HALE ESP Primer System Installation and user guide

ESP Primer System
(Includes: SPV and PVG Valves)
Installation, Operation and
Service Maintenance Manual
Manual p/n: 029-0810-01-0
Hale Products Inc. ◆ A Unit of IDEX Corporation
700 Spring Mill Avenue ◆ Conshohocken, PA 19428 U.S.A.
Telephone: 610-825-6300 ◆ FAX: 610-825-6440
Web......www.haleproducts.com

NOTICE !
Hale Products, Inc. cannot assume responsibility for product failure resulting from
improper maintenance or operation. Hale is responsible only to the limits stated in
the product warranty. Product specifications contained in this manual are subject
to change without notice.
All Hale products are quality components -- ruggedly designed, accurately
machined, precision inspected, carefully assembled and thoroughly tested. In
order to maintain the high quality of your unit, and to keep it in a ready condition, it
is important to follow the instructions on care and operation. Proper use and good
preventive maintenance will lengthen the life of your unit.
ALWAYS INCLUDE THE UNIT SERIAL NUMBER
IN YOUR CORRESPONDENCE.
ECN No REV CHANGE FROM BY DATE APVD
HALE PRODUCTS, INC.
A Unit of IDEX Corporation
Conshohocken, PA 19428 USA
0499 A INITIAL RELEASE LwH 12/23/2006 MAL
WRITTEN BY LwH ISSUE DATE COPYRIGHT ©
NOT TO BE REPRODUCED OR USED TO
MAKE OTHER DRAWINGS OR MACHINERY.
CHECKED BY PW 01/05/2007
Manual p/n: 029-0810-01-0, Rev. -A
Printed in U.S.A.
©Hale Products, Inc. 2007
All Rights Reserved

Contents Page
Table of Contents ❑
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ESP Primer System Instruction Guide
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ESP Primer Installation, Operation and Service Guide
1 Safety Precautions................................................................................................... 7
1.1 Definitions........................................................................................................................... 7
1.2 Guidelines ........................................................................................................................... 8
2 Introduction ........................................................................................................... 11
2.1 ESP Primer Pump............................................................................................................. 11
Figure 2-1: Rotary Vane ESP Priming Pump.........................................................................11
2.2 SPV Priming Valve ........................................................................................................... 12
Figure 2-2: SPV Overview .....................................................................................................12
Overview...........................................................................................................................................12
Configuration Options .......................................................................................................................13
Retrofit Kit Option.......................................................................................................................13
Universal Mount Installation Kit Option ......................................................................................13
Midship Pump Mounted Option.................................................................................................. 13
Primer Mounted on Midship Pump.............................................................................................14
2.3 PVG Priming Valve ........................................................................................................... 14
Figure 2-3: PVG Priming Valves............................................................................................14
2.4 Lubricated ESP Primer System....................................................................................... 14
Figure 2-4: Typical ESP Lubricated System ..........................................................................15
Chart 2-5: Typical Freeze-Up Protection..............................................................................16
3 System Installation ................................................................................................ 17
3.1 Primer Pump ..................................................................................................................... 17
Installation Notes ..............................................................................................................................17
Figure 3-1: Solenoid Connector Arrangement .......................................................................18
Optional Bracket Installation .............................................................................................................19
ESP System Plate Drawings ............................................................................................................ 19
3.2 Valve Installation, SPV or PVG........................................................................................ 19
Figure 3-2: Typical Hale SPV Typical System Layout ...........................................................20
SPV Placard and Pushbutton ...........................................................................................................20
Figure 3-3: SPV Pushbutton Placard Overview.....................................................................21

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3.2 Valve Installation, SPV or PVG - continued
SPV Retrofit Installation, Midship ..................................................................................................... 22
Figure 3-4: Typical SPV / Midship Pump Installation............................................................. 22
Figure 3-5: SPV Retrofit Panel Placard Spacer Layout ......................................................... 23
SPV Retrofit Installation, Universal Mount........................................................................................ 25
Figure 3-6: Typical SPV / Universal Adapter Pump Installation............................................. 25
Figure 3-7: Universal Mount Adapter Dimensions ................................................................. 26
Figure 3-8: Universal Mount Adapter Positions ..................................................................... 26
PVG Installation................................................................................................................................ 27
Figure 3-9: PVG Panel Placard and Valve Plumbing Layout................................................. 28
3.3 Lubricated Primer Installation ...................................................................................... 29
Installation ........................................................................................................................................ 29
Figure 3-10: Typical ESP Lubricated Primer Layout................................................................ 30
Figure 3-11: Pump Fittings ...................................................................................................... 31
4 Primer Operation .................................................................................................. 33
4.1 Priming the Pump ............................................................................................................ 33
5 System Maintenance.............................................................................................. 35
5.1 General Maintenance....................................................................................................... 35
Weekly.............................................................................................................................................. 35
Priming System Test.................................................................................................................. 35
Monthly ............................................................................................................................................. 36
Priming System Test, Dry Vacuum Test .................................................................................... 36
Figure 5-1: PVG Priming Valve Handle ................................................................................. 36
Annually............................................................................................................................................ 37
Clean ESP Priming Pump..........................................................................................................37
Figure 5-2: Primer Pump Parts Overview .............................................................................. 37
5.2 SPV Valve Repair .............................................................................................................39
Figure 5-3: Hale SPV Parts Overview ................................................................................... 40
5.3 PVG Valve Repair ............................................................................................................42
Figure 5-4: Hale PVG Parts Overview ................................................................................... 42
Figure 5-5: PVG Valve Parts Breakdown .............................................................................. 43
Reassembly Hints............................................................................................................................. 44

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5.4 Lubricant Specifications.................................................................................................. 45
Grease, for O-ring Seals...................................................................................................................45
Loctite Sealant ..................................................................................................................................45
Recommended Cleaners ..................................................................................................................45
Lubricants .........................................................................................................................................45
6 Troubleshooting .................................................................................................... 47
Figure 6-1: Troubleshooting Chart......................................................................................... 47
Pump Loses Prime or Will Not Prime...................................................................................47
Primer Solenoid - 12VDC and 24VDC .................................................................................49
Switch is dead - no click is heard.........................................................................................49
Switch chatters, pops or clicks, but the motor does not work. ...........................................49
Switch stays ON (sticks) - motor keeps running. .................................................................50
Figure 6-2: 12VDC Solenoid Arrangement Troubleshooting .................................................50
Figure 6-3: 24VDC Solenoid Arrangement Troubleshooting .................................................50
Express Warranty ................................................................................................. 51
Hale Products, Inc. ..........................................................................................................................52
7 Drawing Package................................................................................................... 53
Hale ESP-12 Priming System .............................................................................................................821A
Hale ESP-24 Priming System .............................................................................................................938A
Hale PVG Valve ..................................................................................................................................480A
Hale SPV Valve, Universal Mount.......................................................................................................828A
Hale SPV Valve, Pump Mount ............................................................................................................819A

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Notes
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Safety ❑
1 Safety Precautions
IMPORTANT !
THE HALE ESP PRIMER SYSTEM, WHICH INCLUDES THE SEMI-AUTOMATIC
PRIMING VALVE (SPV) OR THE PVG PRIMER VALVE, IS DESIGNED FOR OPTI-
MUM SAFETY OF ITS OPERATORS. FOR ADDED PROTECTION, PLEASE FOL-
LOW THE SAFETY GUIDELINES LISTED IN THIS SECTION. ADHERE TO ALL
WARNING, DANGER, CAUTION AND IMPORTANT NOTES FOUND WITHIN THIS
MANUAL.
ALL SUPPLIED DOCUMENTATION MUST BE CAREFULLY READ, UNDERSTOOD
AND ADHERED TO STRICTLY BY ALL INSTALLERS AND OPERATORS BEFORE
ATTEMPTING INSTALLATION OR OPERATION.
WHEN DEVELOPING DEPARTMENTAL APPARATUS OPERATING PROCEDURES,
INCORPORATE THE WARNINGS AND CAUTIONS AS WRITTEN.
Hale is a registered trademark of Hale Products, Incorporated. All other brand and product
names are the trademarks of their respective holders.
1.1 DEFINITIONS
DANGER !
DANGER - Immediate hazard which WILL result in severe personal injury or
death if the warning is ignored.
WARNING !
WARNING - Hazards or unsafe practices which COULD result in severe per-
sonal injury or death if the warning is ignored.
CAUTION !
CAUTION - Hazards or unsafe practices which COULD result in minor or mod-
erate personal injury if the warning is ignored.

❑Safety
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NOTICE !
NOTICE - Practices which could result in damage to the apparatus or other
property.
1.2 GUIDELINES
NOTICE !
THE PROCEDURES IN THIS MANUAL ARE GENERAL OPERATING PROCE-
DURES. THEY DO NOT REPLACE THE PROCEDURES, POLICIES OR GUIDE-
LINES ESTABLISHED BY THE AUTHORITY HAVING JURISDICTION, NOR DO
THEY REPLACE THE RECOMMENDATIONS AND PROCEDURES PROVIDED IN
THE APPARATUS MANUFACTURER'S MANUAL.
REFER TO THE PROCEDURES PROVIDED BY THE AUTHORITY HAVING JURIS-
DICTION ON SETTING WHEEL CHOCKS (TO PREVENT ANY MOVEMENT OF THE
APPARATUS), AS WELL AS LAYOUT AND CONNECTION OF HOSES, VALVES
AND DRAIN COCKS.
❑Use care when removing the primer system, including SPV and PVG valves,
from its packaging to prevent personal injury and/or damage to the
components.
❑Use all mounting bolt holes provided on the primer to support the assembly.
See the appropriate plate drawing, located at the back of this manual, for
additional installation information.
❑Installation should be performed by a trained and qualified installer, such as
your authorized service representative. Be sure the installer has sufficient
knowledge, experience and the proper tools before attempting any installa-
tion.
❑The installer is responsible for observing all instructions and safety precau-
tions in his or her daily routine as dictated by regional safety ordinances or
departmental procedures.
CAUTION !
ALL FASTENERS USED HAVE BEEN SELECTED FOR THEIR APPLICATION.
HALE PRODUCTS DOES NOT RECOMMEND REPLACING FASTENERS WITH
ANYTHING OTHER THAN HALE PART NUMBERS PROVIDED. REPLACING WITH
A WEAKER ALTERNATIVE POSES A SERIOUS SAFETY RISK.
ALL FASTENERS MUST BE INSTALLED WITH A LOCKING ANAEROBIC ADHE-
SIVE/SEALANT, SUCH AS LOCTITE®#246.

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Safety ❑
CAUTION - continued !
BE SURE TO WEAR SAFETY GLASSES WHEN REMOVING AND/OR INSTALLING
FORCE (PRESS) FITTED PARTS. FAILURE TO COMPLY MAY RESULT IN SERI-
OUS INJURY.
❑Parts under spring tension can become projectiles and cause serious injury.
When removing or installing these parts make sure they are restrained and
spring tension is released slowly.
❑Disconnect or turn OFF the master battery switch prior to servicing the Hale
SPV or PVG electrical components. Make sure there is NO power at the
primer solenoid before starting service procedures.
❑Any electrical system has the potential to cause sparks during installation,
service or repair. Take care to eliminate explosive or hazardous environ-
ments during installation, service or repair.
❑Before connecting any cord sets or wiring harnesses, inspect the seal
washer in the connector. If the seal washer is missing or damaged, water
can enter the connector causing corrosion. This could resulting in possible
system failure.
❑DO NOT operate the system at pressures higher than the maximum rated
pressure. Always use the lowest possible relief valve settings to enhance
operator and equipment safety. Also see Section 3 “System Installation” on
page 17 for additional information.
❑Relieve all system pressure, then drain all water from the system before
installing the primer.
❑Use only pipe, hose and fittings which are rated at or above the maximum
pressure rating at which the water pump system operates.
❑Use only pipe, hose and fittings from the priming pump vacuum connection
to the Hale SPV vacuum connection rated for 29 in. Hg. (737 mm) vacuum.
❑Check all hoses for weak or worn conditions after each use. Ensure that all
connections and fittings are tight and secure.
CAUTION
MAKE SURE THE HALE SPV IS LOCATED HIGHER THAN THE PUMP BODY
ALLOWING WATER TO DRAIN FROM THE VACUUM HOSE.
❑If there is primer lubricant in the reservoir, it is recommended to operate
lubricated priming systems weekly to cycle the fresh lubricant through the
primer.

❑Safety
10 ESP Primer System Instruction Guide
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Holding the primer ON for two (2) or three (3) seconds after a prime from
draft will clean out residue in the primer.
❑DO NOT run the primer over forty-five (45) seconds. If prime is not achieved
within 45 seconds, stop and look for causes (air leaks or blocked suction
hoses).
❑Always use caution when handling or disposing of propylene glycol.
❑DO NOT USE ETHYLENE GLYCOL.
❑DO NOT allow coolant to discharge to the ground. Review your departmen-
tal and/or local environmental regulations regarding the use of and disposal
of propylene gylcol coolants.
❑Always follow the manufacturer’s recommended instructions on the label
affixed to the container.

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Introduction ❑
2Introduction
2.1 ESP PRIMER PUMP
Hale recommends and uses Rotary Vane Positive Displacement pumps
(ESP) for priming. Priming pumps are used to evacuate air in the suction
hose and pump. (See Figure 2-1: “Rotary Vane ESP Priming Pump.”)
Figure 2-1: Rotary Vane ESP Priming Pump
The Hale ESP series priming pump is an environmentally friendly primer
that does not require a separate lubricant reservoir.
The vanes and pump body are self-lubricating for maintenance free opera-
tion. An ESP priming pump also uses a single control to open the priming
valve and start the priming motor.
Note: For an optional “ESP Primer lubricated system,” also see heading “Lubri-
cated ESP Primer System” on page 14.)
Hale priming valves open when the priming pump is operated allowing the
air to escape from the pump. Two priming valves offered:
a. Semi-Automatic Priming Valve (SPV / SPVR) - also see heading “SPV
Priming Valve” on page 12.
b. PVG Priming Valve - also see heading “PVG Priming Valve” on page 14.

❑Introduction
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2.2 SPV PRIMING VALVE
The Hale Semi-Automatic Priming Valve (SPV) simplifies the priming opera-
tion of your pump allowing for a faster priming time and longer primer life .
The SPV is a diaphragm-operated valve that opens using the vacuum gen-
erated by the priming pump.
Easily activated by a push button control, the SPV starts the primer motor
creating a vacuum. The vacuum acts on the diaphragm in the valve causing
the port to open allowing vacuum. (See Figure 2-2: “SPV Overview.”)
Figure 2-2: SPV Overview
The SPV conforms to NFPA requirements for priming time and hydrostatic
test when bolted to Hale Midship series pumps. Each valve is factory tested
to 26 in. (660 mm) hg. vacuum and 600 PSIG (41 BAR)
Overview
The SPV mounts directly to the priming connection of Hale Midship series
pumps. Additionally, a universal adapter is available to mount the SPV on
Hale Booster and Volute series pumps. The installer must also supply hose
connections from the adapter to the pump priming connection.
When used on a midship fire pump, the valve mounts to the pump body with
two studs and nuts, standard strainer and seal ring.
A short length of 3/4” (19 mm) ID vacuum hose connects the SPV to the
priming pump, eliminating potential leak points in the priming hose.

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Introduction ❑
The short length of hose also allows for a faster priming time and longer
primer life by reducing the volume that must evacuated.
The priming pump motor is push-button operated, located on the pump
operator panel of the apparatus. There are NO hose connections at the
pump operator panel thus saving valuable space.
Depressing and holding the PRIME push button energizes the priming
pump motor creating a vacuum in the 3/4” (19 mm) ID hose. As sufficient
vacuum is created the diaphragm depresses the spring to OPEN the prim-
ing valve, thus creating a vacuum in the main pump body, priming the main
pump. Once primed, as indicated by water discharging to the ground from
the priming pump outlet, the push button is released to STOP the priming
pump. The SPV then CLOSES for normal pump operation.
Configuration Options
The Hale SPV is available from the factory in four (4) different configura-
tions. A description of each follows, beginning on the next page.
Retrofit Kit Option
The retrofit kit contains the components necessary for installing the Hale
SPV on a midship fire pump. The kit contains a Hale SPV Valve assembly,
panel placard and push button switch.
Universal Mount Installation Kit Option
The Universal Mount Installation Kit contains the components necessary for
installing the Hale SPV on a volute or booster type pump. The kit contains a
Hale SPV Valve assembly, universal mounting adapter, panel placard and
push button switch.
Midship Pump Mounted Option
This option mounts the Hale SPV to the priming flange connection on a
“new” midship pump body. Components included with this option and
shipped with the midship pump are the push button switch, panel placard
and Installation Manual.
When completing the apparatus installation of the Hale SPV, the priming
pump must be mounted on the apparatus with the vacuum hose connected
in addition to the push-button switch and panel placard being installed on
the operator panel.

❑Introduction
14 ESP Primer System Instruction Guide
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Primer Mounted on Midship Pump
This option mounts the Hale SPV to the priming flange connection on a
“new” midship pump body with the priming pump mounted to the pump
gearbox. When this option is ordered, the vacuum hose is connected from
the Hale SPV to the priming pump.
Components included with this option and shipped with the midship pump
are the push button switch, panel placard and Installation Manual.
When completing the apparatus installation of the Hale SPV with this option
the push-button switch and panel placard must be installed on the operator
panel.
2.3 PVG PRIMING VALVE
The PVG is a combination valve and switch and is mounted on the pump
operator’s panel. (See Figure 2-3: “PVG Priming Valves.”)
Figure 2-3: PVG Priming Valves
Pulling the handle out OPENS the valve and energizes the primer motor.
Pushing the handle in de-energizes the primer motor and CLOSES the
valve.
2.4 LUBRICATED ESP PRIMER SYSTEM
The Hale ESP Priming System has a proven history of reliable fast priming
and high vacuum performance when properly maintained and operated in
accordance with the instructions found in your Pump Installation, Operation
and Service Maintenance Manual and in this guide. Under NORMAL oper-
ating conditions (standard climates) our research has found that no lubri-
cant is required.

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Introduction ❑
Figure 2-4: Typical ESP Lubricated System
The Hale ESP Priming System can be converted to a “lubricated system” by
installing “separate” lubricant and discharge tanks and using a Propylene
Glycol / water mixture as the lubricant. (See Figure 2-4: “Typical ESP Lubri-
cated System.”)
Propylene Glycol is a less toxic and more environmentally-friendly coolant
and is recommended over Ethylene Glycol based antifreeze.Propylene Gly-
col (PG) based antifreeze provides comparable system protection to that of
conventional ethylene glycol (EG) based coolants (i.e., freeze, and corro-
sion protection).
Propylene glycol is readily available in automotive supply stores, under the
following brand names:
❑Sierra Antifreeze – use a 50 – 50 mix (www.sierraantifreeze.com)
❑RV & Marine Easy Going Antifreeze, Camco Mfg. – use pure, DO NOT
mix. (www.camco.net)
A 50/50 blend of propylene glycol coolant and water has a freezing point of
-26° F (-32° C) and is applicable under most operating conditions.
If a lower temperature protection is required, it can readily be achieved by
increasing the coolant. (See Chart 2-5: “Typical Freeze-Up Protection,” on
page 16.)

❑Introduction
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IMPORTANT!
IF THERE IS PRIMER LUBRICANT IN THE RESERVOIR, IT IS RECOMMENDED
TO OPERATE LUBRICATED PRIMING SYSTEMS WEEKLY TO CYCLE THE
FRESH LUBRICANT THROUGH THE PRIMER.
HOLDING THE PRIMER ON FOR TWO (2) OR THREE (3) SECONDS AFTER A
PRIME FROM DRAFT WILL CLEAN OUT RESIDUE IN THE PRIMER.
Coolant Water Freezing Point
F° (C°)
50% 50% -26 (-32)
60% 40% -54 (-48)
66% 34% -76 (-60)
Chart 2-5: Typical Freeze-Up Protection

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Installation ❑
3 System Installation
ESP Primer Systems are available mounted to Midship pump gearboxes or to the
pump body on new orders.
3.1 PRIMER PUMP
For the Hale 12 volt ESP Primer System installation instructions see draw-
ing “12 Volt ESP System” on page 54. For the 24 volt ESP Primer System
installation instructions see drawing “24 Volt ESP System” on page 54.
Notes: The 12 and 24 volt drawings offer two sheets, one for mechanical installa-
tion and one for electrical.
For the optional Lubricated ESP Primer System installation instructions and
drawings, see heading 3.3 “Lubricated Primer Installation” on page 29.
Installation Notes
❑Select a mounting location that is rigid, is accessible for maintenance, is
as close as possible to the main pump and with the primer discharge
pointing down (to allow for proper drainage).
Notes:
●Mounting screws and washer are not provided by Hale.
●For competitive brand optional installation, see heading “Optional
Bracket Installation” on page 19. A bracket is available to mount the ESP
primer to a competitive pump. Contact Hale Customer Service for addi-
tional information.
❑Use 1/2” (13 mm) tubing for Hale Booster Pumps.
❑Use 3/4” (19 mm) tubing for Hale Midship Pumps.
❑Use 2-1/2” (64 mm) rubber hose for primer discharge.
❑Suction connection to priming valve is 3/4” NPT.
❑A shut-off valve, i.e., Hale PVG or SPV Priming Valve, must be located in
the priming line between the primer pump and the main pump.
❑Ground the priming pump to the truck chassis, using the ground strap
provided.

❑Installation
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Attach the ground strap from the truck chassis to the priming pump termi-
nal stud to ensure a ground for the motor. See appropriate drawing,
sheet 2.
The ground strap is appropriately sized for a 12 or 24 volt DC, 300 or 150
amp load.
❑To prevent damage to the solenoid plastic housing, when installing or
removing wire leads, DO NOT apply side loads to the nuts. (See Figure
3-1: “Solenoid Connector Arrangement.”)
Figure 3-1: Solenoid Connector Arrangement
❑When using a terminal lug on the battery connection with a 5/16” (8 MM.)
diameter hole, the lower washer is not needed.
❑If the hole is larger than 5/16”, washers are required both above and
below the terminal. Torque to 50 - 60 in. lbs. (6 - 7 N-m) maximum.
DO NOT overtighten to avoid stripping the stud from plastic cap.
❑The solenoid-to-ground terminal, 10-32 UNC, is factory connected and
torqued to 15 - 20 in. lbs. (1.7 - 2 N-m).
DO NOT overtighten to avoid stripping the stud from plastic cap.
❑For complete electrical installation instructions, see sheet 2 of drawing
“12 Volt ESP System” on page 54 or see sheet 2 of drawing “24 Volt
ESP System” on page 54.
NOT FOR MOUNTING

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Installation ❑
NOTICE !
DO NOT RUN THE PRIMER OVER FORTY-FIVE (45) SECONDS. IF PRIME IS
NOT ACHIEVED WITHIN 45 SECONDS, STOP AND LOOK FOR CAUSES (AIR
LEAKS OR BLOCKED SUCTION HOSES).
Optional Bracket Installation
A mounting bracket is available to install the Hale ESP primer pump to
some competitive pumps. Contact Hale Customer Service for additional
information.
ESP System Plate Drawings
Hale ESP-12 Priming Pump, Mechanical Installation,
Sheet 1 of 2 ........................................................................................821A
Hale ESP-12 Priming Pump, Electrical Installation,
Sheet 2 of 2 ........................................................................................821A
Hale ESP-24 Priming Pump, Mechanical Installation,
Sheet 1 of 2 ........................................................................................938A
Hale ESP-24 Priming Pump, Electrical Installation,
Sheet 2 of 2 ........................................................................................938A
(Click above to view)
3.2 VALVE INSTALLATION, SPV OR PVG
When ordered as an option on a new midship fire pump, the Hale SPV
assembly is already mounted to the pump body with the vacuum hose con-
nected to the priming pump (when the primer is ordered mounted to the
gearbox). All that remains is to install the panel placard and push button on
the pump operator panel and make the electrical connections from the
switch to the battery and priming pump solenoid. (See Figure 3-2: “Typical
Hale SPV Typical System Layout,” on page 20.)
If the midship pump is ordered with the primer shipped loose, it must be
attached to the apparatus and the priming hose must be attached to the
Hale SPV or PVG hose connection (3/4” NPT).

❑Installation
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Figure 3-2: Typical Hale SPV Typical System Layout
SPV Placard and Pushbutton
WARNING !
DISCONNECT OR TURN OFF THE MASTER BATTERY SWITCH PRIOR TO
SERVICING THE HALE SPV ELECTRICAL COMPONENTS.
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