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Instructions FTA1100-E Relay Logic Diesel Engine Fire Pump Controller

Instructions Relay Logic Diesel Engine Fire Pump Controllers

INTRODUCTION

Firetrol® FTA1100 combined automatic and manual relay logic diesel engine fire pump controllers are intended 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 NickelCadmium 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 service 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. Caution—Controller is not free standing! Controller must be secured to floor or wall surface before opening door or operating. MOUNTING CONTROLLER— Note—Consult the appropriate job plans to determine 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 washer—if wall mount. Six (6) anchors, bolts and washers—if floor/base mount. Wall Mount— Note—Refer to the controller dimension drawing, DD1100, included in the instruction manual for necessary mounting dimensions.

• FTA 1100

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— Note—Consult the appropriate job plans to determine 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

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 accordance 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. Warning—Use only locations shown on Dimension Drawing DD1100 for conduit entrance. Controller warranty is VOID if any other location is used. Note—All 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. Reference engine wiring diagram and Field Connection 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 appropriate field connection diagram included with the manual.

Warning—Do not use controller wire way for routing external wiring. Wire Sizes— • Use #14 AWG wire minimum for all electrical connections except for battery charger connections. (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:

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

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 “L2”—120 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 connection 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 enclosure 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. Note—Test drain line must be free flowing. Do not use any valves or plugs on this line. Refer to NFPA 20 for correct field piping procedure of sensing line between the pumping system and the controller.

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STOP PRESSURE SET POINT START PRESSURE SET POINT To adjust the pressure switch, open the controller 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 adjustable 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” pressure (including minimum suction pressure) otherwise the pump will run continuously once started. CONTROLS—DESCRIPTION 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

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. Caution—If 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 MAIN SWITCH CB1—AC POWER CB3—BATTERY 1 CB4—BATTERY 2 TEST BATTERY 1 — CURRENT BATTERY 1 — VOLTS BATTERY 2— CURRENT BATTERY 2 — VOLTS

Description Three position switch (MANUAL-OFF-AUTO). AC power circuit breaker (push on—pull off). Battery 1 circuit breaker (push on—pull off). Battery 2 circuit breaker (push on—pull off). Initiate test cycle. Ammeter for showing rate of charge of battery 1. Voltmeter for battery 1. Ammeter for showing rate of charge of battery 2. Voltmeter for battery 2.

BATTERY CHARGERS—DESCRIPTION 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

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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)

ON 1 2 24 V Units 28.0 V* 12 V Units 13.8 V*

1 2 27.0 V 13.5 V

1 2 26.5 V 13.26 V

1 2 25.6 V 13.03 V

Figure B. Maximum output current (Amps) - Switch SW-A (*Factory Setting)

ON 12 & 24 V Units

1 2 10 A*

1 2 8A

1 2 7A

1 2 6A

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.

5 MIN NO TIME 30 MIN

Jumpers located at lower right on PC-1028 to select minimum run time.

Note—The 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 LED’s on the battery chargers should light. The lower LED’s on the battery chargers light in the “float rate” charge mode. If both batteries are charged, the “float rate” (lower LED’s) 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.

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

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Note: If the days are flashing, it indicates the day of the week was not set when setting the time. The timer cannot be programmed 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 (today’s) date. Press “m” key for date and “h” key for month. (If in military time, keys are reversed). 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. Daylight Savings Time Dates Year Spring Date 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

Fall Date 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 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

Fall Date 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 it’s output turned on. To program an “on” event: 1. Press the “Prog.” key. 2. Press the “ “ key once. The ON symbol should appear, “ “. 3. Using the “h” and “m” keys, set the time you want the timer to activate it’s output.

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 “ x “ then the run key “ “ to enter. Up to six days in advance of the holiday, the holiday schedule may be selected to begin on a certain day of the week, and continue from 1 to 99 days. Press the “ x “ 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 “ x “. The holiday program will execute at the programmed time and day, when finished the timer will revert back to normal programs.

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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. 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.

2.

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 automatically advance by one hour and “+1h” will appear in the display. To change to standard time, press “±1h” again; the time base is set back one hour and “+1h” will disappear.

3.

4.

Note—When all wiring and piping connections are complete 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. NOTE—The 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

5.

6.

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). Press CRANK ON BATTERY 1 pushbutton, 1PB. a. Engine contactor C1 (Caterpillar engines, MS1) energized. b. Engine starter energized. CAUTION—Engine starting motor may be damaged due to excessive continuous cranking. Limit continuous cranking time to fifteen (15) seconds. Allow at least fifteen (15) seconds rest before attempting to re-crank. NOTE—Ammeter 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. Cease cranking when engine runs. a. Engine running contact closes energizing engine running relay, ERR and low oil pressure timer on PC-1028. 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. CAUTION—Low Oil Pressure condition outlined above may result in engine damage. IMMEDIATELY place the selector switch in the OFF position. DO NOT RUN ENGINE until problems have been resolved. 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. Manual start on battery—2. a. Repeat steps 1—5 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 energized. b. Switch mis-set remote alarm contacts deenergized. 8. Push TEST pushbutton on controller inner door and hold depressed until engine starts and runs.

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NOTE— Pressing this button energizes the solenoid 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 requirements 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 energize: 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 battery—1 and battery—2. 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 remaining 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. CAUTION—An 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. CAUTION—An engine running with a high temperature 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

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18.

19.

20.

21. 22. 23.

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. Weekly test timer—Operation 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. 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. 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. Shutdown by engine overspeed requires manual reset of the engine overspeed switch. See Step 17. Shutdown by low oil pressure and high temperature would be voided by any other demand for engine run operation. Interlock shutdown—Opening of the interlock contacts will disable all automatic starting and automatic running functions but will not affect manual start or manually started running functions.

SHUTDOWN—OTHER 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 deenergizes, 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. SHUTDOWN—CATERPILLAR 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-OFFAUTO 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. OVERSPEED—SHUTDOWN 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.

Publication NS1100-05 Rev. G (06/00)

General Information Typical Pressure Sensing Line Connection Fire Pump Controllers & Jockey Pump Controllers

Pump Controller

Pressure Sensing Device

Flow

Flow

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. Fire Pump Controller

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

FIRE PROTECTION SYSTEM

Jockey Pump

Jockey Pump Controller

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.

Publication GF100-30 (02/97)