spu manual hifog

Document code / revision: Publishing date:

DOC0001718 B06 Mar 2013

Modular SPUOperating and Maintenance Manual

According to VdS Schadenverhütung GmbH, Anerkennungs-Nr S 4050001, 07 April 2005

ii DOC0001718 B

Published by

Marioff Corporation Oy © 2013 all rights reserved

Virnatie 301300 VantaaFinland Tel. +358 (0)10 6880 000Fax +358 (0)10 6880 010http://www.marioff.com

In case of discrepancy between the original English document and the translated document, the English text prevails.

All rights reserved. Marioff Corporation Oy reserves the right to change or modify the information given in this document, including technical details, without notice. Reproduction of any part of this document without the express written permission of Marioff Corporation Oy is prohibited.

HI-FOG® and Marioff® are registered trademarks of Marioff Corporation Oy. Marioff is part of UTC Climate, Controls and Security Systems, a unit of United Technologies Corp. (NYSE:UTX), which provides high technology products and services to the building and aerospace industries worldwide. More information on Marioff group companies, agents/distributors and references can be found at www.marioff.com.

CAUTIONHI-FOG® systems comprise mechanical components that employ high pressure for water pressurization. HI-FOG® system installation embraces high-pressure testing of discharge tubing. Care must be taken to ensure that all relevant safety procedures are followed during installation to the satisfaction of the authority having jurisdiction and that only competent personnel, appropriately trained and certified, are permitted to install, test, commission and service the system. Marioff group companies and their respective affiliates, officers, employees and representatives shall have no liability whatsoever for the compliance by third parties to the present manual or to any applicable safety procedures.

iiiMarioff Corporation Oy

Table of Contents

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Table of Contents

1. Introduction .................................................................................71.1 Modular design .................................................................71.2 Functionality......................................................................81.3 Installation.........................................................................81.4 More information...............................................................8

2. Warnings and cautions ..............................................................103. General MSPU description.........................................................12

3.1 Master and slave pump units............................................123.2 Tank unit ...........................................................................133.3 Filter unit ...........................................................................143.4 Starter Cabinet..................................................................14

4. Mechanical connections ............................................................184.1 Fastening pump units .......................................................184.2 Preparing tubes ................................................................184.3 Tightening torque for cutting ring tube connections..........184.4 Connecting master and slave pump units.........................19

5. Electrical connections................................................................245.1 Junction box cable connections........................................245.2 Starter Cabinet cable connections....................................24

6. Operation modes ........................................................................267. Starting and stopping.................................................................28

7.1 Automatic start..................................................................287.2 Manual local start..............................................................287.3 Stop after automatic and manual local start .....................287.4 Emergency start (remote) .................................................297.5 Stop after emergency start ...............................................29

8. Resetting......................................................................................309. Maintenance ................................................................................31

9.1 Check all valve positions ..................................................319.2 Check stand-by pressure and pump operation.................329.3 Check electric supply, test lamps .....................................329.4 Visually inspect pump unit and its fittings .........................339.5 Check pump oil levels.......................................................339.6 Check drive chains and flexible coupling..........................349.7 Check air pressure regulator and empty water lock .........359.8 Test run the unit................................................................359.9 Test unit’s max pressure and flow ....................................369.10 Check control cabinet batteries and charger ..................389.11 Check settings of pressure and flow switches

and transducers .....................................................................389.12 Test unit in accordance with service instructions............389.13 Change pump oil.............................................................39

10. Troubleshooting........................................................................4010.1 General faults .................................................................40

iv Marioff Corporation Oy

Modular SPU Operating and Maintenance Manual

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10.2 Alarms.............................................................................41A. APPENDIX - Spare parts..............................................................45B. APPENDIX - Checking water filter................................................47

7Marioff Corporation Oy DOC0001718 B

1. Introduction

This manual describes how to operate and maintain the modular HI-FOG® Sprinkler Pump Unit (MSPU) that is part of a VdS-approved HI-FOG® system. This manual aims to describe the MSPU at a general level; note that the illustrations or details in this document may not reflect exactly the MSPU version supplied if there are customer-specific modifications.

Any changes made to the supplied and installed system or its equipment are allowed only with the written consent from Marioff Corporation Oy.

1.1 Modular design

The modular HI-FOG® Sprinkler Pump Unit (MSPU) is designed to supply high pressure water to a HI-FOG® water mist distribution system used for fire protection. It is used with single-fluid, single-pipe type HI-FOG® sprinkler systems that use water, in the form of a fine mist, as the fire suppressant.

The modular design allows flexibility in construction: a large variety of different versions and pump unit sizes can be built by using the standard modules. The basic modules are pump modules PU2 and PU3, control cabinet, filter, and optionally break tanks and reservoirs.

The basic features of the MSPU are:

• Automatic starts, manual start, and remote start

• Gravity-based (non-electric) water feed to the pump unit

• Break water tank is not normally needed, but can be supplied on request

• Possibility to check the pump unit max pressure and flow on periodic testing

The optional features of the MSPU are:

• Water tank (standard tank size 2000 liters/529 US gallons)

• External feed water pump

• External feed water pump starter in the Starter Cabinet

• Two electric supplies and automatic switchover function

NOTICE! Always refer to project documentation for details of your installation.

8 Marioff Corporation Oy


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• Voltage options

• 60 Hz frequency

• Soft starters

• Connecting cables’ special lengths

1.2 Functionality

The MSPU comprises of pump modules which, upon activation, are started sequentially, thus reducing the electric power peak loads. In stand-by position, the system pressure is maintained at 25 bar (or other system-specific set value) by means of a stand-by pump.

The MSPU can be started automatically, manually, or remotely. The automatic start is activated by flow or by low pressure. The manual start is activated from the Starter Cabinet. The remote start can be included to allow activation by a release panel or a third-party signal.

A fire causes the heat-sensitive bulbs on one or more sprinklers to break. Alternatively, section valves are opened and water starts to flow from the released spray heads. Pressure switches generate a signal to start the MSPU when the pressure decreases. Also, the flow monitor detects the flow and starts the MSPU.

1.3 Installation

The MSPU installation is instructed and described in project-specific documentation. Contact Marioff if you have questions or concerns about the installation or need to get on-site help from an installation team.

Service area

Reserve free space around the unit installation: at least 750 mm on all unit sides, 400 mm above the unit and 800 mm in front of the Starter Cabinet doors (or the width of the doors). This area needs to be kept available for service and maintenance work.

1.4 More information

Refer to the project-specific documentation as well as to the documents listed below for more information.

NOTICE! HI-FOG® system uses high pressure water which can be dangerous if the system is not properly installed.


Marioff diagrams and drawings:

• Hydraulic diagrams and parts lists for the supplied unit

• Electric diagrams and parts lists for the supplied unit

• Dimensional drawing for the supplied unit

Marioff Technical Data Sheets and Manuals:

• DOC0001714 MSPU Overview

• DOC0001715 MSPU02

• DOC0001716 MSPU03

• DOC0001717 MSPU04

• DOC0001719 MSPU05

• DOC0001720 MSPU06

• DOC0001721 MSPU07

• DOC0001722 MSPU08

• DOC0001724 and TE2011 Tank Unit

• TE9004 and TE9018 Filter Unit

• TE1002 SPU Gearbox Chain and Coupling Change

• K0008018 Safety valve sets for SPU and MSPU

• DOC0002101 Marioff Water specification

• P32010 Installation and Pre-Commissioning Manual Land Projects

Third-party documents:

• High pressure plunger pump operating instructions

• Stand-by pump operating and maintenance instructions

• Fire Detection System operating instructions



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2. Warnings and cautions

Cautions give information about possible system hazards. Warnings give information about possible hazards for the users of the MSPU system.

Ensure that all mechanical and electrical assemblies and parts of the MSPU system are used with care and inspected regularly. Ensure that the personnel using the system are

• instructed in the proper use and care

• aware of the performance limitations, and

• aware and observe all warnings and cautions described in this manual.

Cautions

Water used with the HI-FOG® system must be the equivalent of a potable supply. In all cases the input water must be fed through a < 100 μm filter and the chloride concentration MUST not exceed 50 ppm (= 50 mg/l). Under no circumstances add suppression additives to the stored water supply.

Only appropriately trained personnel are permitted to work on, test, and service the MSPU, the sprinkler system, and its associated equipment. When in doubt, contact Marioff representative.

Check, test, and service the MSPU in accordance with the instructions in this manual.

Only use spare parts that are manufactured, supplied, or recommended by Marioff.

If the MSPU is switched off for any reason, take adequate fire precautions, according to your safety procedures, to cover the period that the MSPU is out of operation.

Warnings

The HI-FOG® MSPU produces high-pressure water when operating. To avoid injury to personnel and/or damage to equipment always follow the safety procedures described in this manual and required by the authorities.

NOTICE! Failure to check, test, and service the MSPU in accordance with the instructions given in this manual can jeopardize the reliable operation of the system.


Only qualified personnel are permitted to perform electrical work on the MSPU. Check local safety regulations.

Electrical cabinets may have several power supplies and voltages. Each power supply must be isolated before starting electrical work.

NOTICE! Hazardous voltage will cause death or serious injury.



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3. General MSPU description

This chapter describes the MSPU parts and their functionality.

3.1 Master and slave pump units

The pump unit consists of a master unit, or of a master unit and a slave unit. The master unit consists of the following main parts (see Figure 1 on page 13):

• pump modules

The number of pump modules depends on the system size.

Each pump module consists of one 3-phase electric motor, two plunger pumps, and two unloaders.

• a pneumatic stand-by pump

• pressure and flow indications

• test connection and bypass outlet

The slave unit consists of the following main parts (see Figure 1 on page 13):

• pump modules

• connections to master pump unit


Figure 1. MSPU05: MSPU03 master and MSPU02 slave (used as an example)

3.2 Tank unit

The MSPU pump unit takes inlet water either from a water main supply or from a reservoir. All water which is not needed by the water mist system is lead back to the reservoir or to a drain. The size of the reservoir must be in accordance with the relevant Marioff type approvals and with local rules.

Marioff can supply also a dedicated tank unit for water reservoir; this tank unit is a modular unit built from 2000 liter tank modules. One tank module can also be used as a water break tank to where unused water is circulated when there is no reservoir available or not enough drain capacity.

The tank unit consists of the following main parts (see Figure 2 on page 14):

• plastic water tanks

The number of tanks depends on the system size. In large combinations one tank acts as a master tank and other tanks are slave tanks.

• filter

• piping: water inlet, water outlet, flushing line

• overflow line and unloader line

High pressure water outlet

Junction box

Test valve

Stabilisation valve

Stand-by pump

Flow meter

Water inlet

Electric motor

Pump

Unloader

Test outlet and bypass outlet



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Figure 2. Tank unit assembly for 10m3 system (used as an example)

Tanks can be delivered with water level indicators: either electric level switches or mechanic float valves. Always check project-specific documentation on tank unit mechanical and electrical details.

For more information, see Technical Data Sheet DOC0001724.

3.3 Filter unit

The filter unit is used to purify water to an acceptable level before it reaches the pump unit. The filter size depends on the number of pump modules, but the specification of appropriate filtration level remains the same in all module arrangements.

For more information, see Technical Data Sheets TE9004, TE9018, and DOC0002101.

For filter maintenance, see Appendix B - Checking water filter.

3.4 Starter Cabinet

The Starter Cabinet is used to monitor, operate, and control the MSPU fire protection system. It also indicates all operation and fault signals concerning the pump units and the tank unit. The Starter Cabinet is installed near the pump unit.

Figure 3 and Figure 4 below show the MSPU05 Starter Cabinet as an example. Arrangements vary per model, see the labels on lamps and switches.

For more information, see Technical Data Sheets of the installed pump unit.

Overflow line

Unloader line

Plastic tank

Filter

Water inlet

Water outlet and flushing line


Figure 3. MSPU05 Starter Cabinet (used as an example)

The Starter Cabinet has the following manual operations and selections (numbers in brackets correspond those in Figure 4 on page 17):

• Manual start motor 1–5 (M1–M5)

• Pump Unit manual start (1)

• Buzzer acknowledge (2)

• Alarm reset (3)

• Lamp test (4)

• Voltage metering selection (5)

• Pump Unit manual stop/system reset (6)

The Starter Cabinet has the following indications:

• 230VAC control voltage fault (7)

• Battery charger fault (8)

• Earth fault 24VDC (9)

• Pressure switch PS-1/PS-2 fault (10)

• Compressed air low pressure (11)

• Out of water (12)

• Sprinkler pump malfunction (13)

• Inlet/outlet valve closed (14)

• Circuit breaker released (15)

• Pump Unit motor overload (16)

• Control system on (17)



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• Pump Unit deactivated (18)

• Motor M1.. M5 running

• Main supply on (optional)

• Emergency supply on (optional)

The Starter Cabinet has the following signals out for use by a third-party system:

• Out of water

• Sprinkler pump motor malfunction

• Pump unit fault

• 24VDC control system on/off

• Pump unit deactivated

• Pump unit running

• Stabilisation on

• Pump unit flow

• Line voltage fault

• HI-FOG activated

Optional output signals (instead of Line voltage fault):

• Main power supply fault

• Emergency power supply fault


Figure 4. MSPU05 Starter Cabinet dimensions, operations, selections, and indications (used as an example)

M1 M2

M3

18

5

4

16

17 8

1215

7

11 10

9

13 2

3

1

14

1200

200

1800

6

M4

M5



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4. Mechanical connections

This chapter describes how to connect the different MSPU parts. The master and slave pump units are delivered as separate items that have to be connected when installing the units. All needed parts are included in the delivery.

Note that the MSPU05 is used as an example in the instructions below. Always check the details from project-specific documentation.

4.1 Fastening pump units

The pump units are bolted to the floor by using the fastening holes in the racks. The distance between the pump unit racks is desinged to be 400 mm, but due to the modular design can be modified. However, note the required service area (see chapter “Installation” on page 8).

4.2 Preparing tubes

Bend and cut the tube to the desired shape and length, place the nuts, and pre-cut the cutting ring connections. The tube preparation is described in detail in the document P32010 Installation and Pre-Commissioning Manual Land Projects.

4.3 Tightening torque for cutting ring tube connections

Tighten the nuts with a wrench until resistance is felt, mark the position, and then continue a ¼ turn over the mark. The tightening torque is described in detail in the document P32010 Installation and Pre-Commissioning Manual Land Projects.


4.4 Connecting master and slave pump units

Figure 5 below illustrates the six connection points.

Figure 5. Connecting points of master and slave pump units (MSPU05 as an example)

1

3

2

1 high pressure line (38S ( 38x3) DIN2353

2 test outlet line (38S ( 38x3) DIN2353

3 water inlet pipe (DN80 DIN2642 FLANGE)

∅

∅



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To connect the high pressure line

See Figure 6 below.

Figure 6. Connecting the high pressure line between MSPU05 master pump unit MSPU03 (item A in the figure) and slave pump unit MSPU02 (B)

Step 1. Prepare the high pressure line.

Follow the instructions in the document P32010 Installation and Pre-Commissioning Manual Land Projects.

Step 2. Connect the high pressure line to the master pump and tighten the connection.

Step 3. Connect the high pressure line to the slave pump and tighten the connection.

Step 4. Attach and tighten the clamp on the slave pump connection of the high pressure line.

A

B


To connect the test outlet line

See Figure 7 below.

Figure 7. Connecting the test outlet line and water inlet line between MSPU05 master pump unit MSPU03 (A) and slave pump unit MSPU02 (B)

Step 1. Prepare the test outlet line

Follow the instructions in the document P32010 Installation and Pre-Commissioning Manual Land Projects.

Step 2. Connect the test outlet line to the master pump and tighten the connection.

Step 3. Connect the test outlet line to the slave pump and tighten the connection.

B A



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To connect the water inlet line

See Figure 8 below.

Step 1. Connect the water inlet line to the master pump.

Remember to place the seal between the flange connection.

Figure 8. Connecting the water inlet between MSPU05 master pump unit MSPU03 (A) and slave pump unit MSPU02 (B)

Step 2. Tighten the flange connection.

Tighten the bolts evenly so that the flange fits in smoothly. If you tighten one bolt all the way, the flange will not fit in smooth on all sides. Increase torque gradually, until the correct torque is reached. See Figure 9 on page 23.

Bolt Flange Seal Nut

A

B


Figure 9. Tightening order of the bolts in the flange connection

Step 3. Connect the water inlet line to the slave pump.

Remember to place the seal between the flange connection.

Step 4. Tighten the flange connection.

Tighten the bolts evenly so that the flange fits in smoothly. If you tighten one bolt all the way, the flange will not fit in smooth on all sides. Increase torque gradually, until the correct torque is reached. See Figure 9 above.

1

24

3



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5. Electrical connections

This chapter describes the main electrical connections of the MSPU. For detailed description of the electrical connections, see the Connection Diagram of the supplied unit.

The length of the standard cables is 10 m; special lenghts are available per request.

Note that all external cabling needs to be ordered separately.

5.1 Junction box cable connections

The cable connections of the Junction box include

• pressure and flow switch signals,

• the valve monitoring and control signals, and

• the connection to the Starter Cabinet.

The Junction box connections are illustrated in Figure 10 on page 24.

Figure 10. Junction box cable connections (MSPU05, as an example)

5.2 Starter Cabinet cable connections

The Starter Cabinet has the following connections:


• Main supply

• Motors

• Air compressor

• Junction box (pressure and flow switch signals, valve monitoring and control)

• Water tank (low level switch)

• Alarm panel signals, which are at least the following: HI-FOG® activated, line voltage fault, pump unit fault.

The cable entries for external cabling are illustrated in Figure 11 below.

Figure 11. Starter Cabinet external cabling entries

2 31

1 Main supply connection

2 Motor cables, sensor and switch signals

3 Junction box cables, sensor and switch signals



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6. Operation modes

This chapter describes the various modes of the MSPU: stand-by, operating, off, deactivated, and stabilisation.

Stand-by

Stand-by is the normal state of the system when it is on. In normal use the system MUST always be in stand-by. The following conditions apply for the stand-by mode:

• the MSPU is connected to the electric supply and the main power switch is on

• working air is supplied to the stand-by pump and the pump is operational

• the system pressure is within the set limits (25 bar, or system-specific)

• the control system is operational

• the piping and connections are sound and tight (for more information, see document P32010 Installation and Pre-Commissioning Manual Land Projects)

After stabilisation the system automatically returns to the stand-by mode.

Operating

Operating is when the system is activated and high-pressure water is fed to the HI-FOG® system forming the HI-FOG® mist discharge. The pump unit will maintain the required pressure and flow in the system until a stop signal is given or before the pump runs out of water.

When the MSPU is activated, the pump modules automatically start in sequence, with a few seconds delay between each start, in order to reduce electric peak loads.

If the flow of water required is less than the output of the unit, the unloader valves open and route extra water back to the tank unit or drain.

The low level switch in the break tank or a pressure switch in the feed water line will prevent the unit from starting when there is not enough water, or will stop the motors from running dry. When the redundancy source of water (if applicable) has been connected and/or the water break tank has been refilled, the pumps restart automatically.

Off

Off mode is when the system is shut down for maintenance or repair.


Deactivated

Deactivated state is when the pump unit has been either manually switched off from the main switch or the inlet or outlet water valve has been closed.

Stabilisation

Stabilisation is needed for the system to return to stand-by mode again after a discharge. Stabilisation is automatic; it is started when pressing the system reset button (pump unit manual stop/system reset, item 6 in Figure 4 on page 17) and it takes from about 30 seconds up to a few minutes. During stabilisation the system pressure drops to the stand-by level (25 bars by default).



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7. Starting and stopping

This chapter describes the starting and stopping functions of the MSPU. There are three options for the system start: automatic start, emergency start, and manual local start.

7.1 Automatic start

The MSPU starts automatically if the water pressure drops below a preset value (typically 17 bar) for more than preset time (typically 10 seconds) or if it detects a water flow for 10 seconds in the system.

When the MSPU is activated, the pump modules automatically start in sequence, with a few seconds delay between each start, in order to reduce electric peak loads.

7.2 Manual local start

To manually start the MSPU, press the Pump unit manual start button in the Starter Cabinet.

7.3 Stop after automatic and manual local start

Before stopping the discharge, make sure that

• there is no fire, and

• any released sprinklers or spray heads are isolated and that the section valves are closed so that there is no flow in the HI-FOG® system.

NOTICE! Before initiating a local manual start, check that no fault alarms are on and water is available. Running the system without water may damage the pumps. Starting the pump with the manual switches in the Starter Cabinet overrides the water low level interlocking in automatic and emergency start.

NOTICE! Stopping the pump unit is normally done by the fire officer or fire protection responsible.


To stop the MSPU after automatic and manual local start

Step 1. Stop the flow in the system.

Close the section valve in the discharged area.

Step 2. Check in the pressure gauge that the system pressure is at 130 – 140 bar.

Step 3. Press Pump Unit manual stop/system reset button on the Starter Cabinet.

All motors are turned off and the stabilisation valve opens. The Pump Unit manual stop/system reset signal light is on during stabilisation.

Step 4. Wait for the stabilisation to complete.

When the stabilisation is complete, the Pump Unit manual stop/system reset signal light goes off.

The stopping sequence above can also be applied to situations when an unintentional system discharge has occured.

7.4 Emergency start (remote)

To start the MSPU remotely, press the EMERGENCY START button on the remote location. Note that in standard MSPU systems the button will stay down after it has been pressed.

7.5 Stop after emergency start

To stop the MSPU, press the same EMERGENCY START button on the remote location again.

To reset the MSPU, press the Pump Unit manual stop/system reset button on the Starter Cabinet.

NOTICE! Standard systems do not reset unless the system pressure has reached 130 bar. The pump unit must be run until the pressure has risen above130 bar before resetting the system.



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8. Resetting

A reset after MSPU start and stop is always needed for the system to return to the stand-by mode. Resetting MSPU is an automatic operation sequence and is started by pressing the Pump Unit manual stop/system reset button in the Starter Cabinet. This is described in chapter “Stop after automatic and manual local start” on page 28.“

Before the whole system can be reset, all flow in the system must be stopped; if a sprinkler has released, the section valve must be closed.

In system reset, first the stabilisation valve opens and the pressure in the system drops down to a preset value (typically 22 bar). Then the stabilisation valve closes and the stand-by pump raises the stand-by pressure to the required 25 bar (or other system-specific set value).

Stabilisation takes from about 30 seconds up to a few minutes, during which time an automatic restart is prevented. During stabilisation the emergency start and manual local start is possible.

The Pump Unit manual stop/system reset signal light is on when the system pressure drops from 130 bar to 22 bar. When the signal light goes off, system has returned to stand-by mode.

Reset possible alarms by pressing the Alarm reset button in the Starter Cabinet.

NOTICE! Standard systems do not reset unless the system pressure has reached 130 bar. The pump unit must be run until the pressure has risen above130 bar before resetting the system.


9. Maintenance

This chapter describes the minimum requirements for maintenance routines of the MSPU. Always check project-specific documentation for MSPU and system level maintenance routines and their frequencies.

The table below displays the frequency of maintenance routines and the chapters after the table describe the actual tasks. In addition to the information in Table 1, note the following:

• Other maintenance frequencies may be specified in local laws and regulations or in customer-specific system specifications.

• Refer to the respective third-party manufacturer’s instructions (as delivered with the system) for more information.

Table 1: Maintenance routines for MSPU

*other frequencies may be specified in local laws and regulations or in the system-specific instructions

9.1 Check all valve positions

In stand-by and operating modes the valves must be in the following positions. Numbers in brackets correspond those in “MSPU05 valve locations” on page 32.

Chapter Action Weekly Monthly AnnuallyEvery 5 years

*

9.1 Check all valve positions X X X X

9.2 Check stand-by pressure and pump X X X X

9.3 Check electric supply, test lamps X X X X

9.4 Visually inspect unit and its fittings X X X X

9.5 Check pump oil levels X X X

9.6 Check drive chains and flexible coupling X X X

9.7 Check air pressure regulator and empty water lock

X X X

9.8 Test run the unit X X X

9.9 Test unit flow capacity X X X

9.10 Check pump unit batteries and charger X X X

9.11 Check settings of pressure and flow switches and the transducers

X X

9.12 Test unit in accordance with service instructions X X

9.13 Change pump oil (every 2 years or 200 hours) X



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Open valves

• outlet valve to the sprinkler system (1)

• water inlet valve (2)

• air inlet valve to the stand-by pump (3)

Closed valves

• test valve (4)

Figure 12. MSPU05 valve locations

9.2 Check stand-by pressure and pump operation

Check that the stand-by pressure in the system is set to the correct level (25 bar by default, if not otherwise stated).

Check that the stand-by pump does not start running too often; for example once a day is too often. For more information, see chapter “Stand-by pump striking frequently” on page 41“. A faulty stand-by pump must be replaced with a new one.

For maintenance and overhaul refer to the third-party manufacturers’ operating and maintenance instructions.

9.3 Check electric supply, test lamps

Check the Line voltage meter. When there are two electric feeds (optional feature), a light indicates which feed is in use and thus shown in the Line voltage meter.

24

3

1


Press the Lamp test button in the Starter Cabinet. All signal lights in the Starter Cabinet should be lit (and the buzzer should ring). Change any faulty light bulbs.

9.4 Visually inspect pump unit and its fittings

Check that there is no water or air leaking from the system.

Check that all fittings are tight. Report all abnormal wear and tear, and damage.

9.5 Check pump oil levels

The optimal oil level is at the mid-level of the sight glass. If it is below this level, add more oil. See Figure 13 below.

Figure 13. Check the oil level of the pumps

The oil color should be clear golden brown. If the oil is dirty, cloudy, or grey when the unit is in the stand-by mode, change the oil. See the third-party manufacturer’s pump operating instructions.

NOTICE! The oil appears cloudy when the unit is in the operation mode.



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9.6 Check drive chains and flexible coupling

The drive chains are self-lubricated, which means that they do not need to be greased. To indicate this, there is a notification sticker attached to the gearbox with the following text:

Notice! Do not use grease. This roller chain is self-lubricated.

However, if the drive chains are not maintenance-free (in older pump units) and there is no notification sticker, the drive chains must be well greased. If the chain is dry or rusty, grease the chain by using Shell Kuggfett or an equivalent molybdenum-graphite based grease with heat resistance up to +200°C and good adhesion capability.

Check the condition of the flexible couplings. A slight amount of wear is normal - if any signs of excessive wearing are shown, change the coupling. See Figure 14.

Figure 14. Check the drive chains and the flexible coupling

NOTICE! Switch the unit off before checking the drive chains and coupling. Turn the main switch off and secure it before removing the cover.


Changing the chain and coupling

See Technical data sheet TE1002.

9.7 Check air pressure regulator and empty water lock

Check for leakages.

Make sure that the stand-by pressure is maintained at 25 bar (or other system-specific set value).

9.8 Test run the unit

To test run the unit

Step 1. Close the water outlet valve.

Step 2. Start the pump unit locally, remotely, or automatically.

Vary the way of starting to ensure that all starting modes work.

Step 3. When testing the automatic start locally, note the following.

The low pressure start is tested by closing the air supply to the stand-by pump and fully opening the test valve.

The flow switch start is tested by slowly opening the test valve so the pressure does not drop below 17 bar (or the set default value). See Figure 15.

NOTICE! Before initiating a local manual start, make sure that there is water and that no fault alarms are on. Running the system without water may damage the pumps. Starting the pump with the manual switches in the Starter Cabinet overrides the water low level interlocking in automatic and emergency start.

NOTICE! Make sure that the unit starts to supply water at full working pressure after a short delay. Make sure that all motors and pumps are running.



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Figure 15. MSPU05 test valve (1) and air inlet valve (2) locations

Step 4. Close the test valve if it has been opened for testing.

Step 5. Stop the unit by pressing the Pump Unit manual stop/system reset button on the Starter Cabinet.

Step 6. Open the water outlet valve if has been closed for testing.

Step 7. Check that the pressure in the system returns to the 25 bar stand-by pressure.

If the water outlet valve is closed, the stabilisation takes only seconds.

Step 8. Check that the whole system is reset and in stand-by mode.

9.9 Test unit’s max pressure and flow

The pump unit’s maximum output pressure and maximum flow must be periodically tested (monthly). The pressure can be read from the pump unit’s pressure gauge. The flow can be read from the pump unit’s integral flow meter that is installed to the test outlet.

1

2


To test the unit’s max pressure and flow

Step 1. Close the test valve by lifting the lever to upright position.

Step 2. Start motor 1 manually by turning the motor’s switch to position 1.

Step 3. Check from the pressure gauge that the pressure is at 140 bar.

Step 4. Open the test valve by lowering the test valve lever.

NOTICE! The maximum flow is tested per one motor at a time.

Test valve lever up, valve closed

Pressure gauge



DOC0001718 B

Step 5. Read the maximum flow value from the flow meter.

The nominal flow output is 97,4 liters per one minute per one motor.

Step 6. Stop motor 1 by turning the motor’s switch to position A.

Step 7. Repeat steps 1-6 to other motors.

9.10 Check control cabinet batteries and charger

Check that the charger output voltage is 27.3 – 27.7 V at the battery.

Check the battery capacity with a suitable charge condition meter.

The batteries must be replaced every five (5) years, or more often if the battery is faulty, or the unit is subjected to vibration, large temperature variations, or other severe environmental conditions. Note that especially high ambient temperature reduces the battery life time.

9.11 Check settings of pressure and flow switches and transducers

Check the setting values of pressure switches, transducers, and flow switch. If the switching points have changed regarding the set point, adjust the point to original.

9.12 Test unit in accordance with service instructions

It is recommended that testing is carried out by a Marioff authorised service engineer. Contact Marioff for more information.

Test valve lever down, valve open


9.13 Change pump oil

With new systems the initial oil must be changed after the first 50 running hours (or 2 years), whichever comes first. After the initial oil change, the pump oil must be changed every two (2) years or after 200 running hours, whichever comes first. See Figure 16 on page 39. See also third-party manufacturers’ pump operating instructions.

Figure 16. Change pump oil: the locations of the oil fill and oil drain plugs

Use an ISO VG 220 or SAE 90 class gear oil. Oil quantity is 0,9 litres per pump. See the list below for pump oil recommendations:

• ARAL: Getriebeöl EP 85W-90, Degol BG 220

• BP: Energear 90, Energol GR-XP 220

• CASTROL: EP 90, ALPHA SP 220, ALPHA MW 220

• ESSO: GEAR OIL GX 85W-90, GEAR OIL GP-D 85W-90

• SPARTAN EP 220

• Mobilube GX 85W-90-A

• Mobilgear 630

• Shell SPIRAX GX SAE 80W-90

• NESTE GEAR EP 80W-90



DOC0001718 B

10. Troubleshooting

This chapter lists the possible fault situations and their remedies. If the problem you are facing is not listed here, contact Marioff immediately.

Always when contacting Marioff in troubleshooting situations, have the following information available:

• the project number of the installed system

• the serial number of the pump unit

• detailed description of the fault situation (what was done before the fault situation occured and what happened during the fault situation)

10.1 General faults

This chapter lists the possible general MSPU faults.

10.1.1 Unit will not start

Possible reason: No electric supply.

Solution: Check if the main fuses in the main switchboard have blown. Check if the Starter Cabinet main switch is open or the main circuit breaker has released.

Possible reason: No control voltage.

Solution: Connect supply. Check control voltage fuse of auxiliary voltage transformer.

Possible reason: No water.

Solution: Ensure feed water availability.

Possible reason: Stabilisation phase is on (Pump Unit manual stop/system reset light on the Starter Cabinet is on).

Solution: Wait for completion of stabilisation phase and/or press the Pump unit manual start button on the Starter Cabinet to start the unit.

10.1.2 Unit will not stop

Possible reason: Pressure has not exceeded 130 bar in the system and the emergency start is still activated.

Solution: Run the unit until the pressure reaches 130 – 140 bar and/or deactivate emergency start.

10.1.3 Unit starts unintentionally

Possible reason: Pressure switch is faulty or incorrectly adjusted.


Solution: Adjust or replace pressure switch. Contact Marioff.

Possible reason: Flow switch is faulty or incorrectly adjusted.

Solution: Adjust or replace flow switch. Contact Marioff.

Possible reason: False start signal.

Solution: Check system wiring and signals.

Possible reason: System pressure drops due to system leakage or stand-by pump problem.

Solution: Ensure system is tight. Check air supply to stand-by pump. Check stand-by pump, replace if faulty.

10.1.4 Stabilisation phase not completed

The stabilisation will not start before the system pressure has reached 130 bar. The pump unit must be run until the pressure has risen abo 130 bar before resetting the system is possible.

Possible reason: Pressure switch is faulty or incorrectly adjusted.

Solution: Adjust or replace pressure switch. Contact Marioff.

Possible reason: Stabilisation valve is faulty.

Solution: Replace valve.

10.1.5 Stand-by pump striking frequently

Possible reason: Small leakage in the system.

Solution: Ensure system is tight.

Possible reason: Stand-by pump is faulty.

Solution: Replace stand-by pump.

10.2 Alarms

This chapter lists the MSPU system alarms.

10.2.1 Battery charger fault

Possible reason: No power supply to the charger unit. The fuse F13 is released and causes the Circuit breaker released alarm.

Solution: Reconnect supply.

Possible reason: Charger is faulty.

Solution: Replace charger.



DOC0001718 B

10.2.2 230VAC control voltage fault

Possible reason: No voltage in transformer T 0.3.

Solution: Check power supply and fuse F0.3.

Possible reason: Transformer is faulty.

Solution: Replace transformer.

10.2.3 Earth fault (24VDC)

Possible reason: + or - of the 24VDC control voltage in contact with earth (ground).

Solution: Find the contact point (for example, by opening fuses and disconnecting panels) that causes the earth fault and rectify.

10.2.4 Circuit breaker released

Possible reason: Overload or short circuit.

Solution: If problem rectified or reason not found: switch on open/close. If problem persists, contact Marioff.

10.2.5 Out of water

Possible reason: Water in water tank below “low level” or feed water pressure low in unit without tank.

Solution: Make sure there is a feed water supply to water tank. Check that the water inlet valve is open.

Possible reason: Tank low level switch faulty or stuck; cable fault.

Solution: Rectify or replace.

10.2.6 Pressure switch PS1/PS2 fault

Possible reason: Cable fault. Cable monitoring relay fault.

Solution: Check and replace cable if faulty. Check and replace monitor if faulty.

10.2.7 Compressed air low pressure fault

Possible reason: Compressor fault.

Solution: Check compressor; replace if faulty. Check compressed air supply. If supply in order, check pressure switch and cables.


10.2.8 Sprinkler pump malfunction

Possible reason: If one or more motors do not start, either the motor or the pump is not functioning.

Solution: Check motor circuit breaker and control circuit breaker.

10.2.9 Inlet/outlet valve closed

Possible reason: The valve is not fully open, thus it sets an alarm.

Solution: Check that both valves are fully open.

10.2.10 Pump unit motor overload

Possible reason: A motor is overloaded.

Solution: Reset Thermal overload relay. If problem persists, contact Marioff.

10.2.11 Pump unit fault

This fault is a signal to a third-party system. It is a common alarm set in result of any of the alarms above.

Possible reason: Common MSPU alarm given.

Solution: Check the alarm in the Starter Cabinet and follow the appropriate instructions.

10.2.12 Pump unit deactivated

Possible reason: The main switch has been set to off or inlet/outlet valve has been closed.

Solution: Check that the main switch is set to on and that the inlet/outlet valves are open.

10.2.13 Line voltage fault

This fault is a signal to a third-party system.

Possible reason: Main supply voltage fault.

Solution: Check the system for low voltage, excess voltage, or asymmetric phases. Check phase monitor relay K0.5.

10.2.14 Line voltage fault (with two electric feeds OPTIONAL)

This fault is a signal to a third-party system. It is a common alarm set in result of either the Main power supply fault or Emergency power supply fault.

Possible reason: Main or emergency supply voltage fault.



DOC0001718 B

Solution: Check the system for low voltage, excess voltage, or asymmetric phases. Check phase monitor relay K0.5.

10.2.15 Other faults

Possible reason: Reason not found.

Solution: Contact Marioff.

Note that some faults are automatically remedied and the fault information is lost. In some cases the faults are sent to a third-party system before the automatic remedy takes place and possibly the fault alarm is visible in the third-party system but not in the MSPU anymore. In those events the third-party system needs to be checked according to the manufacturers’ instructions.


A. Appendix - Spare parts

See table below for the available MSPU spare parts.

Parts not listed here are available upon request. Contact Marioff for more information.

Description Type Code Stock Code

Pump NP25/41-140 left E02050

Pump NP25/50-140 left E02055

Seal set for pump models NP25/50 and NP25/41

G40130.1

Pump valve kit for pump models NP25/50 and NP25/41

Manuf. ref. 14.0397 G40135

Pump oil EP SAE80W-90 L53005

Unloader UL262/2 D51023

Repair kit for unloader UL262/2 Manuf. ref. 14.0554 G40011

Electric motor See nameplate Voltage, frequency, power

Drive chain (self-lubricated) 10 B-2 L42 5/8 E04097.1

Drive clutch (green) 42/64 SH Clutch E04019

Drive chain spare part set* V31161 (for motor type 160L)V31181 (for motor type 180L)

Pump support sleeve** M12080

Pressure switch (stabilisation) PN3001 0-250 bar M23064.A

Pressure switch (start signal) PK40 M23014

Pressure switch PEV-1/4-B-OD M23005

Flow monitor SID10ADBFPKG/ US-100-IPF M21012.1

Flow monitor HP756B-030 M02000

Pressure gauge 213.53.63.250B/P ALA M01022

Stand-by pump Trojan Trojan type-J, 11:1 E40040

Seal set for Trojan stand-by pump 10108KP TROJAN-J AIR SIDE G40090

10138KH/11 TROJAN-J WET G40095

Stabilisation valve NS-12 SVM 12-ANN-S12/12-10-0 D01535

Repair kit for stabilisation valve NS-12*** V11070.A

Seal set for stabilisation valve NS-12*** V10101.A

Air regulator unit FRC-1/4 E41015

Safety valve VS200/180-60.5115.18 D-0002599

46 Marioff Corporation OyDOC0001718 B

* Drive chain spare part sets include clutch flex element, clutch, roller chain, sprocket wheel and other needed parts.

**You need 4 pieces of pump support sleeves to pull the pump out when replacing the drive chain. Pump support sleeves are not included in drive chain spare part sets V31161 and V31181.

***See Marioff Spare part and maintenance drawing DMOVSE000862.

****See Marioff Technical data sheet K0008018.

*****Electrical components may vary considerably depending on the project. See project-specific part list for electric spare parts.

Safety valve set**** V-0002692 (for MSPU01-02)V-0002697 (for MSPU03)

Electric spare parts (such as contactors, circuit breakers, relays etc.)*****


B. Appendix - Checking water filter

Follow the instructions below to check the water filter. Check the filter annually and replace if it is dirty, rusty or damaged. Always replace the filter after a fire accident.

Figure 17. Pump unit filter parts and bottom view

To check the water filter

Step 1. Close the water inlet valve.

Step 2. Carefully open the drain plugs in the filter bottom, relieve possible excess pressure and allow water to drain out. See Figure 18.

Use a 19 mm socket.

Figure 18. Open the drain plugs

Bleeding screw

Filter cover

Filter cartridge

Water inlet

Water outlet

Drain plugs


Step 3. Open the filter cover by unscrewing the screws holding the lid in place.

Step 4. Pull out the filter cartridge and check it visually.

Change the cartridge if contaminated.

Step 5. Check the bypass valve.

The filter is equipped with a bypass valve, which allows the feed water flow even if the flow through the filter cartridge would be prevented.

The bypass valve must be closed. If the valve is closed, the upper extension spring is around the guide sleeve (see Figure 19.). If this is not the case (the bypass valve is open), the valve must be reset. For instructions, see “To reset the bypass valve” on page 49. Then continue to Step 6.

Figure 19. Water filter’s bypass valve in the cover

Step 6. Reinstall or replace the filter cartridge.

Step 7. Close the filter drain plugs.

Step 8. Close the filter cover and tighten it with the screws holding the lid in place.

Step 9. When filling the unit via the filter, loose the air bleeding screw located on top of the filter (see Figure 20.) to bleed air from the filter.

Use 8 mm Allen key.


Figure 20. Open the air bleeding screw

Step 10. Carefully open the water inlet valve until water comes out from the water filter bleeding screw.

Step 11. After filling the unit, tighten the air bleeding screw.

To reset the bypass valve

Figure 21. Resetting the bypass valve


Step 1. Remove the locking wire from bypass screws (see Figure 22.).

Figure 22. Remove the locking wire

Step 2. Loosen the bypass screws (see Figure 23.).

NOTE: When loosening the bypass screws, the screw may pop up because of the spring load when it has been screwed open. Hold a cloth in front of the screw to avoid hurting yourself when opening the screw..

Figure 23. Open the bypass screws

Step 3. Remove the upper extension spring (see Figure 24.).

Step 4. Tighten the bypass screws (see Figure 24.).

Figure 24. Remove the upper extension spring and tighten the bypass screw


Step 5. Install the locking wire (see Figure 25.).

Step 6. Reinstall the upper extension spring around the upper guide sleeve (see Figure 25.).

Figure 25. Install the locking wire and upper extension spring

Head Office

Marioff Corporation Oy

P.O. Box 86, FI-01301 Vantaa, Finland

Tel. +358 (0)10 6880 000

Fax +358 (0)10 6880 010

Email: [email protected]

Protecting people, property and business from fire

Information on Marioff group companies, agents/distributors and references can be found at www.marioff.com.

Marioff Corporation Oy reserves the right to change or modify the information given in this document, including technical details, without

notice. HI-FOG® and Marioff® are registered trademarks of Marioff Corporation Oy. Marioff is a part of UTC Climate, Controls and Security Systems, a unit of United Technologies Corp. (NYSE:UTX).

All rights reserved. Reproduction of any part of this document without the express written permission of Marioff Corporation Oy is prohibited.

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