Grundfos AEF Installation And Operating Instructions Manual

Brand: Grundfos

Model: AEF

Type: Installation And Operating Instructions Manual

Fire AEF - electric and diesel driven

Installation and operating instructions

GRUNDFOS INSTRUCTIONS

English (GB)

English (GB) Installation and operating instructions

Original installation and operating instructions.

CONTENTS

Page

1. Symbols used in this document

1.1 Warning description

Safety instructions placed directly on the fire pump set:

1. Symbols used in this document

1.1 Warning description

2. Applications

3. Delivery, transport, storage

3.1 Delivery

3.2 Transport

3.3 Storage

4. Product description

4.1 Fire pump set

4.2 Pump

4.3 Motor

4.4 Controller

4.5 Nameplate

5. Operating conditions

5.1 Minimum inlet pressure

5.2 Maximum inlet pressure

5.3 Minimum flow rate

5.4 Pumped liquids

5.5 Water temperature

5.6 Pump temperature

5.7 Pump speed

5.8 Maximum operating pressure

5.9 Ambient temperature

5.10 Relative air humidity

5.11 Effect of ambient temperature and altitude on electric

motor output

5.12 Effect of ambient temperature and altitude on diesel

engine output

6. Installation

6.1 Installation site

6.2 Foundation

6.3 Levelling

6.4 Pipework

6.5 Alignment

6.6 Air supply

6.7 Exhaust system

6.8 Separate control cabinet

7. Electrical connection

7.1 Checking the direction of rotation on electric units

8. Maintenance

8.1 Maintenance intervals

9. Service, spare parts and accessories

10. Warranty

11. Further documentation

12. Disposal

Warning

Prior to installation, read these installation and

operating instructions. Installation and operation

must comply with local regulations and accepted

codes of good practice.

Warning

If these safety instructions are not observed,

it may result in personal injury.

Caution

If these safety instructions are not observed,

it may result in malfunction or damage to the

equipment.

Note

Notes or instructions that make the job easier

and ensure safe operation.

Warning

Hazardous voltages are present in

this enclosure. Improper use or failure

to take precautions can cause serious

injury, electric shock and (or) damage

to the equipment.

Disconnect all supply sources

(including any foreign circuits) before

working on controller, motor or pump.

Only qualified staff must work on or

around this equipment.

Warning

The mains terminals are still live when

the main switch is in position "OFF".

Warning

Phase-sensitive equipment.

Connect in ABC order.

Warning

The enclosure class and withstand

rating are applicable only if all door

locks are in closed position.

The ambient temperature must be 5 to

50 °C.

Warning

If an overload or a fault current

interruption occurs, check the circuits

to determine the cause of the

interruption. If a fault condition exists,

examine the current-carrying

components and replace them if

damaged. Replace the integrated

current sensors to reduce the risk of

fire or electric shock.

To maintain overcurrent, short-circuit

and earth-fault protection and to

reduce the risk of fire or electric

shock, follow the manufacturer's

instructions for selection of overload

and short-circuit protection.

Lifting points for the entire fire pump

set.

Hazadous voltages are present

inside this enclosure. Serious

injury, electrocution and/or

equipment damage will result of

improper application or if

precaution is not used.

Disconnect all supply sources

(including any foreign circuits)

before working om controller,

motor(s) or pump(s).

Only qualified personnel should

work on or around this

equipment.

LINE TERMINALS ALIVE

WHEN MAIN SWITCH

IS IN “OFF” POSITION

DANGER

PHASE SENSITIVE EQUIPMENT

CONNECT IN ABC ORDER

WARNING

ENCLOSURE AND WITH STAND RATING

APPLICABLE ONLY IF ALL DOORLOCKS

ARE IN A CLOSED POSITION.

CONTROLLER MUST BE INSTALLED IN

AN ENVIROMENT WHERE AMBIENT

TEMPERAURE IS BETWEEN 41°F(5° V)

AND 122°F (50°C)

WARNING

IF AN OVERLOAD OR A FAULT CURRENT

INTERRUPTION OCCURS, CIRCUITS MUST BE

CHECKED TO DETERMINE THE CAUSE OF THE

INTERRUPTION. IF A FAULT CONDITION EXISTS,

THE CURREN-CARRYING COMPONENTS

SHOULD BE EXAMINED AND REPLACED IF

DAMAGED, AND THE INTEFRAL CURRENT

SENSORS MUST BE REPLACED TO REDUCE

THE RISK OF FIRE OR ELECTRICAL SHOCK.

TO MAINTAIN OVERCURRENT, SHORT-CIRCUIT,

AND GROUND-FAULT PROTECTION, THE

MANUFACTURER’S INSTRUCTIONS FOR THE

SELECTION OF OVERLOAD AND SHORT-

CIRCUIT PROTECTION MUST BE FOLLOWED TO

REDUCE THE RISK OF FIRE OR

ELECTRIC SHOCK.

CB FXD63A250 / CFD63A250

SPECIFICALLY SET FOR THIS INSTALLATION

L=1100

5=1900

2=1300

6=2100

3=1500

7=2300

4=1700

h=2500

English (GB)

2. Applications

The Peerless Fire AEF pump sets are designed for fire systems

for supplying water to hose reels, fire hydrants and sprinkler

systems.

The Peerless Fire AEF pump sets with electric motor or diesel

engine must not be used for ordinary pumping of liquids or

common pressure boosting in daily work. The pump sets must

only be used for firefighting.

The pump controller must not be used as a junction box for

supplying other equipment.

3. Delivery, transport, storage

3.1 Delivery

The fire pump set is delivered from factory in an open wooden

box or wooden and cardboard box which is specifically designed

for transport by fork-lift truck or similar device.

3.2 Transport

For lifting the entire fire pump set, use the lifting holes of the base

frame. When lifting, the lifting point must always be above the

centre of gravity of the fire pump set. See fig. 1.

Fig. 1 Correct lifting of fire pump set

3.3 Storage

To prevent water, dust, etc. from entering the pump, all openings

must be covered until all pipes are connected. Apply a suitable

antirust agent on all machined, non-coated surfaces.

The antirust agent must meet these requirements:

• It must not attack rubber parts.

• It must be easy to remove.

• It must be applied according to the instructions of the

manufacturer.

Protect the pump against corrosion and damage if the pump is to

be stored for more than six months before startup:

1. Remove the stuffing box packing.

2. Spray the interior part of the pump housing and the stuffing

box with a water-soluble type of antirust agent.

3. If the pump has not been connected to the pipework, cover

the pump suction and discharge flanges with full natural

rubber gasket material, and blank off these openings with

metal blanking flanges. Use at least four bolts for fastening.

4. Cover the opening of the stuffing box with a non-hygroscopic

tape. The stuffing box gland may be left on the pump shaft,

but must be wired or otherwise securely fastened in position.

5. Coat all exposed painted surfaces with an antirust agent that

can be readily removed with a petroleum distillate product.

6. Make sure that all exposed painted surfaces are dry, clean

and free of grease and other contaminants.

7. Cover the pump with a weather-resistant cover of waterproof

paper or plastic material to protect it against dirt and dust.

8. Inspect the pump at regular intervals during storage.

9. Rotate the shaft by hand every four to six weeks to prevent

pitting of the bearings.

3.3.1 Engine

Engines may be stored for up to 12 months in a dry room after

delivery. We recommend that you protect the engine with an air-

permeable cover. At least once a month, check the engine for

accumulation of dirt or water. Remove any dirt or water

immediately.

If the engine is stored for more than 12 months or stopped for

more than six months, protect it against corrosion and damage:

1. Drain the engine of oil, and replace the oil filter.

2. Fill the engine housing with appropriate oil.

3. Replace the fuel filter.

4. Separate the engine from the pump by removing the coupling.

5. Turn on the engine. Let it run for one or two minutes.

6. Drain oil and cooling liquid.

7. Drain fuel. Loosen the drain screw in the tank bottom and

collect the diesel fuel in a suitable container. After draining,

tighten the drain screw in the tank bottom.

Repeat these steps every six months.

You find more information about point 1-4 and 6 in the service

instructions.

Warning

Only use the fire pump set for the applications

mentioned. Any other use is considered improper

use. Peerless cannot be held responsible for

damage caused by improper use. The liability

rests solely with the operator.

Note

Check the fire pump set carefully on delivery

against the papers and inspect for damage

incurred during transport. Immediately notify the

carrier of any damage or shortage found.

Transport and store it correctly before

installation.

Warning

Only qualified staff must lift the fire pump set.

When lifting the entire fire pump set, never use

the lifting eyes of the individual components.

Use only suitable lifting equipment in proper

condition.

During transport of the fire pump set, the cabinet

door must be closed and locked.

Do not stand or place hands under a component

in such a way that the component would fall on

the hands if dropped.

TM06 0715 0814

Caution

Put a warning label on the engine:

Engine without oil. Do not start the engine.

English (GB)

4. Product description

4.1 Fire pump set

The fire pump set consists of a pump, an electric motor or diesel

engine and a controller. Pump and motor are connected via a

flexible coupling or drive shaft. All components are adapted to

each other and mounted on a common base frame ready for

installation. The base frame is made of steel channel or bent

steel. The controller can also placed separately. The fire pump

set comes ready for operation.

As an example, the most important components of the fire pump

set are shown in fig. 2. It shows an AEF fire pump set with a

Peerless horizontal split-case-pump and an electric motor.

Pump and motor are connected by a flexible coupling.

The controller is installed separately.

Fig. 2 Example of fire pump set

4.2 Pump

The fire pump set comes with a Peerless AEF horizontal split-

case-pump. The pump is FM-approved and UL-listed.

The impeller diameter of both pumps can be reduced to

customise the pump performance to a certain duty point.

The actual impeller diameter may therefore deviate from the

standard diameters stated in catalogues, data sheets etc.

The actual impeller diameter is stated on the pump nameplate.

4.2.1 Split-case-pump

The Peerless AEF horizontal split-case-pump is a non-self-

priming, single-stage pump. It has in-line axial suction and

discharge ports with ANSI flanges. An adapter flange from ANSI

to DIN is available and must be ordered separately. The pumps

are equipped with a stuffing box, and with an automatic air

release valve making venting unnecessary.

4.3 Motor

4.3.1 General description for electric motor

Electric driven fire pump sets are driven by a 2- or 4-pole motor,

typically NEMA design B motors in accordance with UL 1004-s.

The motors are insulation class F and the terminal boxes are

either ODP or TEFC. A service factor of 1.15 is also typically

furnished.

4.3.2 General description for diesel engine

The pump is driven by a stationary 4-stroke diesel engine. It has

been especially adapted to meet the requirements of fire pumps.

The diesel engine is FM-approved and UL-listed.

The rated engine power is adapted to the power requirement of

the pump. The adaptation takes place via the engine speed,

which may therefore not be changed. Depending on power

output, the engines have a turbocharger and, if necessary, also a

charge air cooler.

The engine is typically cooled via a heat exchanger. Water is

supplied from the discharge port of the pump. Before water runs

into the heat exchanger, it flows through a cooling circuit.

See fig. 3. The discharge from the heat exchanger is led via an

open outlet or a visible waste cone back to the suction reservoir.

Fig. 3 Cooling circuit

If the cooling circuit is faulty, and the temperature of the cooling

liquid becomes too high, open isolating valves (pos. C and D) and

close isolating valves (pos. A and B).

4.3.3 Control panel of the engine

The engine is equipped with its own control panel. You can

operate the fire pump set via the controller or via the control panel

of the engine. Normally, operation takes place via the controller.

If the controller fails, only use the control panel of the engine.

Additionally, the control panel of the engine indicates the main

parameters of the engine, such as engine speed, voltage of

battery 1 and 2, oil pressure and temperature of cooling liquid.

The design of the control panel is shown in fig. 4 for JU and JW

engines, and in fig. 5 for three engines. An explanation of the

operating elements and the indicators is given in the table below

fig. 4 and 5. For more information, see the installation and

operating instructions of the engine.

TM06 2243 3814

Pos. Component

1 Base frame

2 Controller

3Pump

4 Automatic air release valve

5 Motor

6 Coupling with coupling guard

Caution

The injection pump has been set from factory,

and the setting must not be changed.

TM04 5066 2609

English (GB)

Fig. 4 Control panel of JU and JW diesel engine

TM06 1271 2014

I1 251

I243376

I4 I5

Pos. Operating element Description

Instructions for

emergency operation

Instructions as how to start

the engine via the control

panel.

2 Selector switch

For selection of automatic or

manual operation.

Manual start switches,

battery 1 or 2

For manual start of engine

with battery 1 or 2.

4 Overspeed reset

If the engine has been

stopped due to an overspeed

condition, reset the overspeed

alarm with this switch when

the problem has remedied.

5 Warning light

Indicates that the selector

switch is not set to

"AUTOMATIC OR MANUAL

STOP".

Overspeed shut down

warning light

Indicates that the engine is

shutdown due to overspeed.

7 Overspeed verification

For testing if the overspeed

function works and the engine

stops in case of overspeed.

The overspeed signal is

generated at 67 % of the rated

speed. Reset overspeed

alarms with the

"OVERSPEED RESET"

switch (pos. 4).

Pos. Indicator Description

Tachometer and

operating hour counter

Shows engine speed and the

number of operating hours

I2 Oil pressure

Shows the oil pressure of the

engine.

I3 Voltmeter, battery 1

Shows the voltage supplied by

battery 1.

I4 Voltmeter, battery 2

Shows the voltage supplied by

battery 2.

I5 Temperature indicator

Shows the temperature of the

cooling liquid.

English (GB)

Fig. 5 Control panel of JX diesel engine

* Electronic control module

TM04 5115 2609

10 11 12

Pos. Operating element Description

1 Engine gauge display

Shows relevant engine

parameters and alarm

messages.

2 Voltmeter, battery 1 or 2

Shows the voltage supplied by

battery 1 or 2.

3 Operating hour counter

Shows the number of

operating hours.

Battery selector switch,

voltmeter

For selection of battery

voltage to be indicated by the

voltmeter.

5 Selector switch

For selection of automatic or

manual operation.

6 ECM selector switch*

Default position is "PRIMARY

ECM". Only in case of a

failure of the primary ECM,

causing the engine to stop or

not to start, manually switch to

"ALTERNATE ECM."

Warning light, manual

operation

Indicates that the selector

switch is not set to automatic

operation.

Warning light, alternate

ECM*

Indicates that the ECM

selector switch is set to

"ALTERNATE ECM".

9 Manual stop switch For manual stop of engine.

Manual crank switch,

battery 1

For manual start of engine

with battery 1.

Manual crank switch,

battery 2

For manual start of engine

with battery 2.

12 Overspeed reset

If the engine has been

stopped due to an overspeed

condition, reset the overspeed

alarm with this switch when

the problem has remedied.

English (GB)

The control panel of the JX6 diesel engine is equipped with an

engine gauge display. See fig. 6.

Fig. 6 Diagnostic gauge of JX6 control panel

During normal operation of the diesel engine, the display will

show the engine speed, temperature of cooling liquid, oil

pressure and voltage of battery 1 or 2 selected with the battery

selector switch. See fig. 6.

Fig. 7 Example of indications during normal operation, JX6

If an alarm occurs, the alarm message will be shown instead of

the engine parameters.

Fig. 8 Example of alarm message, JX6

SPN (Suspect Parameter Number) and FMI (Failure Mode

Identifier) codes will be shown along with a description of the

problem and the corrective action needed. If the word "NEXT"

appears above the arrow buttons, you can view further codes by

scrolling with the arrow buttons. See fig. 6, pos. C. Press the

enter button to return to the parameter screen. See fig. 6, pos. D.

You find an overview of possible alarm messages in the service

instructions together with SPN and FMI codes.

4.4 Controller

4.4.1 General description

The fire pump set is operated via a controller especially sized for

electric motors driving fire pumps. The controller starts the pump

automatically and monitors the motor. It is FM-approved.

As soon as the sprinklers are activated due to an alarm and water

is consumed, the pressure in the discharge pipe will be reduced.

If the pressure falls below the cut-in pressure set on the control

panel, the pump will start automatically.

For test run and setup, manual operation is possible.

The individual controller models differ mainly by starting method

and power range.

Starting method direct on line

This model is used where the electricity works or the capacity of

the power source permits direct-on-line starting.

Full voltage is applied to the motor as soon as the controller

receives a start command.

Starting method star/delta open transitionWhen the controller

receives a start command, the motor is connected in star. After a

time delay, it changes over to delta connection with full voltage to

the motor windings. This controller is of the open transition type.

The motor is disconnected from the mains during the transition

from start (star) to run (delta) mode.

4.4.2 Controller design

The controller is placed in a control cabinet mounted on the base

frame (compact unit) or delivered separately for wall- or floor-

mounting (flex unit). The controller is operated by means of the

control panel in the cabinet door. The control cabinet supplies the

motor with the electricity required for starting and operating the

motor.

TM04 5116 2609

Pos. Designation Description

A Display

Shows the four most important

engine parameters:

• engine speed

• temperature of cooling liquid (°F)

• oil pressure (psi)

• battery voltage (1 or 2).

If an alarm occurs, the alarm

message will be shown instead of

the engine parameters.

B Menu button Opens the main menu.

C Arrow buttons Scrolls through the menus.

D Enter button

Opens selected submenus.

Activates settings and functions.

Indicator light

Engine stopped

(red)

Lights up if a fault occurred that will

stop the diesel engine, such as

overspeed.

Indicator light

Warning (amber)

Lights up if a warning condition

occurs.

TM04 5117 2609

TM04 5118 2609

Note

You cannot make settings in the diagnostic

gauge. Do not use the main menu button.

See fig. 6, pos. B.

English (GB)

4.5 Nameplate

All important data of the fire pump set are stated on the pump

nameplate. See fig. 9.

Nameplate for AEF pump

Fig. 9 Example of nameplate for AEF pump

5. Operating conditions

5.1 Minimum inlet pressure

At any time, there must be a positive inlet pressure.

We recommend a minimum inlet pressure of 5 psi.

5.2 Maximum inlet pressure

The sum of actual inlet pressure plus pump pressure against a

closed valve must always be lower than the maximum

permissible operating pressure. See section 5.8 Maximum

operating pressure. The maximum inlet pressure is a function of

the closed-valve pressure and the maximum pump pressure. It is

stated on the nameplate.

5.3 Minimum flow rate

Only brief periods of operation during start and stop are

permissible with a closed discharge valve. Prolonged operation at

less than 15 to 20 % of the pump's rated capacity will cause

heating of the pumped liquid, impeller erosion, short life of

bearings and packing due to stress or vibration. This may cause

shaft damage and wear on stationary parts on some pumps.

Therefore, we recommend that you install a bypass pipe to

ensure a minimum flow rate of at least 10 % at maximum

efficiency. The minimum flow rate helps to dissipate any

excessive heat and thus protect the pump against overheating.

5.4 Pumped liquids

The pumps are suitable for clean and non-aggressive water, not

containing solid particles or fibres.

5.5 Water temperature

Maximum permissible water temperature is 40 °C.

5.6 Pump temperature

The pumps can handle temperatures from 0 to 120 °C.

5.7 Pump speed

The maximum pump speed is stated on the test report and shown

on the nameplate for the fire pump set.

TM06 2123 3814

Pos. Description

1 Pump type

2 Approvals

3 Type designation

4 Number of stages

5 Actual impeller diameter

6 Serial number

7 Rated flow rate

8 Rated head

9 Rated speed

10 Head at 150 % flow rate

11 Maximum head

12 Maximum power

13 Maximum suction lift

14 Manufacturer

48561

11 14 12

PEERLESS PUMP COMPANY

Indianapolis, IN

Warning

Do not operate the pump at any pressure, flow

rate or liquid temperature other than those for

which the pump was originally purchased. Do not

pump any other liquid than the one for which the

pump was originally purchased without the

consent of Peerless or its authorised

representatives. Disregard of this warning can

result in pump failure and serious personal injury

or death.

Caution

Inadequate inlet pressure will result in cavitation

damage to the impeller and casing.

Caution

Generally, the pump is not allowed to run against

a closed valve, as this may cause an increase in

temperature or formation of steam in the pump.

This may cause damage to the pump.

Caution

Operation of the pump with flow only through the

bypass is not allowed.

English (GB)

5.8 Maximum operating pressure

The maximum operating pressure is stated on the pump

nameplate.

5.9 Ambient temperature

5.9.1 Electric motor

Minimum ambient temperature: 4 °C.

Maximum ambient temperature: 40 °C (50 °C optional).

5.9.2 Diesel engine

Minimum ambient temperature: 4 °C if the engine includes

preheating.

Maximum ambient temperature: The maximum permissible

ambient temperature at the air filter inlet is 49 °C according to

NFPA 20.

5.10 Relative air humidity

The relative air humidity must not be too high, to prevent

condensation of moisture in the air, as this can lead to damage of

the controller or the motor. If humidity is a problem, install a

space heater with a humidistat.

5.11 Effect of ambient temperature and altitude on

electric motor output

If the ambient temperature exceeds 40 °C (fig. 10), or the motor is

installed more than 1000 metres above sea level, the motor must

not be fully loaded due to the low density and consequently low

cooling effect of the air. In these cases, it may be necessary to

use a motor with a higher output.

Fig. 10 Relation between motor output, altitude and ambient

temperature

5.12 Effect of ambient temperature and altitude on

diesel engine output

If the ambient temperature exceeds 25 °C (fig. 11), or if the

engine is installed more than 90 metres above sea level (fig. 12),

the engine must not be fully loaded due to the low density and

consequently low cooling effect of the air. In these cases, it may

be necessary to use a larger engine.

Fig. 11 Relation between engine output and ambient

temperature

Fig. 12 Relation between engine output and altitude

TM00 2189 4198

20 25 30 35 40 45 50 55 60 65 70 75 80

100

[%]

t [°C]

1000 2250 3500 m

TM03 4718 2606TM03 4717 2606

20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95

100

[%]

80 100 120 140 160 180 T [°F]

T [°C]

0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000

[m]

100

[%]

0 2000 4000 6000 8000 10000 12000 14000

[ft]

English (GB)

6. Installation

6.1 Installation site

Place the fire pump set in a clean, dry, frost-free and well-

ventilated location. Make sure that unauthorised persons do not

have access to the location.

Allow sufficient clearance around the pump set to enable

inspection, repair and assembly work.

6.2 Foundation

We recommend that you install the fire pump set on a concrete

foundation which is heavy enough to provide permanent and rigid

support for the entire fire pump set. The foundation must be

capable of absorbing any vibration, normal strain or shock. As a

rule of thumb, the weight of the concrete foundation must be

1.5 times the weight of the fire pump set. Ordinarily, the

proportions used are one part cement to three parts sand and

four parts medium aggregate.

The concrete foundation must have an absolutely level and even

surface. Provide the foundation with anchor bolts to fasten the fire

pump set.

Recommended length and width of the foundation. See fig. 13.

Note that the length and width of the foundation must be 200 mm

larger than the length and width of the base frame.

See dimension x.

You can calculate the minimum height of the foundation (h

) as

follows if the weight of the foundation is assumed to be 1.5 times

the wet weight of the pump set :

The density (δ) of the foundation is usually taken as 2200 kg/m

In installations where low-noise operation is particularly

important, we recommend a foundation with a weight of up to five

times that of the pump.

Fig. 13 Dimensions of foundation

Warning

The installation must be carried out in

accordance with the following instructions.

Non-compliance may result in functional faults

which will damage the pump components.

Caution

Ensure an adequate supply of air for cooling the

motor, diesel engine and control cabinet.

Warning

Make sure that the weight of the fire pump set

and foundation does not exceed the permissible

bearing load of the floor.

pump

× 1.5

× B

× δ

concrete

TM06 0717 0814

English (GB)

6.3 Levelling

Place the fire pump set on the foundation or an even floor and

anchor it with adequately sized anchor bolts. The entire base

frame must be supported uniformly. See figures 14 and 15.

If necessary, use shims for horizontal levelling of the base frame.

Fig. 14 Correct installation

Fig. 15 Incorrect installation

6.4 Pipework

Arrange the suction and discharge piping in the most simple and

direct layout. The pipes must be of an adequate size, taking also

the pump inlet pressure into consideration. The flow direction is

marked with arrows.

Install the pipes so that air locks are avoided, especially on the

suction side of the pump. See fig. 16.

Fig. 16 Correct and incorrect installation of suction pipe

Fit pipe hangers on the wall, ceiling or floor close to the pump on

the suction and the discharge side. See fig. 17.

The pipes must lie true against the pump flanges without being

stressed. Otherwise, the pump may be damaged.

Fig. 17 Fixing points of the pipes

You can install isolating valves on the suction and the discharge

side of the pump.

Warning

Only qualified staff must lift fire pump set.

When lifting the entire fire pump set, never use

the lifting eyes of the individual components.

Use only suitable lifting equipment in proper

condition.

During transport of the fire pump set, the cabinet

door must be closed and locked.

TM06 0718 0814TM06 0719 0814

Warning

Do not put fingers, hands, arms, etc. into the

suction or discharge openings or into any other

opening, such as that of the air relief valve.

Do not touch the rotating impeller, as this can

cause severe injury.

Do not remove protective covers or packaging

until installation.

Caution

The pipework must not stress the pump housing

or transfer any forces to the pump housing.

Noncompliance may damage the pump.

TM04 5122 2609 TM06 0720 0814

English (GB)

6.5 Alignment

6.5.1 Aligning electric motor and pump

Pump and motor are connected by a standard flexible coupling.

If a fire pump set is pre-assembled from factory, the coupling has

been accurately aligned by means of shims inserted under the

pump and motor.

During transport and installation, the pump-motor alignment may

have been affected. Therefore, always check the pump-motor

alignment when you have installed the fire pump set.

The coupling used for connecting the pump and motor is shown in

fig. 18.

Fig. 18 Aligning motor and pump

You find the values for ∅ and s

in the following table. The value

for s1 is 0.1 mm.

6.5.2 Aligning diesel motor and pump

Pump and engine are connected by a drive shaft.

If a fire pump set is pre-assembled from factory, the coupling has

been accurately aligned by means of shims inserted under the

pump and engine.

During transport and installation, the pump-motor alignment may

have been affected. Therefore, always check the pump-motor

alignment when you have installed the fire pump set.

Follow the instructions below to align the diesel engine and the

pump:

1. Remove the coupling guard.

2. Check the drive shaft for proper parallel offset and angular

tolerance.

3. Fit the coupling guard.

4. Connect the battery cables.

At first, check if the bolts of the drive shaft are tightened with the

correct tightening torque. It may be necessary to use a special

torque tool if there is not enough space for a standard socket.

The following steps describe how to align the drive shaft between

the motor and the pump. We recommend that you use a small

pocket scale or ruler with millimetre markings to make all

measurements.

Warning

Before removing the coupling guard, make sure

that the fire pump set has been switched off and

cannot be accidentally switched on.

Caution

Alignment of motor and pump is important for a

long coupling life. This is particularly important

with increased motor speed. Follow the

installation instructions of the coupling

manufacturer.

TM03 2999 5005

Outside

diameter of

coupling,

∅ [mm]

Clearance, s

[mm]

Standard coupling Spacer coupling

Nominal Tolerance Nominal Tolerance

80 - - 4 0/-1

95 - - 4 0/-1

110 - - 4 0/-1

125 4 0/-1 4 0/-1

140 4 0/-1 4 0/-1

160 4 0/-1 4 0/-1

200 4 0/-1 4 0/-1

225 4 0/-1 4 0/-1

250 4 0/-1 4 0/-1

90°

Caution

Alignment of diesel engine and pump is

important for a long coupling life. This is

particularly important with increased engine

speed.

Warning

Before removing the coupling guard, disconnect

the battery cable.

English (GB)

Checking the horizontal parallel offset

A: To check the horizontal parallel offset, the driveshaft must be in

the proper orientation.

1. Rotate the shaft so that the reference "AB" on the flywheel

drive disc is in 12 o'clock position. See fig. 19.

2. Measure from the face of the flywheel drive disc to point E as

shown in fig. 19 (point E is to the furthermost point on the

drive shaft joined bore diameter). See the horizontal offset in

table below.

Checking the horizontal angular alignment

B: With the driveshaft in the same orientation as in step A, check

the horizontal angular alignment of the shaft.

1. Measure from the face of the pump shaft flange to point G as

shown in fig. 19 (point G is to the furthermost point on the

drive shaft joined bore diameter). This measurement must be

equal to the measurement at point E ± 0.5 mm.

Fig. 19 Horizontal alignment

Checking the vertical parallel offset

C: To check the vertical parallel offset, the driveshaft must be re-

orientated.

1. Rotate the shaft 90 ° so the reference "CD" on the flywheel

adapter disc is in 12 o'clock position. See fig. 20.

2. Measure from the face of the flywheel adapter disc to point H.

Point H is furthermost point on the drive shaft joined bore

diameter. See fig. 20. See the vertical offset in table below.

Checking the vertical angular alignment

D: With the driveshaft in the same orientation as in step C, check

the vertical angle alignment of the shaft.

1. Measure the face of the pump shaft flange to point J. Point J

is the same as point G, with the driveshaft rotated 90 °.

See fig. 20. This measurement must be equal to the

measurement at point H ± 1 mm.

Reinstall all guards and grease fittings before reconnecting the

battery cables.

Fig. 20 Vertical alignment

See also the installation and operating instructions for the drive

shaft.

TM06 1531 2614

Flanged

pump hub

Flywheel

adapter disc

TM06 1532 2614

English (GB)

Horizontal and vertical offset for drive shaft

Engine type Drive shaft type

SAE

flywheel

Flywheel

drive disc

Horizontal

offset

[mm]

Vertical

offset

[mm]

Bolt grade

Bolt

torque

[ft/lbs]

JU4H-UFAEA0

CDS10-SC (UL listed) 11.5 CF10 58 ± 1 60 ± 1

(hi-tensile)

JU4H-UF10

JU4H-UF12

JU4H-UF14

JU4H-UF20

JU4H-UF22

JU4H-UF24

JU4H-UFAB26

JU4R-UFAEA9

JU4R-UF09

JU4R-UF11

JU4R-UF13

JU4R-UF19

JU4R-UF21

JU4R-UF23

JU4H-UFAEE8

CDS20-SC (UL listed) 11.5 CF20 68 ± 1.5 70 ± 1

(hi-tensile)

JU4H-UFAEF2

JU4H-UF30

JU4H-UF32

JU4H-UF34

JU4H-UF40

JU4H-UF42

JU4H-UFH0

JU4H-UFH2

JU4H-UFH8

JU4H-UFADJ8

JU4H-UFADJ2

JU4R-UF40

JU4R-UFAEE7

JU4R-UFAEF1

JU6H-UF30

CDS20-S1 (UL listed) 11.5 CF20 68 ± 1.5 70.5 ± 1

(hi-tensile)

JU6H-UF32

JU6H-UF34

JU6H-UFD0

JU6H-UFD2

JU6R-UFAAD9

JU6R-UFAAD1

JU6R-UFAA29

JU6R-UFAA31

JU6R-UFAA33

English (GB)

JU4H-UF50

CDS30-S1 (UL listed) 11.5 CF30 84 ± 1 86.5 ± 1

(hi-tensile)

JU4H-UF52

JU4H-UF54

JU4H-UF58

JU4H-UFAD5G

JU4H-UFADJG

JU4H-UFADP0

JU4H-UFADR0

JU4H-UFADW8

JU4H-UFADY8

JU4R-UF49

JU4R-UF51

JU4R-UF53

JU6H-UF50

JU6H-UF52

JU6H-UF54

JU6H-UF58

JU6H-UF60

JU6H-UF62

JU6H-UF68

JU6H-UF84

JU6H-UFM0

JU6H-UFM2

JU6H-UFM8

JU6H-UFG8

JU6H-UFABL0

JU6H-UFABL2

JU6H-UFABL8

JU6H-UFAD58

JU6R-UFAAG7

JU6R-UFAAL7

JU6R-UFAAL9

JU6R-UFAAL1

JU6R-UFAAM7

JU6R-UFAAM9

JU6R-UFAAM1

JU6R-UFAA57

JU6R-UFAA49

JU6R-UFAA51

JU6R-UFAA53

JU6R-UFAA67

JU6R-UFAA59

JU6R-UFAA61

JU6R-UFAA83

JU6H-UFADM8

JU6H-UFADMG

JU6H-UFADNG

JU6H-UFAB76

JU6H-UFADK0

JU6H-UFADN0

JU6H-UFADQ0

JU6H-UFADR0

Engine type Drive shaft type

SAE

flywheel

Flywheel

drive disc

Horizontal

offset

[mm]

Vertical

offset

[mm]

Bolt grade

Bolt

torque

[ft/lbs]

English (GB)

JU4H-UFAD98

CDS50-SC*

Only at 1470

to 2100 rpm

(UL listed)

N/A

11.5

CF50 109 ± 2 112.5 ± 1

(hi-tensile)

JU6H-UFAAQ8

SC81A (not

UL listed)

JU6H-UFAAPG

JU6H-UFAARG

JU6H-UFADP8

JU6H-UFADP0

JU6H-UFAD88

JU6H-UFAD98

JU6H-UFADT0

JU6H-UFADR8

JU6H-UFADS8

JU6H-UFADS0

JU6H-UFAAS0

JU6H-UFADW8

JU6H-UFADX8

JU6H-UFADX9

JU6H-UFADX10

JU6H-UFADX11

JU6H-UFADX12

JW 6H-UFAD80

JW 6H-UFADD0

JW 6H-UFADF0

JW 6H-UFADJ0

JW 6H-UFAAM8

JW 6H-UFAD70

JW 6H-UFAA80

DP6H-UFAAX8

DP6H-UFAA50

DP6H-UFAA88

DP6HUFAA62

DP6H-UFAA70

DQ6H-UFAA48

DQ6H-UFAA40

DQ6H-UFAA50

DQ6H-UFAA60

DQ6H-UFAA88

DQ6H-UFAA98

Engine type Drive shaft type

SAE

flywheel

Flywheel

drive disc

Horizontal

offset

[mm]

Vertical

offset

[mm]

Bolt grade

Bolt

torque

[ft/lbs]

English (GB)

* CDS50-SC listed drive shafts at 2100 rpm only for JW6H-

UFAA80 and JW6H-UFAD80, 1760 rpm only for DP6H-

UFAA88 and at 1470 rpm only for DP6H-UFAA70. Any other

speed would require the non-listed drive shaft SC81A.

JX6H-UFADF0

N/A

SC2160A (not

UL listed)

11.5

180-10

123.5 ± 1.5 126.5 ± 1

(hi-tensile)

210

JX6H-UFAD60

JX6H-UFADK0

JX6H-UFAD88

JX6H-UFADN0

JX6H-UFADP0

DR8H-UFAA40

DR8H-UFAA5G

DR8H-UFAA68

DR8H-UFAA62

DR8H-UFAA98

DR8H-UFAA92

DS0H-UFAAM0

DS0H-UFAAN0

DS0H-UFAA68

DS0H-UFAA60

DS0H-UFAA98

DS0H-UFAA92

DT2H-UFAA20

DT2H-UFAA58

DT2H-UFAA50*

DT2H-UFAA60

DT2H-UFAA88

SC2390 (not

UL listed)

142.5 ± 1.5 145.5 ± 1.5DT2H-UFAA98

DT2H-UFAA92

Engine type Drive shaft type

SAE

flywheel

Flywheel

drive disc

Horizontal

offset

[mm]

Vertical

offset

[mm]

Bolt grade

Bolt

torque

[ft/lbs]

English (GB)

6.6 Air supply

Figure 21 shows a possible arrangement of supplied and

discharged air ensuring a sufficient supply of fresh air.

Fig. 21 Supply and discharge of air

If required, install louvres to open as soon as the engine starts.

This will ensure an adequate supply of fresh air and removal of

engine heat.

6.7 Exhaust system

Install exhaust pipes as straight and with as few bends as

possible to enable discharge of combustion gases with a

minimum of back-pressure. Install the supplied silencer

horizontally and at a sufficient distance to the engine.

The exhaust system is to be arranged so that no condensation

water can enter the engine.

The exhaust system must be fixed to the building. The flexible

connection piece must not be used to compensate for misaligned

pipework.

The minimum diameter of the exhaust pipes must not be smaller

than that of the exhaust port of the engine.

6.8 Separate control cabinet

The controller must be located as close as practical to the motor

and within sight of the motor.

Ensure easy accessibility to the controller and its components

and adequate air supply for cooling.

Wall-mounted controller

Attach the controller to the structure or wall not less than 305 mm

(12 inches) above floor level. Drill holes in the wall according to

the drilling template on the rear panel of the control cabinet.

Use dowels and screws of adequate size. Use all four mounting

holes.

Floor-mounted controller

Attach the controller to the floor using all holes of the mounting

feet. The mounting feet provides the required 305 mm (12 inches)

clearance for current-carrying parts. We recommend that you use

a concrete slab to avoid water accumulation at the controller's

feet.

TM03 5501 3706

Warning

The exhaust system must be installed correctly

according to local regulations and must have no

leaks. Operation without exhaust system is not

permitted.

Exhaust must be directed safely to the open air

through the exhaust system. Exhaust must not

escape indoors. Risk of suffocation!

Hot exhaust pipes must be protected to prevent

accidental touch. Risk of scalding!

Warning

Installation in hazardous locations and

potentially explosive environments is not

allowed. The controller must be located or

protected so it will not be damaged by water

escaping from pump or pump connections.

Caution

The controller is not designed for outdoor

installation. It must not be exposed to direct

sunlight and must be installed in a dry, well

ventilated but frost-free location.

Warning

When drilling the holes, take care not to damage

any cables or water and gas pipes. Ensure a safe

installation.

English (GB)

7. Electrical connection

See the wiring diagrams supplied with the pump set for correct

connection and cable sizing.

7.1 Checking the direction of rotation on electric units

1. Turn circuit breaker to "ON". If the pump does not start, press

the "START" button A2 and stop immediately.

2. Observe the direction of rotation.

3. If the direction of rotation is not correct, switch off the power

supply, and interchange two phases in the terminal box or in

the controller.

8. Maintenance

8.1 Maintenance intervals

Fire pump set

Visible check: Every six months.

Tightness of bolts, etc.: Every six months.

Alignment, motor and pump: Every six months.

Pump

Stuffing box: Every six months.

Gaskets: Every six months.

Lubrication of bearing: Every six months.

Replacement of bearings: Every six years.

Motor

Motor cables: Every six months.

Lubrication of bearings: Every six months.

Replacement of bearings: Every six years.

Fan: Every three years.

Coupling

Coupling guard: Once a week.

Coupling assembly: Every six months.

Lubrication of drive shaft: Once a year.

Controller

Checking of wire connections: Every six months.

Visible inspection: Every six months.

Testing of indicator lights: Once a week.

Checking of wire connections: Once a year.

Diesel engine

9. Service, spare parts and accessories

The installation and (or) use of such products may negatively

alter and thus impair the specified properties of the fire pump set.

The usage of non-original spare parts and accessories renders

any liability on behalf of Peerless for resulting damages null and

void.

Any malfunctions which cannot be repaired should only be

corrected by Peerless or authorised specialist companies.

Please provide an exact description in the event of a malfunction

so that our service technician can prepare and provide the

appropriate spare parts.

Please obtain the technical data for the system from the

nameplate.

10. Warranty

The warranty is governed by the framework of our general terms

of delivery. Liability for any damage resulting from incorrect

installation, electrical connection or use, as well as liability for

consequential damage, is excluded. The start of the warranty

period is to be verified.

11. Further documentation

These installation and operating instructions are to be used in

conjunction with the following documentation:

• wiring diagram of controller.

• service instructions of the fire pump set.

• service instructions of major components (motor, engine,

control panel).

12. Disposal

This product or parts of it must be disposed of in an

environmentally sound way:

1. Use the public or private waste collection service.

2. If this is not possible, contact the nearest Grundfos company

or service workshop.

Subject to alterations.

Warning

Check that the supply voltage specified on the

nameplate of the control cabinet corresponds to

the local conditions.

The electrical connection should be carried out

by qualified staff in accordance with local

regulations.

Caution

Only watertight hub fittings must be used when

entering the cabinet to preserve the NEMA rating

of the cabinet.

Note

The operator is responsible for ensuring that all

maintenance, inspection and installation work is

performed by qualified staff. A regular

maintenance plan will help avoid expensive

repairs and contribute to trouble-free, reliable

operation. We recommend that you place a

maintenance contract with Peerless.

Warning

Before starting work on the pump, make sure that

the power supply has been switched off and

cannot be accidentally switched on.

Maintenance work must only be carried out by

qualified staff.

Note

You find more detailed information about

maintenance in the service instructions.

Interval

Inspection Replacement

Oil level Once a week -

Oil change with filter - Once a year

Cooling system Once a week -

Cooling liquid - Once a year

Fuel system and filter Once a week Once a year

Exhaust system Once a week -

Air filter Once a week Every six months

V-belt Once a month Once a year

Warning

Spare parts and accessories not supplied by

Peerless are not inspected or approved by

Peerless.

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Grundfos AEF Installation And Operating Instructions Manual

Grundfos AEF Installation And Operating Instructions Manual

Grundfos AEF Installation And Operating Instructions Manual

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