Operations and Maintenance Manual FLA Fire set Plant

DAYLIFF FLA FIRE PUMP SETS INSTALLATION, OPERATION

&
MAINTENANCE INSTRUCTIONS

Version 1:Dayliff FLA©9-2017

Dayliff FLA Fire Set September 2017

 Operations and Maintenance Manual FLA Fire set Plant

Table of Contents
1 PREFACE ................................................................................................................. 1
2 INTRODUCTION ...................................................................................................... 2
2.1 Application.......................................................................................................... 2
3 INSTALLATION ........................................................................................................ 3
3.1 Unpacking .......................................................................................................... 3
3.2 Location ............................................................................................................. 3
3.3 Positioning (Foundation) .................................................................................... 3
3.4 Pipe Work........................................................................................................... 4
3.5 Power Supply ..................................................................................................... 4
4 OPERATION............................................................................................................. 5
4.1 Principle of Operation ......................................................................................... 5
4.2 Dayliff FLA Controls ........................................................................................... 6
4.2.1 Control Panel ............................................................................................... 6
4.2.2 Panel Connection ........................................................................................ 7
4.3 VT Type Pressure Tanks ................................................................................... 8
4.4 Pressure Transducer .......................................................................................... 8
4.5 Initial Start-Up .................................................................................................... 9
4.5.1 Priming ........................................................................................................ 9
4.6 Start Up .............................................................................................................. 9
5 MAINTANANCE...................................................................................................... 10
6 TROUBLE SHOOTING ........................................................................................... 11
6.1 Priming Checks ................................................................................................ 11
6.2 PLC (HMI) Interface Checks ............................................................................ 12
7 SPARE PARTS LIST .............................................................................................. 13
8 RETURN GOODS AUTHORIZATION PROCEDURE ............................................ 14
9 TERMS OF WARRANTY ........................................................................................ 15
9.1 General Liability ............................................................................................... 15
9.2 New Equipment ................................................................................................ 15
9.2.1 General Terms ........................................................................................... 15
9.2.2 Electric Motors ........................................................................................... 16

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9.2.3 Water Pumps ............................................................................................. 17

9.3 Equipment Repairs........................................................................................... 17
9.4 New Installations .............................................................................................. 17
9.5 Proof Of Purchase............................................................................................ 18
10 OPERATING AND CLEANING LOGS................................................................. 19
Appendix A: Assembly drawing ..................................................................................... 20

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List of Figures
Figure 1: Terminal Block Connection ........................................................................................ 8

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List of Tables
Table 1: Dayliff FLA fire pump sets and Specifications .............................................................. 6
Table 2: Pressure Settings ........................................................................................................ 8
Table 3: Dayliff Products Standard Warranty Periods ...............................................................15

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1 PREFACE
Congratulations for purchasing a Dayliff FLA fire pump set. For all firefighting
applications, high levels of equipment performance and dependability are vitally
important for the protection of both lives and property. Dayliff FLA Fire pump Sets
combine quality components, all carefully matched for optimal operational efficiency
with Davis & Shirtliff unmatched pumping expertise and competitive pricing to provide
effective, reliable and easy to install firefighting solutions.

The Dayliff FLA Fire pump Set has been assembled to the NFPA standards and
guarantee a long, trouble free service, though in order to optimize efficiency and
longevity it is important that it is properly installed, operated and maintained.

This manual is a guide to establishing installation, operation and maintenance

procedures. IT IS THEREFORE IMPORTANT THAT MAINTENANCE PERSONNEL
REVIEW THESE INSTRUCTIONS CAREFULLY BEFORE INSTALLATION AND USE.

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2 INTRODUCTION
Application
A large building or a factory requires some kind of fire protection. In most cases, the
public water supply cannot provide enough volume and/or pressure which necessitates
fire pump installation to curb against any fire that might occur within the buildings.
The DAYLIFF FLA Fire pump set has been purpose designed to provide automatic
supply to multiple hose reel or sprinkler outlets for firefighting installations. Standard
sets combine parallel duty diesel and electric powered supply pumps to ensure
serviceability in all conditions as well as a jockey pump to maintain system pressure.
Particular features include:-
 Individual electric motor and diesel engine powered Dayliff DE pump sets
providing standby supply in the event of electrical power failure.
 Separate automatic jockey pump to maintain system pressure and regulate main
pump operation.
 A Pressure transducer to control operations in a progressive jockey pump,
electric pump and diesel pump starting at reducing cut-in pressure.
 Low maintenance diaphragm type pressure vessel to regulate pump cycling.
 Integral control panel providing automatic operation of the supply pumps and
incorporating electrical protection and a DC battery charging.
 Compact frame mounted design incorporating necessary valves and piping for
simple site installation.
Systems are designed to give their rated output at 5 Bar and the standard sizes
available are 40, 60, 100 and 120 m3/hr with the two pump sets operating in parallel,
50% standby output being provided in the event of electrical failure. For particular
applications, special designs incorporating different equipment arrangements and
specifications are available.

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3 INSTALLATION
Unpacking
When a DAYLIFF FLA Fire pump set is delivered to the jobsite, it should be checked
thoroughly to ensure that all required items have been received (as per the packing list)
and that the FLA fire pump set is free of any damage prior to signing the delivery notes.
Location
Before locating the groups of pumps ensure that the room is:-
 Exclusively designed for fire-fighting systems, should have a direct access from the
exterior and should have a fire resistance not less than 60 minutes.
 The room should be in order of preference as follows:-
a. Separated (isolated)
b. Adjacent
c. Within the building but protected by the system.
 Temperatures inside the room should never be less than 100C (40C if there are only
electrical pumps) or higher than 250C (400C if there are only electrical pumps)
 The pump room should also be provided with openings towards the exterior to
guarantee an adequate ventilation to cool the pump drivers.
 Also provide a pipe work for exhaust emissions from the engine. Note that two
pumps may operate together for in time of high demand.
 A safety valve is fitted on the outlet manifold. This valve will open when system
pressure exceeds 8bars. For this reason you are required to connect the outlet
of the safety valve back to the water reservoir to avoid spillage in the plant
room.
 Provide drainage to let water flow out of the room or into a pump well (containing a
drainage pump) to prevent any possible flooding.
Positioning (Foundation)
The ideal positioning can be obtained by fastening the base on a well leveled firm plinth
using steel bolts. Ensure that the frame is level horizontally. The group of pumps should
be positioned inside the pump room such that there is a free space between the group
and the wall or doors is 1m on each of the four sides.

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Pipe Work
The suction and discharge pipes are connected directly to the respective terminations
on the manifolds. Ensure that the pipes are of adequate size and that the levels are
correct such that unnecessary stress is not imposed on the manifolds when tightening
the unions. Use anti-vibrating joints on the suction and delivery pipes to limit stresses
due to vibrations on the pump body and on the tank walls.
Power Supply
The power supply for the control panel of the fire-fighting pumps should be taken
directly upstream the main switch of the power supply to the building. All cables should
be sized at 150% of the maximum possible current at full load and should be protected
against fire or mechanical damages i.e. pass the cables in cable ducts/cable baskets
interred outside the building or through parts of the building where chances of fire is
negligible. The cable should be of single section without junctions.
Electrical connection in the main panel should be such that the power to the fire-fighting
panel is not isolated when the other services are isolated.
Power supply to the firefighting pumps should only be electrically protected against
short circuit, over current and against direct contacts. They shouldn’t be
protected against overload.

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4 OPERATION
Principle of Operation
The Dayliff FLA fire pump set is assembled for duty/standby operation, and provides for
sequential operation of the three pumps, the jockey pump operates at low demands; the
main pumps (2NO.) operate at higher demand levels. The engine pump operates at
high demand levels (especially in places without power or in times of electrical power
loss). The jockey pump and the main pumps are interlocked, meaning that when either
or both the main pumps are operating then the jockey pump stops.
Under normal operations, the jockey pump will be in operation to top up any pressure
deficit in the system (e.g. due to leaks in the line). It will also be able to supply water to
a single hose reel during cleaning operations. The cut in and cut out pressures of this
pump has been set to allow it to operate at low demand.
When there is no water demand all pumps will eventually cut-out and the system will
remain pressurized at the upper cut-out pressure.
In the event that there is a high demand for water, pressure in the pipeline will drop and
as soon as it gets to the cut-in pressure of the main electrical pump, the system will start
immediately.
If the demand for water continues to grow beyond what the main electrical pump can
offer (as in the case of a fire break out), pressure in the pipeline will continue to drop
and as soon as it gets to the cut-in pressure of the Engine Pump, the engine pump will
start immediately. This automatic starting will only occur if the pump selector is on auto
position on the panel.
Please note that the battery should be checked regularly and the engine cranked
periodically (at least 5mins after every 7 days) to ensure a smooth start. (Engine set to
automatically start every Wednesday 12.45 – 12.50pm) – Water may gush out through
the safety valve during this self-test.
In the event that the demand for water drops, the engine pump and the main electric
pumps will continue to run until their cut-out pressures (5 bar) is achieved.
Terminals for a low-level float switch are provided in the control panel. A float switch
should be installed on the supply reservoir for low level protection and connected to the
respective terminals. The switch will stop pump operation if the water level in the

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reservoir falls to a preset low limit in order to protect the pump from "dry running". The
level differential for float switch operation should be set such that pump operation is
inhibited until the reservoir has been refilled to over 30 cm above the preset low level.
The low limit must be set to ensure that the pump does not run dry.

Correct operation of the fire pumps is indicated when, after closing the main delivery
ball valve, the pumps switch off automatically when the system has pressurized to the
set cut out limits. Should there be no strong flow of water when opening a tap on the
outlet pipe work close to the set, or if the pump does not switch off automatically after
the main valve has been closed, refer to the section headed "Fault Finding".
Dayliff FLA Controls
The control panel can be mounted on a frame on the base frame or to the wall in the
pump house. Manual and automatic (pressure controlled) operation of the pumps is
available.

Table 1: Dayliff FLA fire pump sets and Specifications

4.2.1 Control Panel

The panel comprises of a three control panels for the electrical motor, the jockey pump
and the engine. Terminal blocks for dry run protection, oil pressure switch and pressure
transducer, battery charger, 12V DC. The wiring diagram is provided inside the control
Panel.
Key external components are as follows:
1. PLC HMI (Human Machine Interface): The PLC display must be powered at all
times. This is through batteries provided on the fire set and it ensures that PLC
remains ON to monitor the controls when there’s a power loss. On start up the HMI
will display depending on the condition at hand.

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Refer to the PLC HMI in appendix

2. Main Isolator: The isolator controls the main power supply to the panel. The Panel
‘Live’ Indicator lamp will show if the panel is energized. It is VITAL to ensure that the
isolator is switched OFF whenever the panel door is opened.
3. Auto/Off/Manual Switch: Three - three position switches which selects either
automatic mode, OFF or on manual Mode. For the electric pump, Auto ensures that
the pump is operated by the pressure transducer or Manual mode for continuous
operation by-passing the pressure transducer, or "OFF". The pressure transducer
and the pressure gauge are mounted on the pressure tank or on the discharge
manifold.
For the Engine Pump, Auto will allow the Engine pump to start immediately the pressure
drops to the cut-in pressure while in the Hand mode, one can start the Engine manually
using the manual start button on the panel or using the ignition key provided. On this
mode, if the electric switch was not in operation, there is also a handle provided to crank
the engine.
The HMI displays operations that are current. E.g. Engine cranking, Trip due to overload
etc.
Inside the control panel the following components are provided:
It is VITAL to ensure that the isolator is switched OFF whenever the panel door is
opened.
4. Contactors: The starters are provided with thermal overload protection. The
settings should not under any circumstances be changed from the set values.
5. Grid Charger & control: This converts grid AC power to DC power. The power then
charges the battery through the charge control.
6. Control fuses: A 2A fuse is provided for the control circuit. Terminal Block: The
cables for pressure transducer, the float switch (for low level protection) and power
cables to the pumps are terminated at the terminal block as marked on the circuit
diagram.

4.2.2 Panel Connection

NOTE: When connecting batteries, pull out the relays from their sockets and
disconnect the fuse.

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REM: Push the relays into their sockets and connect the fuse after wiring correctly.

Figure 1: Terminal Block Connection

VT Type Pressure Tanks
The installation is equipped with one diaphragm type pressure cylinder of 300 litre
capacity, to control pump cycling.
NEVER pressurize the tank in excess of 8.0 Kg/cm2 (115 psi).

The air valve accepts a standard motor car type gauge for checking pre-charge pressure.
Refer to Section 4.3 for pre-charge pressure specification.
Pressure Transducer
The pressure transducer is rated at 9-28V and 4-20mA. Range and differential settings
are stored in the PLC that controls the whole system. Adjustment of the system's pressure
is not necessary for normal operation as they have been preset at installation to
operate as shown in the Table 2.
Table 2: Pressure Settings
PRESSURE SETTINGS
Cut-in, Cut-out, Pre-charge,
bar bar bar
JOCKEY 3.5 5.0 3.35
ELECTRICAL 3.0 5.0 N/A
DIESEL 2.5 5.0

Please note that the above settings may change on site. Should that be
done, the pre-charge pressure must be 0.15bar below the cut-in pressure
of the lowest pump.

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Initial Start-Up

4.5.1 Priming
Do not start the pump(s) until the suction line has been initially filled with
water
On initial start-up or after any maintenance it is vital to ensure that the pump is properly
primed before re-starting.
Start Up
1. Ensure that the ball valves for the suction, main delivery and the pressure tanks
are open.
2. Switch ON the main isolator and ensure that there is power at the control panel.
Ensure the Engine pump is switched OFF. On start up the HMI will display as:
a. Davis & Shirtliff Fire Set when power supply is healthy.
b. Phase failure when there’s a power/phase loss. This condition is also visible
when the phase sequence is wrong
c. Engine requires service. After 250hrs of engine operation the engine need
to be serviced. To reset press “0” on the keypad.
If condition a. is true proceed by switching on the pumps appropriately otherwise
act to the message.
Refer to the PLC HMI in appendix 1
3. Switch ON the Electric pump by selecting "AUTO" or "MANUAL”.
4. In "AUTO" mode the electric pump will operate until the cut-out pressure is reached
on the discharge side or until the pump is switched off manually. On “MANUAL”
the respective pump will operate continuously till switched OFF manually.
5. To manually switch OFF the electric pump, turn the MANUAL/AUTO switches to
“O” position.
6. For the Engine pump, to be able to test its operation, switch it on Auto or Manual
Mode. On the Manual Mode, the Engine can be started with the press button or
Ignition Key provided.
For the Auto Mode, the engine pump will come on when it gets to the cut-in pressure
(low pressure) and stop at the high pressure. Operating the engine pump will be similar
in operation like the electric pump as detailed above.

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5 MAINTANANCE
The regular attention that the equipment requires following
 Check the pressure tank's pre-charge. We recommend that this be carried out
every six months.
 Check the battery. To be checked weekly to ensure no over/under charging
 Check the Engine to ensure it can easily run by regularly cranking and starting it
up. Run engine at least 5 minutes after every seven days. Run the Main pump for
10 minutes after every seven days.
Note: - To check the pressure tank's air charge, switch off the electric power. Close the
main gate valve on the outlet pipe as well as the gate valve on the suction piping. Drain
water from the pressure tanks by opening the `test' gate valve. (If there is no `test' gate
valve provided, then loosening the union connecting the pressure tank to the piping will
facilitate draining). Check the air charge using a tyre gauge. The correct pressure is
indicated in the table on “Pressure transducer setting section above”. Replenish the air
if necessary and replace the valve cap. Do NOT charge tank to a higher pressure than
indicated as this will reduce the draw off available from the tank between pump stops
and starts. Repeated air loss may indicate a leaky air valve.

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6 TROUBLE SHOOTING
If the pumps do not work, check the following:-
 Is mains power available? (Switch on)
 Are the batteries charged? (Charge the batteries)
 Has the overload relay on the Manual Starter tripped?? If it has, the TRIP
indication will display. Depressing the "RESET" button will reset the starter and
enable the pump to operate.
If after resetting, the starter immediately trips it is essential that
the Davis & Shirtliff service Department be called to check the
installation.
 Is the water level in the tank low? (Low level cut-out has been activated). If all is in
order, switch OFF the main isolator; open the panel door and check:
 Has the pumps been automatically switched off automatically due to high pressure
cut-out?
 Has the MCB tripped?
 Has the control fuse blown?

If these checks do not reveal any fault, call Davis & Shirtliff to check the installation.
Telephone numbers are given at the back of this booklet.
Priming Checks
Failure to achieve a strong flow of water from an outlet the pump room may be
caused by one of the following:-
1. Water level below suction pipe. (This could happen in case of failure of the low
level float switch to stop the pump).
2. Air leaking into suction side.
The Pumps not switching off or are taking too long to switch off may be caused by
one of the following:-
3. A leak in discharge side of plant or tap turned ON.
4. Blockage in suction pipe work or blocked pump impeller.
5. Pump rotating in the wrong direction.
Pump switching on and off frequently may be caused by one of the following:-

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6. Leaking non-return valves, allowing water to run back into the reservoir.
7. Suction or delivery line leaking.
8. Burst diaphragm in the pressure tank.
9. Incorrect pre-charge in diaphragm tank.
PLC (HMI) Interface Checks
PLC HMI (Human Machine Interface): The PLC display must be powered at all times.
This is through batteries provided on the fire set and it ensures that PLC remains ON to
monitor the controls when there’s a power loss.
On start up the HMI will display depending on the condition at hand.
o Davis & Shirtliff Fire Set when power supply is healthy.
o Phase failure when there’s a power/phase loss. This condition is also
visible when the phase sequence is wrong
o Engine requires service. After 250hrs of engine operation the engine
need to be serviced. To reset press “0” on the keypad.
o Main O/L or Jockey O/L. Jockey or main motor overload. Press reset button
on the overload relay
o Engine failed. Press 1 to reset
o Engine Test - Engine set to automatically start every Wednesday 12.45 –
12.50pm) – Water may gush out through the safety valve during this test.

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7 SPARE PARTS LIST

For detailed spare part lists, please refer to the Davis and Shirtliff Spare parts manual or contact
the Davis and Shirtliff to order parts.

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8 RETURN GOODS AUTHORIZATION PROCEDURE

If you wish to return goods for repair, warranty evaluation and/or credit, please have
your original sales order or invoice available when you call Davis and Shirtliff Technical
Support Team.
Davis and Shirtliff Technical Support Representative will provide instructions and a
Return Authorization Number, which needs to be clearly written on the outside of the
box/plant being shipped back to Davis and Shirtliff.
All equipment must be shipped to Davis and Shirtliff with all associated freight costs
paid by the customer unless otherwise specified by Davis and Shirtliff.
Call our Davis and Shirtliff Technical Support with any questions or issues concerning
freight claims and a representative will discuss your situation.

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9 TERMS OF WARRANTY
General Liability
In lieu of any warranty, condition or liability implied by law, the liability of Davis & Shirtliff
(hereafter called the Company) in respect of any defect or failure of equipment supplied
or for any loss, injury or damage attributable thereto is limited to making good by
replacement or repair (at the Company’s discretion) defects which under proper use
appear therein and arise solely from faulty design, materials or workmanship within a
specified period. This period commences after the equipment has been dispatched or, if
applicable, installed by the Company and at its termination all liability ceases.
This warranty applies solely to equipment supplied or work carried out by the Company
and no claim for consequential damages, however arising, will be entertained. Also the
warranty specifically excludes defects caused by fair wear and tear, the effects of
careless handling, lack of maintenance, faulty installation, incompetence on the part of
the equipment user, Acts of God or any other cause beyond the Company’s reasonable
control. Also, any repair or attempt at repair carried out by any other party invalidates all
warranties.

New Equipment
9.2.1 General Terms
Standard warranty period for all the brands including Dayliff Products (hereafter called
the named products) is as detailed in Table 3 below.
Table 3: Dayliff Products Standard Warranty Periods
WARRANTY
PERIOD
BRAND ITEM
Pedrollo PKm60 Pump 3 years
Grundfos, Davey, Pedrollo, KSB, Leader,
Quality, Electric Pumps & 2 years
Nastec, Lorentz, Ajay, Sacem, Dosatron, Seko, Motors
Mapro, Tesla and Dayliff
Dayliff Engine Pumps & 6 months
DDV60

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Davey, Koshin & Elemax Engine Pumps & 1 year

Portable Generators
Dayliff, Lister, Cooper Fixed Speed 2 years
Generators
Solarworld, Dayliff PV Modules 25 years
Ezinc, Dayliff SWH & Tanks 5 years
Champion Sealed Batteries 2 years
Opti, Sundaya DC Lights 6
months
Lorentz, Shurflo, Opti, Sundaya, Dayliff, Steca Solar eqp. & 1 year
Accessories
Dayliff DX & CX GRP Filters 5 years
Certikin, Midas, Aquascape, WACs, Varem, Accessories 1 year
Nastec,
Sensus, Sawo, So~Safe, Atlas Filtri, Hanna
and Dayliff.

The warranty on equipment installed by others is conditional upon the defective unit
being promptly returned free to our workshop and collected thereafter when repaired.
No element of site repair is included in the warranty and any site attendance costs will
be payable in full at standard chargeout rates.
9.2.2 Electric Motors
Standard warranty on new electric motors is two years, whether being part of a named
product or not, though due to the fact that motors can fail due to many factors beyond
the Company’s control, any warranty is conditional upon the following: -

⇒
The motor is provided with an approved control panel, including an
appropriate electro-magnetic starter with correctly rated overload, for all
three phase installations and high current cut-out for single phase
installations. In addition, for all three phase submersible borehole
installations, a high and low voltage plus phase control relay must be
provided.

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⇒
The pump and control panel is permanently installed with fixed electrical
connections. Any installations involving temporary connections will not
be covered by the warranty.
⇒
No claim will be entertained when there is evidence that a motor has
operated with electricity supply beyond the manufacturers specified
limits and tolerances for frequency, voltage and phase symmetry, nor
when there is evidence of incorrect connection to the power supply.
9.2.3 Water Pumps
Most pumps supplied are designed specifically for applications involving clean, cold (up
to 300C) water. No warranty will be provided against wear and subsequent damage if
the pumped water does not conform to this condition unless the pump has been
specified by the Company or the manufacturer for a particular application.
As all pumps are water lubricated serious damage can occur if they are run without
water. For this reason the Company specifically excludes itself from any warranty claims
where there is evidence that damage to the pump has been caused by running dry or
other damage resulting from installation conditions not approved by the manufacturer.
Equipment Repairs
Standard warranty period for all repaired equipment is three months from date of
collection or installation by the Company provided the warranty claim is attributable to a
defect in any spare part fitted during repair. Failures caused by defects in components
not repaired are specifically excluded. Also, due to the fact that failure can be caused by
many factors beyond the Company’s control, the warranty period on re-wound motors is
limited to one month when equipment re-installation is carried out by the Company and
no warranty will be given on re-wound motors when re-installed by others.
New Installations
Standard warranty period for all new installations is six months from date of
commissioning excluding the named products (if applicable) to which their standard
warranty (see Clause 2) is applicable. During the warranty period defects caused by
faulty design, materials or workmanship will be rectified at no charge, though if the
Company is called to site to rectify a defect which on investigation is caused by faulty

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operation, lack of maintenance or general carelessness, all charges for labour, transport
and materials used will be payable in full at the Company’s standard rates.
Proof Of Purchase
Proof of purchase in the form of the original invoice is required to be shown before warranty
repairs are approved.
Davis & Shirtliff Ltd, Kenya, Nairobi, Dundori Road Industrial Area, PO Box 41762 - 00100, Tel: (+254 20) 6968000, Fax: 254 20
557617, d&s@dayliff.com
Davis & Shirtliff (International) Ltd, Kampala, Uganda, Jinja Road, PO Box 22824, Tel: (+256 414) 346337/8, Fax:
346335, d&s@ug.dayliff.com
Davis & Shirtliff Tanzania Ltd, Dar es Salaam, Gerezani Road, PO Box 10725, Tel: (+255 22) 2112516/6, Fax:
2112513, office@tzdayliff.com
Davis & Shirtliff Zambia Ltd, Lumumba Road, PO Box FW 112, Lusaka, Tel/Fax (+250 211) 288010/1, 845010/1,
d&s@zm.dayliff.com
Davis & Shirtliff Rwanda Ltd, Kigali, Muhima Road, BP 7039 (+250) 252 504039, Fax: 504033, sales@dayliff.co.rw
Davis & Shirtliff Ethiopia PLC, Addis Ababa, Urael Bole Tele Rd, PO Box 170540, Tel: (+251 11) 5159341/44, Fax
5159351, d&s@et.dayliff.com
Davis & Shirtliff Sudan, Tong Ping, Juba Nabari Plot No. 9, Tel: (211 956) 397070
14th August 2013

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10 OPERATING AND CLEANING LOGS

Recording data is useful for tracking operating conditions and to optimize operations.

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Appendix A: Assembly drawing

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