Grundfos Hydro EN 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
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..............................4
1.4 General safety warnings ......................5
2. System introduction ........................5
2.1 System description..........................5
2.2 Identification..............................7
3. Receiving the system .......................9
3.1 Transporting the system ......................9
3.2 Inspecting the system ........................9
3.3 Scope of delivery...........................9
3.4 Handling and lifting the system ..................9
4. Installation requirements ....................10
4.1 Location ...............................10
4.2 Diesel pumps with direct air cooling ..............11
4.3 Diesel pumps with water/water heat exchanger .......11
4.4 Diesel tank with containment basin and vent connection ..12
4.5 Exhaust gas outlet of the diesel pumps ............13
4.6 Exhaust back pressure ......................13
5. Mechanical installation .....................14
5.1 Foundation and anchorage....................15
5.2 Connecting the priming circuit ..................15
5.3 Connecting the recirculation circuits ..............15
6. Electrical installation ......................15
7. Functional diagram .......................16
8. Commissioning the system ..................17
9. Startup................................17
9.1 Alignment of the pumps......................17
9.2 Priming the pumps .........................18
9.3 Adjustment of the diesel pump speed .............18
10. Control functions .........................19
10.1 Operating panel for the jockey pump ..............19
10.2 Operating panel for the duty electric pump ..........21
10.3 Operating panel for the duty diesel pump ...........24
11. Service ...............................29
11.1 Maintenance ............................29
11.2 Verification and checks ......................30
12. Storage ...............................31
13. Fault finding ............................32
13.1 The electric pump does not start ................32
13.2 The diesel pump does not start .................32
13.3 The thermal relay trips (only for jockey pump) ........32
13.4 The flow rate of the system is not as desired .........32
13.5 Water hammer in the system...................32
13.6 Leaks from the mechanical seal.................32
14. Technical data ...........................33
14.1 Operating conditions........................33
15. Disposing ..............................33
15.1 Precautions for disposal .....................33
15.2 Disposing of the system......................33
1. General information
Read this document before you install the system.
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.
1.3 Target group
These installation and operating instructions are intended for
professional installers and for the operators of the system.
We recommend that installation is carried out by skilled persons
with technical qualifications required by the specific legislation in
force.
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English (GB)

1.4 General safety warnings
Before starting any operations, read carefully all the
documentation and manuals delivered with the system.
The terminals and wires upstream the main switch of
the control cabinet are live even if the switch is in OFF position.
DANGER
Electric shock
Death or serious personal injury
‐Before any inspection, maintenance, service or repair
of the system, make sure that the main switch is in
OFF position, locked and tagged. Attach suitable
isolation warning signs to prevent inadvertent
reconnection.
‐There are more than one control cabinets. Make sure
that you disconnect the correct one belonging to the
section of the system that needs intervention.
‐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.
‐Do not do maintenance work when the power supply is
switched ON.
WARNING
Electric shock
Death or serious personal injury
‐Before switching on the power supply, make sure that
the electrical insulation and protection are appropriate
to avoid unexpected contact with water.
WARNING
Crushing hazard
Death or serious personal injury
‐Any kind of activity or intervention on the system must
be performed by qualified and authorised persons.
‐Incorrect use may cause serious damage to the
system or even to the entire firefighting system
network.
CAUTION
Toxic material
Minor or moderate personal injury
‐Do not ingest oil, fuel or coolant. In case of accidental
ingestion, refer to the safety sheet of the specific
product.
CAUTION
Slipping hazard
Minor or moderate personal injury
‐Do not spill liquids, such as oil, fuel or coolant on the
floor, as it may get slippery.
‐Use adequate filling tools.
2. System introduction
2.1 System description
The Hydro EN systems 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 systems 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
coupling, bearing bracket and impeller without moving the motor,
pump housing or pipes.
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, can 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 system
starts automatically. The system 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 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.
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 systems.
The systems are equipped with the necessary instrumentation to
simplify the operations during tests and commissioning.
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English (GB)

Jockey pump
A jockey electric pump (always included), operated by a dedicated
control cabinet, automatically guarantees system pressurisation in
case of small leaks, to prevent unjustified start-up of the duty
pumps.
The jockey pump is equipped with a 24-litre tank.
Hydraulic components
The hydraulic components are selected and sized to minimise 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 components include the following:
• 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.
Control cabinet
An independent control cabinet is fitted for each duty pump with
operating and control buttons.
Each pump installed in the system, regardless of jockey or duty
pump either driven by electricity or diesel, is operated and
controlled through a dedicated control cabinet.
The operating modes must be set individually on each control
cabinet according to the specific needs.
Refer to the dedicated sections to each control cabinet for the
available functions and the relative activation procedures.
Accessories
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
- 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.
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10
11
12
13
14
15
9
2
3
4
7
5
6
9
8
TM066086
System components
Pos. Description
1 Diaphragm pressure tank, 24 litre (included)
2 Outlet manifold
3 Isolating valve
4 Control cabinet of the jockey pump
5 Grooved coupling
6 Connection to priming circuit
7 Jockey pump
8 Duty electric pump with spacer coupling
9 Independent inlet for pumps
10 Control cabinet of the standby diesel pump
Pos. Description
11
Fuel tank sized to ensure at least 6 hours of
continuous operation, complete with containment
basin
12
Starting circuit complete with two pressure
switches and a pressure gauge according to the
EN12845 standard
13 Non-return valve
14 Pressure sensor to detect pump operation
15 Standby diesel pump with cardan shaft coupling
6
English (GB)

2.2 Identification
2.2.1 Nameplate
All relevant system data are shown on a nameplate on the base
frame of the system.
7
8
9
10
11
2
1
3
6
5
4
Model:
Part number:
Production order:
Sales order:
Serial number:
Pressure Rating:
Pump 1
Pump 2
Pump 3
Pump 4
Pump 5
Pump 6
Jockey
Hydro EN 40-250/230 YJS ADL-U3-A
100000000001
B6042GIT 122023
99844380
1234567
15
17 (18,7)
1,5
Electric
Diesel
Electric
3x400V, 50Hz
1x230V, 50Hz
3x400V, 50Hz
Assembled in Italy
Driver type P [kW] Panel U-F [V-Hz]
Main supply:
Weight: kg
SEE TABLE
DK - 8850 - Bjerringbro - Denmark
PN16
845
TM079153
Example of nameplate
Pos. Description
1 Type designation
2 Product number
3 Serial number
4List of pumps included in the system and the drive
type of the pumps
5 Country of origin
6 CE mark
7 Power size of each pump
8 Mains supply voltage of each control cabinet
9 System pressure
10 Weight
11 Address of manufacturer
The following diagram shows the location of the nameplates.
1
1
TM079144
Position of the nameplates
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English (GB)

Pos. Description
1 Nameplates
The following nameplates and labels can also be found:
• pump nameplate (one per pump placed on the bearings bracket)
• nameplate of each electric motor or diesel engine (placed on the motor or engine)
• control cabinet label (one per each control cabinet placed on the side of the cabinet 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
Code Explanation Designation
Hydro EN System type
50-250/263 Example: NKF 50-250 impeller ∅263 Pump type
-Y
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 %)
Configuration
JS
JS: With a standard jockey pump
JV: With a customised jockey pump (on request)
NJ: Without a jockey pump (on request)
Jockey pump
A
A: Standard
B: IP55
N: Without control cabinet
X: Special execution control cabinet
Control cabinet
SD DL: Direct-on-line
SD: Star-delta Starting method
-U3
U1: 3 × 400 V, 50 Hz duty electric pump (or standby pump) - 3 × 400 V, 50
Hz jockey electric pump
U2: 1 × 220 V, 50 Hz duty diesel pump (or standby pump) - 3 × 400 V, 50
Hz jockey electric pump
U3: 3 × 400 V, 50 Hz duty electric pump (or standby pump) - 1 × 220 V, 50 Hz duty diesel pump
(or standby pump) - 3 × 400 V, 50 Hz jockey electric pump
Mains supply
-B A: Direct air with fan
B: Water/water heat exchanger
Diesel engine cooling,
if present
-X X: Other versions based on customer specifications (on request) Other versions
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English (GB)

3. Receiving the system
3.1 Transporting the system
The system has been prepared for shipment at the factory to
minimise potential damage during handling and transport.
CAUTION
Crushing hazard
Minor or moderate personal injury
‐Make sure that the cage is firmly anchored on the
truck before shipment.
‐Transport must be carried out by qualified persons.
Do not stress the pump excessively during handling and
transport.
During transport, take action to prevent the pump and
system components from freezing in bad weather
conditions.
3.2 Inspecting the system
Upon receipt of the system, do the following:
1. Make sure that the system and accessories correspond to the
order and there are no missing parts.
2. Make sure that the packaging is intact.
3.3 Scope of delivery
All systems are supplied as factory-tested. The wooden cage
contains:
• 1 Hydro EN system
• installation and operating instructions in digital format
- for the system
- for the duty electric pumps
- for the jockey electric pump
- for the pressure switches
• IOS manual with EC declaration of conformity (in paper copy)
• electrical diagrams of the control cabinets
• assembling and setting verification
• two copies of the nameplate of the system in addition to the one
on the base frame of the system
• 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, request these during the
bidding process.
3.4 Handling and lifting the system
To facilitate handling, systems are shipped from the factory in pre-
assembled blocks designed for transport by forklift or similar lifting
equipment.
WARNING
Overhead load
Death or serious personal injury
‐Make sure that the area below and around the lifted
system is clear of people during operations.
‐Do not allow anyone to stand on, under, or near the
load.
WARNING
Crushing hazard
Death or serious personal injury
‐Before starting any handling operations with the
package, make sure that all the bolts for anchoring the
system to the package are in place.
‐Before lifting, make sure that the load is balanced.
‐Whenever possible, handle the system with a forklift.
‐When using chains or belts, hook the system to the
base in the correct lifting points.
‐Never use the lifting eyes of the individual components
to lift the system.
‐Lock the cabinet door before moving the system.
‐Only use the lifting equipment which is in proper
condition and suitable for lifting the weight and the
shape of the system.
‐Handling operations must be carried out by qualified
and authorised persons.
CAUTION
Crushing hazard
Minor or moderate personal injury
‐Make sure that the package is integral before handling
operations.
CAUTION
Sharp element
Minor or moderate personal injury
‐Use the dedicated DPI (gloves) to remove the
packaging.
TM079146
Lifting the electric system
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English (GB)

TM079145
Lifting the diesel system
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 systems are described in
the EN 12845 standard. You also need to refer to the local
regulations if applicable.
4.1 Location
DANGER
Crushing hazard
Death or serious personal injury
‐The system must be installed in an access-
controlled area. Make sure that only qualified and
authorised persons have access to this area.
‐If the site is left unattended before the installation is
completed, all openings must be covered to prevent
children or any other foreign objects, such
as animals and stones, from entering.
‐Use unbreakable covers that cannot be removed
without tools.
WARNING
Crushing hazard
Death or serious personal injury
‐Leave necessary space in the technical room during
design for installing, using, maintaining and
disassembling the system.
‐The design of the technical 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 technical room dimensions are adequate for the system
to be installed.
• The room has proper air circulation.
The system 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 section Operating conditions.
Pay attention to the correct evacuation of diesel engine
exhaust gases. For this purpose, adequate ventilation ducts must
be installed.
The technical room of the system must be properly sized according
to existing regulations and good practices. You must take the
following into account:
• the overall dimensions of the system
• easy access to the parts of the system for commissioning,
routine checks and maintenance
• adequate air exchange in the room to ensure proper cooling
of the machines.
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 to ensure
elimination of heat generated during operation and adequate
cooling of the machines.
Openings and ventilation ducts for hot air evacuation must be
dimensioned based on analytic calculation.
• Large openings must be protected to prevent people
or animals from entering.
• Use unbreakable protection that cannot be removed
without tools.
Related information
14.1 Operating conditions
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English (GB)

4.1.1 Minimum space
The pictures below give an indication of the minimum free space
to be left around the system.
A
A
A
TM079150
Top view of the technical room
B
TM079149
Side view of the technical room
Pos. Description
A Minimum 800 mm
B Minimum 2400 mm
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
In the system, 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 pressurised even after the engine has been shut off.
CAUTION
Hot surface
Death or serious personal injury
‐Open the coolant tank cap only when the engine is
cold and only if strictly necessary.
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.
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.
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 system 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 system.
For values of minimum flow required to pass through the heat
exchanger, refer to the performance curves of the system.
1
2
3
456
8
7
A
TM079138
Heat exchanger
11
English (GB)

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
8Pressure 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 room ventilation
Related information
5.3 Connecting the recirculation circuits
11.2.2.5 Cleaning the circuit of the heat exchanger
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 to avoid
concentration of fuel vapours in the technical room.
‐Periodically check the integrity of the vent pipe.
CAUTION
Harm to persons
Minor or moderate personal injury
‐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 system or even to the entire
firefighting system network.
‐Smoking and live flames are prohibited when
refuelling.
The diesel pump is 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 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.
1
2
TM079137
Fuel tank
Pos. Description
1 Connection for vent pipe
2 Sight glass
12
English (GB)

4.5 Exhaust gas outlet of the diesel pumps
WARNING
Toxic material
Death or serious personal injury
‐The exhaust pipe and the muffler must be installed
properly so that all the parts are firmly supported
without an extra load on the engine.
‐All connections must be perfectly sealed to avoid gas
leakage inside the technical room.
‐Check periodically the integrity of the exhaust pipe.
‐The outlet of the exhaust pipe must be positioned far
from passage areas or areas where people are
stationed, in accordance with current regulations.
‐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
system to fail.
CAUTION
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.
‐Surfaces may remain hot after the system has been
shut off. Do not touch the hot surface before it cools
down. If it is not possible to wait, wear protective
gloves.
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
using 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 system.
The exhaust gases must be discharged from the technical 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.
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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 system
during its operation.
‐Installations in territories with seismic characteristics
must also be carefully evaluated.
‐Incorrect or not lasting supports may cause serious
damage to the system or even to the entire firefighting
system network.
‐The design and execution of the supports of the
system must be properly carried out in accordance
with the relevant standards and regulations by
specialists commissioned by the client.
Do not step or walk on the components of the system.
Do not place other parts or equipment on the system
components.
The system is supplied in pre-assembled blocks which must be
assembled before performing any operation.
The system must be placed on a flat and smooth surface, for
example, on a solid floor or a concrete foundation.
The control cabinet of the diesel pump must be detached from the
motor frame and fixed to the ground to avoid the propagation of
vibrations to the electrical components.
A robust electrical earth connection between the engine frame and
the control cabinet 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
Earth connection
Pos. Description
1 Cable for earth connection
If necessary, the fuel tank can 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 at the same height, to ensure
that the fuel feeds the injection pump by gravity.
The pipes connected to the system 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 system according to the requirements of the EN
12845 standard so that the weight of the pipes does not rest on the
pumps.
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5.1 Foundation and anchorage
WARNING
Crushing hazard
Death or serious personal injury
‐The anchoring system must guarantee the stability
and alignment of the system over time and have
mechanical characteristics such as withstanding static
and dynamic loads, as well as vibrations of the system
during its operation.
‐Installations in territories with seismic characteristics
must also be carefully evaluated.
‐Incorrect or not lasting anchorage may cause serious
damage to the system or even to the entire firefighting
system network.
‐The design and execution of the anchoring
system must be properly carried out in accordance
with the relevant standards and regulations by
designer appointed by the client.
If a seismic analysis is required, consult the governing
bodies for grouting and foundation requirements.
To avoid critical situations, we recommend that
you contact a civil engineering designer or an equivalent
to check and approve the support structure and anchoring
system.
The system 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 system.
The width and length of the foundation must be larger than the size
of the system 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 system.
• Hydraulic components are not included in the scope of
delivery of the system.
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
‐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.
‐Before installing any connections, check the
compatibility of the system supply voltage.
CAUTION
Harm to persons
Minor or moderate personal injury
‐Before connecting to batteries, make sure that the
cables are connected correctly according to the
electrical diagram.
‐Before charging the batteries, check that the charger
is compatible with the voltage and capacity of the
batteries.
‐This operation must be carried out by qualified
persons.
‐Make sure that the neutralizing powder for battery
acid is always available in the technical room.
‐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.
‐Do not place tools on or near the batteries. This could
result in a short circuit.
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 cabinet and the duty and jockey pumps
are suitable for the mains voltage to be used with.
Make sure that the control cabinet 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 cabinet 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 cabinet.
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7. Functional diagram
PSS
PSS
PSL
PSS PSS
PSL
PSSS
1
3
4
6
9
10
B
2
5
8
7
9
11
C
E12
13
14
D
A
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
Non-return valve
Ball valve
Butterfly valve
Symbol Description
Concentric divergent
Eccentric divergent
[=] Grooved coupling
Flowmeter
PSS
Pressure switch
Pressure gauge
Diaphragm pressure tank
Control cabinet
Drain connection
Power and signal connections
Main and auxiliary flow pipes
Related information
5.3 Connecting the recirculation circuits
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8. Commissioning the system
CAUTION
Pressurised system
Minor or moderate personal injury
‐Before filling and pressurising the pipes, make
sure that all the hydraulic connections are properly
tightened and there are no open circuit parts.
‐Water is under pressure inside the pipes. Be
careful and keep a safe distance from the pipes.
Before commissioning, recharge the batteries for at least 12 hours
with an external battery charger before using them for the system.
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.
9. Startup
WARNING
Automatic startup
Death or serious personal injury
‐The system can start up automatically at any time. The
operating noise level of the system is high and the
system must be installed in an access-controlled area.
‐Ear protection must be carried by, or available to, all
persons authorised to enter the technical room.
‐Observe the health and safety regulations and limit
the exposure of persons to excessive noise.
The system can start up automatically but can only be stopped
manually under automatic operation mode via a dedicated key
removable from the control cabinet. Due to regulation of fire safety
and protection of the system, it is required not to have any
emergency stop.
WARNING
Harm to persons
Death or serious personal injury
‐Clearly indicate where the key is stored in the
technical room.
‐Each time when people enter the technical room, or
before any inspection, maintenance, service or repair
of the system, make sure that the key is available on
site.
WARNING
Pressurised system
Death or serious personal injury
‐Keep a safe distance from the system when you are in
the technical room.
‐Check periodically the proper tightening of hydraulic
connections and the integrity of all the components.
CAUTION
Hot surface
Minor or moderate personal injury
‐Surfaces may remain hot after the system has been
shut off. Do not touch the hot surface before it cools
down. If it is not possible to wait, wear protective
gloves.
For mode of operations and checks, refer to the dedicated section.
9.1 Alignment of the pumps
DANGER
Automatic startup
Death or serious personal injury
‐The system 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 system, make sure that the main switch is in
OFF position, locked and tagged. Attach suitable
isolation warning signs to prevent inadvertent
reconnection.
‐In case of diesel 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.
‐Make sure that you wear suitable clothing on site. Do
not let long hair down, wear loose or frayed clothing or
jewelry to avoid being trapped into the equipment.
‐Do not place fingers, hands, arms or tools into any
openings.
‐Under no circumstances should the system be
operated, when the coupling guard is not in place and
suitably secured.
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Alignment of the duty electric pumps
WARNING
Crushing hazard
Death or serious personal injury
‐Check regularly the alignment of the spacer coupling
based on the operation time.
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 system 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 system 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.
Alignment of the duty diesel pumps
WARNING
Crushing hazard
Death or serious personal injury
‐Check regularly that 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.
9.2 Priming the pumps
Before starting the priming operations, read
the installation and operating instructions.
CAUTION
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
(on request) 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 system.
The following procedure must be repeated for each pump in the
system.
1. Make sure that all the other pumps in the system are switched
off.
2. Close all isolating valves on the outlet side of the pump and test
circuit (if present).
3. Open the inlet isolating 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 manual position and start the pump.
7. Vent the pump.
In some cases, it may be necessary to repeat the procedure
described above several times to completely purge the air from the
pumps.
9.3 Adjustment of the diesel pump speed
Changing the speed of the diesel pump can compromise
the proper functioning of the system and must 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 better meet the demands of the plant, and for this
purpose, fasteners are provided on accelerator which limit the
adjustment possibilities.
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10. Control functions
10.1 Operating 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 allows safe maintenance.
ALARMPOWER
2
1
TM066090
Operating panel for the jockey pump
The operating panel includes the following components and
functions available in the door:
Pos. Description
1 Door-lock disconnector (lockable)
2 Control interface
The control interface 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.
10.1.1 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 cabinet to keep the jockey pump operating in emergency mode.
The wiring diagram shows how to enable this operating mode.
10.1.2 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.
10.1.3 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.
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10.1.4 Jockey pump protection against dry-running
The jockey pump control cabinet is designed for dry-running
protection.
This function is disabled at the factory. The factory setting is DRY %
trimmer set on value zero and physical jumper on the terminal
board.
If necessary, you can activate the dry-running protection during
commissioning.
The dry-running condition can be detected in two ways (according
to a specific setting):
• Through a threshold of current absorbed by the motor,
by setting a value (% of the motor current) to DRY % with
the trimmer. If the detected current is under this set value, the
pump stops and dry-running alarm is activated.
• Through a level switch (not included in the scope of supply),
by setting a value to DRY % (factory set to 0%) with the
trimmer to enable a contact of a level switch that stops the pump
and activates the alarm in case of water shortage.
The alarm automatically resets after one minute if the current value
returns above the set threshold (or the level switch contact is
closed). After three unsuccessful attempts within 60 minutes, a
manual reset is required.
The setting procedure is described in detail in the wiring diagram
supplied with the system.
10.1.5 Prolonged operation alarm
Prolonged operation alarm is given if the pump runs continuously
for more than eight hours.
This function is disabled at the factory and if necessary, can be
activated by the user during commissioning by following the
procedures below:
1. Set the main switch to OFF position.
2. Press and hold the STOP button.
3. Set the main switch to ON position while keeping the STOP
button pressed.
4. After a few flashes of all the LEDs, release the STOP button.
5. Now, by pressing the START button, the thermal alarm LED
turns on and off:
• With the LED on, the function is activated.
• With LED off, the function is deactivated.
6. To confirm the desired selection, wait for five seconds without
pressing any button.
7. Turn the main switch to OFF position.
The alarm condition must be reset manually.
The setting procedure is described in detail in the wiring diagram
supplied with the system.
10.1.6 Jockey pump operating panel alarms
The LEDs on the operating panel, in addition to their main meaning
already described, can signal different alarm conditions by means of
flashing modes.
The table below shows the possible flashing modes.
Flashing
mode
LED ON time
[sec]
LED OFF
time [sec]
Pause
time [sec]
ON 50/50 0.5 0.5 0
ON 3/4 1.5 0.5 0
5 flashes 0.2 0.2 1
10 flashes 0.2 0.2 1
The alarms available are described below.
For more detailed information, refer to the wiring diagram.
LED (mode) Alarm effect Reset Factory
setting
Thermal overload
Alarm condition: the motor current is higher than the set value
(with trimmer AMP %).
ON fix
Pump stop,
LED indication Auto reset 1) Active
Clicson
Alarm condition: the Clicson contact on the motor is tripped.
ON 50/50
Pump stop,
LED indication Manual reset Inactive
Unbalanced main supply phases
Alarm condition: the difference in current between the monitored
phases is greater than 30 %.
ON 3/4
Pump stop,
LED indication Manual reset Active
Missing phase
Alarm condition: in at least one of the monitored phases, the
current is zero.
ON 3/4
Pump stop,
LED indication Manual reset Active
Dry Run protection - analogic (set trimmer DRY % > 0)
Alarm condition: the motor current is lower than the set value (with
trimmer DRY %).
ON fix
Pump stop,
LED indication Auto reset 2) Inactive
Dry Run protection - digital (set trimmer DRY % = 0)
Alarm condition: the contact of the dry-running level switch (not
included in the scope of supply) is open.
ON fix
Pump stop,
LED indication Auto reset1) Inactive
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