts

IPX4

537 mm

292 mm

654 mm

13.2 Kg 15.7 Kg

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 73 dB(A) for

Jet 55-45 PS or 76 dB(A) for Jet 80-45 PS.

- 11 -

7 TROUBLE SHOOTING GUIDE

Symptoms

Pump will not start.

Probable Cause

Electrical supply.

Failed reed switch/PCB/ pressure switch

Recommended static inlet/ outlet heads exceeded.

Internal motor thermotrip activated.

Recommended Action

Check wiring connections.

Check all switches are ‘on’.

Check fuse (see fuse section).

Check circuit breaker is set.

Contact PumpAssist.

Re-position pump (see Section 2 - Location).

Wait for thermotrip to cool and auto-reset and investigate cause of problem before re-starting.

Water starvation to pump.

Pump starts when outlets are off.

or

Pump cycles (hunts) on/off frequently.

Leak in system.

Low charge pressure in pressure vessel.

Pump runs on when all terminal outlets are closed.

Debris under non-return valve sealing face.

Leak in system.

Reed clamp out of position.

Refer to ‘dry running’ section.

Check tap washers, w/c valve washers, pipe joints.

Check charge pressure in pressure vessel

(see Section 5 - Maintenance).

Run at full flow to try and flush away debris or remove, clean or replace non-return valve.

Check tap washers, w/c valve washers, pipe joints.

Ensure reed clamp is fitted correctly in location groove.

Pump runs, but no water.

Reduced flow/performance.

Failed reed switch or P.C.B.

Jammed flow switch.

Pump air locked

Water supply low.

Air bubbles in suction pipe.

Blocked shower head spray plate.

Blocked pipework or pump.

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.

Isolate the pump electrically and hydraulically and remove brass housing that contains the float. Check float for free movement.

Remove priming plug, fill with water.

Refit plug.

Check water level in the supply tank or well and all stopcocks are open.

Check outlet not restricted or blocked.

Check connections are all airtight.

Clean in accordance with manufacturers instructions.

Isolate pump electrically and hydraulically, locate blockage and remove.

Cont ...

- 12 -

7.11 Dry Run Protection:

This pump is fitted with a safety control circuit, which will detect the following



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

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) 844 9800097.

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. 8).



Lift the terminal box lid off.



IMPORTANT – Ensure there is no contact with any of the internal parts of the terminal box.

Cont ...

- 13 -



Briefly reconnect the mains power supply to the pump – the ‘power on’ 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.

Terminal box lid

Retaining screws x 4

‘power on’

light

Fig. 8 Wiring removed for clarity

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.

- 14 -

Cont ...

8 YOUR 1 YEAR GUARANTEE

Congratulations on purchasing a Stuart Turner pump.

We are confident this pump will provide many years of trouble free service as all our products are manufactured to the very highest standard.

All Jet Pressure Sets are guaranteed to be free from defects in materials or workmanship for 1 year from the date of purchase.

Within the guarantee period we will repair, free of charge, any defects in the pump resulting from faults in material or workmanship, repairing 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 product has been purchased within the guarantee term 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.

In the event of a claim please telephone ‘PumpAssist’ or return the pump and flexible hoses with the accessories removed e.g pipes etc. If you have any doubt about removing a pump, please consult a professional.

+44 (0) 844 98 000 97

Proof of purchase should accompany the returned unit to avoid delay in investigation and dealing with your claim.

You should obtain appropriate insurance cover for any loss or damage which is not covered by Stuart Turner Ltd in this provision.

Please record here for your records.

TYPE NO.

SERIAL NO.

DATE PURCHASED

Installers – Register with Stuart Turner and move up to Approved Installer status

We receive thousands of enquiries every month from people seeking a Stuart Turner installer and by registering your details with us, we can offer consumers the opportunity to quickly locate an installer in their area.

Registration is free - simply click on the ‘register as an installer’ link on our homepage at www.stuart-

turner.co.uk and complete a short form which will enable visitors to find your contact details on our web site ‘installer finder’. Alternatively use your smartphone to scan this QR code and go straight to the form.

We’ll do the rest!

In addition we will ensure you receive advance notice on all new product launches and access to any special offers or promotions.

Following initial registration, Stuart Turner offers a professional training programme, enabling you to achieve Approved Installer status and opening the door to a range of additional benefits.

Contact [email protected] for further details.

- 15 -

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 PUMP AS SERIAL

NUMBER BELOW, COMPLIES WITH THE ESSENTIAL REQUIREMENTS OF THE ABOVE E.E.C.

DIRECTIVES.

AND MANUFACTURER STUART TURNER LIMITED

RG9 2AD ENGLAND.

Business Development Director

Stuart Turner are an approved company to BS EN ISO 9001:2008

Stuart Turner Ltd, Henley-on-Thames, Oxfordshire RG9 2AD ENGLAND

Tel: +44 (0) 1491 572655, Fax: +44 (0) 1491 573704 [email protected] www.stuart-turner.co.uk

Issue No. 0915/2-01 Pt. No. 19768