Waterous HLU Series Installation and operating instructions

HLU Series Fire Pump
Installation, Operation, and Maintenance
Form Number: F-2868 Issue Date: Jan 30, 2020
Revision Date: Nov 30, 2022
Waterous Company • 125 Hardman Avenue South • South Saint Paul, MN 55075 • [phone]
www.waterousco.com

Table of Contents
Safety 4
Safety Precautions 4
Introduction 7
Using this Document 7
Viewing the Document Electronically 7
Printing the Document 7
Additional Documentation 7
Symbols 7
Product Overview 8
HLU Series Pump Overview and Versions 8
HLU Pump Operation Overview 9
Pump Components—Intake Side 10
Pressure Mode Controller—Optional 12
Pressure Mode Switch 14
Pump Components—Underside 16
Pump Components—Drive Side with Direct Drive 18
Pump Components—Drive Side with K-Transmission 20
Pump Components—Drive Side with PA-Transmission 22
Operating Limits 24
Maximum pressure 24
Maximum speed 24
Installation 25
Installation Overview 25
Preparing for the Installation 25
Modifying the Equipment 25
Determining the Pump Location 25
Determining Cable and Wire Routing 25
Mounting Holes and Flange Cutout 26
Installing the Pump—HLUD 27
Installing the Pump—HLUK 28
Installing the Pump—HLUPA 29
Installing the Pump Drain Lines—Pump Body 30
Installing the Transmission Drain Lines—K Transmission 31
Installing the Transmission Drain Lines—PA Transmission 32
Connecting the Pump 33
Connecting the Pneumatic Actuator 34
Mode Switch Extension Cable 35
Setting the CANbus Terminating Resistor 36
Adjusting the Flow Controls 37
Operation 38
Enabling the High-Pressure Discharge—Manual Handle 38
Enabling the High-Pressure Discharge—Pressure Mode Controller 39
Operating the Manual Override Mode 40
Maintenance 41
Maintenance Schedule 41
Cleaning the Intake Strainer 42
Checking the Pedestal Oil Level 43
Draining the Pedestal Oil 44
Adding the Pedestal Oil 45

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Safety Introduction Product Overview Installation Oper ation Maintenance
Safety Precautions
• Read and understand all the associated documentation before you begin the
installation.
• Read and understand all the notices and safety precautions.
• Be aware that these instructions are only guidelines and are not meant to be
definitive. Contact Waterous when you have questions about installing,
operating, or maintaining the equipment.
• Do not install the equipment if you are not familiar with the tools and skills
needed to safely perform the required procedures—proper installation is the
responsibility of the purchaser.
• Do not operate the equipment when safety guards are removed.
• Do not modify the equipment.
Regularly check for leaks, worn, or deteriorated parts.
NOTICE
Modifying the equipment
can damage components
and void your warranty.
•
Do not modify the system
or any of its components.
•
Modification
NOTICE
Before Operation
• Read and understand all
the instructions provided.
• Check all fluid levels
and replenish if necessary.
• Remove all shipping plugs
and install the operation
plugs or caps.
NOTICE
Do not allow fluid in the
lines to freeze.
•
Remove all freezable fluid
from the lines before
storing the apparatus.
•
Freeze Damage

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Safety Introduction Product Overview Installation Oper ation Maintenance
NOTICE
•Premature component
failure occurs when
operating beyond
system specifications.
•Do not operate the system
beyond specifications.
Premature Failure
Do not touch the surface
during operation––allow
it to cool after operating.
Hot surface can burn you.
Hot Surface
•
•
Drain the pump after use
and before servicing.
Liquid ejected at high
pressure can cause
serious injury.
High Pressure
•
•
Do not operate beyond
recommended pressure.
Liquid ejected at high
pressure can cause
serious injury.
High Pressure
•
•

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Safety Introduction Product Overview Installation Oper ation Maintenance
Keep clear of moving
parts when the equipment
is operating.
Rotating parts can cause
severe injury or death
Moving Parts
•
•
Direct discharge away
from people and equipment.
Discharge ejected at high
pressure can cause
serious injury and damage.
High Pressure
•
•
Purge all pressure before
servicing.
Liquid ejected at high
pressure can cause
serious injury.
High Pressure
•
•

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Safety Introduction Product Overview Installation Oper ation Maintenance
Use this document to install and operate your Waterous equipment. Understand
the following conditions before continuing with the document:
• The instructions may refer to options or equipment that you may not have
purchased with your system.
• The illustrations in this document are intended to convey concepts. Do not
use the illustrations to determine physical attributes, placement, or
proportion.
• Understand that your application may require additional steps, that are not
described in the illustrations or instructions, to perform the installation.
• The equipment described in this document is intended to be installed by a
person or persons with the necessary skills and knowledge to perform the
installation.
• The equipment described in this document is intended to be operated by a
person or persons with the basic knowledge of operating similar equipment.
• The information in this document is subject to change without notice.
This document is divided into the following sections:
Safety
This section describes general precautions and alert symbols that are in this
document.
Introduction
This section is an overview of the document.
Product Overview
This section describes the components that make-up the system.
Installation
This section describes the installation and initial setup procedures.
Oper ation
This section describes the equipment operation.
Maintenance
This section describes maintenance procedures.
Using this Document
Use the guidelines below when viewing this document.
Viewing the Document Electronically
• View this document in landscape orientation.
• Use the table of contents to navigate directly to that section.
• Text with this appearance is linked to a reference.
Printing the Document
• The document is viewed the best when printed in color.
• The print on both sides and flip on long edge features can provide the
best results.
• Use a 3-ring binder to store the document.
Additional Documentation
Additional documentation is available through the MyWaterous login at
Waterousco.com. Use your serial number to gain access to the service parts
list associated with your system. Dimensional drawings are available through
the Waterous Service department.
Symbols
Here are the symbols found in the document a their definitions.
Drill—This symbol tells you to drill the mounting holes in the
apparatus.
Jig saw—This symbol tells you to make a cutout in the apparatus.

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Safety Introduction Product Overview Installation Oper ation Maintenance
HLU Series Pump Overview and Versions
The HLU series pump has a discharge manifold with 8 normal pressure discharges and 1 high-pressure discharge. A lever on the pump opens a crossover valve
that diverts a portion of the incoming water into the high-pressure discharge, while simultaneously operating the remaining discharges. The pump is available in
several variations. Pump variations include clockwise and counterclockwise rotation, as well as direct drive, or with a transmission. Optional priming and foam
generation systems are also available.
Clockwise Rotation Counterclockwise Rotation
With Direct Drive—HLUD With K-Transmission—HLUK With PA-Transmission—HLUPA

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Safety Introduction Product Overview Installation Oper ation Maintenance
HLU Pump Operation Overview
You can operate the pump in 3 modes: high pressure, low pressure, and simultaneous mode. Each mode is achieved by opening or closing a combination
discharges. Access low pressure mode by closing the crossover valve and opening the low pressure discharges. Access high pressure mode by opening the
crossover valve and closing the low pressure discharges. Access simultaneous mode by opening both the crossover valve for high pressure discharge and the
low pressure discharges. You can open and close the crossover valve manually by using the handle, or with the optional pneumatically actuated pressure mode
control module.
Low Pressure Mode
Access low pressure mode by opening only
the low pressure discharges.
High Pressure Mode
Access high pressure mode by opening only
the high pressure discharge.
Simultaneous Mode
Access simultaneous pressure mode by
opening both the low pressure and high
pressure discharges.

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Safety Introduction Product Overview Installation Oper ation Maintenance
Pump Components—Intake Side
6
5
2
4
3
1
8
2
7

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Safety Introduction Product Overview Installation Oper ation Maintenance
Fire Pump Components—Intake Side
FeatureFeature DescriptionDescription
1Crossover valve handle This opens and closes the crossover valve that diverts a portion of the incoming water into the high-pressure discharge.
2 Low-pressure discharge
manifold
The low pressure discharge offers 6 outlets for 65 mm adapters and 2 outlets for 80 mm adapters. You can install a blind
flange or 1 to 3-inch tapped flanges to the outlets.
3Rotation indicator This indicates the impeller rotation.
4 Serial number plate This displays the pump serial number.
5 Intake manifold This is the inlet for the pump—various intake configurations are available.
6Internal-pressure relief valve This pressure relief valve opens when a predetermined pressure is reached in the discharge manifold.
7 Intake strainer This collects debris that would otherwise flow through the system.
8High-pressure discharge This is the discharge for the high-pressure stage.

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Safety Introduction Product Overview Installation Oper ation Maintenance
Pressure Mode Controller—Optional
The pressure mode controller allows you to remotely actuate the crossover valve. The pressure mode controller is available as a factory installed option.
89
5
6
4
7
2
1
3
3

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Safety Introduction Product Overview Installation Oper ation Maintenance
Pressure Mode Controller—Optional
FeatureFeature DescriptionDescription
1Bracket This mounts the controller to the pump.
2Cylinder This controls the actuation speed of the cylinder.
3Flow control This controls the cylinder movement.
4Controller This houses the electronics and manages operation.
5 Actuator switch connector This connects to the pressure mode switch—DT04-6P.
6Power wire This connects to apparatus power—12 V.
7 CANbus connector This connects to the apparatus CANbus—DT06-3S.
8Solenoid valve This actuates the cylinder.
9 Proximity sensors This senses the cylinder shaft position.

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Safety Introduction Product Overview Installation Oper ation Maintenance
Pressure Mode Switch
3
1
2

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Safety Introduction Product Overview Installation Oper ation Maintenance
Pressure Mode Switch
FeatureFeature DescriptionDescription
1Mounting holes This mounts the switch to the apparatus.
2Mode switch This operates the pressure mode controller.
3Connector This connects to the pressure mode controller—DT06-6S.

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Safety Introduction Product Overview Installation Oper ation Maintenance
Pump Components—Underside
4
2
3
1

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Safety Introduction Product Overview Installation Oper ation Maintenance
Pump Components—Underside
FeatureFeature DescriptionDescription
1Tachometer This measures the impeller shaft rotational speed—4 pulses per revolution.
2Pedestal This mounts the pump to the apparatus.
3 Pedestal drain plug This drains the oil from the pedestal.
4 Pump drain plug This drains the water from the pump.

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Safety Introduction Product Overview Installation Oper ation Maintenance
Pump Components—Drive Side with Direct Drive
1
1
5
2
3
4

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Safety Introduction Product Overview Installation Oper ation Maintenance
Pump Components—Drive Side with Direct Drive
FeatureFeature DescriptionDescription
1Lift point This provides access for a lift or hoist to position the pump assembly into the install location.
2 External pressure relief valve This pressure relief valve is set to open at approximately 650 psi (45 bar) at the factory. When open, the valve flows about
100 gpm (379 l/min), and resets when the pressure reduces to approximately 580 psi (40 bar).
Alternatively, you can choose to substitute the external pressure-relief valve with one with the same specifications as the
valve supplied by Waterous, or employ a speed-governor system that limits the pump speed to 3450 rpm when the
high-pressure discharge is enabled.
Note: The discharge plumbing for the external high-pressure relief must be directed away from people to avoid injury and
equipment to avoid damage. It is the responsibility of the installer to make sure that a high-pressure control system
for the high-pressure discharge is installed and operating properly before the pump is placed into service.
3Thermal relief valve This opens when circulating water reaches a predetermined temperature, allowing cooler water to replace it.
4 Oil-fill cap This is where oil is added to the pedestal.
5PTO companion flange This provides a connection for the PTO drive.

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Safety Introduction Product Overview Installation Oper ation Maintenance
Pump Components—Drive Side with K-Transmission
1
4
1
2
3
1
5
67