Waterous S200-P Series Troubleshooting guide

S200-P Series Centrifugal Fire Pumps
Operation and Maintenance Instructions
Table of Contents
Safety Information................................................................................2, 3
Introduction . . . . . . .. . . . . . . . . . . . . . . .. . . . . . .. . . . . .. . . . . .. . . . . .. . . 4
General Description . . . . . . .. . . . . .. . . . . .. . . . . .. . . . . . . . . . . . . . . . .. . 4
Operational Limits....................................................................................4
Components.............................................................................................5
Operating Instructions
Pumping from Hydrant or in Relay .........................................................6
Pumping from Water Tank . . . . .. . . . . .. . . . . .. . . . . .. . . . . . .. . . . . . . 7
Pumping from Draft . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . . .. . . .. . . . . 8
Read through the safety information
and operating instructions carefully
before using your S200-P Series Fire
Pump.
Fire Hose Testing...................................................................................9
Maintenance...........................................................................................10
Mechanical Seal...................................................................................10
Lubrication...........................................................................................10
Testing....................................................................................................10
NOTE: Instructions subject to change without notice
F-1031, Section 2124-P (Rev. 3/23/17)
Waterous Company, 125 Hardman Avenue South, South St. Paul, MN 55075 USA 651-450-5000
www.waterousco.com

Page 2 of 10
F-1031, Section 2124-P
! WARNING
Death or serious personal injury might occur if proper
operating procedures are not followed. The pump op-
erator, as well as individuals connecting supply or dis-
charge hoses to the apparatus must be familiar with
these pump operating instructions as well as other
operating instructions and manuals for the apparatus,
water hydraulics and component limitation.
! WARNING
Pressure Hazard. May result in personal injury.
Prior to connection or removal of hoses, caps or other
closures with pump intake or pump discharge connec-
tions, relieve pressure by opening drains or bleeder
valves. Bleeder valves should also be used while filling
a hose connected to an intake with water.
! WARNING
Scalding Water Hazard. May result in serious
burns.
When operating the pump, be sure to open at least
one discharge valve slightly to prevent the pump from
overheating. If the pump runs for a few minutes com-
pletely closed, it may heat the water enough to scald
someone when the valve is opened. Overheating can
damage the packing, seals and other pump parts. If
the apparatus builder has installed a by-pass system
or other provision designed to prevent overheating,
opening a discharge valve may be unnecessary.
Safety Information
Read through the safety information and operating instructions before using your Fire Pump.
Intended Uses
The S200-P series pump is a centrifugal water pump that is
intended to be used for firefighting operations. It is an incom-
plete machine that is intended to be incorporated into com-
pleted apparatus such as firefighting vehicles.
The S200-P series pump is not intended to pump fuels, com-
bustible liquids, oil, solids or slurries.
Operator Training
It is intended that the S200-P series pumps will be operated
by personnel trained in firefighting tactics and the use of
centrifugal firefighting water pumps.
Noise
While the pump is in operation, use appropriate ear protec-
tion to guard against the noise generated by the pump.
The maximum sound pressure level is 85dB as measured
at factory conditions.
Pump Operation
Make sure all rotating components are adequately
guarded to prevent accidental contact.
Do not place any object or hand into the intake of the
pump while in operation.
Do not disconnect the discharge hoses while they are
pressurized.
Do not unfasten any component while the pump is in op-
eration.
Use suitable hoists or lifting devices when removing or
installing the pump.
! WARNING
Unexpected Truck Movement. May result in seri-
ous personal injury or death.
Failure to properly shift transmission in accordance to
the transmission operation instructions may result in
unexpected truck movement which may result in
serious personal injury or death.

Page 3 of 10
F-1031, Section 2124-P
Safety Information
Read through the safety information and operating instructions before using your Fire Pump.
WARNING
Hose Testing Hazard. May result in serious personal injury.
Due to a potential for catastrophic hose failure during service testing of fire hose, it is vital that safety precautions be taken to
prevent exposure of anyone to this danger. Fire pumps on fire department apparatus are not designed for and should not be
used for service testing of fire hoses. Hose testing machines should be used for service testing of fire hoses.
WARNING
Pressure Hazard. May result in serious personal injury.
If a fire pump on a fire department apparatus is used for service testing of fire hoses, the procedures in NFPA 1962 MUST
be followed including the use of a fire department gate valve with a ¼-inch (6 mm) hole drilled through the gate installed
between the fire apparatus discharge outlet and the hose test layout to prevent a volume surge from the pump in the event a
hose bursts during testing.
WARNING
Scalding Water Hazard. May result in serious burns.
If a fire pump on a fire department apparatus is used for service testing of fire hoses, pump discharge water must be
circulated through a by-pass system or discharged through a slightly open discharge valve, or some other provision must be
used to prevent overheating. If the pump runs for a few minutes without adequate flow through the pump, water may be
heated enough to scald someone when a valve is opened.

Page 4 of 10
F-1031, Section 2124-P
Introduction
This instruction contains the information needed for operation and maintenance of the S200-P Series fire pump.
General Description
The S200-P series are pedestal mounted fire pumps designed to meet the EN 1028 Standard:
2000 L/min @ 10 bar
2000 L/min @ 15 bar
3000 L/min @ 10 bar
3000 L/min @ 15 bar
Before operating the S200-P pump, read the following instructions carefully.
Operational Limits
Maximum Angle of Inclination
The maximum angle of inclination for pump operation is 15
degrees.
Maximum Pump Speed
The pump has a maximum operating speed that is listed in
Table 1. Do not exceed this speed.
Priming Speed
When priming the pump, the optimal pump speed is 2000
rpm and the recommended maximum priming speed is 2200
rpm.
NOTE: Engaging the primer at speeds higher than 2200
rpm for an extended period of time will not improve
primer performance and will negatively affect service
for life.
Table 1: S200-P Specifications
EN Designation (EN 1028-
1)
FPN 10-2000
FPN 15-2000
FPN 10-3000
FPN 15-3000
Nominal Flow Rate QN
l/min
2000
2000
3000
3000
Nominal Rated Pressure PN
bar
10
15
10
15
Nominal Speed NN
min-1
2970
3610
3180
3780
Maximum Speed No
min-1
3600
4050
3600
4050
Limit Pressure Palim
bar
17
20
17
20
Priming Speed Ns
min-1
2000
2000
2000
2000
Priming Time for 6m
Suction Height (EN 1846-3)
sec
40
(1) DN100
Hose
40
(1) DN100
Hose
40
(2) DN100
Hoses or (1)
DN150 Hose
40
(2) DN100
Hoses or (1)
DN150 Hose
S200-P Series

Page 5 of 10
F-1031, Section 2124-P
as
Body Assembly
Components
Automatic Piston Primer
The body is constructed of corrosion-resistant bronze and
other composite components.
Impeller
The impeller is constructed of bronze.
Impeller Shaft Assembly
The impeller shaft assembly consists of an impeller moun-
ted on a stainless steel shaft with self-lubricated sealed
bearings.
The pump is equipped with two automatic piston primers.
For best performance, operate primers at 2000 rpm (pump
speed). The primers will still perform at lower speeds, but
priming time will increase. Operating the primers at speeds
greater than 2200 rpm will not significantly improve priming
time and can negatively affect service life of the priming
system. Primer may be equipped with a manual shut-off.
Thermal Relief Valve
The thermal relief valve opens 0 the temperature of the wa-
Pedestal (Primer Housing) ter inside the pump reaches 49 C. The valve opens and di-
The pedestal is constructed of anodized aluminum and sup-
ports the piston primers and main bearings. Contains no oil
so no maintenance is required.
Mechanical Seal
The mechanical seal consists of a flat, highly polished
(lapped), self-adjusting (spring-fed) carbon ring that is
sealed in the pump body. The carbon ring presses against
a highly-polished rotating ring that is sealed to and rotates
with the impeller. Mechanical seal is retained in an easily re-
movable seal housing.
Pump Drain
One ¾” drain with a ¼ turn manual valve is provided on the
volute.
verts water to one of the following locations:
To the holding tank, vehicle tank or to atmosphere (ground).
Tachometer Connection
A magnetic pick-up feeds the pump shaft revolutions to a ta-
chometer which displays the pump impeller speed in revolu-
tions per minute (four pulses per revolution).
Lubrication
No lubrication is required as the bearings are sealed, pedes-
tal and primers are oil-free and the mechanical seal is main-
tenance free.
Components

Page 6 of 10
F-1031, Section 2124-P
WARNING
Pressure Hazard. May result in personal injury.
Prior to connection or removal of hoses, caps or other clo-
sures with pump intake or pump discharge connections, re-
lieve pressure by opening drains or bleeder valves. Bleeder
valves should also be used while filling a hose connected to
an intake with water.
WARNING
Scalding Water Hazard. May result in serious burns.
When operating the pump, be sure to open at least one dis-
charge valve slightly to prevent the pump from overheating.
If the pump runs for a few minutes completely closed, it may
heat the water enough to scald someone when the valve is
opened. Overheating can damage the packing, seals and
other pump parts. If the apparatus builder has installed a by-
pass system or other provision designed to prevent overheat-
ing, opening a discharge valve may be unnecessary.
Operating Instructions
Pumping from Hydrant or in Relay
4. Open discharge valves and accelerate engine to obtain
desired discharge pressure and capacity.
5. Set low pressure relief valve or other governing device
to desired pressure (relief valve or governing device not
supplied by Waterous).
1. Open intake, hydrant and other valves as necessary to
allow water to enter the pump.
2. Allow about 30 seconds for water to flow into pump.
3. Engage pump drive in accordance with the vehicle op-
eration instructions and accelerate engine to obtain de-
sired discharge pressure and capacity.
NOTE: The S200-P pump has an automatic priming sys-
tem that will engage or disengage when the discharge
pressure rises above or falls below a predetermined set-
ting.
After Pumping
1. If pumping anything but clean water, remove all intake
and discharge caps, open all valves and open all drains.
Flush entire system with clean, fresh water for several
minutes to remove all traces of impurities.
2. Cycle the piston primers. Operate them until all the fluid
is discharged from the piston primer discharge pipes.
3. If pump is kept full of water when not in use, make sure
water is clean and non-corrosive. Make sure the pump
is completely full or completely drained (never partially
full).
4. Disengage pump drive in accordance with the vehicle
operation instructions.
5. Close all drains and install intake and discharge caps.
NOTICE
Freezing water hazard. May cause damage to the pump.
If the pump is exposed to freezing temperatures, drain all
water from pump, lines and accessories.
NOTICE
This pump has a mechanical seal, limit intake pressure to 75
psi (5 bar) if possible. Although the pump will operate properly
with higher intake pressure, such operation will greatly accel-
erate mechanical seal wear.
NOTICE
Do not attempt to pump more water than is available from the
hydrant or relaying pumper. Always make sure the intake
pressure compound-gage reading stays above zero. Some
fire departments operate at a minimum intake pressure of 15
psi (1 bar) when pumping from hydrant or in relay to prevent
a "soft" intake hose from collapsing.

Page 7 of 10
F-1031, Section 2124-P
WARNING
Pressure Hazard. May result in personal injury.
Prior to connection or removal of hoses, caps or other clo-
sures with pump intake or pump discharge connections, re-
lieve pressure by opening drains or bleeder valves. Bleeder
valves should also be used while filling a hose connected to
an intake with water.
WARNING
Scalding Water Hazard. May result in serious burns.
When operating the pump, be sure to open at least one dis-
charge valve slightly to prevent the pump from overheating.
If the pump runs for a few minutes completely closed, it may
heat the water enough to scald someone when the valve is
opened. Overheating can damage the packing, seals and
other pump parts. If the apparatus builder has installed a by-
pass system or other provision designed to prevent overheat-
ing, opening a discharge valve may be unnecessary.
Pumping from Water Tank
After Pumping
1. If pumping anything but clean water, remove all intake
and discharge caps, open all valves and open all drains.
Flush entire system with clean, fresh water for several
minutes to remove all traces of impurities.
2. Cycle the piston primers. Operate them until all the fluid
is discharged from the piston primer discharge pipes.
1. Open valve(s) in piping between water tank and pump
intake and at least one discharge valve.
2. Allow about 30 seconds for water to flow into pump.
NOTE: The S200-P pump has an automatic priming sys-
tem that will engage or disengage when the discharge
pressure rises above or falls below a predetermined set-
ting.
3. Engage pump drive in accordance with the vehicle op-
eration instructions and accelerate engine to obtain de-
sired discharge pressure and capacity.
3. If pump is kept full of water when not in use, make sure
water is clean and non-corrosive. Make sure the pump
is completely full or completely drained (never partially
full).
4. Disengage pump drive in accordance with the vehicle
operation instructions.
5. Close all drains and install intake and discharge caps.
4. Open discharge valves and accelerate engine to obtain
desired discharge pressure and capacity.
5. Set low pressure relief valve or other governing device
to desired pressure (relief valve or governing device not
supplied by Waterous).
NOTICE
Do not attempt to pump more water than is available from the
water tank. Always make sure the intake pressure compound
gage reading stays above zero.
NOTICE
Freezing water hazard. May cause damage to the pump.
If the pump is exposed to freezing temperatures, drain all
water from pump, lines and accessories.

Page 8 of 10
F-1031, Section 2124-P
WARNING
Pressure Hazard. May result in personal injury.
Prior to connection or removal of hoses, caps or other clo-
sures with pump intake or pump discharge connections, re-
lieve pressure by opening drains or bleeder valves. Bleeder
valves should also be used while filling a hose connected to
an intake with water.
WARNING
Scalding Water Hazard. May result in serious burns.
When operating the pump, be sure to open at least one dis-
charge valve slightly to prevent the pump from overheating.
If the pump runs for a few minutes completely closed, it may
heat the water enough to scald someone when the valve is
opened. Overheating can damage the packing, seals and
other pump parts. If the apparatus builder has installed a by-
pass system or other provision designed to prevent overheat-
ing, opening a discharge valve may be unnecessary.
Pumping from Draft
After Pumping
1. If pumping anything but clean water, remove all intake
and discharge caps, open all valves and open all drains.
Flush entire system with clean, fresh water for several
minutes to remove all traces of impurities.
2. Cycle the piston primers. Operate them until all the fluid
is discharged from the piston primer discharge pipes.
NOTE: To get full capacity, quick prime and maintain
pump efficiency:
a. Position vehicle as near as possible to water supply.
b. Avoid humps and sharp bends in intake hose. Make
sure no part of hose is higher than pump inlet. (Air pock-
ets in intake hose may cause loss of prime or erratic
pump action, and may reduce pump capacity.)
c. Make sure all intake connections are tight and discharge
valves are closed.
d. Immerse intake strainer at least two feet (.5 M) below
water surface to prevent pump from drawing air. (Whirl-
pools forming above intake strainer indicate that strainer
is too close to surface of water.)
e. Make sure intake strainer is far enough from bottom to
prevent sand, gravel and other foreign matter from
being drawn into the pump.
6. Open suction valve (if equipped) as necessary to allow
water to enter the pump.
7. Engage pump drive in accordance to with the vehicle op-
eration instructions and accelerate engine to obtain de-
sired discharge pressure and capacity.
NOTE: The S200-P pump has an automatic priming
system that will engage or disengage when the dis-
charge pressure rises above or falls below a prede-
termined setting.
8. Open discharge valves, and accelerate engine to obtain
desired discharge pressure and capacity.
9. Set low pressure relief valve or other governing device
to desired pressure (relief valve or governing device not
supplied by Waterous).
3. If pump is kept full of water when not in use, make sure
water is clean and non-corrosive. Make sure the pump
is completely full or completely drained (never partially
full).
4. Disengage pump drive in accordance with the vehicle
operation instructions.
5. Close all drains and install intake and discharge caps.
NOTICE
Freezing water hazard. May cause damage to the pump.
If the pump is exposed to freezing temperatures, drain all
water from pump, lines and accessories.

Page 9 of 10
F-1031, Section 2124-P
Fire Hose Testing
WARNING
Hose Testing Hazard. May result in serious personal injury.
Due to a potential for catastrophic hose failure during service testing of fire hose, it is vital that safety precautions be taken to
prevent exposure of anyone to this danger. Fire pumps on fire department apparatus are not designed for and should not be
used for service testing of fire hoses. Hose testing machines should be used for service testing of fire hoses.
NFPA 1962 Standard for the Inspection, Care, and use of Fire Hose, Couplings, and Nozzles and the Service Testing of Fire
Hose provides requirements and testing procedures for service-testing fire hose at least annually. NFPA 1962 includes
procedures for service testing with either a hose testing machine or with a pump on a fire department fire apparatus.
WARNING
Pressure Hazard. May result in serious personal injury.
If a fire pump on a fire department apparatus is used for service testing of fire hoses, the procedures in NFPA 1962 MUST
be followed including the use of a fire department gate valve with a ¼-inch (6 mm) hole drilled through the gate installed
between the fire apparatus discharge outlet and the hose test layout to prevent a volume surge from the pump in the event a
hose bursts during testing.
During fire hose testing with a fire pump on a fire department fire apparatus, the fire pump is required to be operated at high
discharge pressure with little or no flow out of the apparatus.
WARNING
Scalding Water Hazard. May result in serious burns.
If a fire pump on a fire department apparatus is used for service testing of fire hoses, pump discharge water must be
circulated through a by-pass system or discharged through a slightly open discharge valve, or some other provision must be
used to prevent overheating. If the pump runs for a few minutes without adequate flow through the pump, water may be
heated enough to scald someone when a valve is opened.
CAUTION
If a fire pump on a fire department apparatus is used for service testing of fire hoses, operating the pump at high discharge
pressure with little or no flow may result in severe damage to the pump.

Page 10 of 10
F-1031, Section 2124-P
Maintenance
Mechanical Seal
Lubrication
Testing
NOTICE
An annual test should be performed to check pump performance. This will reveal the
condition of the internal components and if any repairs are required.
NOTICE
No lubrication is needed. The bearings are sealed, the primer and pedestal are oil-free
and the mechanical seal is lubricated by water..
NOTICE
Prolonged dry pump operation or operating a dry pump at high speeds will reduce the
life of the mechanical seal.
NOTICE
The pump shaft is sealed with a mechanical seal and no adjustment is required. When
the pump is in operation, the water being pumped lubricates and cools the seal. If the
seal leaks, replace the entire seal.
NOTICE
All pump maintenance can be performed using standard tools.