NFPA20

FIRE WATER PUMP

CONTROLLER

TECHNICAL OPERATING MANUAL

 NFPA20 FW PUMP CONTROLLER MANUAL

CONTENT
1. DESCRIPTION ................................................................................................................................................................ 1
1.1 General ................................................................................................................................................................ 1
1.2 Nameplate ........................................................................................................................................................... 1
1.3 Installation ........................................................................................................................................................... 1
1.3.1 Mounting ................................................................................................................................................. 1
1.3.2 Wiring and Piping Connections ............................................................................................................... 1
2. OPERATION OF CIRCUITS ........................................................................................................................................... 1
2.1 Overview.............................................................................................................................................................. 1
2.2 Starting the fire pump .......................................................................................................................................... 2
2.2.1 Starting principles .................................................................................................................................... 2
2.2.2 Automatic Mode ...................................................................................................................................... 2
2.2.4 Off Mode ................................................................................................................................................. 2
2.2.5 Stop Engine ............................................................................................................................................. 2
2.2.6 Weekly Test ............................................................................................................................................ 2
2.2 DC power supply from two independent sources ................................................................................................ 3
2.2.1 Overview ................................................................................................................................................. 3
2.2.2 Chargers ................................................................................................................................................. 3
2.3 Water Preheating ................................................................................................................................................. 3
2.4 Panel Heater ........................................................................................................................................................ 3
2.5 Weekly Programmable Timer .............................................................................................................................. 3
2.6 DC Voltage Relay ................................................................................................................................................ 3
2.7 Sequential Start Timer (Electronic Time Relay) ................................................................................................... 3
2.8 Digital Pressure Controller ................................................................................................................................... 4
2.9 Managing Alarms and Warning ........................................................................................................................... 4
2.10 Information Display ............................................................................................................................................ 4
2.10.1 Engine Fault .......................................................................................................................................... 4
2.10.2 Auto Control System Error .................................................................................................................... 4
2.10.3 Operating information ............................................................................................................................ 4
2.10.4 Fail to Start ............................................................................................................................................ 4
2.10.5 System Fault ......................................................................................................................................... 4
2.10.6 Overspeed ............................................................................................................................................. 4
2.10.7 Pump on Demand ................................................................................................................................. 5
3. ELECTRICAL SPECIFICATIONS ................................................................................................................................... 5
3.1 Power Supply Voltage ......................................................................................................................................... 5
3.2 Direct Current System ......................................................................................................................................... 5
3.3 Battery ................................................................................................................................................................. 5
3.3.1 Specifications .......................................................................................................................................... 5
3.3.2 Specification ............................................................................................................................................ 5
3.4 Chargers .............................................................................................................................................................. 5
3.4.1 Specification ............................................................................................................................................ 5
3.4.2 Configuration and adjustment ................................................................................................................. 5
3.5 User inputs/outputs .............................................................................................................................................. 6
3.5.1 Inputs ...................................................................................................................................................... 6
3.5.2 Outputs.................................................................................................................................................... 6
4. EXTERNAL CONNECTION ............................................................................................................................................ 6
5. DIESEL ENGINE ............................................................................................................................................................. 6
5.1 Engine ................................................................................................................................................................. 6
5.2 Cooling ................................................................................................................................................................ 6
5.3 Exhaust ................................................................................................................................................................ 6
5.4 Fuel supply .......................................................................................................................................................... 6
5.5 – Pump room ventilation ...................................................................................................................................... 6
6. ALARMS ......................................................................................................................................................................... 7
7. REGULAR MAINTENANCE ............................................................................................................................................ 7
 NFPA20 FW PUMP CONTROLLER MANUAL

1. DESCRIPTION
1.1 General
The FW Pump Controller is designed following the NFPA20.
Most of the parts inside are relay, easy to repair end remove.
The box material is SS316, IP55, and painted.
The components inside and cabling arrangement is following the controller drawing
Earthing is via the earth terminal which is identified by a standardised symbol. The metallic parts, including the
door, are electrically linked to this terminal.
The components are individually identified by a label containing the reference used in the controller drawing (e.g.
WET for the Water Engine Heater) or by a label containing its function (e.g. 'Engine speed (rpm)'). The fuse size is
also indicated.
The internal wires are numbered at both ends (equipotent type references). Identification by different colours is
used for positive and negative for the AC and DC.

1.2 Nameplate
The controller nameplate is fitted to the exterior of the casing so that it is visible, and includes the below information:
Model
S/N
DC voltage/AC voltage
Standard
Date

1.3 Installation
1.3.1 Mounting
The Controller shall be mounted in a substantial manner on a single incombustible supporting structure.
It is designed for both wall mounted and floor mounted. There are four mounting ears provided for the
controller with hard ware designed to support the weight of the controller. For the floor mounting, there is a
mouting feet with hard ware designed to support the weight of the controller, use all holes provided on the
mounting feet and then grount the mounting feet (if the mounting ears is on the controller, take off them first
for keeping the enough space for mouting feet).

1.3.2 Wiring and Piping Connections

Water Connections: The controller must be connected to the pipe system and also to a drain pipe. The water
connections are on the left side of the controller. The connection to the system pressure and drain are 1/2 NPT.
Electrical Wiring: The controller drawings show the areas suitable for incoming power connections. No other
location shall be used. And watertight hub and quick coupler are used for this controller. The installer is responsible
for adequate protection of the controller components against metallic debris or drilling chips.
Incoming Power Connections: The Controller shall be powered by a dedicated source protected by a breaker.
Verify the label on the cabinet to select the correct protection. When connecting or disconnecting the controller,
following the procedure: Connect both batteries before connecting the AC power. Disconnect the AC power before
disconnecting the batteries. WARNING! Disconnecting the batteries while the AC is connected may result in
severe damage to the controller electronic boards.

2. OPERATION OF CIRCUITS
2.1 Overview
The control panel uses a mains power supply in conjunction with the two linked batteries to perform the following
functions:
Start Pump
Control Power Supply
Preheat Water
Monitor
Alarms and warnings
Display information
The control panel can control a diesel engine, its peripherals and its own circuits. When there is a AC Power Fault, all of
the functions will continue to operate except water preheating and battery charging.

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 NFPA20 FW PUMP CONTROLLER MANUAL

2.2 Starting the Fire Pump

2.2.1 Starting principles
The control panel, in combination with the two battery, the pressure transducer and the monitoring pressure switch,
which uses two separate and redundant starting lines where both lines are unaffected by incidents occurring on the
other line or any linked function.
Pressure signal and pressure switch start signal has its own separate connection to the control panel and is linked
to a lockable selector switch.
The selector switch has three positions: “Auto”, “Off” and “Manual” and the key can only be removed when it is on
“Auto” position.
When an auto-start is requested, the control panel makes six successive attempts to start and powers the starter for
15 seconds for each attempt. An automatic permutation system is used to alternate two start attempts on each
battery. The start attempts are separated by a resting interval of 15 seconds.
When the engine is cranking success, the control panel stops the starter, cancels the subsequent start attempts
and activates the 'Engine Running' indicator.
If the engine is not cranking success after six attempted starts, the control panel activates the 'Fail to start' alarm
and light, and then blocks the automatic system.
If the #1 or #2 battery faults during a start sequence, starting is done by automatically using
the battery that is no fault.
Digital voltmeters of batteries are displayed on LCD of controller and are used to check the
voltage of each battery when the starter is used by isolating it from its linked charger. This
means that it is to check that the voltage is sufficient for starting which requires at least 80%
of the nominal voltage.
If a battery is out of action or is not sufficiently charged, then the starting or the various functions of the control
panel can’t be achieved.

2.2.2 Automatic Mode

A start request is initiated in this mode when at least one of the following command inputs occurs:
Low pressure in the pressure transducer
Remote Start Signal
Deluge Valve

The inputs are only activated when the lockable selector switch is in the Auto position. And there is “Test Auto Start”
button for test the function of automatic mode.

2.2.3 Manual Mode

A start request is initiated in this mode when the selector switch is turned to the “Manual” position, and push the button
“Battery #1 or #2 Manual Start” individual or together, then Starting attempts are made immediately and all the control
panel functions are active.

2.2.4 Off Mode

When the selector switch is on “Off” position, it will isolates the pressure switch and pressure transducer, then the
controller will can’t achieve the function “automatic start” or “manual start”.

2.2.5 Stop Engine

Push the "Stop Engine" button (for normal stop: high pressure of pipe) or turn the selector switch to "Off "(for the
emergency stop: low pressure of pipe and engine fault), both of them are manual stop.

If the controller is down (damaged, etc) for some reason after the fire pump is started automatically, then the engine will
automatically stop

WARNING!
When the system is stopped by pushing the “Stop Engine" button on front of the control panel, the selector switch must
be turned on the “off” position to avoid the system being restarted immediately when there is a start request is still
operational.

2.2.6 Weekly Test

When doing the weekly test, only push the “Start of Test” button, then the engine will be started directly.

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 NFPA20 FW PUMP CONTROLLER MANUAL

2.2 DC power supply from two independent sources

2.2.1 Overview
The control panel is fitted with two identical chargers that have the mains supply as their primary power source and
each has a secondary link to a battery. The assembly constitutes two independent direct current sources with all the
operational guarantees described in the previous paragraph.
Each source powers its respective starting system and the two supplies are used in parallel to power the common
part of the control panel.
The chargers operate continuously with automatic control and the charge level shall be checked once per day by
looking at the charge indicators on the front of the control panel.

2.2.2 Chargers
The chargers are adjusted with a 24V DC output depending on the nominal voltage of the battery connected to
them. They operate normally with an input voltage that varies between + 15% and - 10% around a nominal value.
If changes to the mains voltage (+/– 10%) and frequency (+/– 2%) are slow and cumulative, the charger output
voltage remains stable around the set value with the following tolerances:
With batteries connected: +/– 1%
Without batteries connected: +/– 4%
The charging current is highest when the battery voltage is equal to its nominal voltage. There is no significant
charge when the battery floating voltage is 115% of the nominal voltage.

2.3 Water Preheating

The water preheater for the diesel engine is powered from the AC main supply by a protected output (circuit breaker (F4)
+ relay) located inside the control panel.

There is a thermostat inside the preheater; it means that the heater coils are not powered when the engine temperature
is greater than a set threshold or when the pump is running. And the breaker (F4) can be used for cutting the power and
turn off the preheater.

2.4 Panel Heater

There is a controller for controlling the temp and humidity inside the FW
Controller and protect the performance of parts. It is powered from the AC main
supply and it can be adjusted manually according to the environment condition.
Turn the “Panel Heater on & off” Switch to choose the operation or stop.
(See Attached Appendix)

2.5 Weekly Programmable Timer

There is a timer for controlling the start time; it can set the date, time, it is helpful for the weekly test, when the setting
date and time is up, and then the engine can be started automatically.
(See Attached Appendix)

2.6 DC Voltage Relay

An over-voltage and under-voltage relay is used for this FW Controller, it is a protection device, when the voltage of DC
power supply is higher or lower than setting data, it will trigger the alam.
(See Attached Appendix)

Timer DC Voltage Relay

2.7 Sequential Start Timer (Electronic Time Relay)

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 NFPA20 FW PUMP CONTROLLER MANUAL

Sequential Start Timer is used for controlling the time for starting delay, when there are two pump sets which are
interlocked, one is for operation and one is for standby, this timer is used for setting the time interval for start.
(See Attached Appendix)

2.8 Digital Pressure Controller

The digital pressure controller is installed on the front of the FW pump controller;
it is used for setting the pressure for controlling the start, and can show the
pressure data timely on the screen. (See Attached Appendix)

2.9 Managing Alarms and Warning

The FW pump controller is fitted with standard alarms and warnings which are showed by the different colour of the
indicators and the activation of an audible alarm.

Green indicator: Power , Engine and controlling status

Red indicator: Alarm or Major Malfunction – An intervention is required

There is a “Test lamp & Horn” button, push it to test function of all the lamps and the horn.

When there is bell, if the switch “Reset Alarm & Buzzer” on “Left” position, then the horn will stop horn automatically after
4 hours later.
If an audible alarm is triggered, turn the switch “Reset Alarm & Buzzer” on “Right” position, and then the horn will stop
horn even if the cause is still present without the acting on the luminous error indicator. If another error arises that
requires an audible alarm, the signal is reactivated but can once again be stopped.

2.10 Information Display

The control panel can display the 7 pieces of information described below. Each piece of information is provided via
terminals with 1 dry contact (COM, NO, NC). The 'General Error' information is processed by absences such as the
absence of power.

2.10.1 Engine Fault

Low fuel level
High engine water temperature
Starter link error (15 seconds time delay)
Low engine oil pressure (5 second time delay)
Preheating Error (including when the selector switch is in the “off” position)

2.10.2 Auto Control System Error

Lockable selector switch is not in the Auto position

2.10.3 Operating information

Diesel power pump is operating status.

2.10.4 Fail to Start

The system is not working after 6 starting attempts

2.10.5 System Fault

Main supply fault (180 second time delay)
#1& #2 battery fault
#1& #2 charger fault (20 second time delay)
Panel Heater Fault
Warning Fault (This is the common warning for the warning from the engine panel.)

2.10.6 Overspeed
Diesel engine is overspeed

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 NFPA20 FW PUMP CONTROLLER MANUAL

2.10.7 Pump on Demand

The pressure is less than the setting starting pressure, and the pump is on demand and the engine is required to be
started.

3. ELECTRICAL SPECIFICATIONS
3.1 Power Supply Voltage
The voltage of the AC mains supply for the control panel must have the nominal value of 240V – 60Hz within the
following tolerances:
Voltage: +/- 10%
Frequency: +/- 2%
The control panel and its different components are guaranteed to operate within these limits.

If the mains supply is not 240 V, a transformer can be used which should be placed within a separate casing with
appropriate protections.

The maximum power demanded by the system depends mainly on the power of the preheater, for the N series engine is
1.5KW and K series engine is 2KW.

3.2 Direct Current System

The nominal voltage of the direct current system (starter system + batteries + chargers) is 24V. To avoid any confusion,
the applicable value is shown on digital LCD on the front of FW pump controller.

3.3 Battery
3.3.1 Specifications
6 cell lead batteries are used (for starting purposes) providing a nominal voltage of 12V. For 24V applications, each
direct current source is fitted with two 12V batteries connected in series. These batteries do not need any special
maintenance other than checking the level of electrolyte and cleaning timely if necessary. The size of the batteries
depends on the diesel engine used based on the criteria described below.

3.3.2 Specification
The battery specification is chosen according to the follows and assumes that the temperature at the site is at least 10°C
and the diesel engines have been correctly preheated:
The equipment has been selected for its suitability for starting, especially its ability to meet the starter's requirement
as specified by the diesel engine's manufacturer.
Each battery has enough capacity for 6 times (each 15 second) successive starting attempts.
The batteries have sufficient capacity to ensure the starting sequence, i.e. guarantee that the action for six attempts
plus the 'Not started' alarm should still occur after a mains power supply failure lasting 72 hours.
The voltage of a battery providing the direct current required by the starter must not be less than 80% of the
battery's rated value.

3.4 Chargers
3.4.1 Specification
Type Automatically adjusted
Rectification Double alternating
Primary voltage 240V – 60Hz
Operating temperature range - 5°C to + 50°C
Overloading / short circuit protection yes
Nominal secondary voltage 12V DC 24V DC
Floating voltage 13.8V DC 27.2V DC
Secondary current 6A 6A
Consumption 150W 250W

3.4.2 Configuration and adjustment

The chargers used are factory configured with a nominal floating voltage and don’t need intervention or subsequent
adjustment.

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 NFPA20 FW PUMP CONTROLLER MANUAL

3.5 User inputs/outputs

3.5.1 Inputs
The all or nothing inputs to the control panel to which the user connects external contacts have a power consumption of
about 500 microamperes (under a polarity of 5V DC).

3.5.2 Outputs
In addition to the six outputs for displaying information 1 NO contacts and 1 NC contacts for each with the following
characteristics).

Permanent allowable current 8A

Maximum acceptable voltage 250V
Interrupting capacity 120W

4. EXTERNAL CONNECTION
All the connection between the control panel, the fire pump and engine etc are following the controller drawing.
The terminals should be left empty or a jumper should be added, depending on the type of contact.
The on-site cabling arrangement should conform to current practices and applicable standards (i.e. NFPA20,
DEP.33.64.10.10 etc.). The cross-sections of the conductors must be appropriate for the current and avoid
unacceptable voltage reductions.

5. DIESEL ENGINE
The installation and use conditions for the diesel engine turning the pump must comply with Engine Manual.

5.1 Engine
The diesel engine is used at a speed that is no more than 90% of the maximum speed indicated by its manufacturer
on the characteristics curve.
The engine is fitted with a suitable water preheating system
The engine is sized to be able to operate without excessive mechanical or thermal effort at its nominal operating
power for six hours.
The engine has a manual stop and the starter system automatically returns to the automatic starting position after
the manual stop has been used.
The engine is sufficiently well managed so that the change in its speed between the extreme operating levels
(demands of zero and 150%) is no more than +/- 10%.
All belts and moving parts are fitted with suitable mechanical protections.

5.2 Cooling
The diesel engine is cooled by radiator and coolant for the heat exchanging.

5.3 Exhaust
Exhaust gas must be ducted out of the building using piping of a diameter such that the length and accidents do not
result in a loss of loading that is greater than the allowed back-pressure when operating at a top speed of 150%.
The duct outlet must prevent water or birds from entering it.
The exhaust pipe connection must use an expansion joint that avoids all tracking, squashing, stretching or lineage.
The exhaust pipe must be thermally insulated to a height of 1.60 metres from the ground.

5.4 Fuel supply

The engine is supplied by a fuel tank fitted to provide a gravity feed to the injection pump. The fuel tank has a capacity
that provides independent operation that complies with the N.F.P.A. standard.
5.5 – Pump room ventilation
The pump room must have a low and a high ventilation opening. This size and position of these ventilations must be
chosen with care to avoid a significant pressure reduction or temperature rise when the diesel engine is operating.

The user must take all necessary precautions to ensure that the ambient temperature in the premises does not fall below
10°C. If necessary, gate valves can be used that are operated by a direct current motor or a pneumatic piston.

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 NFPA20 FW PUMP CONTROLLER MANUAL

6. ALARMS
Mains Supply
Audible and visible alarm occurs when the mains power supply is cut (180 seconds delay).

1# and 2 # Charger Fault

Audible and visible alarm occurs when the mains power supply is cut or when the downstream fuse is blown. (20 second
time delay)

1# and 2 # Battery Fault

There will be a audible alarm when the battery is low voltage or the battery is disconnected.

Fail to Start
Audible and visible alarm occurs When the engine has not been started after six attempts.

High Engine Temperature:

Audible and visible alarm occurs When the engine coolant temperature is overheat,

Low Oil Pressure:

When there is an oil pressure fault during the engine running, the sensor will disconnect and trigger the audible and
visible alarm. (5 second time delay).

Low Fuel Level:

When the fuel is insufficient, the fuel level sensor will disconnect and trigger the audible and visible alarm.

Panel Heater Fault:

Audible and visible alarm occurs when the FW pump controller panel heater has fault.

Overspeed:
Audible and visible alarm occurs when the engine is overspeed (the engine speed is more than the setting data), and the
engine will emergency stop, then operator shall turn the selector switch to “off” to avoid the automatic start again when
the fault still haven’t being removed (i.e. fuel supply system fault, etc.).

Warning Fault:
When there is input alarm from the engine panel, the audible and visible alarm occurs

Resetting alarms & Buzzer:

Turn the “Reset alarms & buzzer” switch on “left” position for resetting after removing the fault.

7. REGULAR MAINTENANCE
Regular maintenance for the controller is every six month. And the check the follows:
Clean it by the air
Check the fastening of terminal and cable
Check the lamp and horn

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Appendix 1: Panel Heater (A)
Appendix 1: Panel Heater (B)
Appendix 2: Weekly Programmable Timer
Appendix 3: DC Voltage Relay
Appendix 4: Electronic Timer Relay
HHS 18 eries
S
Appendix 5: Digital Pressure Controller