DESIGN SUPPLY INSTALL HUNTER PUMPS ELECTRIC FIRE PUMP SET INSTRUCTION MANUAL Installation, Operation, Maintenance & Warranty 5 Aluminium Close Edgeworth NSW 2285 P: 02 4958 7555 E: Sales@hunterpumps.com > hunterpumps.com
Contents Contents... 2 SECTION 1 ELECTRIC FIRE PUMP SET... 3 1. INTRODUCTION... 3 2. COMMISSIONING... 5 3. INITIAL START UP PROCEDURE... 6 4. TESTING... 7 5. CARE AND MAINTENANCE... 9 SECTION 2 WARRANTY... 10 SECTION 3 PUMP END... 11 1. SOUTHERN CROSS ISO PRO INSTALLATION, OPERATION AND MAINTENANCE MANUAL... 11 SECTION 4 ELECTRIC MOTOR... 12 1. CMG PPA & PPC INDUCTION MOTORS INSTALLATION, OPERATION & MAINTENANCE MANUAL... 12 Hunter Pumps Sales and Service P: 02 4958 7555 E: sales@hunterpumps.com 2
SECTION 1 ELECTRIC FIRE PUMP SET This manual contains important safety and warranty information about your pump. Please read it carefully before installation or operation. Please also ensure that all relevant parties receive a copy. 1. INTRODUCTION Congratulations on your purchase of a Hunter Pumps Electric Fire Hydrant Pump Set. With proper care and by following a few simple guidelines your system will give you many years of dependable service. 1.1 IMPORTANT Only qualified personnel should install, operate and repair your pump system. Any wiring of pumps should be performed by a qualified electrician. 1.2 SAFETY PRECAUTIONS Before installation, operation or maintenance of pump system, read instruction carefully. System operation may cause injury. Take all necessary precautions. Wear necessary protective equipment. Refer to engineers department. Any maintenance of pump systems must be carried out by Authorized Qualified Personnel only. 1.2.1 Warning- Pump may start at any time In normal automatic mode, pumps may start automatically at any time. Before maintenance or any work is carried out on pumps or motors, ensure proper isolation of motors at the relevant controller. 1.2.2 Warning - System is pressurized Under normal operating conditions, the pipes, pumps and components of water supply and pressure systems are pressurized. Before unbolting or dismantling any pipework or equipment, ensure water supply to the areas of maintenance is isolated and water pressure relieved. 1.2.3 Danger - High Voltage Control boxes contain high voltage live wiring and terminals. Entry of control boxes is not permitted except by Authorized Service Personnel only. Ensure controller is correctly isolated before entering. 1.2.4 Caution- Exposed Moving Parts Keep clear of all moving parts on pumps, motors and couplings, and keep area around pump system clear at all times. Hunter Pumps Sales and Service P: 02 4958 7555 E: sales@hunterpumps.com 3
Finally, take care and use common sense when working on or near pumpset, and report all faults to the Maintenance Manager. 1.3 DESCRIPTION Package Fire Hydrant Pumpset has been designed and manufactured to facilitate the automatic and manual operation of electric and diesel fire hydrant pumps, to pump water from storage tank to fire hydrants. System has been supplied as a complete package including electric and diesel pumpsets and associated accessories; jacking pump, pipework and valves, control boxes and other associated equipment. System is activated on opening of hydrant valves, which cause a deep in pressure at pumpset. Shutting down of system is manual only. 1.3.1 ELECTRIC DRIVEN PUMP UNIT: Duty pump is a back pull out centrifugal pump direct coupled to an electric motor via flexible spacer coupling. Pumpset is controlled by 'electric fire pump controller' (E.F.P.C.) which is in constant automatic start mode. On fall of pressure in system to a point lower than jacking pump cut-in; the pump/motor will start via starter in E.F.P.C. Pump/motor can be started manually via 'manual start' button on E.F.P.C. E.F.P.C. Fire pump motor can be isolated by using main isolator on Pipework includes OS&Y isolating valves for isolating pump. 1.3.2 DIESEL DRIVEN PUMP UNIT: Standby pump is a back pull out centrifugal pump direct coupled to a diesel engine via flexible spacer coupling, and is complete with steel fuel tank, mounted adjacent to engine; engine start solenoids; fuel rack solenoid (shut down). Pumpset is controlled by 'diesel Fire Pump Controller' (D.F.P.C.) which is activated at all times to start on large drop of pressure in system (below Electric fire pump start level). Pump/engine can be shut down by pressing 'Stop' button on D.F.P.C. Pump/engine can be started manually by pressing 'Manual Start' button on D.F.P.C. Engine start can be isolated via key switch 'Start Isolator' for maintenance requirements. Pipework includes OS&Y isolating valves for isolating pumps. 1.3.3 JACKING PUMP: System incorporates jacking pump and pressure vessel. Pump is controlled by MAN/OFF/AUTO selector switch on 'Electric Fire Pump Controller' in conjunction with pressure switches mounted on discharge manifold. With selector switch in manual position, pump will run continuously. With selector switch in off position, jacking pump is isolated, with selector switch in Auto position, jacking pump will start on fall of system pressure and shut down once system pressure is reached. Jacking pump system can be isolated using fate valves, and pipework includes check valves. Hunter Pumps Sales and Service P: 02 4958 7555 E: sales@hunterpumps.com 4
2. COMMISSIONING A commissioning service is offered by Hunter Pumps which may or may not have been included in the price of the system. Please read your quotation carefully to determine this. 2.1 COMMISSIONING SHEET System Description: Date: Client: Project: Commissioned by Name: Commissioned by Organisation: DESCRIPTION: COMMISIONED BY (Initial) Pressure Switch Settings Jacking pump cut in Jacking pump cut out Duty pump cut in Standby pump cut in Pressure Tank Charge (when empty) Relief Vale Settings Duty pump valve open at Standby pump valve open at Impeller Sizes Duty pump impeller diameter Standby pump impeller diameter mm mm Hunter Pumps Sales and Service P: 02 4958 7555 E: sales@hunterpumps.com 5
3. INITIAL START UP PROCEDURE Fire pumps have been pre-commissioned and tested to AS 2941-1995 prior to dispatch from workshop however, a site commission is still necessary. It is suggested initial start up is done with the site electrician present. Visual inspections of complete system to ensure fire work connections are in place and nothing is out of order. Open necessary valves to allow water from supply tank to pumpset. Open suction and discharge isolation valves on electric pump, diesel pump and jacking pump. Open bleed ball valve on top manifold to allow air to escape. If jacking pump is a vertical multistage pump a separate bleed valve will be fitted at the top of pump. Open to allow air to escape. Ensure ball valves to pressure switches and gauges are open. Bleed any residual air out of suction manifold via ball valve. Check with site electrician to ensure power is present in both the electric and the diesel panel. Isolate diesel engine start via 'start isolate' key switch on board. Connect battery terminal lugs. (Removed for shipping purpose). Mute audible alarm if necessary. Tum 'mains isolator' switch on - WARNING - electric duty pump will start immediately. Unit can be stopped by pressing 'pump stop' button on electric panel, Check rotation of motor to be correct. (Correct rotation is indicated on pump casing by an arrow). If rotation is incorrect, site electrician should reverse incoming mains. Jacking pump can be switched to automatic to talk up system pressure. (Rotation must be checked on jacking pump if it is 3 phase). Ensure jacking pump shuts down automatically via pressure switch once system is at full pressure. Check current draw of duty and jacking pump to be correct Check engine has correct levels of coolant water, diesel fuel and engine oil prior to start up. Refer to engine manual. Switch 'engine isolate' switch off if system pressure is high, diesel pump should not start. Switch power circuit breaker in diesel panel on. Power available light should illuminate. Check gauges, lights and charge rates. Press 'emergency start' button. WARNING- engine will start immediately. Engine can be stopped by pressing pump stop button and holding on till engine has completely stopped. Hunter Pumps Sales and Service P: 02 4958 7555 E: sales@hunterpumps.com 6
4. TESTING 4.1 PUMP TEST PROCEDURE 4.1.1 AUTOMATIC START TEST Tum hose reel on. Hose reel pump should start & maintain pressure. Tum hose reel off. Pump should stop within 1-2 minutes. (Only applicable if hose reel system installed). Open hydrant. Duty electric pump should start & maintain pressure. Shut hydrant down. Pump should continue to run. Press 'Pump Stop' button on electric panel to shut down pump. Turn 'Main Isolator' on electric panel to 'Off'. Open hydrant. Diesel pumpset should start. Shut hydrant. Diesel pumpset should continue to run. Tum 'Main Isolator' on electric panel back on. Wait approximately ½ a minute then press 'Pump Stop' on diesel panel and hold down until diesel engine has completely stopped. If main electric pump starts at this point follow, shut down procedure. 4.1.2 MANUAL PUMP TEST Jacking Pump -tum jacking pump selector to 'Manual', pump should run and pressure will increase. Return to auto. Electric Pump- press 'Pump Start' on electric panel. Pump will run. Press 'Pump Stop' on electric panel to stop. Diesel Pump - - TEST 1 -press 'Pump Start' on diesel panel and hold down until engine starts. Pump will run. Press 'Pump Stop' on diesel panel and hold down until pump stops completely. - TEST 2- press 'Pump Start- Crank Battery' on emergency start panel and hold down until engine starts. - TEST 3- press 'Pump Start'- Control Battery' on emergency start panel & hold down until engine starts. NOTE: engine can be prevented from starting by turning key switch on diesel panel to isolate. This will cause an alarm condition and should not be left in this position unnecessarily. Fire protection pumpset should be tested and maintained in accordance with relevant Australian Standards including AS 1815.14. Hunter Pumps Sales and Service P: 02 4958 7555 E: sales@hunterpumps.com 7
4.2 WEEKLY TEST SHEET As per relevant Australian Standards including AS 1851.14, your fire protection pumpset is to be fully testing on a weekly basis by suitably qualified fire service personnel. System Description: Date: Client: Commissioned by Name: Commissioned by Organisation: Testing should include but not be limited to the following items: ITEM DESCRIPTION TESTED BY (Initial) 1 Fault Indication 2 Lamp / Alarm test 3 Fuel Level 4 Diesel engine oil level 5 Diesel engine coolant level 6 Battery voltage crank battery V 7 Battey Voltage control battery V 8 Charge amps crank battery amp 9 Charge amps control batter amp 10 Water Level in supply tank (if applicable) 11 System Pressure 12 Test run electric pump in auto mode 13 Electric pump cut in pressure* 14 Test run electric pump in manual mode 15 Electric motor amps amp 16 Test run diesel engine in auto mode 17 Diesel engine cut in pressure* 18 Test run diesel engine in manual mode 19 Test run jacking pump in manual mode 20 General system condition 21 Check for damage and wear on pump system * Refer to pressure tank data sheet to confirm if pressure is correct. Immediately report and condition or impaired function to maintenance manager to action and rectification. Hunter Pumps Sales and Service P: 02 4958 7555 E: sales@hunterpumps.com 8
5. CARE AND MAINTENANCE 5.1 FIRE PUMP SET MAINTENANCE REQUIREMENTS 5.1.1 COUPLINGS Check alignment on a six monthly basis. Check for worn coupling rubbers etc. Alignment should be within 1mm parallel alignment and 2 degrees angle alignment. 5.1.2 PRESSURE VESSEL Check, on a six monthly basis, that air pressure in vessel is in accordance with commissioning information in pressure tank data sheet. 5.1.3 BATTERIES Check, on a two monthly basis serviceability of battery, water level, specific gravity and volts. 5.1.4 RELIEF VALVE See following manufacturers' data sheet. 5.1.5 DIESEL ENGINE Change oil, flush radiator (if applicable), check fan belts, and go through other maintenance procedures, as per manufacturers data sheets. Fire Protection Pumpset must be tested and maintained on a regular basis in accordance with relevant Australian Standards including AS1851-14. 5.2 EMERENGCY PROCEDURE (IN CASE OF FIRE) Pumps should start automatically on loss of pressure. If pumps fail to start, the following procedure should be followed. Manually start electric pump by pressing 'MANUAL START' button on ELECTRIC FIRE PUMP CONTROLLER or on REMOTE PANEL. In the case of fail to start, or power failure, proceed immediately to manually start diesel fire pump by pressing 'MANUAL START' button on DIESEL FIRE PUMP CONTROLLER or on REMOTE PANEL. Should engine fail to start, press 'EMERGENCY MANUAL START' button located on DIESEL ENGINE. If engine cranks but refuses to start, check diesel fuel level in tank. On case of all systems fail, DIESEL ENGINE can be started using standard car battery, either using jumper leads immediately on the start solenoid or in the place of the crank battery. Should pumps be running and there is lack of water at the hydrants, check valves positions. Ensure bypass valves are off. Also check water level in main tank. Hunter Pumps Sales and Service P: 02 4958 7555 E: sales@hunterpumps.com 9
SECTION 2 WARRANTY Items manufactured, supplied and maintained by Hunter Pumps Sales & Service (ABN 40518050187) Hunter Pumps are warranted to be free from defects in material and workmanship for 12 calendar months from the time they originally depart Hunter Pumps factory. Hunter Pumps liability under this warranty, statutory or otherwise, is limited to replacement or repair of the defective part or parts. Such repair or replacement shall be at the absolute discretion of Hunter Pumps. All parts or items subject to a claim under this warranty shall be delivered to and collected from Hunter Pumps factory or an alternative address designated by Hunter Pumps. Exclusions: a. any item not subject of a maintenance agreement with and maintained by Hunter Pumps b. replacement or repair of any perishable or consumable parts or materials c. costs of collection from or delivery to Hunter Pumps of the parts claimed. d. any part or any item on which a repair or alteration has been attempted or made without Hunter Pumps express permission in writing, unless such repair or alteration has been made by Hunter Pumps. e. any parts supplied or manufactured by manufacturers other than Hunter Pumps forming part of the item supplied or manufactured by Hunter Pumps, shall be subject to the terms and conditions and warranties of their respective manufacturers, no warranty is offered by Hunter Pumps on those parts. f. parts used inappropriately, misused or used out of manufacturers specification. g. parts which have failed or been damaged as a result of cavitation, erosion, chemical reaction, electrolytic action, or foreign body. h. parts which have not been maintained in accordance with their manufacturers recommendations. i. parts damaged as a result of ionizing radiation or force majeure. j. fair wear and tear. Items or parts provided by Hunter Pumps under this warranty that repair or replace a defective item shall inherit the balance of outstanding warranty period of the original item. In no event shall Hunter Pumps be liable for any costs or consequential damages or contingent liabilities arising out of the failure of or defect in any part or item manufactured or supplied or maintained by Hunter Pumps. No express, implied or statutory warranty, other than herein set forth is made. Hunter Pumps Sales and Service P: 02 4958 7555 E: sales@hunterpumps.com 10