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ARGO

Firefighting units EN 12845

Instructions for the use and maintenance

Ed. 2011/09 - Rev. 01 - EN - Code 520

INSTRUCTIONS FOR THE USE AND MAINTENANCE - ARGO - EN 12845 Firefighting units

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Translation of the original instructions TABLE OF CONTENTS

«EC» declaration of conformity (fac simile). ..................................................................................................................... page 3

SECTION 1: Description and main characteristics ..................................................................................................... page 5 1.1 Presentation ........................................................................................................................................................... page 5 1.2 Warranty ................................................................................................................................................................ page 5

1.2.1 Warranty exclusions ..................................................................................................................................... page 5 1.3 Description of EN 12845 firefighting units ............................................................................................................... page 6

1.3.1 Identification of EN 12845 firefighting units ................................................................................................... page 6 1.4 Technical characteristics ......................................................................................................................................... page 7

SECTION 2: Handling and installation ......................................................................................................................... page 7 2.1 Safety ........................................................................................................................................................................ page 7

2.1.1 Used terminology ......................................................................................................................................... page 8 2.2 Handling .................................................................................................................................................................. page 8 2.3 Commissioning........................................................................................................................................................ page 9 2.4 Firefighting unit installation room ............................................................................................................................. page 9 2.5 Hydraulic installation ............................................................................................................................................... page 9

2.5.1 Suction piping .............................................................................................................................................. page 9 2.5.2 Flooded suction installation .......................................................................................................................... page 10 2.5.3 Suction lift installation................................................................................................................................... page 10 2.5.4 Flow piping ................................................................................................................................................... page 10 2.5.5 Measurement piping for periodical trials ....................................................................................................... page 11 2.5.6 Automatic recirculation piping ....................................................................................................................... page 11

2.5.7 Packing leakage exhaust piping .................................................................................................................... page 11 2.6 Electrical connections ............................................................................................................................................. page 11

2.6.1 Engine driven pump only .............................................................................................................................. page 11 2.6.2 Electric driven pump or unit with more electric driven pumps and engine driven pump ............................... page 11 2.6.3 Main distribution electric control panel ......................................................................................................... page 12

SECTION 3: Start up and maintenance ....................................................................................................................... page 12 3.1 Before use ............................................................................................................................................................... page 12 3.2 First start up and pressure switch calibration ......................................................................................................... page 13

3.2.1 Jockey pump test ......................................................................................................................................... page 13 3.2.2 «Split-case» electric driven pump ............................................................................................................... page 13 3.2.3 Electric driven pump test .............................................................................................................................. page 13 3.2.4 Engine driven pump test .............................................................................................................................. page 13

3.3 Functioning ............................................................................................................................................................. page 14 3.3.1 Normal functioning ...................................................................................................................................... page 14

3.4 Maintenance............................................................................................................................................................ page 14 3.4.1 Weekly periodical check ............................................................................................................................... page 15 3.4.1 Monthly periodical check .............................................................................................................................. page 15 3.4.3 Three month periodical check ...................................................................................................................... page 15 3.4.4 Six month periodical check ......................................................................................................................... page 16 3.4.5 Annual periodical check .............................................................................................................................. page 16 3.4.6 Three year periodical check ........................................................................................................................ page 16 3.4.7 Cleaning ....................................................................................................................................................... page 16 3.4.8 Disposal ....................................................................................................................................................... page 17 3.4.9 Spare parts .................................................................................................................................................. page 17

ATTACHMENTS: ........................................................................................................................................................... page 18 Attachment 1 - Flooded suction system diagram .......................................................................................................... page 19 Attachment 2 - Suction lift system diagram ................................................................................................................... page 20 Attachment 3A - Wiring diagram for electric driven pump control panel (direct start up) .................................................. page 21 Attachment 3B - Wiring diagram for electric driven pump control panel (star/delta start up - P < 90 kW) ....................... page 22 Attachment 3C - Wiring diagram for electric driven pump control panel (star/delta start up - P ≥ 90 kW) ........................ page 23 Attachment 3D - Control unit for electric driven pump control panel ................................................................................ page 24 Attachment 4 - Engine driven pump: instructions for use and control panel wiring diagram .......................................... page 32 Attachment 5 - Wiring diagram for jockey electric driven pump control panel (electro-mechanical version) .................. page 42 Attachment 6 - Wiring diagram for jockey electric pump control panel (electronic version)............................................ page 43


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Fig. 1 - Firefighting unit identification tag (see par. 1.3.1 page 6)

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Fig. 2 - Lifting and handling (1. Lifting with ropes and hoist; 2. Lifting with lift truck)

Fig. 3 - Suction set assembly (1. Pump suction port; 2. Eccentric reducer; 3. Butterfly isolator valve; 4. Vibration-damping flanged coupling; 5. UNI EN 1092-1 flange; 6. Gasket)

PERFORATE CUT Fig. 4 - Pressure gauge / vacuum gauge perforation


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ATTENTION DO NOT COMMISSION THE FIREFIGHTING UNIT BEFORE HAVING WELL READ AND UNDERSTOOD THIS MANUAL. VARISCO SPA DECLINES EVERY AND ANY RESPONSIBILITY FOR DAMAGE CAUSED BY NEGLIGENCE AND MISSED OBSERVANCE OF WHAT IS REPORTED IN THE PRESENT MANUAL. VARISCO SPA DOES NOT RESPOND TO EVENTUAL DAMAGE CAUSED BY MISINTERPRETATION OF THE INSTRUCTIONS CONTAINED IN THE PRESENT MANUAL AND FOR DAMAGE CAUSE BY FAULTY INSTALLATION AN/OR BY IMPROPER USE OF THE FIREFIGHTING UNIT ITSELF.

SECTION 1 Description and main characteristics

1.1 PRESENTATION This manual reports information and what is deemed necessary for knowledge, good use and regular maintenance of the «EN 12845 Firefighting units», produced by VARISCO SpA - Terza Strada, 9 - Zona Industriale Nord - PADOVA - Italy, hereafter also called Manufacturing Company. Missed observance of what is described in this manual is cause for annulment by the Manufacturing Company of the warranty that it gives to the product. For eventual repairs or revisions that imply operations of a certain complexity, it is necessary to refer directly to the Manufacturing Company, which is in any case completely available to ensure ready and accurate technical assistance. 1.2 WARRANTY All products of VARISCO SpA are guaranteed for a period of 12 months from the date of the first commissioning and in any case for no more than 18 months after the delivery date. Repairs carried out under warranty do not interrupt the cycle of the warranty period. The warranty concerns material and labour defects which compromise the function of the product and make it unsuitable for the use for which the product is intended, as long as they are announced in a timely fashion and in any case no later than 2 days from their discovery. Damage stemming from physical/chemical characteristics of the aspirated liquid, as well as damage of the parts that by nature or destination are subject to wear or to deterioration (seals, membranes, pressure gauges and vacuum gauges, plastic details, rubber, etc.) or that stems from disrespect of the use and/or maintenance instructions, from bad or inadequate use or storage of the product or from changes or repairs carried out by staff not expressly authorised by VARISCO SpA is excluded. The non identifiability of the serial number is cause for exclusion from the warranty. Our warranty performance is expressly subordinate to the fact that the purchaser has met all the obligations matured up until the day of the request and those expiring during the warranty intervention in progress. The decision to emit a credit note, repair or replace the goods, is upon undisputable judgement of VARISCO SpA. Goods may only be returned by written authorization, carriage free, by VARISCO SpA - Padova. All the disassembly/re-assembly expenses of the product from/on the place of installation and any other intervention on the work area will be charged to the purchaser. Repaired or replaced goods will be re-delivered to the purchaser ex works VARISCO SpA - Padova. Returned goods become property of VARISCO SpA. It is intended that the warranty in question absorbs and replaces the warranties or responsibilities foreseen by law, and exclude any other responsibility of VARISCO SpA (damage reimbursement, missed income, recall campaigns, purchaser labour, construction stop, lowering of sales price, etc.). The Padova tribunal will have exclusive jurisdiction in case of controversy. 1.2.1 WARRANTY EXCLUSIONS The warranty expires (other than what is reported in the supply contract): - if an operator maneuver error should occur; - if the damage should stem from insufficient maintenance; - if non original spare parts are used; - if the instructions reported in this manual were not to be followed. Damage stemming from negligence, neglect, misuse and improper use of the Firefighting unit also remains excluded from the warranty. Removal of the safety devices, with which the pump is equipped, will automatically annul the warranty and the responsibilities of the Manufacturing Company.


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1.3 DESCRIPTION OF THE EN 12845 FIREFIGHTING UNITS The Firefighting unit is a «EC» marked machine and is compliant to the essential safety and health requirements and to the prescriptions of Directives 2006/42/EC, 2004/108/EC, 2006/95/EC. The Firefighting unit is compliant to the requirements of technical standard UNI EN 12845, ed. 2009. The firefighting units manufactured by Varisco SpA are made in conformity to standard EN 12845. The standard indicates the requirements and supplies indications for designing, installing and maintenance of fixed installations and automatic sprinkler systems, against fires in buildings and industrial plants. The Firefighting unit is suitable for pumping freshwater in absence of solid bodies, used for feeding water to the automatic firefighting system. The Firefighting unit is made to automatically intervene when the supply of water is requested by any firefighting system use area. It must be installed in proximity to a water reserve of a capacity able to guarantee the unit itself adequate supply autonomy or, in any case, according to the rules dictated by the local Fire Department. The standard unit is made up of: - one or more main pumps, driven by electric or diesel engine; - one or more control panels for automatic start up of each pump; - one low power auxiliary electric driven pump, with the function to keep the system in pressure (compensation). To obtain the maximum guarantee of operational functioning, it is appropriate to foresee a pump driven by diesel engine, which performs at an equal level to the main electro pump/s, to obtain the requested water capacity also in case of lack of electric power. For the electric driven pumps, the control panel includes: - main switch, electronic start up device, fuses, run and stop contactor or star delta started for power higher than 10 kW; - automatic mode off selector, manual on/off buttons and indicators test, start-up indicators. For the pumps driven by diesel engine the control panel includes: - electronic device for automatic start-up and protections; - battery charger with electronic adjustment; - automatic mode off selector, manual on-off buttons; - faulty start-up alarm; - motor functioning meter; - motor preheat system, which allows immediate supply of full power at unit start up. The jockey electric driven pump keeps the system at nominal pressure. Said pump, equipped with own pressure switch, triggers its function to make up for the small system leaks. The opening of one or more use areas determines the start up of the electric driven pump through two appropriately calibrated pressure switches. If more electric driven pumps are installed, they will start up in sequence, controlled by the pressure decrease caused by the opening of a growing number of uses. If the main electric driven pump does not start up due to lack of electric power, or it is stopped due to faults or maintenance, the ulterior pressure decrease controls the automatic start up of the pump with diesel engine. All the units are equipped with interception valves and the connection piping of the engine driven pump is equipped with vibration-damping flanged couplings. DANGER The use of the Firefighting unit for uses different than those intended, and not conforming to what is reported in this manual, other than being considered forbidden, relieves the Manufacturing Company from any responsibility. ATTENTION The Firefighting unit is to be used exclusively for uses specified by the Manufacturing Company: - the construction materials; - the operational conditions (pressure, number of revs, temperature, etc.); - the application sectors. Any other use to which the units may be applied that is not contemplated in this manual relieves the Manufacturing Company from any and every responsibility for damage to persons, animals or things. For use not specified by the Manufacturing Company, contact the VARISCO SpA Technical Office. 1.3.1 IDENTIFICATION OF THE EN 12845 FIREFIGHTING UNITS Each Firefighting unit is equipped with an identification tag (Fig.1) whose data reports: TYPE: identifies the pump and unit model (pump/reducer/motor). SERIAL NUMBER: it is the pump serial number. ITEM: it is the number which connects the pump to the contractual documentation (it is not always indicated).


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m3/h (max): it is the maximum pump capacity, measured at the maximum number of revs (RPM). m (max): it is the maximum operational pump pressure measured at the maximum number of revs (RPM). kW: it is the maximum power applicable to the pump capacity at the maximum number of revs (RPM). RPM (max): it is the maximum number of pump functioning revs. The pump must never exceed said number of revs. kg: it is the weight of the unit excluding the weight of the water in the pump casing, in the piping and of the diesel fuel in the tank. The tag data refer to the test with 20° C water and with density of 1000 kg/m3.

ATTENTION Ensure that the tag with the relative prints are always clearly legible and are not covered by treatments or paint. The reported data must always be cited for eventual requests of spare parts and for assistance interventions. Each Firefighting unit is standard equipped with: - instructions for use and maintenance; - «EC» declaration of conformity. 1.4 TECHNICAL CHARACTERISTICS

ATTENTION The main technical data of the Firefighting unit (power supply, size, weights) is reported in the relative datasheet. Engine driven pump control panel (compliant to regulation EN12845) The engine driven pump control panel are available in the following versions: TYPE NFE-1213 (with 3A battery charger) NFE-1216 (with 6A battery charger) for assembly on board the unit, complete with start up and stop power relays (standard configuration); TYPE NFE-1223 (with 3A battery charger) NFE-1226 (with 6A battery charger) for remote assembly from the unit, without start up and stop power relays, which are in this case contained in a junction box on board the unit (non standard configuration, only possible if requested in order phase).

SECTION 2 Handling and installation

2.1 SAFETY It is mandatory to read this manual very carefully, particularly the safety regulations, paying close attention to the operations that result to be particularly dangerous. The Manufacturing Company declines any and every responsibility for missed observance of the safety and accident prevention regulations described as follows. Pay attention to the danger signals present in this manual, it precedes the signaling of potential danger. The signals have three levels:

DANGER This signal alerts that if the described operations are not correctly carried out, they cause serious lesions, death or long term health risks.


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ATTENTION

This signal alerts that if the described operations are not correctly carried out, they may cause serious lesions, death or long term health risks.

CAUTION

This signal alerts that if the described operations are not correctly carried out, they may cause damage to the firefighting unit. 2.1.1 USED TERMINOLOGY Definitions of specific persons and situations which may directly involve the machine and/or the persons in direct contact with the machine itself are described as follows. • USER: The user is the person, the body or the company which purchased or rented the machine and intends to use it for the uses conceived for the purpose. The machine and the training of those operating around it are His/Her responsibility. • DANGEROUS ZONE: Any zone in proximity of a machine in which the presence of an exposed person constitutes a risk for safety and health of said person. • PERSON EXPOSED: Any person that is entirely or partially in a dangerous zone. • OPERATOR: As such is intended that person, generally, able to function, adjust, carry out maintenance, clean, repair and

transport the machine. • SPECIALISED STAFF: As such are intended those persons especially trained and enabled to carry out maintenance or repairs interventions which require particular knowledge of the machine, of its function, of the safeties, of the intervention modes and that are able to recognize the dangers stemming from use of the machine and therefore may be able to avoid them.

IT IS ABSOLUTELY FORBIDDEN TO:

DANGER

- Inhale toxic, flammable, or oil fog substances. - Carry out maintenance interventions with motor running. - Climb onto the firefighting unit to carry out interventions of any kind. - Intervene on the unit when it is connected to an active remote command. - Avoid touching the moving parts in any way. - Maintenance and adjustment interventions on the Firefighting unit, they must always be carried out with the motor

turned off. - It is absolutely forbidden to use the Firefighting unit by inexpert staff and not in good psycho-physical conditions. - Before commissioning the Firefighting unit, check the perfect integrity of the entire equipment. - Use suitable clothing. Absolutely avoid fluttering clothing or clothing with corners that could somehow be caught in

rotating parts and in moving parts. Use work suits created according to specific safety requisites, gloves, insulation shoes, glasses, noise headset and helmet.

- It is absolutely forbidden for extraneous persons to stop in the operational area. The operator will have to be responsible for distancing eventual extraneous persons.

- Check the Firefighting unit often and periodically, it must always be in optimal state. - Never place hands near moving parts (i.e. belts, junctions, etc.) - Do not place hands near the hot parts of the motor. - Do not climb onto the firefighting unit to carry out interventions of any kind. - Do not set metallic utensils on the battery. - The spare parts must correspond to the needs defined by the manufacturer. Only use original spare parts. - It is absolutely forbidden to remove or tamper with the safety devices. - The use instructions manual must be read, memorized and conserved for the entire duration of the Firefighting unit until its complete disassembly.

If the manual should be lost, request it immediately to the Manufacturing Company.

2.2 HANDLING If it is necessary to transport the Firefighting unit for a long distance, it may be loaded on train wagons and on trucks, operating as described below.

ATTENTION

Before handling the Firefighting unit, it is appropriate to check dimensions and weight by detecting them from the datasheet. This data is important to check the capacity of the equipment for lifting and for the possibility of passage in narrow spaces.


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The Firefighting unit can be lifted, at the loading surface, in two distinct ways: 1) with an appropriate hoist, equipped with scale of an adequate capacity, by hooking the extremities of the metallic wires, or chains, to the perforations present on the unit base and marked for lifting, and proceeding to lift (1 Fig. 2); 2) with lift truck: for this purpose, slip the forks under the Firefighting unit and proceed to lifting (2 Fig.2).

DANGER The transport and transfer operations may be very dangerous if not carried out with the maximum caution: thus distance persons that are not operators; clean, clear and define the transfer zone; check integrity and suitable conditions of the means available. One also has to ascertain that the zone in which one is operating is free from obstacles and that there is sufficient «escape space», by this term one intends a free and secure zone in which one can quickly move if the load were to fall. The surface on which one intends to load the Firefighting unit must be horizontal to avoid possible shifting of the load. Once the Firefighting unit is placed on the eventual means of transportation, ensure that it remains locked in its position. Fix the Firefighting unit to the surface on which it is set through the use of ropes suitable to the mass one intends to block movement. Said ropes must be firmly fixed and well tensioned towards the anchorage point on the resting surface. Once the transport is carried out, firstly free the Firefighting unit from all constraints, check that the status and the position of the same as such to not constitute danger. Thus remove the ropes and proceed to unloading with the same means and modes foreseen for the load. 2.3 COMMISSIONING

DANGER During the commissioning and maintenance operations, it is necessary to foresee safe transfer of all the components by using appropriate harnesses. Handling must be carried out by specialized staff in order to avoid damaging the Unit and causing accidents to the staff, by following the instructions reported in paragraphs “2.1 Safety” and “2.2 Handling”. Exclusively use the lifting rings predisposed on the Firefighting unit. 2.4 FIREFIGHTING UNIT INSTALLATION ROOM During installation apply all the safety dispositions emitted by the competent bodies in the country of use and dictated by common sense. The pumping units must be installed in rooms with a fire resistance not inferior to 60 minutes, used only for firefighting protection. It must be one of the following (in order of preference). a) a separate building; b) a building adjacent to a building protected by sprinklers with direct access to the exterior; b) a room within a building protected by sprinklers with direct access to the exterior. The pump room must be kept at the following minimum temperatures: +4 °C for the pumps driven by electric motor; +10 °C for the pumps driven by diesel engine;

ATTENTION

The pump rooms for pumps driven by diesel engine must be equipped with adequate ventilation in conformity with the recommendations of the engine constructor.

DANGER

Danger of death by asphyxia. Always bring the discharge tube of the diesel engine to the exterior. Between the terminal of the engine exhaust muffler and the fumes exhaust piping, it is necessary to place a flexible stub pipe to isolate the vibrations between the motor itself and the pipe firmly fixed to the building. In the models in units in which the muffler is supplied loose, the connection piping between the combustible gas exhaust on the engine collector and the muffler itself is not supplied. 2.5 HYDRAULIC INSTALLATION 2.5.1 SUCTION PIPING It is recommended to install the unit in flooded suction condition. The installation is considered flooded suction if: - at least two thirds of the suction tank effective capacity are above the pump axis level; - the pump axis is not more than 2 meters above the minimum water level in the suction tank (see UNI EN 12845 par. 9.3.5).


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Suction piping, including all valves and fittings, needs to be designed in a way that ensures that the NPSH available at the pump intake is greater than the NPSH request by at least 1 m, with maximum flow rate request and maximum water temperature (see UNI EN 12845 par. 10.6.2.1).

ATTENTION In order to prevent the possible formation of air pockets in the suction piping, the piping must be placed horizontally or should slope continuously upwards towards the pump. If the pump axis is above the minimum water level a foot valve needs to installed (see UNI EN 12845 par. 9.3.5). The piping must be sustained independently: loads must not be applied to the suction flange of the pump. At the inlet of the suction piping in the accumulation tank it is possible to install an antivortex plate with minimum dimensions specified in UNI EN 12845 Table 12 par. 9.3.5: in this case the distance of the suction piping axis from the minimum water level in the tank (dimension A) can be reduced to 0,10 m. In case of suction lift pumps, in the suction piping, upstream of the foot valve, a filter must be installed. The filter must be installed so that it can be cleaned without emptying the tank. In case of open tanks which feed flooded suction pumps, one must foresee a filter on the exterior of the tank on the suction piping. An interception valve must be installed between the tank and the filter. The filters must possess a passage area of at least 1,5 times the nominal area of the piping and must not allow for the passage of objects with a diameter greater than 5 mm. «Suction sets» may also be supplied separately from the unit. They are loose components to connect, as the Customer's responsibility, to the suction line of the service pumps. Figure 3 describes the components order of assembly. 2.5.2 FLOODED SUCTION INSTALLATION (see Attachment 1) In this type of installation, the diameter if the suction piping must not be less than 65 mm. Also the diameter must be such that the speed must not exceed 1,8 m/s when the pump is working at the maximum required capacity. Where more than one pump is foreseen, the suction piping must be interconnected if equipped with interception valve to allow for each pump to continue to function when the other one is removed to carry out maintenance operations. The interception gates in suction (detail 8) must always be assembled to allow maintenance of the pump itself (for example: disassembly of the pump or cleaning of the relative retainer valve) without having to empty the accumulation tank.

ATTENTION The connections must be adequately sized for the requested capacity. 2.5.3 SUCTION LIFT INSTALLATION (see Attachment 2) In this type of installation, the diameter if the suction piping must not be less than 80 mm. Also the diameter must be such that the speed must not exceed 1,5 m/s when the pump is working at the maximum required capacity.

ATTENTION Where more than one pump is installed, the suction piping must not be interconnected. Vertical distance from the minimum water level (see UNI EN 12845 par. 9.3.5) to the pump axis must not exceed 3,2 meters. In the lowest point of the suction piping a foot valve must be positioned. Each single pump must be connected to an automatic separate priming device, complete with accessories foreseen by UNI EN 12845 standard. The device includes a tank positioned at a higher level (about 1 m) compared to the pump and with a connection piping coming down from the tank to the pump flow. In this connection there must also be a non return valve present. The tank, the pump and the suction piping must be kept constantly full of water also in presence of leaks from the foot valve.

CAUTION Also the eventual jockey electric driven pump will have its own independent suction piping. 2.5.4 FLOW PIPING The flow collector is equipped with two flanges to aid the connections in case of ring systems. If only one flange is used, the free one can be used for recirculation (see paragraph “2.5.5 - Measurement piping for periodical trials”). Pressurized tanks can be optionally supplied (capacity 12 litres), to connect to the flow collector (by the Customer) through an equipped interception valve; the valve must be opened before operating the unit.


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ATTENTION

The collector must be independently sustained: loads must not be applied to the flow flange of the pump. 2.5.5 MEASUREMENT PIPING FOR PERIODICAL TRIALS (see Attachments 1 and 2) To aid periodical function tests, it is useful to create a connection between the pump start up circuits and the accumulation tank, with 1/2” piping (detail 9A). Said connection enables to simulate a pressure drop and therefore start up in automatic, without opening the sprinklers and with no water consumption. A flange a gate is foreseen on the flow of each pump unit (detail 8B) for the measurement of the capacity of the unit itself. The eventual capacity measure (detail 13) will have to be installed in a straight piping tract with a length equal to at least six times the diameter of the pipe itself, both upstream and downstream of the measure itself (Example: pipe DN100; 100x6 = 600; a pipe tract of at least 0,6 meters is needed before and after the measure). 2.5.6 AUTOMATIC RECIRCULATION PIPING (see Attachments 1 and 2) To avoid prolonged functioning of the zero capacity pumps when the place of installation is not always presided it is necessary to install an automatic recirculation system. Since the units have automatic start up but manual stop, they can remain functioning long before being stopped with the danger of overheating of the water contained in the pumps, subsequent vapour formation and breaking of the pump body and seal destruction. On the reduction stub mounted on the flow flange of each main pump, a connection for the recirculation pipe is predisposed (there is also a 2” connection, intended to connect the priming tank when the system is not flooded suction). At the free extremity of the recirculation connection a device will have to be connected (calibrated diaphragm or adjustment valve) to set the recirculation capacity (detail 14). For this purpose, balance valves (10 or 20 revs) may be mounted, commonly used in heating systems. In this point, with the pump stopped, only the static pressure due to the head of the water reserve will be present. When the pump begins to function, the flow pressure will cause the circulation of a capacity proportional to the opening of the balancing valve, and the eventual pressure switch connected to the circuit (detail 7A), will signal the function of the relative pump. A visual indicator of the passage of the recirculation flow (detail 17), which may be supplied as an option, must always be connected to the exhaust of the circuit itself . Check, before commissioning of the unit, that the legible number of revs on the wheel of the balance valve corresponds to the value reported on the warranty slip affixed to the valve itself. 2.5.7 PACKING LEAKAGE EXHAUST PIPING If main pumps with packing seals are employed, there is a tank for the collection of water leaking from the packing rings (it is in the back part of the pump and the shaft support). These tanks are equipped with threaded perforations which allow to connect the piping to convey the reflux water to the exterior. 2.6 ELECTRICAL CONNECTIONS Every pump unit is equipped with own electric control panel. Carry out the electrical connection by entrusting the operation to a qualified operator who will ensure full observance of regulations regarding safety, and in particular: - respect the Country current laws; - checking of correspondence between the values reported in the tag and the network values; - particular attention to the wiring diagram. 2.6.1 ENGINE DRIVEN PUMP ONLY A single phase 230 V 50 Hz line is sufficient. The required power of 1 kVA. In particular cases, with motors with over 150 kW, water cooled motors, etc., a higher power could be requested. In said case consult the Technical Office.

ATTENTION

To allow the engine batteries to remain charging, the 230 V line must be hooked up and the main switch of the engine driven pump control panel must be connected. If, after the installation, the fire prevention unit is deactivated while waiting for the completion of other auxiliary works, it is recommended to disconnect the terminal from the positive terminal of the batteries (being careful to insulate it in order to avoid short circuits) to avoids its discharge through the board's auxiliary circuits. The terminal will have to be re-connected to the actual unit activation. 2.6.2 ELECTRIC DRIVEN PUMP OR UNIT WITH MORE ELECTRIC DRIVEN PUMPS AND ENGINE DRIVEN

PUMP A three phase line of adequate capacity to the total power of the electric driven pumps is requested. In absence of particular requests, the normal voltage considered is 3x400 V 50 Hz. Electric power supply must always be available.


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Power supply for the control panel of the service electric driven pump must be dedicated exclusively to the same and separated by all the other connections. Where allowed by the manager of the electric network, power supply for the control panel of the pump must be taken upstream of the main building power supply switch, and where it is not allowed, through connection from the main switch. All the connecting cables must be protected against fire and mechanical damage. In order to protect the cables from direct exposure to fire, they must pass through the exterior of the building or through those parts of the building where the fire hazard may be overlooked and that are separated by any significant risk of fire through walls, partitions or floors with a fire resistance not inferior to 60 minutes, or that must be equipped with a direct additional protection or grounded. The cables must be made up of a single tract without junctions. 2.6.3 MAIN DISTRIBUTION ELECTRIC CONTROL PANEL The main electrical control panel must be located in a fire prevention compartment used exclusively for power supply. The electrical connections in the main electric control panel must be such that the power supply of the main electric driven pump control panel is not insulated when the other services are insulated. Every switch installed on the power supply line dedicated to the electric fire pump must be labeled as follows:

FIREFIGHTING PUMP MOTOR SUPPLY

NOT TO BE SWITCHED OFF IN THE EVENT OF FIRE

The letters on the label must be at least 10 mm high and must be white on a red background. The switch must be blocked to protect against eventual tampering. In the control panel a terminal is present for the protection conductor (earthing), which will have to be connected to the protection conductor by the user of the unit. For the electric driven pumps with power higher than 7,5 kW (10 CV), star-delta starters are used, so the switch that protects the line of the unit will have to have a magnetic release adequate to carry at east 2,5 times the nominal current of the electric pump, or the sum of the nominal current of each electric driven pump there is more than one.

ATTENTION

For the electric driven pumps fitted with oversized electric motors, in some particular cases, autotransformer starters can be used; in this case contact the Technical Office to obtain the values of the nominal and pick-up currents of the electric pumps, necessary for the choice of the switch which protects the line of the unit. The connection of the cyclic sense of the phases will be checked, without needing to start up the electric pumps, checking the electric network control relays present in the electric driven pump panel: by applying voltage to the control panel, the red led will have to switch on on the device itself. In case of the contrary, invert the two phase conductors in the board input terminal block without touching the connections of the single motors.

ATTENTION Then carry out the check of the rotation direction, starting up each electric driven pump for an instant with the relative manual control: they will have to turn CLOCKWISE, looking at them from the fan side.

SECTION 3 Start up and maintenance

3.1 BEFORE USE

ATTENTION

Before the Firefighting unit operation, the operator must have well read and understood all the parts of this manual and particularly the section dedicated to safety. Before operating the Firefighting unit, check that the equipment is in order, and that all the organs subject to wear and deterioration are fully efficient. After having carried out all the hydraulic connections and mechanically fixed the unit to the floor, it is necessary to check the correct motor alignment (electric motor and diesel engine), elastic coupling joint and pump, before proceeding to start up of the unit.


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Always ensure that the selectors of the functioning mode of the main pumps panel are positioned in «automatic mode excluded» before applying voltage to the boards for the first time; this has the purpose to avoid undesired automatic starts of said pumps in start up phase. The selectors will have to be brought back into «automatic mode included» position at the end of the first start up phase and unit commissioning. Also ensure that the pressure gauges and the vacuum gauges present on the unit are regularly perforated (Figure 4) before the unit commissioning. 3.2 FIRST START UP AND PRESSURE SWITCHES CALIBRATION 3.2.1 JOCKEY PUMP TEST (see Attachments 1 and 2) If the jockey pump exists, allow air to escape from the body of the same through the appropriate cap. Start up the pump by turning the selector on «AUTOMATIC». The pump will have to trigger itself and fill the system. The functioning pressure will be detected on the pressure gauge placed on the flow collector (detail 5), or the one placed on the pressurized tank. Allow air to escape from the firefighting ring, opening the use area gates. By opening the recirculation or a use area one will check the functioning of the jockey pump, that is managed by the two pressure switches connected to the flow of the pump itself (detail 7); one controls the run, the other one the stop. Typical advised values: - START: 1 bar more than the electric driven pump start up pressure; - STOP: 2 bar more than the electric driven pump start up pressure. If the pressure in the network does not increase, there could be a leak in the firefighting ring, or if present, in the foot valves of the main pumps. At this point to the pre-load of the pressurized tank must be carried out (the initial pre-load value, equal to about 2-3 bar, is not sufficient to guarantee correct functioning of the autoclave on the Firefighting unit): the advised value is equal to about 90% of the start up pressure of the jockey pump. 3.2.2 «SPLIT-CASE» ELECTRIC DRIVEN PUMP

DANGER Danger of damaging the pump. DO NOT start up the electric motor before the checks described as follows. If "split-case" type electric driven pumps are mounted (pumps with the casing divided horizontally and with the rotating parts remaining on the lower half-casing which holds the flanges and the piping), the pumping unit is shipped with the elastic coupling joint open; therefore BEFORE starting up the electric motor, disassemble the joint cover and check that the joint is actually open, then remount the joint cover, start up the motor and check that the rotation direction corresponds to that indicated on the pump. Re-close the joint to carry out coupling between motor and pump, remount the joint cover and go on to the following point 3.2.3. 3.2.3 ELECTRIC DRIVEN PUMP TEST (see Attachments 1 and 2) If the electric driven pump exists one will thus try to rotate the relative selector to “AUTOMATIC MODE ON” and decrease the system pressure through opening of recirculation (detail 9A) or of a use area. Check the start up pressure on the pressure gauge mounted on the flow collector.

ATTENTION The pressure gauge mounted on the pressurized tank indicated the existing pressure in the tank itself, not that of the system, because there is a retainer valve (detail 6) between the jockey pump and the flow collector. Advised value for electric driven pump start: not inferior to 0,8*P, where P represents the pressure developed by the pump with closed flow. Electric driven pump stop is manual only, in observance of the standards in force (UNI EN 12845). If the "routine test" option was ordered, the electric driven pump control panel includes a circuit for the weekly automatic pump test; it includes a programming clock, a luminous alarm, a rearm command and a solenoid valve which is already connected to the start up circuit. At the programmed instant, the circuit opens the solenoid valve; the decreasing line pressure determines the start up of the electric pumps. If the pressure does not re-stabilize in the course of the test, at the end of the test an alarm is generated (indicator lamp and remote free contact). At the end of the test the electric driven pump is automatically stopped. The presence of the "routine test" circuit is not requested by the Standard and in any case does not fulfill all the verification obligations required by the Standard (par. 3.4). 3.2.4 ENGINE DRIVEN PUMP TEST (see Attachments 1 and 2)

ATTENTION The diesel engine produces poisonous exhaust gases. Ensure area ventilation. Protect hearing with headset or plugs. Pay particular attention to the hot parts of the engine (exhaust pipe, collectors, head).


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ATTENTION

If the unit stops for long periods of time without connecting the engine pump control panel to the electrical network 230 Vac and with the network disconnection switch in "ON" position, the batteries of the diesel engine will discharge completely and irreparably. In these cases it is the Customer's responsibility to proceed to recharging the batteries at least once a month. Varisco Spa does not respond to malfunction and/or damage of the batteries subsequent to disrespect of this warning. Before this test switch on the disconnetting switch on the control panel of the engine driven pump, to allow preheating of the motor oil (2-4 hours, based on the environment temperature). If there is no time, adjust the accelerator at the minimum to avoid the first start up at maximum regime with a cold motor; after a few minutes of functioning at low regime, gradually bring the motor to nominal regime. As for the electric pump, turn the selector to “AUTOMATIC MODE ON” and decrease the system pressure through the valve (detail 9A) by controlling it on the flow collector pressure gauge (detail 5). Advised value for engine pump start: not inferior to 0,6*P, where P represents the pressure developed by the pump with closed flow. Engine pump stop is manual only, in observance of the regulations in force (UNI EN 12845).

ATTENTION

Always check (through the revs counter function of the engine driven pump control panel) that the number of diesel engine revs corresponds to the number of nominal revs reported in the catalogue; if necessary, act on the motor accelerator control to adjust the number of revs to the nominal value. If the start up pressures are not the desired ones, appropriately adjust the pressure switches. The start up of each main pump is controlled by two pressure switches, with the respective standard contacts: the second pressure switch acts as an aid element in case of malfunction of the first. The two start up pressure switches of each pump must be adjusted to the same intervention pressure value. If the pumps employ packing seals, at the first start up of the unit commission the pumps at least 20-30 minutes before tightening the gland.

ATTENTION Do not tighten until eliminating the leak, before if water does not come out, the sealing zone will not be lubricated and the shaft of the pump will be damaged in short time. 3.3 FUNCTIONING 3.3.1 NORMAL FUNCTIONING All the selectors must be kept on «AUTOMATIC» (jockey pump) or on «AUTOMATIC MODE ON» (main pumps); only in this position may the selector keys be extracted. In case of small leaks of the system or the retainer valves, the jockey electric driven pump will start up for the sufficient time in order to restore the volume of water output from the system. If instead a use area is opened, the same pump will start up to restore the pressure in the network: if the capacity requested by the use area exceeds that of the jockey pump, the pressure drops even more, until determining start up of the main electric pump. If the pressure does not rise again (missed functioning of the electric pump, lack of electric power, excessive water request), the engine driven pump also starts up.

ATTENTION If the electric power is missing or is removed for maintenance, the eventual decrease in pressure in the system will bring to the automatic start up of the engine driven pump. For greater details see Attachment 4: Engine driven pump: instructions for use and control panel wiring diagram. 3.4 MAINTENANCE The various ordinary maintenance operations are described as follows. It is appropriate to keep in mind that a lower cost of employment and long duration of the Firefighting unit depend on the continuous observance of what is reported in this manual. For extraordinary maintenance operations not contemplated in this manual, refer to the Manufacturing Company.

ATTENTION

Regulation UNI EN 12845 pays particular emphasis on periodical tests that must be carried out on the firefighting system, as responsibility of the user of the same, for the purpose of verifying its functionality and reliability in time. The user must carry out an inspection and controls program (see par. 20.2), one must have a test, assistance and maintenance program available (see par. 20.3) and must document and record the activities by conserving the documents in an appropriate file kept in the building.


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The user must ensure that the test, assistance and maintenance program is carried out according to contract by the system installer or by an equally qualified company.

ATTENTION

The centrifugal pump bearings must regularly be greased with lithium grease (20 grams every 200 hours of function). The first greasing is already carried out in the plant.

DANGER

The maintenance operations must be carried out with the motor turned off. After an inspection, check, assistance or maintenance test procedure, the system along with any automatic pump, pressure tank and gravity tank must be brought back to the correct functioning conditions. 3.4.1 WEEKLY PERIODICAL CHECK Checks and registrations a) all the pressure readings of the water and air pressure gauges on the systems, main ducts and pressure tanks; b) all the water levels in the accumulation tanks (pumps priming tanks, if present, and pressurized tanks); c) the correct position of all the main on-off valves. Pumps automatic start up test (electric driven pump and engine driven pump) The tests on automatic pumps must include the following: a) the fuel and lubricant oil levels of the diesel engine must be checked; if the pumps have the support and/or the mechanical seal lubricated with oil, check its level; b) check the diesel engine preheating system (touch the cup with your hand: when the motor is stopped it will have to be at about a 60 °C temperature); c) the water pressure on the start up device must be reduced, thus simulating the automatic start up condition; d) when the pump starts up, the start up pressure must be checked and recorded; e) through the ammeter check that the current absorbed by the electric driven pump does not exceed the electric motor nominal current; f) check that there are no vibrations or anomalous noises that may depend on the wear of rubber tassels of the elastic joint, from the motor or pump bearings; g) check the packing seal of the pumps: it will have to lightly drip (one drop each 20 seconds). h) the oil pressure on the engine driven pumps must be checked, along with the water flow through the systems of open circuit cooling; i) check the battery charge status of the engine through the instruments foreseen on the control panel (voltmeters and ammeters). Diesel engine restart test Immediately after the pump start up test, the diesel engine must be tested as follows: a) the engine must be operated for at least 20 minutes. The engine must subsequently be stopped and immediately re-started using the manual start up test button; b) if the diesel engine is cooled through a radiator, the water level in the primary circuit of the closed circuit cooling system must be checked.

ATTENTION During the test the oil pressure (where the pressure gauges are present), the engine temperatures ad the coolant flow must be monitored. The oil piping must be checked and a general inspection must be carried out to detect eventual fuel, coolant liquid or exhaust fumes leaks. If present in the firefighting room, the heating systems must be checked in order to verify their correct functioning. 3.4.2 MONTHLY PERIODICAL CHECK The level and the electrolyte density of all the start up battery cells of the diesel engine must be checked. If the density is low the battery charger must be checked, and if it is functioning correctly, the battery or the batteries in question must be replaced. 3.4.3 THREE MONTH PERIODICAL CHECK Piping and piping supports The piping and the relative supports must be checked to verify the eventual corrosion and where necessary they must be painted. If necessary the belt wrapped around the piping must be repaired.


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Water feeding and relative alarms The service pumps must start up automatically and the measured pressure and capacity pressure and capacity values must not be inferior to the nominal ones reported in accordance to paragraph 3.2 - First pressure switches start up and calibration. Electric power supply Any eventually present secondary electric power supply deriving from endothermic generators, must be checked to verify its correct functioning. Interception valves All the interception valves which control the flow of water to the firefighting system must be operate to ensure that they are operational and must be locked into normal position again. Spare parts The quantity and conditions of available spare parts must be checked. Diesel engines with heat exchanger The "Y" filters present in the hydraulic circuit upstream of the heat exchanger must be opened and cleaned. 3.4.4 SIX MONTH PERIODICAL CHECK Alarm report connection with the fire station and the supervision station. The system must be verified. 3.4.5 ANNUAL PERIODICAL CHECK Automatic pumps capacity test Every main pump must be tested in the full load condition (through connection of the test line connected to the flow of the pump downstream of the non return valve) and must supply the pressure/capacity values on the tag of the pump. Diesel engine faulty start up test The faulty start up alarm must be tested in conformity with the indications of paragraph 3.2 - First start up and pressure switches calibration. Immediately after this check the motor must be started up by using the manual start up system. Float valves in the priming tank The float valve must be checked to ensure correct function. Diesel engine lubricant oil Replace the oil of the diesel engine at least once a year. The oil deteriorates for continuous preheat even if the motor totals a few hours of running. Electric motors In the electric motors with predisposition to external lubrication, grease the bearings (advised grease quantity: 20 grams approximately). Pressurized tank preload Check the pressurized tank preload pressure; the check will be carried out after having discharged the water contained in the tank, through the valve (see Attachments 1 and 2, detail 9) otherwise the pressure read on the filling valve will not be accountable. 3.4.6 THREE YEAR PERIODICAL CHECK Accumulation and pressurized tanks All the tanks must be examines externally to check the eventual presence of corrosion. They must be emptied, cleaned if necessary and examined internally to check the presence of an eventual corrosion. Where necessary, all the tanks must be re-painted and/or corrosion protection must be restored. On-off valves and non return valves All the on-off and non return valves must be examines and replaced or revised if necessary. In case of doubts on the hydraulic or electrical installation of the units or the function and for eventual intervention requests, contact the VARISCO SpA Assistance Service: Tel. +39 049 82 94 111 - Fax +39 049 80 76 762 - www.variscospa.com 3.4.7 CLEANING At the end of use of the Firefighting unit it is necessary to: - rinse it with clean water if aggressive or fouling liquids were used; - proceed to cleaning of the hydraulic parts if reductions of the characteristics should be detected. If a prolonged stop is foreseen, it is good form to: - completely empty the pump of the Firefighting unit, by using the appropriate exhaust cap, in case there is danger of frost or if the inactivity is prolonged;

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- accurately clean and place in a clean environment. The eventual storage of the Firefighting unit will have to be safe from atmospheric agents and eventual aggressive atmospheres. 3.4.8 DISPOSAL Do not disperse the Firefighting unit, or part of it, into the environment. The metallic parts may be reconverted into raw materials. All the electrical and electronic parts of the pump will have to disposed of according to Country current law. The elastomeric gaskets must be separated and shipped to an authorized dumping ground to be disposed of according to Country current law. Lastly please be reminded that the Manufacturer Company is always available for any assistance and/or spare parts necessity. 3.4.9 SPARE PARTS All the parts that make up the Firefighting unit can be requested to the Manufacturing Company, by specifying: - Type of Firefighting unit (may be detected from the tag). - Firefighting unit serial number (may be detected from the tag). - Year of construction (may be detected from the tag). - Referential number of item desired (may be detected by the spare parts sheets attached). - Means of transportation. In case this entry is not specified, although particular care is dedicated to this service, the Manufacturing Company does not respond to eventual shipping delays due to greater causes. The shipping expenses are always charged to the addressee. The goods travel at the commissioner's own risk and danger even if sold free at destination.


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ATTACHMENTS

Attachment 1 FLOODED SUCTION SYSTEM DIAGRAM..................................................................................... page 19

Attachment 2 SUCTION LIFT SYSTEM DIAGRAM............................................................................................... 20

Attachment 3A WIRING DIAGRAM FOR ELECTRIC DRIVEN PUMP CONTROL PANEL (DIRECT START UP).. 21

Attachment 3B WIRING DIAGRAM FOR ELECTRIC DRIVEN PUMP CONTROL PANEL (STAR/DELTA START UP - P <90 kW) ........................................................................................... 22

Attachment 3C WIRING DIAGRAM FOR ELECTRIC DRIVEN PUMP CONTROL PANEL (STAR/DELTA START UP - P≥90 kW) ............................................................................................ 23

Attachment 3D CONTROL UNIT FOR ELECTRIC DRIVEN PUMP CONTROL PANEL.......................................... 24

Attachment 4 ENGINE DRIVEN PUMP: INSTRUCTIONS FOR USE AND CONTROL PANEL WIRING DIAGRAM………………………………………………………………………………………... 32

Attachment 5 WIRING DIAGRAM FOR JOCKEY ELECTRIC DRIVEN PUMP CONTROL PANEL (ELECTRO-MECHANICAL VERSION) ........................................................................................... 42

Attachment 6 WIRING DIAGRAM FOR JOCKEY ELECTRIC DRIVEN PUMP CONTROL PANEL (ELECTRONIC VERSION) ............................................................................................................... 43


19

Attachment 1 - FLOODED SUCTION SYSTEM DIAGRAM


20

Attachment 2 - SUCTION LIFT SYSTEM DIAGRAM


21

Attachment 3A - WIRING DIAGRAM FOR ELECTRIC DRIVEN PUMP CONTROL PANEL (DIRECT START UP)

Vn = 400 V 3-PHASE Fn = 50 Hz


22

Attachment 3B - WIRING DIAGRAM FOR ELECTRIC DRIVEN PUMP CONTROL PANEL (STAR/DELTA START UP - P < 90 kW)


23

Attachment 3C - WIRING DIAGRAM FOR ELECTRIC DRIVEN PUMP CONTROL PANEL (STAR/DELTA START UP - P ≥ 90 kW)


24

Attachment 3D (1/8) - CONTROL UNIT FOR ELECTRIC DRIVEN PUMP CONTROL PANEL


25

Attachment 3D (2/8) - CONTROL UNIT FOR ELECTRICDRIVEN PUMP CONTROL PANEL


26



27



28



29



30



31



32

Attachment 4 (1/10) - DRIVEN ENGINE PUMP: INSTRUCTIONS FOR USE AND CONTROL PANEL WIRING DIAGRAM

(ON-SKID MOUNTING)


33


(REMOTE MOUNTING)


34



35



36



37

Attachment 4 (6/10) DRIVEN ENGINE PUMP: INSTRUCTIONS FOR USE AND CONTROL PANEL WIRING DIAGRAM


38



39



40



41



42

Attachment 5 - WIRING DIAGRAM FOR JOCKEY ELECTRIC DRIVEN PUMP CONTROL PANEL (ELECTRO-MECHANICAL VERSION)

Vn =

400 V

3-P

HASE

f

n = 5

0 Hz


43

Attachment 6 - WIRING DIAGRAM FOR JOCKEY ELECTRIC DRIVEN PUMP CONTROL PANEL (ELECTRONIC VERSION)

VARISCO SpA Terza Strada, 9 - Z.I. Nord - 35129 PADOVA - Italy Tel. 049 82 94 111 - Fax 049 82 94 373 www.variscospa.com

Vendite Italia: Tel. 049 82 94 111 - Fax 049 82 94 373 [email protected]

International sales: Ph. +39 049 82 94 111 - Fax +39 049 80 76 762 [email protected]

http://www.variscospa.com/

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