spn INSTALLATION OPERATION & MAINTENANCE MANUAL MK7 LPCB DIESEL ENGINE DRIVEN FIRE PUMP CONTROLLER FOR MANUAL & AUTOMATIC ENGINE STARTING DESEL FRE PVP CONTROLLER ‘Customer Panel Serial No Panel Part No. Year of Manufacture SPP Pumps Limited Theale Cross Reading | Berkshire ENGLAND RG31 7SP Telephone: “Document No: W92-003E | Revision No: 5 | #444(0) 1189 323123 Revision Note No:_R 9282 Fax: | Date Issued: — June 2005 | Produced at SPP Pumps 44(0) 1189 323302 a ++Boo DECLARATION OF CONFORMITY OR DECLARATION OF INCORPORATION We SPP Pumps Limited ’ of Theale Cross Reading Berkshire England RG31 7SP Declare that: Equipment LPC Diesel Engine Controller ModeVType: MK7 Serial Number: ‘As shown on the Pump Nameplate in accordance with the following Directive: 73/23/EEC - _ Low Voltage Directive. 89/336 - Electromagnetic Compatibility Directive and its amending directives. have been designed and manufactured to the following specifications: EN 60204-1 Safety of Machinery - Electrical Equipment EN50081 Part 1 EMC Generic Emissions Standard - Domestic prEN50082 Part 2 EMC Generic Immunity Standard - Industrial Environment We hereby declare that the equipment named above has been designed to comply with the relevant sections of the above referenced specifications, The units comply with all essential requirements of the Directive. Signed: Name: Richard Martyn Position Engineering Manager - Authorised to sign on behalf of SPP Pumps Lit Date: 1st October 2004 Dur policy is one of continuous improvement and we reserve the right to alter specifications at any time Page 2 of 20operator inetructions for + Manual New Boo uc} cat Fee Pune Goveber ro CONTENTS Section 1 General Information and Safety Instructions . Section 2. Transport Handling and Storage Section 3 General 3.1 Description... 2.2 Type number 3.3 Dimensions and Construction .. 3.4 Drawings. o 35 Figure 1 - Controller Dimensions 3.6 Figure 2- General Arrangement ~ External 3.7 External Components 3.7.4 Ammeters, 37.2 AC. Isolator 3.7.3 Micro-Controller Module, 3.7.4 Lamptest : 37.5 Battery AB 3.76 — Start/Stop 3.7.7 Hom Mute 37.8 Faultreset 3.7.9 Emergency Manual Start Push Button 3.8 Figure 3 - General Arrangement - Enclosure Internal 3.9 Baltery chargers. « 3.9.1 Figure 5 - Battery Charger vrcronnnnnnannnn 7 OCOMMMEOOEVIIIOOUHOS ED bb 3.10 Figure 7 - Terminal Rail Arrangement 10 3.11. Louvre Control Relay ' 10 3.12 Fuses 10 313. Remote Alarm Contacts 10 314 Figure 8 - General Arrangement - Ooor Internal Soin 10 3.18 Figure 9 - Schematic Circuit Diagram. son ~ 1 Section 4 Operating Philosophy.. 4.1 Engine Speed Detection... 42 Cranking Detection 43 Engine Overspeed Detection 44 Initiation Circutt 45 Manual Star... 48 Engine Shutdown... Section § Installation... 5.1 AC supply system Section 6 Commissioning 6.1 Figure 10 - Interconnection Diagram “ . 14 62 Charging the Batteries 15 63 _ Integrity Checks. vo 15 64 Customer Set-up Parameters «... Errorl Bookmark not defined. 7 65 Engine Automatic Start Cycle son fs 66 Use of ‘Manual Start’ Push Button..... soon sens 67 — Alarm Tests .. “ sess Section 7 Maintenance 74 Daily 72 Weekly 73 Monthly soe 74 Replacing The Frangibie Element in the Emergency Start Module. “18 Section 8 SPARES & SERVICE Gur poly Is one of continuous improvement and we reserve the right fo alter specifications at any time Page 3 of 20,Manual No/Rev wouter vse Bo Goer Soo Section 1 General Information and Safety Instructions Within this manual, safety instructions are marked with safety symbols. been designed with safety in mind. Where hazards cannot be eliminated, the risk has been minimised by the use of terminal shields and other design’ Mn This symbol refers to electrical safety features, Some hazards cannot be guarded against and the instructions below MUST BE COMPLIED WITH for safe operation. These instructions cannot cover all circumstances; YOU ATTENTION fare responsible for using safe working practices at This symbol gives warning of a hazard to the all times. . controller itself, which in turn, could cause @ risk to SPP products are designed for installation in designated areas, which are to be kept clean and free of obstructions that may personal safety. restrict safe access to the controls and Section 2 Transport Handling maintenance access points. and Storage ‘A panel nameplate is fited to each unit and Transport must not be removed. Loss of this plate could make identification impossible. This in tum could affect safety and cause difficulty in obtaining spare parts. Should accidental loss of damage occur, contact SPP Pumps Ltd. immediately. ‘Access to the equipment should be restricted to the personnel responsible for installation, operation and maintenance and they must be trained, adequately qualified and supplied with the appropriate tools for their respective tasks. SPP requires that all personnel that are responsible for installation, operation or maintenance of the equipment, have access to and study the product instruction manual BEFORE any work is done and that they will comply with all local and industry based safety instructions and regulations. Check and confirm that the manual is the relevant copy by comparing the serial number on the identification plate with that on the manual. All controllers are despatched fully assembled, and are protected against corrosion and packed for transport by normal road, rail and sea carriers. Crushing Hazard When ling the controllerfpump unit, use lifting equipment having a safe working load rating suitable for the weight specified. Use suitable slings for liting any controller/pump unit not provided with lifting points. ‘ATTENTION Storage: Upto six weeks: If the controller is not to be used immediately, it should be stored carefully, vertically, in a sheltered, dry location Longer periods: A proprietary moisture absorbent should be placed in the panel and removed during commissioning. Clear and easy access to all controls, Section 3 General gauges and dials etc. MUST be maintained at all times. Hazardous or flammable materials must NOT be stored in the pump 31 house, IMPROPER _|NSTALLATION, OPERATION OR MAINTENANCE OF THIS SPP_SPP PRODUCT COULD RESULT IN INJURY OR DEATH. Description ‘The MK7 LPCB Diesel Engine Controller is @ six attempt engine control unit, designed for {fully automatic engine starting applications, in accordance with the requirements of BS53006 and the LPCB Loss Prevention Standard LPS 1236 when it is adopted Dar policy is one of continuous improvement and we reserve the right to alter specifications at any time Page 4 of 20SPn The controller is designed to start the fire pump automatically, on receipt of a signal indicating pressure fall in the fire protection system. The pumpset will continue to run until shut down manually. MK 7 Di ‘A magnetic pick-up is used to monitor the engine speed. After the fire pump has started it cancels any further oranking and resets the controller for future operation. ‘The controller constantly monitors the speed of the engine and therefore it is possible to check that the starter motor has correctly engaged. Failure to engage correctly will ‘cause the controller to stop the cranking and attempt re-engagement. ‘Should the engine fail to start, after six crank attempts, @ visual and audible alarm is given, ‘An over-ride emergency manual start facility is provided by means of a push button, located behind a hinged cover, which is retained in position by a frangible plastic fitting In accordance with the standards, the controller is also fitted with a manual start facility, which only becomes operative after the engine has been stopped following an automatic start, or if the engine has failed to start after six attempts. Two separate and independent constant voltage battery chargers are provided inside the controller. Either battery can be utilised for ‘automatic’ cranking duty, by means of the “BATTERY AB" push button located on the front of the controller module, Each successive crank attempt will be performed drawing power from the selected battery. if the selected battery has insufficient power to crank the engine, during any stage of the cranking cycle, further cranks are automatically made using the other battery. The controller has single pole, normally closed contacts for the remote monitoring of the engine status Operators Instructions for el Fire Pump Controller 3.2 3.3 3.4 / Manual NoRev w92-003E /5 Type number Various options and alternatives are. available for the MK 7 Controller, as listed below:- Basic Type Number MK7 J LPCB / 24 / NC /240 a b c od e Controller designation Standards Authority © = Control voltage d= Battery chargers NC = Nickel Cadmium. LA = Lead Acid Batteries, e = AC Supply 220 = 220 volts, 380 = 380 volts: 415 = 415 volts. Dimensions and Construction The controller cabinet is rigidly constructed from 1.5mm sheet steel and designed to give protection to IPSS. Height 500mm x Width 500mm x Depth 200mm Drawings This instruction manual contains schematic and layout information and should not need to be read in conjunction with any additional drawings The extemal and internal arrangements for the controller are shown in figures 2 and 3. Dar polcy is one of continuous improvement and we reserve the right to alter specifications at any time Page 5 of 20,vessels ux 20a Ft Pump Sone Bon 3.5 Figure 1 - Controller Dimensions 450 500 | \ 4off FIXING HOLES a ee 7mm DIA. L 60 oe NOTE ; Door hinged on the right hand side - Minimum clearance to open door = 500mm. Controller Weight = 35kg 3.6 Figure 2- General Arrangement - External BATTERY ‘8 BATTERY * = AMMETER ———~| AMMETER EMERGENCY START “ BUSH BUTTON micro. CONTROLLER — MODULE aurostart ANgOLMTOR ac suppty_— : q FRANGIBLE ISOLATOR ~~ ELEMENT ‘Dur policy is one of Continuous improvement and we reserve the right to alter specifications at any time Page 6 of 20Shp 3.7 External Components 3.7.1 Ammeters Individual ammeters are’ provided to indicate the charging current of the batteries. The ammeters are of the moving coil type with a full-scale deflection of 5 amperes and providing an incremental division of 100mA, 3.7.2 A.C. Isolator ‘The isolator is mechanically interocked with its operating handle mounted on the controler door. This ensures that the isolator ts switched to the 'OFF" postion Before the door is epened ATTENTION ‘The'A.C. ISOLATOR’ must alays bein the ‘ON’ pesition Failure to comply with this requirement will ‘prevent the batteries being charged. NOTE : The opening of the AC isolator will cause the “Charger Fault” alarm to operate after a period of approximately five minutes. 3.1.3 Micro-Controller Module “The loge and contol functions of the MKT diesel engine controler are performed by 2 purpose designed micro Eontflier module which Is mounted on the controler door. Fhe module incorporates a 32 character, backcit LCD Gisplay which provides controller status and alam ‘condone inthe form af text messages. |A twatfe Wight” indication philosophy is provided to show immediate status up to @ distance of 10 metres, the indication Ie provided by means of high intensity LED incisors Operators Instructions for : MK 7 Diesel Fire Pump Controller Manual No/Rev W$2-003E /5 GREEN = HEALTHY All parameters are healthy and the controller is available for automatic operation, S00 ad |stanoey GE FAIL A AMBER = WARNING The controller is available for automatic operation. However there is a situation that that requires operator investigation or rectification 5 [sHuTooWN | IFAILED TO START RED SHUTDOWN The controler is not available for automatic operation immediate operator intervention is required In the nesithy “STANDBY’ condtion the text display ofthe ‘module vil show ‘STANDBY’ In the upper line of text and Wil seroll between the selected battery voltage and the {etal operational hous of the ston the lower text line Under running condtons the engine speed is displayed on the lower text hne and inthe event of an alarm the Ful val be displayed on the ower text ine In the event of multiple alarms the alarm condition Information wit scroll on the lower text line ofthe display. ‘The face of the miero-controller madule incorporates five push buttons which provide the fallowing functions: Dur policy is one of continuous improvement and we reserve the right to alter specifications at any time Page 7 of 20Vernanse ns 1 eae Rua Conor Bpo of multiple alarms each alarm must be 274 Lamp est & inva rset This is used to test that the LEDs are functioning. It also checks the integrity of ‘Any fault conditions still present will be LCD display by ‘blanking’ all 32 character displayed when the push button is released segments, This includes resounding of the audible alarm. 3.7.5 Battery A/B NOTE: This is used to toggle the selected The micro-controller module is a special “Automatic” battery from Battery | micro-processor based unit and contains Battery B, whichever battery is selector! wa NO _USER REPLACEABLE components, perform the automatic crank attempts in an automatic starting situation any tampering with the module will invalidate any Warranty claim. The terminal voltage of the selected battery will be displayed on the lower text line. 3.7.9 Emergency Manual Start Push Button 3.7.6 Starv/Stop ‘A push button is located behind the This is used to stop a running engine and to transparent cover mounted on the front of perform a test start following an automatic the controller door. Access to the push run. The start function is only operative in button is gained by pulling the transparent the event of a ‘TEST START REQUIRED’ cover upward, which will break a small being displayed by the text display. frangible cover seal. The seal must be replaced after use. To facilitate an emergency start, the push button must be held in until the engine fires. The push button energises both starter solenoids simultaneously. The Stop function will only be effective if all automatic start signals are absent and a fuel shut-off device is fitted to the engine. ATTENTION The push button must be released the instant that the engine fires. Damage to the starter and ring gear will result if the push button is not released. 3.7.7 Horn Mute This is used to silence the audible alarm. In the event of a subsequent alarm occurring the audible alarm will be re-instated 3.7.6 Fault reset ‘See Maintenance Section for seal replacement The fault reset allows the controller to be Procedure, reset after any alarm condition. In the event 3.8 Figure 3 - General Arrangement - Enclosure internal Internal Layout of the enclosure showing the position of the battery chargers and the terminal rail mounted components. Dur poly is one of continuaus improvement and we reserve the night to alter specifications at any time Page # 0f20S05 3.9 3.9.4 Battery chargers To ensure the maximum reliability of both battery systems, the controller has two completely independent battery chargers, each connected to one set of batteries, This allows the removal of one charger whilst leaving the other fully operational. The battery chargers are of the constant voltage, current limited design employing switch mode technology. Figure § - Battery Charger ser Boost voLtace —/ In the event of a depleted battery the battery charger will initially operate as @ constant current unit timiting the current to the charger capacity by reducing the output voltage. This will result in the initiation of the ‘charger fault’ alarm, Upon restoration of the battery the charger will revert to constant voltage operation and the charger fault condition will automatically reset. Operators Instructions for , MK 7 Diesel Fire Pump Controller Manual No/Rev W92-003E /5 In order to achieve a rapid recharge the battery charger is equipped with a boost charge feature. This raises the float voltage and consequently increases the charging current. The integrity of the battery charger is constantly monitored. If the standing float voltage of the battery charger falls below 96% of the charger setting then the charger is failing to provide the required output This condition will result in the illumination of the amber ‘WARNING’ lamp and the display of ‘CHARGER # FAULT’ on the text display. SOO 0 ee alg : BATTERY — SELECTOR PLUG: \. SET FLOAT VOLTAGE To eliminate nuisance alarms due to the heavy discharge experienced —_ when cranking the engine the charger fault alarm |s inhibited for a period of 30 minutes following an automatic start sequence Constant current operation of the charger can be verified by observing the respective battery-charging ammeter. In constant current made the ammeter will indicate a charge current of 4.0 - 4.5 amperes. Cur polcy is one of continuous improvement and we reserve the right to alter specifications at any time Page 9 of 203.40 Figure 7 - Terminal Rail Arrangement CIRCUIT BATTERY A FUSES BATTERY 8 REMOTE CHARGER CONTROL CHARGER CONTROL ALARM =< eee TERMINALS fala ae = ig | aS aes 2 COMMON CONTACT Af) | PUMP ON DEMAND A2 | PUMP RUNNING A3 | Z LOUVRE JACKET FAILED TO START Ad, AC SUPPLY CONTROL WATER ‘COMMON ALARM AS ISOLATOR RELAY HEATER: PUMP UNAVAILABLE AS 3.11 Louvre Control Relay |S Common Alarm incorporating Automatic Start Unavailable. Engine Failed to Start. High Water Temperature Low Water Temperature Low Water Level Low Oil Pressure. ~ The louvre control relay will be energised whenever the pump is in operation. The initial energisation will occur upon the commencement of the first crank attempt of the engine. Battery Fault. 3.12 Fuses Battery Charger Fault. Engine Overspeed. Separate fuses are provided for the Governor Supply Failure charging and module circuits. Low Fuel Level (For BS EN 12845) AG Pump Unavailable. Fuse — Ref.Circuit Rating FA Battery A Charging Circuit 10 Relays with volt free change-over contact F2 Battery A Module Circuit 2A may be fitted as an option which would F3 Battery B Charging Circuit 108 replace terminals A1 to A6 Fa Battery B Module Circuit 28 3.14 To comply with BS EN 12845 3.13 Remote Alarm Contacts The terminals 23A are included to permit At Common to each alarm contact. the connection of two start initiation ‘A2_ Pump on Demand. pressure switches. In addition terminals 25 ‘A3 Pump Running, & 26 are included for connection of a ow A4 Failed to Start. fuel level switch 3.15 Figure 8 - General Arrangement - Door Internal Dar poley is one of continuous improvement and we reserve the right to alter specifications at any time Page 10 of 20,Operators Instructions for Manual No/Rev apo MK 7 Diesel Fire Pump Controller ~ W92-003E /5 3.46 Figure 9- Schematic Circuit Diagram ‘ur policy s one of continuous improvement and we reserve the right fo alter specifications at any time Page 11 of 20,Manual No/Rev W92-003E /5 Section 4 Operating Philosophy 44 42 43 Engine Speed Detection The diesel engine is equipped with a magnetic pick-up located to detect the passing of the starter ring gear teeth. This produces an output frequency directly proportional to the number of teeth on the flywheel and the engine speed Cranking Detection. The cranking detection level setting monitors that the engine is being turned at sufficient speed to promote combustion. If the cranking speed has not achieved 120 RPM within @ period of four seconds of crank initiation the starter solenoid will be de-energised to withdraw the starter. It will then be re-energised after a one second delay to provide a second crank attempt using the second battery. The cranking procedure will be attempted six times using the second battery set. The controller will display the alarm condition “BATTERY # FAILED, the yellow LED will flash and the audible alarm will sound. It will be necessary to investigate the cause of the failure. If the engine starts at the second attempt the problem is probably due to a failed battery. if however the indication is that both batteries have failed the probability will be that the starter pinion has jammed preventing the starter motor from engaging with the flywheel in Which case the “FAILED TO START” alarm and the Red LED will be activated. ‘When the engine has started and achieved a speed in excess of 500 RPM the engine speed will be displayed on the lower text display, The “Low Oil Pressure” alarm is inhi whilst the engine is stationary and for a period of 10 seconds following the illumination of the “IN OPERATION" indicator Engine Overspeed Detection. ‘Should the engine speed exceed the over- speed setting the "OVERSPEED" alarm message will be shown with the flashing Yellow LED and audible alarm. Operators instructions for MK 7 Diesel Fire Pump Controller 44 45 Spo The over-speed setting will be factory set at 110% of the engine duty speed, Initiation Circuit The initiation circuit will be continuously energised via the pressure switch or other starting device. Confirmation of the energisation of the initiation circuit is confirmed by the message “STANDBY” on the upper text line of the controller module screen. The lower text screen will alternately display the terminal voltage of the selected battery and the number of operating hours completed by the set. De-energisation of the ini circuit will cause the start delay timer to count down. This is displayed on the lower text line of the display. Completion of the count down will cause the initiation of the start sequence. The “START 01 BATT A" or “START 01 BATT B” message and the green LED being illuminated confirm this. The text display will indicate the remaining crank duration time and the terminal voltage of the battery set being used. Should the integrity of the pressure switch circuit be restored prior to the expiry of the delay period the controller will reset to the “STANDBY” condition and no action will be taken. The Start Delay timer is factory set to 1 second, This can be changed if required, see section 6.4, The auto-start sequence can only be terminated by the receipt of an engine running signal or by the operation of the START/STOP push button Manual Start Operation of the module START/STOP push button, when the “TEST START REQUIRED" message is displayed will cause an instant automatic start of the diesel engine utilising the opposite battery to that employed for the previous automatic start During a TEST START the controller will monitor the engine parameters. When the engine is fitted with a fuel solenoid a “LOW OiL PRESSURE”, “HIGH ENGINE TEMPERATURE” or “OVERSPEED" alarm will cause an instant shutdown of the engine. Dar poly is one of continuous Improvement and we reserve the right to alter specifications at any time Page 12 of 20=p 46 Section 5 5A ‘The run time during TEST START is factory set to 30 minutes, after which the set will automatically shut down, Following a fault shutdown the fault will be latched, but the controller will revert to the “STANDBY’ mode and will start automatically in the event of an initiation signal During a TEST START run the upper text line of the controller module display will display “TEST START" and the lower text fine will display the remaining time period. If at any time during a TEST START an initiation signal is received by the controller the shutdown and timer functions will be immediately cancelled and the controller will return to it's normal automatic mode of operation requiring a manual shutdown Engine Shutdown For engines fitted with a fuel solenoid the “START/STOP” push button will stop the engine. Engines not fited with a fuel solenoid can be stopped by operating the manual *STOP" lever on the engine fuel pump. Should a demand signal be present at the controller the push button will be inoperative. Installation AC supply system A single-phase supply is required for the battery chargers. The following considerations must be made: Battery Chargers 480 VA (total) To calculate the current requirement: —___ 480 _ ‘SUPPLY VOLTAGE To avoid inducing noise, into the pressure switch or remote start signal connections, screen cable should be used with the screen earthed at one end only. Operators Instructions for MK 7 Diesel Fire Pump Controller Manual No/Rev W92-003E / 5 Section 6 Commissioning ENSURE THAT THE MAIN AC ISOLATOR IS SWITCHED “OFF” AND ENSURE THAT THE DC FUSES ARE REMOVED BEFORE ANY WORK IS CARRIED OUT ON THE FIRE PUMPSET. ‘~ ON NO ACCOUNT SHOULD ANY COMPONENTS BE REMOVED FROM THE CONTROLLER WHILST THE ENGINE IS RUNNING OR WITH THE CIRCUITS ENERGISED. DO NOT ATTEMPT TO START THE ENGINE WITH ANY COMPONENT REMOVED FROM ‘THE CONTROLLER EXCEPT IN AN EMERGENCY BY MEANS OF THE “EMERGENCY MANUAL START” CIRCUITS: BEFORE CONNECTING THE BATTERY LEADS AND ENERGISING THE AC SUPPLY ENSURE ‘THE PROCEDURE DETAILED BELOW HAS. BEEN FOLLOWED:- 1, Set the ‘AC position. ISOLATOR’ to the ‘OFF’ 2, Open the controller door and ensure that all, components are fitted, and all connectors are in place. 2. Ensure that fuses F1, F2, F3 and F4 are ALL drawn 4. Ensure that the controller has been connected fully in accordance with the controller interconnection diagram (figure 8) prior to connecting the battery leads. To isolate ‘auto-start’ switch, turn the key switch to the ‘off* position. Tur poly is one of continuous improvement and we reserve the right to alter specifications at any time Page 13 of 20,vanes un PBiceel Ee Buns Conver Bon 6.1 Figure 10 - Interconnection Diagram encoun 2 ower ea2| LNENGISED TO STOP SOLENOID gS 5 i woven BES), 4 sumtrma Ss EEE fe seenen trie zn 8 On O44 oOo: - so wee 2 as ate ee wo eoenee wo eapoee = S2fe¢ we ganze ar poly i one Hf SonUaus Improvement and we reser the ‘GH aka specicains at any Ue Wage 14 of 20spp 6.2 Charging the Batteries The batteries should have been bench charged and conditioned, however it may be desirable to “top-up” the charge prior to conducting the commissioning tests, 1, Ensure that the fuses F1 and F3 are drawn. 2. Ensure that the fuses F2 and F4 are drawn and removed from the controller. 3, Insert fuses F1 and F3, close and lock the controller door. 4, Connect the negative leads to both sets of batteries. 5. Connect the respective positive lead to “Battery A” only 6. Close the AC Isolator on the controller and note that ammeter A shows a charging current, 7. Open the AC isolator and the door and replace fuses F3 and Fa. 8, Lock the door and connect the respective positive lead to battery B 9. Close the AC Isolator and check that both ammeters are indicating a charging current, NOTE : The battery chargers are current limiting and will restrict the charging current to @ maximum value of 4.5 Amps. Commissioning of the controller should not commence until the charging current on both ammeters has reduced to less than 0.5A, Before starting the commissioning, ensure that: The AC Isolator is set to the “OFF” position. Fuses F1 and F2 are drawn. ‘STANDBY BATTERY A= 27V OPERATION! OR ‘STANDBY OPERATION = 3.4 HRS. Operators Instructions for MK 7 Diesel Fire Pump Controller Manual No/Rev W92-003E /5 6.3 Integrity Checks. Replace fuse F4. This will cause the controller module to "boot-up", the audible alatm to sound and the “WARNING” lamp will light. The alarm can be muted by operation of the "Hom Mute* push button. Operate the “LAMP TEST” push button to verify the integrity of the indicator lamps and check thatthe 32 segments of the LCD display are blanked. If the upper text line indicates “PRESSURE START" the initiation circuit is open, check the following i No water pressure in the system, thereby allowing the initiation pressure switch to operate, li Pressure . switch incorrectly wired (i.e. closed on fall of pressure, instead of open). lii Broken’ or disconnected wire between the controller and initiation pressure switch. DO NOT CONTINUE UNTIL THE “PRESSURE. START" CONDITION HAS BE REMOVED Replace Fuses F1, F2 and F3 and press the "FAULT RESET” push button three times. The following alarms should be displayed alternately: CHARGE FAILA CHARGE FAIL B. and the amber "WARNING" lamp should light Close the AC isolator the green “HEALTHY” lamp should illuminate and the text display should read “STANDBY’, indicating that the pump set is ready for operation. ITS ESSENTIAL TO TEST THE ENGINE. ‘SPEED INDICATOR BEFORE ALLOWING AN AUTOMATIC START. Failure to carry out this procedure will most likely result in damage to the engine upon use of the automatic start sequence. Dar policy one of continuous improvement and we reserve the right to alter specifications at any time Page 15 of 20,Manual No/Rev w92-003E/5 Ensure that the engine, pump and all valves ‘and control devices are in the correct mode for engine running, Lift the transparent cover protecting the Emergency Start push button, this will allow the use of the emergency start push button, The push button is directly linked to the starter solenoids. In the event that an emergency start is required, lifting the flap up will break the frangible element to expose the emergency start push button. ‘The broken element provides evidence that the emergency start facility has been used. Press and hold the emergency start push button until the engine fires and runs. NOTE: ‘THE PUSH BUTTON MUST BE RELEASED IMMEDIATELY THE ENGINE FIRES, FAILURE TO DO SO MAY CAUSE DAMAGE TO THE STARTER MOTOR ANDIOR TO THE ENGINE The following information will be displayed at the controller module: EMERGENCY START ENGINE SPEED ##i## RPM If the engine speed indicator on the control module does not appear or the speed indication is not correct the fault must be corrected before any further action is taken. The most likely causes are listed below: a). The magnetic pick-up is incorrectly installed. A magnetic pick-up only yields an ‘output when in close proximity to moving ferrous parts. In this case the starter ring gear attached to the engine flywheel. If the {gap is too large the output will be too small to register the engine speed It is possible to adjust the air gap between the magnetic pick-up and the fiywheel teeth. to increase the output that is produced. The magnetic pick-up should be approximately 0.003" from the flywheel. This equates to cone half turn from touching the flywheel teeth. The magnetic pick-up will be destroyed if it comes into contact with the flywheel. Operators Instructions for MK 7 Diesel Fire Pump Controller b). 9). 64 es Check the integrity of the magnetic pick-up. Using an oscilloscope or a digital mult- meter with the capabilty to read frequencies, check that the magnetic pick- up is providing an output across. its terminals . When checking the magnetic pick-up ensure that the signal is being supplied to the input terminals of the Micro Controller (Terminals #19 & #20). - See Schematic Diagram The number of flywheel teeth has been incorrectly set in the controller. This will result in an incorrect speed-reading at the module display. NOTE: Adjustment is by means of an access PIN code only available to authorised SPP Pumps Limited personnel Having successfully completed an emergency start and confirmation of the engine speed indicator, the engine should be stopped by operating the “START/STOP” push button. Customer Set-up Parameters To enter set-up mode, press lamp test and reset together. and The LCD display will prompt for a password, Using the buttons thus: Lamp Test for ‘Down’, Battery AJB for ‘Up’, Start/Stop for ‘Left Alarm Mute for ‘Right Enter the password 0500 and press the reset button to ‘Enter’ The first parameter is for ‘Delay Start’. The permissible range for delay start is between 1 and 30 seconds. Using the buttons select and enter your desired setting, and press reset to enter and save your setting, The second parameter is for ‘shutdown in test for low oll pressure and high water temperature’. Using the up and down buttons toggle between Yes and No, press reset to enter your desired setting, Note This feature contravenes the LPC Rules, however it is included as it is a popular customer request, The final parameter is for ‘shutdown in the event of overspeed’. Using the up and Dur policy is one of continuous Improvement and we reserve the right to alter specifications at any time: Page 16 of 20,BO 65 down buttons toggle between Yes and No, press reset to enter your desired setting, Engine Automatic Start Cycle Initiate an automatic start by reducing the water pressure to the initiation pressure switch, Observe that the "PRESSURE START” | message is displayed on the upper text line ofthe display. After a short delay, depending on the setting of the initial delay, the engine will crank. You should allow the engine to run, Cancel the initiation signal from the pressure switch. Stop the engine. Note that the “TEST START REQUIRED" message is now showing and that the "WARNING" lamp is flashing. Operate the "HORN MUTE" push button to silence the audible alarm Tie the fuel shut-off device in the OFF position, This is in order to prevent the ‘engine from starting. Operate the "START/STOP” push button to itiate an auto-start as before. Allow the engine to perform six attempts at starting. This entails six crank attempts of 15 seconds duration and 10 dwell periods of 10 seconds duration. Note that each crank is performed drawing power from the selected “Automatic” battery. ‘At the end of the sixth attempt the red "SHUTDOWN" indicator will illuminate, the message "SHUTDOWN’ will be displayed, and the audible alarm will sound. Mute the alarm. The following text displays will be shown. SHUTDOWN FAILED TO START and ‘SHUTDOWN MAN START REQUIRED Operators Instructions for MK 7 Diesel Fire Pump Controller 66 Manual No/Rev W92-003E / 5 Cancel the initiation signal and press the “FAULT RESET" push button Untie the fuel shut-off device to allow the engine to run Operate the “START/STOP" push button and allow the engine to start and run Stop the engine. . Operate the “BATTERY A/B" Push button to display “BATTERY A= 27V" Disconnect the positive lead from battery “R’. After a delay of up to one minute the amber WARNING lamp will flash and the text message “BATTERY A FAIL" will be displayed, Initiate an automatic start. The controller will attempt to crank via battery A for four seconds. The controller will fail to receive a signal from the magnetic pick-up indicating that the engine is not cranking, and having detected no engine rotation will terminate the crank attempt. The amber WARNING indicator and audible alarm will pulse and the text message “BATTERY A FAIL” will be displayed. After one second the controller will attempt to re-engage the starter utilising energy from battery B and the engine will crank and run, Cancel the initiation signal and stop the engine. Reconnect the positive lead to battery A and press the "FAULT RESET” push button, Use of ‘Manual Start’ Push Button ‘The “TEST START REQUIRED" message will be displayed following any automatic start or any sequence of six unsuccessful start attempts. Press the “START/STOP" push button. This will initiate the automatic crank sequence drawing power from the opposite battery to that used for the previous automatic start ‘Only when the engine has started as a direct result of the operation of this push button will the “TEST START REQUIRED" message be removed Gur poley & one of continuous improvement and we reserve the ightlo aller specications at any time age 17 of 20Manual No/Rev W92-003E 15 The manual start facility operates in the same manner as the automatic starting procedure and cuts the crank automatically. it is important to note that the controller MUST cut the cranking automatically. After the engine has run for 10 seconds it is possible to check the operation of the low oll pressure alarm. Short the termination on the oil pressure switch to earth (engine metal work). After a short delay the audible alarm should sound the module will display the following message, Note that the engine continues to run, TEST START LOW OIL PRESSURE With the engine stil running test the high water temperature alarm. Short the termination on the high water temperature switch to earth (engine metal work). After 2 delay of approximately ten seconds the audible alarm will sound and the ‘HIGH ENGINE TEMP" message will be displayed Without resetting the controller immediately initiate an automatic start, note that the ‘odule display changes to indicate @ “PRESSURE START. Remove the initiation signal and any ‘shorting links fitted in the above operations ‘and stop the engine by operation of the *START/STOP" push button, ‘The ‘TEST START REQUIRED" message should be displayed again. Press the "FAULT RESET" push button to clear each of the alarm conditions. Each operation will clear the alarm being displayed at the instant of operation of the “FAULT RESET" push button Perform a test start by pressing the *START/STOP" push button and allow the engine to run. Open the initiation circuit and note that the module display indicates "PRESSURE START’ With the initiation circuit open operate the “START/STOP” pushbutton and note that the engine continue to run. ‘Our policy is one of continuous improvement and we resi Operators Instructions for MK 7 Diesel Fire Pump Controller 67 Sop Close the initiation circuit and operate the “STARTISTOP" push button. The engine will stop, Operate the “FAULT RESET" push button to clear the alarm.conditions. Alarm Tests Perform an automatic start by momentarily linking between terminals # 21 and # 22 of the controller terminal rail, allow the engine to start and run. Link between terminals # 15 and # 16 of the controller terminal rail, “COOLANT TEMPERATURE LOW" should be displayed the “WARNING” indicator will pulsate and the audible alarm should sound. Remove Link and operate ‘FAULT RESET push button. Link between terminals # 17 and # 11 of the controller terminal rail, “LOW COOLANT LEVEL" should be displayed the "WARNING" indicator will pulsate and the audible alarm should sound, Remove Link and operate “FAULT RESET” push button. Section7 Maintenance 7A 72 Page 18 of 20, The SPP Pumps Ltd Mk7 Diesel Engine Fire Pump Controller should require very litle maintenance. The following routine checks are recommended to ensure reliable operation. Daily Check that the controller is functional by checking that the green "HEALTHY" indicator is illuminated: Weekly Run the complete fire pump system through both ‘AUTOMATIC START’ and ‘MANUAL. START’ sequences. If you require any information on starting or stopping the engine refer to the commissioning section of this manual and the documentation provided by the engine menufacturer. ‘erve the right to alter specifications at any timeOperators Instructions for Manual No/Rev son mc bie Pump Conon ean Check the battery electrolyte levels in all cells of both battery sets, and where necessary, top up with DISTILLED WATER. Check that the battery terminal connections are tight and free from corrosion. Check that all door-mounted indicators are functioning. Operate the “LAMP TEST" push button to check the integrity of the indicator lamps and the segments of the LCD display screen. 7.3 Monthly Check for loose connections, or signs of abrasion on cable insulation, especially on the engine and between controller and engine where vibration is present. 7.4 Replacing The Frangible Element in the Emergency Start Module. 1. Insert the cover seal into the Emergency Start push button housing as shown. Pull the cover seal tail out through hole in the housing. 2. Feed the other end of the seal through the hole located in the bottom of the hinged cover. Using pliers carefully pull the seal taut and press the hinged cover back to engage the tooth. 3. Using wire cutters trim the excess from the breakable seal ensuring that the tooth remains to hold the hinged cover in position. ‘Our policy is one of continvou Page 19 of 20 is improvement and we reserve the right fo alter specifications at any timeoeses mc Dic Bp Soler Boo Section 8 SPARES & SERVICE SPP Pumps operate a comprehensive Spares and S' be contacted as follows: ervice support network throughout the world, and can SPARES & SERVICE Telephone: **44\(0) 1189 323123 For spare parts, supply only. ask for - Spares Dept. For breakdowns, spare parts and on-site fitting, pump installation and commissioning, and service contracts. ask for - Service Dept. For breakdowns outside office hours. Telephone **44 (0) 1491 201613 Spares & Service Office SPP Pumps Limited General Fax line: #44 (0) 1189 323302 Theale Cross Reading, Berkshire RG31 7SP. ENGLAND Copies of this manual are available from the SPP Pumps Limited Spares & Service Department by quoting the manual reference number and revision number. Direct Fax line: “44 (0) 1189 303259 ine of Continuous improvernent and we reserve the right to alter specifications at any time ‘Our polic Page 20 of 20