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Fire Pump
User Manual
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Xylem Fire Pump User Manual

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INSTRUCTION MANUAL
S13421
REVISION B
INSTALLER: PLEASE LEAVE THIS MANUAL FOR THE OWNER’S USE.
Fire Pump Package Pumping Systems
TABLE OF CONTENTS
SECTION 1 – GENERAL
TEMPERATURE AND VENTILATION
. . . . . . . 2
INPUT VOLTAGE . . . . . . . . . . . . . . . . . . . . . . .
FIELD CONNECTION DIAGRAMS . . . . . . . . .
SECTION 2 – INSTALLATION
PAGE
SECTION 3 – OPERATION
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . 4
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . 5
APPENDIX “A”
2
SYSTEM CHECK LIST – GENERAL,
DIESEL DRIVEN, ELECTRIC DRIVEN . . . . . . . 6
APPENDIX “B”
2
SYSTEM CHECK LIST – ELECTRICAL . . . . . .
PAGE
4
7
NOTE
The information contained in this manual is intended to assist operating personnel by providing information on the characteristics of the purchased equipment.
It does not relieve the user of their responsibility to adhere to local codes and ordinances as defined by the authority having jurisdiction.
Further information pertaining to the installation, operation, and maintenance can be found in the IOM’s for the associated equipment provided.
Any further questions, contact A-C Fire Pump Systems, (847) 966-3700.
SECTION 1 – GENERAL
1.1 DESCRIPTION
Fire Pump Package systems are custom built to the requirements provided by the purchaser. The AC Fire Pump Package is a complete fire protec­tion system. Packaged Fire Pump Systems are designed in accordance with NFPA 20. Packges are factory hydrotested to internal quality stan­dards and NFPA 20 r
1.2 PURPOSE OF MANUAL
1.2.1 This manual is furnished to acquaint you with some of the practical ways to install, operate, and maintain this unit. Read it carefully before doing any work on your unit and keep it handy for future reference. This manual provides general instruc­tions for the installation and maintenance of skid mounted electric motor driven and diesel driven systems with or without enclosures. Fire pump systems consist of but are not limited to: pumps, drivers, controllers, interconnecting piping, fuel systems and fittings.
1.2.2 Equipment cannot operate well without proper care. To keep this unit at top efficiency, follow the recommended installation and servicing proce­dures outlined in this manual.
1.3 SAFETY INSTRUCTION
1.3.1 This safety alert symbol will be used in this manual and on the pump safety instruction decals to draw attention to safety related instructions. When used the safety alert symbol means
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! FAILURE TO FOLLOW THE INSTRUCTION MAY RESULT IN A SAFETY HAZARD.
equirements.
1.3.4 Driver control equipment and electronic controls are connected to hazardous line voltages. When servicing electronic controls, there will be exposed components at or above line potential. Extreme care should be taken to pr shock. Stand on an insulating pad and make it a habit to use only one hand when checking com­ponents. Always use accurate test meters when checking electrical components. Always work with another person in case of an emergency. Disconnect power when performing maintenance. Be sure equipment is properly grounded. Wear safety glasses whenever working on electronic control or rotating equipment.
DANGER: Troubleshooting live control panels exposes personnel to hazardous voltages.
Electrical troubleshooting must only be done by a qualified electrician. FAILURE TO FOLLOW THESE
INSTRUCTIONS WILL RESULT IN SERIOUS PER­SONAL INJURY, DEATH, AND/OR PROPERTY DAMAGE.
DANGER: Internal combustion engines and gas
appliances require adequate combustion air and
ventilation. Refer to equipment manufacturers Instruc­tion, Operation & Maintenance manual. FAILURE TO
FOLLOW THESE INSTRUCTIONS WILL RESULT IN SERIOUS PERSONAL INJURY, DEATH, AND/OR PROPERTY DAMAGE.
DANGER: Batteries emit explosive gases. Make
electrical connections in a well-ventilated area.
FAILURE TO FOLLOW THESE INSTRUCTIONS WILL RESULT IN SERIOUS PERSONAL INJURY, DEATH, AND/OR PROPERTY DAMAGE.
otect against
1.3.2 Refer to the driver manufacturer’s I.O.M. (Installation Operation Manual) for specific instal­lation information.
1.3.3 Even when the pump is stopped, it should be considered "alive" as long as its controller is energized. Keep hands away from the output shaft until the pump has completely stopped and power is disconnected from the driver controller.
WARNING: Pump can start automatically. Keep hands away from output shaft until pump
is completely stopped and input power is removed from the driver control panel. Lockout main power switch while working near the driver output shaft.
FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN SERIOUS PERSONAL INJURY, DEATH, AND/OR PROPERTY DAMAGE.
1.4 HANDLING & STORAGE
1.4.1 Care should be taken to prevent damage due to dropping or jolting when moving the package. Transportation damage should be brought to the carrier’s attention immediately upon receipt.
1.4.2 The fire pump system should be unloaded and handled by qualified personnel.
WARNING: Falling Objects Hazard
Eyebolts or lifting lugs, if provided, are for lifting
only the components to which they are attached. Eyebolts on fire pump enclosures are used for factory assembly only and are not intended to lift the com­plete package. FAILURE TO FOLLOW THESE
INSTRUCTIONS WILL RESULT IN SERIOUS PER­SONAL INJURY, DEATH, AND/OR PROPERTY DAMAGE.
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1.4.3 For periods of storage, the unit should be covered to prevent corr from dirt. It should be stored in a clean, dry loca­tion to prevent condensation as well as protected from freezing. After storage, again check that it is dry before applying power. Specific storage instructions must be followed in accordance with the respective equipment manufacturer’ recommendations.
osion and contamination
s
1.8 POWER WIRING
1.8.1 Power wire types and sizes must be selected based upon conformance with the National Electrical Code and all local codes and restric­tions. In addition, only copper (Cu) wire rated for 75°C (minimum) may be used for the power con­nections. Refer to the input current as listed on the nameplate on the panel door when sizing wire.
CAUTION: Extreme temperatures are to be avoided (below 32°F and above 110°F). FAIL-
URE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN PROPERTY DAMAGE AND/OR MOD­ERATE PERSONAL INJURY.
1.5 TEMPERATURE AND VENTILATION
1.5.1 All electrical equipment is susceptible to failure if operated in ambient temperatures outside of its rating. Refer to respective equipment manufac­turer’s instructions for operating temperature range. The unit should not be operated outside these extremes.
1.6 INPUT VOLTAGE
1.6.1 The Fire Pump Package is specifically designed for a particular voltage. Refer to package specific wiring diagram for proper input voltage.
WARNING: Prevent electrical shocks. Discon­nect the power supply before beginning installa-
tion. FAILURE TO FOLLOW THESE INSTRUCTIONS
COULD RESULT IN SERIOUS PERSONAL INJURY, DEATH, AND/OR PROPERTY DAMAGE.
The voltage tolerance is +10/-10% and phase to phase voltage must not have an imbalance greater than 5 VAC.
1.7 GROUND CONNECTIONS
1.7.1 A grounding terminal is provided for a dedicated ground wire connection. All provisions of the National Electrical Code and local codes must be followed.
WARNING: Conduit grounds are not adequate. A separate ground wire must be attached to the
ground lug provided in the enclosure to avoid poten­tial safety hazards. FAILURE TO FOLLOW THESE
INSTRUCTIONS COULD RESULT IN SERIOUS PERSONAL INJURY, DEATH, AND/OR PROPERTY DAMAGE.
1.9 FIELD CONNECTION DIAGRAMS
1.9.1 Actual equipment manufacturers/models installed are system specific. Refer to specific manufac­turers Installation, Operation & Maintenance Manuals for details unique to each component. The following instruction manual categories are supplied with the system (if applicable): Fire Pump Fire Pump Controller Electric Motor Diesel Engine Jockey Pump Unit Jockey Controller Jockey Pump Relief Valve Main Relief Valve Flow Meter Casing Relief Valve Tamper Switch Sprinkler Flow Switch Altitude Valve Back Flow Preventer Unit Heater AC Louver Exhaust Fan Boiler Eye Wash / Shower Station Package Enclosure
1.9.2 The following field connection diagrams should be reviewed prior to unit installation and operation.
Drawing # Description
Job Specific Print(s) Wiring Diagram Job Specific Print(s) Assembly Drawing
WARNING: Prevent electrical shocks. Discon­nect the power supply before beginning installa-
tion. FAILURE TO FOLLOW THESE INSTRUCTIONS
COULD RESULT IN SERIOUS PERSONAL INJURY, DEATH, AND/OR PROPERTY DAMAGE.
2
SECTION 2 – INSTALLATION
2.1 LOCATION
2.1.1 Locate the pumping system in a clean, well venti­lated and properly drained location. It is recom­mended that the location selected facilitates ease of inspection, maintenance and service. Outside installations require protection from freezing.
DANGER: Heavy load, may drop if not lifted pr
operly. Do not lift the entire unit by compo­nent eyebolts. Eyebolts on fire pump enclosures are used for factory assembly only and are not intended to lift the complete package. F
THESE INSTRUCTIONS COULD RESULT IN SERI­OUS PERSONAL INJURY, DEATH, AND/OR PROP­ER
TY DAMAGE.
2.2 FOUNDATION
2.2.1 This unit is built to give you years of service; install it properly and provide a suitable founda­tion. A base of concrete weighing 2-1/2 times the weight of the unit is recommended. (Check the shipping ticket for unit weight.) Tie the concrete pad in with the finished floor. Use foundation bolts and larger pipe sleeves to give room for final bolt location.
2.2.2 Fire pump packages with electrical conduit below surface may require corrosion protection ap­proved for the condition.
WARNING: Electrical conduit installed below the surface may require a corrosion resistant
protective coating to prevent conduit corrosion and electrical shock. FAILURE TO FOLLOW THESE
INSTRUCTIONS COULD RESULT IN SERIOUS PERSONAL INJURY, DEATH, AND/OR PROPERTY DAMAGE.
2.2.3 Place the unit on its concrete foundation, sup­porting it with steel wedges or shims. These wedges or shims should be put on both sides of each anchor-bolt and midway between bolts, to provide a means of leveling the base.
AILURE TO FOLLOW
2.2.4 After the frame has been leveled and securely bolted to the pad, a good grade of grout should be installed beneath the base. A suggested mix­ture for grout is: one part Portland Cement and two or three parts plain, sharp sand mixed with water until it will pour easily. Commercial grout mixtures with suspended iron particles are avail­able. Wet the concrete base before pouring grout. Build a strong form around the foundation to con­tain grout. Allow the grout to flow around wedges & shims and beneath the entire length of the base flange.
2.3 PIPING CONNECTIONS
2.3.1 Make all necessary system piping connections. Be sure to eliminate any pipe strain on the unit. Support all pipes independently by use of pipe hangers near the unit. Line up the vertical and horizontal piping so that the bolt holes of the flanges match. DO NOT ATTEMPT TO SPRING THE SUCTION OR DISCHARGE LINES INTO POSITION. Refer to assembly drawing for cus­tomer piping connections.
2.3.2 As a rule, ordinary wire or band hangers are not adequate to maintain alignment. It is very impor­tant to provide a strong, rigid support for the suc­tion line. A saddle hanger is recommended.
2.4 SWITCH / ALARM CONNECTIONS
2.4.1 Wire tamper switches, if applicable, to control center. Refer to tamper switch manufacturers installation instructions.
2.4.2 Wire sprinkler line water flow alarm switch, if applicable. Refer to switch manufacturer installa­tion instructions.
2.4.3 Refer to fire pump panel and jockey pump panel wiring diagrams for additional switch/alarm connections.
2.5 MISCELLANEOUS CONNECTIONS
2.5.1 Certain items are shipped loose and are intended to be field installed. Items that may be shipped loose are: hose header and valves, muffler, 10ft fuel tank vent pipe, ball drip valve. If applicable these items are to be installed per the require­ments of NFPA 20 and equipment manufacturer instructions.
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SECTION 3 – OPERATION
3.1 PREPARATION
3.1.1 After package is installed and foundation bolts are tightened, check pump alignment. Refer to specific pump Installation, Operation & Mainten­ance manual for alignment procedures.
3.1.2 On packages with enclosures, inspect doors for proper alignment. Doors may become misaligned during shipping, handling and/or installation. Realign doors to provide and even 1/8" clearance between door and frame.
CAUTION: Failure to maintain a proper clear­ance will cause an interference and/or hardware
misalignment. F
INSTRUCTIONS COULD RESULT IN PROPERTY DAMAGE AND/OR MODERATE PERSONAL INJURY.
3.1.3 Inspect all piping connections. Some joints may have been loosened and not retightened after completion of factory hydrotest to facilitate sys­tem drainage. Joints may also become loose dur­ing transit due to vibration and shock. All joints are to be checked for tightness. Flanged joints should be checked for proper torque of all flange bolts prior to filling the system with fluid.
CAUTION: Failure to check all joints for tight­ness and flange bolts for proper torque could
result in leaks and/or flooding. FAILURE TO FOL-
LOW THESE INSTRUCTIONS COULD RESULT IN PROPERTY DAMAGE AND/OR MODERATE PER­SONAL INJURY.
3.1.4 Before starting all pumps and drivers should be checked for proper lubrication.
3.1.5 Piping should be clean and flushed prior to operation.
AILURE TO FOLLOW THESE
3.1.9 On diesel driven units, prior to filling the fuel tank, inspect fuel line piping connections. Joints may become loose during transit due to vibration and shock. All joints are to be checked for tightness. After filling the fuel tank, inspect the fuel line for leaks. Tighten any joints as required.
CAUTION: Failure to check all joints could result in leaks and/or environmental hazard.
FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN PROPERTY DAMAGE AND/OR MODERATE PERSONAL INJURY.
3.1.10 Prior to start up, ensure valve to hose header and valves on outside of hose header are closed.
3.2 START-UP
3.2.1 The following procedure is suggested for initial start-up.
3.2.2 Fill the system with fluid.
3.2.3 Vent all the high points in the piping system to remove trapped air. Threaded connections are supplied on bypass loops, flow meter loops and pressure sensing lines for venting.
CAUTION: Stuffing Box Damage may occur. Do not run pumps dry. Fill and vent the pump volute
prior to operation. FAILURE TO FOLLOW THESE
INSTRUCTIONS COULD RESULT IN PROPERTY DAMAGE AND/OR MODERATE PERSONAL INJURY.
DANGER: High voltage 3 phase power can kill.
Disconnect and lockout power prior to servicing
unit. FAILURE TO FOLLOW THESE INSTRUCTIONS
WILL RESULT IN SERIOUS PERSONAL INJURY, DEATH, AND/OR PROPERTY DAMAGE.
3.1.6 Refer to specific electrical and mechanical equip­ment manuals for start up instructions.
3.1.7 On electric driven units check all connections to motors and starting devices with wiring diagram.
3.1.8 On diesel driven units check all connections between engine terminal block and control panel.
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3.2.4 PUMP ROTA Check rotation of electric driven fire pump and jockey pump; refer to appropriate pump, driver and controller instruction manuals.
WARNING: Rotating shafts can catch loose clothing. Do not operate the pump without all
guards in place. FAILURE TO FOLLOW THESE
INSTRUCTIONS WILL RESULT IN SERIOUS PER­SONAL INJURY, DEATH, AND/OR PROPERTY DAMAGE.
TION, 3 PHASE MOTORS ONLY.
3.2.7 On diesel driven pumps it is desirable to adjust the main relief valve to ‘crack open’ at shut off head. This affords the valve an opportunity to function, with minimum leakage, weekly during the unit test.
3.2.8 On Jockey pump piping systems with relief valve, adjust relief valve to desired flow at shut of
3.2.9 Pump packing glands should be adjusted, as necessary, to assure an appr stuffing box for adequate lubrication and cooling.
opriate leak at each
f head.
3.2.5 Relief valves are designed to pr system from damage resulting from excess sys­tem pressure. The relief valve is intended to be field adjusted for operating pressure by the owner/operator and it is the responsibility of the owner/operator to make final opening pressure adjustments on the system.
WARNING: Properly adjust relief valves to man­ufacturer’s instructions. FAILURE TO FOLLOW
THESE INSTRUCTIONS WILL RESULT IN SERIOUS PERSONAL INJURY, DEATH, AND/OR PROPERTY DAMAGE.
3.2.6 On electric driven pumps, adjust casing relief valve to desired flow at shut off head.
otect the water
WARNING: Keep fingers and foreign objects away from rotating shafts. FAILURE TO FOL-
LOW THESE INSTRUCTIONS WILL RESULT IN SERIOUS PERSONAL INJURY, DEATH, AND/OR PROPERTY DAMAGE.
3.2.10 If the system is a diesel driven package with enclosure, check and adjust DC louver to ensure smooth operation. A foundation that is not level will cause the linkage to bind and will require adjustment prior to putting the unit into operation.
3.3 MAINTENANCE
3.3.1 Refer to specific component IOM for maintenance information.
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GENERAL
APPENDIX A
– FINAL CHECK LIST
___ 1. Is the unit base properly leveled, grouted and
secured?
___ 2. Ar
___ 4. Is the shut-off valve to the pump suction open?
___ 5. Is the shut-off valve on the discharge line open?
___ 6. Is the piping properly supported so as to pre-
___ 7. Is the distribution system purged of debris and
prior to operation. FAILURE TO FOLLOW THESE
INSTRUCTIONS COULD RESULT IN PROPERTY DAMAGE AND/OR MODERATE PERSONAL INJURY.
___ 8. Are the pump and driver shafts properly
e all lubrication points properly lubricated?
vent strains on unit?
air? Is the system filled?
CAUTION: Stuffing Box Damage may occur. Do not run pumps dry. Fill and vent the pump volute
aligned?
DIESEL INSTALLATION – FINAL
WARNING: Rotating shafts can catch loose
clothing. Do not operate the pump without all
guards in place. FAILURE TO FOLLOW THESE
INSTRUCTIONS WILL RESULT IN SERIOUS PER­SONAL INJURY, DEATH, AND/OR PROPERTY DAMAGE.
___ 9. Is the pump rotation correct?
___ 10. Is there adequate ventilation and air circulation?
___ 11. Have all piping connections been made? Have
all flanged joints been checked for tightness?
___ 12. Has an automatic air release valve been
installed on the top of the casing of each hori­zontal split case pump?
___ 13. Are remote alarm and control panels connected
and in operation as required by NFP
___ 14. Are pump bearings properly lubricated?
___ 15. Is coupling properly lubricated, if required?
A 20?
CHECK LIST
___ 1. Have all electrical connections been made bet-
ween engine terminal block and the controller?
___ 2. Has engine cooling system been filled with 50%
water and 50% antifreeze solution?
___ 3. Has diesel fuel supply tank been properly
installed in accordance with the requirements of NFPA 20? Has vent pipe been installed?
___ 4. Have both fuel ‘supply’ and ‘return’ connections
been made to fuel tank?
___ 5. Has fuel tank been filled with No. 2 diesel fuel?
___ 6. Has oil been added to the engine crankcase as
per diesel manufacturer’s recommendations?
___ 7. Does air cleaner require servicing?
___ 8. Has proper power been supplied to the diesel
controller of adequate amperage as recom­mended by the controller manufacturer?
ELECTRIC DRIVEN INSTALLATION – FINAL CHECK LIST
___ 1. Has the casing relief valve been installed
between the pump discharge and check valve?
___ 9. Have batteries been installed, serviced and cables
connected? Are the batteries fully charged?
DANGER: Charge batteries in a well-ventilated area. FAILURE TO FOLLOW THESE INSTRUC-
TIONS WILL RESULT IN SERIOUS PERSONAL INJURY, DEATH, AND/OR PROPERTY DAMAGE.
___ 10. Has proper power been supplied to the diesel
water jacket heater of adequate amperage and voltage as recommended by the diesel manufacturer?
CAUTION: Do not connect power until diesel engine is filled with coolant or the heater may
burnout. FAILURE TO FOLLOW THESE INSTRUC-
TIONS COULD RESULT IN PROPERTY DAMAGE AND/OR MODERATE PERSONAL INJURY.
___ 2. Are proper electrical connections made to the
control panel and motor (proper voltage and adequate size)?
6
ELECTRICAL
APPENDIX B
WIRING AND CONTROL SETTINGS – FINAL CHECK LIST
___ 1. Does the feeder line voltage correspond to the
unit voltage? Check the unit nameplate or motor terminal connection.
WARNING: Electrical shock hazard. Inspect all
electrical connections prior to powering the unit. Wiring connections must be made by a qualified electrician in accordance with all applicable codes, ordinances, and good practices. FAILURE TO FOL-
LOW THESE INSTRUCTIONS COULD RESULT IN SERIOUS PERSONAL INJURY, DEATH, AND/OR PROPERTY DAMAGE.
___ 2. Are the feeder wires correctly sized for the load?
___ 3. Is the unit properly grounded?
WARNING: Conduit grounds are not adequate.
A separate ground wire must be attached to the ground lug provided in the enclosure to avoid poten­tial safety hazards. FAILURE TO FOLLOW THESE
INSTRUCTIONS COULD RESULT IN SERIOUS PERSONAL INJURY, DEATH, AND/OR PROPERTY DAMAGE.
___ 4. Have all the power terminals in the control panel
been checked for tightness? This is imperative since stranded wires tend to "flow" and become loose after initial installation.
DANGER: High voltage 3 phase power can kill. Disconnect and lock out power prior to servic-
ing unit. FAILURE TO FOLLOW THESE INSTRUC-
TIONS WILL RESULT IN SERIOUS PERSONAL INJURY, DEATH, AND/OR PROPERTY DAMAGE.
7
Xylem
1) The tissue in plants that brings water upward from the roots;
2) a leading global water technology company.
We’re 12,500 people unified in a common purpose: creating innovative solutions to meet our world’s water needs. Developing new technologies that will improve the way water is used, conserved, and re-used in the future is central to our work. We move, treat, analyze, and return water to the environment, and we help people use water efficiently, in their homes, buildings, factories and farms. In more than 150 countries, we have strong, long-standing relationships with customers who know us for our powerful combination of leading product brands and applications expertise, backed by a legacy of innovation.
For more information on how Xylem can help you, go to www.xyleminc.com
Xylem Inc.
10661 Newkirk Street Dallas, TX 75220 Phone: (469) 221-1200 Fax: (214) 357-5861 www.xyleminc.com/brands/bellgossett
Bell & Gossett is a trademark of Xylem Inc. or one of its subsidiaries. © 2012 Xylem Inc. S13421B September 2012
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