Diesel Fire Pump Equipment Manual

INSTALLATION, OPERATION AND
MAINTENACE MANUAL
DIESEL ENGINE FIRE PUMP GROUP
DIESEL ENGINE PUMP GROUP INSTALLATION, OPERATION AND MAINTENANCE MANUAL
Content
1. Introduction.......................................................................................................................................................................................... 1
2. Safety/Caution/Warnings...................................................................................................................................................................1
2.1 General..................................................................................................................................................................................... 1
2.2 Installation, Moving and Transportation...............................................................................................................................1
2.3 Fire Proofing and Explosion Protection...............................................................................................................................1
2.4 Safety Guard............................................................................................................................................................................2
2.5 Chemical................................................................................................................................................................................... 2
2.6 Noise......................................................................................................................................................................................... 2
3. Diesel Engine Pump Group Structure.............................................................................................................................................3
3.1 Description............................................................................................................................................................................... 3
3.2 Diesel Engine...........................................................................................................................................................................3
3.3 Electric Power System of Diesel Engine.............................................................................................................................3
3.4 Cooling System.......................................................................................................................................................................3
3.5 Preheating................................................................................................................................................................................ 6
3.6 Fuel Tank and Common Base...............................................................................................................................................6
3.7 Coupling.................................................................................................................................................................................... 6
3.8 Silencer and Exhaust System...............................................................................................................................................6
3.9 Control system.........................................................................................................................................................................6
4. Moving, Towing and Storage.............................................................................................................................................................6
4.1 Moving....................................................................................................................................................................................... 6
4.2 Lifting Position.........................................................................................................................................................................6
4.3 Open Packing and Keep........................................................................................................................................................7
4.4 Storage..................................................................................................................................................................................... 7
4.5 Pumps Storage........................................................................................................................................................................8
5. Installation............................................................................................................................................................................................ 8
5.1 Foundation............................................................................................................................................................................... 8
5.2 Installation Process.................................................................................................................................................................8
5.3 Common Base Assembly.......................................................................................................................................................9
5.4 Grouting.................................................................................................................................................................................... 9
5.5 Coupling Alignment.................................................................................................................................................................9
5.6 Whole Group Installation......................................................................................................................................................10
5.7 Outlet and Inlet pipes............................................................................................................................................................10
5.8 Pump Installation...................................................................................................................................................................11
5.9 Location for Pump Installation.............................................................................................................................................11
5.10 Pipe for Pump Suction and Discharge.............................................................................................................................11
6. Air Intake............................................................................................................................................................................................ 11
6.1 Ventilation for Pump Room..................................................................................................................................................12
6.2 Exhaust and installation of exhaust pipe...........................................................................................................................12
6.3 Fuel System...........................................................................................................................................................................14
6.4 Fire precautions.....................................................................................................................................................................15
6.5 Batteries..................................................................................................................................................................................16
6.6 ReduceNoise.........................................................................................................................................................................16
7. Operation Principle........................................................................................................................................................................... 16
8. Operation........................................................................................................................................................................................... 16
8.1 General................................................................................................................................................................................... 16
8.2 Pre-Start Checks...................................................................................................................................................................16

8.3 Automatic and Remote Control...........................................................................................................................................17
8.4 Manual Startup and Shutdown............................................................................................................................................17
8.4 Emergency Start-up..............................................................................................................................................................18
8.5 Weekly Test............................................................................................................................................................................ 18
9. Control System..................................................................................................................................................................................18
9. Control System..................................................................................................................................................................................19
9.1 References.............................................................................................................................................................................20
9.2 Construction information......................................................................................................................................................20
9.3 Operation of Circuits.............................................................................................................................................................20
9.3.1 Overview....................................................................................................................................................................20
9.3.2 Starting the Pump.....................................................................................................................................................21
9.3.3 Direct Current Power Supply from Two Independent Sources.........................................................................22
9.3.4 Water Preheating......................................................................................................................................................22
9.3.5 Monitoring..................................................................................................................................................................23
9.3.6 Managing Alarms and Errors..................................................................................................................................23
9.3.7 Information Display...................................................................................................................................................23
9.4 Electrical Specifications.......................................................................................................................................................24
9.4.1 Power Supply Voltage..............................................................................................................................................24
9.4.2 Direct Current System.............................................................................................................................................24
9.4.3 Battery........................................................................................................................................................................25
9.4.4 Chargers....................................................................................................................................................................25
9.4.5 User inputs/outputs..................................................................................................................................................25
9.5 External Connector...............................................................................................................................................................26
9.6 Alarm....................................................................................................................................................................................... 26
10. Pump Maintenance........................................................................................................................................................................ 27
10.1 General................................................................................................................................................................................. 27
10.2 Preventive Maintenance....................................................................................................................................................27
10.3 Pump Disassembly.............................................................................................................................................................27
10.4 Failures and Reasons........................................................................................................................................................29
11. Engine Instruction and Maintaince...............................................................................................................................................32
11.1 Engine Description..............................................................................................................................................................32
11.2 Engine Maintenance...........................................................................................................................................................32
1. Introduction
This diesel pump unit is designed for fire-fighting system. It is easy to being operated by only placing and adding
water/cooling liquid, fuel, lubricating oil and battery electrolyte. It is efficient emergency capacity.
This manual is for maintenance and operation. If the diesel engine manual and pump manual can be referred to at
the same time, it will help to ensure that the pump group keeps operating at maximum performance and efficiency for a
long life. If in dirty or dusty environments more attention, it must be serviced more frequent to keep the set running
properly.
Make sure that the installation, adjustment and maintenance must be operated by the qualified people.
2. Safety/Caution/Warnings
2.1 General
Please note the follows during the installation, operation and maintenance to avoid the accidents. The diesel engine
pump group must be operated by the professional person.
Warning
 Read and understand all safety precautions and warnings before operating or performing maintenance. Fail to
follow the instructions, procedures, and safety precautions in this manual may increase the possibility of accidents
injuries.
 Start the pump set only in safe condition.
 Only start the equipment when it is in safe condition. If not sure that the diesel fire pump set is safe or not, do not
start the engine.
 If the diesel fire pump set is unsafe, stick the danger notices and disconnect the main switch of battery so that it
cannot be started and reconnect it when the pump set is in normal condition.
 Cut the main switch of battery and disconnect the battery negative (-) lead before repairing or cleaning inside the
equipment if necessary.
 Install and operate this pump group must completely comply with relevant national or local environmental emission
codes, standards or other requirements.
2.2 Installation, Moving and Transportation

Before installing, moving and transporting the diesel engine pump group, please keep the follows in mind.
Warning
 Make electrical connections in compliance with relevant standards, codes and other requirements which includes
the requirements for grounding and leakage protection.
 The installation of fuel tank and fuel system must in compliance with relevant codes, standards or other
requirements.
 Engine exhaust emissions are hazardous to personnel. The exhaust for all indoor pump sets must be piped
outdoors via leak – free piping in compliance with relevant codes, standards and other requirements. Exhaust pipe
and silencer must keep away from flammable substance and fume from the exhaust outlet will not be a hazard.
 Running of diesel engine would have noise; so that the installation will not only keep the normal running of
equipment also comply with local standard which is approved by environmental assessment provisions.
 Never lift the diesel fire pump set by the engine or pump lifting lugs. Lifting the pump set with the separate rings (if
installed) which is connect to the base frame.
 Ensure that lifting rigging and supporting structure is in good condition and has a capacity for the load.
 Keep all people away from the diesel pump set when it is suspended.
2.3 Fire Proofing and Explosion Protection

Fuels and fumes of diesel pump group can be flammable and potentially explosive. The pump room must be equipped
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with fire extinguishers. Please pay attention to the follows:
Warning
 Ensure that the pump room is properly ventilated.
 Keep the room, floor and diesel pump group clean. When there is spills of fuel, oil, battery electrolyte or coolant
occur, they should be cleaned up immediately.
 Never store flammable liquids near the engine.
 Oily rags should be stored in containers which covered with metal.
 Do not smoke or allow sparks flames or other sources of ignition around the fuel or batteries, fuel vapor can be
explosive. Hydrogen gas generated by charging batteries is also explosive.
 Turn off the power of the battery charger before connecting or disconnecting with battery.
 Keep electrically conductive object, such as tools, away from exposed electrical parts such as terminals to avoid
arcing or sparks, the arcing might ignite fuel or vapor.
 Do not refill the fuel tank when the equipment is running.
 Do not attempt to operate the pump group when there is fuel leakage.
 If the engine fail to start many times. There will create excessive unburned fuel gas in the exhaust system which
can create a potentially explosive condition. Exhaust the gas and then start the engine.
2.4 Safety Guard

The diesel pump group is designed with guards for protection from moving and hot parts to avoid the injury of people.
Warning
 Do not operate the pump set when the safety guards are removed. When the diesel pump group is running, do not
put the hands into or near the guards to do maintenance or for any other reason.
 Keep hands, arms, long hair, loose clothing and jewelry away from pulleys, belts and other moving parts. （Caution:
Some moving parts can not be seen clearly when the engine is running）.
 Keep away from the hot oil, hot coolant, hot exhaust gas, hot surfaces and sharp edges and corners.
 Wear protective clothing including gloves and hat when working around the diesel pump group.
 Do not remove the cap of heat exchanger until the coolant has been cooled. Then loosen the cap slowly to relieve
any excess pressure before removing the cap completely.
2.5 Chemical
Fuels, oils, coolants lubricants and battery electrolyte used in this diesel pump group must be treated properly, if not, it
will be harmful to the people.
Warning
 Do not swallow or have skin contacted with fuel, oil, coolant, lubricants or battery electrolyte. If swallowed, take the
medical treatment immediately and do not induce vomiting. For skin contact, wash the skin with soap and water.
 Do not wear clothing with fuel or lube oil.
 Wear an acid resistant apron, face shield or goggles when handling the battery. If the skin is splashed with the
electrolyte, flush it immediately with much of water.
2.6 Noise
The unit shall produce 105dBA noise if the unit is without the shell. Continuous exposure under more than 85dBA noise
will damage hearing.
Warning!
Ear protection must be worn when working around the engine.
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3. Diesel Engine Pump Group Structure
Standard：NFPA20
3.1 Description
The diesel engine pump group includes: Diesel Engine, Water Pump, Main Control Panel and Engine Conrol Panel,
Fuel Tank, Coupling, Coupling Guard, Exhaust pipe, Cooling Loop, Heat Exchanger, Expansion Water Box, Battery etc.
Fig.1 Diesel Engine Group
3.2 Diesel Engine

Diesel engine is the power of pump group; it is especially designed for the pump set and has reliable performance. The
engine is industrial type with 4 strokes, turbocharger, electronic actuator which control or change the engine speed. It
equipped with cylindrical air filter, oil filter.
3.3 Electric Power System of Diesel Engine

The diesel electrical is supplied with 24VDC. This system includes the starter, battery, battery rack and generator
The battery is charged by the charger on the control panel with the main supply, or by the generator on the engine.
3.4 Cooling System

The diesel engine pump group uses the water cooling (water/water- heat exchanger cooling), cooling water is get from
the pump outlet, go through the exchanger, then being drainaged to the water tank or other place(decided by client).
(See Fig. 2 and Fig.3 )
Cooling system： includes the heater exchanger and cooling loop, expansion water box .
Heat Exchanger: achieve the water-water cooling, (Fill the heater exchanger with anti-freezing liquid (-25 ℃))
Cooling Loop: In the normal condition, the entire valve on the cooling loop is open except the ball valve on the top of
“口”, when the gate valve is completely opened and the pressure is still less than 1 bar(Maybe need clean the strainer
valve), open the ball valve on the top of “口”. And keep the pressure between the max 2bar and min 1 bar. (See Fig.4
and Fig.5)
Expansion Water Box: Always keep the level to the “Low”.
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Cooling System
Fig.2 Cooling System (internal)
Fig.3 Cooling System (external)
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Cooling Loop：
Fig.4 Normal Situation
Fig. 5 Emergency Situation
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3.5 Preheating
There is a Preheating device which keeps the engine easy to be started. When the engine is standby, the preheater is
operating and cut off when the engine is started.
3.6 Fuel Tank and Common Base

The engine and pump are coupled together and mounted on a common base. The fuel tank is designed near the engine
group common base as the big capacity and it is enough for over 8 hours full load running.
3.7 Coupling
The universal coupling is used for the diesel pump group. This coupling not only can transfer the power but also can
adjust the shaft alignment; it is a perfect capacity of angular compensation, compact structure, high transmission
efficiency, even can reduce the vibration.
3.8 Silencer and Exhaust System

An exhaust silencer is provided for installation with the diesel pump group. The silencer and exhaust system can reduce
noise and directly exhaust the gas to outdoor.
3.9 Control system

Control panel is conneted with the control center and the engine group to realize the remote control and site control, and
also protecting pump group from being damaged which is caused by incorrect cooperation, and the main conrol panel
cooperates with the engine control panel to achieve the function such as the control, alam, display and so on.
4. Moving, Towing and Storage

4.1 Moving
The diesel pump group is specifically designed for ease moving. Do not open the box before lifting except it is subject to
the conditions. Improper handling can cause the accident, even seriously damage the components. Use a forklift to lift
pump group or carefully pushed/pulled after laying roll bar under common base.
Warning!
 Never lift the diesel pump group by rings of the engine or pump.
 Check the lifting rigging and supporting structure is in good condition and in suitably loading.
 Keep all people away from the diesel pump group when it is suspended.
Before lifting the unit, a set of soft lifting belts should be used to avoid the wire rope too thick and too hard which may
damage the equipment.
If lifting un-packaged bare unit, a protection baffle shall be added between the hoist cable and equipment to protect the
machine from bumps, operation. Let the hook get to the reserved hole on the common base, check the connection and
the tightening of the screws.
Caution: lifting point must be gravity center (closer to the diesel engine) rather than the center of the machine, so that it
can be vertically lifted. Once the machine leave the ground, it is necessary to prevent the wire rope kink or rocking the
machine by the dragline. Do not lift in the wind. Place the unit on a flat place which is able to withstand the weight of the
unit.
4.2 Lifting Position

Lifting the unit is most important in all of the installation steps.
 Lifting the unit’s place should be open and good vision, smooth, practical ground and no water.
 Do not put the unit to the place where may be fallen trees, poles overwhelming, other vehicles frequent activities or
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adjacent crane operations which may fall the object.

 Have enough space for moving the unit.
 Use the building structure as lifting, sufficient load must be taken into account.
Fig.6 Lifting
4.3 Open Packing and Keep

 Unpacking of external packing must be done near install site. Unpacking of protective package must be done by
debugging engineer after installation.
 Equipment installers, owners of construction and quality unit staff must attend the unpacking of unit, check by items
and make a record.
 Recording must including content, case no., case qty., and package condition, device name, model, and
specifications, list and technical parameters of equipment.
4.4 Storage
When diesel engine pumps group arrival, if they can not be installed immediately, it should be stored in a place where a
clean, dry and slow change in ambient temperature is. For long time storage, It must be protected against water vapor,
dust and other objects, and the tarpaulin or other suitable cover can be used.
 Storage preparation：Long - term storage will have the decisive impact. Proper storage preparations can minimize
the impact.
 Diesel engine Storage: storing diesel engines for over eight months must follow the below steps: mix the 2% 5th
composite rust inhibitor with diesel to run for 10 minutes, the fuel system and combustion chamber will full of
archive oil, in order to avoid the corrosion of parts. Provisional decision to change the storage time, please read
diesel engine manual for the correct steps.
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 Battery Storage: Battery storage, if using maintenance-free batteries: required charging every eight weeks time (4
weeks for tropical regions), fully charged. If it is open type lead acid battery, charge it every four weeks (2 weeks for
tropical regions), it must be fully charged.
4.5 Pumps Storage

 Use the appropriate lubricating grease to seal the water pump bearings, so as to prevent water vapor from entering
the bearing.
 It is a packing seal, remove the gland, packing seal and lantern rings.
 The pump suction and outlet, and other openings must be covered with cardboard or sealing cover to prevent
objects from entering the pump inside.
 Regularly turning and rotating shaft to prevent water vapor from corrosion of bearing.
5. Installation
 If unit must be taken outside the building temporary, do not unpack the package.
 Don't let the machine exposed to air pollution, for example, the dust, metal dust, fiber dust, smoke, lampblack,
evaporation gas or other pollution of the construction site;
 Keep enough space for installation. Do not let any part of the unit as support point for other equipments;
 Non-equipment construction workers can not go into the room;
 During the whole process of the installation, unit must have jacket protection to avoid from raining, snow, wind and
sand, collision, welding burns, artificial trample. If installing other device over pump set, protective measures must
be prepared and cover the pump group to prevent equipment from damaging or dirt entering. The staff mustn’t
stand on the device for operation; the pump set can not hold the scaffolding and platform load force.
Warning!
Prohibit connecting, start battery and run the equipment without authorization.
5.1 Foundation
Diesel engine and pump have one common base; the whole group can be fixed on the good foundation by the ground
bolts. During installing this unit, only need bolt to fit on a good foundation。
Foundation: The best foundation is an independent reinforced concrete, the strength is up to C20, and dimension is
200mm than the group size. The foundation can provide a rigid support to the unit and prevent the wobble and vibration,
foundation thickness can be determined according to different models, but the area can not be smaller than the common
base (considering dynamic load, the common base must be withstand more than 5 times of unit weight, ensure that
bellowing concrete is fulfilling with backfill gravel soil and steel bar). If the unit is going to install on the building which is
higher than floor, the building structure must be able to withstand the dynamic weight of pump group. Calculate pump
running frequency and check whether there is resonance with the building, also take the stored fuel and accessories
weight into consideration.
Buildings must comply with local building regulations, if the floor is usually wet, the foundation would be higher than the
floor, or design the drainage ditches. So that there is a dry place where is convenient for repair / maintenance, and also
minimize the corrosion metal common base.
5.2 Installation Process

 The "layout line" in place and correction leveling should be proceeding before the equipment in place. Mark the
equipment edge and high lines on the foundation, delineate the installation baseline, axis, plane geometry, size and
elevation in deviation range of ± 10mm.
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 The foundation must fully meet the vibration requirements, and be strong enough to prevent the unit from being
distorted or misplaced.
 Do not interrupt until the completion of the entire height of 150mm when casting the foundation. The scratches and
slot of the common base surface should be prepared before the concrete dries, ensure the bonding layer of grout
surface, the anchor bolt placement in the concrete should meet the length of it, as shown in Figure 7 going through
the common base and tighten the nut and washer. Leave a few days for concrete maintenance before the common
base wedge iron grouting. Holes for secondary grout strength should be one class higher than the foundation and
use the non-shrink concrete.
5.3 Common Base Assembly

 Place the diesel pump group on the concrete foundation, the bolts pass through the hole of common base.
 During placing and removing the common base support, re-check the concentricity and pump flange (the common
base no need to do the leveling).
 After tightening the anchor bolts nut, check the concentricity of the pump and engine.
 Check the correct connection between the pipelines and pump flange, and make sure that there is no deformation
on both sides of inlet/outlet flange.
 Confirm that the grout is completely dry before connecting pipeline and pump (72 hours is one condition of drying).
5.4 Grouting
The grout fills the concrete foundation, so as to uniform the
bearing of unit weight and prevent loose. After leveling unit,
follow the below steps to grout correctly (See Figure 7). Around
scratches and slotted concrete foundation format the solid
portion of the grout.
 Fully floating on the concrete foundation, remove the
water of surface.
 Fully fill the concrete foundation with grouting, if
necessary, exclude the internal air.
 Check the anchor bolt is loose or not after the grout dries,
tighten the nut and check.
 Tighten the nut and check the concentricity of the unit.
 Brush the undercoat when 14 days after grouting or
completely dry to prevent air and moisture from entering.
Fig.7 Lifting
5.5 Coupling Alignment
Universal coupling is used for this diesel engine pump group, it include whole fork and intermediate, in order to keep the
angular velocity of driving shaft and driven shaft (ω1=ω2 ), must be Satisfy the following three conditions
1. The dip angle of the intermediate and the driven shaft must be equal : β1=β2
2. The shaft fork head at the two ends of the intermediate must be on the same plane
3. The centerline of driving shaft, driven shaft and the intermediate must be on the same plane.
5.6 Whole Group Installation

 Check the damage of the water pump and the engine;
 The concrete foundation should be firm, smooth surface;
 Insert anchor bolts into the screw holes of common base then put the pump on the foundation, and measure
horizontal of the shaft end or outlet by the level gauge, the pace of the pump feet and foundation which close to the
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anchor bolts must pad.

 After adjusting the pump’s level, grout to the anchor bolt. After sturdy evenly, tighten the anchor bolts and re- adjust
the level, and then to the base grouting.
Correct the concentricity of the engine shaft and the pump shaft, so that the two shafts can be on the same level.
Excircle concentricity tolerance of two coupling axis is 0.1mm, end clearance tolerance along circumference allows
0.1 mm, end clearance uneven tolerance along circumference is 0.3mm (connected inlet/outlet pipeline, respectively
checked again, still meets the above requirements);
 Do not uses the pump to support the pipe, there should have the supporter for the pipeline near the pump.
 Keep a space of 4 to 5 mm between the foundation and the common base; precisely adjust the group with
adjustment screw. Centering in coupling.
 Pipe installation steps must be follow the process procedures
 First install the inlet pipe, then install outlet pipe, fix it on the foundation after check the leveling.
 Assemble taper pipes, elbows, soft butt-welding assembly on the inlet and outlet pipe according to the design
direction and configuration requirements, clear it, fix the firmware and make the supporting bracket.
 According to the piping configuration and the measured geometry measurement, piecewise welding and make
the pipe rack. When collecting with the collector pipe, firstly connect manifold docking segment and then
produce as entity. When linking, use the screw as directional to confirm the position for soft connect, but not
tightened temporarily, after cleaning the pipes and tighten the pipe support. When doing the tightening, the
devices can not displacement.
5.7 Outlet and Inlet pipes

When installing the pump piping, pay attention to the follows:
 Generally get the pipeline coupled to the pump, can not use the pump to couple the pipeline, and otherwise can not
achieve the final alignment.
 The inlet/outlet pipe should be independently supported and near the pump. The pump can not be treated as the
pipe support points. Pipeline use the support tube frame at the interval required. If there is adjustable tube in the
pipeline, the tube frame support must install nearest the pump. ! Note: The weight of the pipe shall not cause
any load on the pump.
 It is recommended that increase the length of the outlet and inlet pipe at the place of pump connection, which can
reduce the hydraulic losses by using the adjustable elbow.
 Install pipes should not use the unnecessary bending as far as possible.
 Pipe connection must be sealed and soft connection. When using the adjustable tube, inlet tube should be installed
eccentric reducers on the top and keep level, shrink tube on the discharge pipe and vertical pipe can be installed by
conical tube. (See Fig.9) Avoid the fluctuation of the liquid within the tube, the error using as the liquid fluctuations
and contraction will prevent the normal use of the pump, as the gas chamber will be formed in the pipeline.
 The inlet pipes should as much as possible short and straight, the length of the straight pipe in front of the entrance
must not less than three times the diameter of the inlet pipe, horizontal inlet pipe must be gradually increased to the
pump inlet , have little slope 20 / 1000.
 The outlet pipe must be provided with a constant head/check valve or slow closing checks valve + gate + flow
control valve. The constant head/check valve prevents excessive pressure to return to the pump and the water
hammer when the engine is stopped, and to prevent startup on load and overload.
5.8 Pump Installation
Preparation
 Remove the covering, thoroughly clean each openings ;
After more than 12 months, and storing over 12 hours, remove the lubricating grease in the bearing, clean by the
kerosene and re –greased.
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5.9 Location for Pump Installation

 The pump should be installed near water, using the shortest or most direct suction pipes.
 The installation should take full account of the ease of maintenance: a large enough space and height should be
retained in order to use the crane lifting unit.
√ × ×
Fig.9 Diameter Changes
5.10 Pipe for Pump Suction and Discharge

 All piping connected to the pump should be a separate solid support, in order to eliminate or reduce the vibration
and the load of the pipeline to the pump.
 The suction and discharge pipe diameter should not be less than the diameter of the pump outlet and inlet pipes.
The pipeline configuration pressure levels should ≥ 1.6MPa.
 Inlet and outlet pipe should be configured shock absorption and maintenance, installation soft connect (soft rubber
connect), out of the tube on the soft connection with limited bit models, the withstand voltage of the performance of
2.5MPa. And with a non-return valve and safety valve, exhaust valve at the outlet.
 The suction line should be short and less elbow. The suction port can not higher than the inlet of the pimp. 5 to
20 /1000 slightly inclined.
 When using adjustable tube, the length should not be less than the size of the diameter of 5-7 times. Suction pipe
use the eccentricity, level flat installation method. The length of suction pipe should not be less than the straight
pipe 3D (1050/600) to take effective remedial measures should not meet environmental restrictions. Inhaled the
clean water, and configure the filter valve or strainer when necessary.
 The pressure hole of the discharge line should be located in or below the pipe centerline; the installation can not
hump to avoid air remaining in the pipeline.
6. Air Intake
Air for engine combustion must be clean and as cool as possible. Normally this air can be drawn from the area
surrounding the pump set via the engine mounted air filter. However, in some cases due to dust, dirt, or heat, the air
around the set is unsuitable. In these cases an inlet duct should be fitted. This duct should run from the source of clean
air (outside the building, another room, etc.) to the engine mounted air filter. Do not remove the air filter and mount it at a
remote location as this can increase the possibility of dirt leaking through the ductwork and into the engine inlet. To
ensure that this type of installation will not have a detrimental effect on the operation of the pump set, the design of the
inlet duct should be approved by the factory.
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6.1 Ventilation for Pump Room

The engine, pump and exhaust piping radiate heat which can result in a temperature high enough to adversely affect the
performance of the pump set. It is therefore important that adequate ventilation is provided to keep the pump set cooling.
Proper air flow, and leave a air inlet and outlet (See fig.10), the air comes from the air inlet and go out from the air outlet,
there is a air circulation which keep the fresh water supply.(the blow cooling water, and the upper hot water)
Fig.10 Ventilation Design for Pump Room
 The air inlet and exit openings should be large enough to ensure free flow of air into and out of the room.
 Both the inlet and exit openings should have louvers for weather protection. These may be fixed but preferably
should be movable in cold climates so that while the pump set is not operating the louvers can be closed. It can
keep the room warm. For automatic starting pump sets, the louvers must be movable they can automatic open or
close. They should be programmed to open immediately upon starting the engine. The force of radiator air should
not be depended upon to open the louvers vanes unless the system has been specifically designed.
 This diesel engine pump group use the heat exchanger cooling system, the radiated heat from the pump set must
still be removed from the room.
6.2 Exhaust and installation of exhaust pipe

The purpose of the engine exhaust system is exhausting the fume and odor to outside, where the fume and odor will not
become an annoyance or hazard, and to reduce noise. A suitable exhaust silencer must be incorporated into the exhaust
piping to reduce the noise level from the engine. It can be fitted either inside or outside the building (See Fig. 11).
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Fig.11 Exhaust System Installation Drawing

Warning!
 No leak exhaust pipe must be used when the pump set is indoor. The installation of exhaust pipe must comply with
relevant norms, standards and other requirements.
 Ensure that the hot exhaust silencer and exhaust pipe are away from flammable substances.
 Ensure that fume from the exhaust outlet will not be a hazard.
 During designing an exhaust system, the primary consideration is not exceeding the allowable back pressure
permitted. Excessive back pressure seriously affects engine efficiency, durability and fuel consumption. To limit the
back pressure the exhaust piping should be as short and straight as possible. Any required bends should have a
curve radius of at least 1.5 times the inside diameter of the pipe. If it is over than 10m, the pipe diameter must be
larger and redesign.
 Other exhaust design criteria are as follows:
 A flexible connection between the exhaust manifold and the piping system must be used to prevent
transmission of engine vibration to the piping and the building and to allow for thermal expansion and any
slight misalignment of the piping. (See Fig.12)
 Ensure that the silencer and all pipes are well supported to limit strain on the connectors which could result in
cracks or leaks.
 Exhaust system components located indoor must be insulated to reduce heat radiation and noise levels. Pipes
and the silencer, whether located inside or outside the building, must be located very far away from any
combustible material, the silencer must be horizontal installed.
 Any long horizontal or vertical piping should slope install and include drain traps at the lowest points to prevent
water from reaching the engine or silencer.
 Where the pipe goes through a wall，there must be keep a space (Min.5mm) between the pipe and wall hole.
(the pipe will expand in hot) There may also be an expansion joint in the pipe to compensate for lengthwise
thermal expansion or contraction (See Fig.12).
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 The outer end of the exhaust pipe, if horizontal, should be cut at 60°. A rain hood or cap is needed if there is
vertical pipe to prevent the rain or snow from entering the exhaust system. (See Fig.12).
 The exhaust pipe must not be connected to other smoke tube or other such as ：boiler smoke tube or smoke
pipe of canteen.
 Exhaust pipe installation should be as short as possible and to reduce elbow, in particular to avoid the 90 °
bend with small radius. Piping should increase the diameter of the exhaust pipe and large bending radius
fittings or 45 ° bend when installing long pipes and more turns.
Note: Non - professional design muffler (especially low-noise muffler) may affect the output power of the engine and
even lead to abnormal running of equipment. The lifting of the exhaust pipe, muffler and the construction process of the
building:
Fig.12 Exhaust System Detail Installation Drawing

Construction Warning:
 Construction of auxiliary facilities, pipes, brackets are not applied to the unit gravity.
 All pipes must have their own support frame, axial extension bracket should have guide bracket. Do not fix in the
pipeline system, compensation telescopic is equipped (Bellows).
 Exhaust pipe welding can be closed after fully removing welding slag and other debris.
 Welded pipes are especially careful not to let the welding arc harm stainless steel bellows (can not be repaired).
 Especially to prevent welding slag ignited welding wires and plastic parts of the unit.
 Beware of welding slag and debris falling into the engine and pumps, flammable liquids in the device, caution fires.
 Forbidden to stand on equipment for the operation!
6.3 Fuel System

The fuel system for the pump set must be capable of delivering a clean and continuous supply of fuel to the engine.
Warning!
 Fixed unit split fuel tank installation must meet local specifications.
 Smoking is not allowed! Sparks or flame is not allowed. Volatile fuel and oil would explode.
 Fuel System must be can supply the fuel to the engine continuously, connect with the engine with the fuel pipe, can
supply fuel for 8 hours full load running.. The fuel lines can be any fuel compatible material such as steel pipe or
flexible hoses that will tolerate environmental conditions.
Note: the engine haven’t diesel when delivered, before starting the engine firstly, must be fully fill the diesel (#0).
Caution
 Do not use galvanized pipe or fittings for the fuel system.
 Fuel delivery and return lines should be at least as large as the fitting sizes on the pump set, and overflow piping
should be one size larger. For longer runs of piping or low ambient temperature, the size of these lines should be
increased to ensure adequate flow. Flexible piping should be used to connect to the engine to avoid damage or
Page 15 of 37
leaks caused by engine vibration.

 The fuel delivery line should pick up fuel from a height no lower than 50 mm from the bottom of the tank (away from
the drain valve)
 Clean oil is very important for the useful life and reliability of diesel, the first stage filter should be installed between
delivery pump and diesel filter. The valve for drain off water and sediment should be installed at the converse end of
delivery pump.
Warning!
 Non-ferrous metal parts(such as galvanized pipe , aluminum pipe, copper pipe, copper valves , etc.) are prohibiting
using in the oil containers, oil pipelines, fittings, valves.
 Engine room tank can not be too small in principle. If the fuel tank is too small is not conducive to the heat
dissipation of the engine temperature oil return, especially the units continuous running several hours. The
proposed design of the fuel tank for more than four hours.
 Float / the pointer instrument or transparent polycarbonate resin tube are used in for directions of fuel level, the
ordinary glass tube level gauge for level indication of the tank must not be used, as potential safety hazards maybe
exist.
 Return pipe diameter must be not less than the diameter of the oil supply line, laying maximum height can not
exceed one meter the engine back oil exports, or back oil pressure will be too high and affect the normal working of
the engine, seriously may cause security incidents. In addition: prohibiting the installation valve in the oil return
pipe.
6.4 Fire precautions

When installing the unit, must also consider the following measures:
 Fire escapes should be set in the engine room (not debris piled) Once fire, the staff can rescue and convenient to
leave.
 The construction site must be equipped with adequate fire extinguishers / or automatic fire extinguishing system.
 More detailed safety measures please refer to the local construction specifications.
Warning!
 Ensure adequate ventilation of the pump roon.
 Ensure the cleaning of the pump room, the floor and the unit. If have any leakage of fuel, electrolyte, or coolant,
clean them immediately.
 Never store flammable liquids near the diesel engine.
 Rags with oil should be stored in covered metal containers.
 It is not permitted to smoke or sparking near the battery and fuel, or other behaviors may cause fire. Because an
explosion may caused by the volatile gas fuel and hydrogen during battery charging (may some reasons the battery
leaks).
 Before connecting or disconnecting the battery, power off the battery charger.
 Conductive objects, such as tools, should stay away from exposed electrification parts, such as the output
electrodes, in order to prevent the electric arc or spark to cause an explosion because of the fuel or gas.
 Do not inject fuel into the fuel tank in the case of the running of the machine or site unclean.
 Do not try to start when known to have a fuel leak.
 Excessive unburned gas in the exhaust system will be accumulating when multiple starts unsuccessful. You must
especially careful, because there are potential explosion hazard. Drain away the gas first, and then start.
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6.5 Batteries
Warning
 No smoking! No spark near the battery, the spark may cause explode because of hydrogen during charging the
battery.
 The battery should be located as close as possible to the pump set and also accessible for maintain. If may affect
the starting capability if the wire is too long.
6.6 ReduceNoise
It is important to control noise during installation. There are many methods to control the noise.
Warning
 Ear protection must be worn during operating or working around an operating diesel fire pump set.
 Exhaust Silencer: it reduces noise with different model, normally including: industrial environment, the home
environment, high demand, top demand.
 Shell: it can water-proof and reduce the noise, these shells are specially designed for special noise level
requirements.
 Other way to reduce noise: when the unit is installed within the building, there is a variety of noise-reducing
equipment such as anechoic chamber, separated ventilation fan mufflers and walls of sound-absorbing materials
can reduce noise.

7. Operation Principle
Diesel engine fire pump group is as a standby device, when the unit receives effective signals or when motor pump is
power off or lack of phase, the pump unit can automatically start. At the same time, the control cabinet can monitor the
running state, the condition of pump room etc, to realize the control, alarm and display functions, ultimately acheve the
purpose of in automatic put out the fire or control the fire.
8. Operation
8.1 General
The diesel pump set is equipped with an advanced electronic control system. It allows the operator manually or
automatically control of the diesel pump set. It has protection circuits to sound an optional alarm and even shutdown the
set if problems occur.
The following shows the detail about start and stop. There is manual, automatic, remote control.
8.2 Pre-Start Checks

Warning
As diesel pump set with auto control system can be started remotely without warning, always ensure the control panel is
switched off before carrying out any checks.
 Ensure the power control switch/key switch is off
! Diesel engine normally consumes lube oil at a rate of 0.25 percent of the fuel consumption.
 Timely check the diesel oil and coolant, add according to scale if needed.
Warning
! During filling the fuel tank, do not smoke or use an open flame nearby.
 Check the fuel level, fill if necessary.
 Check the engine alternator belts – tighten if necessary.
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 Check all hoses for loose connections and tighten or replace if necessary.
 Check the battery terminals for corrosion – clean if necessary.
Warning
! When working with the batteries do not smoke or use an open flame in the vicinity. Hydrogen gas from batteries is
explosive.
! Do not short circuit battery output electrode.
 Check the battery electrolyte level – fill with distilled water if necessary. If the battery is new and has never been
charged, fill with suitable premixed electrolyte and charge.
 Check the control panel and the diesel pump set for heavy accumulation of dust and dirt – clean if necessary.
These can pose an electrical hazard or give rise to cooling problems.
 Check the air filter blockage indicator, change a new filter if it is blocked.
 Clear the area around the diesel pump set of any insecure items that could inhibit operation or cause injury. Ensure
cooling air ventilation screens are clear, not blocked.
 Visually checks the entire diesel pump set for signs of leaks from the fuel system, cooling system, lubrication oil and
oil seal.
 Regularly drain exhaust system condensate traps, if equipped.
 Before commission, must open the pump discharger valve.
8.3 Automatic and Remote Control

Engine Automatic and Remote Control is achieved by the main control panel. When the unit receives effective signals
(Remote Sign or when the pipe pressure is low than the setting data of pressure controller or the pressure swith) or when
motor pump is power off or lack of phase, the pump unit can automatically start.(See section 9.3.2).
 Start-up：When there is a starting sign, Engine will have 6 try start-up(15S running, 15S stop), If the information
'System started' is displayed during an attempt, the control panel stops the starter, cancels the subsequent start attempts
and activates the 'System running' indicator. If the 'System started' information has not been displayed after six
attempted starts, the control panel activates the 'Fail to start' alarm, displays the corresponding information and blocks
the automatic system.
 Shut-down：Pressing the “Stop’ button, and then turn the slector switch to “”0” the engine can be normal stoped.
Turn the selector switch on “0’” mode, the engine can be stopped any time emergency. (Note: When pressing the “Stop’
button, the system would reduce speed, cooling and then stop. But turn the selector switch on “0’”, the pump set will stop
emergency.Do not turn the selector switch on “0’” randomly.,especially the equipment is in full load condition, this would
cause damage to engine.
Note: When finishing this running, turn the selector switch on “Auto’ mode and keep the diesel engine pump
group is in the automatic conditions again.
8.4 Manual Startup and Shutdown

There are two methods can start the engine manually: Started by main control panel or Started by engine control panel.
 Started by Main Control Panel
 Start-up ： Turn the selector switch on “Manual’ mode, push the”1# bat’ and “2# bat” together or individual,
then the engine can be started directly.
 Shut-down ： Pressing the “Stop’ button, and then turn the slector switch to “”0” the engine can be normal
stoped. Turn the selector switch on “0’” mode, the engine can be stopped any time emergency. (Note: When pressing the
“Stop’ button, the system would reduce speed, cooling and then stop. But turn the selector switch on “0’”, the pump set
will stop emergency.Do not turn the selector switch on “0’” randomly.,especially the equipment is in full load condition,
this would cause damage to engine.
Note: When finishing this running, turn the selector switch on “Auto’ mode and keep the diesel engine pump
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group is in the automatic conditions again.

 Started by Engine Control Panel
Normal, the selector switch of Engine Control Panel is “Auot” mode.
 Start-up ： Turn the selector switch on “Manual’ mode, push the”1# bat’ and “2# bat” together or individual,
then the engine can be started directly.
 Shut-down：Turn the selector switch on “Auto’ mode, the engine can be stoped.
8.4 Emergency Start-up

There are two emergency starters, who are connected with the
battery and engine starter directly, when the main control panel and
engine control panel out of use, this method can emergency start
the engine. (When the two control panel is no problem, if keep the
selector switch on “0”, the emergency starter will can’t be used.)
 Start-up ： Hold the “Bladk Head” of 2 emergency starter

together or individual, pull up it, then the engine can be directly Lift up
started.
Note：
 Except over speed shut down is automatic, all of the stop is by manual。
 When you push the “Stop”Buttion, for starting the engine again, need reset first and and solve the problem
firstly and then can start again.
8.5 Weekly Test

 The engine can do the six trying start(Start 15S , Stop
15S ): for testing the engine, battery, control system,.(Caution: Take
off the start output module when doing the six trying start, otherwise,
the engine will be directed started.)
 For Weekly Test, need set the pressure data of pressure
controller and pressure swith (the pressure swith is stanby part,
when the pressure controller has some problem, it can guarantee
the automatic start),
See the below Fig.
Line 1: For adjusting the pressure (by the ball valve).
Line 2: For Week Test, Press the “Weekly Test” botton, the solenoid
valve will automaticly open, and then the test can be started.
Remark: the loop pressure is the same as system pipe pressure.
Pressure Control Loop
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9. Control System
Engine Control Panel
Main Control Panel
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This diesel engine fire-pump group can achieve the auto, remote or manual control (including the monitory, alarm etc.)
operated by two control panels. One is main control panel and another is the engine control panel. Both of them can not
operation together to control, only when the main control panel can’t work, the engine control panel can achieve its
control function and vice verse), at the same times When the 2 control panel can’t operate, the engine can be started by
Emergency Starter for emergency start.
9.1 References
 Regulated in accordance with N.F.P.A Standards
 NF C15 100 – Installations électriques BT (Low voltage electrical installations)
 NF EN60 439.1 – Ensembles appareillage BT (Low voltage equipment assemblies)
 NF EN60 259 – Degré de protection des enveloppes (casing protection levels)
 NF EN60 947 – Appareillage BT (Low voltage equipment)
 NF EN60 269 – Fusibles (Fuses)
 89/392/CEE (with amendments 91/368, 93/44 and 93/68) - Machines Directive
 73/23/CEE (with amendment 93/68) - Low Voltage Directive
 89/336/CEE (with amendment 92/31 and 93/68) – Electromagnetic compatibility Directive
9.2 Construction information

 The control panel complies with the standards and regulations specified above.
 The basic casing is commercial painted steel sheet with a protection rating of IP55. The assembly with the
equipment fitted does not have the original level of protection but remains suited to the environmental conditions,
especially a humid ambience.
 The equipment and cabling is done in accordance with the electrical diagram.
 Earthing is via the earth terminal which is identified by a standardised symbol. The metallic parts, including the door,
are electrically linked to this terminal.
 The components are individually identified by a label containing the reference used in the electrical plan (e.g. PCH
for the water pre-heater switch) or by a label containing its function (e.g. 'Engine speed (rpm)'). The fuse size is also
indicated.
 The internal wires are numbered at both ends (equipotent type references) with the exception of the negative
polarity (Earthing) which is allocated the colour white with reference 0. Identification by different colours is used for
the motor safety cabling.
 The connections from the electronic plate to the connection terminals and the display card use prefabricated flat
jumper cables without identification of the conductors but with error proof connectors at their ends.
9.3 Operation of Circuits

9.3.1 Overview
The control panel uses a mains power supply in conjunction with the two linked batteries to perform the following
functions:
 Start the power pump
 Provide a direct current power supply from two independent sources
 Preheat water
 Monitor
 Manage alarms and warnings
 Display information
The control panel can control a diesel engine, its peripherals and its own circuits. All functions continue to operate in the
absence of a mains supply except water preheating and battery charging.
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9.3.2 Starting the Pump

9.3.2.1 Starting Principles
 The control panel, in combination with the two battery, the pressure transducer and the monitoring pressure switch,
uses two separate and redundant starting lines where both lines are unaffected by incidents occurring on the other
line or any linked function.
 Each pressure switch (contact opening type) has its own separate connection to the control panel and is linked to a
lockable selector switch that can isolate it. The selector switch has three positions: Auto, Stop and Manu and the
key can only be removed when it is in the Auto position. The modes linked to these three positions are described
below.
 When a Test Start is requested, the control panel makes six successive attempts to start and powers the starter for
15 seconds for each attempt. An automatic permutation system is used to alternate two start attempts on each
battery. The start attempts are separated by a resting interval of 15 seconds.
 If the information 'System started' is displayed during an attempt, the control panel stops the starter, cancels the
subsequent start attempts and activates the 'System running' indicator.
 If the 'System started' information has not been displayed after six attempted starts, the control panel activates the
'Fail to start' alarm, displays the corresponding information and blocks the automatic system.
 If the battery 1 or 2 error information is displayed during a start sequence, starting is done using only the battery
that is not signalling an error.
 The control panel detects a speed signal from a magnetic pick-up fixed on the motor's housing opposite the crown
gear. Exceeding a minimum threshold provokes the 'System started' information. Exceeding a maximum threshold
blocks the automatic system and displays an overspeed information (visual and sound alarm, alarm display).
 Digital voltmeters are displayed on the LCD screen and are used to check the voltage of each battery when the
starter is used by isolating it from its linked charger. This means that it is possible to check that the voltage is
sufficient for starting which requires at least 80% of the nominal voltage.
 If a battery is out of action or is not sufficiently charged, this does not compromise starting or the various functions
of the control panel.
 There is a Pressure controller, It can show the pressure and set the pressure data.
9.3.2.2 Automatic Mode

A start request is initiated in this mode when at least one of the following
command inputs occurs:
 Fall in pressure of the pressure transducer
 Fall in pressure switch pressure
 Fall in the priming tank level
The inputs are only activated when the lockable selector switch is on the “Auto”
position.
Automatic starting by the transducer or pressure switch is shown on the LED
display on the front of the control panel (transducer or pressure switch starting) Pressure Controller
9.3.2.3 Manual Mode

A start request is initiated in this mode (Main control panel or engine control panel) when the selector switch is moved to
the Manu position. Starting attempts are made immediately and all the control panel functions are active.
9.3.2.4 Off Mode
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Moving the selector switch to the Stop position to isolate the pressure switch and pressure transducer.
Moving the selector switch to the Stop position prevents manual or automatic starting .
The mode is displayed on the LCD screen as follows:
 Manual mode if the selector switch is on Manu.
 Auto mode if the selector switch is on Auto.
 Off mode if the selector switch is on stop.
9.3.2.5 Emergency Start

Started by the Emergecy Starter（Operated by hands）
9.3.2.6 Emergency Stop

Pressing the “Stop’ button, the engine can be normal stoped. Turn the selector switch on “Off’” mode, the engine can be
stopped any time emergency. (Note: When pressing the “Stop’ button, the system would reduce speed, cooling and then
stop. But turn the selector switch on “Off’”, the pump set will stop emergency.Do not turn the selector switch on “Off’”
randomly.,especially the equipment is in full load condition, this would cause damage to engine.
WARNING!
The system can be stopped when operating by pressing the push “Stop”button on the front of the control panel. The
selector switch must be put in the “Off”position to stop the engine before using the STOP push button to avoid the
system immediately restarting if a start request is still operational.
9.3.3 Direct Current Power Supply from Two Independent Sources

9.3.3.1 Overview
 The control panel is fitted with two identical chargers that have the mains supply as their primary power source and
each has a secondary link to a battery. The assembly constitutes two independent direct current sources with all the
operational guarantees described in the previous paragraph.
 Each source powers its respective starting system and the two supplies are used in parallel via a non-return diode
to power the common part of the control panel.
 The chargers operate continuously without automatic control and the charge level is checked once per day by
looking at the charge indicators on the front of the control panel.
9.3.3.2 Chargers
 The chargers are adjusted with a 12V or 24V DC output depending on the nominal voltage of the battery connected
to them. They operate normally with an input voltage that varies between + 15% and - 10% around a nominal value
of 230V AC (60Hz).
 If changes to the mains voltage (+/– 10%) and frequency (+/– 2%) are slow and cumulative, the charger output
voltage remains stable around the set value with the following tolerances:
 With batteries connected: +/– 1%
 Without batteries connected: +/– 4%
The charging current is highest when the battery voltage is equal to its nominal voltage. There is no significant charge
when the battery floating voltage is 115% of the nominal voltage.
9.3.4 Water Preheating

 The water preheater for the diesel engine is powered from the mains by a protected output (circuit breaker + relay
card (K19)) located in the control panel.
 The circuit breaker is calibrated for the power of the heater coils and is fitted with a differential unit set to 30mA to
Page 23 of 37
ensure staff safety. The K19 relay is fitted to a plate and slaved to a thermostat fitted to the engine's cylinder head
and the 'System started' display. This means that the heater coils are not powered when the engine temperature is
greater than a set threshold or when the power pump is operating.
 An 'On Off' selector switch located on the front of the control panel turns the preheater off at any time.
‘
9.3.5 Monitoring
The control panel monitors the following:
 Battery 1 and 2 voltage (digital voltmeter on the LCD screen)
 Battery 1 charge rate (digital ammeter on the LCD screen)
 Battery 2 charge rate (digital ammeter on the LCD screen)
 Fuel level (analogical indicator on mechanical gauge)
 Oil pressure (analogical manometer)
 Oil Temperature (analogical thermometer)
 Alternator Current (analogical amperemeter)
 Water temperature (analogical thermometer)
 Engine speed(Speed odometer)
 Time counter (tachymeter)
The degree of error for the equipment is no more than +/- 5% except for the tachymeter where it is +/-25 rpm.
9.3.6 Managing Alarms and Errors

 The control panel is fitted with standard alarms and warnings which include optional functions. The detail of the
different indicators is also repeated in the operator's manual for the system.
 They comply with the requirements of Appendix 1 in terms of the colour of the indicators and the activation of an
audible alarm. For information, unless otherwise indicated, the general principle is as follows:
 Green indicator: installation receiving power
 Yellow indicator: problem - an intervention is required
 Red indicator: alarm or major error - urgent intervention required
 Each problem or error signal is self maintaining until the 'Cancel errors' push button on the control panel is used.
Pressing this button is only effective if the cause of the alarm or error is no longer present
 If an audible alarm is triggered, it can be stopped by pressing the 'stop horn' push button even if the cause is still
present without this acting on the luminous error indicator. If another error arises that requires an audible alarm, the
signal is reactivated but can once again be stopped.
 It is possible to check that the indicators are working correctly by pressing the 'Test lights' push button on the front
of the control panel.
9.3.7 Information Display

The control panel can display the 7 pieces of information described below. Each piece of information is provided via
terminals with 2 dry contacts (1NO + 1NF) with no common point. The 'General Error' information is processed by
absences such that the absence of power to the control panel results in this error being displayed.
9.3.7.1 Engine Failure

This output combines the following errors:
 Low level engine water (10 second time delay)
 Low fuel level
 High engine water temperature
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 Starter link error (15 seconds time delay)

 Low engine oil pressure (5 second time delay)
 Preheating error (including when the selector switch is in the Stop position)
9.3.7.2 Auto Control Error

 Lockable selector switch is not in the Auto position
9.3.7.3 Operating information
 Diesel power pump is operating
9.3.7.4 Fail to Start

The system is not working after 6 starting attempts
9.3.7.5 System Failure

This output combines the following errors:
 Lack of mains power (180 second time delay)
 Battery 1 and 2 errors
 Charger 1 and 2 error (50 second time delay)
 Low water tank level
 Low priming tank level (15 second time delay)
 Low sprinkler room temperature
 Ventilation gate valves not open with system operating (50 seconds time delay)
9.3.7.6 Overspeed
 Diesel engine overspeed
9.3.7.7 Pump required starting the engine

 System in the process of starting, indicates a pressure below the starting threshold
9.4 Electrical Specifications

9.4.1 Power Supply Voltage
The voltage of the mains supply for the control panel must have the nominal value of 230V – 60Hz within the following
tolerances:
 Voltage: +/- 10%
 Frequency: +/- 2%
The control panel and its different components are guaranteed to operate within these limits.
If the mains supply is not 230 V, a transformer can be used which should be placed within a separate casing with
appropriate protections.
The maximum power demanded by the system depends mainly on the power of the preheater recommended for the
diesel engine used. In most cases the requirement is between 2 and 4 kW.
9.4.2 Direct Current System

The nominal voltage of the direct current system (starter system + batteries + chargers + cards) is 12V or 24V depending
on the value selected by the diesel engine manufacturer. To avoid any confusion, the applicable value is shown on the
information plate.
The electronic parts can accept either voltage as the 12V and 24V control panels have similar designs. The only
difference is the type of charger and the nominal voltage of the auxiliary relays.
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9.4.3 Battery
9.4.3.1 Specifications
6 cell lead batteries are used (for starting purposes) providing a nominal voltage of 12V. For 24V applications, each direct
current source is fitted with two 12V batteries connected in series. These batteries do not need any special maintenance
other than checking the level of electrolyte and cleaning from time to time if necessary. The size of the batteries depends
on the diesel engine used based on the criteria described below.
9.4.3.2 Sizing
The battery size depends on the following criteria and assumes that the temperature in the premises is at least 10°C and
the diesel engines have been correctly preheated:
 The equipment has been selected for its suitability for starting, especially its ability to meet the starter's needs as
specified by the diesel engine's manufacturer.
 Each battery has enough capacity for 6 successive 15 second starting attempts.
 The batteries have sufficient capacity to ensure the starting sequence, i.e. six attempts plus the 'Not started' error,
should it occur, after a mains power supply failure lasting 72 hours.
The system's consumption in stand-by is about 400 mA which requires deducting a capacity of about 29 Ah from the
nominal battery capacity for a 72 hour mains power supply cut before making the start attempts.
The voltage of a battery providing the direct current required by the starter must not be less than 80% of the battery's
nominal value.
9.4.4 Chargers
9.4.4.1 Specifications
Type Automatically adjusted
Rectification Double alternating
Primary voltage 230V – 50Hz
Insulation voltage 3750 V
Operating temperature range - 5°C to + 50°C
Overloading / short circuit protection yes
Nominal secondary voltage 12V DC 24V DC
Floating voltage 13.8V DC 27.2V DC
Secondary current 10A 10A
Consumption 150W 250W
9.4.4.2 Configuration and Adjustment

The chargers used are factory configured with a nominal floating voltage and need no intervention or subsequent
adjustment.
9.4.5 User inputs/outputs

9.4.5.1 Inputs
The all or nothing inputs to the control panel to which the user connects external contacts have a power consumption of
about 500 microamperes (under a polarity of 5V DC).
9.4.5.2 Outputs
In addition to the five outputs for displaying information (two NO contacts and two NC contacts for each with the following
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characteristics), the user has a 4A contact (closed when the power pump system is operating) to manage the ventilation
gate valves.
Permanent allowable current 2A
Maximum acceptable voltage 250V
Interrupting capacity 120W
9.5 External Connector

 All the connection options between the control panel, the power pump and the installation are shown schematically
in the electrical diagram
 As the control panel is fitted with all the optional functions included in the rules, some inputs/outputs may not be
used. In this event, the terminals should be left empty or a jumper should be added, depending on the type of
contact.
 The on-site cabling should conform to current practices and applicable standards. The cross-sections of the
conductors must be appropriate for the current and avoid unacceptable voltage reductions.
9.6 Alarm
 Mains Failure
When the mains power supply is cut off (180 seconds + 21 seconds time delay).
 Charger 1 and 2 Error
When the mains power supply is cut off (180 seconds time delay) or when the downstream fuse is blown. (20 second
time delay)
 Battery 1 and 2 Error:
When battery unable to be operated.
Disconnect a battery to obtain the alarm.
 Starter Error
When the connection between the control panel and the starter has some problems. (15 second time delay).
Disconnect the starter coil supply.
 Pressure Switch Not Automatic
Pressure switch and pressure sensor are no longer operating automatically.
Set the appropriate selector switch to Stop or Manu.
 Fail to Start
When the engine fails to start after six attempts.
Hold the engine stop handle and lower the pressure, the alarm will occur after six start attempts.
 Engine Temperature Alarm
When the engine is higher temperature.
Shunt the sensor to obtain the error.
 Oil Pressure Alarm
When there is an oil pressure error during the engine is running.
Disconnect the sensor to obtain the error when the engine is not running.
Earth the sensor when the engine is running to obtain the error (5 second time delay).
 Diesel Level Alarm
When the level of diesel is insufficient.
Disconnect the sensor from the fuel tank to obtain the error.
 Diesel Leak Alarm
When diesel tank is leakage (presence of diesel in the run-off tank or the double skin).
Page 27 of 37
Lower the bulb in the tank to obtain the error.

 Diesel High Level Alarm
When there is an overfull diesel tank (more than 99% full).
Disconnect the sensor from the fuel tank to obtain the error.
 Absence of Engine Water
When there is a low cooling fluid level. (10 second time delay)
Disconnect the sensor to obtain the error.
 Pre-Heating Alarm
When there is an engine preheating error.
Press the vigi 30 mA test button in the control panel or set the selector switch to stop to obtain the error.
 Overspeed
Whena diesel engine is overspeed.Engine emergency stop.
Turn automatic starting off.Press the test button on the front of the control panel to obtain the error (the engine rpm must
be greater than 2,000 rpm or at 1,700 rpm to perform the test).An external input dry contact option is available for
triggering the alarm on terminals 0 and 9.
 Water Tank High or Low Alarm
When there is a high or low level in the pump water tank.
Lower or raise the level bulbs in the tank to obtain the error
 Sprinkler Room tTemperature Alarm
When there is a low temperature in the sprinkler room (4°C).
Lower the thermostat until the alarm is reached to obtain this error.
 Ventilator gate valve error
When the gate valves have not been opened during the engine is running.
Press on the gate valve stops when the engine is running to obtain this error.
In stand-by, disconnect a stop to obtain the error.
 Resetting alarms
Push the “Reset Fault’ button on the front of the control panel
10. Pump Maintenance

10.1 General
Pump is developed according to advanced technology. The product passes through strict quality control. When pump
running, the medium, flow, speed, density, pressure and temperature can not be exceeded the limited value set in
techno-document so insure running of pump conform the regulation of operating manual.
The model/specification, data, factory/serial No. of pump were indicated in nameplate, any question or repeat ordering
spare parts refer to these data.
10.2 Preventive Maintenance

Please pay attention to follow problems during the pump running：
 Pump must run stably.
 Pump do not allowed running empty.
 In order to preventing temperature rising of medium, pump can not running in case of closing outlet valve for a long
time.
 Temperature of bearing can not be exceeded 90℃（194F） when ambient temperature reach 30℃（80F）, and
100℃（212F）when rising again；
 It should be checked oil level periodically if using washy-lube for bearing.
 Do not close outlet valve when pump running, if fitted.
Page 28 of 37
 Check and started spare-pump periodically.

 Check assistant pipeline whether connect all right.
 Check the flexible element of couplings, replace it when worn.
10.3 Pump Disassembly

It should be insured that pump will not run suddenly before disassembly, the inlet and outlet valve must be closed, pump
must be cooled to ambient temperature and excluded air, pressure must be released. See pump manual for further
information.
Page 29 of 37
10.4 Failures and Reasons
Abnormal warming of the pump casing
Bearing temperature is too high

Power consumption is too large
Reason Method to eliminate
Noise, shock and not steady

Pump pressure is too high
Pump pressure is too low
Pump stop pump water

Pump flow is too large
Pump flow is too small
No water after start
Pump leakage
Seal leakage
-The operating point is not the - Re - adjustment of the operating
＃＃＃＃＃＃＃＃
design point point
- The air in pump or pipeline

- Exhaust
＃ is not drained or lack of pump
-Install vent valve
irrigation
-Clean the impeller

- Check equipment impurities
- Clog of the water inlet - Clean up the blockage in the pump
＃＃＃＃＃＃ piping or impeller and piping
- Check the filter and inlet pipeline
diameter
- Improve inlet conditions

- Air bubbles in the pipeline - Adjust the piping layout
＃＃＃
- Mounted exhaust valve
- Check the operating status

- Improve inlet conditions
- Increasing the inlet pressure
- Suction head is too high
- Increase the inlet pressure by
＃＃ - Effective NPSH too low
＃＃＃ throttle
- The water level is too low
- Reduce the pump mounting height
- If the loss of pipeline is too much,
change the inlet pipeline
- Clean up the seal pipes, if possible,
add the sealing liquid or increase
the pressure from the outside
＃＃＃＃ -Shaft seal leak - Check the water tank level
- Replace the shaft seal
- Replace the gasket
- Replace sleeve
- Change power two -phase
connector
- Check the circuit connection
＃＃＃＃ - Turn in the opposite
- Check the impeller position, if it is
necessary, change the impeller
position
- Increase speed
- Replace the bad fuse
＃＃＃＃ - Speed is too low - Check the circuit connection
- Check the distribution box
- Installed a larger size impeller
- Check and adjust the operating
point
＃＃＃＃ -Internal loss - Increase the inlet pressure by
throttle
Page 30 of 37
- Check the chemical properties and

the solids content of the medium
- Replacement of worn parts
- Re - adjustment of the operating
-The pump inlet pressure is point
＃＃ lower than the value of the - Increase the inlet pressure by
contract throttle
-The proportion and the - Reduce the rotate speed

viscosity of the medium is - If you have a fixed overload, cutting
＃
greater than the value of the impeller
contract
＃＃ - Axis is incorrect -Replace
-Low down the rotate speed

＃＃＃＃ -Rotate speed is too fast - If you have a fixed overload, cutting
impeller
- Check
- Tighten the bolt
- Connecting bolts loose - Replace the gasket
＃ - Improperly sealed - Check the pump tubing
connection , it is necessary to reduce
the piping layout
- Check the flushing and sealing
liquid pressure
- Cleaning the seal piping , if
possible, the sealing liquid use an
-Shaft seal wear external water supply or increase the
＃
pressure
- Replace the shaft seal
- Replacement of worn parts
- Replace shaft sleeve
- Change the pipeline
- If the pipeline is too much
- The liquid flow of pump inlet resistance, it is necessary to change
＃＃＃＃
pipe is poor the inlet tube
- Check the piping distorted or
deformed, and correct.
- Adjust
-Gland, end caps, the seal - Replace
＃＃ gland is installed wrong or - Corrected
fillers wrong - Replace the packing
- Replace of worn parts
- Check the flushing and sealing
liquid pressure
- Cleaning the seal piping , if
- Lack of coolant or cooling
＃＃ possible with an external sealing
chamber contaminated
liquid water or increase the pressure
- Increased coolant flow
- Clean coolant
- Re-adjust
- Check piping connections and
-Pump improperly adjusted or pump installation, reduce the piping
＃＃
pipes have resonance layout if necessary
- Piping connections use damping
materials
- Lubricants too little , too - Cleanup

＃
much or inappropriate - Replace
Page 31 of 37
- Increase or decrease , or
replacement of oil
-Check and adjust the operating
point
＃ -Axial force is too large
-Check the operation state
-Check the inlet flow
- Replace the bad fuse

＃＃＃ -Two-phase operation - Check the circuit connection
- Check the distribution box
＃＃＃ -Bearing damage -Replace
- Clean rotor
＃＃＃ -Rotor imbalance
- Rotor rebalance
- Re- adjust the operating point

- Increase speed
- Fully open the inlet valve
＃＃ -The flow is too small
- Fully open the outlet valve
- Re - calculated or measured
hydraulic losses
-Delta connection can not be - Check the circuit connection

＃＃
used in pump - Check the distribution box
- Change inlet conditions

- Raise the minimum water level
- Reduce the speed of the water flow
of the inlet pipeline
＃＃＃＃ - The pump inlet into the air
＃ - Increase the inlet pressure
- Check the air tightness of the inlet
pipe, if necessary add gasket
- Replace bad piping
- Change inlet conditions
- Check the operating status
＃ -Foul air (abnormal voice )
- Increase the inlet pressure
- Reduce the pump mounting height
- Check
- The solid of base is not
＃＃＃ - Reform
enough
- Correct
- Re- adjust the operating point

＃＃＃＃＃ -Not allow parallel operation
- Change the pump head
- Adjust
- Check the rotor
-Friction between impeller - Check the impeller position
＃＃＃＃
and pump shell - Check the pipe connections to
ensure that the pump is not under
stress
- Exhaust
The air bubbles is not allowed - Check the air tightness of the inlet
＃＃＃
in the medium pipe, if necessary install gasket
- Install exhaust valve
Page 32 of 37
11. Engine Instruction and Maintaince

11.1 Engine Description
 General: The engine that powers the diesel pump set is an industrial, heavy duty diesel engine that has been
selected for its reliability and efficiency in operation. It is specifically designed to power diesel pump sets. The engine is a
4-stroke compression ignition type with all the accessories necessary to provide a reliable power supply. Full details of
the engine are provided in the engine manual. This section gives a brief discussion of the major systems and how they
are integrated into the diesel pump set.
 The diesel engine is used at a speed that is no more than 90% of the maximum speed indicated by its manufacturer
on the ICN class characteristics curve.The engine is fitted with a suitable water preheating system and, where necessary,
with a turbo pre-greaser, which allows it to operate at normally within 15 seconds of a start instruction being given. The
engine is sized to be able to operate without excessive mechanical or thermal effort at its nominal operating power for six
hours.The engine has a manual stop and the starter system automatically returns to the automatic starting position after
the manual stop has been used.The engine is sufficiently well managed so that the change in its speed between the
extreme operating levels (demands of zero and 150%) is no more than +/- 10%.
 Cooling System：The diesel engine is cooled by a non-recycling water heat exchanger where the water inlet valve
is controlled by the engine's oil pressure. This system provides for cooling of the surface heat of the engine, and internal
cooling of the engine by the water circulating. The thermostat maintains coolant temperature at a level for efficient
operation of the engine.
It is important to pay careful attention to air flow around the diesel pump set to ensure proper cooling. Following the
installation instructions can ensure satisfactory performance.
Check the cooling loop every month: close the ball valve near the pump outlet, and take of the strainer valve, clean it by
the clean water, after assembly the strainer valve, and then open the ball valve near the pump outlet.
 Engine Speed Controlling: Two ways to control engine speed, “constant speed or constant head”. The speed
control system can constant unit speed in a fixed value by inspecting unit speed. Or we can inspect pump set outlet
pressure and change pump set speed so as to constant pump set pressure in a fixed value to adapt load changing(for
the detail please see diesel engine speed controller and digital pressure controller manual). The engine speed is directly
related to pump set output, if the engine speed changes, it would certaily affect power output(directly affect head and
flow).
This speed controller is used to adjust engine speed and also fuel amount. When the load (flow) of unit is added, it will
add fuel for engine. When the load is reduced, it will reduce fuel amount.
 Fuel System: The engine is supplied by a fuel tank fitted to provide a gravity feed to the injection pump.
Exhaust System: Exhaust systems are provided to reduce the noise level of the engine and to direct the exhaust gas to
where they will not be a hazard. Exhaust gas must be ducted out of the building using piping of a diameter such that the
length and accidents do not result in a loss of loading that is greater than the allowed back-pressure when operating at a
top speed of 150%.The duct outlet must prevent water or birds from entering it.The exhaust pipe connection must use an
expansion joint that avoids all tracking, squashing, stretching or lineage.The exhaust pipe must be thermally insulated to
a height of 1.60 metres from the ground.
11.2 Engine Maintenance

 Normal maintenance: every 1 year or 50 hours.
 Caution: when the engine have a many problem and need do the overhaul maintain, cut the main supply by the
main supply switch。
 The Engine Manual supplied with this manual contains detailed information on maintaining the engine. It also
includes a comprehensive trouble shooting guide for engine faults.
Page 33 of 37

Diesel Fire Pump Equipment Manual

Uploaded by

Diesel Fire Pump Equipment Manual

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INSTALLATION, OPERATION AND

8.2 Pre-Start Checks...................................................................................................................................................................16

2.2 Installation, Moving and Transportation

2.3 Fire Proofing and Explosion Protection

with fire extinguishers. Please pay attention to the follows:

2.4 Safety Guard

3. Diesel Engine Pump Group Structure

Fig.1 Diesel Engine Group

3.2 Diesel Engine

3.3 Electric Power System of Diesel Engine

3.4 Cooling System

Fig.2 Cooling System (internal)

Fig.3 Cooling System (external)

Fig.4 Normal Situation

Fig. 5 Emergency Situation

3.6 Fuel Tank and Common Base

3.8 Silencer and Exhaust System

3.9 Control system

4. Moving, Towing and Storage

4.2 Lifting Position

adjacent crane operations which may fall the object.

4.3 Open Packing and Keep

4.5 Pumps Storage

5.2 Installation Process

5.3 Common Base Assembly

5.6 Whole Group Installation

anchor bolts must pad.

5.7 Outlet and Inlet pipes

5.9 Location for Pump Installation

5.10 Pipe for Pump Suction and Discharge

6.1 Ventilation for Pump Room

Fig.10 Ventilation Design for Pump Room

6.2 Exhaust and installation of exhaust pipe

Fig.11 Exhaust System Installation Drawing

Fig.12 Exhaust System Detail Installation Drawing

6.3 Fuel System

leaks caused by engine vibration.

6.4 Fire precautions

8.2 Pre-Start Checks

8.3 Automatic and Remote Control

8.4 Manual Startup and Shutdown

group is in the automatic conditions again.

8.4 Emergency Start-up

 Start-up ： Hold the “Bladk Head” of 2 emergency starter

8.5 Weekly Test

Pressure Control Loop

Engine Control Panel

Main Control Panel

9.2 Construction information

9.3 Operation of Circuits

9.3.2 Starting the Pump

9.3.2.2 Automatic Mode

9.3.2.3 Manual Mode

9.3.2.4 Off Mode

9.3.2.5 Emergency Start

9.3.2.6 Emergency Stop

9.3.3 Direct Current Power Supply from Two Independent Sources

9.3.4 Water Preheating

9.3.6 Managing Alarms and Errors

9.3.7 Information Display

9.3.7.1 Engine Failure

 Starter link error (15 seconds time delay)

9.3.7.2 Auto Control Error

9.3.7.4 Fail to Start

9.3.7.5 System Failure

9.3.7.7 Pump required starting the engine

9.4 Electrical Specifications

9.4.2 Direct Current System

9.4.4.2 Configuration and Adjustment

9.4.5 User inputs/outputs

9.5 External Connector

Lower the bulb in the tank to obtain the error.

10. Pump Maintenance

10.2 Preventive Maintenance

 Check and started spare-pump periodically.

10.3 Pump Disassembly

＃＃ - Axis is incorrect -Replace

＃＃＃ -Bearing damage -Replace