Grundfos Hydro 50-250/263 YJS ASD-U3-B User manual

Hydro EN
Grundfos firefighting systems
Installation and operating instructions
Hydro EN
Installation and operating instructions
(all available languages)
http://net.grundfos.com/qr/i/99901851
GRUNDFOS INSTRUCTIONS

Hydro EN
English (GB)
Installation and operating instructions ..........................................................4
Български (BG)
Упътване за монтаж и експлоатация.........................................................36
Español (ES)
Instrucciones de instalación y funcionamiento ...................................................70
Français (FR)
Notice d'installation et de fonctionnement .....................................................103
Ελληνικά (GR)
Οδηγίες εγκατάστασης και λειτουργίας........................................................136
Italiano (IT)
Istruzioni di installazione e funzionamento .....................................................170
Lietuviškai (LT)
Įrengimo ir naudojimo instrukcija ............................................................202
Português (PT)
Instruções de instalação e funcionamento .....................................................234
Română (RO)
Instrucţiuni de instalare şi utilizare ...........................................................268
Русский (RU)
Паспорт, Руководство по монтажу и эксплуатации.............................................301
Türkçe (TR)
Montaj ve kullanım kılavuzu ................................................................336
Українська (UA)
Інструкції з монтажу та експлуатації ........................................................368
(AR) 
    ......................................................................402
Declaration of conformity ................................................................434
3
Table of contents

English (GB) Installation and operating instructions
Original installation and operating instructions
Table of contents
1. General information ........................4
1.1 Hazard statements..........................4
1.2 Notes ..................................4
1.3 Target group..............................5
1.4 General safety warnings ......................5
2. Product introduction........................6
2.1 Product description .........................6
2.2 Identification..............................7
3. Receiving the product.......................9
3.1 Inspecting the product........................9
3.2 Documentation ............................9
3.3 Transportation of the product ...................9
3.4 Handling and lifting the product ..................9
4. Installation requirements ....................10
4.1 Installation room ..........................10
4.2 Diesel pumps with direct air cooling ..............11
4.3 Diesel pumps with water/water heat exchanger .......11
4.4 Diesel tank withcontainmentbasin andventconnection . ..13
4.5 Exhaust gas outlet of the diesel pumps ............14
4.6 Exhaust back pressure ......................14
5. Mechanical installation .....................15
5.1 Foundationandanchorage ....................16
5.2 Connecting the priming circuit ..................16
5.3 Connecting therecirculation circuits...............16
6. Electrical installation ......................16
7. Functional diagram .......................17
8. Startup................................18
8.1 Alignment of the pumps......................18
8.2 Priming the pumps .........................19
9. Control functions .........................20
9.1 Control panel ............................20
9.2 Operating modes..........................30
10. Service ...............................31
10.1 Maintenance ............................31
10.2 Verificationsand checks ......................31
11. Storage ...............................33
12. Fault finding ............................34
12.1 The electric pump does not start ................34
12.2 The diesel pump does not start .................34
12.3 The thermal relay trips (onlyfor jockey pumps) ........34
12.4 The flow rate of thepumpset is notas desired .........34
12.5 Water hammer in the system...................34
12.6 Leaks from the mechanical seal.................34
13. Technical data ...........................35
13.1 Operating conditions........................35
14. Disposing..............................35
14.1 Precautionsfordisposal ......................35
14.2 Disposing of the product .....................35
1. General information
Read this document before you install the product.
Installation and operation must comply with local
regulations and accepted codes of good practice.
1.1 Hazard statements
The symbols and hazard statements below may appear in Grundfos
installation and operating instructions, safety instructions and
service instructions.
DANGER
Indicates a hazardous situation which, if not avoided, will
result in death or serious personal injury.
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious personal injury.
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate personal injury.
The hazard statements are structured in the following way:
SIGNAL WORD
Description of the hazard
Consequence of ignoring the warning
• Action to avoid the hazard.
1.2 Notes
The symbols and notes below may appear in Grundfos installation
and operating instructions, safety instructions and service
instructions.
Observe these instructions for explosion-proof products.
A blue or grey circle with a white graphical symbol
indicates that an action must be taken.
A red or grey circle with a diagonal bar, possibly with a
black graphical symbol, indicates that an action must not
be taken or must be stopped.
If these instructions are not observed, it may result in
malfunction or damage to the equipment.
Tips and advice that make the work easier.
4
English (GB)

1.3 Target group
These installation and operating instructions are intended for
professional installers and for the operators of the product.
We recommend that installation is carried out by skilled persons
with technical qualifications required by the specific legislation in
force.
1.4 General safety warnings
Before starting any type of operation, read carefully all the
documentation and manuals delivered together with
the product.
Water is in pressure inside the piping.
CAUTION
Pressurised system
Minor or moderate personal injury
‐Before filling and pressurizing the pipes, make
sure that all the hydraulic connections are properly
tightened and that there are no parts of the circuit
open.
‐Keep attention and safe distance from the piping.
‐Make sure to gradually decrease the pressure and
empty the piping before operating. This operation must
be carried out by qualified personnel.
CAUTION
Toxic material
Minor or moderate personal injury
‐Do not ingest oil, fuel or coolant. In case of ingestion,
refer to the safety sheet of the specific product.
The fire pump set can start up automatically at any time.
WARNING
Automatic startup
Death or serious personal injury
‐The operating noise level of the product is
high and the product must be installed in a access-
controlled area.
‐Ear protection should be carried by, or readily
available to, all persons authorized to enter the pump
room.
‐Observe health and safety regulations and limit
the exposure of personnel to excessive noise.
WARNING
Electric shock
Death or serious personal injury
‐Before switching on the power supply, make sure
that the electric insulation and protection is correct in
order to avoid unexpected contact with water.
DANGER
Electric shock
Death or serious personal injury
‐Before any inspection, maintenance, service or repair
of the product, make sure that the mains switch is in
OFF position, locked and tagged. Attach suitable
isolation warning signs to prevent inadvertent
reconnection.
‐In case of diesel-driven pumps, isolate the fuel supply
to the engine and disconnect the batteries by
removing the negative terminal connector, before
working on any part of the fuel supply or control
system.
DANGER
Mechanical injury
Death or serious personal injury
‐If the system is not set as out of order, it is mandatory
to maintain a safe distance from any of its parts.
DANGER
Trapping hazard
Death or serious personal injury
‐Make sure that you wear suitable clothing on site. Do
not wear loose or frayed clothing, long free hair or
jewellry to avoid being trapped into the equipment.
DANGER
Automatic startup
Death or serious personal injury
‐Do not place fingers, hands, arms, tools and so on into
any opening.
WARNING
Trapping hazard
Death or serious personal injury
‐During your presence in the technical room, keep your
distance from the pumping system.
Surfaces may remain hot after fire pump set has been shut off.
CAUTION
Hot surface
Minor or moderate personal injury
‐Do not touch hot surfaces. Wait for their cooling.
‐If it is not possible to wait, wear protective gloves.
CAUTION
Slipping hazard
Minor or moderate personal injury
‐Do not spill liquids (oil, fuel and coolant) on the floor
which could become very slippery.
Use adequate filling tools.
Any kind of activity or intervention on the fire pump must
be operated by qualified and authorized personnel.
Incorrect use can cause serious damage to the fire pump
set or even to the system.
5
English (GB)

The fire pump set can only be stopped manually under automatic
operation mode via a dedicated key removable from the control
panel. Due to the regulation for fire and the active protection of the
pumping system, it is required not to have any emergency stop.
Clearly indicate which location in the technical room the
key is stored.
Each time when the personnel enters the technical room,
or before any inspection, maintenance, service or repair of
the product, make sure that the key is available on site.
Check periodically the proper tightening of hydraulic
connections and the integrity of all the components.
2. Product introduction
2.1 Product description
The Hydro EN pump sets for automatic sprinkler systems are in
compliance with the requirements of EN 12845 - Fixed firefighting
systems - Automatic sprinkler systems - Design, installation and
maintenance.
The Hydro EN pump sets are designed for automatic sprinkler
systems such as single, superior single, duplicate or combined
water supply sources.
The pumps are of the back pull-out design, enabling removal of the
motor, coupling, bearing bracket and impeller without disturbing the
pump housing or pipes.
All pump sets are supplied as factory-tested units. In addition, the
diesel pumps are supplied with a factory test report as required by
the EN 12845 standard.
The range consists of the following types:
• S version: One or two duty pumps operated by an electric motor.
• Y version: Two duty pumps. One pump is operated by an
electric motor and the other pump is operated by a diesel
engine.
• T version: One or two duty pumps operated by a diesel engine.
Duty pumps
Each duty pump, built on a robust baseplate, is able to deliver
100% of the required flow rate.
In case of a two-pump system, the second pump is an active
backup in case the first is not effective.
The system with three duty pumps is also available upon request,
each delivering 50% of the required flow rate (two pumps in
operation simultaneously deliver the required performance).
In case of catching fire, the network pressure drops, the pump set
starts automatically. The pump set continues to run until someone
stops it manually. If necessary and permitted by local regulation,
you can activate the "automatic stop function" (always included but
factory-disabled) that automatically shut down the running duty
pump through an adjustable timer.
The shape of the QH curve is stable.
Motors or engines are sized according to EN12845 prescriptions.
The diesel pump is cooled in one of the following solutions
according to the power size:
• with direct air
• with water/water heat exchanger.
The fuel tank is sized to ensure at least 6 hours of continuous
operation and is equipped with a containment basin and vent
connection.
An industrial silencer is supplied as standard for diesel pump sets.
Jockey pump
A jockey electric pump (always included), operated by a dedicated
control panel, automatically guarantees system pressurization in
case of small leaks, in order to prevent unjustified start-up of the
main pumps.
The jockey pump is equipped with a 24-litre tank.
Control unit and other components
The hydraulic components are selected and sized in order to
minimize the pressure losses and the water speed in compliance
with the requirements in the EN 12845 standard, at any flow rate
value stated on the performance curve.
The systems described above include the following:
• an independent control panel for each duty pump with operating
and control buttons
• two pressure switches for each duty pump which are
hydraulically connected to each other with a manifold of 15 mm
in diameter
• a pressure switch on each duty pump to detect the actual
pressure supplied
• connection for the priming circuit and connection for the
recirculation circuit to prevent overheating of the pump when
running against closed valves.
The pump sets are equipped with the necessary instrumentation to
simplify these operations during tests and commissioning.
Scope of supply and accessories
All pump sets are supplied as factory-tested. In addition, the diesel
pumps are supplied with a factory test report as required by the EN
12845 standard.
The scope of supply can be completed with the following
accessories:
• a suction kit dedicated for installation in suction-lift or in positive
head conditions, including:
- an eccentric divergent pipe with a controlled taper,
- a vacuum pressure gauge, and
- an isolating valve (not included in the version for installation
in suction-lift conditions).
All accessories are sized according to the prescriptions of the
standard.
• a testing kit including a flowmeter, valves and straight pipe
sections to get the optimum flow rate reading.
6
English (GB)

2.2 Identification
2.2.1 Nameplate
All relevant system data are shown in a nameplate on the base
frame of the pump set.
Type:
Prod No:
Serial No:
Made in Italy
Grundfos Pompe Italia S.r.l., 20060 Truccazzano, Italy
Hydro EN 50-250/263 YJS ASD-U3-B
99844392
A21000001
Power kW
Jockey pump:
Electric pump:
Main supply (*)
2,2
37
Diesel pump: 41
3x400V / 50Hz
3x400V / 50Hz
1x220V / 50Hz
(*) Control panel main supply
2
1
3
4
4
46
6
8
7
5
5
5
6
TM079153
Example of nameplate
Pos. Description
1 Type of the pump set
2 Product number
3 Serial number
4List of pumps included in the pump set and the drive
type of the pumps
5 Power size for each pump
6 Main supply voltage of each control panel
7 CE mark
8 Country of origin
The following diagram shows the location of the nameplates.
1
1
TM079144
Pos. Description
1 Nameplates
Position of the nameplates
7
English (GB)

The following nameplates and labels can also be found:
• pump nameplate (one per pump placed on the bearings bracket)
• the nameplate of each electric motor or diesel engine (placed on the motor or engine)
• control panel label (one per each control panel placed on the side of the panel or the inner side of the front door, depending on the model).
2.2.2 Type key
Example Hydro EN 50-250/263 -Y JS A SD -U3 -B -X
Pos. 1 2 3 4 5 6 7 8 9
Pos. Description
1Pump set type:
Hydro EN
2Pump type:
50-250/263 (Example: NKF 50-250 impeller ∅263)
3
Configuration:
S1: One duty electric pump (100 %)
S2: One duty electric pump and one standby electric pump (100 % + 100 %)
S3: Two duty electric pumps and one standby electric pump (50 % + 50 % + 50 %)
T1: One duty diesel pump (100 %)
T2: One duty diesel pump and one standby diesel pump (100 % + 100 %)
T3: Two duty diesel pumps and one standby diesel pump (50 % + 50 % + 50 %)
Y: One duty electric pump and one standby diesel pump (100 % + 100 %)
Y1: Two duty electric pumps and one standby diesel pump (50 % + 50 % + 50 %)
Y2: One duty electric pump, one duty diesel pump and one standby diesel pump (50 % + 50 % + 50 %)
4
Jockey pump:
JS: With a standard jockey pump
JV: With a customised jockey pump (upon request)
NJ: Without a jockey pump (upon request)
5
Control panel:
A: Standard
B: IP55
N: Without control panel
X: Special execution control panel
6
Starting method:
DL: Direct-on-line
SD: Star-delta
7
Main supply:
U1: 3 x 400 V, 50 Hz duty electric pump (or standby pump) - 3 x 400 V, 50 Hz jockey electric pump
U2: 1 x 220 V, 50 Hz duty diesel pump (or standby pump) - 3 x 400 V, 50 Hz jockey electric pump
U3: 3 x 400 V, 50 Hz duty electric pump (or standby pump) - 1 x 220 V, 50 Hz duty diesel pump (or
standby pump) - 3 x 400 V, 50 Hz jockey electric pump
8
Diesel engine cooling, if present:
A: Direct air with fan
B: Water/water heat exchanger
9Other versions:
X: Other versions based on customer specifications (upon request)
8
English (GB)

3. Receiving the product
3.1 Inspecting the product
On receipt of the product, do the following:
1. Make sure that the pump set corresponds to the order and that
accessories, if any, are not missing.
2. Make sure that the packaging is intact.
3.2 Documentation
All pump sets are delivered with the following documents in
digital format:
• installation and operating instructions for the pump set with EC
declaration of conformity
• installation and operating instructions for the duty electric pumps
• installation and operating instructions for
the jockey electric pumps
• installation and operating instructions for the pressure switches
• electrical diagrams of the control panels
• assembling and setting verification
• two copies of the nameplate of the pump set in addition to the
one on the base frame of the pump set
• pump performance curves.
If available, the kit for measuring the flow rate is supplied with the
installation and operating instructions of the flowmeter.
If a diesel pump is available, the following documents are also
delivered:
• installation and operating instructions for the diesel engine
• safety data sheet for the batteries
• factory test report for the diesel pump as described in the EN
12845 standard.
If you need specific documents or any additional hard or digital
copies of the documents listed above, please request
these during the bidding process.
3.3 Transportation of the product
The pump set has been prepared for shipment at the factory to
minimize potential damage due to handling and transport.
Do not stress the pump excessively during handling and
transport.
Make sure that the cage is firmly anchored on the truck
before shipment.
Transport must be carried out by qualified personnel.
During transport, take action to prevent the pump and
system components from freezing in bad weather
conditions.
3.4 Handling and lifting the product
Before starting operation, read carefully all documentation
and manuals delivered together with the fire pump set.
DANGER
Overhead load
Death or serious personal injury
‐Make sure that the area below and around the lifted
product is clear of people during operations.
WARNING
Overhead load
Death or serious personal injury
‐Only use the lifting equipment whichis in proper
condition and is suitable to lift the weight and the
shape of the fire pump set.
CAUTION
Sharp element
Minor or moderate personal injury
‐Use the dedicated DPI (gloves) to remove the
packaging.
To facilitate handling, pump sets are shipped from the factory in pre-
assembled blocks designed for transport by forklift or similar lifting
equipment.
Never use the lifting eyes of the individual components to
lift the system.
Make sure that the package is integral before operations.
Before you start any handling operation of the
package, make sure that all the bolts to anchor the
product to the package are in place.
Handling operations must be carried out by qualified and
authorized personnel.
Whenever possible, handle the fire pump set with a
forklift.
Before lifting, make sure that the load is balanced.
When using chains or belts, lift the fire pump set to the
base by the correct lifting points.
Lock the cabinet door before moving the fire pump set.
9
English (GB)

TM079146
Lifting the electric unit.
TM079145
Lifting the diesel unit.
See also the installation and operating instructions for the diesel
engine.
4. Installation requirements
Refer to the system design for the information of the room
installation, specifically for the construction works, ventilation, air
exchange, power supply system and the evacuation
of the exhaust gases of the diesel engine. The installation must be
carried out timely by specialists appointed by the client in
compliance with relevant regulations and provisions.
The main criteria for installing firefighting pump sets are described
in the EN 12845 standard. You also need to refer to the local
regulations if applicable.
4.1 Installation room
Leave necessary space in the installation room during
design for installing, using, maintaining and disassembling
the fire pump.
The design of the installation room must be carried out by
a qualified designer appointed by the client in accordance
with local regulations.
Before installation, make sure the following items are fulfilled:
• The installation room dimensions are adequate for the pump set
to be installed.
• The room has proper air circulation.
The product must be installed in an access-
controlled area. Make sure that only qualified persons
have access to this area.
If the site is left unattended before the installation is
completed, all openings must be covered to
prevent foreign objects from entering, such as children,
animals and stones.
Use unbreakable covers that cannot be removed without
tools.
The Hydro EN pump sets must be installed in a weatherproof room
protected from freezing. The room must be well ventilated to
ensure proper cooling of the electric motors and diesel engines.
Make sure that the operating conditions do not exceed those stated
in Technical data.
Pay attention to the correct evacuation of diesel engine
exhaust gases. For this purpose, adequate ventilation ducts must
be installed.
The installation room of the pump set must be properly sized
according to regulations in force and good practices. You must take
the following into account:
• the overall dimensions of the pump set
• easy access to the parts of the pump set for commissioning,
routine checks and maintenance
• the need to have an adequate exchange of air in the room to
ensure proper cooling of the machines.
10
English (GB)

The pictures below give an indication of the minimum free space
to be left around the pump set.
A
A
A
TM079150
• A: Minimum 800 mm
Top view of the installation room
B
TM079149
• B: Minimum 2400 mm
Side view of the installation room
When sizing room openings for effective air exchange,
also consider the place of installation and the presence of
other machines or heat sources in the same room.
The installation of motors and engines in closed environments
always requires proper circulation of fresh air in the room in order to
ensure elimination of heat generated during operation and
adequate cooling of the machines.
Openings and ventilation ducts for hot air evacuation should be
dimensioned based on analytic calculation.
• Large openings must be protected in order to
prevent people or animals from entering.
• Use unbreakable protection that cannot be removed
without tools.
Related information
13.1 Operating conditions
4.2 Diesel pumps with direct air cooling
A fan, driven by the engine itself, generates air flow that is
conveyed to the engine and ensures cooling. The heat is then
released into the environment and must be extracted from the
room.
4.3 Diesel pumps with water/water heat exchanger
WARNING
Hot surface
Death or serious personal injury
‐Open the coolant tank cap only when the engine is
cold and only if strictly necessary.
In the Hydro EN pump sets, the cooling of liquid-cooled engines is
provided by a water/water heat exchanger with an expansion tank.
When the engine is warm, a pressure, which will cause hot liquid to
be discharged by extreme forces, is created in the cooling circuits.
This results in a danger of burning. The cooling circuits may remain
hot and pressurized even after the engine has been shut off.
The engine is cooled by the water of the firefighting system.
Do not let the engine run at a speed lower than the
nominal speed. A low speed rotation may cause an
insufficient cooling flow of water through the heat
exchanger and a possible engine damage due to
overheating.
The heat exchanger cooling system has the following parts:
• a water/water heat exchanger with expansion tank
• a manometer with indication of the operational area at the inlet
of the expansion tank
• a circuit consisting of a filter and a valve with hydraulic control
and pressure regulator
• a bypass circuit with gate valve.
Do not restrict or block the outlet of the heat exchanger.
Avoid long and tortuous routes that can restrict the flow of
passage water. Do not fit any component in the outlet pipe
(gate valve or other) that can affect the proper circulation
of cooling water.
Install the outlet pipe of the heat exchanger to visually
inspect the effectiveness and correctness of water
circulation.
The heat exchanger outlet must be installed close to the
diesel pump.
Clean the filter regularly, and make sure that there is
proper water circulation in the cooling system.
Make sure that the flow through the cooling system meets
the minimum requirement as specified in the technical
documentation for the specific model.
The outlet of the heat exchanger must be connected to
the drain pipe with a flexible joint to avoid any mechanical
stress on the heat exchanger.
11
English (GB)

The heat exchanger circuit is connected to the pump outlet just
before the check valve with a pipe of appropriate size.
During pump operation, a part of the flow of the pump set circulates
through the heat exchanger to provide cooling for the diesel engine.
This flow does not contribute to the supply of the firefighting system
and must be considered in the hydraulic calculation and when
choosing the pump set.
For values of minimum flow required to pass through the heat
exchanger, refer to the performance curves of the pump set.
1
2
3
456
8
7
A
TM079138
Heat exchanger
Pos. Description
A. Outlet of the cooling flow
1. Isolating valve: Normally open
2.
Bypass isolating valve: Normally closed
The bypass line must only be used for
service purposes.
3. Isolating valve: Normally open
4Valve with hydraulic control: Normally closed
It opens when the motor starts.
5. Flow regulator: To adjust the inlet flow to the exchanger
6. Filter
7. Heat exchanger with expansion tank
8. Pressure gauge with the optimum operational area
indicated
Most of the heat is dissipated by the described cooling
system. Despite this, the running engine emits a certain amount of
energy in the form of heat into its environment. Therefore, it is
necessary to ensure that the ventilation openings are sized to
maintain the desired temperature in the room.
The following figure shows a possible solution:


TM079152
Example of ventilation room
Related information
5.3 Connecting the recirculation circuits
10.2.2.5 Cleaning the circuit of the heat exchanger
12
English (GB)

4.4 Diesel tank with containment basin
and vent connection
CAUTION
Toxic material
Minor or moderate personal injury
‐The fuel vent pipe must be installed properly and
make sure that all the parts are firmly supported and
all the connections are perfectly sealed in order to
avoid concentration of fuel vapours in the technical
room.
‐Periodically check the integrity of the vent pipe.
Smoking and live flames are prohibited when refuelling.
During refuelling, use adequate refuelling tools and
avoid lifting excessive loads, which can cause falls or
musculoskeletal problems.
Use appropriate lifting techniques and do not bend the
waist.
Only use suitable fuel (refer to the engine manual). The
unsuitable fuel can ignite flames and/or cause serious
damage to the fire pump set or even to the system.
The diesel pump are equipped with a fuel tank equipped with a
containment basin. The capacity of the containment basin equals to
the capacity of the tank itself.
The basin prevents diesel from leaking if the tank breaks or leaks.
As seen in the figure below, there is a sight glass (pos. A) on the
side of the basin for a visual check of the tank. The diesel tank is
also supplied with a connection for the vent pipe (pos. B).
B
A
TM079137
Pos. Description
A Sight glass
B Connection for vent pipe
Fuel tank
13
English (GB)

4.5 Exhaust gas outlet of the diesel pumps
WARNING
Toxic material
Death or serious personal injury
‐All connections must be perfectly sealed in order to
avoid gas leakage inside the technical room.
‐Check periodically the integrity of the exhaust pipe.
‐The discharge of the exhaust pipe must be positioned
far from passage areas or areas where people are
stationed, in accordance with current regulations.
Surfaces may remain hot after the fire pump set has been shut off.
DANGER
Hot surface
Death or serious personal injury
‐The exhaust pipe and the muffler must be insulated
and protected by materials suitable for high
temperatures, to avoid contacting with extremely hot
parts and to prevent heat from being released into the
technical room.
‐Check periodically the integrity of the insulation layer.
‐Do not touch the hot surface before it cools down.
‐If it is not possible to wait, wear protective gloves.
The design and installation of the exhaust pipe must be
carried out by a qualified designer, appointed by the client,
in accordance with local regulations.
Incorrect sizing of the exhaust pipe can cause the fire
system to fail.
The exhaust gas duct must be:
• arranged to allow the gas to exit outdoors directly or through a
pipe, depending on the regulations in force at the place of
installation
• protected from weather conditions
• positioned so that they do not disturb people or damage any
equipment
• made of steel, sufficiently strong and perfectly sealed.
• installed properly so that all the parts including the muffler are
firmly supported without an extra load on the engine.
If the muffler is directly mounted on the engine, use
a flexible joint to connect the exhaust outlet pipe to avoid
any mechanical stress on the engine.
Due to thermal expansion of the exhaust gas ducts, we recommend
to use compensation joints suitable for the application.
A suitable condensation collection and a drain point is also
required.
4.6 Exhaust back pressure
Wrong sizing of the exhaust pipe can affect correct
operation of the pump set.
As previously stated, the exhaust gases must be discharged from
the installation room avoiding long ducts. Long ducts create a high
back pressure, this makes the discharge of the gases difficult and
reduces the efficiency of the engine.
After having followed all the precautions for discharging the exhaust
gases in an optimum manner, it is necessary to check the back
pressure value at the exhaust by measuring it under the
following conditions:
• with the exhaust gas system in its final configuration
• after warming up the engine
• at full load
• at the nominal speed of the engine defined for the specific
model.
The resulting value cannot be greater than the maximum value
recommended by the manufacturer of the engine.
14
English (GB)

5. Mechanical installation
WARNING
Crushing of hands
Death or serious personal injury
‐All pipes must be supported.
‐Supports for pipes and components must guarantee
the stability over time and have mechanical
characteristics such as withstanding static and
dynamic loads, as well as vibrations of the pump
set during its operation.
Do not step or walk on the components of the pump sets.
Do not place other parts or equipment on the pump set
components.
Installations in territories with seismic characteristics must
also be carefully evaluated.
The design and execution of the supports of the pump
set must be properly carried out in accordance with the
relevant standards and regulations by specialists
commissioned by the client.
Incorrect or not lasting supports may cause serious
damage to the fire pump set or even to the system.
The pump set is supplied in pre-assembled blocks which need to be
assembled before performing any operation.
The pump set must be placed on a flat and smooth surface, for
example, on a solid floor or a concrete foundation.
The control panel of the diesel pump must be detached from the
motor frame and fixed to the ground in order to
avoid the propagation of vibrations to the electrical components.
A robust electrical earth connection between the engine frame and
the control panel stand must be made with a cable with
a large cross-section (equal to or larger than that of the delivered
cable) or a metal braid.
1
1
TM079132
Pos. Description
1. Cable for earth connection
Earth connection
The fuel tank can, if necessary, be removed from the motor frame.
In this case, make sure that the tank is positioned on the same
foundation as the engine, or at least to the same height, to ensure
that the fuel feeds the injection pump by gravity.
The pipes connected to the pump set must be of adequate size
and the inlet pipes must comply with the criteria listed in the EN
12845 standard regarding the water speed in the pipes (1.8 m/s for
positive head installation and 1.5 m/s for suction-lift installation).
Special attention must be paid to choosing components and the
path of the inlet pipes which must ensure that
the available NPSH at the pump inlet port is at least 1 m greater
than the required NPSH, at the maximum flow rate required.
Always prevent the inlet pipe from having a reverse gradient that
results in a drain-trap effect.
If the inlet pipe fails to deliver the liquid to the pump in
this condition, it can lead to noisy operation, swirling of liquid
around the suspended pump , premature bearing failure
and cavitation damage to the impeller and inlet of the casing.
Installation of pipe supports is always required on the outlet and
inlet side of the pump set according to the requirements of the EN
12845 standard so that the weight of the pipes do not rest on
the outlet manifold (and on the inlet manifold, if present) or on the
pumps.
15
English (GB)

5.1 Foundation and anchorage
The anchoring system must guarantee the stability and
alignment of the fire pump set over time and have
mechanical characteristics such as withstanding static
and dynamic loads, as well as vibrations of the unit during
its operation.
The design and execution of the anchorage of the pump
set must be properly carried out in accordance with the
relevant standards and regulations by designer appointed
by the client.
Installations in territories with seismic characteristics must
also be carefully evaluated.
If a seismic analysis is required, consult the governing
bodies for grouting and foundation requirements.
Incorrect or not lasting anchorage may cause serious
damage to the pump set or even to the whole system.
In order to avoid critical situations, we recommend that
you contact a civil engineering designer or an equivalent
to check and approve the support structure and
anchorage system.
The Hydro EN pump set must be placed on a flat surface such as
a solid floor or a concrete foundation.
As a rule of thumb, the weight of the concrete foundation should
be at least 1.5 times the weight of the pump set.
The width and length of the foundation must be larger than the size
of the pump set it accommodates.
The fastening must ensure tightness over time and must withstand
the vibration of the system during operation.
5.2 Connecting the priming circuit
In accordance with the requirements of the EN 12845 standard, the
pumps are equipped with connections for priming as a mandatory
requirement for suction-lift installation.
1. Connect the priming circuit by using the 2-inch connection on
the pump set.
• Hydraulic components are not included in the scope of
delivery of the pump set.
5.3 Connecting the recirculation circuits
In accordance with the requirements of the EN 12845 standard, the
pumps are equipped with connections for the recirculation circuit.
1. In the case of electric pumps or diesel pumps with direct air
cooling, use the 1-inch plug available on the outlet side to
connect the recirculation circuit to the inlet tank.
2. In the case of diesel pumps with water/water heat exchanger
cooling system, the circulation is performed through the cooling
system.
• See the dedicated section for diesel pumps with water/water
heat exchanger.
• Use the functional diagram as reference.
Related information
4.3 Diesel pumps with water/water heat exchanger
7. Functional diagram
6. Electrical installation
WARNING
Electric shock
Death or serious personal injury
‐Before any inspection, maintenance, service or repair
of the product, make sure that the mains switch is in
OFF position, locked and tagged. Attach suitable
isolation warning signs to prevent inadvertent
reconnection.
‐Typically, there is more than one control panel. Make
sure you have disconnected the correct panel with
respect to the section of the system on which you
have to intervene.
WARNING
Electric shock
Death or serious personal injury
‐Before starting any connection, check the compatibility
of the system power supply voltage .
DANGER
Electric shock
Death or serious personal injury
‐Do not do maintenance work when the power supply is
ON.
The design of the electric system and the electrical
installation must be carried out by a qualified electrician,
appointed by the client, in accordance with local
regulations.
The terminals and wires upstream of the main switch of
the control panel are supplied even if the switch is in OFF position.
Make sure that all connections, including the electrical
connections, are correct and are carried out in accordance with all
the applicable regulations and provisions in terms of security and
fire prevention.
Make sure that the control panel and the duty and jockey pumps
are suitable for the mains voltage to be used with.
Make sure that the control panel is mechanically disconnected from
the frame of the diesel engine and is fixed to the ground.
A robust earth connection between the engine frame and the
control panel stand must be made with a cable of a large cross-
section (equal to or larger than that of the delivered cable)
or a metal braid.
Use connection cables of adequate cross-section for
the current required by the pump and in compliance with
the requirements of the EN 12845 standard.
Refer to the wiring diagrams supplied in the scope of delivery for
the electrical connections of the control panel.
16
English (GB)

7. Functional diagram
PSS
1
PSS
PSL
PSS PSS
PSL
PSSS
2
3
45
8
67
9
9
12
11 13
14
10
A
BCD
E
TM066085
Functional diagram
Pos. Connection/description
1Independent inlet connection
for the duty electric pump
2Independent inlet connection
for the standby diesel pump
3 Inlet connection for the jockey pump
4Recirculation circuit connection
for the duty or standby electric pump
5Recirculation circuit connection for the duty or
standby diesel pump with direct air cooling
6Priming circuit connection for the duty or
standby electric pump
7Priming circuit connection for the duty or
standby diesel pump
8 Priming circuit connection for the jockey pump
9 System outlet connection
10 Connection for technical room sprinkler
11 Test circuit outlet
12 Diesel tank vent
13 Cooling circuit outlet with water/water heat
exchanger, if present
14 Diesel engine exhaust gas outlet
A Scope of supply limits
B Duty electric pump
C Jockey pump
D Standby diesel pump
E Diaphragm pressure tank
Symbol Description
Check valve
Ball valve
Symbol Description
Butterfly valve
Concentric divergent
Eccentric divergent
[=] Grooved coupling
Flowmeter
PSS
Pressure switch
Pressure gauge
Diaphragm pressure tank
Control panel
Drain connection
Power and signal connections
Main and auxiliary flow pipes
Related information
5.3 Connecting the recirculation circuits
17
English (GB)

8. Startup
Before starting any type of operation, carefully read the
contents of this installation and operating instructions
and the accompanying documentation.
WARNING
Electric shock
Death or serious personal injury
‐Do not place tools on or near the batteries. This could
result in a short circuit.
‐Before connecting to batteries, make sure that the
cables are connected correctly according to the
electrical diagram.
CAUTION
Slipping hazard
Minor or moderate personal injury
‐Avoid spilling liquids (oil, fuel and coolant) on the floor
which could become very slippery.
Use adequate filling tools.
Correctly top up the fluids (oil, coolant and fuel) in the
engine.
• Before commissioning, recharge the batteries for at least 12
hours with an external battery charger before using them for
the pump set.
Do not weld near the batteries and make sure that
there is a good ground connection to
avoid current leakage that can damage the batteries.
Before charging the batteries, check that the charger
is compatible with the voltage and capacity of the
batteries.
These operations must be carried out by qualified
personnel.
Make sure that the neutralizing powder for battery
acid is always available in the technical room.
Prime the pumps by filling the inlet pipes and the pumps with liquid,
making sure that no air pockets are left in the system.
• Check the alignment of the couplings of the pumps after fixing
all the hydraulic connections.
• Make sure that all the gate valves for the heat exchanger circuit
are fitted in the operational configuration.
• Make sure that all connections, including the electrical
connections, are correct and are carried out in accordance
with all the applicable regulations and provisions in terms of
security and fire prevention.
• Check the tightness and sealing of all hydraulic connections.
• Make sure that the positioning and tightening of the exhaust gas
duct for the diesel pump is correct.
• Make sure that there is adequate ventilation in the room to
ensure proper cooling of machines in order not to exceed the
operating conditions.
For mode of operations and checks, refer to the dedicated section.
8.1 Alignment of the pumps
8.1.1 Alignment of duty electric pumps
DANGER
Automatic startup
Death or serious personal injury
‐The fire pump set can start up automatically at any
time. If the system is not set as out of order, it is
mandatory to keep a safe distance from any of
its parts.
‐Before any inspection, maintenance, service or repair
of the product, make sure that the mains switch is in
OFF position, locked and tagged. Attach suitable
isolation warning signs to prevent inadvertent
reconnection.
DANGER
Trapping hazard
Death or serious personal injury
‐Make sure that you wear suitable clothing on site. Do
not wear loose or frayed clothing, long free hair or
jewellry to avoid being trapped into the equipment.
‐Do not place fingers, hands, arms, tools, etc. into any
opening.
Under no circumstances should the fire pump set be
operated, when the coupling guard is not in place and
suitably secured.
Check the alignment regularly based on the operation
time of the pump set.
The coupling between the pump and electric motor is operated via
spacer coupling. The alignment of this coupling is of fundamental
importance for the proper functioning of the pump set and must be
carried out by trained persons.
Although the motors and pumps are aligned with precision in the
factory, after having them installed and connecting the pump set to
the pipes, further alignment must be performed.
This is necessary due movement and tensions occurred during
• transport
• pipe connection.
It is also important to check the alignment after the first
startup, when the machine has reached working temperature.
Follow the detailed procedure in the relevant installation and
operating instructions of the pump.
18
English (GB)

8.1.2 Coupling of duty diesel pumps
DANGER
Automatic startup
Death or serious personal injury
‐The fire pump set can start up automatically at any
time. If the system is not set as out of order, it is
mandatory to keep a safe distance from any of
its parts.
‐Before any inspection, maintenance, service or repair
of the product, make sure that the mains switch is in
OFF position, locked and tagged. Attach suitable
isolation warning signs to prevent inadvertent
reconnection.
‐In case of diesel-driven pumps, isolate the fuel supply
to the engine and disconnect the batteries by
removing the negative terminal connector, before
working on any part of the fuel supply or control
system.
DANGER
Trapping hazard
Death or serious personal injury
‐Make sure that you wear suitable clothing on site. Do
not wear loose or frayed clothing, long free hair or
jewellry to avoid being trapped into the equipment.
‐Do not place fingers, hands, arms, tools, etc. into any
opening.
Under no circumstances should the fire pump set be
operated, when the coupling guard is not in place and
suitably secured.
Check on a regular basis, if all screws are in place
and correctly tightened.
The coupling between the pump and diesel engine is operated
via cardan shaft. This kind of coupling do not require specific
alignment.
8.2 Priming the pumps
Before starting the priming operations, read
the installation and operation instructions.
WARNING
Electric shock
Death or serious personal injury
‐Make sure that all protections and cover of the electric
parts are in place and secured.
CAUTION
Pressurised system
Minor or moderate personal injury
‐Pay attention to the direction of the vent hole and
make sure that no person can be hurt by the
escaping liquid.
In the case of suction-lift installations, an automatic priming
device is provided and installed for each duty pump.
During commissioning and when necessary (for example, in case of
service), ensure correct priming of the pump. Refer also to the
documentation for the pumps supplied with the pump set.
The following procedure must be repeated for each pump in the
pump set.
1. Make sure that all the other pumps in the pump set are switched
off.
2. Close all shut-off valves on the outlet side of the pump and test
circuit (if present).
3. Open the inlet gate valve of the pump to prime.
4. Remove the priming cap and slowly pour water into the pump
until it is completely filled.
5. Put the cap back on and carefully close it.
6. Set the operating mode selector switch of the pump to
prime to MAN position and start the pump.
7. Vent the pump.
In some cases, it may be necessary to repeat the procedure
described above several times in order to completely purge the air
from the pumps.
8.2.1 Adjustment of the diesel pump speed
Changing the speed of the diesel pump can compromise
the proper functioning of the pump set and should only be
performed by qualified persons.
A low rotation speed implies a lower flow of water to the
heat exchanger and a possible engine damage due to
overheating.
The rotation speed of the diesel pump is fixed at the factory during
testing operations. It is possible to adjust the speed during the first
start-up to be able to better meet the demands of the plant, and for
this purpose, fasteners are provided on accelerator which limit the
adjustment possibilities.
19
English (GB)

9. Control functions
9.1 Control panel
9.1.1 Control panel for the jockey pump
The jockey pump is controlled by a dedicated panel that
automatically manages the operation of the pump based on the
state in a low-voltage powered pressure switch, isolated from the
network by a transformer.
The starting method of the electric motor is direct-on-line (DL).
A lockable general door-lock disconnector (pos. A) allows safe
maintenance.
ALARMPOWER
B
A
TM066090
Control panel for the jockey pump
The panel includes the following components and functions
available in the door:
Pos. Component
A Door-lock disconnector (lockable)
B Control interface
The control interface (pos. B) has the following luminous indications
and actuation keys:
• LED - power supply present
• LED - pump running
• LED - automatic operating mode active
• LED - intervention of thermal protection
• LED - Intervention of protection against dry running.
Manual START button (unstable condition)
STOP button
Button to enable automatic operation
By pressing this button, the pump starts and stops
according to the pressure switch setting.
9.1.1.1 Operating modes of jockey pump
Manual operating mode
Start the pump manually by pressing and
holding the START button. The pump stops once the START button
is released.
Automatic operating mode
Push the automatic mode button. The pump starts and stops
according to the pressure switch setting.
The automatic mode can be disabled by pressing the STOP button.
Emergency operating mode (control board failure)
Use the emergency operating mode only when you
are replacing the control board. In this operating mode, all
the protections are not active.
If the control board is in failure, you can move a connector inside
the panel to keep the jockey pump operating in emergency mode.
The wiring diagram shows how to enable this operating mode.
Related information
9.2 Operating modes
9.1.1.2 Motor thermal protection setting
You can set the motor protection current by setting the dip switch
(SW1) to select one out of the eight values. The setting procedure
is described in detail in the wiring diagram supplied with the system.
Each one of the above values, if needed, can be increased up to
130% by setting on the trimmer AMP%.
If the motor current is above the set value, the pump stops and a
dedicated LED is lit.
If the current value returns below the set threshold, the alarm
resets automatically after one minute. After three unsuccessful
attempts within five minutes, a manual reset is required.
9.1.1.3 Clicson motor protection
If the motor of the jockey pump is equipped with a Clicson, this can
be used to identify the condition of overtemperature and to stop the
pump.
The alarm condition must be reset manually.
This function is disabled at the factory and if necessary, can be
activated by the user during commissioning by removing the
bridge between the relevant terminals and connecting the Clicson.
Refer to the wiring diagram for the Clicson connection.
20
English (GB)