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Parts of diesel engine, exhaust pipe and cooling pipework are hot when the engine is running and for
some time after engine stops. Keep clear of these areas during these times.
ELECTRIC PUMP
To STOP push the pump stop button or turn off the main isolator
DIESEL PUMP
To START push and hold either (or both) emergency start button until engine starts
To STOP push and hold the pump stop button for 10 seconds
If the diesel motor won’t STOP or continues to crank over turn the key switch to isolate.
Then press stop or pull the yellow lever on the side of the motor.
Refer notice on diesel tank for correct isolation and de-isolation procedures.
1. MAINTENANCE
Fire Protection Pumpset must be tested and maintained on a regular basis in accordance
with relevant Australian Standards including AS1851-14. Regular testing to be carried out by a
fire systems maintenance contractor. For routine servicing please contact ALLIED PUMPS
SERVICE (08) 9350 1000.
The Australian Standard prohibits automatic shut down of fire pumps. The fire pumps will
not automatically shut down after they have started and must be manually stopped.
The fire pump system generates alarm and warning outputs which must be connected to an
adequate external warning device or system and maintained to the relevant Australian
Standards. Procedures must be instigated to ensure warning signals are responded to in a
competent manner, on a 24 hour per day basis.
4. MONITORING EQUIPMENT
The Fire Pumps must never be allowed to run unattended (with the exception of a
jacking pump). Pumps must be constantly monitored by suitably qualified personnel while pump
is running.
The Fire Pumps must not be used other than for the intended purpose, ie fire
protection, training and system pressure maintenance. Failure to comply with this may void
warranty.
Pump room must be adequately vented and drained. Failure to do this may result in severe
damage to property and personnel. Radiator cooled engines should have the radiator exhaust air
ducted directly out of the exhaust room with a suitably sized duct. Ventilation should be
sufficient to cope with the radient heat load of the engine and ensure there is less then 10˚C
temperature load rise down ambient during a 30 minute fell load operation. Radiator cooled
engines should have the radiator exhaust air ducted directly out of the pump room with a
suitably sized vent.
7. EXHAUST
Diesel exhaust must be piped to a suitable external location in a manner that will preclude the
entry of water. Exhaust pipework should include a condensate trap and must be sized to engine
manufacturer’s recommendations. Exhaust pipework and accessories must be logged in a
suitable method to industry standards. If the pipe run is more than 10 metres, the pipe diameter
will need to be increased. Refer to diesel engineer.
9. Fire Protection Pumpset is to be located out of the influence of direct weather and sunlight.
1. PLANTROOM
Pumpset must be installed in a well ventilated area. Mechanical ventilation may be required in
limited ventilation area. Pumpset should be protected from weather (rain and UV). Plantroom
must have a minimum of 1m clear all around the pumpset for pumpsets up to 110kW and
greater to suit for larger sizes.
2. MOUNTING
Pumpset must be mounted on a level concrete pad on rubber resilient pads provided. Pumpset
to be anchored down securely. Great care should be taken not to twist base when tightening
down – ie. do not force base down with anchor bolts.
3. PIPEWORK CONNECTIONS
Pipework connections include:
a) Main suction from tank – care must be taken to ensure there are no leaks, no potential air
locks (ie. air will automatically bleed from suction line) and no prohibited devices in the
suction line (refer AS2941-2013)
b) Main discharge to fire protection system
c) Relief valve connection back to storage tank
d) Diesel heat exchanger outlet to drain (discharge must be visible)
e) Electric Pumpset Only – Circulation relief valve to drain (discharge must be visible)
f) Test line back to supply tank
4. Please ensure that heat exchange of waste pipework is of adequate size. Pipework size to be at
least the same size as the outlet of the heat exchanger. EACH ENGINE MUST HAVE ITS
OWN PIPE RUN TO WASTE AND BE VISIABLE IN ACCORDANCE WITH
AS2941-2013.
5. ELECTRIC CONNECTION
Electrical connections include separate supply for each pumpset, including the jacking pump:
a) Diesel Pumpset – Single phase 15A supply to operate control system. Supply to be classed
‘essential supply’ and in fire rated cabling.
b) Electric Pumpset – Suitable sized 3 phase neutral and earth supply capable of starting
motors. Supply is essential and should be fire rated cabling. Supply shall be in accordance
with AS3000 and be suitable for inrush current.
c) Jackering/hose reel Pump – 3 or 1 phase supply to suit motor size.
6. COUPLING
Coupling alignment must be checked after installation. Transit and/or installation may have
disturbed coupling alignment. Alignment should be within 1mm parallel alignment and 2
degrees angle alignment. Alignment should be rechecked after the first month and 6 monthly
thereafter.
7. PLANTROOM
Pump room must be adequately drained. Drainage should be sufficient to cope with a
catastrophic failure of any component without flooding the pump room.
9. CONTROL OUTPUTS
It is critical that the system outputs (including power on, pump(s) run, faults) should be
monitored on a continuous basis with a management plan in place to respond to signals.
Unattended running can cause damage to pump equipment and associated building/grounds.
10. ALARMS
Remote audible and visual alarm should be installed in a suitable location. Interwiring required.
13. BATTERIES
Prior to system being commissioned, BATTERIES must be left disconnected and stored
correctly as per manufacturers recommendations. If it is likely that there is any length of time
(in excess of 6 months) from delivery of pumpset to commission, arrangements can be made
for ALLIED PUMPS to retain batteries at time of delivery and make them available for
collection at time of commission. Failure to follow procedure may cause battery failure which
is not covered by warranty.
Fire pumps have been pre-commissioned and tested to AS 2941-2013 prior to dispatch from workshop
however a site commission is still necessary. It is suggested initial start up is done with the site
electrician present.
1. Visual inspection of complete system to ensure pipework connections is in place and nothing is
out of order.
3. Open suction and discharge isolation valves on electric pump, diesel pump and jacking pump.
5. If jacking pump is a vertical multistage pump, a separate bleed valve will be fitted at the top of
pump. Open to allow air to escape. Close once water starts flowing.
7. Bleed any residual air out of suction manifold via ball valve.
8. Check the site electrician to ensure power is present in both the electric and the diesel panel.
9. Isolated diesel engine start via ‘start isolate’ key witch on board.
12. Turn ‘mains isolator’ switches on – WARNING electric duty pump will start immediately. Unit
can be stopped by pressing ‘pump stop’ button on electric panel.
13. Check rotation of motor to be correct. (Correct rotation is indicated on pump casing by an
arrow). If rotation is incorrect, site electrician should reverse incoming mains.
14. Jacking pump can be switch to automatic to talk up system pressure. (Rotation must be
checked on jacking pump it if is 3 phase.)
15. Ensure jacking pump shuts down automatically via pressure switch once system is at full
pressure.
17. Check diesel engine has correct levels of coolant water, diesel fuel and engine oil prior to start
up. Refer to engine manual.
18. Switch ‘engine isolate’ switch off if system pressure is high, diesel pump should not start.
20. Press ‘emergency start’ Button. WARNING engine will start immediately. The engine can be
stopped by pressing pump stop button and holding on till engine has completely stopped.
1) Turn Hose Reel on. Hose Reel Pump should start and maintain pressure. Turn Hose Reel off.
Pump should stop within 1-2 minutes. (Only applicable if Hose Reel System installed).
2) Open Hydrant. Duty diesel Pump should start and maintain pressure. Shut Hydrant down.
Pump should continue to run. Press ‘Pump Stop; button on electric panel to shut down pump.
3) Turn ‘Main Isolator’ on duty diesel panel to ‘Off’. Open Hydrant. Standby Diesel Pumpset
should start. Shut Hydrant. Diesel Pumpset should continue to run. Turn ‘Main Isolator’ on
electric panel back on. Wait approx ½ minute then press ‘Pump Stop’ on diesel panel and hold
down until diesel engine has completely stopped. If main electric pump starts at this point
follow shut down procedure in step 2.
1) Jacking Pump – Turn Jacking Pump selector to ‘Manual’, pump should run and pressure will
increase. Return to auto.
NOTE: Engine can be prevented from starting by turning key switch on diesel panel to isolate. This will
cause an alarm condition and should not be left in this position unnecessarily.
Fire Protection Pumpset should be tested and maintained in accordance with relevant Australian
Standards including AS1851.14.
After operating fire pump set, the system should be visually inspected. Check engine levels, exhaust
system (including exhaust flap if fitted) to ensure all is back to normal condition.
Pumps should start automatically on loss of pressure. If pumps fail to start, the following procedure
should be followed.
Manually start diesel pump by pressing ‘MANUAL START’ Button on DIESEL FIRE PUMP
CONTROLLER or on REMOTE PANEL.
In the case of failure to start or power failure, proceed immediately to manually start diesel fire pump
by pressing one of the ‘MANUAL START’ buttons on DIESEL FIRE PUMP CONTROLLER or on
REMOTE PANEL.
Should engine fail to start, press the second ‘MANUAL START’ button located on DIESEL FIRE PUMP
CONTROLLER.
If engine cranks but refuses to start, check diesel fuel level in tank.
In case of all systems fail, 12 volt DIESEL ENGINE can be started using standard car battery, either
using jumper leads immediately on the start solenoid or in the place of the crank battery. A 24 volt
DIESEL ENGINE requires two 12 volt batteries connected in series.
Should pumps be running and there is lack of water at the hydrants, check valves positions. Ensure
bypass valves are off. Also check water level in main tank.
A shut down is performed with the controls mounted on front of ‘Diesel Fire Pump Controller’.
Press red ‘Stop’ button mounted on face of ‘Electric Fire Pump Controller’ (Motor may attempt to
start if controller is still receiving a start signal.)
CAUTION: The jacking pump is designed to maintain system pressure. Isolating jacking pump is likely to
result in a main pump start up.
COUPLINGS
Check alignment after the first month then on a ongoing 6 monthly basis. Check for worn coupling
rubbers etc. Alignment should be within manufacturers recommendations.
PRESSURE VESSEL
Check, on a 6 monthly basis, that air pressure in vessel is charged and at correct pressure. Air
pressure should be checked when there is no water pressure in system. Air pressure can be checked
with a tyre pressure gauge. Air pressure in vessel should be charged (without water pressure) to
approximately 50 kPa below ‘cut in’ of jacking pump.
BATTERIES
Check, on a 2 monthly basis serviceability of battery, voltage and charge amps and in accordance with
AS1851. Check battery temperature, liquid level (if applicable) and that the battery is maintained and
replaced in accordance with the current Australian Standards. Ensure that the appropriate warning
stickers and covers as required by Australian Standards are in place.
DIESEL ENGINE
Change oil, flush radiator (if applicable), check fan belts, and go through other maintenance procedures,
as per Diesel Engine Manual.
PUMPSET
Fire Protection Pumpset must be tested and maintained on a regular basis in accordance with relevant
Australian Standards including AS1851-14.
MOUNTS
BOLTS/FASTENINGS
Check bolts/nut tensions for correct levels after the first month and then on a 6 monthly ongoing basis.
Weekly
1 Fault indication
2 Lamp / alarm test
3 Fuel level
4 Diesel engine oil level
5 Diesel engine coolant
6 Battery voltage – crank battery
7 Battery voltage – control battery
8 Charge amps – crank battery
9 Charge amps – control battery
10 Water level in supply tank (if applicable)
11 System pressure
12 Test run electric pump in auto mode
13 Electric pump cut in pressure*
14 Test run electric pump in manual mode
15 Electric motor amps
16 Test run diesel engine in auto mode
17 Diesel engine cut in pressure*
18 Test run diesel engine in manual mode
19 Test run jacking pump in manual mode
20 General system condition
21 Check for damage or wear on pump system
22 Exhaust system – gas and water leaks
23 Drain condensate trap
24 Clean heat exchange feed filter. Check heat exchange flow rate
If any condition exists or functions is not correct report immediately to maintenance manager for
immediate action and rectification.
Date:
Service Personnel:
CONTACT INFORMATION
Electric Fire Pump Controller (E.F.P.C.) is supplied from Distribution Board and has the function of
controlling Electric Pump / Motor and Jacking Pump.
PHASE SELECTOR SWITCH – To select the phase that is to be monitored by the Ammeter.
STOP – To Stop Pump / Motor after being started by automatic or manual means.
LAMP / ALARM TEST – To test indicator lights and alarm for serviceability.
MANUAL: Pump will run. (Do not leave unattended in this mode)
Jacking Pump controller (JPC) requires a separate supply and has the function of automatically
controlling the jacking pump start and stop
MAN / OFF / AUTO (Jacking Pump) – Selector Switch to control function of Jacking Pump.
START ISOLATOR – Key lockable selector switch to prevent diesel engine starting should
maintenance on engine be required.
LAMP/ALARM TEST – To test indicator lights and aural alarm for serviceability
OVERSPEED TEST – To simulate an overspeed fault. Engine must be running and the start isolator in
the ‘isolate’ position. Engine will shut down & alarm raised when operated. Reset set fault via the ‘fault
re-set’.
ALARM RESET – To reset fault once fault condition has been rectified
CRANK/CONTROL CHARGER VOLT METERS – To indicate rate of charge into batteries from
electric chargers in D.F.P.C.
ALTERNATOR CHARGE CURRENT – To indicate rate of charge from alternator or engine to crank
battery.
FUEL TANK LEVEL – To indicate the level of the fuel in the fuel tank. Below 70%, the low fuel light will
illuminate and alarm activates.
A380 SERIES
A480 SERIES
A485 SERIES
A490 SERIES
POW ER TO P ER FO R M
SAFETY PRECAUTIONS
Ensure all precautions are followed carefully.
Never attempt to perform maintenance work, adjustments or resetting whilst the engine is
moving.
Make sure no people or animals are in the vicinity of the engine before starting it.
Never disable or tamper with the safety devices on the engine.
Always use safety gloves and heat resistant clothing when operating or working on a hot
engine.
EXHAUST PRECAUTIONS
Do not inhale exhaust fumes. It contains carbon monoxide, a colourless, odorless and
extremely dangerous gas which can cause unconsciousness or death.
Use respiratory protection when working in the vicinity of engine exhaust fumes.
Do not operate the engine indoors or in a poorly ventilated area unless exhaust fumes are
ducted outside.
Keep the exhaust pipe free of external objects.
REFUELLING PRECAUTIONS
FIRE PREVENTION
Direction of
crankshaft rotation Counter Clockwise
(facing to flywheel)
Cooling method Forced Water Cooling
Starting method Electric
Net mass (kg) 185 210 220 250
SPECIFICATION OF MAIN ACCESSORIES
DESIGNATION SPECIFICATION
Type 1 or BQ pump
Fuel injection pump
Governor All speed, mechanical centrifugal
Model P21
Fuel injector
Nozzle Set Single hole, pintle-type ZS4SI
Type Rotor
Speed(r/min) 1300
Lube Pump
Capacity(L/min) 18
Pressure (kpa) 0.4
Type Centrifugal, volute, single suction
Speed(r/min) 3000
Water Pump
Capacity (L/min) 80
Lift(m) 5
Type Series DC motor
Starting Motor Model QD138C
Voltage (V) 12
Type Silicon rectifying shunt dynamo
Model JF11
Alternator Dynamo
Power(W) 350
Voltage (V) 14
Type Single stage, paper element
Fuel filter
Model C0506A
Lube Oil Filter Type Single stage, paper element
Air filter Type Single stage, paper element
Temp Sender 287-23ohms
Oil Pressure Sender 10-199ohms
Radiator
Heat Exchange
MAG Pick Up
Stop Solenoid Power to close fuel supply.
TECHNICAL MAINTENANCE OF DIESEL ENGINE
Check oil level of diesel engine oil, is it between upper and low limit.
Check coolant level every day and top up with identical mixture when necessary.
Regular Check and Maintenance are very important for normal operation and durability of
the engine. The following table indicates what is necessary and when to maintain the engine.
Item/ Time Daily After 20 100 hours 250 500 hours 1000
hours or every hours or every 6 hours or
or 1 3 months months every
month year
Check & tighten the nut &
screw
Check & fill machine oil
Second
First
Change lubricating oil Time &
Time
Later
Change oil filter
Check oil leakage
Clean fuel tank
Change fuel filter
Check nozzle
Check injection pump
Check pipeline of fuel (Change if
necessary)
Airfilter (Clean) Every month or 50 hours
Coolant/Water heat
exchanger/radiator
DIESEL MSDS
NALCOOL MAXIMUM MSDS
MOBIL DEVAC MX 15W-40 MSDS
SEALED MAINTENANCE FREE LEAD ACID
BATTERY MSDS
alliedpumps.com.au
Warranty does not cover equipment that is not being tested and maintained to AS1851.
Warranty does not cover pump systems that are not monitored on a continuous basis. Part
of monitoring requirement is a suitable management plan to attend to alarm and running
signals immediately.
Warranty does not cover damage resulted from ingress of water into the engine via the
exhaust system or other means.
Australian Standards AS2941-2013 preludes the use of shutdown protection devices that shut down
equipment in the case for malfunction. Consequently any damage result from equipment continuing to
operate whilst an abnormal condition is present is expressly excluded from manufactures warranty.
If buyer requires our services in respect of site inspection or service outside of what is covered by
Manufacturers’ warranties, then Buyer should enter into a separate agreement with ALLIED PUMPS in
respect to the same. In the event of no such separate agreement, all operation, calibrating, cleaning and
maintenance of plant is the responsibility of the buyer.
ALLIED PUMPS have not acted as a consultant or charged design fees on this project, and are in no way
responsible for, nor guarantee any particular level or performance of equipment supplied unless such
guarantee is specially given in writing.
Under no circumstances is ALLIED PUMPS liable for any direct or consequential loss or damage to
persons or properties of any nature due to any cause whatsoever.
Application of warranties is conditional on ALLIED PUMPS having received in cash the total contact
price. Furthermore, ALLIED PUMPS reserves the right to withdraw any code compliance, Australian
Standard compliance or selection compliance, should the contract not be paid in full.
Concrete Submersible Pump Station Manual