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SPU Manual Hifog
SPU Manual Hifog
SPU Manual Hifog
Published by
Marioff Corporation Oy
2013 all rights reserved
Virnatie 3
01300 Vantaa
Finland
Tel. +358 (0)10 6880 000
Fax +358 (0)10 6880 010
http://www.marioff.com
In case of discrepancy between the original English document and the translated
document, the English text prevails.
All rights reserved. Marioff Corporation Oy reserves the right to change or modify the
information given in this document, including technical details, without notice.
Reproduction of any part of this document without the express written permission of
Marioff Corporation Oy is prohibited.
HI-FOG and Marioff are registered trademarks of Marioff Corporation Oy. Marioff is part
of UTC Climate, Controls and Security Systems, a unit of United Technologies Corp.
(NYSE:UTX), which provides high technology products and services to the building and
aerospace industries worldwide. More information on Marioff group companies, agents/
distributors and references can be found at www.marioff.com.
CAUTION
HI-FOG systems comprise mechanical components that employ high pressure for water
pressurization. HI-FOG system installation embraces high-pressure testing of discharge
tubing. Care must be taken to ensure that all relevant safety procedures are followed
during installation to the satisfaction of the authority having jurisdiction and that only
competent personnel, appropriately trained and certified, are permitted to install, test,
commission and service the system. Marioff group companies and their respective
affiliates, officers, employees and representatives shall have no liability whatsoever for the
compliance by third parties to the present manual or to any applicable safety procedures.
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Table of Contents
Table of Contents
1. Introduction .................................................................................7
1.1 Modular design .................................................................7
1.2 Functionality......................................................................8
1.3 Installation.........................................................................8
1.4 More information...............................................................8
2. Warnings and cautions ..............................................................10
3. General MSPU description.........................................................12
3.1 Master and slave pump units............................................12
3.2 Tank unit ...........................................................................13
3.3 Filter unit ...........................................................................14
3.4 Starter Cabinet..................................................................14
4. Mechanical connections ............................................................18
4.1 Fastening pump units .......................................................18
4.2 Preparing tubes ................................................................18
4.3 Tightening torque for cutting ring tube connections..........18
4.4 Connecting master and slave pump units.........................19
5. Electrical connections................................................................24
5.1 Junction box cable connections........................................24
5.2 Starter Cabinet cable connections....................................24
6. Operation modes ........................................................................26
7. Starting and stopping.................................................................28
7.1 Automatic start..................................................................28
7.2 Manual local start..............................................................28
7.3 Stop after automatic and manual local start .....................28
7.4 Emergency start (remote) .................................................29
7.5 Stop after emergency start ...............................................29
8. Resetting......................................................................................30
9. Maintenance ................................................................................31
9.1 Check all valve positions ..................................................31
9.2 Check stand-by pressure and pump operation.................32
9.3 Check electric supply, test lamps .....................................32
9.4 Visually inspect pump unit and its fittings .........................33
9.5 Check pump oil levels.......................................................33
9.6 Check drive chains and flexible coupling..........................34
9.7 Check air pressure regulator and empty water lock .........35
9.8 Test run the unit................................................................35
9.9 Test units max pressure and flow ....................................36
9.10 Check control cabinet batteries and charger ..................38
9.11 Check settings of pressure and flow switches
and transducers .....................................................................38
9.12 Test unit in accordance with service instructions............38
9.13 Change pump oil.............................................................39
10. Troubleshooting........................................................................40
10.1 General faults .................................................................40
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10.2 Alarms.............................................................................41
A. APPENDIX - Spare parts..............................................................45
B. APPENDIX - Checking water filter................................................47
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1. Introduction
This manual describes how to operate and maintain the modular HI-FOG Sprinkler
Pump Unit (MSPU) that is part of a VdS-approved HI-FOG system. This manual aims to
describe the MSPU at a general level; note that the illustrations or details in this document
may not reflect exactly the MSPU version supplied if there are customer-specific
modifications.
Any changes made to the supplied and installed system or its equipment are allowed only
with the written consent from Marioff Corporation Oy.
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Voltage options
60 Hz frequency
Soft starters
Connecting cables special lengths
1.2 Functionality
The MSPU comprises of pump modules which, upon activation, are started sequentially,
thus reducing the electric power peak loads. In stand-by position, the system pressure is
maintained at 25 bar (or other system-specific set value) by means of a stand-by pump.
The MSPU can be started automatically, manually, or remotely. The automatic start is
activated by flow or by low pressure. The manual start is activated from the Starter
Cabinet. The remote start can be included to allow activation by a release panel or a thirdparty signal.
A fire causes the heat-sensitive bulbs on one or more sprinklers to break. Alternatively,
section valves are opened and water starts to flow from the released spray heads. Pressure
switches generate a signal to start the MSPU when the pressure decreases. Also, the flow
monitor detects the flow and starts the MSPU.
1.3 Installation
The MSPU installation is instructed and described in project-specific documentation.
Contact Marioff if you have questions or concerns about the installation or need to get onsite help from an installation team.
NOTICE! HI-FOG system uses high pressure water which can be dangerous if
the system is not properly installed.
Service area
Reserve free space around the unit installation: at least 750 mm on all unit sides, 400 mm
above the unit and 800 mm in front of the Starter Cabinet doors (or the width of the
doors). This area needs to be kept available for service and maintenance work.
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Third-party documents:
High pressure plunger pump operating instructions
Stand-by pump operating and maintenance instructions
Fire Detection System operating instructions
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Cautions
Water used with the HI-FOG system must be the equivalent of a potable supply. In all
cases the input water must be fed through a < 100 m filter and the chloride concentration
MUST not exceed 50 ppm (= 50 mg/l). Under no circumstances add suppression additives
to the stored water supply.
Only appropriately trained personnel are permitted to work on, test, and service the
MSPU, the sprinkler system, and its associated equipment. When in doubt, contact
Marioff representative.
Check, test, and service the MSPU in accordance with the instructions in this manual.
NOTICE! Failure to check, test, and service the MSPU in accordance with the
instructions given in this manual can jeopardize the reliable operation of the
system.
Only use spare parts that are manufactured, supplied, or recommended by Marioff.
If the MSPU is switched off for any reason, take adequate fire precautions, according to
your safety procedures, to cover the period that the MSPU is out of operation.
Warnings
The HI-FOG MSPU produces high-pressure water when operating. To avoid injury to
personnel and/or damage to equipment always follow the safety procedures described in
this manual and required by the authorities.
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Only qualified personnel are permitted to perform electrical work on the MSPU. Check
local safety regulations.
Electrical cabinets may have several power supplies and voltages. Each power supply
must be isolated before starting electrical work.
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High pressure
water outlet
Junction box
Electric motor
Pump
Water inlet
Unloader
Test valve
Stabilisation
valve
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Overflow line
Unloader line
Plastic tank
Filter
Water inlet
Tanks can be delivered with water level indicators: either electric level switches or
mechanic float valves. Always check project-specific documentation on tank unit
mechanical and electrical details.
For more information, see Technical Data Sheet DOC0001724.
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The Starter Cabinet has the following manual operations and selections (numbers in
brackets correspond those in Figure 4 on page 17):
Manual start motor 15 (M1M5)
Pump Unit manual start (1)
Buzzer acknowledge (2)
Alarm reset (3)
Lamp test (4)
Voltage metering selection (5)
Pump Unit manual stop/system reset (6)
The Starter Cabinet has the following indications:
230VAC control voltage fault (7)
Battery charger fault (8)
Earth fault 24VDC (9)
Pressure switch PS-1/PS-2 fault (10)
Compressed air low pressure (11)
Out of water (12)
Sprinkler pump malfunction (13)
Inlet/outlet valve closed (14)
Circuit breaker released (15)
Pump Unit motor overload (16)
Control system on (17)
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15
12
17
18
13
M1
M2
M3
M4
3
M5
11
10
14
4
16
200
1800
1200
Figure 4. MSPU05 Starter Cabinet dimensions, operations, selections, and indications (used as an example)
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4. Mechanical connections
This chapter describes how to connect the different MSPU parts. The master and slave
pump units are delivered as separate items that have to be connected when installing the
units. All needed parts are included in the delivery.
Note that the MSPU05 is used as an example in the instructions below. Always check the
details from project-specific documentation.
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3
2
1 high pressure line (38S ( 38x3) DIN2353
2 test outlet line (38S ( 38x3) DIN2353
3 water inlet pipe (DN80 DIN2642 FLANGE)
Figure 5. Connecting points of master and slave pump units (MSPU05 as an example)
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Figure 6. Connecting the high pressure line between MSPU05 master pump unit MSPU03 (item A in the figure) and slave
pump unit MSPU02 (B)
Step 2. Connect the high pressure line to the master pump and tighten the
connection.
Step 3. Connect the high pressure line to the slave pump and tighten the
connection.
Step 4. Attach and tighten the clamp on the slave pump connection of the high
pressure line.
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Figure 7. Connecting the test outlet line and water inlet line between MSPU05 master pump unit MSPU03 (A) and slave
pump unit MSPU02 (B)
Step 2. Connect the test outlet line to the master pump and tighten the
connection.
Step 3. Connect the test outlet line to the slave pump and tighten the
connection.
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A
B
Bolt
Flange
Seal
Nut
Figure 8. Connecting the water inlet between MSPU05 master pump unit MSPU03 (A) and slave pump unit MSPU02 (B)
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3
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5. Electrical connections
This chapter describes the main electrical connections of the MSPU. For detailed
description of the electrical connections, see the Connection Diagram of the supplied unit.
The length of the standard cables is 10 m; special lenghts are available per request.
Note that all external cabling needs to be ordered separately.
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Main supply
Motors
Air compressor
Junction box (pressure and flow switch signals, valve monitoring and control)
Water tank (low level switch)
Alarm panel signals, which are at least the following:
HI-FOG activated, line voltage fault, pump unit fault.
The cable entries for external cabling are illustrated in Figure 11 below.
2 3
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6. Operation modes
This chapter describes the various modes of the MSPU: stand-by, operating, off,
deactivated, and stabilisation.
Stand-by
Stand-by is the normal state of the system when it is on. In normal use the system MUST
always be in stand-by. The following conditions apply for the stand-by mode:
the MSPU is connected to the electric supply and the main power switch is on
working air is supplied to the stand-by pump and the pump is operational
the system pressure is within the set limits (25 bar, or system-specific)
the control system is operational
the piping and connections are sound and tight (for more information, see document
P32010 Installation and Pre-Commissioning Manual Land Projects)
After stabilisation the system automatically returns to the stand-by mode.
Operating
Operating is when the system is activated and high-pressure water is fed to the HI-FOG
system forming the HI-FOG mist discharge. The pump unit will maintain the required
pressure and flow in the system until a stop signal is given or before the pump runs out of
water.
When the MSPU is activated, the pump modules automatically start in sequence, with a
few seconds delay between each start, in order to reduce electric peak loads.
If the flow of water required is less than the output of the unit, the unloader valves open
and route extra water back to the tank unit or drain.
The low level switch in the break tank or a pressure switch in the feed water line will
prevent the unit from starting when there is not enough water, or will stop the motors
from running dry. When the redundancy source of water (if applicable) has been
connected and/or the water break tank has been refilled, the pumps restart automatically.
Off
Off mode is when the system is shut down for maintenance or repair.
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Deactivated
Deactivated state is when the pump unit has been either manually switched off from the
main switch or the inlet or outlet water valve has been closed.
Stabilisation
Stabilisation is needed for the system to return to stand-by mode again after a discharge.
Stabilisation is automatic; it is started when pressing the system reset button (pump unit
manual stop/system reset, item 6 in Figure 4 on page 17) and it takes from about 30
seconds up to a few minutes. During stabilisation the system pressure drops to the standby level (25 bars by default).
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NOTICE! Before initiating a local manual start, check that no fault alarms are on
and water is available. Running the system without water may damage the pumps.
Starting the pump with the manual switches in the Starter Cabinet overrides the
water low level interlocking in automatic and emergency start.
NOTICE! Stopping the pump unit is normally done by the fire officer or fire
protection responsible.
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Step 2. Check in the pressure gauge that the system pressure is at 130 140
bar.
Step 3. Press Pump Unit manual stop/system reset button on the Starter
Cabinet.
All motors are turned off and the stabilisation valve opens. The Pump Unit manual stop/
system reset signal light is on during stabilisation.
NOTICE! Standard systems do not reset unless the system pressure has reached
130 bar. The pump unit must be run until the pressure has risen above130 bar
before resetting the system.
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8. Resetting
A reset after MSPU start and stop is always needed for the system to return to the stand-by
mode. Resetting MSPU is an automatic operation sequence and is started by pressing the
Pump Unit manual stop/system reset button in the Starter Cabinet. This is described in
chapter Stop after automatic and manual local start on page 28.
Before the whole system can be reset, all flow in the system must be stopped; if a sprinkler
has released, the section valve must be closed.
In system reset, first the stabilisation valve opens and the pressure in the system drops
down to a preset value (typically 22 bar). Then the stabilisation valve closes and the standby pump raises the stand-by pressure to the required 25 bar (or other system-specific set
value).
Stabilisation takes from about 30 seconds up to a few minutes, during which time an
automatic restart is prevented. During stabilisation the emergency start and manual local
start is possible.
The Pump Unit manual stop/system reset signal light is on when the system pressure
drops from 130 bar to 22 bar. When the signal light goes off, system has returned to standby mode.
Reset possible alarms by pressing the Alarm reset button in the Starter Cabinet.
NOTICE! Standard systems do not reset unless the system pressure has reached
130 bar. The pump unit must be run until the pressure has risen above130 bar
before resetting the system.
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9. Maintenance
This chapter describes the minimum requirements for maintenance routines of the
MSPU. Always check project-specific documentation for MSPU and system level
maintenance routines and their frequencies.
The table below displays the frequency of maintenance routines and the chapters after the
table describe the actual tasks. In addition to the information in Table 1, note the
following:
Other maintenance frequencies may be specified in local laws and regulations or in
customer-specific system specifications.
Refer to the respective third-party manufacturers instructions (as delivered with the
system) for more information.
Table 1: Maintenance routines for MSPU
Every 5
years
Chapter
Action
Weekly
Monthly
Annually
9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8
9.9
9.10
9.11
9.12
9.13
*other frequencies may be specified in local laws and regulations or in the system-specific
instructions
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Open valves
outlet valve to the sprinkler system (1)
water inlet valve (2)
air inlet valve to the stand-by pump (3)
Closed valves
test valve (4)
1
3
2
4
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Press the Lamp test button in the Starter Cabinet. All signal lights in the Starter Cabinet
should be lit (and the buzzer should ring). Change any faulty light bulbs.
The oil color should be clear golden brown. If the oil is dirty, cloudy, or grey when the unit
is in the stand-by mode, change the oil. See the third-party manufacturers pump
operating instructions.
NOTICE! The oil appears cloudy when the unit is in the operation mode.
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NOTICE! Switch the unit off before checking the drive chains and coupling.
Turn the main switch off and secure it before removing the cover.
The drive chains are self-lubricated, which means that they do not need to be greased. To
indicate this, there is a notification sticker attached to the gearbox with the following text:
Notice! Do not use grease. This roller chain is self-lubricated.
However, if the drive chains are not maintenance-free (in older pump units) and there is
no notification sticker, the drive chains must be well greased. If the chain is dry or rusty,
grease the chain by using Shell Kuggfett or an equivalent molybdenum-graphite based
grease with heat resistance up to +200C and good adhesion capability.
Check the condition of the flexible couplings. A slight amount of wear is normal - if any
signs of excessive wearing are shown, change the coupling. See Figure 14.
Figure 14. Check the drive chains and the flexible coupling
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Step 3. When testing the automatic start locally, note the following.
The low pressure start is tested by closing the air supply to the stand-by pump and fully
opening the test valve.
The flow switch start is tested by slowly opening the test valve so the pressure does not
drop below 17 bar (or the set default value). See Figure 15.
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Figure 15. MSPU05 test valve (1) and air inlet valve (2) locations
Step 4. Close the test valve if it has been opened for testing.
Step 5. Stop the unit by pressing the Pump Unit manual stop/system reset
button on the Starter Cabinet.
Step 6. Open the water outlet valve if has been closed for testing.
Step 7. Check that the pressure in the system returns to the 25 bar stand-by
pressure.
If the water outlet valve is closed, the stabilisation takes only seconds.
Step 8. Check that the whole system is reset and in stand-by mode.
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Step 1. Close the test valve by lifting the lever to upright position.
Step 3. Check from the pressure gauge that the pressure is at 140 bar.
Pressure gauge
Step 4. Open the test valve by lowering the test valve lever.
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Step 5. Read the maximum flow value from the flow meter.
The nominal flow output is 97,4 liters per one minute per one motor.
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Figure 16. Change pump oil: the locations of the oil fill and oil drain plugs
Use an ISO VG 220 or SAE 90 class gear oil. Oil quantity is 0,9 litres per pump. See the list
below for pump oil recommendations:
ARAL: Getriebel EP 85W-90, Degol BG 220
BP: Energear 90, Energol GR-XP 220
CASTROL: EP 90, ALPHA SP 220, ALPHA MW 220
ESSO: GEAR OIL GX 85W-90, GEAR OIL GP-D 85W-90
SPARTAN EP 220
Mobilube GX 85W-90-A
Mobilgear 630
Shell SPIRAX GX SAE 80W-90
NESTE GEAR EP 80W-90
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10. Troubleshooting
This chapter lists the possible fault situations and their remedies. If the problem you are
facing is not listed here, contact Marioff immediately.
Always when contacting Marioff in troubleshooting situations, have the following
information available:
the project number of the installed system
the serial number of the pump unit
detailed description of the fault situation (what was done before the fault situation
occured and what happened during the fault situation)
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10.2 Alarms
This chapter lists the MSPU system alarms.
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Solution: Check the system for low voltage, excess voltage, or asymmetric phases. Check
phase monitor relay K0.5.
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Description
Type Code
Stock Code
Pump
NP25/41-140 left
E02050
Pump
NP25/50-140 left
E02055
G40130.1
G40135
Pump oil
EP SAE80W-90
L53005
Unloader
UL262/2
D51023
G40011
Electric motor
See nameplate
E04097.1
42/64 SH Clutch
E04019
M12080
M23064.A
PK40
M23014
Pressure switch
PEV-1/4-B-OD
M23005
Flow monitor
SID10ADBFPKG/ US-100-IPF
M21012.1
Flow monitor
HP756B-030
M02000
Pressure gauge
213.53.63.250B/P ALA
M01022
E40040
G40090
G40095
SVM 12-ANN-S12/12-10-0
D01535
V11070.A
V10101.A
FRC-1/4
E41015
Safety valve
VS200/180-60.5115.18
D-0002599
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* Drive chain spare part sets include clutch flex element, clutch, roller chain, sprocket
wheel and other needed parts.
**You need 4 pieces of pump support sleeves to pull the pump out when replacing the
drive chain. Pump support sleeves are not included in drive chain spare part sets V31161
and V31181.
***See Marioff Spare part and maintenance drawing DMOVSE000862.
****See Marioff Technical data sheet K0008018.
*****Electrical components may vary considerably depending on the project. See projectspecific part list for electric spare parts.
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Bleeding screw
Water outlet
Filter cover
Filter cartridge
Water inlet
Drain plugs
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Step 3. Open the filter cover by unscrewing the screws holding the lid in place.
Step 4. Pull out the filter cartridge and check it visually.
Change the cartridge if contaminated.
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Step 10. Carefully open the water inlet valve until water comes out from the
water filter bleeding screw.
Step 11. After filling the unit, tighten the air bleeding screw.
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Step 1. Remove the locking wire from bypass screws (see Figure 22.).
Figure 24. Remove the upper extension spring and tighten the bypass screw
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Figure 25. Install the locking wire and upper extension spring
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