Grundfos Fire DNF User manual

Fire DNF,
Fire HSEF - diesel
GRUNDFOS INSTRUCTIONS
Installation and operating instructions

Declaration of Conformity
We, Grundfos, declare under our sole responsibility that the products
Fire DNS and Fire HSEF - diesel, to which this declaration relates, are in
conformity with these Council Directives on the approximation of the laws
of the EC Member States:
— Machinery Directive (98/37/EC)
Standards used: EN 12100-1: 2003, EN 12100-2: 2003 and
EN 809: 1998.
— Low Voltage Directive (2006/95/EC)
Standards used: EN 60204-1: 2006 and EN 60439-1: 1999.
— EMC Directive (2004/108/EC)
Standards used: EN 61000-6-2: 2005 and EN 61000-6-3: 2007.
Wahlstedt, 1st September 2009
Stephan Göttsche
General Manager
2

3
CONTENTS
Page
1. Symbols used in this document 3
2. Applications 4
3. Delivery, transport, storage 4
3.1 Delivery 4
3.2 Transport 4
3.3 Storage 5
4. Product description 5
4.1 Fire pump set 5
4.2 Pump 7
4.3 Engine 7
4.4 Controller 11
4.5 Functions 15
4.6 Operating and alarm messages 18
5. Settings 21
5.1 Settings via DIP switches 21
5.2 Settings via display 22
6. Identification 23
6.1 Type keys 23
6.2 Nameplates 26
7. Technical data 27
7.1 Complete fire pump set 27
7.2 Pump 27
7.3 Engine 28
7.4 Battery 28
7.5 Controller 28
8. Operating conditions 28
8.1 Minimum inlet pressure 28
8.2 Maximum inlet pressure 28
8.3 Minimum flow rate 28
8.4 Pumped liquids 28
8.5 Liquid temperature 28
8.6 Pump speed 28
8.7 Maximum operating pressure 28
8.8 Ambient temperature 29
8.9 Relative air humidity 29
8.10 Effect of ambient temperature and altitude
on engine output 29
9. Installation 29
9.1 Installation site 29
9.2 Foundation 29
9.3 Vibration dampening 30
9.4 Levelling 30
9.5 Pipework 31
9.6 Bypass 31
9.7 Connection to the cooling system 31
9.8 Connection to the pressure sensor 31
9.9 Priming tank and test pipe 31
9.10 Fresh air supply 31
9.11 Exhaust gas system 32
9.12 Alignment 32
9.13 Separate fuel tank 33
9.14 Separate control cabinet 34
10. Electrical connection 34
10.1 Controller on base frame 34
10.2 Wall- and floor-mounted controller 34
10.3 Connection to standard alarm relays 35
10.4 Connection to optional alarm relays 35
11. Start-up 36
11.1 Check before start-up 36
11.2 Start-up 36
11.3 Setting of cut-in and cut-out pressures 36
12. Operation 36
12.1 Automatic operation 36
12.2 Manual operation 37
12.3 Test run 37
12.4 Retrieving and printing data 37
13. Taking the pump out of operation 39
14. Maintenance 39
14.1 Fire pump set 39
14.2 Maintenance intervals 39
14.3 Pump 40
14.4 Diesel engine 40
14.5 Coupling 43
14.6 Controller 43
15. Fault finding 44
16. Service, spare parts and accessories 45
17. Warranty 45
18. Further documentation 45
19. Dimensions, weights and engine data 46
19.1 Dimensions and weights 46
19.2 Engine data 48
20. Disposal 49
1. Symbols used in this document
Safety instructions placed directly on the fire pump set:
Warning
Prior to installation, read these installation and
operating instructions. Installation and operation
must comply with local regulations and accepted
codes of good practice.
Warning
If these safety instructions are not observed, it
may result in personal injury.
Warning
If these instructions are not observed, it may lead
to electric shock with consequent risk of serious
personal injury or death.
Warning
The surface of the product may be so hot that it
may cause burns or personal injury.
Warning
The sound pressure level is so high that hearing
protection must be used.
Caution
If these safety instructions are not observed, it
may result in malfunction or damage to the
equipment.
Note
Notes or instructions that make the job easier
and ensure safe operation.
Warning
The engine starts automatically.
Use hearing protection.
Warning
Do not remove safety devices.
Warning
Fill the engine with a cooling liquid
consisting of a mixture of 50 %
coolant and 50 % water before start-
up.
Warning
The pressure in the equalisation tank
must not exceed 60 psi or 4.1 bar.
Warning
In order to prevent damage, the
cooling circuit must be connected
before making the electrical
connection of the cooling water
heater.
WARNING
THIS EQUIPMENT STARTS
AUTOMATICALLY
USE EAR PROTECTION
C13187
WARNING
KEEP
GUARDS
IN PLACE
C13190
WARNING
PREMIXING 50%
TREATED WATER
AND 50% ANTI/FREEZE
COOLANT SOLUTION
PRIOR TO INSTALLING
IS REGUIRED
C13185
WARNING
60 P.S.I. MAX.
C13182
WARNING
C13187
TO PREVENT HEATER DAMAGE.
INSTALL ENGINE COOLANT BEFORE
HEATHER IS ENERGIZED
120 VAC
+5% -10% SINGLE PHASE
1500 W P/N: C124091 12.6 AMPS

4
2. Applications
The Grundfos Fire HSEF and DNF pump sets are designed for
fire systems for supplying water to hose reels, fire hydrants and
sprinkler systems.
The Grundfos Fire HSEF and DNF pump sets with diesel engine
must not be used for ordinary pumping of liquids or common
pressure boosting in daily work. They should only be used for fire
fighting.
The pump controller must not be used as a junction box for
supplying other equipment.
3. Delivery, transport, storage
3.1 Delivery
The fire pump set is delivered from factory in an open wooden
box or wooden/cardboard box which is specifically designed for
transport by fork-lift truck or similar device.
3.2 Transport
For lifting the entire fire pump set, use the lifting holes of the base
frame. When lifting, the lifting point should always be above the
centre of gravity of the fire pump set. See fig. 1.
Fig. 1 Correct lifting of fire pump set
Warning
In order to prevent damage, the drive
shaft must be lubricated regularly with
the correct lubricant.
Warning
Do not let the engine run without an air
filter.
This may cause personal injury or
damage to the engine.
Warning
This lifting point is only for lifting the
engine, not the entire fire pump set.
Warning
Hazardous voltages are present in this
enclosure. Improper use or failure to
take precautions can cause serious
injury, electric shock and/or damage
to the equipment.
Lifting points for the entire fire pump set.
Warning
The fire pump set must only be used for the
applications mentioned. Any other use is
considered improper use. Grundfos cannot be
held responsible for damage caused by improper
use. The liability rests solely with the operator.
DRIVESHAFT MUST BE LUBRICATED
PRIOR TO START UP AND EVERY
12 MONTHS FOLLOWING WITH A
N.L.G.I GRADE 1 OR 2 GREASE.
REFER TO OPERATOR AND MAINTENANCE
MANUAL FOR CORRECT PROCEDURE.
CAUTION
C13258
CAUTION
DO NOT RUN ENGINE WITHOUT
AIR FILTER INSTALLED.
PERSONAL INJURY OR
ENGINE DAMAGE MAY
RESULT.
C13191
!
WARNING
LIFTING BRACKET
IS FOR ENGINE ONLY
C13186
Hazadous voltages are present
inside this enclosure. Serious
injury, electrocution and/or
equipment damage will result of
improper application or if
precaution is not used.
Disconnect all supply sources
(including any foreign circuits)
before working om controller,
motor(s) or pump(s).
Only qualified personnel should
work on or around this
equipment.
Note
Check the fire pump set carefully on delivery
against the papers and inspect for damage
incurred during transport. Immediately notify the
carrier of any damage or shortage found.
Transport and store it correctly before
installation.
Warning
Lifting the fire pump set should only be done by
qualified personnel.
When lifting the entire fire pump set, never use
the lifting eyes of the individual components.
Use only suitable lifting equipment in proper
condition. See also weight specifications in
section 7. Technical data.
During transport of the fire pump set, the cabinet
door must be closed and locked.
Do not stand or place hands under a component
in such a way that the component would fall on
the hands if dropped.
TM03 7770 4806

5
3.3 Storage
3.3.1 Pump
To prevent water, dust, etc. from entering the pump, all openings
must be covered until pipes are connected. Apply a suitable
antirust agent on all machined, non-coated surfaces.
The antirust agent must meet these requirements:
• It must not attack rubber parts.
• It must be easy to remove.
• It must be applied according to the instructions of the
manufacturer.
If the pump must be stored for more than six months before start-
up, it must be protected against corrosion and damage:
1. Remove the stuffing box packing.
2. Spray the interior part of the pump case and the stuffing box
with a water-soluble type of antirust agent.
3. If the pump has not been connected to the pipework, cover the
pump suction and discharge flanges with full natural rubber
gasket material, and blank off these openings with metal
blanking flanges. Use at least four bolts for fastening.
4. Cover the opening of the stuffing box with a non-hygroscopic
tape. The stuffing box gland may be left on the pump shaft, but
must be wired or otherwise securely fastened in position.
5. Coat all exposed painted surfaces with an antirust agent that
can be readily removed with a petroleum distillate product.
6. Make sure that all exposed painted surfaces are dry, clean and
free of grease and other contaminates.
7. Cover the pump with a weather-resistant cover of waterproof
paper or plastic material to protect it against dirt and dust.
8. Inspect the pump at regular intervals during storage.
9. Rotate the shaft by hand every four to six weeks to prevent
pitting of the bearings.
3.3.2 Engine
Engines may be stored for up to 12 months in a dry room after
delivery. It is advisable to protect the engine with an air-
permeable cover. At least once a month, the engine should be
checked for accumulation of dirt or water. Any dirt or water must
be removed immediately.
If the engine is stored for more than 12 months or stopped for
more than six months, it must be protected against corrosion and
damage:
1. Drain the engine of oil, and replace the oil filter.
See service instructions.
2. Fill the engine housing with MIL-L-21260 oil.
See service instructions.
3. Replace the fuel filter. See service instructions.
4. Separate the engine from the pump by removing the coupling.
See service instructions.
5. Turn on the engine. See section 12.2 Manual operation.
Let it run for one or two minutes.
6. Drain oil and cooling liquid. See service instructions.
7. Drain fuel. To do so, loosen the drain screw in the tank bottom
(fig. 50, pos. A) and collect the diesel fuel in a suitable
container. After draining, tighten the drain screw in the tank
bottom.
Repeat these steps every six months.
4. Product description
4.1 Fire pump set
The fire pump set consists of a pump, a diesel engine with fuel
tank, and a controller. Pump and engine are connected via a drive
shaft or a flexible coupling. All components are adapted to each
other and mounted on a common base frame ready for
installation. The base frame is made of steel channel. The
controller and fuel tank can also be placed separately. This is
normally done in connection with JW6 and JX6 diesel engines.
The fire pump set comes ready for operation. The engine is filled
with cooling water, engine oil, etc. The batteries are filled with
acid and charged. The fuel system is vented, and the fuel tank
has a small quantity of diesel fuel. The correct engine speed has
been preset from factory.
As an example, the most important components of the fire pump
set are shown in figures 2 and 3. They show an HSEF pump set
with a Grundfos horizontal split case pump and a 4-cylinder
diesel engine, type JUH4, without turbocharger and charge air
cooler. Pump and engine are connected by a drive shaft. The
controller is mounted on the common base frame, and the fuel
tank is placed separately. The fuel tank is not shown.
Caution
Put a warning label on the engine:
Engine without oil. Do not start the engine.

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Fig. 2 Fire pump set with JU4H and JU6H diesel engine, front view
Fig. 3 Fire pump set with JU4H and JU6H diesel engine, back view
TM04 5064 2609TM04 5065 2609
1
11
22
23
29
53
26
17
2
2428
21
16
12
19
18
Pos. Component
1 Base frame
2 Controller
3Pump
4 Automatic air release valve (not shown)
5 Coupling with coupling guard
6 Fuel tank (not shown)
7 Manual filling pump for fuel tank (not shown)
8 Tank cap (not shown)
9 Filling level indicator, fuel tank (not shown)
10 Fuel tap (not shown)
11 Control panel of diesel engine
12 Air filter
13 Turbocharger (not this model)
14 Charge air cooler (not this model)
15 Device for crankshaft venting (optional, not shown)
16 Flexible exhaust pipe (not fitted)
17 Heat exchanger
18 V-belt with protective cover
19 Starter
20 Starter batteries (not shown)
21 Diesel injection pump
22 Fuel suction pump
23 Fuel filter
24 Cooling water circuit
25 Cooling water heater (not shown)
26 Cooling water drain
27 Oil pump (not shown)
28 Oil filter
29 Oil dipstick
30 Oil filler cap (not shown)
Pos. Component

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4.2 Pump
The fire pump set comes with a Grundfos HSEF horizontal split
case pump or a Grundfos DNF end-suction pump. The pumps are
FM-approved and UL-listed.
The impeller diameter of both pumps can be reduced to
customise the pump performance to a certain duty point. The
actual impeller diameter may therefore deviate from the standard
diameters stated in catalogues, data sheets etc. The actual
impeller diameter is stated on the pump nameplate.
4.2.1 Split case pump
The Grundfos HSEF horizontal split case pump is a non-self-
priming, single-stage pump. It has inline axial suction and
discharge ports with PN 10 or PN 16 ANSI flanges. An adapter
flange from ANSI to DIN is available and must be ordered
separately. The pumps are equipped with a stuffing box, type
SNEA or SNFA (see section 6.1.4 Type key for stuffing box), and
with an automatic air release valve making venting unnecessary.
4.2.2 End-suction pump
The pumps are non-self-priming, single-stage Grundfos DNF
standard pumps with spiral housing. The pumps have an axial
suction port and a radial discharge port with PN 10 or PN 16
DIN flanges.
The DNF pump is equipped with a stuffing box, type SNEA or
SNFA. See section 6.1.4 Type key for stuffing box.
4.3 Engine
4.3.1 General description
The pump is driven by a stationary 4-stroke diesel engine from
John Deere. It has been especially adapted to meet the
requirements of fire pumps. The diesel engine is FM-approved
and UL-listed.
The rated engine power is adapted to the power requirement of
the pump. The adaptation takes place via the engine speed,
which may therefore not be changed. The combinations of diesel
engines and pumps are shown in section 19. Dimensions,
weights and engine data. Depending on output, the engines have
a turbocharger and, if necessary, also a charge air cooler.
The engine is cooled via a heat exchanger. The water is diverged
from the discharge port of the pump. Before the water runs into
the heat exchanger, the water flows through a cooling circuit.
See fig. 4. The discharge from the heat exchanger is led via an
open outlet or a visible waste cone back to the suction reservoir.
Fig. 4 Cooling circuit
If the cooling circuit is faulty, and the temperature of the cooling
liquid becomes too high, close isolating valves (pos. A and B),
and open isolating valves (pos. C and D).
4.3.2 Control panel of the engine
The engine is equipped with its own control panel. The fire pump
set can be operated via the controller or via the control panel of
the engine. Normally, operation takes place via the controller.
Only if the controller fails, the control panel of the engine should
be used.
Additionally, the control panel of the engine indicates the main
parameters of the engine, such as engine speed, voltage of
battery 1 and 2, oil pressure and temperature of cooling liquid.
The design of the control panel is shown in fig. 5 for JU/JW
engines, and in fig. 6 for JW engines. An explanation of the
operating elements and the indicators is given in the table below
fig. 5 and 6. How to start the engine via the control panel is
described in section 12.2.2 Manual operation via control panel of
diesel engine.
Caution
The injection pump has been set from factory,
and the setting must not be changed.
TM04 5066 2609
CD
AB

8
Fig. 5 Control panel of JU/JW diesel engine
TM04 5114 2609
WARNING
THIS EQUIPMENT STARTS
AUTOMATICALLY
USE EAR PROTECTION
C13187
I24336
I3 I4 I5
I1 2 5 1
CAUTION
DO NOT RUN ENGINE WITHOUT
AIR FILTER INSTALLED.
PERSONAL INJURY OR
ENGINE DAMAGE MAY
RESULT.
C13191
!
Pos. Operating element Description
1Instructions for
emergency operation
Instructions as how to start the
engine via the control panel.
2 Selector switch For selection of automatic or
manual operation.
3Manual crank switches,
battery 1 or 2
For manual start of engine with
battery 1 or 2.
4 Overspeed reset
If the engine has been stopped
due to an overspeed condition,
the overspeed alarm must be
reset with this switch when the
problem has remedied.
5 Warning light
Indicates that the selector
switch is not set to
"AUTOMATIC OR MANUAL
STOP".
6 Overspeed verification
For testing if the overspeed
function works and the engine
stops in case of overspeed.
The overspeed signal will be
generated at 67 % of the rated
speed. Overspeed alarms
must be reset with the
[OVERSPEED RESET] switch
(pos. 4).
Pos. Indicator Description
I1 Tachometer and
operating hour counter
Shows engine speed and the
number of operating hours.
I2 Oil pressure Shows the oil pressure of the
engine.
I3 Voltmeter, battery 1 Shows the voltage supplied by
battery 1.
I4 Voltmeter, battery 2 Shows the voltage supplied by
battery 2.
I5 Temperature indicator Shows the temperature of the
cooling liquid.

9
Fig. 6 Control panel of JX diesel engine
* Electronic control module
TM04 5115 2609
9
7
5
3
1
8
6
4
2
10 11 12
Pos. Operating element Description
1 Power view gauge
Shows relevant engine
parameters and alarm
messages.
2 Voltmeter, battery 1 or 2 Shows the voltage supplied by
battery 1 or 2.
3 Operating hour counter Shows the number of
operating hours.
4Battery selector switch,
voltmeter
For selection of battery voltage
to be indicated by the
voltmeter.
5 Selector switch For selection of automatic or
manual operation.
6 ECM selector switch *
Default position is "PRIMARY
ECM". Only in case of a failure
of the primary ECM, causing
the engine to stops or not to
start, manually switch to
"ALTERNATE ECM."
7Warning light, manual
operation
Indicates that the selector
switch is not set to automatic
operation.
8Warning light,
alternative ECM *
Indicates that the ECM
selector switch is set to
"ALTERNATE ECM".
9 Manual stop switch For manual stop of engine.
10 Manual crank switch,
battery 1
For manual start of engine with
battery 1.
11 Manual crank switch,
battery 2
For manual start of engine with
battery 2.
12 Overspeed reset
If the engine has been stopped
due to an overspeed condition,
the overspeed alarm must be
reset with this switch when the
problem has remedied.

10
The control panel of the JX6 diesel engine is equipped with a
diagnostic gauge. See fig. 7.
Fig. 7 Diagnostic gauge of JX6 control panel
During normal operation of the diesel engine, the display will
show engine speed, temperature of cooling liquid, oil pressure
and voltage of battery 1 or 2 selected with the battery selector
switch (fig. 6, pos. 4).
Fig. 8 Example of indications during normal operation, JX6
If an alarm occurs, the alarm message will be shown instead of
the engine parameters.
Fig. 9 Example of alarm message, JX6
SPN (Suspect Parameter Number) and FMI (Failure Mode
Identifier) codes will be shown along with a description of the
problem and the corrective action needed. If the word "NEXT"
appears above the arrow buttons, further codes can be viewed by
scrolling with the arrow buttons (fig. 7, pos. C). Press the enter
button (fig. 7, pos. D) to return to the parameter screen. An
overview of possible alarm messages is given in the service
instructions together with SPN and FMI codes.
TM04 5116 2609
Pos. Designation Description
A Display
Shows the four most important
engine parameters:
• engine speed
• temperature of cooling liquid (°F)
• oil pressure (psi)
• battery voltage (1 or 2).
If an alarm occurs, the alarm
message will be shown instead of
the engine parameters.
B Menu button Opens the main menu.
C Arrow buttons Scrolls through the menus.
D Enter button Opens selected submenus.
Activates settings and functions.
E
Indicator light
Engine stopped
(red)
Lights up if a fault occurred
that stops the diesel engine
(e.g. overspeed).
FIndicator light
Warning (amber)
Lights up if a warning condition
occurs.
TM04 5117 2609
FE
A
D
CB
TM04 5118 2609
Note
No settings can be made in the diagnostic gauge.
Do not use the main menu button (fig. 7, pos. B).