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DOC TITLE
PROJECT
MAINTENANCE MANUAL
HULL NO.
: CMHI(JS)-151-1 / CMHI(JS)-151-2
EDITION
OWNER
SYSTEM
SFI CODE
: 00
DOC TITLE
F03
NO
SUB. DOC NO
REV
COPY
00
1E
REVISION
DATA
:
:
PREPARED BY
CHECKED BY
APPROVAD BY
00
10-Dec-14
01
02
03
04
05
Steven Chn
MANUFACTURER:
Marioff Corporation Oy Plaza Business park Halo yritie 24, 01510 Vantaa, Finland
Tel. +358 (0)9 870 851 Fax +358 (0)9 8708 5399 www.marioff.com
AUTHORIZED DISTRIBUTOR:
Oakwell International Trading (Shanghai) Co., Ltd./ Room403, Building H, Huaxin Science and Technology Park, 142 Tian Lin Road,Shanghai 200233, China
Tel:+86-21-64325985 Fax:+86-21-64696073 www.oakwell.com.sg
SPU
Operating and Maintenance Manual
Published by
Marioff Corporation Oy
2014 all rights reserved
Plaza Business Park Halo
yritie 24
01511 Vantaa
Finland
Tel. +358 (0)10 6880 000
Fax +358 (0)10 6880 010
http://www.marioff.com
In case of discrepancy between the original English document and the translated
document, the English text prevails.
All rights reserved. Marioff Corporation Oy reserves the right to change or modify the
information given in this document, including technical details, without notice.
Reproduction of any part of this document without the express written permission of
Marioff Corporation Oy is prohibited.
HI-FOG and Marioff are registered trademarks of Marioff Corporation Oy. Marioff is part
of UTC Building & Industrial Systems, a unit of United Technologies Corp. (NYSE:UTX),
which provides high technology products and services to the building and aerospace
industries worldwide. More information on Marioff group companies, agents/distributors
and references can be found at www.marioff.com.
CAUTION
HI-FOG systems comprise mechanical components that employ high pressure for water
pressurization. HI-FOG system installation embraces high-pressure testing of discharge
tubing. Care must be taken to ensure that all relevant safety procedures are followed
during installation to the satisfaction of the authority having jurisdiction and that only
competent personnel, appropriately trained and certified, are permitted to install, test,
commission and service the system. Marioff group companies and their respective
affiliates, officers, employees and representatives shall have no liability whatsoever for the
compliance by third parties to the present manual or to any applicable safety procedures.
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Table of Contents
Table of Contents
1. Introduction .................................................................................7
1.1 More information...............................................................7
2. Warnings and cautions ..............................................................8
3. General SPU description............................................................10
3.1 Unit description .................................................................10
3.1.1 Main parts ......................................................................10
3.1.2 Starter cabinet ...............................................................13
3.2 Operating description........................................................14
4. Operating instructions ...............................................................15
4.1 System in stand-by mode .................................................15
4.2 Start ..................................................................................15
4.2.1 Automatic start...............................................................15
4.2.2 Manual start - remote.....................................................15
4.2.3 Manual start - local ........................................................15
4.3 Pump unit in operation......................................................16
4.4 System stop and reset ......................................................16
4.5 Clearing up after system operation...................................17
5. Maintenance ................................................................................18
5.1 Inspection and maintenance frequencies .........................18
5.2 Inspection and maintenance procedures..........................19
5.2.1 Check all valve positions ...............................................19
5.2.2 Check the stand-by pressure and pump........................19
5.2.3 Check electric supply, test lamps ..................................19
5.2.4 Visually inspect the pump unit and its fittings ................19
5.2.5 Check oil level of the pumps..........................................20
5.2.6 Check drive chains and flexible coupling .......................20
5.2.7 Check air pressure regulator and empty water lock ......21
5.2.8 Check water filter and separator....................................22
5.2.9 Test run the unit.............................................................24
5.2.10 Check pump unit batteries and charger.......................24
5.2.11 Check the setting values of pressure and flow
switches and transducers .......................................................25
5.2.12 Test the unit in accordance with service instructions...25
5.2.13 Check breather cap filter..............................................25
5.2.14 Replace suction hoses (BSPU) ...................................25
5.2.15 Change pump oil (every 2 years or 200 hours) ...........25
6. Troubleshooting..........................................................................27
6.1 General faults ...................................................................27
6.1.1 Unit will not start ............................................................27
6.1.2 Unit will not stop.............................................................27
6.1.3 Unit starts unintentionally...............................................27
6.1.4 Water accumulators released unintentionally (if fitted) ..28
6.1.5 Stabilisation phase not completed .................................28
6.1.6 Stand-by pump striking frequently .................................28
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1. Introduction
This manual describes how to operate and maintain the HI-FOG Sprinkler Pump Unit
(SPU). This manual describes the SPU at a general level and the illustrations in this
manual may not reflect exactly the SPU model or version supplied.
The diagrams and parts lists supplied with each unit are specific for the supplied unit.
Any changes made to the supplied and installed system or its equipment are allowed only
with the written consent from Marioff Corporation.
Third-party documents
High pressure plunger pump operating instructions
Stand-by pump operating and maintenance instructions
Fire detection system operating instructions
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Warnings
The HI-FOG SPU produces high-pressure water when operating. To avoid injury to
personnel and/or damage to equipment always follow the safety procedures described in
this manual and required by local and/or national authorities.
Only qualified personnel are permitted to perform electrical work on the SPU. Check local
safety regulations.
Electrical cabinets may have several power supplies and voltages. Before starting
electrical work, isolate each power supply.
Cautions
Water used with the HI-FOG system must be the equivalent of a potable supply. In all
cases the input water must be fed through a < 100 m filter and the chloride concentration
MUST not exceed 50 ppm (= 50 mg/l). Under no circumstances add suppression additives
to the stored water supply.
Only appropriately trained personnel are permitted to work on, test and service the SPU,
the sprinkler system and its associated equipment. When in doubt, contact Marioff
representative.
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Check, test and service the SPU in accordance with the instructions in this manual.
NOTICE! Failure to check, test and service the SPU in accordance with the
instructions given in this manual can jeopardize the reliable operation of the
system.
Only use spare parts that are manufactured, supplied, or recommended by Marioff.
If the SPU is switched off for any reason, take adequate fire precautions, according to your
safety procedures, to cover the period that the SPU is out of operation.
NOTICE! If the system includes a water cylinder accumulator, it will be released if
the SPU main switch is turned off, when the system is activated. Before carrying
out any service, testing or maintenance work, remove the plug from the
accumulator release valve to avoid unintentional release. Remember to replace the
plug.
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Refer to the figure below for SPU main parts (SPU 05+1 used as an example).
Starter cabinet
Air inlet
Break-water tank
Gearbox
Stand-by pump
Test valve
Overflow outlet
Safety valve
Pump
Electric motor
Mounting frame
Breather cap
High pressure water
outlet
Water inlet
Water filter
Redundancy water
feed inlet (optional)
Separator (optional)
Separator drain
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Starter cabinet
Air inlet
Break-water tank
Gearbox
Stand-by pump
Test valve
Overflow outlet
Safety valve
Pump
Electric motor
Mounting frame
Breather cap
High pressure water
outlet
Water inlet
Water filter
Redundancy water
feed inlet (optional)
Separator (optional)
Separator drain
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NOTICE! The starter cabinet layout is only an example and the cabinet
configuration varies depending on the pump unit size and project. See project
documentation for details of the installed system and refer to labels on lamps/
switches.
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4. Operating instructions
4.1 System in stand-by mode
In normal use the system must be in the stand-by mode. The system is in the stand-by
mode when:
the SPU is connected to the electric supply and the main power switch is on
working air is supplied to the stand-by pump and the pump is operational
the system pressure is within the set limits
the control system is operational
the piping is sound and tight (see Marioff Installation manuals P32010 and
DOC0004462)
4.2 Start
4.2.1 Automatic start
The SPU will automatically start to operate if it detects a water flow and/or if the water
pressure drops below a preset value (typically 17 bar) for more than preset time (typically
10 - 20 seconds) (depending on the system size).
The redundant motor, if supplied, will automatically start if one of the motors does not
start or stops operating.
To stop the unit press and hold the Reset button for one (1) second. Make sure that there is
no fire before you stop the unit. If there is still flow in the system after the reset period the
unit will restart (see chapter 4.4). Isolate the sections where there is flow.
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NOTICE! Starting the pump with the pump activation switches will override all other
protection. Before carrying out a local manual start, check that no fault alarms are
on.
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The stabilisation valve will close when the pressure in the system drops to a preset value
(typically 22 bar). After that, the stand-by pump in the pump unit automatically increases
the pressure in the system to the stand-by pressure (typically 25 bar). Restart is prevented
during the stabilisation period. When the reset phase is completed the pump unit
automatically switches to the stand-by mode.
You can also stop the water discharge from the SPU by closing the ball valve located on
the unit, but this is only recommended in the case of unintentional release. This action
will not stop the motors.
Standard vessel systems will not reset properly unless the system pressure has reached
130 bar. The pump unit must be run until the pressure has risen above this point before
resetting the system by pressing the Reset button for one second.
Step 1. Empty the break water tank of redundancy water via the drain valve.
Step 2. Manually run the pump for a period long enough to remove all the
redundancy water from the pump unit, the break water tank and/or
the system piping.
Step 3. Change the water filter cartridge.
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5. Maintenance
5.1 Inspection and maintenance frequencies
This chapter describes the minimum requirements for maintenance routines of the SPU.
Always check the project-specific documentation for SPU and system level maintenance
routines and their frequencies.
In addition to the information in the table below, note the following:
Other maintenance frequencies may be specified in local laws and regulations or in
customer-specific system specifications.
Refer to the third-party manufacturers instructions (as delivered with the system) for
more information.
Chapter
Action
Weekly
Monthly
Annually
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
5.2.6
5.2.7
5.2.8
5.2.9
5.2.10
5.2.11
5.2.12
5.2.13
5.2.14
5.2.15
Every 5
years
x
x
*other frequencies may be specified in local laws and regulations or in the system-specific
instructions
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Open valves
outlet valve to the sprinkler system
fresh water supply valve
air inlet to the stand-by pump
Closed valves
test valve
sea-water / redundancy water valve
drain valve
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Check that all fittings are tight. Report all abnormal wear and tear, damage, etc.
The oil color should be clear golden brown. If the oil is dirty, cloudy or grey when the unit
is in the stand-by mode, change the oil.
NOTICE! The oil appears cloudy when the unit is in the operation mode.
See the manufacturers pump operating instructions. See also examples of recommended
pump oil types in chapter Change pump oil (every 2 years or 200 hours) on page 25.
NOTICE! Switch the unit off before checking the drive chains and coupling. Turn
the main switch off and secure it before removing the cover.
The drive chains are self-lubricated, which means that they do not need to be greased. To
indicate this, there is a notification sticker attached to the gearbox with the following text:
Notice! Do not use grease. This roller chain is self-lubricated.
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However, if the drive chains are not maintenance-free (in older pump units) and there is
no notification sticker, the drive chains must be well greased. If the chain is dry or rusty,
grease the chain using Shell Gadus S3 Wirerope T or an equivalent molybdenum-graphite
based grease with heat resistance up to +200C and good adhesion capability.
Check also the condition of the flexible couplings. A slight amount of wear is normal - if
any signs of excessive wearing are shown, change the coupling.
The chain and coupling can be changed by removing the pump module (make sure that
the pump unit is off before starting this job). Four items of Marioff tool M12080 are
needed. See Technical data sheet TE1002 Standard HI-FOG SPU Gearbox chain and
coupling change.
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Step 2. Make sure that the unit starts to supply water at full working pressure
after a short delay.
Step 3. Make sure that all motors and pumps are running (except the
redundancy module, if supplied).
Step 4. If the redundancy module is supplied, test it by opening the control
fuse (F x.1) of one of the running motors.
Step 5. Reset the unit after testing by pressing the Reset button (close test
valve and open outlet valve if opened/closed).
Step 6. Check that the pressure in the system returns to the 25 bar stand-by
pressure after a few minutes.
Step 7. Check that the whole system is reset and operational.
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5.2.11 Check the setting values of pressure and flow switches and
transducers
Check the settings of pressure switches, transducers and flow switch. If the switching
points have changed regarding the set point, adjust the point to original.
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Sight glass
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6. Troubleshooting
This chapter lists the possible fault situations and their remedies. If the problem you are
facing is not listed here, contact Marioff immediately.
When contacting Marioff in troubleshooting situations, have the following information
available:
the project number of the installed system
the serial number of the pump unit
detailed description of the fault situation (what was done before the fault situation
occured and what happened during the fault situation)
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Solution: Adjust or replace pressure switch (must be correctly adjusted, contact Marioff).
Possible reason: Flow switch is faulty or incorrectly adjusted.
Solution: Adjust or replace flow switch (must be correctly adjusted, contact Marioff).
Possible reason: Small leakage in the system.
Solution: Ensure system is tight.
Possible reason: False start signal.
Solution: Check system wiring and signals.
Possible reason: System pressure drops due to system leakage or stand-by pump
problem.
Solution: Ensure system is tight. Check air supply to stand-by pump. Check stand-by
pump (refer to manufacturers instructions) and replace if faulty.
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6.2 Alarms
This chapter lists the SPU system alarms.
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Type Code
Stock Code
Pump (SPU)
NP25/41-140 right
E02052
Pump (SPU)
NP25/41-140 left
E02050
Pump (SPU)
NP25/50-140 right
E02056
Pump (SPU)
NP25/50-140 left
E02055
Pump (BSPU)
NP25/60-140 right
M-0005964
Pump (BSPU)
NP25/60-140 left
M-0005963
Pump (BSPU)
NP25/70-140 left
M-0005961
Pump (BSPU)
NP25/70-140 right
M-0005962
Manuf.ref. 14.0884
G40130.1
Manuf.ref. 14.0397
G40135
Manuf.ref. 14.0655
V-0006475
Manuf.ref. 14.0654
V-0006474
Pump oil
EP SAE80W-90
L53005
Unloader
UL262/2
D51023
Manuf.ref. 14.0554
G40011
Hose assembly
28L90-R-28LA-270AY
A-0006099
Electric motor
See nameplate
E04097.1
42/64 SH green
E04019
M12080
M23064.A
M23065.A
Float switch
A01090 Besta
M22125.1
100 m
BFP7G10W1.0
E05085
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E05086
SID10ADBFPKG/
US-100-I PF
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M21012.1
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E40040
G40090
G40095
FRC-1/4
E41015
SVM 12-ANN-S12/12-10-0
D01535
V11070.A
V10101.A
D-0005755
*Drive chain spare part sets include clutch flex element, clutch, roller chain, sprocket
wheel and other needed parts.
**You need 4 pieces of pump support sleeves to pull the pump out when replacing the
drive chain. Pump support sleeves are not included in drive chain spare part sets V31161
and V31181.
***See Marioff Spare part and maintenance drawing DMOVSE000862.
****See Marioff Technical data sheet K0008018.
*****Electrical components may vary considerably depending on the project. See projectspecific part list for electric spare parts.
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Head Office
Marioff Corporation Oy
Plaza Business Park Halo
yritie 24, P.O. Box 1002
Information on Marioff group companies, agents/distributors and references can be found at www.marioff.com.
01511 Vantaa
Marioff Corporation Oy reserves the right to change or modify the information given in this document, including
Finland
technical details, without notice. HI-FOG and Marioff are registered trademarks of Marioff Corporation Oy. Marioff is
part of UTC Building & Industrial Systems, a unit of United Technologies Corp. (NYSE:UTX).
All rights reserved. Reproduction of any part of this document without the express written permission of Marioff
Corporation Oy is prohibited.