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SPU Operating and Maintenance Manual

SPU
Operating and
Maintenance Manual
Document number P31000 (27 Jan 2004)

Marioff Corporation Oy, P.O. Box 86, Virnatie 3, FIN-01301 Vantaa, Finland,
tel +358 9 870 851, fax +358 9 8708 5399, e-mail info@marioff.fi, www.hi-fog.com

Document number P31000 I


SPU Operating and Maintenance Manual

Terms and conditions


Marioff cannot be held responsible for the safe and efficient operation of the system and its components if it has not been
installed and set up in accordance with the instructions given in the Installation Manual and operated and maintained in
accordance with the instructions given in the SPU Operating and Maintenance Manual (this manual).

In addition, Marioff cannot be held responsible for the safe and efficient operation of the system and its components if
unauthorised modifications have been made or service has been carried out by unauthorized persons.

Marioff Corporation Oy reserves the right to revise and improve its products and recommended system configurations as
it deems necessary without notification. The information contained herein is intended to describe the state of HI-FOG
products and system configurations at the time of its publication and may not reflect the product and/or system configurations
at all times in the future.

II Document
number P31000
SPU Operating and Maintenance Manual

Contents
1. Introduction .................................................................................... 1
1.1 Associated documentation ........................................................................... 1
2. Warnings and precautions ............................................................ 2
3. General SPU description ............................................................... 3
3.1 Unit Description ............................................................................................ 3
3.1.1 Main parts .................................................................................................... 4
3.1.2 Main Controls ............................................................................................... 5
3.2 Operating description ................................................................................... 6
4. Operating Instructions ................................................................... 7
4.1 System in stand-by mode ............................................................................ 7
4.2 Start.............................................................................................................. 7
4.2.1 Automatic start ............................................................................................. 7
4.2.2 Manual start – remote .................................................................................. 7
4.2.3 Manual start – local ...................................................................................... 8
4.3 Pump unit in operation ................................................................................. 8
4.4 Stopping and resetting the system ............................................................... 8
4.5 Clearing up after system operation .............................................................. 9
5. Service and Maintenance ............................................................ 10
5.1 Inspection and maintenance frequencies .................................................. 10
5.2 Inspection and maintenance procedures .................................................... 11
5.2.1 Check the valve positions ...........................................................................11
5.2.2 Check the stand-by pressure and pump operation .....................................11
5.2.3 Check the electric supply, test lamps ......................................................... 12
5.2.4 Visually inspect the pump unit and its fittings ............................................ 12
5.2.5 Check the oil level of the pumps ................................................................ 12
5.2.6 Check the drive chains and flexible coupling ............................................. 13
5.2.7 Check air pressure regulator and empty water lock .................................. 14
5.2.8 Check the water filter and separator .......................................................... 14
5.2.9 Check breather cap filter ............................................................................ 16
5.2.10 Test run the unit ....................................................................................... 16
5.2.11 Check the pump unit batteries and charger ............................................. 17
5.2.12 Clean and check setting values of the pressure and flow switches and ......
transducers ............................................................................................... 17
5.2.13 Test unit is accordance with the commissioning instructions ................... 17
5.2.14 Change pump oil ...................................................................................... 18
6. Trouble shooting .......................................................................... 19
Appendix A - Spare parts ................................................................. 21
Attachment ........................................................................................ 22

Document number P31000 III


SPU Operating and Maintenance Manual

IV Document
number P31000
SPU Operating and Maintenance Manual

1. Introduction
This manual describes how to operate and maintain the
HI-FOG Sprinkler Pump Unit (SPU). This manual de-
scribes the SPU at a general level and the illustrations
in this manual may not reflect exactly the SPU model or
version supplied.
The diagrams and parts lists supplied with each unit are
specific for the supplied unit.

Any changes made to the system or its equipment must


comply to the above requirements and must only be
carried out with the written consent from Marioff Corpo-
ration.

A general system layout is included in this manual as


an attachment. Refer to the diagram specific for your
system for more detailed system information.

1.1 Associated documentation


- High pressure plunger pump operating instructions

- Stand-by pump operating and maintenance instruc-


tions

- Data sheets for specific units as applicable

- Hydraulic diagrams and parts lists for specific unit

- Electric diagrams and parts lists for specific unit

- Dimensional drawing for specific unit

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SPU Operating and Maintenance Manual

2. Warnings and precautions


- CAUTION
The HI-FOG SPU produces high-pressure water when operating. To avoid
injury to personnel and/or damage to equipment always follow the safety pro-
cedures described in this manual and required by local and/or national authori-
ties.

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

- Only personnel who are appropriately trained are permitted to work on, test
and service the SPU, the sprinkler system and its associated equipment. In
case of doubt, contact the nearest Marioff representative!

- Check, test and service the SPU in accordance with the testing and servicing
instructions in this guide.
FAILURE TO CHECK, TEST AND SERVICE THE SPU IN ACCORDANCE
WITH THE INSTRUCTIONS GIVEN IN THIS GUIDE CAN JEOPARDIZE THE
RELIABLE OPERATION OF THE SYSTEM

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


MARIOFF.

- If the SPU is switched off for maintenance or some other reason, take ad-
equate fire precautions, according to your safety procedures, to cover the
period that the SPU is out of operation.

- NOTE! If the system includes a water cylinder accumulator, it will be released


if the SPU main switch is turned off, when the system is activated. Before
carrying out any service, testing or maintenance work, remove the plug from
the accumulator release valve to avoid unintentional release. Remember to
replace plug.

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SPU Operating and Maintenance Manual

3. General SPU description


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

The SPU consists of the following main parts:


- one or more pump modules (the number will de-
pend on the SPU installed, refer to the system
specifications).
Each pump module consisting of one 3-phase
electric motor, two plunger pumps and two un-
loaders

- an electric control and monitoring system (relay)

- a break-water tank
NOTE: Units may also be supplied without a break-
water tank

- a separator (optional) and filter in the inlet from the


water feeding system

- a pneumatic stand-by pump


Power is supplied to the SPU either from the Main
Switch Board (MSB) or the Emergency Switch Board
(ESB). The switching between the MSB and the ESB is
done automatically.
A feed pump or hydrophore supplies fresh water to the
SPU. In addition to the fresh water inlet the SPU may
be connected to a fire main or another water source for
redundancy.

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SPU Operating and Maintenance Manual

3.1.1 Main parts

Arrangements vary per model - refer to labels.

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3.1.2 Main Controls


The illustration shows the SPU 5 type

Manual start switch, lamp and motor ampere meter (x 5)

1 2 3

4 5 6 7

8 9 10 11

1. Main Switchboard Power


supply indication lamp

2. Emergency Switchboard
Power supply indication lamp

3. 230 VAC control voltage fault

4. Control system on lamp Main power switch

5. 24 VDC power supply failure

6. 24 VDC earth fault


Optional fresh water feed pump manual start
7. Reset switch and lamp switch, lamp and motor ampere meter

8. Pump unit fault

9. Out of water

10. Nitrogen pressure low

11. Lamp test push button

Arrangements vary per model - see labels on lamps/switches.

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SPU Operating and Maintenance Manual

3.2 Operating description


Standby mode = normal mode when the system is on.
In normal use the system MUST always be in the
standby mode

Operating mode = the system is activated

Off = system shut down for maintenance/repair

A pressure of 25 bar (or other system specific set value)


is maintained in the system when it is in the standby
mode.
A fire will cause the heat-sensitive bulbs on one of more
sprinklers to break.
Alternatively, section valves are opened and water will
start to flow from the released spray heads.
The flow monitor will detect the flow and start the SPU.
A pressure switch will start the SPU if the flow monitor
malfunctions.
The SPU can also be started manually, either locally by
turning the start switch(es) on the control cabinet, or
remotely by sending a start signal to the control cabinet.
When the SPU is activated, the pump modules are
automatically started in sequence, with a few seconds
delay between each start, in order to reduce electric
peak loads. If the flow of water required is less than the
output of the unit, the un-loader valves open and route
extra water back to the break tank.
High-pressure water will now be fed to the HI-FOG
system forming the HI-FOG mist.
After the SPU has been stopped it must be reset. The
stabilisation phase takes a few minutes, during which
the system pressure drops to the stand-by level and
then the unit returns to the standby mode.

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4. Operating Instructions
4.1 System in stand-by mode
In normal use the system MUST be in the stand-by
mode. The system is in the standby mode when:
- the SPU is connected to the electric supply and the
main power switch is on

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


pump is operational

- the system pressure is within the set limits

- the control system is operational

- the piping is sound and tight (see Installation


Manual)

4.2 Start
4.2.1 Automatic start
The SPU will automatically start to operate if it detects a
water flow and/or if the water pressure drops below 17
bar for more than 10 - 20 seconds (depending on sys-
tem size).

The redundant motor, if supplied, will automatically start


if one of the motors does not start or stops operating.
To stop the unit press and hold the “RESET” button for
one (1) second. Make sure that there is no fire before
stopping the unit. If there is still flow in the system after
the reset period the unit will restart (see section 4.4) -
isolate the sections where there is flow.

4.2.2 Manual start – remote


Push the emergency start button on the remote control
panel (if provided) to start the SPU. Push the emer-
gency start button a second time to stop the pump.
The unit must be reset after this. See section 4.4.

4.2.3 Manual start – local


Turn the pump activation switches in the pump unit
control cabinet to the ”1” position to switch the pumps
on.

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SPU Operating and Maintenance Manual

Stop the pumps by turning the switch to ”A” position.


The pump must be reset after this. See section 4.4.

NOTE
Starting the pump with these switches will override all
other protection. Before carrying out a local manual
start, check that no fault alarms are on.

4.3 Pump unit in operation


When the pump unit has received a start signal it will
maintain the required pressure and flow in the system
until a stop signal is given or the pump runs out of
water.

The low level switch in the break tank or a pressure


switch in the feed water line will prevent the unit from
starting, or will stop the motors to prevent them from
running dry. When the redundancy source of water (if
applicable) has been connected and/or the break tank
has been refilled, the pumps will restart automatically.

If the “HI-FOG activated” mode is on and the pressure


drops below 30 bar for 15 seconds, or if there is a
power cut, or if the motors cannot be started for some
other reason, a signal is automatically given to release
the water accumulator unit (if fitted).

4.4 Stopping and resetting the system


Make sure that there is no fire before stopping the unit.
Make sure that any released sprinklers/spray heads are
isolated and the section valves are closed so that there
is no flow into the HI-FOG system.

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Press and hold down for one (1) second the “RESET”
button on the pump unit or, if fitted, on the release or
mimic panels. The pump motors will stop (if started
automatically), the stabilisation valve will open (de-
creasing the system pressure) and the alarms will clear.

The stabilisation valve will close when the pressure in


the system drops to 22 bar. After that, the stand-by
pump in the pump unit automatically increases the
pressure in the system to the 25 bar stand-by pressure.
Restart is prevented during the stabilisation period
(RESET light flashing). When the reset phase is com-
pleted the pump automatically switches to the stand-by
mode.

The water discharge from the SPU can also be stopped


by closing the ball valve located on the unit, but this is
only recommended in the case of unintentional release.
This action will not stop the motors.

Standard vessel systems will not reset properly unless


the system pressure has reached 130 bar. The pump
unit must be run until the pressure has risen above this
point before resetting the system by pressing the
“RESET” button for one second.

Resetting after a “Manual emergency start” (manual


start - remote):

- The pump must be shut down by pressing the same


“EMERGENCY START” button that was used to
start the system.
- The system must then be resetted by pressing the
“RESET” button for one second.

4.5 Clearing up after system operation


If sea water or a similar redundancy source was used,
the complete system must be flushed with fresh water.
The pump must be run manually for a period long
enough to remove ALL the sea water from the pump
unit, the break water tank and/or the system piping. The
water filter cartridge must be changed, too.

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SPU Operating and Maintenance Manual

5. Service and Maintenance


5.1 Inspection and maintenance frequencies

Annually
Monthly
Weekly
No Action

*
5.2.1 Check the valve positions X X X X
5.2.2 Check the stand-by pressure and pump X X X X
5.2.3 Check electric supply, test lamps X X X X
5.2.4 Visually inspect unit and its fittings X X X X
5.2.5 Check oil level of the pumps X X X
5.2.6 Check the drive chains and flexible coupling X X X
5.2.7 Check air pressure regulator and empty water X X X
lock
5.2.8 Check water filter and separator X X X
5.2.9 Check breather cap filter X X X
5.2.10 Test run the unit X X X
5.2.11 Check pump unit batteries and charger X X
5.2.12 Clean and check the setting values of the X
pressure and flow switches and the transducers
5.2.13 Test unit in accordance with the commissioning X X
instructions
5.2.14 Change pump oil every 2 years or 200 hours X

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

5.2 Inspection and maintenance procedures


This section describes how to carry out the inspections
and maintenance listed in the above table.

Treat as urgent, the notification of any factors liable to


have a detrimental effect on the performance of the
pump unit or the HI-FOG system.

Refer to the respective manufacturers instructions (as


delivered with the system) for more specific information.

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5.2.1 Check the valve positions


In stand-by and operating modes the valves must be in
following positions:
- OPEN, the outlet valve to the sprinkler system

- CLOSED, the test valve

- OPEN, the fresh water supply valve

- OPEN, the air inlet to the stand-by pump

- CLOSE, sea-water / redundancy water valve

- CLOSE, drain valve.

5.2.2 Check the stand-by pressure and pump


operation
Check that the stand-by pressure in the system is set to
the correct level (25 bar, if not otherwise stated) and
ensure the stand-by pump does not start running too
often (if it does it indicates that there is leakage in the
system). A faulty stand-by pump must be replaced with
a new one.
For maintenance and overhaul refer to the manufactur-
er’s operating and maintenance instructions.

5.2.3 Check the electric supply, test lamps


Make sure that the SPU is receiving power.

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SPU Operating and Maintenance Manual

5.2.4 Visually inspect the pump unit and its


fittings
Make sure that there is no water or air leaking from the
system. Make sure that all fittings are tight. Report all
abnormal wear and tear, damage, etc.

5.2.5 Check the oil level of the pumps


The oil level shall be at the mid-level of the sight glass.
If it is below this level, add more oil. The oil should be a
clear golden brown. If the oil is dirty, cloudy or grey
when the unit is in the stand-by mode, it must be
changed.
(Note the oil will appear cloudy when it is in the opera-
tion mode).
See the manufacturer’s pump operating instructions.

Sight glass

Correct level Refill

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SPU Operating and Maintenance Manual

5.2.6 Check the drive chains and flexible


coupling
SWITCH THE UNIT OFF!
MAIN SWITCH OFF AND SECURED BEFORE

!
CAUTION
REMOVING THE COVER!

The chain must be well greased. If the chain is dry or


rusty, grease the chain using Shell Kuggfett or an
equivalent molybdenum-graphite based grease with
heat resistance up to +200°C and good adhesion capa-
bility.

Cover
Chain

Flexible coupling

Check also the condition of the flexible couplings. A


slight amount of wear is normal - if any signs of
excessive wearing are shown, the coupling must be
changed.

The chain and coupling can be changed by removing


the electric motor (make sure that the pump unit is off
before starting this job).

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SPU Operating and Maintenance Manual

5.2.7 Check air pressure regulator and empty


water lock
Check for leakages and make sure that the stand-by
pressure is maintained at 25 bar (or other system spe-
cific set value).

5.2.8 Check the water filter and separator


Replace the filter annually or if it is dirty.
1. Close the water intake valve

Cover 2. Open the drain plug and allow the water to drain out

3. Open the filter cover and pull out the filter cartridge
and check it visually; change if contaminated

4. Check the by-pass valve.


If it is open, the upper extension spring is not
around the upper guide sleeve, it must be closed,
see “Resetting the by-pass valve” below.
Filter
5. Reinstall or replace the filter cartridge

6. Close the drain plug on the filter

7. Carefully open the water intake valve


Note: on some models the filter tube is glued to the
cover, i.e. it opens at the filter base.

Drain plugs
(underside)

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SPU Operating and Maintenance Manual

Resetting the by-pass valve


If the by-pass valve is closed the extension spring will
be positioned around the upper guide sleeve.
By-pass valve closed

Extension spring

Upper guide sleeve

If the by-pass valve has opened the extension spring


By-pass valve open will not be around the upper guide sleeve.

Extension spring

It must be repositioned. To do this:


By-pass screws - remove locking wire from by-pass screws.
- loosen the by-pass screws
- remove the upper extension spring
- tighten the by-pass screws
- install the locking wire
- reinstall the upper extension spring around the upper
guide sleeve.

Visually examine the separator (if fitted). Ensure the


purging orifice at the bottom of the separator is open.

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SPU Operating and Maintenance Manual

5.2.9 Check breather cap filter


Check the breather cap filter on top of the break water
tank. Replace every second year or if it is dirty.

5.2.10 Test run the unit


Start the pump unit locally, remotely or automatically.
Vary the way of starting occasionally to ensure that all
the starting modes work.
When testing locally, the pressure start is tested by
closing the air supply to the standby pump and fully
opening the test valve. The flow switch start is tested by
slowly opening the test valve so the pressure does not
drop below 17 bar (or the set value).

NOTE 1
Starting the pump with the manual switches on the
starter cabinet will override all protections. Make sure
that there is water and that no fault alarms are on.

NOTE 2
If a water accumulator unit is fitted, remove the plug
from the solenoid release valve or close the gas cylin-
der valves to prevent unintentional release. Remember
to reset the accumulator unit after testing.

Make sure that the unit starts to supply water at full


working pressure after a short delay. Make sure that all
motors and pumps are running (except the redundancy
module, if supplied).
If the redundancy module is supplied, test it by opening
the control fuse (F x.1) of one of the running motors.

Reset the unit after testing by pressing the reset button


(close test valve and open outlet valve if opened/
closed). Check that the pressure in the system returns
to the 25 bar standby pressure after a few minutes.
Check that the whole system is reset and operational.

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5.2.11 Check the pump unit batteries and charger


Ensure the charger output voltage is 27.3 ... 27.7 V at
the battery. Check the battery capacity with a suitable
charge condition meter.
The batteries must be replaced every three (3) years, or
more often if the battery is faulty, or the unit is subjected
to vibration, large temperature variations or other sever
environmental conditions.

5.2.12 Clean and check setting values of the


pressure and flow switches and transducers
Check the settings of pressure switches, -transducers
and flow switch. If the switching points have changed
regarding the set point, adjust the point to original. If
necessary, clean the sensor tip with a soft cloth. Build-
up adheres (e.g. lime) can be removed with common
vinegar cleansing agent. Do not scratch the surface to
avoid problems in the future.

5.2.13 Test unit is accordance with the


commissioning instructions
The commissioning record provided with the system
acts as an instruction as well. It is recommended this
job is carried out by a Marioff authorised service engi-
neer.

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SPU Operating and Maintenance Manual

5.2.14 Change pump oil


Also refer to paragraph 5.2.6 and the Speck-Triplex-
Plunger pump operating instructions.

The oil must be changed every 2 years or after 200


running hours, whichever comes first. With NEW sys-
tems the initial oil must be changed after 50 running
hours (or 2 years), whichever comes first. Use an ISO
VG 220 or SAE 90 class gear oil.

Oil fill plug

Oil drain plug

Oil fill plug

Oil drain plug


(underside)

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6 Trouble shooting
FAULT REASON REMEDY
General
Unit will not start No electric supply Connect supply
No control voltage Connect supply
No water Ensure feed water availability
Stabilisation phase on Wait for completion of
stabilisation phase
Stabilisation phase not Check reason and rectify.
completed for > 5 min, see Contact Marioff if problem
below persists
Unit starts Pressure switch SP27 faulty or Adjust or replace pressure
unintentionally incorrectly adjusted switch (must be correctly
adjusted, contact Marioff)
Flow switch SP29 faulty or Adjust or replace flow switch
incorrectly adjusted (must be correctly adjusted,
contact Marioff)
Small leakage in system Ensure system is tight
False start signal Check system wiring and
signals
System pressure drops due to Ensure system is tight. Check
system leakage or standby air supply to stand-by pump.
pump problem Check pump, clean and
grease (refer to
manufacturer’s instructions.
Replace if faulty
Water accumulators Operational fault caused by The water accumulator will
released unintentionally • opening main switch (control release if the start signal is on
(if fitted) voltage still on, start signal and the pressure stays below
active, pressure decreasing 30 bar (or set value) for more
=> water accumulator than 15 seconds (or set
released) value). Before testing or
• test valve kept open so that servicing the unit the water
pressure stays below 30 bar accumulator solenoid valve
for more than 15 seconds should be disconnected
Pressure switch SP25 faulty or Adjust or replace pressure
incorrectly adjusted switch (must be correctly
adjusted, contact Marioff)
Stabilisation phase not Pressure switch SP28 faulty or Adjust or replace pressure
completed incorrectly adjusted switch (to be correctly
adjusted, contact Marioff)
Stabilisation valve faulty Replace valve
Stand-by pump striking Small leakage in system Ensure system is tight
frequently
Fuses blown Establish reason for disengaged If problem rectified or reason
fuses – and rectify. not found – re-connect. If
problem persists, contact
Marioff

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SPU Operating and Maintenance Manual

FAULT REASON REMEDY


Alarms given
Nitrogen pressure low Pressure in nitrogen cylinders Refill / replace nitrogen
(if connected to water below alarm set value cylinders
accumulator unit)
Alarm circuit cut Re-connect
Battery charger fault No power supply to the charger Reconnect supply
or unit
Faulty charger Replace
230 VAC control voltage No voltage in transformer T 0.3 Check power supply and fuse
fault (F10)
Faulty transformer Replace
Earth fault (24 VDC) + or – in contact with “ground” Find contact point (by
opening fuses, disconnecting
panels, etc. that causes earth
fault) and rectify
Circuit breaker released Overload or short circuit in If problem rectified or reason
electric coupling not found – re-connect. If
problem persists, contact
Marioff
Out of water Water in break tank below “low Make sure there is a feed
level” (or feed water pressure water supply
low in unit without tank)
Tank low level switch faulty or Rectify or replace
stuck
NOTE! If this happens in an emergency and it is certain that all
valves to fresh water supply are open, switch over to the
redundant water source (sea water or equivalent)
Pump unit fault Common alarm given in See above
combination with one of above
OTHER FAULTS Reason cannot be found Contact Marioff for
assistance or advice

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Appendix A - Spare parts


Description Type Code Stock Code
Pump NP25/41-140 right E 02052
Pump NP25/41-140 left E 02050
Pump NP25/50-140 right E 02056
Pump NP25/50-140 left E 02055
Electric motor See nameplate Voltage,
frequency, power
Drive chain Chain D501 l 42 E04097
Drive clutch (original red or white) 42/64 SH Clutch E04019.1
Drive clutch (original green) E04019
Pressure switch (monitoring) PN3021 0-250 Bar M23065
SP 27 & SP 28
Pressure switch (release signal) PN5021 0-250 Bar M23064
SP25
Break water level switch A01090 Besta M22125.1
Water filter cartridge E32005
Breather cap filter BFP7610W1.0 E05085
Flow monitor SID10ADBFPKG/U M21010.1
S-100-I PF
Stand-by pump M8 LVE E40005
Other parts are available upon request.

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SPU Operating and Maintenance Manual

Attachment
Typical HI-FOG fire protection system

pressurised air
Connection to
pump 25 bar
Pneumatic
stand-by

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SPU Operating and Maintenance Manual

This sheet is for personal notes.

Document number P31000 23


SPU
Operating and
Maintenance Manual
Document number P31000 (27 Jan 2004)

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