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Instructions

FTA1100-E
Relay Logic Diesel Engine
Fire Pump Controller
INTRODUCTION
Firetrol

FTA1100 combined automatic and manual


relay logic diesel engine fire pump controllers are in-
tended for starting and monitoring fire pump diesel
engines. They are available for use with 12 or 24 volt
negative ground systems using lead acid or Nickel-
Cadmium batteries. FTA1100 fire pump controllers are
listed by Underwriters Laboratories Inc., in accordance
with UL218, Standard for Fire Pump Controllers, CSA,
Standard for Industrial Control Equipment (cUL), and
approved by Factory Mutual. They are built to meet or
exceed the requirements of the approving authorities
as well as NEMA and the latest editions of NFPA 20,
Installation of Centrifugal Fire Pumps, and NFPA 70,
National Electrical Code.
These instructions are intended to assist in the
understanding of the installation and operation of the
FTA1100. Read through these instructions thoroughly
prior to connecting the controller. If there are any
questions unanswered in these instructions, please
contact the local Firetrol representative or factory ser-
vice department.
MOUNTING LEGS (OPTIONAL)
Procedure
1. If legs were supplied, unpack legs and mounting
hardware.
2. Inspect legs for damage.
3. Place shipping carton tube on floor and gently
lay the controller, on its back, on top of tube.
4. Attach each leg to the bottom of the enclosure
using the 3 nuts, and washers provided for each
leg . Tighten nuts securely.
5. After legs are securely attached, stand the
controller up on its legs for floor mounting. Each
leg has 3 holes on the bottom for anchoring to
the floor or base plate.
CautionController is not free standing!
Controller must be secured to floor or wall
surface before opening door or operating.
MOUNTING CONTROLLER
NoteConsult the appropriate job plans to deter-
mine controller mounting location. Controller must be
mounted within 20 feet of the engine.
Tools and Materials (all mounting):
1. Assortment of common hand tools of the type
used to service electromechanical equipment.
2. Drill for drilling wall/floor anchor holes.
3. Hand level.
4. Tape measure.
5. Four (4) anchors with bolts and washerif wall
mount. Six (6) anchors, bolts and washersif
floor/base mount.
Wall Mount
NoteRefer to the controller dimension drawing,
DD1100, included in the instruction manual for
necessary mounting dimensions.
The controller is wall mounted by using four (4)
wall anchors, 2 anchors for the top ears and 2
anchors for the bottom mounting slots. The ears and
slots are dimensionally on the same center-line for
ease in mounting.
1. Using either the dimension print or by measuring
the distance between the center lines of the 2
lower slots, transcribe this dimension onto the
wall. Note: The bottom edge of the enclosure
should be a minimum of 12" (305 mm.) from the
floor in case flooding of the pump room occurs.
2. Drill and put 2 anchors into the wall for the 2
lower slot mounts.
3. Mark on the wall, the location of the holes in the
upper mounting ears.
4. Drill and put 2 anchors into wall for the upper
mounts.
5. Install bolts and washers in 2 lower anchors,
leaving a gap between the washer and wall.
6. Lift the controller and place the mounting slots
down onto the 2 lower anchor bolts. Do not
tighten bolts.
7. Align holes in upper mounting ears and install 2
bolts and washers in anchors.
8. Tighten all 4 anchor bolts.
9. Check to be sure enclosure door opens freely
and that enclosure is level.
Floor/Base Plate Mount
NoteConsult the appropriate job plans to deter-
mine controller mounting location.
Refer to the controller dimension print, DD1100,
included in the instruction manual for necessary
mounting dimensions.
The controller is floor/base plate mounted by
using the 3 pre-drilled holes in each leg. The holes
are dimensionally on the same centerline for ease in
mounting.
1. Using either the dimension print or by measuring
distance between the centerlines of the holes on
one leg, transcribe these dimensions onto the
floor/base plate.
2. Drill 3 holes in floor/base plate for anchoring the
leg.
3. Mark location of holes for opposite leg and drill 3
more holes.
4. Secure controller to floor/base plate with bolts
and washers and tighten.
5. Check to be sure enclosure door opens freely
and that enclosure is level.
NS1100-05 Rev. G
Page 1 of 8
Instructions
Relay Logic Diesel Engine
Fire Pump Controllers

FTA
1100
MAKING ELECTRICAL CONNECTIONS
Important Precautions
Prior to making any field connections:
1. Verify that the following information is compatible
with other related equipment on the project:
Firetrol catalog number
Engine voltage and polarity of grounding
Incoming line voltage and frequency
System pressure
2. Project electrical contractor must supply all
necessary wiring for field connections in accor-
dance with the National Electrical Code, local
electrical code and any other authority having
jurisdiction .
3. Open door of enclosure and inspect internal
components and wiring for any signs of frayed or
loose wires or other visible damage.
4. Refer to the appropriate field connection drawing
in the manual for all wiring information.
Procedure
All field connections, remote alarm functions and
AC wiring must be brought into the enclosure near
the bottom. (See dimension drawing DD1100 for
exact location). Proceed as follows:
1. Use a hole punch, not a torch nor a drill, and
punch a hole in the enclosure for the size conduit
being used.
2. Install necessary conduit.
WarningUse only locations shown on Dimen-
sion Drawing DD1100 for conduit entrance.
Controller warranty is VOID if any other location
is used.
NoteAll field wiring connections are connected
to the terminal block located at the bottom of the
enclosure. Terminals 1 through 12 are for
interconnection to the corresponding numbered
terminals on the engine terminal block. All
terminals are not used in all controllers. Refer-
ence engine wiring diagram and Field Connec-
tion Diagram FC1100.
Terminals 13 through 85, are for connecting
remote alarm functions and optional features.
AC line connections are made to terminals L1
and L2. A ground lug, marked G is provided for
grounding. This AC circuit should come from a
distribution panel and have a circuit breaker
rated for 25 Amps, sized in accordance with the
National Electrical Code and other local codes.
L1 should be hot (black wire) of 120 Volt system,
L2 should be neutral (white wire). On 220 Volt
systems, both L1 and L2 wires should be hot
(black).
3. Pull all wires necessary for field connections,
remote alarm functions, AC power and all other
optional features. Allow enough excess wire
inside enclosure to make up connections to the
terminal block. Be sure to consult the appropri-
ate field connection diagram included with the
manual.
WarningDo not use controller wire way for
routing external wiring.
Wire Sizes
Use #14 AWG wire minimum for all electrical
connections except for battery charger connec-
tions. (Battery chargers connected to terminals 6,
7,8, and 11.)
On terminals 6, 7, 8, and 11, use the following
information to determine wire sizes:
4. Make all field connections to remote alarm
functions and any other optional features. Do
not connect AC power.
5. Verify AC line voltage and frequency with the
controller data plate on the enclosure door prior
to connecting AC power.
6. Connect AC power to L1 and L2120 Volt,
60 Hz or as called for on controller.
7. Connect remote normally open START
pushbutton wires to terminals 13 and 14 (if
used).
8. If deluge valve is used, remove jumper from
terminals 16 and 17. Connect wires from
normally closed contact on deluge valve to
terminals 16 and 17.
9. Connect remote normally open shutdown
interlock wires to terminals 11 and 15 (if
used).
10. Check to see that all connections are both
correctly wired (in accordance with field connec-
tion diagram) and tight.
11. Close enclosure door.
MAKING SYSTEM PRESSURE CONNECTIONS
The FTA1100 controller requires one (1) System
Pressure connection from the system piping to the
enclosure. The connection fitting, 1/2" FNPT, is
provided on the bottom, external side of the enclo-
sure for this purpose.
The Test Drain connection, located to the left of
the System Pressure connection, should be piped
to a vented drain or to waste. The Test Drain is
used only briefly during the weekly test cycle.
NoteTest drain line must be free flowing. Do not
use any valves or plugs on this line.
Refer to NFPA 20 for correct field piping proce-
dure of sensing line between the pumping system
and the controller.
NS1100-05 Rev. G
Page 2 of 8
Linear feet (in conduit run)
from controller to terminal
block on engine
Maximum
Wire Size
0' to 25' (0 to 7.62 m.)
25' to 50' (7.62 m. to 15.24 m.)
#10 AWG
#8 AWG
START PRESSURE
SET POINT
NS1100-05 Rev. G
Page 3 of 8
STOP PRESSURE
SET POINT
ENGINE Pilot Light
OVERSPEED
FAILED TO START Pilot Light
HIGH ENGINE WATER Pilot Light
TEMPERATURE
LOW OIL Pilot Light
PRESSURE
CHARGER Pilot Light
MALFUNCTION
Inside the controller enclosure and accessible
only by a key lock door handle is the main control
panel. Unlock and open the enclosure door.
CautionIf AC power connections have been made,
exercise extreme care once door is open to avoid
electrical shock.
With the enclosure door open, the following
controls are accessible:
Name Description
MAIN SWITCH Three position switch
(MANUAL-OFF-AUTO).
CB1AC POWER AC power circuit breaker
(push onpull off).
CB3BATTERY 1 Battery 1 circuit breaker
(push onpull off).
CB4BATTERY 2 Battery 2 circuit breaker
(push onpull off).
TEST Initiate test cycle.
BATTERY 1 Ammeter for showing rate
CURRENT of charge of battery 1.
BATTERY 1 Voltmeter for battery 1.
VOLTS
BATTERY 2 Ammeter for showing rate
CURRENT of charge of battery 2.
BATTERY 2 Voltmeter for battery 2.
VOLTS
BATTERY CHARGERSDESCRIPTION
The battery chargers are dual-rate chargers
producing a maximum of 10 Amps each at full rate.
As the battery approaches full charge, the charger
automatically switches to a float rate mode. This float
rate helps to prolong battery life. An LED on each
charger will light when the charger is in float rate.
Fully or nearly fully charged batteries show a very
low indication of charging rate, which may or may not
be detectable on the control panel ammeters.
The battery chargers are adjustable for voltage
and current. Two switch assemblies on the front of
the battery chargers adjust the maximum output
voltage (switch SW-V) and the maximum output
current (switch SW-A). Adjusting the maximum
voltage (and amperes) has the effect of adjusting the
float rates so that the charger can be set back slightly
in order to insure against boiling the electrolyte.
For the initial start-up, the switch settings should
remain at the factory set positions. After a period of
one week, if the batteries display symptoms of
excessive gassing or if the battery chargers have not
To adjust the pressure switch, open the control-
ler door and locate the pressure switch at the bottom
left of the enclosure. Controllers are shipped with
protective packing material around the mercury
switch inside the pressure switch. Remove the plastic
cover, the packing material, the round warning label
and replace the cover. The upper adjustable pointer
determines the stop pressure and the lower adjust-
able pointer determines the start pressure. The
difference between the two settings is the operating
differential between the start-stop switch operations.
The upper (stop) pressure switch setting must be set
at a pressure less than the fire pump churn pres-
sure (including minimum suction pressure) otherwise
the pump will run continuously once started.
CONTROLSDESCRIPTION
Mounted on the flange of the enclosure and
accessible with the door closed are the following
controls:
Name Description
CRANK ON Pushbutton to manually
BATTERY 1 crank engine on battery
#1.
CRANK ON Pushbutton to manually
BATTERY 2 crank engine on battery
#2.
Note Above controls are for manually cranking the
engine and are operable only when the main
selector switch (inside the enclosure) is in the
MANUAL position.
STOP RESET Pushbutton to stop
BATTERY TROUBLE engine, when main switch
is in AUTO only and all
starting causes have
returned to normal (stand
by).
AUDIBLE ALARM Silenced with Main
Switch by selecting OFF
position.
The following are located on the controller flange:
CONTROLLER Pilot Light
IN AUTO
BATTERY 1 Pilot Light
TROUBLE
BATTERY 2 Pilot Light
TROUBLE
NoteThe 5 minute minimum run time may be used for
initial testing and set-up, but the controller should be
returned to 30 minutes minimum run time for a
service condition.
INITIAL START-UP
1. Close circuit breaker CB-1 to power the main
transformers supplying the battery chargers. The
upper LEDs on the battery chargers should light.
The lower LEDs on the battery chargers light in
the float rate charge mode. If both batteries are
charged, the float rate (lower LEDs) will both light
and very low charging current will be observed on
the ammeters.
2. Close circuit breakers CB-3 and CB-4 to power line
1A through both the battery chargers and the
batteries. Flange-mounted pilot lights BATTERY 1
TROUBLE and BATTERY 2 TROUBLE should
illuminate. Push the STOP-RESET button, the two
trouble lights should go out and the two green
LED's on the battery monitoring module (PC-1729)
should light. The battery monitoring module is
factory adjusted to alarm battery trouble at 1/2
nominal voltage. If the flange mounted trouble
lights do not go out, and the LED's on the battery
module do not light. Check battery voltage, battery
connections and battery voltage and amperage. If
trouble lights persist consult the factory.
automatically switched to the float charge mode,
the output voltage switch (SW-V) should be adjusted
to the next lower setting (see Figure A). After a day
or two, the system should be reinspected and if
required, the chargers should be readjusted to the
next lower setting. Repeat the procedure until the
system is operating satisfactorily.
The current setting switches (SW-A) are factory
set at 10 Amps and should not be adjusted unless
recommended by the battery manufacturer. See
Figure B for adjustment settings.
Figure A. Maximum output voltage (Volts) - Switch
SW-V (*Factory Setting)
Figure B. Maximum output current (Amps) - Switch
SW-A (*Factory Setting)
PRIOR TO INITIAL CONTROLLER START-UP
1. Read FTA1100 instruction manual thoroughly
and carefully.
2. Before conducting the initial start-up, consult the
pump and engine manufacturers instruction
manuals to verify that all necessary engine,
pump, and related equipment service and
adjustments have been performed.
START-UP OPERATION
Selector Switch and Circuit Breaker Check
1. Place MANUAL-OFF-AUTO Selector switch in
OFF position.
2. Place circuit breakers (CB-1, CB-3, CB-4) in off
positions.
Incoming Power Check
1. Energize the incoming 120 Volt AC line to
Terminal L1 and L2 (or voltage called for on
controller).
Pressure Switch Check
1. System pressure must be above the stop setting
on the pressure switch (if below start setting,
controller will attempt to the start engine on initial
start-up).
Minimum Run Time /Shutdown Mode Check
1. The controllers are shipped from the factory set for
a 30 minute minimum run time. To select a 5
minute or no minimum run time, move the jumper
on printed circuit board PC-1028.
Note: Selecting no minimum run time sets the
controller for manual stop only.
NS1100-05 Rev. G
Page 4 of 8
2 1 2
26.5 V
13.26 V
25.6 V
13.03 V
6 A
2 1
7 A
2
ON
1 2 1 2 1
28.0 V*
13.8 V*
27.0 V
13.5 V
24 V Units
12 V Units
1 2 1 2 1
10 A* 8 A
12 & 24
V Units
ON
5 MIN
NO TIME
30 MIN
Jumpers located at
lower right on PC-1028
to select minimum run
time.
SETTING THE TIME
Note: If the h and m keys are held down longer than 2
seconds, the numbers will advance rapidly.
Press and hold the key during the following:
1. Press h to advance to the current hour
2. Press m to advance to the current minute
3. Press Day to advance to the current day
NS1100-05 Rev. G
Page 5 of 8
Note: If the days are flashing, it indicates the day of the week
was not set when setting the time. The timer cannot be pro-
grammed unless the day of the week is entered.
SELECTING AM/PM OR MILITARY TIME
To toggle between AM/PM or Military (24 Hr.) time press and
hold the h key and press the 1h key.
DAYLIGHT SAVINGS TIME
Manual - Each year, in the Spring, press 1h to advance the
time an hour. In the Fall, press 1h to set back an hour.
Automatic - Note: It is only necessary to program the
changeover dates once. The timer will then automatically
change the time at 2:00AM on the first Sunday in April and the
last Sunday in October until the year 2079.
1. Press and hold the 1h key and press the Day key once.
If in AM/PM mode, 12:31 (Dec. 31) will be flashing. If in
military time mode, 31:12 will be flashing.
2. Enter the current (todays) date. Press m key for date
and h key for month. (If in military time, keys are re-
versed).
3. Press 1h once, a 2 under Tu and year appears in
display. Press m key to set the current year.
4. Press 1h once, a 3 under We and AU appears in
display, which indicates preset European dates.
5. Press m key once so display shows cHA.
6. Press 1h once, a 4 under Th and date appears in
the display.
7. Enter the date for the spring time change. Press h for
month and m to select day. (See chart for dates).
8. Press 1h once, a 5 under Fr and the fall time change
date appears in display. Press h for month and m to
select day. (See chart for dates).
9. Press key to enter run mode.
Year Spring Date Fall Date
Daylight Savings Time Dates
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
April 2
April 1
April 7
April 6
April 4
April 3
April 2
April 1
April 6
April 5
April 4
October 29
October 28
October 27
October 26
October 31
October 30
October 29
October 28
October 26
October 25
October 31
Year Spring Date Fall Date
2011
2012
2013
2014
2015
2016
2017
2018
2019
2020
2021
April 3
April 1
April 7
April 6
April 5
April 3
April 2
April 1
April 7
April 5
April 4
October 30
October 28
October 27
October 26
October 25
October 30
October 29
October 28
October 27
October 25
October 31
PROGRAMMING SCHEDULES
The timer can be programmed for 42 on/off events. There
must be an off event for each on event or the timer will
constantly have its output turned on. To program an on
event:
1. Press the Prog. key.
2. Press the key once. The ON symbol should ap-
pear, .
3. Using the h and m keys, set the time you want the
timer to activate its output.
x
x
x
4. Press the Day key. A blinking line will appear under
a day. If you wish the timer to activate on that day,
press the Day key to go to the next day. If you do not
want to activate the timer on that day, press the Sel.
key to delete the day. Continue until only the days you
want are selected.
5. Press the Prog. key to store the settings.
To program an off event:
1. Press the Prog. key until a free (unprogrammed)
screen appears.
2. Press the key twice. The OFF symbol should
appear, .
3. Using steps 3,4 and 5 above, program the time and
days you would like the timer to deactivate.
REVIEWING PROGRAMS
To review the programs, press Prog. key. Programs
will appear in the order they were entered with repeated
presses of the key. After all programs have been reviewed,
the blank display will appear to allow entering another
program. Another press of the Prog. key will display
the number of free programs available.
CHANGING A PROGRAM
Select the program to be changed using the Prog. key.
New days may be added or deleted using the Day and
Sel. keys. Hour and minute can be changed using the
h and m keys. Press Prog. or to store the
program changes.
DELETING A PROGRAM
Press Prog. key until the desired program is displayed.
Press m key to :59, then once more to blank out. Press
h key to 11PM, then once more to blank out. Press the
run key , the display will flash for several seconds
and then enter the run mode.
RESETTING ALL
Pressing Res key will delete ALL programs, the time of
day and daylight savings date settings.
HOLIDAY PROGRAM
A Holiday program may be entered for use on holidays or
vacation periods. This can be used to turn the timer off
during a specific period of time, temporarily overriding
the normal program functions. Press Prog. key to first
free program. Press key twice until the off symbol
appears. Use h and m keys to set the time that
the timer will turn off. Press the holiday key then the
run key to enter.
Up to six days in advance of the holiday, the holiday sched-
ule may be selected to begin on a certain day of the week,
and continue from 1 to 99 days. Press the key once.
Press Day key to select start day. Press Sel. key to
select number of days the program will run. Press the
run key to return to run mode. Display will show .
The holiday program will execute at the programmed time
and day, when finished the timer will revert back to nor-
mal programs.
2. Pressing the key a second time [ ] appears in
the display indicating the load is switched
permanently ON.
3. Pressing the key a third time, [ ] appears in the
display indicating the load is switched permanently
OFF.
4. Pressing the key a fourth time returns to automatic
appears in the display.
Load Indicator
The load is shown in the display as either on or off.
Battery Powered Reserve
In case of power failure, the built-in nickel-cadmium battery
maintains the time of day, program storage and LCD display
for 150 hours. During power outage relays are de-energized.
Daylight Savings/Standard Time Change
When a time change to Daylight Savings time is required,
press 1h once. The time base in the unit will automati-
cally advance by one hour and +1h will appear in the dis-
play.
To change to standard time, press 1h again; the time
base is set back one hour and +1h will disappear.
NoteWhen all wiring and piping connections are com-
plete and verified to be correct, the controller is ready for
initial start up.
OPERATING SEQUENCE CONDITIONS NORMAL
System Pressure Satisfied
Deluge Valve (if used) Closed, DVR
Energized
AC Power Supply Normal
Battery Charger Normal,
CHRG-1 and
CHRG-2
Weekly Test Timer Off
Remote Start Open
Shutdown Interlock (if used) Closed
Battery No. 1 Charged 1CR
energized
Battery No. 2 Charged 2CR
energized
MANUAL START
1. Place MANUAL-OFF-AUTO selector switch in MANUAL
position.
NOTEThe controller is field selectable for AUTO
START with main switch in manual. By inserting a
jumper between terminals 80 and 80A with the main
switch in manual and the jumper installed, the controller
NS1100-05 Rev. G
Page 6 of 8
will NOT void automatic start signals. See AUTO
START conditions.
a. Selector switch Mis-set remote alarm activated.
b. LOW OIL PRESSURE pilot light 4PL energized.
c. Engine Fuel Valve energized.
d. Controller in Auto Pilot Light 7PL energized (If
jumper 80 to 80A is installed).
2. Press CRANK ON BATTERY 1 pushbutton, 1PB.
a. Engine contactor C1 (Caterpillar engines, MS1)
energized.
b. Engine starter energized.
CAUTIONEngine starting motor may be damaged
due to excessive continuous cranking. Limit continu-
ous cranking time to fifteen (15) seconds. Allow at
least fifteen (15) seconds rest before attempting to
re-crank.
NOTEAmmeter 1, 1AM should read approximately
10 Amps while the engine is being cranked, then as
the engine runs it should decrease to about 5 Amps.
When the engine runs, its charging alternator
(generator) charges both batteries, but not at the
same rate.
3. Cease cranking when engine runs.
a. Engine running contact closes energizing engine
running relay, ERR and low oil pressure timer on
PC-1028.
4. Engine mounted oil pressure switch should open and
de-energize LOW OIL PRESSURE, 4PL pilot light.
a. If engine oil pressure does not increase to open
the switch contacts within the set time the low oil
pressure contacts on PC-1028 will energize 6CR
and lock in.
b. Alarm relay ETR will become energized and
remote engine trouble alarms will be activated.
c. Controller mounted audible alarm will sound.
CAUTIONLow Oil Pressure condition outlined
above may result in engine damage. IMMEDI-
ATELY place the selector switch in the OFF
position. DO NOT RUN ENGINE until problems
have been resolved.
5. Engine will keep running until it is shutdown by
placing the selector switch in OFF position or the
engine overspeed switch operates. See step 17,
Overspeed Shutdown.
6. Manual start on battery2.
a. Repeat steps 15 using CRANK ON BATTERY
2 pushbutton.
AUTO START
CONDITIONS NORMAL
7. Place MANUAL-OFF-AUTO selector switch in AUTO
position.
a. CONTROLLER IN AUTO pilot light 7PL ener-
gized.
b. Switch mis-set remote alarm contacts de-
energized.
8. Push TEST pushbutton on controller inner door and
hold depressed until engine starts and runs.
MANUAL OPERATION
1. While in the Run mode, ( symbol is displayed),
pressing the key will reverse the load status
(switch load OFF if it is ON, or switch ON if it is OFF).
A hand symbol appears in display to indicate the
override is active. At the next scheduled switching
time, automatic time control will resume, eliminating
the override.
NS1100-05 Rev. G
Page 7 of 8
NOTE Pressing this button energizes the sole-
noid drain valve on controller, bleeding pressure
from the pressure switch causing engine controller
to automatically start the engine.
9. Release TEST pushbutton after engine is running.
a. Engine running remote alarms are activated,
and de-energizes solenoid valve, satisfying
system pressure.
b. If controller is configured for automatic start
and manual only stop (jumper on PC-1028
placed on manual stop or removed), the
controller will stop only if pressure is restored
at the pressure switch and controller is
manually stopped. If pressure is above stop
setting, push STOP RESET BATTERY
TROUBLE pushbutton, 4PB; if all require-
ments are normal, the engine will shutdown.
c. If controller is configured for automatic start
and automatic stop (jumper on PC-1028
placed on 5 or 30 min), the controller will
automatically stop the engine after the
minimum run period expires and all conditions
are returned to normal.
10. Signals for auto-start are as follows:
a. System pressure drops to start set point .
b. Remote start contact closes.
c. Deluge valve contact opens de-energizing
DVR.
d. Weekly test timer or TEST pushbutton. See
steps 18 and 20.
e. AC power failure (Optional). See step 19 and
20.
11. Occurrence of any of the call to start conditions
energizes the automatic start relay, ASR and
10CR. Closure of the ASR relay contacts ener-
gize:
a. Engine fuel valve (for Caterpillar engines,
Relay 10CR de-energizes fuel shutdown
solenoid through SR1).
b. Engine cranking circuits.
c. Minimum run period timer (for auto shutdown
only). Minimum run timer is part of PC-1028.
12. Cranking circuit operates as follows:
a. PC-1028 crank limit timer starts 165 second
time cycle to limit total cranking duration time.
b. Timer sets 15 seconds crank period.
c. Timer sets 15 seconds rest period between
cranks.
d. Relays 3CR and 4CR operate to alternate
cranks between battery1 and battery2.
Three 15 second cranks per battery. NOTE
In the event that a battery is inoperative, the
respective battery monitor relay, 1CR or 2CR,
will de-energize. This will prevent the battery
alternating crank relays from operating and
will lock the cranking circuit onto the remain-
ing battery.
e. If the engine does not start within the 165
second time, the timer will expire on PC-1028
and energize the engine trouble alarm relay,
ETR, de-energize the cranking circuits, sound
the audible alarm, energize the ENGINE
FAILED TO START pilot light, 6PL, and
activate the remote engine trouble alarm.
Placing the selector switch in the OFF position
will reset the control circuits. CHECK THE
ENGINE STARTING EQUIPMENT AND FUEL
SYSTEM.
13. When engine reaches running speed, the engine
mounted speed switch will close, energizing the
controller engine running relay ERR and the oil
pressure timer section of PC-1028.
a. Remote engine running alarm contacts are
activated.
b. ERR contacts operate to inhibit cranking
circuits.
14. Engine oil pressure should increase, opening the
engine mounted low oil pressure switch.
15. If the oil pressure fails to increase, the oil pressure
timer will time out, energizing relay 6CR. Relay
6CR will lock in, sound the audible alarm and
energize relay ETR to activate the remote engine
trouble alarms. The controller does not shutdown
the engine on low oil pressure unless the start was
initiated by a test condition. See step 20.
CAUTIONAn engine running with a low oil
pressure condition may be damaged. If
operation of the engine is not essential at this
time, it should be shutdown by placing the
selector switch in the OFF position. All
possible causes of low oil pressure should be
investigated and corrected immediately so that
system can be returned to normal operation.
16. Whenever the controller control switch is in the
MANUAL OR AUTO position, the engine water
temperature is monitored through the temperature
switch on the engine. Closure of this contact will
energize relay 5CR, HI-TEMP pilot light 5PL, the
audible alarm, relay ETR and activate the remote
engine trouble alarm. This will not stop the engine,
nor will it prevent the engine from starting.
CAUTIONAn engine running with a high tem-
perature condition may cause engine damage.
Causes of high temperature should be
investigated and corrected immediately.
17. An engine overspeed condition will immediately
shutdown the engine and lock it out until the
overspeed switch on the engine has been reset.
(Overspeed is normally set at 120% rated RPM.)
The overspeed switch on the engine will operate to
close the engine fuel valve and to energize
controller relay OSR, overspeed pilot light 3PL, the
audible alarm, relay ETR, and will activate the
remote engine trouble alarm. Relay ERR will also
de-energize, deactivating the remote engine
running alarm signals. The engine overspeed
Publication NS1100-05 Rev. G (06/00)
switch must be reset manually before the engine
can be restarted. The audible alarm on the
controller and the remote engine trouble alarm
may be silenced by placing the controller
switch in the OFF position. The remote alarm
for MANUAL-OFF-AUTO switch mis-set will be
activated. If the control switch is placed in the
AUTO or MANUAL position before the engine
overspeed switch has been reset, the alarm on
the controller and the remote alarm will be
reactivated. NOTE: The engine is solely
responsible for engine shutdown in overspeed.
18. Weekly test timerOperation of weekly test
timer WTR will energize the solenoid drain
valve on the controller to take the pressure
switch to atmosphere,initiating an automatic
run sequence. The engine will run until the
weekly test timer resets (minimum 30 minutes)
and all other demand signals have been
satisfied. If the engine continues to run, it
indicates that some other demand still exists.
See step 20 for safety shut-downs.
19. AC power failure start (optional)Adds timer
PFTR. Adjustable timing range 10 -180
seconds. An AC power loss to the battery
charger will cause PFTR to de-energize
starting the PFTR timing circuit. If the AC
power is not restored within this time limit, the
timer contact will close, energizing the test
circuit. See step 20 for safety shutdowns.
20. An engine start by weekly test timer, test
pushbutton, or by AC power failure start is
considered a nonessential start. Safety engine
shut down circuits for the following conditions
are included in this controller:
a. Engine overspeed.
b. Engine low oil pressure.
c. Engine high temperature.
21. Shutdown by engine overspeed requires
manual reset of the engine overspeed switch.
See Step 17.
22. Shutdown by low oil pressure and high
temperature would be voided by any other
demand for engine run operation.
23. Interlock shutdownOpening of the interlock
contacts will disable all automatic starting and
automatic running functions but will not affect
manual start or manually started running
functions.
SHUTDOWNOTHER THAN
CATERPILLAR ENGINES
Shutdown normally occurs when pressure is
restored by the pressure switch and the minimum
run timer portion of PC-1028 is allowed to expire,
which de-energizes relay ASR and 10CR. ASR
performs the functions of a holding circuit to allow
the timing of the crank circuit and also of energizing
wire 1 (terminal 1) on the engine, energizing the fuel
solenoid. When ASR drops out, the fuel solenoid de-
energizes, stopping the engine.
The above sequence requires that the jumper
not be placed (on PC-1028 to manual stop or be
removed) allowing the controller to shutdown in the
automatic mode. If selected for manual stop, the
engine must be stopped manually.
SHUTDOWNCATERPILLAR ENGINES
In the above example, the engine has shutdown
because the fuel solenoid has been de-energized by
the drop-out of ASR.
Caterpillar engines require that the fuel solenoid
be energized to shutdown. ASR and 10CR must be
de-energized (Main selector switch, MANUAL-OFF-
AUTO must be in OFF or AUTO). This allows wire
12 (terminal 12) to become energized and SR1 on
the engine to become energized. These conditions
allow the engine fuel solenoid to energize to stop the
engine if selected for auto stop.
OVERSPEEDSHUTDOWN
Engine overspeed is a shutdown condition and
is detected by contacts mounted on the engine
which energize relay OSR. OSR1, when energized
will open the line (in series with ASR contacts)
disabling the crank cycle. This prevents a start by
ASR, disabling the weekly test circuit and the
manual test circuit. Terminal #1 remains energized
to supply voltage to overspeed circuits on the
engine.
The Caterpillar engine requires energizing the
fuel solenoid to stop. As explained above, wire 12 is
normally energized by means of MR and 10CR
contacts. In an overspeed condition, wire 12 is
energized by OSR contacts paralleling that line,
energizing terminal 12, stopping the engine.
Overspeed disables the crank cycle, prevents
start by ASR, disables the weekly test circuit and the
manual test circuit.
General Information
Typical Pressure Sensing Line Connection
Fire Pump Controllers & Jockey Pump Controllers
Pump Controller
Pressure
Sensing
Device
Bronze Check Valve With 3/32" Orifice in Clapper
Note: If water is clean, ground-face unions with
non-corrosive diaphragms drilled for 3/32" orifices
may be used in place of the check valve.
1/2" Globe Valve
1/2" x 1/2" x 1/4" Tee with 1/4" Plug
1/2" Non Corrosive Pressure Sensing Line
If excessive water "hammer" (wave action) causes
erratic operation of the pressure sensing device or
pressure recorder, a supplemental air chamber or
pulsation damper may be needed.
WATER
SUPPLY
Fire
Pump
Controller
Fire
Pump
Jockey
Pump
Controller
Jockey
Pump
FIRE PROTECTION
SYSTEM
NFPA 20
7-5.2.1 Water Pressure Control. There shall be provided a pressure-actuated switch having independent high and low calibrated adjustments in the
controller circuit. There shall be no pressure snubber or restrictive orifice employed within the pressure switch. This switch shall be responsive to water
pressure in the fire protection system. The pressure sensing element of the switch shall be capable of withstanding a momentary surge pressure of
400 psi (27.6 bars) without losing its accuracy. Suitable provision shall be made for relieving pressure to the pressure-actuated switch to allow testing
of the operation of the controller and the pumping unit.
(A) For all pump installations (including jockey pumps) each controller shall have its own individual pressure sensing line.
(B) The pressure sensing line connection for each pump (including jockey pumps) shall be made between that pump's discharge check valve and
discharge control valve. This line shall be corrosion-resistant metallic pipe or tube, and the fittings (brass, copper, or series 300 stainless steel)
shall be of 1/2 inch (12.7 mm) nominal size. There shall be two check valves installed in the pressure sensing line at least 5 ft. (1.5 m) apart with
a 3/32 inch (2.4 mm) hole drilled in the clapper to serve as dampening.
(C) There shall be no shutoff valve in the pressure sensing line.
(D) Pressure switch actuation at the low adjustment setting shall initiate pump starting sequence (if pump is not already in operation).
A-7-5.2.1 Installation of the pressure sensing line in between the discharge check valve and the control valve is necessary to facilitate isolation of the
jockey pump controller (and sensing line) for maintenance without having to drain the entire system.
Flow Flow
Publication GF100-30 (02/97)