Installation, Operation, and

Maintenance manual
AC6102 Rev 7

Centrifugal Split Case Fire Pumps

Series 8100, 8150, 8200, 9100

Original Instructions
Series 8100/8150/8200/9100 Fire Pump

1 AC6102 Rev 07
 EU Declaration of Conformity
Pump supplied complete with driver
We: Fluid Handling LLC
A-C Fire Pump Systems
8200 N. Austin Ave.
Morton Grove, IL 60053, USA,
This declaration of conformity is issued under the sole responsibility of the manufacturer.

The manufacturer of this equipment, declare that the product Horizontal Split Case Centrifugal Fire Pump,
Series 8100, 8150, 8200, and 9100 with sizes of the pump reflected as a series of letters and numbers as
follows: No letter, or letter H, followed by one or two digits denoting inlet pipe size, followed by one or two
digits denoting outlet pipe size, followed by one or two digits denoting impeller diameter, followed by F, may
be followed by S, M, L or XL
to which this declaration relates, is in conformity with and fulfills the relevant provisions and essential
requirements of the following European Directive(s), Standard(s) or other normative document(s):
- Machinery Directive (2006/42/EC).
- Low Voltage Directive (2014/35/EU).
- EMC Directive (2014/30/EU).
References to the relevant harmonized standards used or references to the other technical specifications in relation to which
conformity is declared:
- EN 809:1998+A1:2009. - EN ISO 14120:2015.
- EN ISO 12100:2010. - EN ISO 13857:2008.
- EN 12162:2001 +A1:2009. - EN 60204-1:2006+A1:2009.(models with motor drivers)
- EN ISO 20361: 2015. - EN 61000-6-2:2005. (models with diesel engines drivers)
- EN ISO 4871: 2009. - EN 55011:2009+A1:2010. (models with diesel engines drivers)

EC Declaration of Incorporation
Pump supplied without driver
We: Fluid Handling LLC
A-C Fire Pump Systems
8200 N. Austin Ave.
Morton Grove, IL 60053, USA,
This declaration of incorporation is issued under the sole responsibility of the manufacturer.
The manufacturer of this equipment, declare that the product Horizontal Split Case Centrifugal Fire Pump,
Series 8100, 8150, 8200, and 9100 with sizes of the pump reflected as a series of letters and numbers as
follows: No letter, or letter H, followed by one or two digits denoting inlet pipe size, followed by one or two
digits denoting outlet pipe size, followed by one or two digits denoting impeller diameter, followed by F, may
be followed by S, M, L or XL
to which this declaration relates, is in conformity with and fulfills the relevant provisions and essential
requirements of the following European Directive(s), Standard(s) or other normative document(s):
- Machinery Directive (2016/42/EC).
References to the relevant harmonized standards used or references to the other technical specifications in relation to which
conformity is declared:
- EN 809:1998+A1:2009. - EN ISO 12100:2010.

The pump covered by this declaration must not be put into service until the equipment into which it is to be
incorporated has been declared in conformity with the provisions of the Directive.
The technical file can be supplied, in response to a reasoned request by the competent national authorities, through our
authorized representative established in the European Community:

Xylem Service Italia S.r.l.,

Via Vittorio Lombardi 14,
36075 Montecchio Maggiore,
Vicenza, Italy.

Signed for and on behalf of Fluid Handling LLC by:

Brian Buscher Morton Grove, Illinois

Global Product Manager October, 2022

AC6102 Rev 07 2
Series 8100/8150/8200/9100 Fire Pump

3 AC6102 Rev 07
 5.2.3 Engine driven pump units (Model 150E) ……… 12

Table of contents

1 Introduction ………………………………………………. 8 5.3 Storage ………………………….…………………. 13

1.1 General …………………………………………… 8 5.3.1 Temporary storage ……………………………… 13
1.2 Target Group ……………………………........... 8 5.3.2 Long Term Storage ……….…………………… 13
1.3 Safety symbols used in this manual ……........... 8
6 Description ……………………………………………..…. 14
1.4 Manufacturer ………………………………........... 8
1.5 Additional technical documents ………………… 8 6.1 General …………………………………………… 14
6.2 Designation ………..……………………………. 14
2 Safety ………………………………………………………… 8 6.3 Nameplate ………..……………………………… 14
2.1 General …………………………………………… 8 6.3.1 Pump nameplate ………………………………… 14
2.2 Intended use …………………………………….. 8 6.3.2 Pump unit nameplate …………………………… 14
2.3 Improper use ……………………………............ 8 6.4 Design detail ……………………………………… 15
2.4 Warning and Instruction Labels ……………….. 9 6.4.1 Casing …………..…………………………………. 15
2.5 Personnel qualifications and training ………… 9 6.4.2 Impeller …………………………………………….. 15
2.6 Safety awareness ………………………………… 9 6.4.3 Shaft ……………………………………………… 15
2.7 Safety instruction for the user …………………. 9 6.4.4 Shaft sleeves ……………………………………… 15
2.8 Safety instructions for maintenance, inspection, 6.4.5 Stuffing box ……………………………………… 15
and installation ……………………………………. 9
6.4.6 Casing rings ……………………………………….. 15
2.9 Noise Emissions ………………………………….. 9 6.4.7 Bearings ……………………………………..…….. 15
2.10 Unauthorized modification and manufacture of
spare parts ………………………………………… 9 6.4.8 Bearing housings …….………………………..…. 15
6.4.9 Baseplate ………………………………………….. 15
2.11 Product Warranty …………………………………. 10
6.4.10 Coupling ………………………………..………….. 15
2.11.1 Coverage ………………………………………….. 10
6.4.11 Coupling Guard ………………….…….…………. 15
2.11.2 Limitations ……………………………………….... 10
6.4.12 Rotation ……………………………………………. 15
2.11.3 Warranty Claim …………………………………… 10
6.5 Noise characteristics ……………………….……. 16
3 Applications ………………………………………………... 10 6.6 Scope of supply …………………….…………….. 16
6.7 Dimension and weights ………………………….. 16
4 Operational Limits ………………………………………. 10
7 Installation …………………….……..….…………………. 16
4.1 Pumped liquids ……………………………………. 10
7.1 Location ……………………………………..…….. 16
4.2 Liquid temperature ……………………………….. 10
7.2 Foundation ………………………………….…….. 16
4.3 Pressure limits ……………………………………. 10
7.3 Leveling the baseplate …………………….…….. 17
4.4 Ambient temperature …………………………….. 10
7.4 Grouting …………………………………..……….. 17
4.5 Pump speed ………………………………………. 10
7.5 Initial Alignment ……………………………….….. 18
5 Delivery, handling, and storage ………………………… 11 7.5.1 Straightedge method of alignment …………….. 18

5.1 Delivery ……………………………………….…. 11 7.5.1.1 Angular alignment ……………………….……….. 18

5.2 Handling ………………………………………… 11 7.5.1.2 Parallel Alignment ………………………….…….. 18

5.2.1 Bare shaft pump (Model 100) …….……………. 11 7.5.2 Dial indicator method of alignment …………….. 18

5.2.2 Complete pump unit (Model 150M) …………… 11 7.5.2.1 Angular alignment ……………………….……….. 19

5.2.2.1 Lifting Pump, Motor and Baseplate….………… 11 7.5.2.2 Parallel Alignment ………………………….…….. 19

5.2.2.2 Vertical – Half Pedestal – Model 200……… 12 7.5.3 Alignment of grid couplings …….….….. 19

5.2.2.3 Vertical – Full Pedestal – Model 300……… 12 7.5.3.1 Mount seal and hubs …………………….………. 19

AC6102 Rev 07 4
Series 8100/8150/8200/9100 Fire Pump

9.2 Maintenance interval ……………….……………. 29

7.5.3.2 Gap and Angular alignment (X-Y) ……………… 19 9.3 Lubrication ……………………………….…….….. 29
7.5.3.3 Parallel Offset Alignment (P) …………...………. 19 9.3.1 Lubricating grease requirements ………….…… 29
7.5.3.4 Insert Grid …………………………………………. 19 9.3.2 Grease lubrication ……………………….…….…. 30
7.5.3.5 Pack with grease and assemble covers ………. 19 9.3.3 Lubrication procedure ……………………………. 30
7.6 Pipe connections …………………………………. 20 9.4 Packed stuffing box …………….………………… 30
7.6.1 Suction and discharge piping general 9.4.1 Packing specifications …………………………… 30
precautions ………………………………………… 20
9.4.2 Packing maintenance ……………………………. 30
7.6.2 Maximum forces and moments allowed on
pump flange …………………………………..…… 21 9.4.3 Removal of packing ……………………………… 30

7.6.2.1 8100 series Horizontal split case maximum 9.4.4 Installing packing …………………………………. 30
forces and moments allowed ………………….… 21 9.4.5 Packing adjustment ………………………………. 31
7.6.2.2 8150 series Horizontal split case maximum
forces and moments allowed ………………….… 21 10 Service ……………………………………………………… 32
7.6.2.3 8200 series Horizontal split case maximum
10.1 Tools required …………………………………….. 32
forces and moments allowed ………………….… 21
10.2 Dismantling ………………………………………... 32
7.6.2.4 9100 series Horizontal split case maximum
forces and moments allowed …………………… 22 10.2.1 Rotating Element …………………………………. 32
10.2.2 Bearing housing ………………………………….. 32
7.6.3 Suction piping ………………………………...…… 23
10.2.3 Shaft seal - gland packing ………………………. 32
7.6.4 Discharge piping …….……………………………. 24
10.2.4 Shaft sleeve ……………………………………….. 33
7.6.5 Bypass piping ……………………………………… 24
10.2.5 Impeller and casing wear rings …………………. 33
7.6.6 Cooling system ……………………..……..……… 24
10.3 Examination of parts ……………………………... 33
7.6.7 Exhaust system ……………………………...…… 24
10.3.1 Casing and impeller ……………………………… 33
7.6.8 Pressure gages ……………………..…….……… 25
10.3.2 Shaft and sleeve ………………………………….. 33
7.6.9 Stuffing box lubrication …………………..……… 25
10.3.3 Gaskets and O-rings ……………………………... 33
7.6.9.1 General guidelines ………………………..……… 25
10.3.4 Bearings …………………………………………… 33
7.6.9.2 Packing …………………………………..………… 25
10.3.5 Bearing isolators and lip seals …………………. 33
7.7 Final Alignment ………………………….………… 25
10.4 Assembly ………………………………………….. 33
7.8 Electrical Connection …………………..………… 25
10.4.1 Wear Rings ………………………………….…….. 33
8 Start-up, operation and shutdown ……………...……… 26 10.4.2 Impeller …………………………………………….. 34

8.1 Start-up …………………………………..………… 26 10.4.2.1 Series 8100, 8150 and 9100 …………….……… 34

8.1.1 Preparation for start-up ………………..………… 26 10.4.2.2 Series 8200 ……………………………………….. 35

8.1.2 Priming …………………………………..………… 26 10.4.3 Bearings and bearing housings ………………… 35

8.2 Coupling Guard ………………..……….………… 26 10.4.3.1 Series 8100 ……………………………………….. 35

8.2.1 Removing the coupling guard ………….…….… 27 10.4.3.2 Series 8150 ……………………………………….. 36

8.2.2 Installing the coupling guard ……………………. 27 10.4.3.3 Series 8200 ……………………………………….. 36

8.3 Operation ………………………………..………… 28 10.4.3.4 Series 9100 ……………………………………….. 36

8.3.1 General procedure ……………………..………… 28 10.4.4 Rotating Element …………………………………. 36

8.3.2 Optional Checklist ……………………..………… 28 10.4.4.1 Series 8100 ……………………………………….. 36

8.4 Shutdown ………………………………..………… 28 10.4.4.2 Series 8150 ……………………………………….. 36

8.5 Returning to service ……..………….…………… 28 10.4.4.3 Series 8200 ……………………………………….. 36

8.6 Freeze protection ……………..…….…………… 28 10.4.4.4 Series 9100 ……………………………………….. 37

8.7 Field testing ………………………….…………… 28 10.4.5 Casing Gaskets …………………………………… 37

10.4.6 Stuffing Box Assembly – Packing ……………… 37
9 Maintenance ……........................................................... 29 10.5 Tightening torques ……………………………….. 37
9.1 General …………………………………………… 29 10.5.1 Casing Bolts ………………………………………. 37

5 AC6102 Rev 07
 10.5.1.1 Tightening sequence …………………………….. 37
10.5.2 Other Bolt Locations ……………………………… 38
10.6 Spare Parts ………………………………………... 38

10.6.1 Ordering Spare Parts …………………………….. 38

10.6.2 Storage of spare parts …………………………… 38

11 Troubleshooting …………………………………………… 39

12 Replacement Parts ………………………………………… 41

12.1 Series 8100 Horizontal Split Case Fire Pump … 41

12.2 Series 8150 Horizontal Split Case Fire Pump … 43
12.3 Series 8200 Horizontal Split Case Fire Pump … 45
12.4 Series 9100 Horizontal Split Case Fire Pump … 47

A Appendix …………………………………………………..… 49

A1 Coupling Guard Removal - non CE version …... 50

A2 Changing pump rotation …………………………. 51

AC6102 Rev 07 6
Series 8100/8150/8200/9100 Fire Pump

7 AC6102 Rev 07
 NOTICE
1 Introduction Instructions that are not safety related but
pertain to the operation of the pump.
1.1 General
The A-C Fire Pump product line of horizontal split case
WARNING
centrifugal fire pumps are the product of careful
The sound pressure is so high that hearing
engineering and skilled workmanship and, if properly
protection must be used.
installed, maintained, and operated, should deliver
efficient and trouble-free service.
This manual introduces the user to the pump unit and its
intended uses. It is extremely important that the NOTICE
instructions for operating the pump safely are read, Read the installation, operation and
understood and followed prior to handling the pump. maintenance instructions.
These instructions do not consider local regulations. The
user alone is responsible for ensuring that such
regulations are observed, including by those who are
installing the pump unit. 1.4 Manufacturer
A-C Fire Pump Systems
CAUTION 8200 N. Austin Avenue
Read this manual carefully before installing, Morton Grove, Illinois 60053
operating, using and maintaining the pump. USA
Improper use of the pump can cause Tel.: +1-847-966-3700
personal injury and damage to property, and
may void the warranty. Web: www.acfirepump.com

NOTICE 1.5 Additional technical documents

Save this manual for future reference, and
keep it readily available at the location of the
unit.
1.2 Target Group
This manual is intended for use by personnel with
qualified training and experience in the operation and
maintenance of pumps used for fire suppression.
• Order-related documents.
• Operating and maintenance instructions, motor, (if
applicable).
• Operating and maintenance instructions, engine, (if
applicable).
• Supplier documentation, (coupling, etc.).
• Documentation on accessories, (if applicable).
• General dimensional drawing of the pump unit.
• Performance curve of the pump.

1.3 Safety symbols used in this 2 Safety

manual
2.1 General
WARNING This manual contains general installation, operating and
If these safety instructions are not followed, it maintenance instructions that must be observed to ensure
could result in serious personal injury or death, safe pump operation and to prevent personal injury and
or property damage. damage to property.

CAUTION 2.2 Intended Use

If these safety instructions are not followed, it
could result in equipment malfunction of
damage.
WARNING
Electric Shock Hazard, failure to follow safety
instructions could result in personal injury or
death.
The standard horizontal split case pump is designed for
use in the fire suppression applications, with each pump
being designed according to customer requirements.
The pump must only be operated with the operating limits
described in this manual and other applicable documents
listed in section 1.5, Additional technical documents.

2.3 Improper Use

WARNING
The surface of the pump may be so hot that it
may cause burns or personal injury.
The operational safety of the pump unit can only be
guaranteed, if the pump is used in accordance with the
specifications in the sections of this manual. The
operational limits as stated on the pump unit’s nameplate
must never be exceeded.

AC6102 Rev 07 8
Series 8100/8150/8200/9100 Fire Pump
2.4 Warning and Instruction Labels
The safety instructions labels placed directly on the pump
must be observed and legible at all times. If the labels are
missing or illegible, contact your local A-C Fire Pump
representative for a replacement.
WARNING
Rotating Components.
Disconnect and lockout power
before servicing. Do not operate
without all guards in place.
Consult installation and service
instruction sheet before
operating or servicing. Failure
to follow instructions could
result in injury or death.
WARNING
Eyebolts or lifting lugs if provided
are for lifting only the components
to which they are attached.
Failure to follow instructions could
result in property injury or death.
WARNING
Do not operate at or near zero
flow (closed shutoff valve).
Explosion could result. Failure
to follow these instructions
could result in property
damage, severe personal injury
or death.
CAUTION
Do not run pump dry. Seal
damage may occur. Inspect
pump seal regularly for leaks.
Replace as required. For
lubrication requirements,
consult service instructions.
Failure to follow instructions
could result in injury or property
damage.
CAUTION
Coupler alignment is required!
Level and grout pump before
use! Check alignment before
grouting, after system is filled,
after servicing pump, and as
required. Consult the service
instructions for details. Failure
to follow these instructions
could result in injury, or
property damage.
2.5 Personnel qualifications and
training
All personnel involved in the operation, installation,
inspection and maintenance of the pump unit must be
qualified to perform the work involved. If the personnel do
not already possess the necessary knowledge and skill,
appropriate training and instruction must be provided.
9 AC6102 Rev 07
2.6 Safety Awareness
The safety directions contained in this manual, health and
safety regulations as well as any internal work, operating
and safety rules issued by the user must be observed.
2.7 Safety instructions for the user
• Guards which are installed to prevent accidental
contact with moving parts must not be removed while
the pump is in operation.
• Electrical hazards must be prevented. Refer to the
relevant safety regulations of the region in which the
pump is installed.
2.8 Safety instructions for
maintenance, inspection and
installation
The user must ensure that all maintenance, inspection
and installation work shall be performed by authorized and
qualified personnel who are familiar with this manual.
Allow the pump to cool down to ambient temperature, the
pump must be depressurized and the liquid must be
drained.
Work in the pump unit must always be performed only
when it is completely stopped and de-energized. The
shutdown procedure described in this manual must be
observed without fail.
Immediately after completion of the work, all guarding
must be re-installed.
Before putting into operation, the procedure; outlined in
section 8, Start-up, operation and shutdown; must be
followed.
2.9 Noise Emissions
The pump unit produces a sound pressure level exceeding
85 dB(A). When performing the weekly functional test, it is
recommended that hearing protection be worn by the
personnel operating the equipment.
WARNING
The sound pressure is so high that hearing
protection must be used.
2.10 Unauthorized modification and
manufacture of spare parts
Changing or modifying the pump or pump unit is only
permitted after consulting A-C Fire Pump. The safety of
the pump can only be guaranteed if original spare parts
and accessories, which are authorized by A-C Fire Pump
are used. A-C Fire Pump does not assume responsibility
for outcomes that result from using non-original parts.
 2.11 Product Warranty 4 Operational Limits
2.11.1 Coverage WARNING
Do not operate the pump at pressures, flow
A-C Fire Pump undertakes to remedy defects in their rate or liquid temperature other than those for
products under these conditions: which the pump has been rated. Failure to
• The faults are due to defects in design, materials, or follow these instructions could result in
workmanship. serious personal injury or death, or property
• The faults are reported to a local sales and service damage.
representative within the warranty period, as
described in the Terms and Conditions of Sale Pumps are not to be operated outside the operating limits
provided with the Sales Contract. as stated on the nameplate.
• The product is used only under the conditions that
are described in this manual.
4.1 Pumped liquids
• The monitoring equipment that is incorporated in the The pumps are suitable for clean water that does not
product is correctly connected and in use. contain solid particles or fibers.
• All service and repair work is performed by qualified
personnel. 4.2 Liquid temperature
Maximum permissible liquid temperature for motor driven
2.11.2 Limitations pump units is 105°F [40°C].
The warranty does not cover defects that are caused by Maximum permissible liquid temperature for engine driven
these situations: pump units is dependent on the cooling water
• Deficient maintenance. requirements as identified in the Engine Manufacturer’s
Installation Manual.
• Improper installation.
• Modifications or changes to the product that are The pump is designed to handle temperatures up to 250°F
made without consulting an A-C Fire Pump [120°C].
authorized representative.
• Incorrectly executing repair work. 4.3 Pressure limits
• Normal wear and tear.
The maximum working pressure for the horizontal split-
A-C Fire Pump assumes no liability for these situations: case series of pumps are as follows:
• Bodily injuries. Maximum
• Material damages. Casing Working
• Economic losses. Type
Material Pressure psi
[bar]
2.11.3 Warranty Claim Cast Iron 225 [15]
8100
A-C Fire Pump products are manufactured to the highest Ductile Iron 375 [25]
quality standards with expected reliable operation and 8150 8x6x14F Ductile Iron 380 [30]
long life. However, should the need for a warranty claim
arise, contact your local sales and service representative. 8150 8x6x15F Ductile Iron 450 [26]
8150 16x10x22F Ductile Iron 325 [22]
Cast Iron 450 [30]
8200
3 Applications Ductile Iron 650 [45]
Cast Iron 250 [17]
A-C Fire Pump Horizontal Split Case Centrifugal Fire 9100
Pumps are designed to provide water to stand pipe, Ductile Iron 375 [25]
sprinkler, and hydrant systems for fire suppression in
industrial and commercial facilities. Table 1 Maximum Working Pressure

WARNING 4.4 Ambient temperature

Using the pump in an application other than
as described is considered improper use. A-C
Fire Pump shall assume no liability for
product that is used improperly.
Maximum ambient temperature for motor drive pump units
is 105°F [40°C], based on the maximum ambient rating of
the motor.
Maximum ambient temperature for engine driven pump
units is identified in the engine manufacturer’s installation
manual.

4.5 Pump Speed

The pump speed is listed on the nameplate on the pump
unit.

AC6102 Rev 07 10
Series 8100/8150/8200/9100 Fire Pump

5 Delivery, handling, and

storage

5.1 Delivery
The pump is delivered from the factory in a container
specially designed for transport by fork-lift truck or a
similar vehicle. Upon receipt, check the pump visually to
determine whether any damage has happened during
transport or handling.
Pumps and drivers are normally shipped from the factory
mounted on a baseplate. Parts and accessories can be
packaged in a separate container and shipped with the pump
or attached to the baseplate.
If any damage has occurred, promptly notify the carrier’s
agent.

5.2 Handling
WARNING
Personal protective equipment should be
worn when handling this equipment. Fig. 1 How to lift a Model 100
Transportation & installation of this
equipment should only be performed by
qualified personnel. A professional rigging 5.2.2 Complete Pump unit (Model 150M)
company should be consulted before lifting
the pump assembly. Only use properly sized,
certified lifting equipment & lifting devices, 5.2.2.1 Lifting Pump, Motor and Baseplate
including slings, suitably rated for the weights Lifting the pump less motor or the pump, motor, & baseplate
to be lifted. Slings, when used, must be of should be done by utilizing a forklift under the entire unit
identical materials to avoid differences in (Fig.2). Always take extra precaution to ensure the weight is
stretch rates. Do not use lifting devices that balanced & equally distributed across both forks. When the
are frayed, kinked, unmarked, or worn. Lifting baseplate of the assembly is structural channel construction,
eyebolts fitted on single components of the the pump and base plate should be set in place first. The
assembly (pump or motor) must not be used motor should then be separately lifted & mounted to the unit.
to lift the complete assembly. Failure to
observe these instructions could result in
equipment or property damage, serious Pump, base, and driver assemblies where the base length
injury, or death. exceeds 100 inches may not be safe to lift as a complete
assembly. Damage to the baseplate may occur. If the driver
has been mounted on the baseplate at the factory, it is safe to
NOTICE lift the entire assembly. If driver has not been mounted at the
Dispose of all packing materials in accordance factory and the overall baseplate length exceeds 100 inches,
with local regulations. do not lift the entire assembly consisting of pump, base, and
driver. Instead lift the pump and baseplate to its final location
without the driver. Then mount the driver.
The pump assembly can arrive in a variety of ways. It can be
shipped as pump end only (bare pump), pump less motor, or
pump, motor, & baseplate. Use the following recommended
ways of handling pump assemblies.

The pump assembly should remain horizontal during

transport and lifting.

5.2.1 Bare Shaft Pump (Model 100)

Lifting the pump end only (bare pump) should be done by
placing one end of the slings around or as close to the
casing barrel as possible (See Fig. 1). After the slings are
attached to the unit, recheck to ensure they are securely
in place. Make sure the slings are adjusted to obtain an
even lift.

11 AC6102 Rev 07
 5.2.2.3 Vertical – Full Pedestal – Model 300
Install eyebolts in the three holes provided at the top of the
support, being sure to tighten securely. Attach nylon sling,
chain or wire rope using latch hook or standard shackle and
end loop. Be sure to use shoulder eyebolts that are
manufactured per ANSI B18.15 and sized to fit the holes
provided. Be sure lifting equipment is of sufficient length to
keep the lift angle less than 30° from the vertical (See Figure
4).

Fig. 2 How to lift a Model 150M pump unit large base

5.2.2.2 Vertical – Half Pedestal – Model 200

WARNING
Do not use the lugs on the pump upper
casing to lift the pump unit.

Fig. 4 How to lift a Model 300

Place nylon sling, chain or wire rope around both flanges.
Use a latch hook or standard shackle and end loops. Be
sure the lifting equipment is of sufficient length to keep the
lift angle less than 30° from the vertical (See Figure 4).
5.2.3 Engine driven pump units (Model
150E)
Before lifting engine driven pump unit, refer to the engine
manufacturer’s instructions.

Fig. 3 How to lift a Model 200

AC6102 Rev 07 12
Series 8100/8150/8200/9100 Fire Pump

5.3 Storage

CAUTION
Damage due to dirt and humidity resulting in
corrosion and contamination of the pump
unit.

NOTICE
For special protection of electric motors, diesel
engines, and couplers, refer to the
manufacturer’s instruction for their long term
storage procedures.

5.3.1 Temporary Storage

If the pump is not to be installed and operated soon after
arrival, store it in a clean, dry place having slow moderate
changes in ambient temperature. Leave piping connection
covers in place to keep dirt and other foreign material out
of the pump casing.
Shaft extensions and other exposed machine surfaces
should be coated with an easily removable rust
preventative such as Valvoline Tectyl 502-C.
Rotate the pump shaft 10-15 times twice a month to coat
the bearings with lubricant and to retard oxidation,
corrosion, and to prevent false brinelling of the bearings.

5.3.2 Long Term Storage

Storage longer than six months is considered long term
storage. Follow the same procedure for temporary storage
with the following additions.
Remove the gland and the packing from the stuffing box.
Apply a corrosion inhibiting oil soluble product such as Cortec
Corporation VpCI-329, to the interior of the pump casing and
the stuffing box. [Prepare the corrosion inhibiting solution per
the manufacturer’s instructions].
Seal the end of the stuffing box with waterproof tape
Add 1/2oz [14g] of Cortec VpCI-329 to the bearing frames,
seal all vents and apply waterproof tape around the grease
seals.
Rotate the pump shaft 10-15 turns times at least every three
months to prevent the shaft from seizing up.

13 AC6102 Rev 07
 Item Description
6 Description 1 Manufacturer

6.1 General 2 Approval Agencies

The horizontal split case centrifugal fire pump is a single 3 Size

stage [series 8100, 8150 and 9100] and two stage [series 4 Model Type
8200] non self-priming pump.
5 Serial number
6.2 Designation 6 Head [feet]
The fire pump can be identified by size designation stated 7 Rated flow rate [GPM]
on the nameplate; for example, H10 X 8 X 17F-S
represents: 8 Rated pressure [psi]
9 Speed [RPM]
Code Description 10 Number of stages
No prefix=Cast iron A48;
H 11 Net pressure developed [psi]
H=Ductile iron A536
10 Suction inlet size ANSI 12 Net pressure at 150% of flow [psi]

8 Discharge outlet size ANSI 13 Maximum power [BHP]

17 Nominal impeller diameter 14 Maximum suction pressure [psi]

S-small, M-medium, L-large 15 Inboard bearing number
F-S
capacity impeller
16 Outboard bearing number
Table 2 Key for size designation
17 Country of origin
18 Impeller diameter [in]
6.3 Nameplate
Table 3 Nameplate of a Fire-pump
6.3.1 Pump nameplate
The nameplate shows all important data of the pump. It is 6.3.2 Pump unit nameplate
attached to the upper casing. Records for the pump are
referenced by the serial number and it must, therefore, be The nameplate shows all important data of the pump unit.
used to order all spare and replacement parts. [The last It is attached to the upper casing.
digit of the serial number indicates the specific pump on
orders of more than one pump].

Fig. 5 Nameplate of a Fire pump unit

Fig. 4 Nameplate of a Fire pump

AC6102 Rev 07 14
Series 8100/8150/8200/9100 Fire Pump

Item Description 6.4.4 Shaft sleeves

1 Manufacturer The shaft sleeves are made of bronze and protect the
shaft from wear and from contact with the pumped liquid.
2 CE Mark Shaft sleeves are locked in place by threaded bronze
shaft sleeve nuts. An O-ring is furnished under the sleeve
3 Type
to prevent leakage.
4 Pump Size
5 Model series 6.4.5 Stuffing Box
6 Serial number The stuffing box consists of die formed, graphite coated,
synthetic fiber packing rings; and a split type gland to
7 Engine type [engine driven pump units] permit removal and access to the packing. [The 8100
stuffing box housing is made of cast iron, and is separate
8 Motor voltage from the pump casing]. The stuffing box housing is drilled
9 Frequency and tapped for drain connections.

10 Impeller diameter [mm]

6.4.6 Casing Rings
11 Rated flow rate [m3/hr]
The casing rings are made of bronze and are installed
12 Head [m] with an anti-rotation device and designed to restrict
leakage across the ring fit.
13 Power [kW]
14 Speed [RPM] 6.4.7 Bearings
15 Pump unit weight [kg] The bearings are grease lubricated rolling type selected to
carry radial and thrust loads. The outboard bearing is
16 Date of manufacture retained to handle the axial thrust.
17 Country of origin
6.4.8 Bearing Housings
Table 4 Nameplate of a Fire pump unit
The bearing housings are bolted to the pump and are
piloted to assure positive alignment of the rotating
6.4 Design detail element. The housings provide a fit for the inboard
bearing that allows freedom for thermal expansion while
the outboard bearing(s) are clamped in place in order to
6.4.1 Casing take all the thrust loads and keep the rotating element in
its proper axial location. Openings for adding grease and
The pump casing is made from Cast Iron or Ductile Iron, draining grease are provided.
and is an axially-split double suction volute design with the
suction and discharge flanges and mounting feet cast
integrally with the lower casing half. 6.4.9 Baseplate
Tapped and plugged holes are provided for priming, vent, The baseplate is a welded construction, manufactured
drain, and gauge connections. The upper casing half can from steel and is sufficiently rigid to support the pump and
be removed without disturbing the suction or discharge the driver.
piping. Pump flanges are made with ANSI Class 125 or
250 drillings, and come in the following combinations, 6.4.10 Coupling
[Suction/Discharge]: 125/125; 125/250; and 250/250.
The coupling is of the flexible type. The coupling hubs are
The suction and discharge are on a common centerline in secured to the driver and the driven shafts by a setscrew
the vertical direction for all pump model types; and on a located over the key.
common horizontal centerline for model types 8100, 8150
and 9100.
6.4.11 Coupling Guard
6.4.2 Impeller The coupling guard is made of metal, and meets the
requirements of EN ISO 13857.
The impeller is an enclosed double suction type made of
bronze, which is statically and hydraulically balanced. The
impeller is firmly secured to the shaft by a key positioned 6.4.12 Rotation
by shaft sleeves and both locked in place by shaft sleeve
lock nuts. Pumps have a clockwise or counterclockwise rotation
when viewed from its driven end.

6.4.3 Shaft
The shaft is made of AISI 1045 or 4140 steel and of ample
size to operate under load with a minimum deflection.

15 AC6102 Rev 07
 6.5 Noise characteristics 7 Installation
The maximum measured A-weighted sound pressure level This section describes the installation of a complete
[LpA] for the pump and motor, measured at a distance of pump unit.
3.3 ft. [1m] from the pump, under full load, in accordance
with EN ISO 3746 is 90dB.
CAUTION
The maximum measured A-weighted sound pressure level Installations should be performed by persons
[LpA] for the pump and diesel engine, measured at a qualified in the setting up of pumping
distance of 3.3 ft. [1m] from the pump, under full load, in equipment.
accordance with EN ISO 3746 is 106dB.

WARNING
6.6 Scope of supply All electrical work should be carried out by
qualified personnel.
The pump unit includes the following items:
• Pump
• Driver, (motor or engine) 7.1 Location
• Baseplate
• Coupling WARNING
• Coupling guard Engine-driven pump units:
The engine must be provided with adequate
ventilation to satisfy the requirements of the
combustion system, and allow adequate
6.7 Dimensions and weights dissipation of radiated heat and exhaust
Refer to the general dimensional drawing supplied with emissions.
the pump unit
Install the pump in a well-ventilated, dry place above the floor
level wherever possible. Take care to prevent the pump from
freezing during cold weather when not in operation.
The pump should be installed with sufficient space around it
to facilitate ventilation and accessibility for inspection,
maintenance and service. A clear space with ample head
room should be allowed for the use of an overhead crane or
hoist to lift the unit.
Install the pump as near to the suction supply as possible,
with the shortest and most direct suction pipe practical. The
total dynamic suction lift (static lift plus friction losses in
suction line) should not exceed the limits for which the pump
was sold.
When installing the pump, consider its location in relation to
the system to assure that sufficient Net Positive Suction Head
[NPSH] is available at the pump inlet connection. Available
NPSH [NPSHA] must always equal or exceed the required
NPSH [NPSHR] of the pump.
The pump must be primed before starting. Whenever
possible, the pump should be located below the fluid level to
assure priming. This condition provides a positive suction
head on the pump. It is also possible to prime the pump by
pressurizing the suction vessel.

7.2 Foundation
We recommend that the pump unit should be installed on a
concrete foundation, sufficiently substantial to absorb
vibration and to form a permanent, rigid support for the
baseplate.
A base of concrete weighing 3 to 5 times the weight of the
pump unit is recommended.
The foundation should be 3 to 6 inches [75 to 150mm] longer
and wider than that of the baseplate that will be installed.
Foundation bolts must match those of the base plate. The
foundation should be poured without interruption to within 1/2
to 1-1/2 inches [12.7 to 38.1mm] of the finished height. The
top surface of the foundation should be well scored and

AC6102 Rev 07 16
Series 8100/8150/8200/9100 Fire Pump
grooved before the concrete sets; this provides a bonding
surface for the grout.
Foundation bolts should be set in concrete as shown in Fig.
6. An optional 4 inch [102mm] long sleeve around the bolts at
the top of the concrete will allow some flexibility in bolt
alignment to match the holes in the base plate. Allow enough
bolt length for grout, shims, lower base plate flange, nuts and
washers. The foundation should be allowed to cure for
several days before the base plate is shimmed and grouted.
In installations where lower sound and vibration levels are
particularly important, we recommend a foundation with a
mass of at least 5 times that of the complete pump unit.
Fig. 6 Foundation
7.3 Leveling the baseplate
WARNING
Lifting devices must be sufficiently strong and
must only be used by authorized persons.
Eyebolts or lifting lugs, if provided, are only for
lifting the components to which they are
attached. Do not stand underneath suspended
loads. A failure in the lifting device or rigging
can result in serious personal injury or death,
or property damage.
NOTICE
This procedure assumes that a concrete
foundation has been prepared with anchor or
hold down bolts extending up ready to receive
the pump unit. It must be understood that the
pump and driver have been mounted and rough
aligned at the factory. If the driver is to be field
mounted, consult AC Fire Pump for
recommendations. AC Fire Pump cannot
assume responsibility for final alignment.
Use blocks and shims under the baseplate for support at the
anchor bolts and midway between bolts, so as to position the
baseplate approximately 1 inch [25.4mm] above the concrete
foundation, with studs extending through holes in the base
plate, as shown in Fig. 7.
By adding or removing shims under the base, level and
plumb the pump shaft and flanges. The baseplate does not
have to be level.
Draw anchor nuts tight against base, and observe pump and
motor shafts or coupling hubs for alignment. (Temporarily
17
remove coupling guard, see section 8.2 Coupling Guard, for
checking alignment.)
If alignment needs improvement, add shims or wedges at
appropriate positions under the baseplate, so that
retightening of the anchor nuts will shift the shafts into closer
alignment. Repeat this procedure until a “reasonable
alignment” is reached.
NOTE: Reasonable alignment is defined as that which is
mutually agreed upon by pump contractor and the accepting
facility (final operator).
Check to make sure that the piping can be aligned to the
pump flanges without placing pipe strain on either flange.
Pour grout in the base plate completely (see section 7.4
Grouting) and allow grout to dry thoroughly before attaching
piping to pump. (24 hours is sufficient time with approved
grouting procedure.)
Fig. 7 Leveling of pump unit
7.4 Grouting
Grout compensates for uneven foundation, distributes the
weight of the pump unit, and prevents shifting. Use an
approved, non-shrinking grout, after setting and leveling the
unit, (see Fig. 7).
Build a strong form around the foundation to contain the
grout. Soak the top of the concrete foundation thoroughly,
and then remove any surface water. The base plate should
be completely filled with grout.
After the grout has thoroughly hardened, check the
foundation bolts and tighten if necessary. Check the
alignment after the foundation bolts are tightened.
Approximately 14 days after the grout has been poured or
when the grout has thoroughly dried, apply an oil base paint
to the exposed edges of the grout to prevent air and moisture
from coming in contact with the grout.
AC6102 Rev 07
 7.5 Initial Alignment
WARNING
Disconnect and lock out power before
performing alignment. Failure to follow these
instructions could result in serious personal
injury.
NOTICE
The alignment procedures that follow are for
motor driven pump units. Alignment procedures
for Engine-driven pump units are available in
the Engine manufacturer’s Installation Manual.
7.5.1 Straightedge method of alignment
The most simple alignment check is with a straight edge and
calipers. This method is the least accurate, but will serve if a
dial indicator or laser is not available.
7.5.1.1 Angular Alignment
With coupling hubs stationary, use calipers to measure the
gap between the coupling hubs at 90° intervals. Adjust and/or
shim equipment until the gap difference at all points around
the hubs is within the coupling manufacturer’s guidelines,
(see Fig. 8).

WARNING
Replace coupler guard after performing
alignment. Failure to follow these instructions
could result in serious personal injury.

CAUTION
Misalignment causes excessive wear, vibration,
and bearing loads that result in premature
bearing failure and ultimate seizing of the pump. Fig. 8 Angular Alignment

NOTICE 7.5.1.2 Parallel Alignment

Alignment should be made before connecting
the pipes; if not, it may not be possible to move
the pump, and it will be difficult to move the
driver.
NOTICE
Read Coupling Manufacturer instructions
supplied with the pump unit before attempting to
perform alignment.
With coupling hubs stationary, lay straight edge flat against
the rim of the coupling hub at 90° intervals to determine
vertical and horizontal alignment offsets. Adjust and/or shim
equipment until the straight edge lies flat against both hub
rims, vertical and horizontal. Check the coupling
manufacturer’s guidelines for the permissible gap, (see Fig.
9).

When a complete pump unit comes pre-assembled from

the factory, the coupling has been accurately aligned by
means of shims inserted under the pump and driver.
The pump/driver could have become misaligned during
transport and installation. Misalignment can be angular,
Fig. 9 Parallel Alignment
parallel, or a combination of these, and in the horizontal and
vertical planes.
7.5.2 Dial indicator method of alignment
Proper alignment is essential for correct pump operation.
This should be performed after base plate has been properly The dial indicator should be used when greater alignment
set and grout has dried thoroughly according to instructions. accuracy is required. Check the coupling manufacturer’s
guidelines for the acceptable alignment tolerances.
Alignment should be made by moving and shimming the
driver only until the coupling hubs are within the
recommended tolerances, and should be made at operating
temperatures under normal conditions.
All measurements should be taken with the pump and driver
foot bolts tightened.
There are two types of misalignment encountered with
flexible couplings: angular misalignment, in which the shafts
are not parallel, and parallel misalignment, where the shafts
are parallel but not on the same axis.
There are three methods commonly used to determine
misalignment:
1. Straight edge and calipers. Fig. 10 Dial Indicator
2. Dial indicator
3. Laser Alignment Equipment (see manufacturer’s
instructions for use).

AC6102 Rev 07 18
Series 8100/8150/8200/9100 Fire Pump

7.5.2.1 Angular Alignment
To check angular alignment, mount dial indicator (A) to the
coupling half (X), and position the dial indicators button on the
face of the opposite coupling half (Y). Scribe index lines on
both coupling hubs as shown in Fig. 10. Set the dial to zero,
rotate both coupling halves together, so that the index lines
match; ensuring that the indicator button always indicates off
the same spot. Check the coupling manufacturer’s guidelines
for the acceptable alignment tolerances.
The clearance must not exceed the Parallel Offset installation
limits specified in Table 5.
If adjustment is needed, loosen the motor bolts and add or
remove an equal amount of shims under each motor foot to
align the height. To correct side misalignment, strike the side
of the motor foot with a mallet.
Tighten the motor bolts and check again. Re-check alignment
in all directions, if a correction is made. Repeat the process
until the desired result is obtained.

7.5.2.2 Parallel Alignment

To check parallel alignment, mount dial indicator (P) to the
coupling half (X), and position the dial indicators button on the
outside diameter of the opposite coupling half (Y), (see Fig.
10). Set the dial to zero, rotate both coupling halves together,
so that the index lines match; ensuring that the indicator
button always indicates off the same spot. Check the coupling
manufacturer’s guidelines for the acceptable alignment
tolerances.

7.5.3 Alignment of grid couplings Fig. 12 Using Straight edge

The following procedure is intended for mounting and

alignment of Rexnord Industries, LLC and Clarke Fire 7.5.3.4 Insert Grid
Protection Products, Inc., Type T10 Close Coupled Grid
Couplings. Completely pack gap and grooves with coupling manufacturer
supplied grease before inserting grid. When grids are
Alignment is shown using a spacer bar and straight edge, furnished in two or more segments, install them so that all cut
which has been prove to be accurate for many industrial ends extend in the same direction as shown in Fig. 13. This
applications. However, for superior final alignment, the use of will ensure correct grid contact with non-rotating pin in cover
dial indicators is recommended, per 7.5.2. halves.
7.5.3.1 Mount Seal and Hubs
Clean all metal parts using non-flammable solvent. Coat the
seals lightly with coupling manufacturer supplied grease and
place on shafts before mounting shaft hubs. Install keys and
mount hubs with flange faces flush with the shaft ends.
Reposition hubs on shafts as required achieving the hub gap
specified in table 5. The length of engagement on each shaft
should be approximately equal to the shaft diameter. Tighten
the setscrews. Fig. 13 Grids magnified
7.5.3.2 Gap and Angular Alignment (X-Y)
Spread the grid slightly to pass over the coupling teeth and
Use a spacer bar equal to thickness to the gap specified in seat with a soft mallet, (see Fig. 14).
Table 5. Insert bar, as shown above to the same depth at 90°
intervals and measure clearance between the bar and hub
face with feeler gage. The difference in minimum and
maximum measurements must not exceed the angular
installation limits specified in Table 5.

Fig. 14 Seating the grid

7.5.3.5 Pack with grease and assemble covers

Fig. 11 Using Spacer Bar
7.5.3.3 Parallel Offset Alignment (P)
Align so that a straight edge rests squarely, (or within the
limits specified in Table 5 on both hubs as shown above and
also at 90° intervals, (see Fig. 12). Check with feeler gages.
Completely pack the spaces between and around the grid
with as much grease as possible and wipe off excess flush
with top of the grid. Position seals on hubs to line up with the
grooves in the cover. Position gaskets on flange of lower
cover half and assemble covers so that the match marks are
on the same side, (see Fig. 15). Secure cover halves with
fasteners tightening to torque specified in Table 5.

19 AC6102 Rev 07
 Cover Maximum
Fastener Allowable
SIZE Lube Wt.
Tightening Speed
Torque (rpm)

in.lb Nm oz g

1040T 100 11.3 3600 1.90 54

1050T 200 22.6 3600 2.40 68

1060T 200 22.6 3600 3.00 86

1070T 200 22.6 1800 4.00 114

1080T 200 22.6 1800 6.10 172

Table 5 Continued
7.6 Pipe connections
CAUTION
Do not draw piping into place by using force
at the flanged connections of the pump. Pipe
strain adversely affects the operation of the
Fig. 15 Cover installation pump, which could result in serious injury or
damage.

7.6.1 Suction and discharge piping general

precautions
WARNING
Do not operate coupling without proper When installing the pump piping, be sure to observe the
lubrication. following precautions:
1. Piping should always be run to the pump.
2. Do not move pump to pipe. This could make final
CAUTION alignment impossible.
Ensure that the lube plugs are installed in the 3. Use pipe hangers or other supports at necessary
cover. intervals to provide support.
4. When expansion joints are used in the piping system
they must be installed beyond the piping supports
closest to the pump.
5. It is usually advisable to increase the size of both
suction and discharge pipes at the pump connections to
decrease the loss of head from friction.
6. Install piping as straight as possible, avoiding
unnecessary bends. Where necessary, use 45° or long
radius 90° fittings to decrease friction losses.
7. Make sure that all piping joints are air-tight.
8. Where flanged joints are used, assure that inside
Fig. 16 Misalignment and End Float diameters match properly.
9. Remove burrs and sharp edges when making up joints.
Maximum forces and moments allowed on the pump flanges
Installation Limits
vary with the pump size and series. To minimize these
forces and moments that may, if excessive, cause
misalignment, hot bearings, worn couplings, vibration and
Parallel Angular Hub Gap End Float premature pump failure, the following should be observed:
Size
Offset (P) (x-y) ± 10% (Min) 2 x F
1. Prevent excessive external pipe loading.
MAX MAX MAX MAX MAX MAX MAX MAX 2. Never “spring” piping when making any connections.
INCH mm INCH mm INCH mm INCH mm
3. Anchor independently both the suction and discharge
1040T 0.01 0.15 0 0.08 0.13 3 0.21 5.36 piping near the pump and properly aligned so that no
strain is transmitted to the pump when the flange bolts
1050T 0.01 0.20 0 0.10 0.13 3 0.21 5.38
are tightened.
1060T 0.01 0.20 0.01 0.13 0.13 3 0.26 6.55 4. Do not install expansion joints next to the pump or in
any way that would cause a strain on the pump resulting
1070T 0.01 0.20 0.01 0.13 0.13 3 0.26 6.58 from system pressure changes. It is recommended that
tie bolts and spacer sleeves should be used with
1080T 0.01 0.20 0.01 0.15 0.13 3 0.29 7.32
expansion joints to prevent pipe strain.
Table 5 Misalignment and End float The tables in 7.6.2 summarize the maximum forces and
moments allowed on 8100, 8150, 8200, and 9100 series
Horizontal Split Case fire pump casing.

AC6102 Rev 07 20
Series 8100/8150/8200/9100 Fire Pump

7.6.2 Maximum forces and moments allowed on pump flange

7.6.2.1 8100 series Horizontal Split Case maximum forces and moments allowed
Maximum forces (F) in lbf (N) and moments (M) in lbf.ft (Nm)
Size Suction Discharge
Fx Fy Fz Mx My Mz Fx Fy Fz Mx My Mz
37 46 40 20 25 51 28 30 38 24 25 30
3X2X11
(165) (205) (178) (27) (34) (69) (125) (133) (169) (33) (34) (41)
143 178 102 103 129 258 32 40 47 20 25 51
6X4X9
(636) (792) (454) (140) (175) (350) (142) (178) (209) (27) (34) (69)
143 178 102 103 129 258 32 40 47 20 25 51
6X4X10
(636) (792) (454) (140) (175) (350) (142) (178) (209) (27) (34) (69)
143 178 102 103 129 258 32 40 47 20 25 51
6X4X11
(636) (792) (454) (140) (175) (350) (142) (178) (209) (27) (34) (69)
124 155 88 89 112 224 33 42 44 21 26 54
6X4X12
(552) (689) (391) (121) (152) (304) (147) (187) (196) (28) (35) (73)
143 178 102 103 129 258 117 147 89 91 114 229
6X6X9
(636) (792) (454) (140) (175) (350) (520) (654) (396) (123) (155) (311)
143 178 102 103 129 258 117 147 89 91 114 229
8X6X9
(636) (792) (454) (140) (175) (350) (520) (654) (396) (123) (155) (311)
201 251 116 156 195 390 117 147 89 91 114 229
8X6X10
(894) (1116) (516) (212) (264) (529) (520) (654) (396) (123) (155) (311)
201 251 116 156 195 390 117 147 89 91 114 229
8X6X12
(894) (1116) (516) (212) (264) (529) (520) (654) (396) (123) (155) (311)
181 227 116 156 195 390 80 100 71 57 72 144
8X6X13
(805) (1010) (516) (212) (264) (529) (356) (445) (316) (77) (98) (195)
227 284 150 202 253 506 68 85 78 53 66 132
8X6X18
(1010) (1263) (667) (274) (343) (686) (302) (378) (347) (72) (89) (179)
170 213 116 156 195 390 117 147 89 91 114 229
8X8X12
(756) (947) (516) (212) (264) (529) (520) (654) (396) (123) (155) (311)
195 244 133 179 223 447 90 112 92 75 93 187
8X8X17
(867) (1085) (592) (243) (302) (606) (400) (498) (409) (102) (126) (254)
463 579 274 463 579 1158 150 187 129 133 166 333
10X8X17
(2059) (2575) (1219) (628) (785) (1570) (667) (832) (574) (180) (225) (452)
514 643 304 514 643 1287 167 208 143 148 184 370
10X8X20
(2286) (2860) (1352) (697) (872) (1745) (743) (925) (636) (201) (250) (502)
490 613 270 544 680 1361 169 211 153 168 211 422
12X10X18
(2180) (2727) (1201) (738) (922) (1846) (752) (939) (681) (228) (286) (572)

7.6.2.2 8150 series Horizontal Split Case maximum forces and moments allowed
Maximum forces (F) in lbf (N) and moments (M) in lbf.ft (Nm)
Size Suction Discharge
Fx Fy Fz Mx My Mz Fx Fy Fz Mx My Mz
201 251 116 156 195 390 117 147 89 91 114 229
8x6x15
(894) (1116) (516) (212) (264) (529) (520) (654) (396) (123) (155) (311)
201 251 116 156 195 390 117 147 89 91 114 229
8x6x14
(894) (1116) (516) (212) (264) (529) (520) (654) (396) (123) (155) (311)
623 779 323 865 1081 2163 196 245 160 207 259 518
16X10X22
(2771) (3465) (1437) (1173) (1466) (2933) (872) (1090) (712) (281) (351) (702)

7.6.2.3 8200 series Horizontal Split Case maximum forces and moments allowed
Maximum forces (F) in lbf (N) and moments (M) in lbf.ft (Nm)
Size Suction Discharge
Fx Fy Fz Mx My Mz Fx Fy Fz Mx My Mz
454 568 300 404 506 1012 136 170 156 106 132 264
8X6X14
(2019) (2526) (1334) (548) (686) (1372) (605) (756) (694) (144) (179) (358)
454 568 300 404 506 1012 136 170 156 106 132 264
8X6X18
(2019) (2526) (1334) (548) (686) (1372) (605) 756 (694) (144) (179) (358)

21 AC6102 Rev 07
 7.6.2.4 9100 series Horizontal Split Case maximum forces and moments allowed
Maximum forces (F) in lbf (N) and moments (M) in lbf.ft (Nm)
Size Suction Discharge
Fx Fy Fz Mx My Mz Fx Fy Fz Mx My Mz
193 242 167 226 282 565 79 98 108 92 115 230
12X8X21
(858) (1076) (743) (306) (382) (766) (351) (436) (480) (125) (156) (312)
193 242 167 226 282 565 79 98 108 92 115 230
12X8X22
(858) (1076) (743) (306) (382) (766) (351) (436) (480) (125) (156) (312)
571 714 284 666 833 1666 196 245 160 207 259 518
14X10X20
(2540) (3176) (1263) (903) (1130) (2259) (872) (1090) (712) (281) (351) (702)
623 779 323 865 1081 2163 215 268 192 298 373 746
16X12X23
(2771) (3465) (1437) (1173) (1466) (2933) (956) (1192) (854) (404) (506) (1012)

AC6102 Rev 07 22
Series 8100/8150/8200/9100 Fire Pump
Fig. 17 Load and Moment orientation for Horizontal Split Case
fire pump casings
Notes:
1) F = External force (tension or compression (+/-))
2) M = External moment (clockwise or counter-
clockwise)
3) ∑F=√ Fx2 + Fy2 + Fz2 , (∑F = resultant force).
4) ∑M=√ Mx2 + My2 + Mz2, (∑M = resultant moment).
5) The nozzle loads applied to the pump flanges
must not exceed the values given in the tables.
6) Values given are for loads applied concurrently in
+ or – direction. Individual forces and moments
can be increased provided that ∑F and ∑M are
not exceeded.
23
7.6.3 Suction piping
The sizing and installation of the suction piping is extremely
important. It must be selected and installed so that pressure
losses are minimized and sufficient liquid will flow into the
pump when started and operated. Many NPSH (Net Positive
Suction Head) problems can be directly attributed to improper
suction piping systems.
Suction piping should be short in length, as direct as
possible, and never smaller in diameter than the pump
suction opening.
A minimum of ten (10) pipe diameters between any elbow or
tee and the pump should be allowed. If a long suction pipe is
required, it should be one or two sizes larger than the suction
opening, depending on its length.
CAUTION
An elbow should not be used directly before
the suction of a double suction pump if its
plane is parallel to the pump shaft. This can
cause an excessive axial load or NPSH
problems in the pump due to an uneven flow
distribution. If there is no other choice, the
elbow should have straightening vanes to
help evenly distribute the flow.
Eccentric reducers should be limited to one pipe size
reduction each to avoid excessive turbulence and noise.
They should be of the conical type. Contour reducers are not
recommended. When operating on a suction lift, the suction
pipe should slope upward to the pump nozzle.
A horizontal suction line must have a gradual rise to the
pump. Any high point in the pipe can become filled with air
and prevent proper operation of the pump. When reducing
the piping to the suction opening diameter, use an eccentric
reducer with the eccentric side down to avoid air pockets.
NOTE: When operating on suction lift never use a concentric
reducer in a horizontal suction line, as it tends to form an air
pocket in the top of the reducer and the pipe. Some correct
and incorrect suction piping arrangements are shown in Fig.
18.
When installing valves in the suction piping, observe the
following precautions: If the pump is operating under static
suction lift conditions, a foot valve may be installed in the
suction line to avoid the necessity of priming each time the
pump is started.
This valve should be of the flapper type, rather than the
multiple spring type, sized to avoid excessive friction in the
suction line. (Under all other conditions, a check valve, if
used, should be installed in the discharge line, see section
7.6.4 Discharge Piping).
When foot valves are used, or where there are other
possibilities of “water hammer,” close the discharge valve
slowly before shutting down the pump.
Where two or more pumps are connected to the same
suction line, install gate valves so that any pump can be
isolated from the line.
Gate valves should be installed on the suction side of all
pumps with a positive pressure for maintenance purposes.
Install gate valves with stems horizontal to avoid air pockets.
AC6102 Rev 07
 Globe valves should not be used, particularly where NPSH is
critical.
The pump must never be throttled by the use of a valve on
the suction side of the pump. Suction valves should be used
only to isolate the pump for maintenance purposes, and
should always be installed in positions to avoid air pockets.
Fig. 18 Suction piping arrangements
AC6102 Rev 07
7.6.4 Discharge piping
If the discharge piping is short, the pipe diameter can be the
same as the discharge opening. If the piping is long, the pipe
diameter should be one or two sizes larger than the
discharge opening. On long horizontal runs, it is desirable to
maintain an even a grade as possible. Avoid high spots, such
as loops, which will collect air and throttle the system or lead
to erratic pumping.
A slow closing check valve and an isolating gate valve should
be installed in the discharge line. The check valve (triple duty
valve), placed between pump and gate valve, protects the
pump from excessive back pressure, and prevents liquid
from running back through the pump in case of power failure.
The gate valve is used in priming and starting, and when
shutting the pump down.
7.6.5 Bypass Piping
Where the suction supply is of sufficient pressure to be of
material value without the pump, the pump shall be installed
with a bypass.
The bypass pipe diameter shall be at least as large as the
discharge pipe diameter.
7.6.6 Cooling System
NOTICE
This section is only applicable to engine-
driven pump units that have water cooled
heat exchangers.
The cooling water supply for a heat exchanger-type engine
shall be from the discharge of the pump taken off prior to the
pump discharge check valve.
The cooling water flow shall be set based on the maximum
ambient cooling parameters provided by the Engine
Manufacturer.
7.6.7 Exhaust system
NOTICE
This section is only applicable to engine-
driven pump units.
WARNING
Exhaust emissions must be discharged to a
safe point outside the pump room where they
shall not affect persons or endanger buildings.
Operation of an engine without an adequate
exhaust system can result in serious personal
injury.
WARNING
Exhaust pipes are hot and will cause serious
injury if touched.
Each pump engine shall have an independent exhaust
system. The exhaust pipe shall not be any smaller in
diameter than the engine exhaust outlet and shall be as short
as possible.
24
Series 8100/8150/8200/9100 Fire Pump
The exhaust pipe shall be covered with high-temperature
insulation or otherwise guarded to protect from personal
injury.
The exhaust pipe and muffler, if used, shall be suitable for the
use intended, and the exhaust back-pressure shall not
exceed the engine manufacturer’s recommendations.
Exhaust pipes shall be installed with clearances of at least 9
inch [229mm] to combustible materials.
7.6.8 Pressure Gages
Properly sized pressure gages should be installed in both the
suction and discharge nozzles in the gauge taps provided.
The gauges will enable the operator to easily observe the
operation of the pump, and also determine if the pump is
operating in conformance with the performance curve.
7.6.9 Stuffing box lubrication
7.6.9.1 General guidelines
Contaminants in the pumped liquid must not enter the
stuffing box. These contaminants may cause severe
abrasion or corrosion of the shaft, or shaft sleeve, and rapid
packing deterioration; even plugging the stuffing box flushing
and lubrication system.
The stuffing box must be supplied at all times with a source
of clean, clear liquid to flush and lubricate the packing.
This is normally achieved with a supply from the pump
discharge volute to the stuffing box. A control valve may be
fitted into the supply line to control the pressure to the
stuffing box.
7.6.9.2 Packing
Pumps are normally packed before shipment. If the pump is
installed within 60 days after shipment, the packing will be in
good condition with a sufficient supply of lubrication.
If the pump is stored for a longer period, it may be necessary
to repack the stuffing box. In all cases, however, inspect the
packing before the pump is started.
It is important to establish the optimum flushing pressure that
will keep contaminants from the stuffing box cavity. If this
pressure is too low, fluid being pumped may enter the stuffing
box. If the pressure is too high, excessive packing wear may
result; and extreme heat may develop in the shaft causing
higher bearing temperatures.
The most desirable condition, therefore, is to apply seal water
at a flow rate of approximately 0.25 gpm [0.95 lpm] at a
pressure approximately 15-20 psig [1 bar] above the
maximum stuffing box pressure. [Approximately one [1] drop
per second.]
NOTE: Packing adjustment is covered in section 9,
Maintenance.
25
7.7 Final alignment
WARNING
Do not operate pump with coupling out of
alignment. Ensure final coupling alignment is
within the values according to the coupling
manufacturer’s instructions. Coupling, pump,
or driver failure may occur. Failure to follow
these instructions could result in serious
personal injury.
After connecting piping to the pump, rotate the shaft several
times by hand to ensure that there is no binding and all parts
are free. Recheck the coupling alignment, as previously
described, to ensure that there is no pipe strain. Correct, if
necessary, by adjusting the motor only.
7.8 Electrical Connection
WARNING
Risk of electric shock. All electrical
connections shall be performed by a qualified
electrician in accordance with all applicable
codes, ordinances and good practices.
Failure to follow these instructions could
result in serious injury, death and/or property
damage.
WARNING
Risk of injury due to rotating parts. Isolate the
motor from its supply voltage and keep it locked
out when performing any work on the pump.
NOTICE
Follow the instructions of the motor
manufacturer.
NOTICE
Engine-driven pump units: The requirement for
the electrical connection of the engine unit is
covered in the engine manufacturer’s
Installation Manual.
The operating voltage and frequency are marked on the
motor nameplate.
The motor must be suitable for the power supply at the
installation site.
The electrical connections should be carried out as shown
on the motor nameplate and/or the terminal box.
AC6102 Rev 07

8 Start-up, operation and
shutdown
8.1 Start-up
WARNING
Start-up should be carried out by authorized
personnel. Do not start the pump until all pre-
start-up checks have been performed
CAUTION
Do not start the pump until it has been
completely filled with liquid and vented. The
pump must not run dry as this will result in
serious damage to the pump.
WARNING
Electric Shock Hazard: Electrical connections
are to be made by qualified personnel, in
accordance with applicable codes,
ordinances, and good practices.
NOTICE
See also installation and operating
instructions for the electric motor, if
applicable.
NOTICE
See also installation and operating
instructions for the diesel engine, if
applicable. We recommend that you register
the diesel engine with the manufacturer
before start-up. Otherwise, the engine
manufacturer cannot provide any warranty if
the engine is faulty.
8.1.1 Preparation for startup
WARNING
Unexpected Start-up Hazard: Disconnect and
lockout power before performing pre-start-up
checks. Failure to follow these instructions
could result in serious personal injury or
death.
Before the initial start of the pump, perform the following
inspections:
1. Remove all corrosion protection materials, referenced
in section 5.3 Storage, in accordance with the
manufacturer’s recommendations.
2. Check alignment between pump and driver, (motor or
engine). See section 7.5 Initial Alignment.
3. Check that all pipes and hoses are installed correctly.
4. Check all electrical connections. Check voltage, phase,
and frequency.
5. Check suction and discharge piping and pressure
gauges for proper operation.
6. Check that all safety devices are installed.
7. Turn rotating element by hand to assure that it rotates
freely.
8. Check stuffing box adjustment, lubrication, and piping.
9. Check driver lubrication.
AC6102 Rev 07
10. Assure that pump bearings are properly lubricated.
11. Assure that coupling is properly lubricated, if required.
12. Assure that pump is full of liquid and all valves are
properly set and operational, with the discharge valve
closed and the suction valve open. Purge all air from top
of casing.
13. Check rotation. Be sure that the driver operates in the
direction indicated by the arrow on the pump casing as
serious damage can result if pump is operated with
incorrect rotation.
8.1.2 Priming
NOTICE
Flushing: New and old systems should be
flushed to eliminate all foreign matter. Heavy
scale, welding splatter and wire or other large
foreign matter can clog the pump impeller.
If the pump is installed with a positive head on the suction, it
can be primed by opening the suction valve, and loosening
the vent plug on top of the casing (Do not remove), allowing
air to be purged from the casing.
If the pump is installed with a suction lift, priming must be
done by other methods such as foot valves, ejectors, or by
manually filling the casing and suction line.
All drains should be closed when filling the system. Filling
should be done slowly so that excessive velocities do not
cause rotation of the pumping elements which may cause
damage to the pump or its driver. The adequacy of the piping
anchors and hangers may be checked at this time by
mounting a dial indicator off of any rigid structure not tied to
the piping and setting the indicator button on the pump flange
in the axial direction of the nozzle.
If the indicator moves, as the filling proceeds, the anchors
and supports are not adequate or set properly and should be
corrected.
8.2 Coupling Guard
WARNING
Unexpected Start-up Hazard: Disconnect and
lockout power before performing pre-start-up
checks. Failure to follow these instructions
could result in serious personal injury or
death.
NOTICE
The coupling guarding described herein
refers to guarding that is supplied by A-C Fire
Pump for pumps that have a motor driver. For
pumps with an engine driver refer to the
engine manufacturers instructions, supplied
with the pump unit.
NOTE: The coupling guard fasteners have devices that keep
them from completely detaching from the guard or the pump.
Do not remove these devices or separate the fasteners from
the guard or the pump.
NOTE: Do not spread the inner and outer guards more than
necessary for guard removal or installation. Over-spreading
the guards may alter their fit and appearance.
26
Series 8100/8150/8200/9100 Fire Pump

8.2.1 Removing the coupling guard

1. Identify the parts of the coupling guard, see Fig. 19.
2. Unfasten the (4) cap screws, [item 6], that secure the
outer guard, [item 8], to the inner guard, [item 5].
3. Spread the outer guard, [item 8], and pull it off the inner
guard, [item 5].
4. Remove the (4) cap screws, [item 6], that holds the
inner guard, [item 5], to the support brackets, [item 2].
5. Spread the inner guard, [item 5], and pull it over the
coupling.
1 2
8.2.2 Installing the coupling guard
1. Identify the parts of the coupling guard, see Fig. 19.
2. Attach the support brackets, [item 3], to the inboard
bearing housing of the pump, [item 1], using (4) cap
screws, [item 4] and (4) flat washers, [item 3]; (if a new
installation). See step 1.
3. Spread the inner guard, [item 5]; and place it over the
coupling.
4. Attach the inner guard, [item 5], to the support brackets,
[item 2]; using (4) cap screws, [item 6], and (4) screw
retainers, [item 7]. See step 2. 3
5. Spread the outer guard, [item 8]; and place it over the
inner guard, [item 5]. See step 3.
6. Position the outer guard, [item 8] so that its slots line up
with the hardware on the inner guard, [item 5]. See step
4.
7. Attach the outer guard, [item 8], to the inner guard,
[item 5]; using (4) cap screws, [item 6], and (4) screw
retainers, [item 7]. Do not tighten so as to allow the
outer guard to slide over the inner guard. See step 3.
8. Slide the outer guard, [item 8], towards the motor so
that there is less than a 1/4 in. [6.35 mm] of the motor
shaft exposed. See step 4.
9. Holding the outer guard in this position, tighten the (4) 4
cap screws.
Fig. 19 Coupling Guard

27 AC6102 Rev 07
 8.3 Operation
WARNING
Pump units have a sound pressure level
higher than 85 dB(A). Hearing protection
must be worn when the pump is running.
WARNING
Do not operate the pump at or near zero flow,
i.e. closed discharge valve. Explosion could
result. Failure to follow these instructions
could result in serious personal injury and
part damage.
WARNING
Do not operate the pump unless all guarding
are in place.
8.3.1 General Procedure
1. Close drain valves and valve in discharge line.
2. Open fully all valves in the suction line.
3. Slowly turn on seal water to the stuffing box. (If pumped
fluid is dirty or if leakage of air is to be prevented, these
lines should be always left open.)
4. Prime the pump. [NOTE: If the pump does not prime
properly, or loses prime during start-up, it should be shut
down and the condition corrected before the procedure
is repeated.]
5. Start the pump driver (Engines may require warming up;
consult the manufacturer’s instructions).
6. When the pump is operating at full speed, open the
discharge valve slowly. This should be done promptly
after start-up to prevent damage to pump by operating
at zero flow.
7. Adjust the liquid seal valves to produce the
recommended pressure for the packed stuff box.
8.3.2 Optional Checklist
NOTICE
This section applies to parameters that
contribute to assessing the performance of
the pump unit.
1. Driver/Pump Rotation: Check the rotation each time that
the motor leads have been disconnected. Be sure that
the driver operated in the direction indicated by the
arrow on the pump casing.
2. Flow: An accurate measurement of the flow rate is
difficult to in the field. Venturi meters, flow nozzles,
orifice plates, or timing the draw down in a wet well are
all possible methods. Record any reading for future
reference.
3. Pressure: Check and record both suction and discharge
pressure gauge readings for future reference.
4. Power: Record voltage, amperage per phase, kilowatts if
an indicating wattmeter is available, and the pump
speed.
5. Temperature: Check and record the bearing temperature
using a thermometer. Temperature should not exceed
225°F [107°C] for polyurea-greased bearings and180°F
[82°C] for lithium-greased bearings.
AC6102 Rev 07
8.4 Shutdown
WARNING
Escaping pressurized liquids. Liquid draining
from the pump could result in personal injury
and equipment damage.
NOTICE
This section applies to the complete pump
unit. See also installation and operating
instructions for the driver, (electric motor or
diesel engine), and controller.
The following steps will take care of most normal shutdowns
of the pump, i.e. maintenance or to make any further
adjustments of process piping, valves, etc., as required.
1. Shut off power supply to the driver.
2. Close suction and discharge valves.
3. Close seal liquid valves. (If pumped liquid is dirty, or if
leakage is to be prevented, these lines should always
be left open, except when the pump is completely
drained.)
4. Open drain valves as required.
8.5 Returning to service
After long-term storage and before commissioning, check
seals, bearings, and lubrication.
8.6 Freeze Protection
CAUTION
If heat is used to keep the pump from
freezing, do not let the temperature rise
above 150°F [66°C].
Pumps that are shut down during freezing conditions should
be protected by one of the following methods:
1. Drain the pump; remove all liquid from the casing.
2. Keep fluid moving in the pump and insulate or heat the
pump to prevent freezing.
8.7 Field testing
A performance curve for the pump-unit is included in the
document package shipped with the pump unit or it can be
obtained from A-C Fire Pump. This can be used in
conjunction with a field test, if one is required.
All A-C Fire Pump tests and curves are based on the
Hydraulic Institute Standards. Any field tests must be
conducted according to these standards.
Unless otherwise specifically agreed, all capacity, head, and
efficiencies are based on factory tests using clear water at a
temperature not greater than 85°F [29°C].
28
Series 8100/8150/8200/9100 Fire Pump

9 Maintenance 9.2 Maintenance Interval

Inspection intervals should be carried out in accordance with
WARNING
the maintenance table, Table 6.
Rotating parts. Disconnect and lock out power
before performing maintenance. Failure to
follow these instructions could result in serious

Every six months

personal injury.

Annually
Monthly
Weekly
WARNING
Electrical Shock Hazard. Action
Disconnect and lock out power before
performing maintenance. Failure to follow
these instructions could result in serious
personal injury. Test run the pump X
Check pump/driver alignment X
NOTICE
It is the operator’s responsibility to ensure that Check bearing housing temperature X
all maintenance work is performed by Check bearing grease X
authorized and qualified personnel.
Check the stuffing box leak rate X
NOTICE Lubricate bearings X
Read the installation and operation
instructions for the driver and coupling for Check anchor bolts and tighten X
maintenance requirements not covered in this Check coupling guard bolts and tighten X
instruction.
Check for unusual noise and vibration X
Check the pump and piping for leaks X
Check pump shaft end play X
9.1 General Check impeller assembly for wear X
A regular inspection and maintenance program must be Test pump against performance curve X
planned and followed in order to keep the pump in good
working condition. We suggest a permanent record be kept of Table 6 Maintenance Interval
the periodic inspections and maintenance performed on your
pump. This recognition of maintenance procedure will keep
your pump in good working conditions, and prevent costly 9.3 Lubrication
breakdowns.
9.3.1 Lubricating grease requirements
Use a high-quality grease lubricant corresponding to NLGI
Grade 2. The recommended grease lubricants are shown in
Table 7.

Polyurea-based grease (pumps built after December 2014)

Manufacturer Brand Name

Exxon Mobil Polyrex EM
Chevron SRI NLGI 2
Shell Gadus S5 T100 2

Lithium-based grease (pumps built before December 2014)

Manufacturer Brand Name

Exxon Mobil Mobilux EP 2
Chevron Multifak EP2
Shell Gadus S2 V100 2

Table 7 Recommended Grease Lubricants

29 AC6102 Rev 07
 9.3.2 Grease Lubrication
WARNING
Never check the temperature of the bearing
frame by hand, use a temperature measuring
device.
CAUTION
Greases of different bases (lithium, polyurea,
etc.) may not be compatible when mixed.
Mixing greases can result in reduced
lubricant life and premature bearing failure.
Grease lubricated ball bearings are packed with grease at the
factory and ordinarily will require no attention before starting,
provided the pump has been stored in a clean, dry place prior
to its first operation.
The bearing temperature, measured at the bearing frame,
should never exceed 225°F [107°C] for polyurea-based
grease, and 180°F [82°C] for lithium-based grease when
checked monthly. Should the temperature of the bearing
frame rise above the limit, the pump should be shut down to
determine the cause.
9.3.3 Lubrication procedure
CAUTION
Over-greasing is the most common cause of
overheating and premature bearing failure.
CAUTION
Use only manual grease gun. High pressure
may damage the bearings or seals, cause
unnecessary loss of grease, create a danger of
overheating due to over-greasing, and produce
unsightly conditions around the bearing.
Add grease while the pump is stopped to avoid overloading.
Adequate lubrication is assured if the level of grease is
maintained at about the capacity of the bearing and 1/3 to 1/2
of the cavity between the bearing and grease fitting. Any
greater amount will, as a rule, be discharged by the seal or
vent and be wasted.
To lubricate the bearings with grease, proceed as follows:
1. Remove dirt from the grease fitting.
2. Fill the grease cavities through the fittings with the
recommended grease.
3. Wipe off any excess grease.
4. Run the pump to distribute the grease.
The bearing temperature usually increases after you re-
grease due to an excess supply of grease. Temperatures
return to normal as the pump runs and purges the excess
grease from the bearings.
9.4 Packed Stuffing Box
9.4.1 Packing specifications
Pumps are supplied with a graphite-coated general service
fiber packing as standard, using Y.C. Industries Grade 608D,
or equivalent.
AC6102 Rev 07
9.4.2 Packing maintenance
In accordance with the maintenance schedule, the packing
should be visually inspected once a month and the leakage
rate checked. If the leakage rate is excessive then the gland
nuts may be tightened, until the required leak rate is obtained,
which should be least 40 to 60 drops per minute.
When the gland follower has reached the limit of its
movement and the packing cannot be compressed any
further, all of the packing should be removed and replaced.
Never reuse old and lifeless packing or merely add some
new rings.
9.4.3 Removal of Packing
WARNING
Ensure that the pump has cooled sufficiently to
allow safe handling of the stuffing box. A
packing tool should be used to remove all old
packing from the stuffing box. Make sure the
stuffing box is thoroughly cleaned before new
packing is installed. Also check the condition of
the shaft or sleeve for possible scoring or
eccentricity. Any parts with significant damage
should be replaced.
9.4.4 Installing Packing
New packing may be supplied as molded rings made to
specified dimensions or, more usually, as a length of coil.
When supplied as a continuous length, it is necessary to cut
off lengths of material to make the required number of rings.
Usually 5 or 6 rings are required per stuffing box.
If molded rings are used, the rings should be opened
sideways and the joints pushed into the stuffing box first.
If coil packing is used, wrap the packing around the shaft and
mark the cutting position. The packing should be cut 1/8-1/4
in. [3-6mm] over size. The larger the shaft diameter, the more
excess length is required. The packing must not be cut
undersized. Cut one ring to accurate size with either a butt or
mitered (45°) joint. (An accurately cut butt joint is superior to a
poor fitting mitered joint).
Fit the ring over the shaft to assure proper length. Then
remove and cut all other rings to the first sample. When the
rings are placed around the shaft a tight joint should be
formed.
Place the first packing ring around the shaft, and form a neat
butt or mitered joint between the two ends. Push the ring into
the stuffing box. Push the joint first, then the side opposite to
the joint, and then the two remaining sides. It is essential that
the two packing ends are pushed tightly together.
Push the ring to the bottom of the stuffing box, applying
reasonable pressure to ensure that the ring is seated properly
but it is not over compressed.
NOTICE
The packing rings must be fitted individually
and under no circumstances should complete
sets be fitted as a unit.
The rings are installed one at a time, each ring seated firmly
and the joints staggered at about 90° rotation from each
preceding joint. For 3 adjacent rings, use the 4, 8 and 12
o’clock positions.
30
Series 8100/8150/8200/9100 Fire Pump

Check the shaft to ensure that it can be rotated after fitting

each packing ring.
Fit as many rings as possible into the stuffing box without
having any packing protruding, and without over-compressing
the packing
NOTE: The last ring in each box may not be required until
after the pump has operated for a period of time.
NOTE: When supplied, the seal cage will replace the third
packing ring from the bottom of the stuffing box. The seal
cage must be aligned with the seal water inlet when the
packing is compressed.
Bring the gland follower up squarely against the last packing
ring and tighten the nuts evenly to finger pressure.

9.4.5 Packing Adjustment

Install the proper flush set up. Start the pump and allow the
packing to leak freely at start-up. During the break-in period,
adjustments should be made gradually (tightening the gland
nuts one 1/4 revolution at a time), allowing 5 to 10 minutes
between adjustments.
After the break-in period, the leakage rate can be controlled
to 40 to 60 drops per minute.

31 AC6102 Rev 07
 for 8150, 8200 and 9100 can be identified by the description
in the parts lists.
10 Service
10.2.1 Rotating Element
The procedures outlined in this section cover the dismantling
and reassembly of four different model types of Horizontal 1. Isolate driver and lock out power supply in accordance
Split Case fire pumps: with local regulations.
2. Isolate suction and discharge valves.
1. 8100 3. Remove coupling guards and separate the coupling to
2. 8150 disconnect the pump from the driver.
3. 8200 4. Drain the pump by opening the vent plug [0-910-0] and
4. 9100 removing the drain plugs [0-910-0] on the suction and
discharge nozzles.
When working on the pump, use accepted mechanical
5. Remove flush lines [0-952-0], if supplied.
practices to avoid unnecessary damage to parts. Check
6. Series 8150, 8200 and 9100: Remove gland bolts,
clearances and conditions of parts when pump is dismantled
washers, and slide gland away from the lower casing.
and replace if necessary. Steps should usually be taken to
7. Remove all casing main joint cap screws [2-904-1] and
restore impeller and casing ring clearance when it exceeds
dowels [2-916-1].
three times the original clearance.
8. Using the slot in the casing main joint, separate the
casing halves with a pry bar. Lift the upper half casing
WARNING [2-001-0] by the cast lugs.
Rotating parts. Disconnect and lock out
power before servicing. Failure to follow NOTE: Some casings have jacking screws.
these instructions could result in serious
personal injury. 9. Series 8100 only: Tap the stuffing boxes [3-073-9] with
a soft-headed hammer to break the seal between the
WARNING stuffing box and the lower casing [2-001-0].
Electrical Shock Hazard. 10. Series 8150, 8200 and 9100: Remove packing and seal
Disconnect and lock out power before servicing. cage from each stuffing box.
Failure to follow these instructions could result 11. Series 8150, 8200 and 9100: Remove cap screws
in serious personal injury. which hold the bearing housings to the lower casing.
12. The rotating element may now be removed. Carefully lift
WARNING the complete rotating element, protecting the packing
During dismantling/assembly of the pump, surface on the outside diameter of the shaft sleeve [3-
ensure that lifting devices are sufficiently 009-9] from damage and place on two support blocks.
strong and that the pump-unit and parts are
secured to prevent tipping over. Failure to
follow these instructions could result in
10.2.2 Bearing Housing
serious personal injury and part damage. 1. Remove four cap screws [3-904-9] from each bearing
housing [3-025-3, 3-025-4] and remove the bearing
CAUTION housings from the shaft [3-007-0].
Before dismantling the pump, ensure that 2. Bend back the lock-washer tab and remove locknut [3-
genuine AC-Fire Pump parts are available. 516-4] and lock-washer [3-517-4] from the outboard
end of the shaft and, using a bearing puller, remove the
bearing [3-026-4] from the shaft. Remove the inboard
end bearing [3-026-3] in the same manner.
10.1 Tools required NOTE: Locknut and lock-washer are not used on inboard
In order to assemble and disassemble the pump, the end bearings.
following tools are required:
3. Series 8200 and 9100: Remove bearing covers out of
bearing housings. Pull deflectors off the shaft. Slide
• Hex wrenches stuffing box bushings off the shaft.
• Open end wrenches
• Spanner wrench 4. Series 8150: Remove the four cap screws [3-904-9]
• Torque wrench with sockets from each bearing housing [3-025-3, 3-025-4] and
• Feeler gauges remove the bearing housings from the bearing brackets
• Range of screwdrivers [3-025-5]. Remove the snap ring [3-177-3] (outboard
• Soft mallet side only), bearings [3-026-2] and backing snap rings
• Bearing pullers [0-915-0]. Remove the bearing brackets from the shaft.
• Bearing induction heater
• Allen wrenches 10.2.3 Shaft seal – gland packing
• Dial indicators
• Lifting sling 1. Series 8100: Slide both stuffing boxes [3-073-9] off the
shaft, working deflector rings [3-136-9] off the shaft at
the same time.
10.2 Dismantling 2. Remove the lip seals [3-177-9] from the stuffing box.
3. Remove the gland bolts [1-904-9], gland halves [1-014-
Refer to section 12, Replacement Parts, for exploded 9], packing [1-924-9] and, if supplied, seal cage [1-013-
drawings and parts lists. Part numbers listed in this procedure 9] from each stuffing box. Remove the O-rings [3-914-1]
refer to the 8100 series pumps; corresponding part numbers from the stuffing boxes.

AC6102 Rev 07 32
Series 8100/8150/8200/9100 Fire Pump

10.2.4 Shaft sleeve 10.4 Assembly

Refer to section 12, Replacement Parts, for exploded
1. Loosen set screws [3-902-3] in shaft nuts [3-015-9] and
drawings and parts lists. Part numbers listed in this procedure
then remove shaft nuts using pin spanner wrench.
refer to the 8100 series pumps; corresponding part numbers
Remove O-rings [3-914-9] from the counter-bore in
for 8150, 8200 and 9100 can be identified by the description
shaft sleeve. Remove the shaft sleeves [3-009-9] from
in the parts lists.
the shaft.

10.2.5 Impeller and casing wear rings 10.4.1 Wear Rings

1. Impeller rings [0-004-0] (when fitted) should be heated
1. The impeller and casing rings can now be removed if
up to approximately 300°F - 400°F [150°C - 200°C] and
required.
then slipped onto the impeller. Using gloves hold rings
2. When removing the rotating element, the casing wear
against the impeller shoulder until they cool.
rings [3-003-9] will be attached to the impeller [4-002-0]
2. Slide the casing rings [3-003-9] over the impeller hubs
by locking pins [3-943-9] inserted into the casing ring
before mounting the rotating element into the lower
and located in grooves in the lower half casing.
casing, ensuring that the locking pins in the rings locate
3. If impeller rings [0-004-0] are also fitted, they are shrunk
into the grooves in the casing.
onto the impeller, and can be removed by cutting with a
3. Check the wear ring clearance against the appropriate
cold chisel.
pump size in Table 8.

10.3 Examination of parts Wear Ring

Pump Size Series/Type
Clearance in [mm]
3X2X11F-S
CAUTION
Used parts must be inspected before 6X4X9F
assembly to ensure that the pump will
6X4X10F-M
operate correctly.
6X4X11F
6X4X12F
10.3.1 Casing and impeller
6X6X9F
Inspect for excessive wear, pitting, corrosion, erosion or
damage and any sealing surface irregularities. Replace as 8X6X9F
necessary. 8X6X10F
8X6X12F 8100
10.3.2 Shaft and sleeve
8X6X12F-M
Replace if grooved, pitted or worn.
8X6X13F
8X6X18F
10.3.3 Gaskets and O-rings 0.015 - 0.017
8X8X12F
After dismantling, discard and replace. [0.38 – 0.43]
8X8X17F
10.3.4 Bearings 10X8X17F
10X8X20F
12X10X18F
CAUTION
Do not reuse the ball bearings. 8x6x14F-S
8X6X14F-L 8200

It is recommended that bearings are not reused after 8x6x18F

removal from the shaft. 12X8X21F
12X8X22F-M
10.3.5 Bearing isolators and lip seals
14X10X20F 9100
1. The lubricant, bearings and bearing housing seals are
16X12X23F
to be inspected for contamination and damage.
Damaged parts should be replaced. 14X10X20F-L
2. If bearing damage is not due to normal wear and the .015 - .019
lubricant contains adverse contaminants, the cause 8x6x14F
[.38 - .48]
should be corrected before the pump is returned to
.015 - .019
service. 8x6x15F 8150 [.38 - .48]
3. Bearing isolators (if used) should be inspected for
damage but are normally non-wearing parts and can be 0.019 – 0.021
16X10X22F
usually reused. [0.48 – 0.53]

Table 8 Wear ring clearance

33 AC6102 Rev 07
 10.4.2 Impeller
Pump Size A Packing Size
10.4.2.1 Series 8100, 8150 and 9100
1. Assemble the impeller key [3-911-1] in the shaft [3-007- 3X2X11F-S 8.755
0]. 0.375
2. Check the impeller [4-002-0] and casing to determine 6X4X9F 9.312
the correct impeller rotation, and locate the impeller on 6X4X10F-M 10.625 0.500
the shaft in accordance with Figs. 20 and 21 and
Tables 9 and 10. 6X4X11F 10.750
3. Starting with the outboard end, apply a 6.4mm [1/4 inch]
bead of RTV silicone sealant, (Dow Corning or 6X4X12F 9.755
equivalent), at the impeller hub face, making sure to fill 0.375
up the keyway. 6X6X9F 9.312
4. Slide the sleeve [3-009-9] onto the shaft, rotating the
sleeve to evenly distribute the silicone sealant. 8X6X9F 9.755

8X6X10F 10.625 0.500

NOTE: The pin in each shaft sleeve must seat in the
impeller key slot. (Not used on 8150) 8X6X12F 9.755 0.375
5. Place the sleeve O-ring [3-914-9] onto the shaft, into the 8X6X12F-M
sleeve counter-bore. Assemble the shaft sleeve nut [3- 10.625
015-9] 8X6X13F
6. Repeat steps (3)-(5) for the inboard shaft sleeve, O-ring
and nut. Wipe off excess RTV silicone sealant. 8X6X18F
10.625
8X8X12F
0.500
8X8X17F
11.495
10X8X17F

10X8X20F 11.620

12X10X18F 11.495

8x6x14F-L
12.566
8X6X14F-S 0.500

8x6x15F 12.4

16x10x22F 19.259 0.625

Table 9 Series 8100 and Series 8150 Impeller location

Fig. 20 Series 8100 and Series 8150 Impeller location

Fig. 21 Series 9100 Impeller location

AC6102 Rev 07 34
Series 8100/8150/8200/9100 Fire Pump

Pump Size A Packing Size

12X8X21F
13.50
12X8X22F-M

14X10X20F 0.625
15.81
16X12X23F

14X10X20F-L 16.60

Table 10 Series 9100 Impeller Location

10.4.2.2 Series 8200

1. Assemble the impeller key [3-911-1] in the shaft [3-007-
0].
2. Identify the first and second stage impellers [4-002-0] by
the casted label, and locate the second stage impeller
on the shaft in accordance with Fig. 22 and Table 11.
3. Pre-assemble the interstage bushing [3-034-1] and the
diaphragm [3-231-0] as follows:
i. Install O-rings [3-914-7, 3-914-8] in the three
grooves of the interstage bushing.
ii. Lightly press the bushing into the diaphragm,
locating the hole in the bushing over the pin in the
diaphragm. Install snap ring [3-915-0] to secure
the assembly.
4. Slide the interstage bushing assembly over the shaft
and place over the rear hub of the impeller.
5. Place the other impeller on the shaft and slide over the
interstage bushing until it touches the impeller already 10.4.3 Bearings and bearing housings
installed.
10.4.3.1 Series 8100
6. Apply a 1/4 in. [6.4mm] bead of RTV silicone sealant,
(Dow Corning or equivalent), uniformly about the shaft 1.
sleeve [3-009-9] inside diameter, covering an area of
about 1/2 in. [12.8mm] at each impeller end of the
sleeve. Also apply sealant to the face of the impellers.
7. Slide the shaft sleeves onto the shaft to evenly
distribute the sealant. Rotate until the pin in the sleeve
engages into the keyway of the impellers and push the
sleeves against the impeller face until the sleeve is
flush against the face. Wipe off excess RTV silicone
sealant. 2.
8. Place the sleeve O-ring [3-914-9] onto the shaft, into the
sleeve counterbore. Assemble the shaft sleeve nut [3- 3.
015-9].
4.
5.
6.
7.
Fig. 22 Series 8200 Impeller location
Pump Size A Packing Size
8x6x14F-S
8X6X14F-L 12.06 0.500
8x6x18F
Table 11 Series 8200 Impeller Location
Press a new lip seal [3-177-9] into each stuffing box [3-
073-9]. Before installing the seal, lubricate it with
lightweight oil.
NOTE: Lip seals should seat against the machined
shoulder in the bracket.
NOTE: The seal lip or pressure side of the seal should
point away from the bearings [3-026-3, 3-026-4].
Lubricate and roll O-ring [3-914-1] into the groove of
each stuffing box.
Slide the outboard stuffing box on the shaft so that the
shaft end extends through the packing area, but does
not enter the lip seal. This will permit the installation of
the deflector [3-136-9].
Slide the deflector over the shaft end then carefully
push the shaft end through the lip seal and slide the
stuffing box fully onto the shaft.
Heat the bearing [3-026-4], using either a dry heat, or a
10-15% soluble oil and water solution.
NOTE: Do not exceed 275°F [135°C].
Using gloves slide the heated bearing onto the shaft
against the shaft shoulder.
Install the lock washer [3-517-4] and locknut [3-516-4]
on the outboard end of the shaft. Ensure that the
locknut is secured and then bend over the tabs on the
lock washer.
NOTE: A lock washer and locknut are not installed on
the inboard end of the shaft.

35 AC6102 Rev 07
 8. Allow the bearing to cool to room temperature. Coat the
exposed sides with 2 to 3 oz. [55 to 85 g] of the
recommended grease.
9. Coat the inside of the bearing housing [3-025-4] with
grease and slide into place over the bearing. Attach the
bearing housing to the stuffing box with four cap screws
[3-909-9].
10. Repeat steps for the inboard end.
10.4.3.2 Series 8150
1. Install slingers [3-136-9] onto shaft.
2. Press a new lip seal [3-177-2] into bearing brackets
[3-025-5].
NOTE: Seal lip or pressure side of seal must point
away from the bearing.
3. Place bearing brackets onto shaft. Install backing snap
rings [0-915-0] into the shaft grooves.
4. Heat the bearings [3-026-2], using either a dry heat, or
a 10-15% soluble oil and water solution.
NOTE: Do not exceed 275°F [135°C].
5. Using gloves slide the heated bearings onto the shaft.
The shielded side of the bearing goes on first.
6. Install the beveled snap ring [3-177-3] into the groove
on the shaft, outboard side only.
7. Slide the bearing housings [3-025-3, 3-025-4] into place
over the bearings.
10.4.3.3 Series 8200
1. Press a new lip seal [3-177-9] into each bearing cap [5-
018-0].
NOTE: Seal lip or pressure side of seal must point away
from the end of the shaft the lip seal is assembled on.
2. Place two O-rings [6-914-9] on each stuffing box
bushing [6-008-0], and then slide over the shaft sleeve
with the beveled end facing the impeller.
3. Slide the deflectors [3-136-9] and bearing caps onto the
shaft. Install snap ring [5-915-3] on the inboard side of
the shaft. Install the split ring [5-050-4] and retaining
collar [5-421-4] on the outboard side of the shaft.
4. Heat the bearings [3-026-3-026-4], using either a dry
heat, or a 10-15% soluble oil and water solution.
NOTE: Do not exceed 275°F [135°C].
5. Using gloves slide the heated bearing [3-026-3] onto the
inboard end of the shaft against the snap ring.
6. Using gloves slide the two heated bearing [3-026-4]
onto the outboard end of the shaft. These bearings
must be installed back to back. Place the first bearing
on the shaft; when installing the second bearing, push
against the inner race to remove all clearance between
the inner races of the two bearings, and between the
inner race of the first bearing and the retaining collar.
7. Install the lock washer [3-517-4] and locknut [3-516-4]
on the outboard end of the shaft. Ensure that the
locknut is secured and then bend over the tabs on the
lock washer.
8. Allow the bearings to cool to room temperature. Coat
the exposed sides with 2 to 3 oz. [55 to 85 g] of the
recommended grease.
9. Slide the bearing housings [3-025-3, 3-025-4] into place
over the bearing. Attach the bearing caps to the bearing
housing with four cap screws [5-904-9].
AC6102 Rev 07
10.4.3.4 Series 9100
1. Press bearing isolators [1-333-1] in each bearing cover
[3-018-3, 3-018-4]. Install gaskets [3-409-9] on each
bearing cover.
NOTE: Inboard bearing cover [3-018-3] is 1/4 in.
[6.4mm] less in width than outboard [3-018-4].
2. Slide bearing covers onto the shaft. Install the snap
rings [3-915-9]. Install thrust washer on the outboard
end.
3. Heat the bearings [3-026-2], using either a dry heat, or
a 10-15% soluble oil and water solution.
NOTE: Do not exceed 275°F [135°C].
4. Using gloves slide the heated bearing [3-026-2] onto the
shaft against the snap ring on the inboard end and the
thrust washer on the outboard end.
5. Install the lock washer [3-517-4] and locknut [3-516-4]
on the outboard end of the shaft. Ensure that the
locknut is secured and then bend over the tabs on the
lock washer.
6. Allow the bearings to cool to room temperature. Coat
the exposed sides with 2 to 3 oz. [55 to 85g] of the
recommended grease.
7. Press a bearing isolator [1-333-1] in the inboard bearing
housing and an oil seal [3-177-4] in the outboard
bearing housing.
8. Slide the bearing housings [3-025-2] into place over the
bearings. Attach the bearing covers to the bearing
housing with two cap screws [3-904-9].
10.4.4 Rotating element
After completion of the preceding steps, carefully place the
shaft assembly into the lower half pump casing.
10.4.4.1 Series 8100
1. Set the rotating element in the pump casing [2-001-0],
assuring correct rotation. Locate both stuffing box
tongues in their respective casing grooves.
2. Locate pins [3-943-9] in the stuffing box and the casing
wear rings in their respective slots at the casing parting
line. Correct any O-ring bulging.
10.4.4.2 Series 8150
1. Set the rotating element in the pump casing [2-001-0],
assuring correct rotation. Correctly locate casing ring
pins in the casing main slot. (Sliding the inboard bearing
housing towards the coupling slightly will ease
assembly).
2. Bolt the outboard bearing housing in place. Ensure that
both housings are seated properly in the lower half
casing.
3. Bolt inboard bearing housing in place. Rotating element
should now turn freely.
4. Adjust the shaft sleeve nuts to get the impeller centered
in the casing water passage.
5. Tighten the sleeve nut set screws.
10.4.4.3 Series 8200
1. Set the rotating element in the pump casing [2-001-8],
assuring correct rotation. Correctly locate casing ring
pins, stuffing box bushing pins, and interstage
diaphragm pins in the casing main joint slots. (Sliding
36
Series 8100/8150/8200/9100 Fire Pump
the inboard bearing housing towards the coupling
slightly will ease assembly).
2. Bolt the outboard bearing housing in place. Ensure that
both housings are seated properly in the lower half
casing.
3. Bolt inboard bearing housing in place. Rotating element
should now turn freely.
10.4.4.4 Series 9100
1. Set the rotating element in the pump casing [2-001-8],
assuring correct rotation. Correctly locate casing ring
pins in the casing main slot. (Sliding the inboard
bearing housing towards the coupling slightly will ease
assembly).
2. Bolt the outboard bearing housing in place. Ensure that
both housings are seated properly in the lower half
casing.
3. Bolt inboard bearing housing in place. Rotating element
should now turn freely.
10.4.5 Casing Gaskets
1. The main casing joint gasket can be made using the
upper and lower half as a template. Lay the gasket
material on the casing joint and mark it by pressing it
against the edges of the casing. Trim the gasket by
lightly tapping with a ball peen hammer so that it is flush
with the inside edges of the casing.
2. Precut casing gaskets [2-123-5, 2-123-6] can be
ordered to minimize the amount of trimming.
3. Clean the gasket surfaces of the casing. Apply a
multipurpose spray adhesive, (3M Super 77, or
equivalent) to the lower half of the casing.
4. Within one minute of spraying, set the untrimmed
gaskets [2-123-5, 2-123-6] in place on the lower half
casing, align the holes in the casing and press the
gaskets firmly against the lower half casing face in the
area coated by the adhesive.
5. Machined casing bores must remain sharp at the casing
parting line.
6. The gaskets must be flush with the bore in order to
contact the O-rings so as to prevent leakage around the
stuffing box. (Series 8100 only)
7. Lower the upper half casing [2-001-0] into place using
the tapered dowel pins [2-916-1], ensuring the stuffing
box and bearing housing are correctly aligned.
8. Tighten the upper half casing joint bolts to the correct
torque.
10.4.6 Stuffing Box Assembly – Packing
Install two rings of packing and tap fully to bottom of stuffing
boxes. Install seal cage [1-013-9] and ensure that it will line
up with the seal water inlet when the packing is compressed.
Install the remaining rings. Loosely fit the gland [1-014-9]
square with the stuffing box and connect the flush lines.
37
10.5 Tightening Torques
10.5.1 Casing Bolts
The standard bolt class is SAE J429 or higher with a non-
lubricated thread. The torque values listed in Table 12 shall
be applied on the pump casing bolts.
CAUTION
Gasket compression: Non-metallic gaskets
incur creep relaxation, before starting the
pump ensure that the casing bolts are
tightened to the correct torque.
NOTICE
Tightening sequence: Torqueing bolts to the
correct values in accordance with the correct
bolt tightening pattern is essential for obtaining
the proper gasket compression so that no
leakage can occur at the main joint. Always use
a torque wrench when tightening casing bolts.
10.5.1.1 Tightening sequence
Tighten the casing bolts in accordance with the following bolt
tightening pattern, see Fig. 23:
1. Tighten the four corner bolts marked 1 - 4.
2. Working outward along the shaft axis toward the stuffing
boxes in opposite quadrants, tighten bolts in regions 5 -
8.
3. Working outward along the flanges and in opposite
quadrants, tighten bolts in zones 9 - 12.
4. Repeat sequence 1 - 3.
Tighten the casing bolts in five steps:
1. Tighten bolts loosely by hand in the first instance,
according to the bolt tightening pattern, then hand
tighten evenly.
2. Using a torque wrench, torque to a maximum of 30% of
the full torque first time around, according to the bolt
tightening pattern. Check that the casing flange is
compressing the gasket evenly.
3. Torque to a maximum of 60% of the full torque,
according to the bolt tightening pattern.
4. Torque to the full torque, according to the bolt tightening
pattern.
5. Perform final pass at full torque, in a clockwise direction
on adjacent bolts.
AC6102 Rev 07
 10.5.2 Other bolt locations

Torque
Grade Head
Bolt Size Max Value
SAE Identification
ft-lb [N.m]

5/16-18 11 [15]

3/8-16 20 [27]

7/16-14 32 [43]

1/2-13 G2 49 [66]

5/8-11 97 [132]

Fig. 23 Bolt tightening pattern

3/4-10 172 [230]

1-8 250 [340]

Torque 3/8-16 31 [42]

Grade Head
Bolt Size Min. Value
SAE Identification
ft-lb [N.m]
1/2-13 G5 75 [101]

5/8-11 150 [203]

5/8-11 G5 140 [190]
5/16-18 11 [15]
B8
1/2-13 45 [61]

5/8-11 B8 75 [100]
Table 13 Torque requirements for other bolts

10.6 Spare Parts

3/4-10 12pt 300 [405] 10.6.1 Ordering Spare Parts
When ordering parts always provide the following
&
information to the A-C Fire Pump distributor in your region:
7/8-9 G8 350 [475] 1) Pump Serial Number
2) Pump Size and Type
1-8 400 [540] 3) Description of Part
4) Part number
8150 5) Quantity required
700 [950]
7/8-9 6) Billing and Shipping instructions
7) Date required
12pt
8150 The pump size and serial number are shown on the pump
900 [1220]
1-8 nameplate; refer to section 6, Description.
The part numbers and descriptions are shown in section 12,
Table 12 Torque requirements for Casing bolts Replacement Parts, which also indicates a list of
recommended spare parts for the pump.

10.6.2 Storage of spare parts

Spare parts should be stored in a clean dry area. Inspection
and re-treatment of metallic surfaces (if necessary) with a
corrosion inhibitor is recommended at six (6) month
intervals.

AC6102 Rev 07 38
Series 8100/8150/8200/9100 Fire Pump

11 Troubleshooting
Between regular maintenance inspections, be alert for signs of driver or pump trouble. Common symptoms
are listed below. Correct any trouble immediately and avoid costly repair and shutdown.

WARNING
Disconnect and lock out power to the pump
before trying to determine a failure. Failure to
follow these instructions could result in
serious personal injury.

39 AC6102 Rev 07
 Table 14 Troubleshooting List

AC6102 Rev 07 40
Series 8100/8150/8200/9100 Fire Pump

12 Replacement Parts

12.1 Series 8100 Horizontal Split Case Fire pump

Fig. 23 Exploded view of 8100 Horizontal Split Case Fire Pump

41 AC6102 Rev 07
 Table 15 List of components 8100 Horizontal Split Case Fire pump

Cat. No. Description Qty Cat. No. Description Qty

0-910-0 Pipe Plug (Casing) 5 3-025-3 Housing, Inboard Bearing 1

0-912-0 Pipe Fitting 3 3-025-4 Housing, Outboard Bearing 1

0-944-0 Spirol Pin (Shaft Sleeve) 2 3-026-3 Bearing, Inboard 1

0-950-0 Pipe Nipple 2 3-026-4 Bearing, Outboard 1

0-952-0 Tubing & Connectors 2 3-073-9 Stuffing Box 2

1-013-9 Seal Cage 2 3-136-9 Deflector 2

1-014-9 Gland, Packing 2 3-177-9 Lip Seal 2

1-904-9 Cap Screw (Gland) 4 3-516-4 Locknut, bearing 1

1-909-9 Washer (Gland) 4 3-517-4 Lockwasher, bearing 1

1-924-9 Packing 12 3-902-3 Shaft Nut Set Screw 2

2-001-0 Casing, Lower Half 1 3-904-9 Cap Screw (Bearing Housing) 8

2-001-0 Casing, Upper Half 1 3-910-9 Pipe Plug (Bearing Housing) 4

2-123-5 Gasket, Casing (Suction) 1 3-911-1 Impeller Key 1

2-123-6 Gasket, Casing (Discharge) 1 3-911-2 Coupling Key 1

2-904-1 Cap Screw (Casing) VARIES 3-914-1 O-Ring (Stuffing Box) 2

2-916-1 Casing Taper Pin 2 3-914-2 O-Ring (Casing Ring) 2

3-003-9 Casing Ring Assembly 2 3-914-9 O-Ring (Shaft Sleeve) 2

3-007-0 Shaft 1 3-943-9 Spirol Pin 4

3-009-9 Shaft Sleeve 2 4-002-0 Impeller 1

3-015-9 Nut, Shaft Sleeve 2

Bold Face: Recommended spare parts.

AC6102 Rev 07 42
Series 8100/8150/8200/9100 Fire Pump

12.2 Series 8150 Horizontal Split Case Fire pump

Fig. 24 Exploded view of 8150 Horizontal Split Case Fire Pump

43 AC6102 Rev 07
 Table 16 List of components 8150 Horizontal Split Case Fire pump

Cat. No. Description Qty Cat. No. Description Qty

0-905-0 Grease Fitting 2 3-009-2 Shaft Sleeve 2

0-909-0 Washer 4 3-015-9 Shaft Sleeve Nut 2

0-910-7 Pipe Plug 1/4 NPT Sstl 8 3-025-3 Housing, Inboard Bearing 1

0-910-8 Pipe Plug 2 3-025-5 Bearing Bracket 2

0-910-9 Pipe Plug 2 3-025-4 Housing, Outboard Bearing 1

0-915-0 Snap Ring Bearing 2 3-902-3 Setscrew 4

0-952-1 Hex Bushing 1 3-136-9 Slinger 2

0-952-2 Nipple 1/4 NPT x 1-1/2 1 3-177-2 Lip Seal 2

0-952-3 Tee 1/4 NPT 1 3-026-2 Bearing 2

0-952-4 Needle Valve 1/4 NPT 2 3-177-3 Beveled Snap Ring 1

0-952-5 Tubing 4 3-904-8 Cap Screw 8

0-952-6 Connector 1/4 OD X 1/4 NPT 2 3-904-9 Cap Screw 8

2-001-0 Casing, Lower Half 1 3-911-1 Impeller Key 1

2-001-0 Casing, Upper Half 1 3-911-2 Coupler Key 1

2-123-5 Gasket, Casing (Suction) 1 4-002-0 Impeller Bronze w/O-Rings 1

2-123-6 Gasket, Casing (Discharge) 1 3-914-9 O-Ring Sleeve 2

2-904-1 Cap Screw (Casing) 42 3-943-9 Pin, Wear Ring 2

2-904-2 Cap Screw (Casing) 4 6-924-0 Packing 10

2-916-1 Casing Taper Pin 2 6-013-2 Lantern Ring 2

3-003-2 Casing Ring Bronze 2 6-014-0 Gland 4

3-007-0 Shaft 1 6-902-2 Cap Screw 4

Bold Face: Recommended spare parts.

AC6102 Rev 07 44
Series 8100/8150/8200/9100 Fire Pump

12.3 Series 8200 Horizontal Split Case Fire pump

Fig. 25 Exploded view of 8200 Horizontal Split Case Fire Pump

45 AC6102 Rev 07
 Table 18 List of components 8200 Horizontal Split Case Fire pump

Cat. No. Description Qty Cat. No. Description Qty

1-952-0 Bleed Line 1 3-026-4 Bearing, Outboard 2

1-952-0 Flush Line 1 5-050-4 Split Ring 1

0-910-9 Pipe Plug 14 5-421-4 Retaining Collar 1

1-013-9 Seal Cage 2 3-169-9 Deflector 2

1-014-9 Gland 2 3-177-9 Lip Seal 2

1-901-9 Gland Bolt 4 3-516-4 Locknut 1

1-909-9 Washer, Gland Bolt 4 3-514-4 Lockwasher 1

1-924-9 Packing Ring 10 3-902-9 Set Screw 2

2-001-7 Casing, Upper Half 1 5-904-9 Bearing Cover Bolt 8

2-001-8 Casing, Lower Half 1 3-911-1 Key (Impeller) 1

2-123-5 Gasket, Casing (Suction) 1 3-911-2 Key (Coupling) 1

2-123-6 Gasket, Casing (Discharge) 1 3-914-9 O-Ring (Shaft Sleeve) 2

2-904-1 Cap Screw (Casing) VARIES 3-914-9 O-Ring (Stuffbox Bushing) 4

1-439-0 Dowel 2 6-008-0 Stuffbox Bushing 2

3-003-9 Casing Ring Assembly 2 3-034-0 Interstage Bushing 1

3-007-0 Shaft 1 3-231-0 Interstage Diaphragm 1

3-009-9 Shaft Sleeve 2 3-914-7 O-Ring (Interstage Bushing) 3

3-015-9 Shaft Sleeve Nut 2 5-915-0 Snap Ring (Bearing) 1

5-018-0 Bearing Housing Cover 2 3-915-0 Snap Ring (Interstage Bushing) 1

3-025-3 Bearing Housing 1 4-002-0 Impeller 2

3-026-3 Bearing, Inboard 1

Bold Face: Recommended spare parts

AC6102 Rev 07 46
Series 8100/8150/8200/9100 Fire Pump

12.4 Series 9100 Horizontal Split Case Fire pump

Fig. 26 Exploded view of 9100 Horizontal Split Case Fire Pump

47 AC6102 Rev 07
 Table 19 List of components 9100 Horizontal Split Case Fire pump

Cat. No. Description Qty Cat. No. Description Qty

0-901-0 Valve 2 3-015-9 Shaft Sleeve Nut 2

0-910-0 Pipe Plug 20 3-018-3 Bearing Housing Cover (Inboard) 1

0-950-0 Pipe Nipple 2 3-018-4 Bearing Cover (Outboard) 1

0-952-0 Tubing 2 3-025-2 Bearing Housing 2

1-013-2 Seal Cage 2 3-026-2 Bearing 2

1-014-2 Gland 2 3-078-9 Thrust Washer (Outboard) 1

1-333-1 Bearing Isolator 3 3-177-4 Lip Seal (Outboard Bearing) 1

1-904-9 Gland and Housing Bolt 12 3-409-9 Gasket (Bearing Housing Cover) 2

1-909-9 Washer, Gland Bolt 4 3-516-4 Locknut 1

1-924-9 Packing Ring 12 3-517-4 Lockwasher 1

2-001-7 Casing, Upper Half 1 3-902-9 Set Screw (Shaft Sleeve Nut) 2

2-001-8 Casing, Lower Half 1 3-904-9 Gland and Cover Bolt 4

2-123-5 Gasket, Casing (Suction) 1 3-911-1 Key (Impeller) 1

2-123-6 Gasket, Casing (Discharge) 1 3-911-2 Key (Coupling) 1

2-904-1 Cap Screw (Casing) VARIES 3-911-3 Key (Shaft Sleeve) 2

2-916-9 Taper Pin 2 3-914-9 O-Ring (Shaft Sleeve) 2

3-003-9 Casing Wear Ring 2 3-915-9 Snap Ring 2

3-007-0 Shaft 1 3-943-9 Spirol Ring 2

3-009-9 Shaft Sleeve 2 4-002-0 Impeller 1

Bold Face: Recommended spare parts

AC6102 Rev 07 48
Series 8100/8150/8200/9100 Fire Pump

A. Appendix

49 AC6102 Rev 07
 A1 Coupling Guard Removal and Installation (Non CE version)

NOTE: Do not spread the inner and outer guards more than necessary for guard removal or installation. Over-
spreading the guards may alter their fit and appearance.

A1.1 Removal
1. Remove the two (2) cap screws that hold the outer (motor side) coupler guard, (item 1); to the support
bracket(s), (items 3 (and item 6)).
2. Spread the outer guard and pull it off the inner guard, (item 2).
3. Remove the cap screw that holds the inner guard to the support bracket, (item 3).
4. Spread the inner guard and pull it over the coupler.

A1.2 Installation
1. Attach the Support Brackets, (items 3 and 4 preassembled); to the bearing housing, (if a new installation).
Spread the inner guard, (item 2); and place it over the coupler.
2. With the inner guard straddling the support bracket, (item 3); install a cap screw through the hole (or slot) in
the support bracket and guard located closest to the pump. Do not tighten the capscrew.
3. Spread the outer guard, (item 1); and place it over the inner guard.
4. Install the outer guard cap screws by following the step stated below which pertains to your particular
pump:
4.1 For pumps with a motor saddle support bracket, (item 5): Ensure the outer guard is straddling the
support arm, (item 6); and install but do not tighten the two remaining cap screws.
Locate the support arm, (item 6) between the outer guard ends, align the support arm with the holes in
the outer guard and the holes in the motor saddle support bracket, (item 5).
4.2 For pumps without a motor saddle support bracket: Insert the spacer washer, (item 7); between the
holes located closest to the motor in the outer guard, and install, but do not tighten, the two remaining
cap screws.
5. Position the outer guard so it is centered on the shaft, and so there is less than a 1/4 in. (6.35mm) of the
motor shaft exposed. On guards that utilize a slotted support bracket, the inner guard will have to be
positioned so there is only a 1/4 in. (6.35mm) of the pump shaft exposed.
6. Holding the guard in this position, tighten the three (3) cap screws.

FIG A1 Coupler Guard Exploded View for typical Motor Driven HSC Fire pump

AC6102 Rev 07 50
Series 8100/8150/8200/9100 Fire Pump

A2 Changing Pump Rotation

Every series Horizontal Split-case Centrifugal Fire Pumps can be operated clockwise or counter-clockwise when viewed
from the coupling end of the pump. If you wish to reverse the suction and discharge nozzles, this can be accomplished with
the same pump as follows:
NOTE: Refer to the disassembly and assembly procedures in section 10 of this manual for proper disassembly and
assembly techniques.

A2.1 Procedure
1. Remove the impeller from the shaft, turn it 180° and replace it on the shaft. (Follow the disassembly procedures given in this
manual.)
2. With the rotating element out of the casing, remove the casing from the baseplate and turn 180°.
3. Set the rotating element back in the casing and reassemble the pump.
NOTE: The impeller and the casing are in the same relationship to each other as they were originally. The shaft and
motor are also in the same relationship to each other as they were originally.
4. Reassemble pump and realign the coupling as called for in the alignment instructions in section 7.
5. The rotation of the motor must be changed by switching the motor leads.

NOTE: Unless the motor rotation is reversed the impeller will run backwards.

FIG A2 Correct relationship of impeller and casing HSC Fire pump

51 AC6102 Rev 07
 COMMERCIAL WARRANTY
Warranty. For goods sold to commercial buyers, Seller warrants the goods sold to Buyer hereunder (with the
exception of membranes, seals, gaskets, elastomer materials, coatings and other "wear parts" or consumables all
of which are not warranted except as otherwise provided in the quotation or sales form) will be (i) be built in
accordance with the specifications referred to in the quotation or sales form, if such specifications are expressly
made a part of this Agreement, and (ii) free from defects in material and workmanship for a period of one (1) year
from the date of installation or eighteen (18) months from the date of shipment (which date of shipment shall not
be greater than thirty (30) days after receipt of notice that the goods are ready to ship), whichever shall occur first,
unless a longer period is specified in the product documentation (the “Warranty”).

Except as otherwise required by law, Seller shall, at its option and at no cost to Buyer, either repair or replace any
product which fails to conform with the Warranty provided Buyer gives written notice to Seller of any defects in
material or workmanship within ten (10) days of the date when any defects or non-conformance are first manifest.
Under either repair or replacement option, Seller shall not be obligated to remove or pay for the removal of the
defective product or install or pay for the installation of the replaced or repaired product and Buyer shall be
responsible for all other costs, including, but not limited to, service costs, shipping fees and expenses. Seller shall
have sole discretion as to the method or means of repair or replacement. Buyer’s failure to comply with Seller’s
repair or replacement directions shall terminate Seller’s obligations under this Warranty and render the Warranty
void. Any parts repaired or replaced under the Warranty are warranted only for the balance of the warranty
period on the parts that were repaired or replaced. Seller shall have no warranty obligations to Buyer with respect
to any product or parts of a product that have been: (a) repaired by third parties other than Seller or without
Seller’s written approval; (b) subject to misuse, misapplication, neglect, alteration, accident, or physical damage;
(c) used in a manner contrary to Seller’s instructions for installation, operation and maintenance; (d) damaged
from ordinary wear and tear, corrosion, or chemical attack; (e) damaged due to abnormal conditions, vibration,
failure to properly prime, or operation without flow; (f) damaged due to a defective power supply or improper
electrical protection; or (g) damaged resulting from the use of accessory equipment not sold or approved by Seller.
In any case of products not manufactured by Seller, there is no warranty from Seller; however, Seller will extend to
Buyer any warranty received from Seller’s supplier of such products.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ANY AND ALL OTHER EXPRESS OR IMPLIED
WARRANTIES, GUARANTEES, CONDITIONS OR TERMS OF WHATEVER NATURE RELATING TO THE GOODS
PROVIDED HEREUNDER, INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE, WHICH ARE HEREBY EXPRESSLY DISCLAIMED AND EXCLUDED.
EXCEPT AS OTHERWISE REQUIRED BY LAW, BUYER’S EXCLUSIVE REMEDY AND SELLER’S AGGREGATE LIABILITY
FOR BREACH OF ANY OF THE FOREGOING WARRANTIES ARE LIMITED TO REPAIRING OR REPLACING THE
PRODUCT AND SHALL IN ALL CASES BE LIMITED TO THE AMOUNT PAID BY THE BUYER FOR THE DEFECTIVE
PRODUCT. IN NO EVENT SHALL SELLER BE LIABLE FOR ANY OTHER FORM OF DAMAGES, WHETHER DIRECT,
INDIRECT, LIQUIDATED, INCIDENTAL, CONSEQUENTIAL, PUNITIVE, EXEMPLARY OR SPECIAL DAMAGES,
INCLUDING BUT NOT LIMITED TO LOSS OF PROFIT, LOSS OF ANTICIPATED SAVINGS OR REVENUE, LOSS OF
INCOME, LOSS OF BUSINESS, LOSS OF PRODUCTION, LOSS OF OPPORTUNITY OR LOSS OF REPUTATION.

Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not
apply to you. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the
above exclusions may not apply to you. This warranty gives you specific legal rights, and you may also have
other rights which may vary from state to state.

To make a warranty claim, check first with the dealer from whom you purchased the product or call the
following number for the name and location of the nearest dealer providing warranty service. For Goulds Water
Technology contact 315-568-7123. For all other products, contact 847-966-3700.

AC6102 Rev 07 52
Xylem |’zīləm|
1)) The tissue in plants that brings water upward from the root
2)) a leading global water technology compan

We’re a global team unified in a common purpose: creating advanced

technology solutions to the world’s water challenges. Developing new
technologies that will improve the way water is used, conserved, and re-used in
the future is central to our work. Our products and services move, treat, analyze,
monitor and return water to the environment, in public utility, industrial,
residential and commercial building services settings. Xylem also provides a
leading portfolio of smart metering, network technologies and advanced
analytics solutions for water, electric and gas utilities. In more than 150 countries,
we have strong, long-standing relationships with customers who know us for our
powerful combination of leading product brands and applications expertise with
a strong focus on developing comprehensive, sustainable solutions.

For more information on how Xylem can help you, go to www.xylem.com

Xylem Inc. The original instruction is in English. All non-English

8200 N. Austin Avenue
Morton Grove, Illinois 60053
USA
Tel: (847) 966-3700
Fax: (847) 966-1914
www.xylem.com/acfirepump
instructions are translations of the original instruction.
© 2022 Xylem Inc.
Xylem and A-C Fire Pump are trademarks of Xylem Inc.
or one of its subsidiaries. All other trademarks or
registered trademarks are property of their respective
owners.
AC6102_7_en
INSTALLATION AND MAINTENANCE MANUAL FOR
ELECTRIC FIRE PUMP CONTROLLERS
MODEL GPX

1
 Table of Contents
1. Introduction

2. Installation

3. Main Features

4. Home

5. Alarms

6. Configuration
7. History

8. Service

9. Download Manuals

10. Language

11. Technical Documents

GPXV2-Manual-EN v2.2.0.0
Table of Contents
Introduction...................................................................................................................................................................... 5
Types of Electric Fire Pump Controllers .................................................................................................................... 5
Methods of Starting/Stopping ..................................................................................................................................... 6
Installation ....................................................................................................................................................................... 8
FCC Regulations and Radio Standards Specification (RSS) Rules .......................................................................... 8
Location ...................................................................................................................................................................... 8
Mounting .................................................................................................................................................................... 9
Storage ....................................................................................................................................................................... 9
Wiring and Connections ............................................................................................................................................. 9
Water Connections ..................................................................................................................................................... 9
Electrical Wiring ......................................................................................................................................................... 9
Electrical Connections................................................................................................................................................ 9
Energy Consumption.................................................................................................................................................. 9
Sizing.......................................................................................................................................................................... 9
Incoming Power Connections ..................................................................................................................................10
Motor Connections ...................................................................................................................................................10
Terminal Strip Descriptions ......................................................................................................................................11
Quick Start-Up Guide ...............................................................................................................................................12
Main Features ...............................................................................................................................................................19
The ViZiTouch ..........................................................................................................................................................19
Alarm Bell .................................................................................................................................................................19
First Setup ................................................................................................................................................................19
ViZiTouch: Manual Rebooting Method .....................................................................................................................20
Pressure Transducer Test........................................................................................................................................20
Home .............................................................................................................................................................................21
Home (Menu) ...........................................................................................................................................................21
Screen Saver ...........................................................................................................................................................23
Alarms ...........................................................................................................................................................................24
Alarms (Menu) ..........................................................................................................................................................24
Configuration .................................................................................................................................................................27
Config (Menu) ..........................................................................................................................................................27
NumPad Page ..........................................................................................................................................................28
Date and Time Page ................................................................................................................................................28
User Login Page / KeyPad Page .............................................................................................................................29
Advanced Configuration Page .................................................................................................................................30
Control Timers ..........................................................................................................................................................30
Alarms ......................................................................................................................................................................31
Sensor Selection ......................................................................................................................................................32
Outputs .....................................................................................................................................................................35
Update Program Page .............................................................................................................................................36

3
 Factory Settings .......................................................................................................................................................36
Interlock Lockout ......................................................................................................................................................37
Inputs........................................................................................................................................................................38
I/O Card Info .............................................................................................................................................................38
Network ....................................................................................................................................................................39
Reboot ViZiTouch ....................................................................................................................................................39
History ...........................................................................................................................................................................40
History (Menu) ..........................................................................................................................................................40
Events Page .............................................................................................................................................................41
Pressure Curves ......................................................................................................................................................41
Power Curves ...........................................................................................................................................................42
Saved Logs ..............................................................................................................................................................43
Pump Curves ...........................................................................................................................................................44
Statistic .....................................................................................................................................................................45
All Time Statistics .....................................................................................................................................................45
First Service Statistics ..............................................................................................................................................46
Last Service Statistics ..............................................................................................................................................47
Download .................................................................................................................................................................47
Service ..........................................................................................................................................................................48
Service .....................................................................................................................................................................48
Download Manuals ........................................................................................................................................................49
Language ......................................................................................................................................................................49
Technical Documents ....................................................................................................................................................49

4
 Introduction
Electric fire pump controllers are designed to start an electric motor driven fire pump. It can either start the fire
pump manually through the local start pushbutton or automatically through the sensing of a pressure drop in the
sprinkler system. The fire pump controller is supplied with a pressure transducer. The fire pump can be stopped
manually with the local stop pushbutton or automatically after the expiration of a field programmable timer. In both
cases, stopping is only allowed if all starting causes have disappeared.

Types of Electric Fire Pump Controllers

FIRE PUMP CATALOG NUMBER

MODEL No. EXAMPLE: GPA - 208 / 50 / 3 / 60

Model Prefix: GPA
Voltage: 208 V
HP Rating: 50 HP
Phase: 3
Frequency: 60 Hz

ACROSS-THE-LINE STARTER

MODEL GPA:
This model is intended to be used where the local utility or the capacity of the power source permits
across-the-line starting.
Full voltage is applied to the motor as soon as the controller receives a start command.

REDUCED VOLTAGE STARTERS

These models are intended to be used where the local utility or the capacity of the power source does not permit
full voltage starting.
In all the reduced voltage models, the manual “EMERGENCY RUN” device will initiate across-the-line starting.

MODEL GPP: PART WINDING STARTER

This model requires the use of a motor with two separate windings and 6 power conductors between the
controller and the motor.
Upon a start command, the first winding is connected to the line immediately. The second winding is
connected to the line after a very short time delay.

MODEL GPR: AUTOTRANSFORMER STARTER

This model does not require a multi-connection motor. It only requires 3 conductors between the controller
and the motor.
Upon a start command, an autotransformer is utilized to supply reduced voltage to the motor. After a time
delay, the autotransformer is shunted out and the motor is connected to full voltage by a closed transition
switching sequence.

MODEL GPS: SOLID STATE STARTER

This model does not require a multi-connection motor. It only requires 3 conductors between the controller
and the motor.
Upon a start command, a solid-state starter is utilized to supply a step less ramp-up voltage to the motor
until the motor reaches its full speed. At that time, a fully horsepower rated by-pass contactor is energized
connecting the motor directly to full voltage and eliminating all heat loss within the solid-state starter.
This controller also features a soft motor stopping mode and a hard stop mode. For a hard stop, hold the
stop pushbutton until the motor stop.

5
 MODEL GPV: ACCELERATION RESISTOR STARTER
This model does not require a multi-connection motor. It only requires 3 conductors between the controller
and the motor.
Upon a start command, a set of acceleration resistors in each phase is utilized to supply a reduced
voltage to the motor. After a time delay, the resistors are shunted out and the motor is connected to full
voltage by a closed transition switching sequence.

MODEL GPW: WYE-DELTA CLOSED TRANSITION STARTER

This model requires a multi-connection motor and 6 conductors between the controller and the motor.
Upon a start command, the motor is connected to the line in the wye connection. After a time delay, the
motor is reconnected to the line in the Delta configuration applying full voltage to the motor windings by a
closed transition switching sequence.

The power source does not « see » any open circuit during the transition from wye to delta. During the
transition from Wye to Delta, a resistor bank is connected in the starting circuit and allows to keep the
motor coils energized. An 80 second delay is then triggered and prevent the motor from stoping. This
delay allows the resistors to cool down and will only be triggered if the transition occur. An emergency
stop can still be perform by pulling the disconnecting mean handle.

MODEL GPY: WYE-DELTA OPEN TRANSITION STARTER

This type of starter requires a multi-connection motor and 6 conductors between the controller and the
motor.
Upon a start command, the motor is connected to the line in the Wye connection. After a time delay, the
motor is reconnected to the line in the Delta configuration applying full voltage to the motor windings. This
controller is of the open transition type. The motor is disconnected from the line during the transition from
start (wye) to run (delta) mode.

Methods of Starting/Stopping
The controllers are available as combination automatic / non-automatic with provision for manual or automatic
shutdown (an automatic shutdown is only possible after an automatic start).

METHODS OF STARTING

AUTOMATIC START
The controller will start automatically on low pressure detection by the pressure sensor when the pressure drops
below the cut-in threshold.

MANUAL START
The motor can be started by pressing the START push button, regardless of the system pressure.

REMOTE MANUAL START

The motor can be started from a remote location by momentarily closing a contact of a manual push button.

REMOTE AUTOMATIC START, DELUGE VALVE START

The motor can be started from a remote location by momentarily opening a contact connected to an automatic
device.

EMERGENCY START
The motor can be started manually by using the emergency handle. This handle can be maintained in a closed
position.

Important: to avoid damaging the contactor, it is recommended to start the motor in this manner:
1) Shutdown the main power by using the main disconnect means,
2) Pull the emergency handle and lock it in closed position,
3) Turn the power back on by using the main disconnect means.

SEQUENTIAL START
In case of a multiple pump application, it may be necessary to delay the automatic (pressure drop) starting of each
motor to prevent simultaneous starting of all motors.
6
FLOW START, HIGH ZONE START
The pump can be started by opening/closing a contact on the FLOW/ZONE START/STOP input.

WEEKLY START
The engine can be started (and stopped) automatically at the preprogrammed time.

TEST START
The motor can be started manually by pressing the run test button.

METHODS OF STOPPING

MANUAL STOP
Manual stop is done by pressing the priority STOP push button. Note that pressing the stop push button will
prevent the motor from restarting as long as the button is pressed, plus a two second delay.

AUTOMATIC STOP
Automatic stop is possible only after an automatic start and this function has been activated. When this function is
enabled, the motor is automatically stopped 10 minutes after the restoration of the pressure (above the cut-out
threshold) given that no other run cause is present.

FLOW STOP, HIGH ZONE STOP

If the controller has been started by the FLOW/ZONE START/STOP input and the signal has returned to normal,
the motor will be stopped given that no other run cause is present.

EMERGENCY STOP
The emergency stop is always possible in any starting condition and is done by using the main disconnecting
means located on the door.

7
 Installation
The GPx electric fire pump controller is cULus listed, FM certified and is intended to be installed in accordance with
the latest edition of the Standard of the National Fire Protection Association for the Installation of Centrifugal Fire
Pumps, NFPA20 2016 (Centrifugal Fire Pumps) and

in the USA, National Electrical Code NFPA 70

in Canada, Canadian Electrical Code, Part 1

others * Local Electrical Codes *

*Only American and Canadian applicable codes have been considered during the design of the controllers and the
selection of components.
Except, in some cases, the controller is also seismic approved and has been tested in accordance with the ICC-ES
AC156, IBC 2015, CBC 2016, OSHPD Special Seismic Certification Preapproval – OSP and ASCE 7-10 Chapter
13 standards. Proper installation, anchoring and mounting is required to validate this compliance report. Refer to
this manual and drawings to determine the seismic mounting requirements and location of the center of gravity (you
may need to contact factory). The equipment manufacturer is not responsible for the specification and performance
of anchorage systems. The structural engineer of record on the project shall be responsible for anchorage details.
The equipment installation contractor shall be responsible for ensuring the requirements specified by the structural
engineer of record are satisfied. If detailed seismic installation calculations are required, please contact the
manufacturer for the performance of this work.

FCC Regulations and Radio Standards Specification (RSS) Rules

To comply with FCC and Industry Canada RF exposure compliance requirements, a separation distance of at least
20 cm must be maintained between the antenna of this device and all nearby persons. This device must not be co-
located or operating in conjunction with any other antenna or transmitter.

This device complies with Industry Canada licence-exempt RSS standard(s). Operation is subject to the following
two conditions: (1) this device may not cause interference, and (2) this device must accept any interference,
including interference that may cause undesired operation of the device.

This device complies with part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) This
device may not cause harmful interference, and (2) this device must accept any interference received, including
interference that may cause undesired operation.

Note: This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to
part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference
when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate
radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful
interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful
interference in which case the user will be required to correct the interference at his own expense.
“Changes or modifications not expressly approved by the party responsible for compliance could void the user's
authority to operate the equipment.”

Location
The controller shall be located as close as practical to the motor it controls and shall be within sight of the motor.
The controller shall be located or protected so that it will not be damaged by water escaping from the pump or pump
connections. Current carrying parts of the controller shall be not less than 12 in. (305 mm) above the floor level.

Working clearances around the controller shall comply with NFPA 70, National Electrical Code, Article 110 or
C22.1, Canadian Electrical Code, Article 26.302 or other local codes.
8
The controller is suitable for use in locations subject to a moderate degree of moisture, such as a damp basement.
The pump room ambient temperature shall be between 39°F (4°C) and 104°F (40°C).

The standard controller enclosure is rated NEMA 2. It is the installer's responsibility to insure that either the
standard enclosure meets the ambient conditions or that an enclosure with an appropriate rating has been
provided. Controllers must be installed inside a building and they are not designed for outside environment. The
paint color may change if the controller is exposed to ultraviolet rays for a long period of time.

Mounting
The fire pump controller shall be mounted in a substantial manner on a single incombustible supporting structure.
Wall mounted controllers shall be attached to the structure or wall using all four (4) mounting ears provided on the
controller with hardware designed to support the weight of the controller at a height not less than 12 in. (305 mm)
above floor level. Floor mounted controllers shall be attached to the floor using all holes provided on the mounting
feet with hardware designed to support the weight of the controller. The mounting feet provide the necessary 12 in.
(305 mm) clearance for current carrying parts. For seismic applications, the mounting arrangement should be rigid
wall and base only. The structural engineer of record on the project shall be responsible for anchorage details.

Storage
If the controller is not installed and energized immediately, Tornatech recommend following the instructions from the
chapter 3 of the NEMA ICS 15 standard.

Wiring and Connections

Water Connections
The controller must be connected to the pipe system according to the latest edition of NFPA20 and also to a drain
pipe. The water connections are on the left side of the controller. The connection to the system pressure is a Male
½ NPT. If a drain is present, the connection to the drain is a tapered connection for plastic tubing.

Electrical Wiring
The electrical wiring between the power source and the fire pump controller shall meet the latest edition of NFPA
20, NFPA 70 National Electrical Code Article 695 or C22.1 Canadian Electrical Code, Section 32-200 or other local
codes. Electrical wiring shall be typically sized to carry at least 125% of the full load current (FLC or FLA) of the fire
pump motor.

Electrical Connections
A licensed electrician must supervise the electrical connections. The dimension drawings show the area suitable for
incoming power and motor connections. No other location shall be used. Only watertight hub fittings shall be used
when entering the cabinet to preserve the NEMA rating of the cabinet. The installer is responsible for adequate
protection of the fire pump controller components against metallic debris or drilling chips. Failure to do so may
cause injuries to personnel, damage the controller and subsequently void warranty.

Energy Consumption
Standby power: 10W

Sizing
Incoming power terminals on the controller are suitable to accept wire based on that selection with insulation not
less than 60°C. (Refer to terminal diagram for terminal sizes.)
The electrical wiring between the fire pump controller and the pump motor shall be in rigid, intermediate, or liquid
tight flexible metal conduit or Type MI cable and meet the requirements of NFPA 70 National Electrical Code or
C22.1 Canadian Electrical Code or other local codes.
The number of conductors required varies depending on the model of starter:
3-wires plus ground sized at 125% of full load current for models GPA, GPR, GPS and GPV.
6-wires plus ground sized at 125% of 50% of the motor full load current for GPP model.
6-wires plus ground sized at 125% of 58% of the motor full load current for GPY and GPW models.

9
Incoming Power Connections
Incoming normal power is to be connected to terminals located on the disconnecting means IS.
- For 3 phases motor: identified L1-L2 and L3.
- For single phase motor: identified L1 and L3

Motor Connections
Motor wires shall be connected to terminals identified by:
- T1-T2 and T3 located on main contactor (1M) for models GPA, GPR, GPS and GPV
- T1-T2 and T3 located on contactor (1M) and T7-T8 and T9 located on contactor (2M) for model GPP
- T1-T2 and T3 located on contactor (1M) and T6-T4 and T5 located on contactor (2M) for models GPY and GPW
It is the responsibility of the installer to obtain connection information on the motor and to assure that the motor is
connected as per the motor manufacturer recommendations. Failure to do so may cause injuries to personnel,
damage the motor and/or the controller and subsequently void warranty on both items.

10
Terminal Strip Descriptions Electric IO Board

Alarm output terminals (DPDT Relay, C:Common,

NC:Normally Closed, NO:Normally Open):
A: Motor Run
B: Power Available (Failsafe relay)
C: Phase Reversal
D: Pump Room Alarm
E: Motor Trouble
F: Factory Reserved
Field input terminal (Dry Contact Only: Voltage Free):
G: Remote Manual Start (NO)
H: Lockout (NO)
I: Remote Automatic Start (NC)
J: Deluge Valve (NC)
K: Factory Reserved 3 (NO)
L: Flow/Zone Start/Stop (NO)
M: Factory Reserved 2 (NO)
N: Factory Reserved 1 (NO)
Factory IO:
O: Analog Input sensor (depending on the options)
P: Analog Input sensor (depending on the options)
Q: PT2 Discharge Pressure sensor (redundant opt. only)
R: PT1 Discharge Pressure sensor
S: Emergency Handle limit switch
T: Communication ports to ViZiTouch and IO cards
U: Alarm Bell
V: Test Solenoid Valve
W: Shunt Trip
X: Factory Reserved
Y: 24VAC input power
Z: Main Coil power relay
AA: Delay Coil power relay
BB: Input Current sensing and Ground Fault detecting
CC: Ground
DD: Input Voltage sensing

11
Quick Start-Up Guide

The rating label is the most important label. It must be read carefully to ensure the compatibility between the
controller and the installation.

Verify that the controller is installed securely on the wall, or optionally on the mounting stand.

12
Make sure to drill holes for the motor and power connections and run the cables inside the panel, all in accordance
with the specifications in order to minimize interference with other equipment.

Verify and/or install the proper water connections for the water input and the drain. They must be securely installed
and tightened. Refer to the silkscreen markings on the plastic cover.

13
Connect the input power and the motor on their respective terminals. Secure with the appropriate torque as
indicated on the torque label and verify all connections. Secure the door in closed position then put the circuit
breaker disconnecting means in ON position. Verify the readings on the controller main screen.

Once the controller has booted up, the “First Start Up” page appears. The controller will automatically detect and
display the frequency of the power source. It is then possible to manually choose the frequency of the voltage.
Press “User Login” and enter a valid authorization code. Once logged in, press “Power”.

14
Verify that the normal voltage shown at L1-L2, L2-L3 and L1-L3 (nominal) is the same as what is written on the fire
pump controllers nameplate. The fire pump controller will validate the nominal voltage automatically versus what it
has been built for.

If all is adequate green check marks will appear.

To continue to next step, press “ ˂ First Start Up “

Press “Motor Rotation”

Press the “Start” button to start the electric motor and validate that the electric motor is rotating in the correct
direction. If it is not rotating in the correct direction adjus the motor connections as per below. Press the “Stop”
button to stop the electric motor.

15
Once the motor rotation has been checked, go back to the controller start-up page and press the “Verify pressure”
button.

WARNING!
On a Wye-Delta closed transition starter, if the transition from Wye to Delta occurs (after 5 to 8 seconds depending
on the motor HP), the manual stop push button will be disabled for 80 seconds. To stop the engine before the end
of the 80 second delay, use the disconnecting mean handle.

Press “Pressure”.
- Verify that the pressure reading on the screen matches with the calibrated pressure gauge installed on the
sensing line.
- Choose the desired units of measurement for pressure reading.
- Adjust, if required, the range of the digital pressure gauge at Max. Pres.
- Insert the Cut-Out and Cut-In pressure values of the fire pump.
- Insert, if so desired, the Cut-Out and Cut-In pressure values of the jockey pump.

Note: The jockey pump Cut-Out and Cut-In values must be set at the jockey pump controller itself. Inserting these
values at the Fire Pump Controller is only for pressure recording data purposes.

To continue to next step, press “ ˂ First Start Up “.

16
Go back to the controller start-up page and press the “Other Configuration” button. Enter the time and date. Select
the “Automatic shutdown” and the duration the pump will keep running after the automatic stop if an automatic stop
is desired. Select the frequency at which the periodic test will occur, the day of the week, the hour and the duration
of the test. Also, enter the duration of the Manual Run Test.

From the “Home” page, verify that the displayed values are correct.

17
The “First Start up” is now completed. The controller is fully installed and configured.

18
 Main Features
The ViZiTouch

A: Power LED 3 colors: Pulsing green if the ViZiTouch is properly powered.

B: Start button: Used to manually start the motor.
C: Stop button: Used to stop the motor if all starting conditions are gone.
D: Not used.
E: Run Test button: Used to start the manual run test. Be aware that water will flow through the drain during the
test.
F: Front USB Connector: USB Device connector used for file download, software updates, service reports.
G: Touch Screen: 7 inch color touch screen LCD with protective cover.
H: Locking mechanism for the protective cover of the screen. Push to open.
I: CANBUS connector for communication with IO board.
J: Side USB connector.
K: Ethernet connector.

Warning
After 2 years of service, the Vizitouch battery may become less efficient and could lose the time after a shutdown.

Alarm Bell
The alarm bell is activated under default faulty conditions stated by the NFPA20 standard.

Any of these conditions will energize the alarm bell but may be silenced, except in some cases, by pressing on the
the “Silence bell” button on the Alarms page. When silenced, the alarm bell restarts ringing if a new fault occurs or if
the alarm conditions remain unchanged after 24 hours. The alarm bell automatically stops ringing if alarm
conditions are not present anymore.

Note: Other optional or user defined conditions can also activate the bell and can be configured by the user. See
section 5 and verify drawings affixed inside the cabinet for more details.

First Setup
The First Setup must be done prior to using the controller. Completing the First Setup is the only way to access the
homepage and enable the automatic mode of the controller.

19
ViZiTouch: Manual Rebooting Method
If required, here is the procedure to manually reboot the ViZiTouch:
1- Turn OFF all disconnecting means to de-energize the ViZiTouch. The ViZiTouch's screen should turn black.
2- Press the stop button or wait until the ViZiTouch's LED extinguishes.
3- Wait 10 seconds.
4- Turn ON all disconnecting means.

Pressure Transducer Test

The controller will test the pressure transducer at least once a week if no manual run test or no weekly test has
been conducted. During the test, the pressure reading will drop to zero but the controller will not see it as a starting
request. This pressure drop will be recorded in the “Pump Curve” page and in the logs with the message.

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 Home
Home (Menu) Home

1
2
3
4
5
6
7

The home page displays all controller statuses and important values of the controller. This includes all voltages,
currents, pressures, motor state and status, as well as all timers and motor starting sequences.

A: Navigation bar: Pressing this icon will open a navigation menu on the left side of the screen:

1-Go to Home page

2-Go to Alarms page
3-Go to Configuration page
4-Go to History page
5-Go to Service page
6-Go to Download Manual page
7-Select Controller Language

B: Name of the page.

C: Displays the date, time and ambient temperature.

D: Motor power voltage. Each box represents an individual phase voltage between the two adjacent lines.

E: Current. Each circle represents an individual line current.

F: Motor contacts. An animation shows the contactor opened or closed depending on the signal sent to the main
coil.

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G: The electric motor. It will be grey if the motor is stopped, green if a “Motor Run” signal is detected and red if a
“Fail to start” has occurred. Pressing on the motor will redirect the user to the “Last Service Statistics” page, which
monitors all relevant statistics concerning the controller since the last service.

H: The motor configuration symbol shows how the motor is wired to the contactor(s). This symbol is used to show if
the motor is in a starting configuration (Wye wiring, for example) or in a permanent running configuration (i.e. delta
wiring)

Permanent delta motor connection.

Temporary wye motor connection.

Temporary auto-transformer motor connection.

Temporary primary resistor motor connection.

Temporary solid state starter motor connection.

Temporary part-winding motor connection.

I: Representation of the motor starting or stopping cause. The reason why the motor is running will be displayed in a
message box. Possible choices include, but are not limited to:

EMERGENCY: Manual motor starting activated by the emergency handle.

MANUAL: Manual motor starting activated by the START push button.

REMOTE MANUAL: Manual motor starting activated by a remote start contact.

DELUGE: Automatic motor starting activated by a deluge valve.

AUTO: Automatic motor starting activated by pressure drop.

REMOTE AUTO: Automatic motor starting activated by remote equipment.

FLOW: Automatic motor starting activated by a signal in the FLOW/ZONE START/STOP input.

HIGH ZONE: Automatic motor starting activated by a signal in the FLOW/ZONE START/STOP input.

WEEK TEST: Automatic motor starting activated by a scheduled test.

RUN TEST: Automatic motor starting activated by the run test push button.

This message can also indicate the reason why the motor is not running despite the fact that a request is being
made. Possible choices include, but are not limited to:

LOCKED ROTOR CURRENT (not on GPL models): A locked rotor current alarm has not been cleared on the
alarms page and prevents the motor from starting.

LOW PRESSURE: A low suction pressure prevents the motor from running, This functionality is optional.

LOW WATER: A low water reservoir level prevents the motor from running, This functionality is optional.
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LOW ZONE: A not running lower zone controller prevents the motor from running. This functionality is optional.

LOCKED: An interlock signal is preventing the motor from running.

J: Timers. The sequential start timer (on-delay) will start timing upon an Automatic start request (pressure drop,
deluge valve or remote auto signal). The motor will only start if the request stays active for the duration of this timer.
The “Duration” of the run period timer (off –delay) for automatic shutdown will start timing once the start request
disappears. The pump will stop at the expiration of this timer if the starting reason is no longer present. If a periodic
test has been programmed, the remaining time will be displayed. If a manual run test has been energized, the
remaining time will be displayed.

K: The discharge pressure gauge. It allows for a precise reading of the actual system pressure.The Cut-In (between
the yellow and the red section) and the Cut-Out (between the green and the yellow section) set point values are
indicated on the gauge. These values will also be represented by a red and green line on the gauge, allowing a
quick comparison between the actual pressure and the set points. The actual pressure is shown in the centre of the
gauge along with the unit of measure (psi, bar etc). The maximum allowable pressure is also indicated on the
gauge and will scale the gauge accordingly. A full screen image of the gauge will appear by pressing anywhere on
the gauge.

L: Status Bar. The Status Bar appears across the bottom of the display. It displays three statuses that describe the
primary configuration of the controller: Pressure actuated or Non-pressure Actuated, Automatic Controller or Non-
automatic, Manual or Automatic Shutdown.

If an alarm or a warning is active, a colored rectangle will appear over the Status Bar and will display the error
message. This notification will be yellow for a warning and red for an alarm. If more than one error is active, the
display will alternate between the error messages. The messages will disappear when the alarm or warning starting
cause is no longer present.

Screen Saver
After 5 minutes of inactivity on the ViZiTouch, the screen will dim it's brightness to 25%. After 10 minutes of
inactivity on the ViziTouch, the “Black Screen” screen saver will activate. Its goal is to expand the lifetime of the
LCD screen. The screen saver will be instantly deactivated if the engine is running or if an alarm is activated. To
manually deactivate it, simply touch the screen or any membrane button. After deactivation, the screen saver will
always redirect to the “Home” page. It will also log off any user by resetting the security level to 0 and save any new
modifications to the settings.

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 Alarms
Alarms (Menu) Configuration > Advanced > Alarms

This page displays the list of currently active and occurred alarms. Alarms with adjustable parameters can be set in
the Config ˃ Advanced ˃ Alarms pages (see section 6).
An alarm is called ACTIVE when its triggering condition is still valid.
An alarm is called OCCURRED when its triggering condition has been active, but is no longer true.
Alarms representing serious concerns will have a red triangle with an exclamation point in the center at the end of
the alarm message.
Alarms representing simple warnings will have a yellow triangle with an exclamation point in the center at the end of
the alarm message.
Pressing on the Bell Test button will ring the bell for three seconds.
To silence the bell, press the SILENCE button.
Pressing on the RESET button will reset OCCURRED alarms only.
Alarms ending with ** are available on transfer switch models only

The table displays system events:

- Date and time stamp of the alarm in the YYYY.MM.DD HH:mm:SS format
- Alarm message
- State: OCCURRED or ACTIVE
- Color Code Icon:
Red: The event is an alarm
Yellow: The event is a warning

Complete list of alarms :

- Normal Phase Reversal: Activates when the phase order on the normal power does not match the correct value of
the controller. Each time a service is acknowledged on the ViZiTouch, the controller synchronises the correct phase
order to the one detected on the normal power.

- Phase Loss L1: This alarm is activated if the first phase of the normal power connection does not meet the
qualification criteria.

- Phase Loss L2: Activates if the second phase of the normal power connection does not meet the qualification
criteria.

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- Phase Loss L3: Activates if the third phase of the normal power connection does not meet the qualification criteria.

- Lock Rotor Current: Activates when a lock rotor condition has been detected on the normal power. Note that the
motor will not be permitted to start on the normal power as long as this alarm has not been reset from the alarms
page.

- Fail to start: Activates if there is and under-current draw of two phases when the motor should be running. A 20
second factory set delay is used to give the motor enough time to start before signalling this alarm.

- Automatic Transfer Sw. Trouble**: After a factory programmed delay, activates upon detection of any of the
following transfer switch data: The alternate position and normal position limit switches are both activated OR none
of the alternate position or the normal position limit switches are activated OR the voltage reading on the load side
of the motor contactor does not match the reported input power .

- Loss of power: Activates when a complete loss of normal power is detected.

- Service Required: Activates when service is due for the controller. This occurs when the date set in the service
page has passed or if no service has ever been done.

- Undercurrent: Activates when current is under 30% of FLA and the motor has been running for 15 seconds.

- Overcurrent: Activates when current is above 150% of FLA.

- Undervoltage: Activates when normal power voltage is below 80% of nominal voltage.

- Overvoltage: Activates when normal power voltage is above 115% of nominal voltage.

- Phase Unbalanced: Activates when there is a difference of more than 10% of nominal voltage between the normal
power voltage readings.

- Weekly Test Cut-In Not Reached: Activates if the Cut-In is not reached during a manual or weekly test. At the end
of the 20s timer, if the Cut-In is not reached, the test may still be successful at starting the motor if the pressure has
dropped by at least 5 PSI.

- WT Check WT Solen: Activates if the pressure does not drop a minimum of 5 PSI during the manual run test or
the weekly test. Indicates a failure with the Test Solenoid Valve.

- PT Fault Detected: Occurs if the pressure reading is out of its normal range. Additionnally, if an optional dual
pressure sensor is installed, it will be activated if the two pressure transducers show different readings. Further
investigation is advised to determine what caused the different readings. Note that the controller will always choose
the lowest pressure reading to determine the actual system pressure. Also, if the voltage powering the transducer is
below 0.5V or over 4.5V the alarm will be activated.

- Alternate Power Phase Reversal**: Activates when the phase order on the alternate power does not match the
correct value of the controller. Each time a service is acknowledged on the ViZiTouch, the controller synchronises
the correct phase order to the one detected on the normal power.

- Alternate IS Tripped/Opened**: Activates when the AIS is either tripped or opened. This alarm condition rings the
bell and cannot be silenced.

- Alternate CB Tripped/Opened**: Activates when the ACB is either tripped or opened. This alarm condition rings
the bell and cannot be silenced.

- I/O Electric Communication Error: Activates if no communication between the ViZiTouch and the electric I/O card
could be established for 15 seconds. This alarm is critical and triggers the bell as well as deactivating the failsafe
Power Available output relay. If this alarm persists for more than 1 minute, the controller will reboot to try to fix the
problem.

- I/O Transfer Switch Communication Error**: Activates if no communication with the transfer switch I/O card could
25
be established for 15 seconds. This alarm is critical and triggers the bell bell as well as deactivating the failsafe
Power Available output relay. If this alarm persists for more than 1 minute, the controller will reboot to try to fix the
problem.

- Alternate Side LRC**: Activates when a lock rotor condition has been detected on the alternate power. Note that
the motor will not be permitted to start on the alternate power as long as this alarm has not been reset from the
alarms page.

- Low ambient temperature: Activates when the ambient temperature is below the factory set value (5° Celsius).

- Control Voltage Not Healthy: Activates when the 24VAC power input to the I/O cards is below the acceptable
functional range.

- Motor Trouble: Activates when a motor related alarm condition is present (overcurrent, undercurrent, fail to start or
ground fault).

- Pump Room Alarm: Activates when a pump room related alarm condition is present (overvoltage, undervoltage,
phase unbalanced).

- Pump on demand: Activates when the pressure is below the cut-in set-point on an automatic pressure actuated
controller.

- Invalid Cut-In: Activates when the Cut-In value is not acceptable on a pressure actuated cont

26
 Configuration
Config (Menu) Config

The main configuration page is used to setup all basic configuration parameters and provides a quick means of
changing the most common settings.
There are seven (7) access parameter boxes; Pressure, Periodic Test, Run Test, Automatic Shutdown, Date &
Time, Advanced and User Login. Each parameter requires a specific access level to set or change values.

User Login:
The padlock icon indicates the current authorization level. A locked padlock indicates that only basic settings can be
changed. Press on the padlock to enter an authorization code to unlock additional settings. An unlocked padlock
showing an authorization number indicates that some settings are unlocked. Press on the padlock again when you
have concluded your operation to logout and to save any changes made in the configuration.

Pressure:
The main pressure parameters can be set inside the box at the top of the page.
- Pressure reading: Can be selected as PSI, kPa, bar, FoH, or mH20.
- Input Device: Can be selected as Pressure transducer 1 or 2
- Maximum Pressure: Can be set between the Cut-Out value and 9999.
- Cut-Out: Can be set between the Cut-In value and the Maximum Pressure value. (The Cut-Out should be set
before the Cut-In).
- Cut-In: Can be set below the Cut-Out value.

Periodic Test:
The Periodic Test can be selected as “weekly”, “every other week” or “monthly”. The day of the week, the time of
day for the test and the test Duration can also be specified in this box.

Run Test Configuration:

The Run Test Configuration box is where the duration of the run test time is set. A timer between 1 and 30 minutes
can be selected.

Automatic Shutdown:
If enabled, the Automatic Shutdown will automaticly stop the pump after the demand dissapears. A timer between 1
and 1440 minutes can be selected.

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Advanced:
Go to the advanced configuration pages.

Date & Time Configuration:

Select to display the Date Time page.

NumPad Page

The NumPad is activated every time the user presses on a white square box representing a number that can be
set. On top of the NumPad, the current parameter is shown. The box at the top of the NumPad displays the range
of values accepted for that particular parameter. The box will turn red if the value entered is out of range. Pressing
the “X” button in the circle will set the value to zero “0”. Once a value that falls within the range is selected, the box
will turn blue. The button with a blue “X” inside a white arrow is used as a “backspace”. Pressing the “OK” button
will enter the new value and the screen will return to the previous page. Pressing anywhere outside the numpad
view will cancel the edition process and leave the value previously selected.

Date and Time Page

Select the Year by pressing inside the year box and enter the value, or use the left and right arrows to simply
decrement or increment the value. Likewise, select the month by pressing on the month box and select the value
from the list shown, or use the left and right arrows to cycle through the choices.
Once set, press on the proper day to select the actual day, if different. The time is set by pressing the two square
boxes under the clock; the left sets the hours and the right sets the minutes. Press the Update button to commit the
28
changes. A dialog box will appear to confirm the change “Date and Time”. The user may cancel the changes by
pressing the “Cancel” button. Please note that changing the date and time will have an effect on the logs
chronology.
The time zone can also be changed using the box in the bottom-right corner.

User Login Page / KeyPad Page

User Login KeyPad:

This page allows the user to log into a higher security level by entering a password. If the password is valid, the text
field will turn green and if it is invalid, the text field will turn red. An “X” button appears in the text field as soon as a
character is entered, allowing for a quick erase of the written password.

Shortly after being entered, each character will be displayed as an “*”. To view the whole password, press the eye
on the top left corner.

If the password is invalid for a consecutive number of times, the user will be redirected to the “Service Dealer” page,
allowing the user to communicate with the appropriate Service Dealer.

If the password is valid, the “Configuration” page will reload and the access security level will be shown inside the
lock. To log off, click on the lock and the user security level will return to “0”

29
Other KeyPads:
The KeyPad is activated every time the user presses on a grey rectangle box with white text representing a text that
can be set. The “X” button allows the user to cancel editing the value. The back arrow erases the last entered
character. Simply click the “OK” button once the value is set. This type of text field is mostly used to generate a
digital text indication for a custom alarm input.

Advanced Configuration Page Config > Advanced

This page is the portal to all the advanced configuration parameters of the ViZiTouch. Pressing on a tab will redirect
to the corresponding page.

Control Timers Config > Advanced > Control Timers

This page is used to adjust the timers.

Transition Timer
This timer sets the time delay of the transition between the starting reduced voltage and the full voltage. (Not for
GPA model).
Time Range: 1-3600 Seconds

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Sequential Start Timer
This timer sets the time delay between a demand becoming active and the starting of the motor. (Optional).
Time Range: 0-3600 Seconds

Run Period Timer

This timer sets the time the motor will keep running after the demand is resolved.
Time Range: 1-1440 Minutes

Alarms Configuration > Advanced > Alarms

Most alarms are not configurable in the field, but some are with the appropriate password level. If it's configurable,
the checkboxes will be in white. Otherwise the checkboxes will be grey. Also, the two last fields: Value Usage and
Analog Value are not always visible.

Start Test: The alarm can be tested using this button. This test will only announce the chosen alarm. It will activate
the bell if the alarm is audible and will activate any output relays associated with this alarm. The test will not activate
other common alarms or other components. To stop the testing, press the “Stop Test” button.

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Enable: Check this box to enable the Alarm/Warning.

Alarm: Makes this signal an alarm (red display). Otherwise, it will be a warning (yellow display).

Audible: Check this box to make the bell ring while this alarm is active.

Silence Duration: Set the time this Alarm will remain silenced.

Annunciate when occurred: Check this box to keep activated any associated relay even when this alarm has
occurred.

Acknowledgeable: Check this box to make the alarm acknowledgeable. If an alarm is ackowledged, the bell will be
silenced and the alarm IO board Output will stop being active. To acknowledge an alarm, go to the alarm list page
and press the blue “Active” status on the right of the alarm. The “Active” status should change to “Acknowledge”.

Timer On: It is the time delay between the triggering of the condition and the activation of the alarm.

Timer Off: It is the time delay between the stopping of the condition and the deactivation of the alarm.

Analog Value Usage: It is used to describe the activation range of the alarm. “Lower Than”, “Higher Than” and
“Between” can be selected. The corresponding value has to be entered.

Text: This field can be used to change the name of the alarm that will be displayed while this alarm is active. Note
that changing the factory set name of an alarm will disable any translation of this alarm to different languages.

Hysteresis: In the “Analogue Value Usage” field, it is possible to chose “Hysteresis Low Setpoint” and “Hysteresis
High Setpoint”. Both Analog Low Value and High Value needs to be selected for this mode to be effective. For the
“Hysteresis Low Setpoint”, the alarm will be trigger if the chosen signal goes below the “Low Setpoint” and will be
reset when the signal rise above the “High Setpoint”. For the “Hysteresis High Setpoint”, the alarm will be trigger if
the chosen signal goes above the “High Setpoint” and will be reset when the signal falls below the “Low Setpoint”.

Sensor Selection Config > Advanced > Sensors

All analog sensors, voltage sensors, a current sensor and a Ground fault sensor can be calibrated by accessing this
page. The Analog Input 1 is dedicated to the Pressure Transducer 1. The other Analog Input depends on the
controller options.

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Every sensor, except the line Voltage and the Current sensor can be calibrated the same way. The Signal
destination, the Unit type, the Unit, the Min and Max value are variables that are set in factory but the calibration
can be made in the field.

There are three ways of calibrating a sensor that can be chosen in the windows below "Sensor value".

-Sensor value: Connect an external measurement tool that is already calibrated (like a Manometer to calibrate a
pressure sensor). Bring the system to calibrate to a low point. While looking at the measurement tool, press the
read button (the button with a circular arrow). The value that was displayed on the measurement tool when the read
button was pressed needs to be enter in the "Low" window below the Desired value. Repeat these steps with a high
value. Then press compute. For the PT1, only a high value is required.

-Theorical voltage: Use a graphic of the theorical sensor's voltage response (usually given in the datasheet of the
sensor). Enter a low point (value, voltage) and a high point. Then press compute.

-Theorical current: Same as the theorical voltage, but with amperes.

For better results, use two points that are far apart, but in the normal range of the sensor.

For the pressure transducer PT1, the low point (zero) is automatically acquired during first power up. It can be re-
acquired by pressing the blue round arrow. The high point needs to be entered in order to calibrate the sensor.
33
To calibrate the line voltage sensor, use an external voltmeter that is already calibrated. With the control panel
under power:
- Read the voltage between L1 and L2, and press the first white box under “Sensor value”.
- Enter the voltages in the first white box below “Desired”.
- Read the voltage between L2 and L3, and press the second white box under “Sensor value”.
- Enter the voltages in the second white box below “Desired”.
- Read the voltage between L1 and L3, and press the third white box under “Sensor value”.
- Enter the voltages in the third white box below “Desired”.
- Press the “Compute” button.

To calibrate the current sensor, use an already calibrated current clamp. With the control panel under voltage and
the motor not powered, enter “0” in the white box under “Desired”. Press the higher “Read all” button. Start the
motor by pressing the manual start button on the ViZiTouch and wait for the motor to reach the full speed. Take a
reading with the current clamp on one line and press the lower “Read all” button. Enter the value taken with the
current clamp in the white box under “Desired”and at the right of “High”. Press Compute.

Important Notice!
Every analog sensor cable used for this controller should be shielded. The shield has to be grounded on the motor
side. Not complying to these recommendations may affect the controller good functioning and void its warranty.

34
Outputs Config > Advanced > Outputs

This page is used to see the logic of the signals that will activate the Outputs on the IO board and to test those
Outputs. The TB6 output can also be configured from this page.

Electric card outputs:

- SV
- ST
- AB
- CR4
- CR5
- TB1 (Motor Run)
- TB2 (Power Available)
- TB3 (Normal Phase Reversal)
- TB4 (Pump Room Alarm)
- TB5 (Motor Trouble)
- TB6 (Configurable)

Pressing on an Output will lead to this page:

The first box from the top is used to change the name of the Output. For the output's logic, a combination of 5 digital
inputs can be selected. Each input can be an alarm or a signal from a list and can be inverted by pressing the
35
NO/NC contact symbol at the left of the screen. A logical AND or OR can combine the chosen inputs and the exit
can also be inverted by pressing the NO/NC contact symbol at the right of the screen.

Pressing the “Test” button, at the bottom of the screen, will change the state of the output for one second. Note:
activating some outputs may cause the motor to start.

Update Program Page Config > Advanced > Update Program

This page is used to update the controller software. A USB key or a network connection with the software update is
needed.

Factory Settings Config > Advanced > Factory Settings

This page is used to visualize the program version, the serial number and the model of the controller.

Some parameters can be changed on this page, but be careful, modifying a parameter will change the basic
operation of the controller. Afterwards the controller may no longer respect the NFPA standard.
- Automatic Controller: Enable automatic starting causes.
- Pressure Actuated Controller: Enable the automatic controller to start following a pressure drop.

36
It is possible to reload a past configuration by pressing the "reload configuration" button. Dates with an "*" are
settings following a "Service".

Do not change a parameter on this page without previously consulting a Tornatech representant.

Interlock Lockout Config > Advanced > Interlock Lockout

This page is used to configure the Lockout input and the Interlock output parameters. To be active those options
need to be assigned to an Input or an Output on the IO board.

Lockout is an Input that prevents the motor from starting.

-Shutdown Motor: If enabled, the lockout signal will also act as a shutdown and will stop the motor if it is running.
-Enable in Manual: If checked, activation of the lockout input will prevent the Manual start.
-Enable in Automatic: If checked, activation of the lockout input will prevent the Automatic start.
-Enable in Remote: If checked, activation of the lockout input will prevent the Remote start.
-Enable in Flow: If checked, activation of the lockout input will prevent the Flow start.

Interlock is an Output that prevents a second motor from starting.

-Main coil required: If enabled, the controller will wait to have the main starting coil signal before putting Interlock
active.
-Enable in manual: If checked, this option will activate the output Interlock on a Manual start.
-Enable in auto: If checked, this option will activate the output Interlock on an Automatic start.
-Enable in remote manual: If checked, this option will activate the output Interlock on a Remote Manual start.
-Enable in start stop: If checked, this option will activate the output Interlock on a Start Stop mode.

37
Inputs Config > Advanced > Inputs

This page is for vizualisation purpose only. It allow the user to verify which signal is mapped on which controller's
input.

I/O Card Info Config > Advanced > IO Card Info

This page is used to visualize the ViZitouch and the IO Card registers by pressing on the blue arrows on the right of
the screen. Expansion Cards can also be installed via this page.

38
Network Config > Advanced > Network

This page displays the IP address, the Subnet Mask, the Default Gateway and the DNS1-2-3 of the controller. All
those parameter can be changed manually by checking the box on the upper left corner. To apply the change,
press on the blue arrow in the bottom right corner.

Reboot ViZiTouch Config > Advanced > Reboot ViZitouch

If this button is pressed, the ViZiTouch will reboot. Any change will be saved.

39
 History
History (Menu) History

This page is used to access all data related to events, statistics, pressure history, power logs and the downloading
of this information via one of the two USB ports.

-Events: This button leads to the “Events” page, which displays the events from the most recent 500 logs. Each
event log contains the date and time of occurrence as well as a brief description of the event.

-Pressure/Power Curves: This button leads to the “Pressure Curves” / “Power Curves” page accordingly, which
displays all relevant pressure/power information from the most recent 500 logs.

-Saved Logs: This button leads to a page where past logs can be viewed.

-Pump Curve: This button leads to the “Pump Curves” page.

-Statistics: This button leads to the “Statistics” page, which leads to “All Time Statistics”, “First Service Statistics”
and “Last Service Statistics” pages.

-Download: This button leads to the “Download” page, which allows the user to download information, including the
user manual, drawings, logs, statistics and configuration.

40
Events Page History > Events

The Events Page shows the events from the last 500 logs which occurred in chronological order. The first column is
the date, the second one is the time of occurrence and the third column is the “Event message”. To obtain a log that
is older than thoses events, visit the “Saved Logs”.

Pressure Curves History > Pressure Curves

On this page, a graphic of the “System Pressure”, the “Cut-in”, the “Cut-Out”, the main pump “Engine Run” and the
“Jockey Pump Run” through time can be viewed. By pressing on the screen, the caption will disappear or will be
displayed. The time scale can be changed by pressing the time span desired on top of the screen (from 1 minute to
2 weeks). The blue arrows on both sides of the graphic are used to navigate through time. The blue button in the
bottom left corner leads to the table used to generate this graph.

41
This table allows viewing of the exact values used to generate the Pressure Curves with the precise time. Pressing
the blue button on the top left corner will return to the graph page.

Power Curves History > Power Curves

On this page, a graphic of the 3 line voltages, the 3 line currents and the motor running through time can be viewed.
By pressing on the screen, the caption will disappear or will be displayed. The time scale can be changed by
pressing the time span desired on top of the screen (from 1 minute to 2 weeks). The blue arrows on both sides of
the graphic are used to navigate through time. The blue button in the bottom left corner leads to the table used to
generate this graph.

42
This table allows viewing of the exact values used to generate the Power Curves with the precise time. Press the
blue button on the top left corner to return to the graph page.

Saved Logs History > Saved Logs

This page is used to access all past log files. Each log file is a CSV file containing the time, the date, the Cut-in, the
Cut-out, the system pressure, the 3 line voltages and currents, the engine run signal, the jockey pump run signal
and the log event message. Each file can contain up to 1 MB of data. The month and year are shown in the title.
Each time a CSV file is full, a new one is created with an incremented number in the title. Press on the file to
consult this content.

43
The logs are arranged chronologically. To select the displayed data, press on the filter icon in the top center of the
screen.

From this page, the selected values will be displayed. Press on “Log File” at the top left of the screen to go back to
the logs table.

Pump Curves History > Pump Curves

This page is intended to help the customer generate the pump performance curve. In Auto mode, the controller will
sample the water flow exiting the pump, the system pressure and the suction at the entrance of the pump. The
appropriate sensor has to be installed for this mode to work. Each time the variation of a variable is important
enough, the controller will record the values and ring the bell. In manual mode, the user can manually enter the
values to generate the pump curve.

44
Statistic History > Statistics

This page leads to 3 other Statistics pages: “All Time Statistics”, “First Service Statistics” and “Last Service
Statistics”.

All Time Statistics History > Statistics > All Time Statistics

The “All Time Statistics” contains two parameters:

- Since: The date the controller has been powered for the first time.
- On Time: The amount of time the controller has been On for.

45
First Service Statistics History > Statistics > First Service Statistics

This page allows the user to view the “First Setup Statistics”. The parameters are:
From:
- Since: Date of the first setup
- On Time: Time the controller spent On, in DAYS-HOURS:MINUTES-SECONDS
Motor:
- On Time: Time the motor spent On, in DAYS-HOURS:MINUTES-SECONDS
- Start Count: Number of times the motor has started
- Last Started On: Last time the motor started
Pressure:
- Minimum: Smallest pressure value
- Minimum Occurred On: Date the smallest value happened
- Maximum: Biggest pressure value
- Maximum Occurred On: Date the biggest value happened
- Average: Average pressure since first start-up
Temperature
- Minimum: Smallest temperature value
- Minimum Occurred On: Date the smallest value happened
- Maximum: Biggest temperature value
- Maximum Occurred On: Date the biggest value happened
- Average: Average temperature since first start-up
Jockey Pump Running
- On Time: Time the Jockey Pump spent On, in DAYS-HOURS:MINUTES-SECONDS
- Start Count: Number of times the Jockey Pump has started
- Last Started On: Last time the Jockey Pump started

46
Last Service Statistics History > Statistics > Last Service Statistics

This page allows the user to view the “Last Setup Statistics”. The parameters are the same as the ones from the
“First Setup Statistics” page but from the “Last Service”.

Download History > Download

This page is used to download Statistics, PCB information, name plate information, logs, the manual, the factory
settings and the current settings. A USB key needs to be inserted in the USB slot prior to entering this page in order
to download.

47
 Service
Service

Informations on how to reach technical support, concerning the commissioning date, the last service date and the
next service due date is available on this page. It is the client responsibility to make sure that the proper
maintenance is done on the controller. A reminder for the “Service” can be selected from these options: OFF, ½
year, 1 year, 1 ½ years, 2 years and 3 years. The next service will be determined using the last service and the
chosen service interval. This service must be done by an accredited technician.

A proper password must be enter for the “Service Done” button to be available. This button should only be pressed
by an authorized person after a completed service.

The “Live View” page is where the user can grant or refuse the remote access demands.

The “Nameplate Information” page contains all the information found on the nameplate.

The Jockey Pump Cut-Out and Cut-In can be set on this page.

It is possible to install a custom Service card on this page. Contact Tornatech for more information.

48
 Download Manuals
Pressing on the question mark will redirect to the download page. A pdf version of the manual can be downloaded
on an USB device.

49
 Language
The language displayed on the ViZiTouch can be selected on this page.

50
 Technical Documents
Patents
Country Title Grant No
CA Mechanical activator for contactor 2741881
US Mechanical activator for contactor US8399788B2
CA Mechanical activator for electrical contactor 165512
CA Mechanical activator for electrical contactor 165514
US Mechanical activator for electrical contactor D803794
US Mechanical activator for electrical contactor Patent pending
002955393-
EP Mechanical activator for electrical contactor 0001/2
AE Mechanical activator for electrical contactor Patent pending
AE Mechanical activator for electrical contactor Patent pending
CA Fire pump digital operator 163254
US Fire pump digital operator interface D770313
AE Fire pump digital operator interface Patent pending
EP Fire pump digital operator interface 002937250-0001
CA System and method for detecting failure in a pressure sensor of a fire pump system Patent pending
US System and method for detecting failure of a pressure sensor in a fire pump system Patent pending

51
 Pre-Field Acceptance Test
TORNATECH MODEL GPX
WITH OR WITHOUT GPU TRANSFER SWITCH
ELECTRIC FIRE PUMP CONTROLLER
PRE- FIELD ACCEPTANCE TEST
CHECK LIST
Note: This document should be an official indication of whether or not the installation and general condition
of the equipment is adequate for a field acceptance test. This document should also aid the individual
responsible for executing the field acceptance test to decide whether or not to carry out the field acceptance
test of the equipment.
Installation Check List: YES NO
Verify that the nameplate of the Fire Pump Controller corresponds with the AC voltage
1
available.
Visual inspection for any damage to the exterior of the Fire Pump Controller. Make sure
2
the enclosure, alarm bell, selector switch, membrane and display are not damaged.
Verify that the Fire Pump Controller has been installed within sight of the pump and engine
3
or motor.
Verify that the Fire Pump Controller has been installed not less than 12 inches from the
4
floor of the mechanical room.
Verify that all electrical connections to the Fire Pump Controller are done using liquid tight
5
conduit and connectors.
With the Fire Pump Controller door open, visually inspect for any drill chips, dirt or foreign
6 objects in the bottom of the enclosure, loose wires, broken components and general
proper electrician workmanship.
Verify that the correct Normal Power AC voltage is supplied to the controller by taking a
7
voltage reading at the incoming terminals of the isolating switch (IS).
8 Verify that the motor leads are connected for the corresponding starting method.
Initial Power-Up Check List: YES NO
Controller door must be closed and latched with Normal Power Disconnecting Means
1 handle in the OFF position. If a Transfer Switch is supplied, its door must be closed and
latched with the Alternate Power Isolating Switch handle in the OFF position.
2 Verify that the Emergency Start Handle is in the OFF position.
3 Place the Disconnecting Means handle in the ON position.
Verify that the Normal Power voltage and hertz displayed on the digital screen are the
4
same as measured in point 7 of the Installation Checklist above.
5 Verify that there is no Phase Reversal Alarm.
Note: A manual or automatic start must only be executed if the motor and the pump have
YES NO
been cleared to be started by their respective official service technicians.
1 Place the Disconnecting Means handle in the ON position.
2 Push the START pushbutton. The motor will start.
Verify the motor rotation:
• If the motor rotation is correct, no adjustment is required.
3
• To correct the motor rotation, change motor connection leads 1 and 3 (A and C) at the
run contactor
Verify any alarms that would appear on the digital display screen. Correct any alarm
4
condition.
Set the Cut-Out and Cut-In settings by following the ViZiTouch documentation. You need
5 to be logged in to modify these settings. Verify the automatic start by dropping the system
pressure below the Cut-In setting.
Stop the motor by pressing the “STOP” membrane button. Note: the motor will only stop if
6
the system pressure is above the cut-out setting.

52
Tornatech Controller S/N: _________________________________________

Installation address: _________________________________________

_________________________________________

_________________________________________

Check list completed? _____________Yes _____________ No

Check list completed by: __________________________________________

Company: __________________________________________

Date: __________________________________________

Witnessed By: __________________________________________

Comments: ___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

53
 Field Acceptance Test Report
TORNATECH MODEL GPX
WITH OR WITHOUT GPU TRANSFER SWITCH
ELECTRIC FIRE PUMP CONTROLLER
FIELD ACCEPTANCE TEST REPORT
Complete this first section if it was not completed during the Pre-Field Acceptance test
Note: A manual or automatic start must only be executed if the motor and the pump
YES NO
have been cleared to be started by their respective official service technicians.
1 Place the Disconnecting Means handle in the ON position.
2 Push the START pushbutton. The motor will start.
Verify the motor rotation:
• If the motor rotation is correct, no adjustment is required.
3
• To correct the motor rotation, change motor connection leads 1 and 3 (A and C) at
the run contactor
Verify any alarms that would appear on the digital display screen. Correct any alarm
4
condition.
Set the Cut-Out and Cut-In settings by following the ViZiTouch documentation. You
5 need to be logged in to modify these settings. Verify the automatic start by dropping
the system pressure below the Cut-In setting.
Stop the motor by pressing the “STOP” membrane button. Note: the motor will only
6
stop if the system pressure is above the cut-out setting.
Phase Reversal Verification YES NO
Verify or simulate phase reversal
Overcurrent Protection
Controller nameplate info Electric Motor nameplate info
1
FLC: __________A FLC: __________A
LRC: __________A LRC: __________A

Motor Starts
Normal Power YES NO
1 6 manual starts
2 6 automatic starts
3 6 Emergency Handle starts
4 1 remote/deluge valve start

Field Settings:
Cut-Out Pressure: ________

Cut-In Pressure: ________

Minimum run period timer activated?

Yes: _____ Set at _____minutes. No: _____

Sequential Start Timer?

Yes: _____ Set at _____seconds. No: _____

Weekly Test Enabled?

Yes: _____ Start (date and time) ___________ No: _____

Stop (date and time) ___________

54
Alarm Contacts Connections:
Fire Pump Controller

Motor Run connected? _____Yes _____ No

Power Available connected? _____Yes _____ No

Phase Reversal connected? _____Yes _____ No

Other contacts supplied and connected? _____Yes _____ No

Tornatech Controller S/N: _________________________________________

Installation address: _________________________________________

_________________________________________

Field Acceptance Test completed? _____Yes _____ No

Field Acceptance completed by: __________________________________________

Company: __________________________________________

Date: __________________________________________

Witnessed By: __________________________________________

Company: __________________________________________

The undersigned witness has been made aware of the NFPA20 article 14.4 Periodic Inspection, Testing and
Maintenance which stipulates that “Fire pumps shall be inspected tested and maintained in accordance with
NFPA25 – Standard for the Inspection, Testing and Maintenance of Water Based Fire Protection Systems”

Comments: _____________________________________________________________________________

_____________________________________________________________________________

_____________________________________________________________________________

_____________________________________________________________________________

_____________________________________________________________________________

55
56
 Project:
Customer:
Engineer:
Pump Manufacturer:

Technical Data
Submittal Document
Model GPY
Full Service Reduced Voltage
Wye-delta Open
Electric Additive (Foam) Pump Controller

Contents:
Data Sheets
Dimensional Data
Wiring Schematics
Field Connections

Note: The drawings included in this package are for controllers

covered under our standard offering. Actual AS BUILT
drawings may differ from what is shown in this package.
August 2020
 Technical Data
Model GPY Electric Additive (Foam) Pump Controller

3L3 1M T3
From normal
3L2 T2
incoming power through
Disconnecting Means 3L1 T1

(IS/CB)*
M
CR4
1M 2M T5
CR5 1S T4
2M
T6
CR5 2M
3L1
1S
1S

3L2

Built to NFPA 20 (latest edition)

Underwriters Laboratory (UL) UL218 - Fire Pump Controllers
Standard, FM Global Class 1321/1323
Listings,
New York City Accepted for use in the City of New York by the Department of Buildings
Approvals and
Certifications Seismic Certification See page 6 for details
Optional
CE Mark Various EN, IEC & CEE directives and standards
Protection Rating
□ Standard: NEMA 2
Optional
□ NEMA 12 □ NEMA 4X-304 sst painted □ IP54
□ NEMA 3 □ NEMA 4X-304 sst brushed finish □ IP55
Enclosure □ NEMA 3R □ NEMA 4X-316 sst painted □ IP65
□ NEMA 4 □ NEMA 4X-316 sst brushed finish □ IP66
Accessories Paint Specifications
• Bottom entry gland plate • Red RAL3002
• Lifting Lugs • Powder coating
• Keylock handle • Glossy textured finish

*Please see Disconnecting Means details on page 3.

This is a Marketing document. Please consult factory if additional information is required.

August 2020 2
Manufacturer reserves the right to modify this information without notice
 Technical Data
Model GPY Electric Additive (Foam) Pump Controller

Choose one of the following configurations:

□ A8 - Additive (Foam) pump controller / non pressure actuated without pressure transducer and
run test solenoid valve
□ A8A - Additive (Foam) pump controller with pressure transducer and run test solenoid valve
□ A8B - Additive (Foam) pump controller with pressure transducer and run test solenoid valve in
Additive (Foam) stainless steel
Pump Controllers
Add any of the following options if required:
□ D40 - Dump valve circuitry, 24VDC Max2A
□ Cx79 - Low foam additive level complete with visual indication and alarm contact (DPDT)
□ Cx081 - Provision for proof pressure switch for low additive pressure complete with visual indication
and alarm contact. (Proof pressure switch provided by others.)

Shortcircuit 200V to 208V 220V to 240V 380V to 416V 440V to 480V 575V to 600V
Withstand 60Hz 60Hz 50 Hz / 60Hz 60Hz 60Hz
Rating HP (kw)

Standard 100kA
5 - 150 (3.7 - 110) 5 - 200 (3.7 - 149) 5 - 300 (3.7 - 223) 5 - 450 (3.7 - 335) N/A
Optional 150kA

Standard 50kA 200 (149) 250 (186) 350 - 450 (261 - 335) 500 (373)
5 - 500 (3.7- 373)
Optional 100kA N/A N/A N/A N/A

Optional 200kA 5 - 150 (3.7 - 110) 5 - 200 (3.7 - 149) 5 - 300 (3.7 - 223) 5 - 450 (3.7 - 335) N/A

Ambient Standard: Optional:

Temperature
Rating
□ 4°C to 40°C / 39°F to 104°F □ 4°C to 55°C / 39°F to 131°F
** Only supplied if configuration A8A or A8B is required.

This is a Marketing document. Please consult factory if additional information is required.

August 2020 Manufacturer reserves the right to modify this information without notice 3
 Technical Data
Model GPY Electric Additive (Foam) Pump Controller

Surge
Surge arrestor rated to suppress surges above line voltage
Suppression
• Isolating switch and circuit breaker assembly:
- Door interlocked in the ON position
- Isolating switch rated not less than 115% of motor full load current
Disconnecting
- Circuit breaker continuous rating not less than 115% of motor full load current
Means
- Overcurrent sensing non-thermal type, magnetic only
- Instantaneous trip setting of not more than 20 times the motor full load current
• Common flange mounted operating handle
Service Entrance
Suitable as service entrance equipment
Rating
Emergency Start • Flange mounted • Integrated limit switch
Handle • Pull and latch activation • Across the line start (direct on line)
Locked Rotor • Operate shunt trip to open circuit breaker • Trip between 8 and 20 seconds
Protector • Factory set at 600% of motor full load current
Electrical • Voltage phase to phase (normal power)
Readings • Amperage of each phase when motor is running
Pressure • Continuous system pressure display
Readings** • Cut-in and Cut-out pressure settings
• Pressure readings with date stamp
• Event recording with date stamp
Pressure and
• Under regular maintained operation, events are stored in memory for the life of the controller.
Event recorder***
• Data viewable on operator interface display screen
• Downloadable by USB port to external memory device
• Pressure transducer and run test solenoid valve assembly for fresh water application
• Pressure sensing line connection 1/2” Female NPT
Pressure
• Drain connection 3/8”
Sensing**
• Rated for 0-500PSI working pressure (standard display at 0-300PSI)
• Externally mounted with protective cover
Audible Alarm 4” alarm bell - 85 dB at 10ft. (3m)
• Power available • Deluge valve start • Pump on demand/Automatic start
• Motor run • Remote automatic start • Pump room temperature (ºF or ºC)
Visual Indications
• Periodic test • Remote manual start • Lockout
• Manual start • Emergency start

Visual
• Control voltage not healthy • Overcurrent • Pump on demand
• Invalid cut-in** • Overvoltage • Pump room alarm
• Lock rotor current • Phase loss L1 • Service required
Visual & Audible • Loss of power • Phase loss L2 • Undercurrent
Alarms • Low ambient temperature • Phase loss L3 • Undervoltage
• Motor trouble • Phase unbalanced • Check weekly test solenoid**
• Phase reversal • Pressure transducer fault detected • Weekly test cut-in reached**
Visual and audible
• Fail to start

** Only supplied if configuration A8A or A8B is required.

***Pressure recordings only if configuration A8A is required.

This is a Marketing document. Please consult factory if additional information is required.

August 2020 4
Manufacturer reserves the right to modify this information without notice
 Technical Data
Model GPY Electric Additive (Foam) Pump Controller

DPDT-8A-250V.AC
• Power available
• Phase reversal
• Motor run
• Common pump room alarm (field re-assignable)****
• Overvoltage
• Undervoltage
Remote Alarm
• Phase unbalance
Contacts
• Low pump room temperature
• High Pump room temperature
• Common motor trouble (field re-assignable)****
• Overcurrent
• Fail to start
• Undercurrent
• Low foam additive level
• Embedded microcomputer with software PLC logic
ViZiTouch V2 • 7.0” color touch screen (HMI technology)
Operator Interface • Upgradable software
• Multi-language
• Protocol: Modbus
Communication
• Connection type: Shielded female connector RJ45
Protocol
• Frame Format: TCP/IP
Capability
• Addresses: See bulletin MOD-GPx
• Start on pressure drop
Automatic Start • Remote start signal from automatic device
• Deluge valve start
• Start pushbutton
Manual Start • Run test pushbutton
• Remote start from manual device
• Manual with Stop pushbutton
Stopping
Operation • Automatic after expiration of minimum run timer *****
• Minimum run timer (off delay) *****
Field Adjustable &
Timers • Sequential start timer (on delay)
Visual Countdown
• Periodic test timer
• Pressure
Actuation
• Non-pressure
Visual Indication
• Automatic
Mode
• Non-automatic

****Tornatech reserves the right to use any of these three alarm points for special specific application requirements.
*****Can only be used if approved by the AHJ

This is a Marketing document. Please consult factory if additional information is required.

August 2020 Manufacturer reserves the right to modify this information without notice 5
 Technical Data
Model GPY Electric Additive (Foam) Pump Controller

Seismic
TRU Compliance, LLC
Certification TWEI Project No.: 15014
A Tobalski Watkins Affiliate
Company
Mounting
Rigid base and wall mounting
details
Seismic
Building Test Seismic AFLX-H ARIG-H AFLX-V ARIG-V
Certification
Code Criteria Parameters
SDS z/h IP
Seismic IBC
Information ICC- 2.0 1.0 1.5 3.20 2.40 1.33 0.53
2015, ASCE 7-10
ES
CBC Chapter 13
AC156 3.2 0.0 1.5 3.20 1.28 2.13 0.85
2016

RRS for Nonstructural Components Testing

10.0
Spectral Response Acceleration (g)

1.0

0.1
0.1 1.0 10.0
Frequency, f (Hz)

Horiz. Level 1 Vert. Level 1

Notes:
• Components are tested in accordance with ICC-ES AC156, IBC 2015 & CBC 2016.
• OSHPD Special Seismic Certification Preapproval (OSP)

This is a Marketing document. Please consult factory if additional information is required.

August 2020 6
Manufacturer reserves the right to modify this information without notice
 Technical Data
Model GPY Electric Additive (Foam) Pump Controller

A4 Flow switch provision High water reservoir level c/w visual indication
C18
and alarm contact (DPDT)
A9 Low zone pump control function
C19 Emergency start alarm contact (DPDT)
A10 Middle zone pump control function
C20 Manual start alarm contact (DPDT)
A11 High zone pump control function
C21 Deluge valve start alarm contact (DPDT)
Non-pressure actuated controller w/o pressure
A13
transducer and run test solenoid valve C22 Remote automatic start alarm contact (DPDT)
Lockout/interlock circuit from equipment C23 Remote manual start alarm contact (DPDT)
A16
installed inside the pump room
High pump room temperature alarm contact
Built in alarm panel (120V.AC supervisory C24
(DPDT)
power) providing indication for:
• Audible alarm & silence pushbutton for motor Second set of standard alarm contacts (DPDT)
B11 C25
run, phase reversal, loss of phase. (Typical for city of Los Angeles and Denver)
• Pilot lights for loss of phase & supervisory Additional visual and alarm contact (Specify
Cx
power available function) (DPDT)
Built in alarm panel same as B11 but 220- Low suction pressure transducer for fresh
B11B
240VAC supervisory power D1 water rated at 0-300PSI with visual indication
High motor temperature c/w thermoster relay and alarm contact
B19A
and alarm contacts (DPDT) Low suction pressure transducer for sea water
High motor temperature c/w PT100 relay and D1A rated at 0-300PSI with visual indication and
B19B alarm contact
alarm contacts (DPDT)
Ground fault alarm detection c/w visual Pressure transducer and run test solenoid
B21 D5 valve for fresh water rated for 0-500PSI (for
indication and alarm contact (DPDT)
factory calibration purposes only)
CX081 Low foam additive level
Pressure transducer and run test solenoid
D5D
C1 Extra motor run alarm contact (DPDT) valve for sea water rated for 0-500PSI
C4 Periodic test alarm contact (DPDT) D10 Omit mounting feet (when applicable)
C6 Low discharge pressure alarm contact (DPDT) High withstand rating for:
• 200V to 208V @ 150HP max. = 150kA*
Low pump room temperature alarm contact • 200V to 208V @ 200HP = 100kA*
C7
(DPDT) • 220V to 240V @ 200HP max. = 150kA*
Low water reservoir level alarm contact • 220V to 240V @ 250HP = 100kA*
C10 D13
(DPDT) • 380V to 415V @ 300HP max. = 150kA*
High electric motor temperature alarm contact • 380V to 415V @ 350HP to 450HP = 100kA*
C11 • 440V to 480V @ 400HP max. = 150kA*
(DPDT)
• 440V to 480V @ 450HP to 500HP = 100kA*
High electric motor vibration c/w visual • 600V @ 500HP max. = 100kA*
C12
indication and alarm contact (DPDT)
High withstand rating for:
Pump on demand / automatic start alarm • 200V to 208V @ 150HP max. = 200kA*
C14
contact (DPDT) D13B • 220V to 240V @ 200HP max. = 200kA*
C15 Pump fail to start alarm contact (DPDT) • 380V to 415V @ 300HP max. = 200kA*
• 440V to 480V @ 400HP max. = 200kA*
C16 Control voltage healthy alarm contact (DPDT)
D14 Anti-condensation heater & thermostat
Flow meter valve loop open c/w visual
C17
indication and alarm contact (DPDT)

Note: Options chosen from this page are not electrically represented on the wiring schematics in this submittal package.

This is a Marketing document. Please consult factory if additional information is required.

August 2020 Manufacturer reserves the right to modify this information without notice 7
 Technical Data
Model GPY Electric Additive (Foam) Pump Controller

D14A Anti-condensation heater & humidistat L01 Other language and English (bilingual)
Anti-condensation heater & thermostat & L02 French
D14B
humidistat
L03 Spanish
D15 Tropicalization
L04 German
D18 CE Mark with factory certificate
L05 Italian
Modbus with RTU frame format and RS485
D26
connection L06 Polish
Motor heater connection (external single L07 Romanian
D27 phase power source and heater on/off
contact) L08 Hungarian
Motor heater connection (internal single L09 Slovak
D27A phase power source and heater on/off
contact) L10 Croatian

D28 Customized drawing set L11 Czech

L12 Portuguese
Field programmable I/O board -
D34A
5 Input / 5 output L13 Dutch
Redundant pressure transducer for fresh L14 Russian
D36
water rated for 0-500PSI
Redundant pressure transducer for sea L15 Turkish
D36A
water rated for 0-500PSI L16 Swedish
L17 Bulgarian
L18 Thai
L19 Indonesian
L20 Slovenian
L21 Danish
L22 Greek
L23 Arabic
L24 Hebrew
L25 Chinese

Additional Options:

Note: Options chosen from this page are not electrically represented on the wiring schematics in this submittal package.

This is a Marketing document. Please consult factory if additional information is required.

August 2020 8
Manufacturer reserves the right to modify this information without notice
 Technical Data
Model GPY Electric Additive (Foam) Pump Controller

ViZiTouch V2 Operator Interface

®

PMS 295 PMS 361 Noir

Home

2 3

8
5 6 7

1 - Color touch screen 3 - Screen protector

2 - Onscreen menu 4 - Power LED (3 colors)
• HOME page 5 - START button
• ALARM page 6 - STOP button
• CONFIGURATION page 7 - RUN TEST button
• HISTORY page 8 - USB port
• SERVICE page
• MANUAL page
• LANGUAGES page

This is a Marketing document. Please consult factory if additional information is required.

August 2020 Manufacturer reserves the right to modify this information without notice 9
Electric Additive (Foam) Pump Controller Model: GPA/GPY
Dimensions Built to the latest edition of the NFPA 20 standard
39 3/8" [999]
38 3/8" [976]
1/2" [12] 21 3/4" [552] 36" [914]

18" [457] 34 1/2" [876]

See Notes

69 1/8" [1756]

68" [1727]
65 7/8" [1673]
62" [1576]
Optional

22 3/4" [577] 33 5/8" [854]

1" [25] Adjustable Feet

40" [1016]
Sensing Line Connection - 1/2 " F.NPT 38" [965]
11" [279] 1" [25]
Drain - 3/8 " M.TUBE

10" [255]
Voltage / Power Table 11 5/8" [294]
Normal
11" [279]
Power and
16" [406]
Motor Leads
Voltage Min HP Max HP Entrance

208 200
Notes: 1 1/4" [31] 3 1/2" [89]
1" [25] 14" [356]
- Standard NEMA: NEMA 2
220 - 240 250 - Standard paint : textured red RAL 3002.
- All dimensions are in inches [millimeters].
380 - 400 - 415 350 450 - Center of ViZiTouch screen: 61-5/8" [1564] from Bottom.
- Bottom conduit entrance through removable gland plate recommended.
440 - 480 450 500 - Use watertight conduit and connector only.
- Protect equipment against drilling chips.
600 N/A - Door swing equal to door width.
- Seismic mounting to be rigid wall and base only.
Drawing for information only. Projection
Manufacturer reserves the right to modify this drawing without notice.
Contact manufacturer for "As Built" drawing.

REV. DESCRIPTION DD/MM/YY Drawing number

NYC
Dpt of Building
Approved
GPX-DI3673 /E
0. First issue 24/05/17
2017 All right reserved. This drawing and the information contained or depicted herein are the sole property of Tornatech Inc. Copies are communicated to the recipient in strict confidence and may not be retransmitted, published, reproduced, copied or used in any manner, including as the basis for the manufacture or sale of any products, without the express prior written consent of Tornatech Inc.
Electric Additive (Foam) Pump Controller
Reduced Voltage / Wye-Delta (Open Transition)
Model: GPY
Wiring schematic Built to the latest edition of the NFPA 20 standard
IS1 CB1
1L3 3L3 CT3 1M**
1L2 3L2 CT2
1L1 3L1 CT1

White

White

White
CR4

Black

Black

Black
17
ST1 1M 3L3 64 66 68 2M**
65 67 69
SA1 CR5
18
1S
20
3L2
3L1
2M
4 2 3L1 CR5 2M
19 21
1S To J2-J3-J4 To J76
1S
2
1
3L2
NO NO +
C J40 J14 AI4
Motor Run C
TB1
NC NC -
2
1

NO NO +
C J42 J15 AI3
Power Available C
TB2
NC NC -
2
1

NO NO +
C J37 J16 AI2
Phase Reversal C
TB3
NC NC -
2
1
Red ***
NO NO
J39
+
White
PT1
Pump Room Alarm C C J17 AI1
TB4 Black
NC NC -

1
2

NO
LS1 **
NO LS1-1
C J41 LS1
Motor Trouble C
TB5 J54 LS1-2
NC NC
2
1
UP
NO J20
NO
C J55
Low Foam Additive Level *** C
TB6 DOWN
NC NC J8
VMB1
Black - +
J46 Red
AB1
AB
Remote Manual Start IN1

SV
SV1-1 Brown SV1 ***
Lockout IN2 J43 SV1-2 Blue

I/O
Foam Pump Automatic Start J1* IN3

4
Deluge Valve J45
J2* IN4 ST 2
J25
IN5
J44 24V in XTR1
IN6 24V out 3L2
X1 H2
1 24VAC
Proof Pressure Switch *** IN7 J47 24VAC 3 X2 H1
3L1
Low Foam Additive Level *** IN8
NC
J36 CR4-1
CR4
C
CR4-2
CR4
NO

NC
J38 CR5-1
CR5
C
CR5-2
CR5
NO

GF

69
L3 68
J76 67
L2 66 To CT1-CT2-CT3 Legend

65 1M-2M Contactors
1S Contactor
L1 64
AB Alarm Bell
CB Circuit Breaker
CR Control Relay

J53 CT Current Transformer

EB Electric I/O Board
IS Isolating Switch
J Jumper
J4 L3 3L3 LS Limit Switch
PT Pressure Transducer
SA Surge Arrester

J3 L2 ST Shunt Trip
3L2 To 3L1-3L2-3L3
SV Solenoid Valve
VMB ViZiTouch Main Board

EB1 J2 L1 3L1 XTR Transformer

* Remove jumper to use this feature Drawing for information only.

** Contact closes when emergency start is in "ON" position Manufacturer reserves the right to modify this drawing without notice.
Contact manufacturer for "As Built" drawing.
*** Optional
REV. DESCRIPTION DD/MM/YY Drawing number
NYC
Dpt of Building
Approved
GPY-WS670 /E
0 First issue 24/05/17
2017 All right reserved. This drawing and the information contained or depicted herein are the sole property of Tornatech Inc. Copies are communicated to the recipient in strict confidence and may not be retransmitted, published, reproduced, copied or used in any manner, including as the basis for the manufacture or sale of any products, without the express prior written consent of Tornatech Inc.
Electric Additive (Foam) Pump Controller Model: GPY
Terminal Diagram and Sizing Built to the latest edition of the NFPA 20 standard

3 Phases
Bonding Incoming Power
Ground

Notes:
Power Terminals 1 - For proper wire sizing, refer to NFPA70 and NEC (USA) or CEC (Canada) or local code.
L1 L2 L3 2 - Controller suitable for service entrance in USA.
Models : GPY IS1 3 - For more accurate motor connections refer to motor manufacturer or motor nameplate.
4 - Controller is phase sensitive. Incoming lines must be connected in ABC sequence.
5 - Field wiring and lug sizes are based on copper conductors only.
2M 1M Do not use aluminium conductors.
T6 T4 T5 T1 T2 T3

Isolating Switch (IS) Field Wiring according to Bending Space (AWG or MCM). TERMINALS L1 - L2 - L3 (Use Copper Conductors Only)

Bending
Space 5 " (127 mm) 8 " (203 mm)

HP
5 7.5 10 15 20 25 30 40 50 60
Voltage

208 1x (10 to 1/0) 1x (8 to 1/0) 1x (8 to 1/0) 1x (6 to 1/0) 1x (4 to 1/0) 1x (3 to 1/0) 1x (2 to 1/0) 1x (1/0 to 250) 1x (3/0 to 250) 1x (4/0 to 250)

220 to 240 1x (10 to 1/0) 1x (10 to 1/0) 1x (8 to 1/0) 1x (6 to 1/0) 1x (4 to 1/0) 1x (4 to 1/0) 1x (3 to 1/0) 1x (1 to 250) 1x (2/0 to 250) 1x (3/0 to 250)

380 to 416 1x (10 to 1/0) 1x (10 to 1/0) 1x (10 to 1/0) 1x (8 to 1/0) 1x (8 to 1/0) 1x (6 to 1/0) 1x (6 to 1/0) 1x (4 to 1/0) 1x (3 to 1/0) 1x (3 to 1/0)

440 to 480 1x (10 to 1/0) 1x (10 to 1/0) 1x (10 to 1/0) 1x (10 to 1/0) 1x (8 to 1/0) 1x (8 to 1/0) 1x (6 to 1/0) 1x (6 to 1/0) 1x (4 to 1/0) 1x (3 to 1/0)

600 1x (10 to 1/0) 1x (10 to 1/0) 1x (10 to 1/0) 1x (10 to 1/0) 1x (10 to 1/0) 1x (8 to 1/0) 1x (8 to 1/0) 1x (6 to 1/0) 1x (6 to 1/0) 1x (4 to 1/0)

Bending
Space 12 " (305 mm) 16 " (406 mm)

HP
75 100 125 150 200 250 300 350 400 450 500
Voltage

208 1x (300 to 500) 1x (500) 2x (4/0 to 500) 2x (250 to 500) 2x (400 to 600) -------- -------- -------- -------- -------- --------

220 to 240 1x (250 to 500) 1x (350 to 500) 2x (3/0 to 500) 2x (4/0 to 500) 2x (350 to 500) 2x (500 to 600) -------- -------- -------- -------- --------
2x (400 to 500)
380 to 416 1x (1/0 to 250) 1x (3/0 to 250) 1x (250) 1x (300 to 500) 2x (3/0 to 250) 2x (4/0 to 500) 2x (300 to 500) 2x (500 to 600) 2x (600) --------
2x (400 to 500)
440 to 480 1x (1 to 250) 1x (2/0 to 250) 1x (3/0 to 250) 1x (4/0 to 250) 1x (350 to 500) 2x (3/0 to 250) 2x (4/0 to 500) 2x (300 to 500) 2x (350 to 500) 2x (400 to 600) 2x (500 to 600)

600 1x (3 to 1/0) 1x (1 to 250) 1x (2/0 to 250) 1x (3/0 to 250) 1x (250 to 500) 1x (350 to 500) 2x (3/0 to 250) 2x (4/0 to 500) 2x (250 to 500) 2x (300 to 500) 2x (350 to 500)

Bending
Space 5 " (127 mm) 8 " (203 mm) 12 " (305 mm)

Wiring Size for motor connection for Models GPY (AWG or MCM). TERMINALS T1 - T2 - T3 - T4 - T5 - T6 (Use Copper Conductors Only)

HP
5 7.5 10 15 20 25 30 40 50 60
Voltage

208 1x (14 to 10) 1x (12 to 10) 1x (10) 1x (8 to 2) 1x (8 to 2) 1x (6 to 2) 1x (6 to 1/0) 1x (4 to 2/0) 1x (2 to 3/0) 1x (1 to 3/0)

220 to 240 1x (14 to 10) 1x (12 to 10) 1x (10) 1x (8 to 2) 1x (8 to 2) 1x (6 to 2) 1x (6 to 1/0) 1x (4 to 2/0) 1x (3 to 2/0) 1x (2 to 3/0)

380 to 416 1x (14 to 10) 1x (14 to 10) 1x (14 to 10) 1x (12 to 10) 1x (10) 1x (10) 1x (8 to 2) 1x (6 to 2) 1x (6 to 2) 1x (4 to 1/0)

440 to 480 1x (14 to 10) 1x (14 to 10) 1x (14 to 10) 1x (12 to 10) 1x (12 to 10) 1x (10) 1x (10 to 2) 1x (8 to 2) 1x (6 to 2) 1x (6 to 2)

600 1x (14 to 10) 1x (14 to 10) 1x (14 to 10) 1x (14 to 10) 1x (12 to 10) 1x (12 to 10) 1x (10) 1x (10 to 2) 1x (8 to 2) 1x (8 to 2)

HP
75 100 125 150 200 250 300 350 400 450 500
Voltage

208 1x (2/0 to 3/0) 1x (3/0) 1x (250 to 300) 2x (1/0 to 300) 2x (3/0 to 350) -------- -------- -------- -------- -------- --------

220 to 240 1x (1/0 to 3/0) 1x (3/0) 1x (4/0 to 300) 1x (300) 2x (2/0 to 300) 2x (4/0 to 350) -------- -------- -------- -------- --------

380 to 416 1x (4 to 2/0) 1x (2 to 2/0) 1x (1/0 to 3/0) 1x (2/0 to 3/0) 1x (4/0 to 300) 1x (300) 2x (2/0 to 300) 2x (3/0 to 300) 2x (4/0 to 350) 2x (4/0 to 350) --------

440 to 480 1x (4 to 2/0) 1x (3 to 2/0) 1x (2 to 3/0) 1x (1/0 to 3/0) 1x (2/0 to 3/0) 1x (4/0 to 300) 1x (300) 2x (1/0 to 300) 2x (2/0 to 300) 2x (3/0 to 350) 2x (4/0 to 350)

600 1x (6 to 2) 1x (4 to 2/0) 1x (3 to 2/0) 1x (2 to 3/0) 1x (1/0 to 3/0) 1x (2/0 to 3/0) 1x (4/0 to 300) 1x (250 to 300) 1x (300) 2x (1/0 to 300) 2x (2/0 to 300)

Drawing for information only.

Manufacturer reserves the right to modify this drawing without notice.
Contact manufacturer for "As Built" drawing.

REV. DESCRIPTION DD/MM/YY Drawing number

NYC
Dpt of Building
Approved
GPX-TD672 /E
0 First issue 24/05/17
2017 All right reserved. This drawing and the information contained or depicted herein are the sole property of Tornatech Inc. Copies are communicated to the recipient in strict confidence and may not be retransmitted, published, reproduced, copied or used in any manner, including as the basis for the manufacture or sale of any products, without the express prior written consent of Tornatech Inc.
Electric Additive (Foam) Pump Controller Model: GPX
Terminal Diagram and Sizing Built to the latest edition of the NFPA 20 standard

Control Terminals (EB1) Remote Alarm Terminals (EB1)

Terminals Wire Size: Terminals Wire Size:
24 - 12 AWG 24 - 12 AWG
0.5 Nm 0.5 Nm

2
Normally open NO
Normally closed Closes to alarm C
Opens to alarm NC
Remote Manual Start Close to start pump IN1 J25 Motor Run J40
1
Normally open TB1
NO
Normally closed Closes to alarm C
Opens to alarm NC

2
Normally open NO
Normally closed Closes to alarm C
Opens to alarm NC
Lockout Close to block start IN2 J25 Power Available J42
1
Normally open TB2
NO
Normally closed Closes to alarm C
Opens to alarm NC

2
Normally open NO
Normally closed Closes to alarm C
Opens to alarm NC
Foam Pump Automatic Start Open to start pump J1* IN3 J25 J37
Phase Reversal Normally open
1
TB3
NO
Normally closed Closes to alarm C
Opens to alarm NC

2
Normally open NO
Normally closed Closes to alarm C
Opens to alarm NC
Deluge Valve Open to start pump J2* IN4 J25 Pump Room Alarm ** J39
1
Normally open TB4
NO
Normally closed Closes to alarm C
Opens to alarm NC

2
Normally open NO
Normally closed Closes to alarm C
Opens to alarm
Alarm Inputs (EB1) Motor Trouble **
Normally open
1
NC
J41
TB5
NO
Terminals Wire Size: Normally closed Closes to alarm C
24 - 12 AWG
0.5 Nm Opens to alarm NC

2
Normally open NO
Normally closed Closes to alarm C
Opens to alarm NC
Low Foam Additive Level *** J55
1
Proof Pressure Switch *** Close to signal alarm IN7 J25 Normally open TB6
NO
Normally closed Closes to alarm C
Opens to alarm NC

Low Foam Additive Level *** Close to signal alarm IN8 J25
Network Connection (VMB1)
Shielded Female Connector RJ45

Modbus TCP/IP I/O

* Remove jumper to use this feature Drawing for information only.

** Re-assignable Manufacturer reserves the right to modify this drawing without notice.
*** Optional Contact manufacturer for "As Built" drawing.

REV. DESCRIPTION DD/MM/YY Drawing number

NYC
Dpt of Building
Approved
GPX-TD673 /E
0 First issue 24/05/17
2017 All right reserved. This drawing and the information contained or depicted herein are the sole property of Tornatech Inc. Copies are communicated to the recipient in strict confidence and may not be retransmitted, published, reproduced, copied or used in any manner, including as the basis for the manufacture or sale of any products, without the express prior written consent of Tornatech Inc.