Hubbell LX-1500 User Manual

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Hubbell Industrial Controls, Inc.

HUBBELL

A subsidiary of Hubbell Incorporated

50 Edwards St.

 

 

Madison, OH 44057

 

 

 

Telephone (440)

428-1161

 

FAX (440)

428-7635

Instruction Manual

Fire Pump Controller

Model LX-1500

Limited Service

Electric

Publication No. 197

April, 2000

Limited Service Fire Pump Controller

Table of Contents

 

I Introduction..................................................................................................................................

3

II Specifications and Certifications ................................................................................................

3

Specifications ................................................................................................................................

3

Certifications .................................................................................................................................

4

III Receiving, Handling, and Storage.............................................................................................

4

IV Installation .................................................................................................................................

4

V Sequence of Operation ................................................................................................................

5

VI Start Up Procedure....................................................................................................................

7

VII Maintenance .............................................................................................................................

9

Preventive Maintenance.................................................................................................................

9

Troubleshooting.............................................................................................................................

9

Coil and Contact Replacement .....................................................................................................

10

VIII Limited Service Fire Pump Controller Parts.......................................................................

11

Attachments

Typical Controller Schematic

Typical Field Connection Diagram

Notes

Refer to job drawings for options.

For combination Automatic Transfer Switch/Fire Pump Controller applications, refer to Publication No. 186 for the LX-250Transfer Switch or Publication No. 195 for theLX-350Transfer Switch, for details.

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Limited Service Fire Pump Controller

I Introduction

The Hubbell Limited Service Fire Pump Controller provides automatic and manual control of small electric motor driven fire pumps and booster pumps of 30 horsepower or less.

All Controller components are inside the cabinet with indicating lights and switch handles located next to the door. A pressure switch initiates automatic starting of the pump motor. The Controller monitors the power phases and voltage. The CIRCUIT BREAKER DISCONNECTING MEANS handle has a door interlock feature to prevent opening the door when the switch is closed. The Controller also has anEMERGENCY MANUAL CONTROL handle to start the fire pump manually.

CIRCUIT

BREAKER

 

EMERGENCY

DISCONNECTING

 

MANUAL

 

CONTROL

MEANS

 

 

 

Incoming

 

To

Phase

 

 

Fire Pump Motor

Line

 

 

L1 M1 T1

 

Surge

 

 

Suppressor

 

 

Control

PLM

Pressure

Panel

 

Switch

 

Control

 

 

Transformer

Figure I-1 Block diagram ofLX-1500showing one phase

II Specifications and Certifications

Specifications

Voltage

208, 240, 380, 480C

Phase Loss/Reversal Module

A-B-Cphase rotation

200 Series

208–240VAC, 60 Hz, 3 phase

300 Series

380–415VAC, 50 Hz, 3 phase

400 Series

440–480VAC, 60 Hz, 3 phase

Maximum Voltage

10% of highest nominal voltage

Maximum Frequency Shift

0.1 Hz

Phase Loss

18% of low voltage in one phase

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Limited Service Fire Pump Controller

 

 

 

Undervoltage Trip

15% below set point

Time Delays

Pick-up,1.5 s, fixed

 

Drop-out,1.5 s, fixed

Output Relays

10 A, 120 VAC

 

5 A, 240 VAC

Indication

green LED, on for A-B-Cphase rotation

Surge Suppressor

650 V rating

Temperature

Operating: −4° F to 104° F (−20° C to 40° C)

 

Storage: −4° F to 182° F (−20° C to 85° C)

Certifications

The Hubbell Limited Service Electric Fire Pump Controller is built to NFPA 20 requirements. The Controller is listed by:

Underwriters Laboratory

Factory Mutual

Underwriters Laboratory Canada

New York City

Canadian Standards Association

 

III Receiving, Handling, and Storage

1.Immediately upon receipt, carefully unpack and inspect the Controller for damage that may have occurred in shipment. If damage or rough handling is evident, file a damage claim with the transportation carrier.

2.If the Controller must be stored, cover it and place in a clean, dry location. Avoid unheated locations where condensation can result in damage to the insulation or corrosion of metal parts.

IV Installation

1.Consult the motor nameplate to determine voltage, current, and horsepower rating and compare with the Controller nameplate for matching data.

2.Release the door interlock by moving the CIRCUIT BREAKER DISCONNECTING MEANS to theOFF position.

3.Inspect the control transformer’s primary connections for agreement with the line voltage of the incoming power.

4.Exercise all switches and contactors, without power, to see that they operate freely.

5.Choose a location or base for the Controller that is non-combustibleand within site of the motor. The base should not be subject to excessive vibration that may cause erratic operation of the PS (pressure switch). The Controller should be leveled so that the PS is level. Sight across the PS cover screws.

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Limited Service Fire Pump Controller

Caution: Before drilling and punching holes in the cabinet for wiring connections, cover the components inside the cabinet with a protective covering. Debris may cause shorts or prevent operation of components.

6.Punch holes in the top or the bottom of the cabinet for conduit.

7.Connect the water pressure sensing line to the PS (1/4 NPT internal, 3/4-16external, brass) fitting on the bottom of the cabinet. For further details, consult the latest edition of NFPA 20.

8.Connect the power supply conductors to the line side of the CIRCUIT BREAKER in the correctA-B-Cphase sequence.

9.Connect the motor conductors to the load side of the motor contactor.

Note

Refer to the Controller field connection diagrams. Per the requirements of NFPA 20, conductors are sized for no less than 125% of the motor FLC (full load current) and not more than the lug sizes provided, as shown on the Controller field connection diagrams. Refer to the NFPA 70 (NEC) for cable ratings. Secure conductors inside the cabinet so they do not interfere with or come in contact with the components.

10.Connect the remote alarm contacts. Refer to the supplied Controller field connection diagram for terminal points.

V Sequence of Operation

The PLM (phase loss/reversal monitor) provides contact output for phase loss and undervoltage (PLM-2)in addition to a separate contact output for phase rotation(PLM-1).Both output relays energize if all three phases are present and the phases are in the proper rotation. If a phase loss or undervoltage condition occurs, only the phase loss relayde-energizes.If the phases are reversed relative to the sequence on the PLM, only the phase reversal relayde-energizes.If there is a total loss of thethree-phasevoltage, both output relaysde-energize.

Closing the CIRCUIT BREAKER DISCONNECTING MEANS energizes the PLM and the control transformer. After a3–5second delay, contactsPLM-1open and thePHASE REVERSAL light should go off. If there is a phase reversal,PLM-1remains closed to turn on thePHASE REVERSAL light and energize the PRR (phase reversal relay) to provide remote indication of phase reversal. ThePLM-2contacts also close, after the3–5second delay, to turn on thePOWER AVAILABLE light and energize the PFR (phase failure relay) to provide remote indication that power is available.

Automatic Start - When the PS (pressure switch) contacts close due to a decrease in pressure, the CR relay coil energizes. The CR contacts close to energize the TR1 timing relay, factory set at 10 minutes, to begin timing. The TR1 contacts close to latch the CR relay and bypass the PS. The CR contacts also energize contactor coil M1 to start the motor. If the pressure increases, the PS contacts open tode-energizethe CR relay and stop the motor, if TR1 has timed out. If TR1 is

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Limited Service Fire Pump Controller

still timing, the CR relay remains energized and the motor continues to run for the duration of the timer setting.

Pressing the STOP push button stops the motor even if TR1 is timing. If the Controller does not have a TR1 timing relay, the pump motor runs until theSTOP push button is pressed.

Manual Local Start - Pressing theSTART push button energizes relay LRSR. The LRSR contacts close to latch the LRSR relay and energize the M1 contactor coil to start the motor. The motor runs until theSTOP button is pressed tode-energizethe LRSR coil.

Manual Stop – Connecting the jumper wire betweenTB2-4andTB2-5bypasses the TR1 timing relay contacts. When this jumper is installed, the motor runs until theSTOP button is pressed.

Remote Start - The remote start circuit requires the closure of remote contacts to start the motor. Closing the remote contacts energizes the LRSR relay. The LRSR contacts close and latch the LRSR relay until theSTOP button is pressed.

Deluge Valve Start – A normally closed remote switch energizes the optional deluge valve relay (DVR). Opening the remote switchde-energizesthe DVR, closing the DVR contacts in parallel with the PS contacts, to energize the CR relay and the TR1 timing relay. When the remote switch closes, the DVR contacts open tode-energizethe CR relay and stop the motor, if TR1 has timed out.

Lockout – (This feature is not allowed per NFPA 20 and is permitted only when acceptable to the authority having jurisdiction.) The lockout circuit requires the closure of remote contacts to stop the motor. Closure of the contacts energizes the LK relay. Contacts LK open to deenergize the CR relay and stop the motor. If the remote contacts open while the pressure is low, the motor restarts.

EMERGENCY MANUAL CONTROL - The emergency start handle should only be used if the Controller fails to start automatically or with theSTART push button. The motor runs until the handle is returned to theOFF position or theCIRCUIT BREAKER is opened. To start the motor when control power is not available,push the T-handle in and rotate counterclockwise (45°) to lock in the full ON position in a fast and continuous motion.

Caution: Failure to engage the handle in a fast and continuous motion can result in damage to the contactor and failure to start the motor.

Pump Run Contacts - The pump run contacts transfer any time the M1 contactor is closed by either electrical or mechanical means.

Phase Loss Contacts - The phase loss contacts transfer when line or control power is lost or the line voltage drops more than 15 percent.

Phase Reversal Contacts - The phase reversal contacts transfer when there is a phase reversal, rotation other thanA-B-C.

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Limited Service Fire Pump Controller

VI Start Up Procedure

Danger: Shocks, burns, or death may result from high voltage.

Caution: Only personnel who are familiar with the power distribution system and this manual should be allowed to perform this procedure.

1.Verify that the motor nameplate horsepower and voltage match the Controller nameplate.

2.Verify that the CIRCUIT BREAKER DISCONNECTING MEANS is open. Check with the electrician to see if the Controller is connected directly to the main transformer. If so, apply theService Disconnect label above theCIRCUIT BREAKER handle operator.

3.Verify that the PLM is set to the line voltage.

4.Verify that the customer connections to the CIRCUIT BREAKER and contactor are properly tightened.

5.Carefully remove the foam packing from the PS (pressure switch) between the mercury switch and the bourdon tube. Remove the installation instructions above the tube. Replace plastic cover.

6.Adjust the PS set points on the right side of the switch to meet water system requirements. Set the upper pointer to the required STOP (HIGH) pressure setting. Set the lower pointer to the required START (LOW) pressure setting.

The scale on the PS is only for initial positioning of the pointers. During testing of the Controller, verify the PS settings by referring to the system pressure gage. Readjust settings as necessary to obtain desired STOP and START settings. Refer to the instructions packed in the PS and NFPA 20 for more information on adjusting the settings.

7.Verify that the minimum run timer TR1 is set for 10 minutes, per NFPA 20. The timer can be field set as required by local jurisdiction.

8.Close the cabinet door and close the CIRCUIT BREAKER DISCONNECTING MEANS. After a five second delay, verify that thePOWER AVAILABLE light is on. If equipped with a Transfer Switch, verify that the green LED on the PRM (phase reversal monitor) is on after afive-seconddelay. If the LED’s are not on, open theCIRCUIT BREAKER and change any two leads (L1, L2, and L3) on the PLM. If equipped with a Transfer Switch, change the same two leads on the PRM.

Caution: Note that the pump should be primed and the water source available before running to avoid damage to the pump. To avoid flooding, ensure the sprinkler system is completely installed and ready to be pressurized.

9.Bump the motor by pressing theSTART button and then press theSTOP button, to check for proper rotation. If not correct, open theCIRCUIT BREAKER and change any two leads on the load side of the M1 contactor.

10.Press the START push button. Verify that the motor starts properly and runs at full speed.

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Limited Service Fire Pump Controller

11.Press the STOP push button to stop the motor.

12.Start and stop the motor with the EMERGENCY MANUAL CONTROL handle. Push and rotate theT-handlein aquick motion to lock the contactor in theON position to start. Rotate theT-handleclockwise and release to stop the motor.

Caution: Failure to engage the handle in a fast and continuous motion can result in damage to the contactor and failure to start the motor.

If equipped with an LX-250orLX-350Automatic Transfer Switch, complete the following additional tests:

1.Verify connection of the engine generator set start wires to TB-1andTB-2at the top of theLX-250Transfer Switch power panel or toTB8-1andTB8–2on the left side of theLX-350Transfer Switch power panel.

2.Close the FIRE PUMP (emergency)ISOLATING SWITCH and open theCIRCUIT BREAKER. The Automatic Transfer Switch should transfer to the alternate source per system requirements.Bump the motor to check for proper rotation. If incorrect, move theFIRE PUMP ISOLATING SWITCH to theOFF position and switch the generator set off using the switch located on the generator. Switch any two leads on the line side of theFIRE PUMP ISOLATING SWITCH. Return the generator set control switch to the Auto position and close theFIRE PUMP ISOLATING SWITCH. The generator set may start.

3.Operate the pump on the alternate (emergency) source using the START andSTOP push buttons.

4.Close the CIRCUIT BREAKER. The Control Module should now be sensing normal power and timing for retransfer. Press theBYPASS RETRANSFER TO NORMAL push button to return the Transfer Switch to the normal position.

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Limited Service Fire Pump Controller

VII Maintenance

Danger: Do not open the Controller cabinet until ALL power is disconnected. Shocks, burns, or death may result from high voltage.

Caution: Only personnel who are familiar with the power distribution system and this manual should be allowed to inspect or perform maintenance on the Controller.

Preventive Maintenance

A.Protect the equipment against accumulation of dust and metal chips.

B.Protect the equipment against conditions that result in excessive moisture.

C.Exercise the equipment every week as part of routine maintenance to verify the integrity of the Controller, Transfer Switch, generator set, power conductors, pump, and motor.

D.Field lubrication is not necessary or required for the Controller.

Troubleshooting

 

Hazardous voltage

! DANGER

will shock, burn,

or cause death.

 

Do not touch

 

until ALL power

 

is disconnected.

Warning: Disconnect ALL power supply sources to the Controller before servicing to prevent shock or accident hazard.

Before attempting any troubleshooting on the Controller, verify that the cause of a problem is not due to the motor, pump, or power source. Then visually inspect the Controller for component damage and lose wiring. If the problem cannot readily be resolved, review the Sequence of Operation section for proper operation. Then refer to the supplied wiring diagram and schematic and use a volt/ohm meter to check the wiring to determine which component is faulty.

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Limited Service Fire Pump Controller

Coil and Contact Replacement

Coil

Spring

 

Clip

Coil

Retainers

 

 

Magnet

Assembly

Figure VI-1 Magnet Assembly and Retainers

 

Coil Replacement*

Contact Replacement*

 

 

 

1.

Isolate all power sources.

Complete steps 1 through 5 in left column.

 

 

 

2.

While pressing against the coil, pull up slightly

Remove the magnet assembly from the molded

 

on the coil retainers and swing away from coils.

cover and movable arm.

 

 

 

3.

Pull the magnet assembly, coil, molded cover,

Remove the return spring from the center of

 

and movable arm from the contactor.

movable arm.

 

 

 

4.

Remove the spring clip and remove the

Remove the molded cover from movable arm.

 

armature from movable arm.

 

 

 

 

5.

Remove the coil from the magnet.

Press and slide the movable contact and spring

 

 

from movable arm.

 

 

 

6.

Replace the coil and reassemble.

Remove the screws holding stationary contacts

 

 

in place and remove stationary contacts.

 

 

 

7.

 

Replace contacts and reassemble.

 

 

 

Notes for re-assembly*:

a.The molded cover only fits one way.

b.The magnet and movable arm fit either way but operates more quietly if reassembled the same way before removal.

c.Do not attempt to remove or replace arc traps in cover.

*Source: General Electric, GEH-5168

Page 10 of 12

Limited Service Fire Pump Controller

VIII Limited Service Fire Pump Controller Parts

Spares

Symbol

Description

Function

Part No.

 

 

 

 

 

1

CR, LRSR

High Voltage Relay

Starting Relay

31658141

1

LK, PFR,

2-PoleRelay

Control Relay

31658123

 

PRR

 

 

 

 

 

 

 

 

2

FU1, FU2

Fuse, 1 A, MDL-1

Control Power

57361726

 

 

 

 

 

1

TR1

Timing Relay, octal

Min. Run Time

31658111

 

 

 

 

 

 

 

Octal socket

TR1

48518012

 

 

2-PoleRelay socket

LK, PRR, PFR

48518018

 

 

High Voltage Relay socket

CR, LRSR

48518022

 

 

 

 

 

1

PLM

Phase Monitor, 208–240V

Phase Loss/Reversal

57418398

 

Phase Monitor, 440–480V

57418399

 

 

 

 

 

 

 

 

1

XFMR

Transformer,

Control Power, 120 V

57511355

 

208/230/380/460 V

 

 

 

 

 

 

 

 

 

1

PS

Pressure Switch, 10-300PSI

1 NC contact

57501023

 

 

 

 

 

 

EPR

Pressure Recorder, 300 PSI

Battery driven

57501013

 

 

 

 

 

 

 

Operating handle

Circuit Breaker

57504087

 

 

 

 

 

 

 

Emergency Manual T-handle

 

91158006

 

 

Emergency Operator Push Rod

Emergency Operator

91158005

 

 

Emergency Push Rod Pin

 

57401033

 

 

 

 

 

 

PB1

Push button NO, green

Start push button

80320105

 

PB2

Push button NC, red

Stop push button

80320104

 

 

 

 

 

2

PL4, 5, 6, 7

Bulb

Indicating lights

80324905

 

 

 

 

 

 

PL4, 5, 6, 7

Lamp Socket

Indicating lights

402066520

 

 

 

 

 

 

PL5, 6, 7

Red lens

Phase Reversal

402067520

 

PL4

Clear lens

Power Available

402157520

 

 

 

 

 

 

SS

Surge Suppressor

Surge suppression

402165820

 

 

 

 

 

Page 11 of 12

Limited Service Fire Pump Controller

Spares

Symbol

Description

Function

Part No.

 

 

 

 

 

 

 

Breaker, 15 A

 

57504463

 

 

Breaker, 20 A

 

57504373

 

 

Breaker, 25 A

 

57504371

 

 

Breaker, 30 A

 

57504103

 

 

Breaker, 40 A

 

57504378

 

CB

Breaker, 50 A

Circuit Breaker

57504389

 

(Note 3)

Breaker, 60 A

Discounting Means

57504346

 

 

Breaker, 70 A

 

57504347

 

 

Breaker, 90 A

 

57504348

 

 

Breaker, 110 A

 

57504541

 

 

Breaker, 125 A

 

57504101

 

 

Breaker, 150 A

 

57504344

 

 

 

 

 

 

 

Contactor, 200/208

 

57300333

 

M1

Contactor, 220/240

Main Contactor

57300330

 

 

Contactor, 440/480

 

57300331

 

 

 

 

 

 

 

Contactor Coil, 200/208

 

57300570

 

 

Contactor Coil, 220/240

 

57300571

 

 

Contactor Coil, 440/480

 

57300573

 

 

 

 

 

 

 

 

Pump Run Contact

 

 

M1a1, M1b1

Auxiliary Contact, M1

1 NO and 1 NC

57300391

 

 

 

Contact

 

 

 

 

 

 

Notes

1.Specify Controller serial number, model number, horsepower, and voltage when ordering parts.

2.Refer to Bulletin 1000 for information on one-yearparts and labor warranty.

3.Consult factory for Spectra Circuit Breakers with high interrupt ratings.

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