Stuart Turner 28474 Manuel utilisateur

Cont ...

INSTALLATION INSTRUCTIONS

SERVICE KIT - MONSOON NEGATIVE PUMPS (Pre - 2008) Part No. 28474

- N1.5, N2.0 & N3.0 bar variants only.

Note: 1) Quantities are to cover a twin pump, singles use half.

2) See relevant section for detailed instructions.

Fig. 1

24 (Section 2)

Capacitor (note ratings)

25 (Section 3)

PCB

26 (Sections 2, 3 & 4)

Adhesive foam pad

7 (Section 1)

Woodruff key

9 (Sections 1 & 6)

‘O’-ring

(ID 24.6 mm)

3 (Section 1)

Stainless washer

(OD ¾ ")

14 (Section 1)

Screws (M4 x 16 mm)

16 (Section 8)

Clip

4 (Section 1)

Rotary seal

5 (Section 1)

Seal Counterface

6 (Section 1)

‘O’-ring

(ID 66.4 mm)

1 (Sections 1 & 6)

Screws (M6 x 35 mm)

28 (Section 4)

Reed switch

23 (Sections 2, 3 & 5)

Screws (K40 x 16 mm)

29 (Section 4)

Strain relief bush

18 (Sections 1 & 6)

‘O’-ring (ID 15.0 mm)

11 (Section 2)

Non-return

valve assembly

22 (Section 5)

Pressure switch

20 (Section 7)

Pressure vessel (0.6 litre)

19 (Sections 1 & 5)

Rubber washer (G ½ “)

27 (Section 1 & 4)

Reed switch tie wrap

17 (Section 1)

‘O’-ring (ID 14.0 mm)

21 (Sections 1 & 5)

Bonded seal

15 (Section 8)

Magnetic float

13 (Section 1)

‘O’-ring (ID 19 mm)

2 (Section 1)

Circlip

12 (Section 2)

‘O’-ring

(ID 21 mm)

10 (Section 2)

Non-return

valve holder

8 (Section 1)

Thrower

31 Strainer

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• COMPLETE KIT CONTENTS

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) 800 31 969 80.

ITEM QTY ITEM QTY

1 Screws (M6 x 35 mm) 8 17 ‘O’-Ring (ID 14 mm) 3

2 Circlip 2 18 ‘O’-Ring (ID 15 mm) 2

3 Stainless Washer (OD ¾ ") 2 19 Rubber Washer (G ½ “) 1

4 Rotary Seal Assembly 2 20 Pressure Vessel (0.6 litre) 1

5 Seal Counterface 2 21 Bonded Seal 1

6 ‘O’-Ring (ID 66.4 mm) 2 22 Pressure Switch 1

7 Woodruff Key 2 23 Screws (K40 x 16 mm) 4

8 Thrower 2 24 Capacitor (1 off each variant) 2

9 ‘O’-Ring (ID 24.6 mm) 4 25 PCB 1

10 Non-Return Valve Holder 2 26 Adhesive Foam Pad 1

11 Non-Return Valve Assembly 2 27 Reed Switch Tie Wrap 2

12 ‘O’-Ring (ID 21 mm) 2 28 Reed Switch 2

13 ‘O’-Ring (ID 19 mm) 2 29 Strain Relief Bush 3

14 Screws (M4 x 16 mm) 4 30 Applicator Tool (not shown) 1

15 Magnetic Float 2 31 Strainer 2

16 Clip 2

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 PREPARATION

To prepare the pump to accept the service kit parts, each pump part must be removed noting

its exact position and sequence (Fig. 1).

Now clean all the individual parts. Before fitting the new service kit parts, the pump and seal

type must be identified.

• CONTENTS PAGE

Section 1 Mechanical seal replacement .................................. 3

Section 2 Capacitor replacement ....................................... 7

Section 3 Printed circuit board replacement ............................... 9

Section 4 Reed switch replacement ..................................... 13

Section 5 Pressure switch replacement .................................. 16

Section 6 Non-return valve replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Section 7 Pressure vessel replacement ................................... 21

Section 8 Magnetic float replacement ................................... 23

Section 9 Strainer ................................................... 24

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SECTION 1 - MECHANICAL SEAL REPLACEMENT

The parts required to replace the seal (one end only) are:

ITEM QTY ITEM QTY

1 Screws, (M6 x 35 mm) 4 9 ‘O’-Ring (ID 24.6 mm x 2.4 mm c/sec) 2

2 Circlip 1 14 Screws (M4 x 16 mm) 4

3 Stainless Washer (OD ¾ ”) 1 17 ‘O’-Ring (ID 14 mm) 2

4 Rotary Seal Assembly 1 19 Rubber Washer (G ½ “) 1

5 Seal Counterface 1 21 Bonded Seal 1

6 ‘O’-Ring (ID 66.4 mm x 1.78 mm c/sec) 1 27 Reed Switch Tie Wrap 2

7 Woodruff Key 1 30 Seal Applicator Tool (not shown) 1

8 Thrower 1

• DISASSEMBLY

To access the mechanical seal assembly the flow switch assemblies must first be removed

(Fig. 2).

Flow Switch Assemblies:-

Fig. 2

*Flow switch body assembly

Note: Alternative pressure

vessels shown

This kit can be used to service the

pump only.

The control module is not included

and needs to be purchased

separately.

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Cont ...

To identify which components are required, the following exploded view details the pump

components along with the serviceable parts.

Fig. 4

Flow switch, transfer pipe

& pressure vessel assembly

Fig. 3

Single variation pump head.

Control module not shown.

Note: Alternative pressure

vessel (20) shown.

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Cont ...

To disassemble the pump, the following items are required to be removed in the sequence

detailed (Fig. 4).

• Remove screws (A) and lift complete assembly away and position next to pump ensuring no

stress is placed on the cables.

• Remove 4 screws (item 1) and gently prise off the pump body – note ‘O’-ring (item 6)

between pump body and mounting plate.

• Slide impeller away from shaft and remove woodruff key (item 7) – (see note: Fig. 5).

• Remove circlip (item 2) and mechanical seal parts. (items 3 & 4).

• Gently prise off mounting plate.

• Remove Counterface (item 5) from its mounting plate location.

• Note: Other parts are supplied in this kit and can be used as shown in Fig. 4 if replacement

required.

Note:

Difficulties may be experienced in the removal of the impeller. To overcome this, two

screwdrivers can be used to gently lever the impeller away from the shaft as detailed (Fig. 5),

ensuring equal pressure is applied to each side of the component to avoid bending the shaft.

• MAINTENANCE & CARE BEFORE REASSEMBLY

To allow ease of reassembly, along with correct functioning of the pump, the following points

on reassembly are necessary:

• All pump parts must be free from debris and assembled in the correct order.

• The impeller must be a slide fit on the shaft.

• The seal must always be replaced as a complete unit.

• SEAL IDENTIFICATION & ASSEMBLY

The seal is shown in order of identification in Fig 6.

A Seal Counterface complete with rubber cup washer.

B Rotary seal assembly.

C Stainless steel Washer.

D Seal retaining clip.

Fig. 5

NOTE: DO NOT USE EXCESSIVE

FORCE, AS THIS MAY DAMAGE THE

COMPONENTS

Fig. 6

Rotary seal assembly

Location plate

Spring

Counterface

Rubber cup washer

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Cont ...

To assemble the seal correctly, the shaft must be clean and the following steps carried out.

1. Use End 1 of the applicator tool to push the seal counterface (item A) firmly into the

housing, ensuring it is located flat against the back of the mounting plate housing.

2. Now use End 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 counterface (Fig. 7). 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 rotary seal

assembly (Fig. 8)

3. The washer (item C) can then be placed on the shaft and the whole assembly held into

position by locating the Circlip (item D) in the groove and pushing it into position (Fig. 9)

WARNING: Do not install the circlip onto full shaft diameter, it must only be located in the

groove.

• REASSEMBLY

• Reassembly of the remaining pump parts is the reverse of disassembly instructions, ensuring

all re-used parts are clean, and new replacement parts fitted as required.

• Secure pump body screws to a torque of 2.6 Nm (item 1).

• Screws (A) to be tightened to 1.5 Nm of torque.

• INITIAL OPERATING INSTRUCTIONS

• 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.

Fig. 7 Fig. 8 Fig. 9

End 2 Applicator Tool (Item 30)

End 1

Fig. 10

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Cont ...

SECTION 2 - CAPACITOR REPLACEMENT

The parts required to replace the capacitor are:

ITEM QTY ITEM QTY

23 Screws, Self Tapping (K40 x 16 mm) 4 26 Adhesive Foam Pad 1

24 Capacitor 1

• CAPACITOR - USED ON MONSOON UNIVERSAL PUMPS

7 µf - N1.5, N2.0, N3.0 bar Single

N1.5, N2.0 bar Twin

10 µf - N3.0 bar Twin

• 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

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 reassembly to the same factory pattern is always maintained.

Fig. 12

Capacitor

rating

Terminal box lid

Fig. 11

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Cont ...

Reference Fig 11:

• Remove 4 screws (item 23), and carefully remove terminal box lid.

• IMPORTANT: Take note of capacitor wiring connection and colours before removal.

Disconnect and remove capacitor (item 24) and foam securing pad (item 26), make note of

pad fitted position.

Damaged components must be replaced. Contact Stuart Turner for

advice on replacements not supplied with kit.

• REASSEMBLY

Reassembly is the reverse of the disassembly instructions, with new replacement parts fitted

as required.

Note: For correct installation the capacitor must be connected, secured and positioned as

detailed (Figs. 13 & 14).

Secure terminal box lid screws to a torque of 0.8 Nm (item 23).

IMPORTANT NOTE: For correct pump rotation, ensure both blue wires are connected to the

linked capacitor terminals as shown.

• INITIAL OPERATING INSTRUCTIONS

• 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.

Receptacle at 45o

(approximately)

Fig. 13 Fig. 14

24 Receptacle at 45o

(approximately)

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Cont ...

SECTION 3 - PRINTED CIRCUIT BOARD REPLACEMENT

The parts required to replace the printed circuit board are:

ITEM QTY ITEM QTY

23 Screws, Self Tapping (K40 x 16 mm) 4 26 Adhesive Foam Pad 1

25 Printed Circuit Board 1

Note: - 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) 800 31 969 80.

• 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

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Cont ...

To view the light the following procedure must be followed:-

• Isolate the mains electrical power supply from the pump.

• Remove the four screws (item 23) retaining the terminal box lid.

• Lift the terminal box lid off.

• IMPORTANT – 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 Nm.

• 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

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 reassembly to the same factory pattern is always maintained.

Indication light

Terminal box lid

Fig. 15 Wiring removed for clarity

S2 S2S3 S3

MAIN WINDING

THERMOTRIP CAPACITOR

START WINDING

FLOWSWITCH

REED (S3)

BLUE

BROWN

BLACK RED

GREEN/

YELLOW

BLUE

BROWN L

S2 S3 S3 S2

FLOWSWITCH

REED (S2)

PRESSURE

SWITCH (S1)

230 VAC/1PH/50Hz

SUPPLY

Fig. 16 Twin

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