Danfoss Semco SEM-SAFE User manual

END USER MANUAL
SEM-SAFE® HIGH-PRESSURE WATER MIST PUMP UNIT
REVISION 4, MAY 2016

End User Manual
High-Pressure Water Mist Pump Unit
Revision 4, May 2016
Copyright 2016 by Danfoss Semco A/S.
All rights reserved. No part of this manual may be reproduced, distributed, or transmitted in any form or by
any means, including photocopying, recording, or other electronic or mechanical methods, without the prior
written permission of Danfoss Semco. For permission request, please contact us:
Danfoss Semco A/S
Middelfartvej 9, 5000 Odense C, Denmark
Tel.: [phone]
Fax: [phone]
E-mail: [e-mail]
Web: www.danfoss-semco.com

END USER MANUAL
OPERATION AND MAINTENANCE OF HIGH PRESSURE WATER MIST PUMP UNIT
REVISION 4, MAY 2016
PAGE 3 / 48
Foreword
This End User Manual provides basic understanding as well as guidance for operation and
maintenance of the SEM-SAFE®High-Pressure Water Mist Pump Unit manufactured by Danfoss
Semco A/S. This manual is prepared for system owners and users of the SEM-SAFE®High-
Pressure Water Mist Pump Unit. If you encounter any problems with the system, please contact
Danfoss Semco A/S Service department (email: [email protected]).

PAGE 4 / 48
END USER MANUAL
OPERATION AND MAINTENANCE OF HIGH PRESSURE WATER MIST PUMP UNIT
REVISION 4, MAY 2016
Table of Contents
Introduction.................................................................................................................................71
Safety instructions for SEM-SAFE®pump unit..................................................................71.1
General Safety instructions..............................................................................................71.1.1
Workplace Safety.............................................................................................................71.1.2
Electrical Safety...............................................................................................................71.1.3
Personal Safety ................................................................................................................81.1.4
Personal Safety Equipment..............................................................................................81.1.5
Copyright, Confidentiality Statement and Trademark ........................................................81.2
Liability ...............................................................................................................................91.3
Health and safety.................................................................................................................91.4
Reservation clause.............................................................................................................101.5
System description....................................................................................................................112
General system description ...............................................................................................112.1
General description of Wet Pipe Water Mist System........................................................11
2.2
General description of Dry Pipe Water Mist System........................................................112.3
General description of Pre-action Water Mist System......................................................112.4
General description of Deluge Water Mist System...........................................................122.5
Pump unit component description ............................................................................................123
Pump unit with unit tank ...................................................................................................123.1
Pump unit with supply manifold (without unit tank) ........................................................133.2
High-pressure pumps.........................................................................................................143.3

END USER MANUAL
OPERATION AND MAINTENANCE OF HIGH PRESSURE WATER MIST PUMP UNIT
REVISION 4, MAY 2016
PAGE 5 / 48
Electric motors ..................................................................................................................153.4
Pilot pump (optional in Land and Marine applications)....................................................153.5
Unit without pilot pump (marine systems)........................................................................153.6
Unit tank............................................................................................................................153.7
Supply manifold ................................................................................................................163.8
High-pressure manifold.....................................................................................................173.9
Valves...............................................................................................................................183.10
Pressure controlling and monitoring devices ....................................................................183.11
Filter system ......................................................................................................................193.12
Emergency back-up system...............................................................................................203.13
Standard Unit Control Panel..............................................................................................213.14
Land application ............................................................................................................213.14.1
Marine application.........................................................................................................253.14.2
VdS Unit Control Panel.................................................................................................293.14.3
FM Global Unit Control Panel.......................................................................................323.14.4
Pump unit operation..................................................................................................................344
Pump unit activation..........................................................................................................344.1
Increasing discharge capacity in a fire situation................................................................344.2
Shut-down of pump unit after activation (fire suppression)..............................................344.3
Reestablishment of the SEM-SAFE®system after starting up..........................................354.4
Pump unit maintenance.............................................................................................................365
Maintenance of land units according to CEA 4001 ..........................................................365.1

PAGE 6 / 48
END USER MANUAL
OPERATION AND MAINTENANCE OF HIGH PRESSURE WATER MIST PUMP UNIT
REVISION 4, MAY 2016
Maintenance according to FM Global...............................................................................395.2
Maintenance according to VdS Schadenverhütung...........................................................425.3
Maintenance of marine units according to MSC.1/Circ. 1432..........................................455.4

END USER MANUAL
OPERATION AND MAINTENANCE OF HIGH PRESSURE WATER MIST PUMP UNIT
REVISION 4, MAY 2016
PAGE 7 / 48
Introduction1
Safety instructions for SEM-SAFE®pump unit1.1
The SEM-SAFE® system is a high-pressure water mist system and consists of nozzles, pump unit,
section valves, piping system, etc. The SEM-SAFE®High-Pressure Water Mist Pump Unit and
system operates under high pressure and high voltage.
Care must be taken when operating the SEM-SAFE®High-Pressure Water Mist Pump Unit.
Installation, test, commissioning and service of the system is only to be carried out by appropriately
trained, competent personnel. It must be ensured that all relevant procedures are followed to the
satisfaction of the authority having jurisdiction, defined as organization, office, or individual
responsible for approving equipment, materials, an installation or a procedure.
General Safety instructions1.1.1
WARNING
Read all safety instructions and instructions.
If the safety instructions and the instructions are not followed, there is a risk of electric shock and /
or serious injury.
Save all warnings and instructions for future use.
Workplace Safety1.1.2
a) Make sure to keep the area around the pump unit free and clean. Disorder in the work area
increases the risk of accidents.
b) Make sure that other people and especially children are kept away from the pump unit when
the pump unit is operating.
Electrical Safety1.1.3
a) The SEM-SAFE®pump unit is always connected to high voltage during standby and
operation.
b) The door on the Unit Control Panel should never be opened by anyone other than educated /
trained personnel as there is an increased risk of electric shock.
c) The main switch should always be switched off during replacement of electrical
components. If the main switch is not switched off there will be an increased risk of
electrical shock.

PAGE 8 / 48
END USER MANUAL
OPERATION AND MAINTENANCE OF HIGH PRESSURE WATER MIST PUMP UNIT
REVISION 4, MAY 2016
IMPORTANT. When the work is finished on the pump unit, the main switch
must be turned on again. If the main switch is not turned on, the SEM-SAFE®pump unit
will not activate if a fire occurs in the protected areas.
Personal Safety1.1.4
a) Always use personal safety equipment (See chapter 1.1.5 Personal Safety Equipment).
Safety equipment will reduce personal injuries.
b) When replacing mechanical or electrical components on the pump unit, the main switch
should always be switched off. If this is not done, there will be an increased risk of injury.
IMPORTANT. When the work is finished on the pump unit, the main switch
must be turned on again. If the main switch is not turned on, the SEM-SAFE®pump unit
will not activate if a fire occurs in the protected areas.
Personal Safety Equipment1.1.5
a) Persons staying in the area, during operation of the SEM-SAFE®pump unit must wear
hearing protection.
b) Persons who work with service and maintenance of SEM-SAFE®pump unit must wear hand
protection.
c) Persons who work with service and maintenance of SEM-SAFE®pump unit must wear
safety shoes.
Copyright, Confidentiality Statement and Trademark1.2
This manual is the property of Danfoss Semco A/S, is confidential information and shall only be
used for carrying out operation and maintenance of the SEM-SAFE®High-Pressure Water Mist
Pump Unit. The manual shall not, in whole or in part, be reproduced, copied, disclosed or used as
the basis for manufacture, marketing or sale without the prior written permission of Danfoss Semco
A/S.

END USER MANUAL
OPERATION AND MAINTENANCE OF HIGH PRESSURE WATER MIST PUMP UNIT
REVISION 4, MAY 2016
PAGE 9 / 48
The content of this manual reflects the state of the art and experience at the time of issuing,
however, Danfoss Semco A/S will constantly improve systems, procedures and instructions.
Consequently, Danfoss Semco A/S will reserve the right to revise and improve this manual without
prior notification.
All trademarks in this manual are property of Danfoss Semco A/S. Danfoss Semco A/S logotype is
a registered trademark and is property of Danfoss Semco A/S. All rights reserved.
Liability1.3
This manual is prepared for system owners, operators and occupants (hereinafter referred to as End
User) of the SEM-SAFE®High-Pressure Water Mist Pump Unit that will perform periodic
scheduled test and maintenance of the pump unit.Test and maintenance must be done according to
this manual, which specifies daily, weekly, monthly and annual check procedures. These tasks shall
be performed only by personnel who have developed competence through for example training and
experience. The pump unit must be serviced by an approved installer at least once per year.
The SEM-SAFE®High-Pressure Water Mist Pump Unit is intended for use only in accordance with
the instructions in this manual. Any use which is not consistent with the content of this manual is
considered incorrect. Operation and maintenance of the SEM-SAFE®High-Pressure Water Mist
Pump Unit shall be carried out in accordance with this manual. It is the responsibility of the End User
to ensure that requirements in this manual comply with applicable legislation in the area where the
SEM-SAFE®High-Pressure Water Mist Pump Unit is used.
The End User shall ensure that the fire risk has not changed after the system and thus the SEM-
SAFE®High-Pressure Water Mist Pump Unit was installed and the system / application became
operational. The End User shall also ensure that all necessary information is available and if any doubt
exists, it is the responsibility of the End User to verify with Danfoss Semco A/S.
Danfoss Semco A/S cannot be held responsible for SEM-SAFE®High-Pressure Water Mist Pump
Units that have not been operated, maintained or used in accordance with this manual.
Health and safety1.4
Danfoss Semco A/S health and safety procedures and environmental policies according to OHSAS
18001, ISO 14001 and rules and regulations on the local territory shall be strictly followed.
Furthermore, it is the End User’s responsibility to ensure that territorial legislation and on-site
safety regulations are followed during operation and maintenance of the SEM-SAFE®High-
Pressure Water Mist Pump Unit.

PAGE 10 / 48
END USER MANUAL
OPERATION AND MAINTENANCE OF HIGH PRESSURE WATER MIST PUMP UNIT
REVISION 4, MAY 2016
Reservation clause1.5
Danfoss Semco A/S can accept no responsibility for possible errors in catalogues, brochures and
other printed material.
Danfoss Semco A/S reserves the right to alter its products without notice. This also applies to
products already on order provided that such alterations can be made without subsequent changes
being necessary in specifications already agreed.

END USER MANUAL
OPERATION AND MAINTENANCE OF HIGH PRESSURE WATER MIST PUMP UNIT
REVISION 4, MAY 2016
PAGE 11 / 48
System description2
General system description2.1
The SEM SAFE®High-Pressure Water Mist System consists of nozzles, pipe work, section valves
and pump unit and can be classified as one of the following four different types of systems:
Wet Pipe Water Mist System
Dry Pipe Water Mist System
Pre-action Water Mist System
Deluge Water Mist System
The SEM SAFE®High-Pressure Water Mist Pump Unit can serve any combination of these four
systems.
General description of Wet Pipe Water Mist System2.2
The wet system is a system using automatic nozzles attached to a piping system permanently filled
with water at maintained standby pressure. The system is activated when a thermal-sensitive glass
bulb in the automatic nozzle bursts, which is caused by an increase of the temperature at the nozzles
during fire. This creates a pressure drop in the system which activates the SEM SAFE®High-
Pressure Water Mist Pump Unit that immediately delivers water under high pressure to activated
water mist nozzle(s) located in the area of fire.
General description of Dry Pipe Water Mist System2.3
Dry pipe water mist system is a system using automatic nozzles attached to piping system
containing air under standby pressure. Protected sections are separated from the supply sources by
dry pipe section valve(s). The system is activated when a thermal-sensitive glass bulb in the
automatic nozzle bursts, which is caused by an increase of the temperature at the nozzles during
fire. It allows the water pressure to open a dry pipe section valve. The water then flows into the
piping system and discharges through any activated water mist nozzles located in the area of fire.
General description of Pre-action Water Mist System2.4
A pre-action water mist system is used where special precautions are required to avoid the water
mist being released unexpectedly in the protected rooms. It is using automatic nozzles attached to a
piping system containing air under standby pressure, with a supplemental detection system installed
in the same area at the water mist nozzles. The actuation of the detection system opens a valve that
allows water to flow into the piping system and discharge through any activated water mist nozzles.

PAGE 12 / 48
END USER MANUAL
OPERATION AND MAINTENANCE OF HIGH PRESSURE WATER MIST PUMP UNIT
REVISION 4, MAY 2016
General description of Deluge Water Mist System2.5
A deluge water mist system uses open (nonautomatic) nozzles attached to a piping system that is
connected to a high-pressure pump unit through a section valve which is opened by means of a
detection system installed in the same area as the water mist nozzles or manually. When the section
valve opens, water flows into the piping system and discharges through all water mist nozzles
attached to the system.
Pump unit component description3
The SEM-SAFE®High-Pressure Water Mist Pump Unit is constructed in a modular design. It
consists of 1 to 8 electrically driven high-pressure pumps supplying a high-pressure manifold,
control panel (UCP), pilot pump (to maintain pressure in the system in stand-by mode) and pressure
and flow controlling devices. All assemblies are mounted on a common skid frame.
Pump unit with unit tank3.1
During operation of the SEM-SAFE®High-Pressure Water Mist Pump Unit with unit tank, the water
from the unit tank is pressed from the pump through a non-return valve and into a common high-
pressure manifold. From there, water is discharged into sections of the protected area and reaches
water mist nozzles. The system pressure is regulated by a pressure relief valve, which is also a
dedicated safety valve, capable of bypassing the total capacity of the high-pressure pumps (when a
section valve or main valve is closed). The excess water from the valve is returned to the unit tank.
The picture below shows an example of a pump unit with the unit tank and water filter attached to
it. A detailed description of components is presented in the following chapters.

END USER MANUAL
OPERATION AND MAINTENANCE OF HIGH PRESSURE WATER MIST PUMP UNIT
REVISION 4, MAY 2016
PAGE 13 / 48
Pump unit with supply manifold (without unit tank)3.2
During operation of a SEM-SAFE®High-Pressure Water Mist Pump Unit with supply manifold
instead of unit tank, the water under low pressure (min. 1-3 bar) is delivered from an outside reservoir
into the supply manifold on the SEM-SAFE®High-Pressure Water Mist Pump Unit. Delivery is
performed either with the help of a booster pump between the reservoir and the supply manifold or
with the reservoir tank placed on a higher level than the SEM-SAFE®High-Pressure Water Mist
Pump Unit, ensuring positive water flow.
From the supply manifold, through the hoses, water is discharged into high-pressure pumps, which
are raising the water pressure to system pressure. Then, water under high pressure reaches the water
mist nozzles in protected areas.
The picture below shows an example of a SEM-SAFE®High-Pressure Water Mist Pump Unit with
the supply manifold. A detailed description of components is presented in the following chapters.
Figure 1. SEM-SAFE®High-Pressure Water Mist Pump Unit with unit tank

PAGE 14 / 48
END USER MANUAL
OPERATION AND MAINTENANCE OF HIGH PRESSURE WATER MIST PUMP UNIT
REVISION 4, MAY 2016
High-pressure pumps3.3
The high-pressure pumps are stainless steel, water-lubricated
positive displacement pumps with multiple pistons mounted in a
rotating cylinder, which reduce ripple and pulsation in the
discharge water stream. A typical SEM-SAFE®High-Pressure
Water Mist Pump Unit consists of 1 to 8 electrically driven,
stainless-steel high-pressure pumps.
During SEM-SAFE®High-Pressure Water Mist Pump Unit
activation, high-pressure pumps are pumping water from the water
supply to the manifold, discharging it to sections of the protected
area.
Figure 3. High-pressure pump
with electric motor
Figure 2. SEM-SAFE®High-Pressure Water Mist Pump Unit with supply manifold

END USER MANUAL
OPERATION AND MAINTENANCE OF HIGH PRESSURE WATER MIST PUMP UNIT
REVISION 4, MAY 2016
PAGE 15 / 48
Electric motors3.4
SEM-SAFE®High-Pressure Water Mist Pump Unit consists of 1 to 8 electric motors, each one
attached to a high-pressure pump.
Pilot pump (optional in Land and Marine applications)3.5
The function of the pilot pump is to establish and maintain a
pilot/standby pressure in the pipe system. The pilot pump will not
activate the SEM-SAFE®High-Pressure Water Mist Pump Unit. The
pilot pressure is set to a maximum 14 bar and minimum 10 bar and is
monitored by the system pressure transmitter.
Unit without pilot pump (marine systems)3.6
A SEM-SAFE®High-Pressure Water Mist Pump Unit without pilot pump is started by signal from a
separate Fire Detection Panel, or manually from the Valve Operation Panel (VOP), Local Call
Points or from the Unit Control Panel (UCP) by operating the pump start button. These systems are
mainly dry pipe Local Application or Total Flooding Systems.
Unit tank3.7
The unit tank is made of stainless steel grade AISI 316, the capacity of the tank is adapted to the
discharge capacity of the SEM-SAFE®High-Pressure Water Mist Pump Unit. As standard, the unit
tank capacities are 820l, but for large capacity units the tank capacity is 1200l. There is also
available a version of unit tank with capacity of 300l for special applications.)
One basic function of the unit tank is to establish an air gap between the supply source (public water
supply) and the water contained in the water mist system (backflow protection according to
standard DS/EN 1717). Its other function is supplying clean filtered water to the high-pressure
pumps and receiving surplus water from the pressure relief valve. Tank and pump skid must have
earth grounding.
Figure 4. Pilot pump

PAGE 16 / 48
END USER MANUAL
OPERATION AND MAINTENANCE OF HIGH PRESSURE WATER MIST PUMP UNIT
REVISION 4, MAY 2016
Example of unit tank automatic filling facilities for Land application:
Figure 5. Example of unit tank
Supply manifold3.8
The supply manifold delivers the water under low pressure (min. 1-3 bar) from the outside reservoir
into the SEM-SAFE®High-Pressure Water Mist Pump Unit. Delivery is performed either with the
help of a booster pump between the reservoir and the supply manifold or with the reservoir tank
placed on a higher level than the pump unit, ensuring positive water flow.
Alarm Level
Function
L5: Alarm at too high a
level
Alarm shown in display, system failure relay is de-energized and
high level relay is energized.
L4: Stop filling level
De-energize filling solenoid valve.
L3: Tank filling level
Energize filling solenoid valve.
L2: Alarm at too low a level
in tank
Activates alarm for low level in tank, shown in display, system
failure relay is de-energized and low level relay is energized.
L1: Low-low level in tank
Activates alarm in display, system failure relay is de-energized, all
high pressure pumps stopped.
Automatic pump restart at rising level in tank < 35cm

END USER MANUAL
OPERATION AND MAINTENANCE OF HIGH PRESSURE WATER MIST PUMP UNIT
REVISION 4, MAY 2016
PAGE 17 / 48
High-pressure manifold3.9
The high-pressure manifold collects and discharges water pumped from the pilot pump (wet system)
or high-pressure pumps through the main valve into the water mist distribution pipe system. The
main components attached to the manifold are described in the following chapters.
Figure 6. Example of supply manifold
Figure 7. Example of high-pressure manifold

PAGE 18 / 48
END USER MANUAL
OPERATION AND MAINTENANCE OF HIGH PRESSURE WATER MIST PUMP UNIT
REVISION 4, MAY 2016
Valves3.10
Main valve
The main valve is used for isolating the high-pressure pump system
from the rest of pipe system during service and maintenance.
Test valve
The test valve is used for the following operations and pump start procedures during maintenance
and service:
Relieving pressure on the high-pressure manifold
during maintenance and service operations
Test of pilot pump start and stop when pressure falls
High-pressure pump start when pressure falls, by 6 bar
pressure transmitter, by simulating system pressure
drop when the main valve is in the closed position
High-pressure start on falling pressure, 6 bar pressure
switch (back-up start) by simulating system pressure
drop when the main valve is in the closed position
Relieve pressure during manual start of high-pressure
pump(s)
Pressure controlling and monitoring devices3.11
Pressure relief valve
The purpose of the pressure relief valve is to maintain the
system pressure at the desired pressure level at any given
discharge and to avoid over pressurization. It is done by
relieving surplus pumping capacity back to the unit tank and
thereby keeping the system pressure constant at the pre-set
level.
The standard SEM-SAFE®High-Pressure Water Mist Pump
Unit is provided with one pressure relief valve installed in each
Figure 8. Main valve
Figure 9. Test valve
Figure 10. Example of
pressure relief valve

END USER MANUAL
OPERATION AND MAINTENANCE OF HIGH PRESSURE WATER MIST PUMP UNIT
REVISION 4, MAY 2016
PAGE 19 / 48
line between the high-pressure manifold and the high-pressure pump discharge gate. For VdS, FM
Global, and marine SEM-SAFE®High-Pressure Water Mist Pump Units, one single large capacity
pressure relief valve is used for the complete unit. The pressure relief valve is pre-set at the factory
acceptance test, and this setting should not be altered. Any service or repair of the valve should be
carried out by a service engineer.
System pressure transmitter
The system pressure transmitter has the following functions:
Displaying the actual system pressure in the alarm
display on the Unit Control Panel (UCP)
Start of the pilot pump or re-charge of pressure level at
system pressure of ca. <10bar
Stop of the pilot pump at system pressure of ca. >14bar
(Land applications) or ca. >12bar (Marine applications)
Initiating the high-pressure pump start sequence at
pressure level of less than 6bar (Land application) or
less than 10bar for more than 10 seconds (Marine
application)
The system pressure transmitter is monitored for wire break and short circuit. Wire break in the
cabling will not cause pump start.
Pressure switch
The 6 bar pressure switch is back-up for the system pressure transmitter used in Land applications
in order to secure monitoring of the system pressure, in case the system pressure transmitter has a
malfunction. The 6 bar pressure switch will activate the high-pressure pump starting sequence if
pressure is below 6 bar. A leak alarm is initiated if the pilot pump starts more than 2 times within 5
minutes
Filter system3.12
In order to avoid contamination, clogging of water mist nozzles and malfunction of pumps and
valves, the extinguishing water has to be filtered before it is delivered into the SEM-SAFE®High-
Pressure Water Mist Pump Unit. On pump units with a unit tank, the filter is mounted before the
water supply reaches the tank. On pump units with a supply manifold, the filter is mounted before
the water supply reaches the supply manifold, under condition that it is going through the booster
pump beforehand. If there is no booster pump, the filter must be placed before the reservoir tank.
Figure 11. Pressure transmitter

PAGE 20 / 48
END USER MANUAL
OPERATION AND MAINTENANCE OF HIGH PRESSURE WATER MIST PUMP UNIT
REVISION 4, MAY 2016
The required grade of filtration is 10µmeter. The ΔP across the filter cartridge should be limited to
1.5bar. Minimum water supply pressure through the filter system should not be less than 2.5bar and
max. 5.4bar.
Emergency back-up system3.13
In case of loss of power from the main supply and pressure drop under 5bar, the emergency back-up
system (cylinder unit) shall be capable of supplying the required pressure to the most remote nozzle in
the system, until emergency power is available for the pumping system, or not less than 1 minute of
operation. The capacity of the emergency back-up system shall contain the amount of water (H2O) to
cover the largest section of nozzles for 1
minute at the design pressure.
Nitrogen (N2) is used as prime mover of the
water for immediate operation in case of
pressure drop and power failure in a fire
situation. The (N2) is supplied in standard gas
cylinders at a filling pressure of about 200bar.
A pressure regulating device is mounted on the
(N2) cylinder bank in order to maintain the
system pressure at its pre-set value.
Figure 12. Emergency back-up system –N2cylinders
Figure 12. Filters