Foam Proportioning - Diesel Tank-Data Book-1.pdf

A Original Issue 19-FEB-08 KIDDE RZ JN

REV. DESCRIPTION DATE EXEC. REV. APPR.

CONTRACTOR DOCUMENT Nr.: 1155-01-90-T0-8015101-DM1 REVISION: A

PISCO PLANT – EPC 12

BLOCK 56 – CAMISEA EXPANSION PROJECT TITLE:

SKZZ-66025 DATA BOOK INGENIERIA DE PROYECTO

SCALE DOCUMENT Nr: Revision

1155-01-90-T0-8015101-DM1 A

All the information contained in this document is confidential and property of OWNER. The total or partial copy or reproduction thereof is prohibited without previous authorization..

-REPLACE: Page 1 of 4

F:\Share\Sistema de Gestion de Calidad\Proyecto Pisco\rev em 1155-01.doc

Perú Corp. S.A.

INDICE DATA BOOK DE EQUIPOS

1. NATIONAL FOAM AER-O-LITE 3% AFFF FOAM CONCENTRATE 3

2. 4BWC3-A-MOR ILBP PROPORTIONING MODULE 3

3. SKID MOUNTED ILBP PROPORTIONING SYSTEM 3

4. 1000 GAL. FIBERGLASS FOAM LIQUID STORAGE TANK 4

5. 2 IN. PRESSURE VACUUM VENT 4

6. FLEXIBLE CONNECTORS 4

7. NATIONAL FOAM SEALER OIL 4

1. NATIONAL FOAM AER-O-LITE 3% AFFF FOAM CONCENTRATE

1.1. Data Sheet NFC300. 1.2. Material Safety Data Sheet NMS300. 1.3. Certificates

1.3.1. U.L. Listing GFGV.EX1734

2. 4BWC3-A-MOR ILBP PROPORTIONING MODULE

2.1. Outline Assembly Drawing D-39-16-EC (C) 2.2. Data Sheet NPR160 2.3. Certificates

2.3.1. U.L. Listing GFGV.EX1734 2.4. Operating & Maintenance Manual for In-Line Balanced Pressure Proportioning

Module (1298-9940-8)

3. SKID MOUNTED ILBP PROPORTIONING SYSTEM (W/30 GPM PUMP)

3.1. Outline Assembly Drawing CPDF-1155-103 (B) 3.2. Operating & Maintenance Manual for In-Line Balanced Pressure Proportioning

System (1298-9936-2). 3.3. Weg Three-Phase Induction Motor

3.3.1. Data Sheet. 3.3.2. Dimensional Drawing 3.3.3. Installation and Maintenance Manual for NEMA Low Voltage Electric

Motors 3.4. Edwards Model 80-428 SDF Foam Concentrate Pump

3.4.1. Data Sheet 3.4.2. Pump Curve 3.4.3. Certificates

3.4.3.1. U.L. Listing GKWT.EX5231 3.4.4. Maintenance Manual

3.5. Firetrol FTA750 Limited Service Controllers 3.5.1. Product Description 3.5.2. Specifications 3.5.3. Sequence of Operation

3.5.4. Wiring Schematic WS750-308 3.5.5. Field Connections FC750-306 3.5.6. U.L. Listing QYZS.EX2662

4. 1000 GAL. FIBERGLASS FOAM LIQUID STORAGE TANK

4.1. Outline Assembly Drawing CPDF-1155-109 (B)

5. 2 IN. PRESSURE VACUUM VENT

5.1. Data Sheet NPR310.

6. FLEXIBLE CONNECTORS

6.1. Data Sheet NPR320.

7. NATIONAL FOAM SEALER OIL

7.1. Data Sheet NFC950. 7.2. Material Safety Data Sheet NMS950.

SECTION 1:

NATIONAL FOAMAER-O-LITE 3% AFFFFOAM CONCENTRATE

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SKZZ-66025

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1.2

Section 3. HAZARDS IDENTIFICATION

Potential Health Effects

InhalationVapors are minimal at room temperature. If product is heated or sprayed as an aerosol, airborne material may cause respiratory irritation.

Skin Contact Contact with liquid may cause moderate irritation or dermatitis due to removal of oils from the skin.

Eye Contact Product is an eye irritant.

IngestionNot a hazard in normal industrial use. Small amounts swallowed during normal handling operations are not likely to cause injury; swallowing large amounts may cause injury or irritation.

Additional Health Effects Existing eye or skin sensitivity may be aggravated by exposure.

Carcinogenicity Information No data available.

Section 4. FIRST AID MEASURES

InhalationNo specific treatment is necessary since this material is not likely to be hazardous by inhalation. If exposed to excessive levels of airborne aerosol mists, remove to fresh air. Seek medical attention if effects occur.

Skin Contact In case of skin contact, wash off in flowing water or shower. Launder clothing before reuse.

Eye Contact In case of eye contact, flush eyes promptly with water for 15 minutes. Retract eyelids often to ensure thorough rinsing. Consult a physician if irritation persists.

IngestionSwallowing less than an ounce is not expected to cause significant harm. For larger amounts, do not induce vomiting. Give milk or water. Never give anything by mouth to an unconscious person. Seek medical attention.

NMS#300 Page 2 of 8 10/01/07

Section 5. FIRE FIGHTING MEASURES

Flammable Properties Flash Point: >200°F

Fire and Explosion Hazards Avoid contact with water reactive materials, burning metals and electrically energized equipment.

Extinguishing Media Product is an extinguishing media. Use media appropriate for surrounding materials.

Special Fire Fighting Instructions This product will produce foam when mixed with water.

Section 6. ACCIDENTAL RELEASE MEASURES

Safeguards (Personnel) NOTE: Review FIRE FIGHTING MEASURES and HANDLING (Personnel) sections before proceeding with clean-up. Use appropriate Personal Protective Equipment during clean-up.

Accidental Release Measures

ConcentrateStop flow if possible. Use appropriate protective equipment during clean up. For small volume releases, collect spilled concentrate with absorbent material; place in approved container. For large volume releases, contain and collect for use where possible. Flush area with water until it no longer foams. Exercise caution, surfaces may be slippery. Prevent discharge of concentrate to waterways. Disposal should be made in accordance with federal, state and local regulations.

Foam/Foam Solution See above. Flush with water. Prevent discharge of foam/foam solution to waterways. Do not discharge into biological sewer treatment systems without prior approval. Disposal should be made in accordance with federal, state and local regulations.

Section 7. HANDLING AND STORAGE

Handling (Personnel) Avoid contact with eyes, skin or clothing. Avoid ingestion or inhalation. Rinse skin and eyes thoroughly in case of contact. Review HAZARDS and FIRST AID sections.

StorageRecommended storage environment is between 20°F (-7°C) and 120°F (49°C). Store product in original shipping container or tanks designed for product storage.

NMS#300 Page 3 of 8 10/01/07

Section 8. EXPOSURE CONTROLS/PERSONAL PROTECTION

Engineering ControlsSpecial ventilation is not required.

Personal Protective Equipment

RespiratoryRecommended exposure limits (OSHA-PEL and ACGIH-TLV) have not been determined for this material. The need for respiratory protection should be evaluated by a qualified health specialist.

Protective ClothingRubber or PVC gloves recommended.

Eye Protection Safety glasses, face shield or chemical splash goggles must be worn when possibility exists for eye contact. Contact lenses should not be worn. Eye wash facilities are recommended.

Other Hygienic Practices Use good personal hygiene practices. Wash hands before eating, drinking, smoking, or using toilet facilities. Promptly remove soiled clothing and wash thoroughly before re-use.

Exposure Guidelines

Exposure Limits (2-Methoxymethylethoxy) Propanol (34590-94-8)

PEL(OSHA)100 ppm, 8 hr. TWA Skin 150 ppm, 15 min. STEL Skin

TLV (ACGIH) 100 ppm, 8 hr. TWA Skin 150 ppm, 15 min. STEL Skin

Section 9. PHYSICAL AND CHEMICAL PROPERTIES

Physical Data

Boiling Point: Not applicable

Vapor Pressure: Not applicable

Vapor Density: Not applicable

Melting Point: Not applicable

Evaporation Rate: <1 (Butyl Acetate = 1.0)

Solubility in Water: 100%

NMS#300 Page 4 of 8 10/01/07

pH: 8.0

Specific Gravity: 1.03 @ 25°C

Freezing Point: 12°F (-11°C)

Odor: Mild, pleasant

Form: Liquid

Color: Straw yellow

Section 10. STABILITY AND REACTIVITY

Chemical Stability Stable.

Incompatibility, Materials to AvoidAvoid use of product on burning metals, electrically-energized equipment and contact with water reactive materials.

Polymerization Will not occur.

Section 11. TOXICOLOGICAL INFORMATION

Mammalian Toxicity

IngestionThis material was not toxic when administered to Wistar Albino rats at an acute oral dose of 5g/kg body weight.

EyeAnimal testing indicates this material is a primary eye irritant when tested undiluted on New Zealand Albino Rabbits.

SkinAnimal testing indicates this material is not a primary skin irritant when tested undiluted on New Zealand Albino Rabbits.

InhalationNo data available at this time.

Carcinogenic, Developmental, Reproductive, Mutagenic Effects No data available on this material.

NMS#300 Page 5 of 8 10/01/07

Section 12. ECOLOGICAL INFORMATION

Ecotoxicological Information Aquatic Toxicity 96 hr. Flow Through LC50 for Fathead Minnows (pimephales promelas) is reported to be greater than 1000 ppm.

Environmental Fate

BOD5 Concentrate 239,000 mg/kg

BOD5 3% solution 8,750 mg/kg

COD Concentrate 400,000 mg/kg

Section 13. DISPOSAL CONSIDERATIONS Aer-O-Lite 3%, as sold, is not a RCRA-listed waste or hazardous waste as characterized by 40 CFR 261. However, State and local requirements for waste disposal may be more restrictive or otherwise different from Federal regulations. Therefore, applicable local and state regulatory agencies should be contacted regarding disposal of waste foam concentrate or foam/foam solution.

ConcentrateDo not discharge into biological sewer treatment systems without prior approval. Specific concerns are high BOD load and foaming tendency. Low dosage flow rate or antifoaming agents acceptable to the treatment plant may be helpful. Do not flush to waterways. Disposal should be made in accordance with federal, state and local regulations.

Foam/Foam SolutionAer-O-Lite 3% foam solution can be treated by waste water treatment facilities. Discharge into biological sewer treatment facilities may be done with prior approval. Specific concerns are high BOD load. Dilution will reduce BOD and COD factors proportionately. Low dosage flow rate or antifoaming agents acceptable to the treatment plant may be helpful. Do not flush to waterways. Disposal should be made in accordance with federal, state and local regulations.

NOTE: As a service to our customers, National Foam has approvals in place with disposal facilities throughout the U.S. for waste water treatment and solidification and landfill of our foam liquid concentrates and foam solutions. If required, National Foam, Inc. can also provide information on the disposal of drums used for shipping our concentrates. Please contact National Foam’s Risk Management Administrator at (610) 363-1400 for additional information.

NMS#300 Page 6 of 8 10/01/07

Section 14. TRANSPORTATION INFORMATION

Shipping Information Proper Shipping Name: Fire Extinguisher Charges or Compounds N.O.I., Class 70 National Motor Freight Code: 69160, Sub 0 Hazard Class: None UN Number: None

Section 15. REGULATORY INFORMATION

U.S. Federal Regulations

Toxic Substances Control Act (TSCA) All components of this product are listed in the TSCA inventory.

Superfund Amendments and Reauthorization Act of 1986 (SARA), Title III

Section 302/304 There are no components of this material with known CAS numbers which are on the Extremely Hazardous Substances (EHS) list.

Section 311 & 312 Based on available information, this material contains the following components which are classified as the following health and/or physical hazards according to Section 311 & 312:(2-Methoxymethylethoxy) Propanol 34590-94-8 (Flammability)

Section 313 This material does not contain any chemical components subject to Section 313 reporting requirements.

COMPREHENSIVE ENVIRONMENTAL RESPONSE, COMPENSATION, AND LIABILITY ACT (CERCLA) This material does not contain any components subject to the reporting requirements of CERCLA.

OTHER REGULATORY INFORMATIONCanadian Environmental Protection Act (CEPA). All ingredients are listed on the DSL (Domestic Substance List).

STATE REGULATIONS

PENNSYLVANIA RIGHT-TO-KNOW HAZARDOUS SUBSTANCES LIST

PA Hazardous Substances present at levels greater than 1%: 1, 2 Propanediol 57-55-6 (2-Methoxymethylethoxy) Propanol 34590-94-8

NMS#300 Page 7 of 8 10/01/07

Section 16. OTHER INFORMATION

NFPA Rating WHMIS Rating

Health 0 D2BFlammability 0 Reactivity 0

ADDITIONAL INFORMATION

Revision Summary5/3/96 ...........Revised to ANSI format. 10/2/96 ......... Updated Section 12 - Environmental Fate. 2/5/99 ........... Added MSDS number, updated Sections 1,3,4,6,7,9,11,12,13,15. 08/10/00 ....... Revised Section 1 and 2. 09/10/03 ....... Updated Sections 2, 5, 9, 14, 15, 16. 05/03/05 ....... Updated Section 9. 10/01/07 ....... Updated Address.

For further information, see National Foam Product Data Sheet for Aer-O-Lite 3%.

The information contained herein is furnished without warranty either expressed or implied. This data sheet is not a part of any contract of sale. The information contained herein is believed to be correct or is obtained from sources believed to be generally reliable. However, it is the responsibility of the user of these materials to investigate, understand and comply with federal, state and local guidelines and procedures for safe handling and use of these materials. National Foam, Inc. shall not be liable for any loss or damage arising directly or indirectly from the use of this product and National Foam, Inc. assumes no obligation or liabilities for reliance on the information contained herein or omissions herefrom.

October 1, 2007

NMS#300 Page 8 of 8 10/01/07

Foam Liquid Concentrates

Aer-O-Lite, nominal 3 percent Aqueous Film Forming Foam, +20 F minimum storage and use temperature. Hydrocarbon fuels only.

GFGV.EX1734Foam Liquid Concentrates

Page Bottom

See General Information for Foam Liquid Concentrates

KIDDE FIRE FIGHTING NATIONAL FOAM DIV EX1734

SUITE 3600

180 SHEREE BLVD

PO BOX 695

EXTON, PA 19341 USA

Foam concentrates for use with the following equipment:

AER-O-LITE, 3 PERCENT

PROPORTIONERS-BALANCED PRESSURE VALVES WITH CONTROLLERS

DescriptionController Size In.

Orifice Size In. Flow GPM

National, 1-1/2 in. Model 1.5 BPRV 2 0.203 60-225

4 0.500 106-1564

6 0.703 106-2968

National, 2 in. Model 2.0 BPRV 4 0.500 106-1564

6 0.703 106-2968

8 1.250 850-4209

National, 1-1/2 in. Model 1.5 PRV or 1.5 PRV MOR 2 0.203 60-225

4 0.500 106-1564

6 0.703 106-2968

National, 2 in. Model 2.0 PRV or 2.0 PRV MOR 4 0.500 106-1564

6 0.703 106-2968

8 1.250 850-4209

Copyright © 2008 Underwriters Laboratories Inc.®Last Updated on 2006-11-27

1.3.1

SECTION 2:

4BWC3-A-MOR ILBPPROPORTIONING MODULE

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SKZZ-66025

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2.2

Foam Liquid Concentrates

Aer-O-Lite, nominal 3 percent Aqueous Film Forming Foam, +20 F minimum storage and use temperature. Hydrocarbon fuels only.

GFGV.EX1734Foam Liquid Concentrates

Page Bottom

See General Information for Foam Liquid Concentrates

KIDDE FIRE FIGHTING NATIONAL FOAM DIV EX1734

SUITE 3600

180 SHEREE BLVD

PO BOX 695

EXTON, PA 19341 USA

Foam concentrates for use with the following equipment:

AER-O-LITE, 3 PERCENT

PROPORTIONERS-BALANCED PRESSURE VALVES WITH CONTROLLERS

DescriptionController Size In.

Orifice Size In. Flow GPM

National, 1-1/2 in. Model 1.5 BPRV 2 0.203 60-225

4 0.500 106-1564

6 0.703 106-2968

National, 2 in. Model 2.0 BPRV 4 0.500 106-1564

6 0.703 106-2968

8 1.250 850-4209

National, 1-1/2 in. Model 1.5 PRV or 1.5 PRV MOR 2 0.203 60-225

4 0.500 106-1564

6 0.703 106-2968

National, 2 in. Model 2.0 PRV or 2.0 PRV MOR 4 0.500 106-1564

6 0.703 106-2968

8 1.250 850-4209

Copyright © 2008 Underwriters Laboratories Inc.®Last Updated on 2006-11-27

2.3.1

2.4

- i - 12/98

TABLE OF CONTENTS

Text Page

Table of Contents ........................................................................................................................... i - iiWarning-Failure to Read Manual ...................................................................................................... iiiSafety Information ............................................................................................................................. iiiNF Red Alert Fire Emergency Service ............................................................................................. iii

CHAPTER 1 - INTRODUCTIONCHAPTER 1 - INTRODUCTIONCHAPTER 1 - INTRODUCTIONCHAPTER 1 - INTRODUCTIONCHAPTER 1 - INTRODUCTION

General Description ........................................................................................................................ 1-1

CHAPTER 2 - INSTALLATIONCHAPTER 2 - INSTALLATIONCHAPTER 2 - INSTALLATIONCHAPTER 2 - INSTALLATIONCHAPTER 2 - INSTALLATION

Cautions and Notes for In-Line Balanced Pressure Proportioning System ................................ 2-12-1. Recommended Materials of Construction ..................................................................................... 2-2

A. With Synthetic Based Polar Solvent/AFFF & Conventional AFFF Foam Concentrates ..... 2-2B. Protein Based Foam Concentrates ......................................................................................... 2-2• Figure 2-1 In-Line Balanced Pressure Proportioner Module

3" to 8" Wafer Style with Manual Override ...................................................................... 2-3• Figure 2-2 In-Line Balanced Pressure Proportioner Module

3" to 8" Wafer Style without Manual Override ................................................................. 2-4• Figure 2-3 In-Line Balanced Pressure Proportioner Module

2" to 8" Flanged Style ........................................................................................................ 2-52-2. Installation and Start-Up: ILBP Module ......................................................................................... 2-6

A. Off Loading ............................................................................................................................... 2-6B. Installation ................................................................................................................................. 2-6C. Operating Requirements .......................................................................................................... 2-7

CHAPTER 3 - OPERATING PROCEDURESCHAPTER 3 - OPERATING PROCEDURESCHAPTER 3 - OPERATING PROCEDURESCHAPTER 3 - OPERATING PROCEDURESCHAPTER 3 - OPERATING PROCEDURES

3-1. Minimum Inlet Pressure Requirements ......................................................................................... 3-1• Figure 3-1 NF Ratio Controller Minimum Inlet Pressure vs. Solution Flow Chart ............... 3-1• Figure 3-2 Operating Schematic Drawing -

RCW Style ILBP Module With Manual Override ............................................................. 3-2• Figure 3-3 Operating Schematic Drawing -

RCW Style ILBP Module Without Manual Override ........................................................ 3-3• Figure 3-4 Operating Schematic Drawing -

RCF Style ILBP Module With Manual Override............................................................... 3-4

12/98 - ii -

3-2. ILBP Module Operation .................................................................................................................. 3-53-3. ILBP Module Manual Override (Manual Regulation) .................................................................... 3-53-4. Shutdown ......................................................................................................................................... 3-6

CHAPTER 4 - INSPECTION AND MAINTENANCECHAPTER 4 - INSPECTION AND MAINTENANCECHAPTER 4 - INSPECTION AND MAINTENANCECHAPTER 4 - INSPECTION AND MAINTENANCECHAPTER 4 - INSPECTION AND MAINTENANCE

4-1. Inspection and Maintenance .......................................................................................................... 4-14-2. Testing After System Maintenance................................................................................................ 4-14-3. Annual Testing ................................................................................................................................ 4-1

• Table 4-1 Recommended Inspection & Maintenance Schedule ........................................... 4-24-4. General ............................................................................................................................................ 4-24-5. Water Powered Ball Valves ........................................................................................................... 4-24-6. Electrically Actuated Valves .......................................................................................................... 4-34-7. Control System................................................................................................................................ 4-34-8. Flushing - ILBP Module .................................................................................................................. 4-4

A. ILBP Module With Diaphragm Valve Manual Override Capability ....................................... 4-4B. ILBP Module Without Diaphragm Valve Manual Override Capability .................................. 4-4

CHAPTER 5 - TROUBLESHOOTINGCHAPTER 5 - TROUBLESHOOTINGCHAPTER 5 - TROUBLESHOOTINGCHAPTER 5 - TROUBLESHOOTINGCHAPTER 5 - TROUBLESHOOTING

5-1. Troubleshooting .............................................................................................................................. 5-1• Table 5-1 Troubleshooting ....................................................................................................... 5-1

5-2. No Proportioning ............................................................................................................................. 5-15-3. Low Percent of Proportioning ......................................................................................................... 5-25-4. High Percent of Proportioning ........................................................................................................ 5-35-5. No Flow at Discharge Device(s) .................................................................................................... 5-45-6. Low Flow at Discharge Device(s) .................................................................................................. 5-45-7. No Operation ................................................................................................................................... 5-4

APPENDIX - FACTORY MUTUAL APPROVALSAPPENDIX - FACTORY MUTUAL APPROVALSAPPENDIX - FACTORY MUTUAL APPROVALSAPPENDIX - FACTORY MUTUAL APPROVALSAPPENDIX - FACTORY MUTUAL APPROVALS

A-1. Universal Gold 3% .......................................................................................................................... A-1A-2. Aer-O-Lite 3% ................................................................................................................................. A-1A-3. Aer-O-Water 3EM ........................................................................................................................... A-2

Text Page

TABLE OF CONTENTS

WARNING:This manual has been prepared as an aid and guide for personnel involved in the installation, operation andmaintenance of a National Foam In-Line Balanced Pressure Proportioning Module and must be kept with themodule. All instructions must be read and understood thoroughly before attempting any installation, operationor maintenance to this module. Failure to follow any instructions can result in personal injury and/or damageto this equipment.

SAFETY INFORMATION

The International Safety Alert Symbol - - is used with one of the following signal words to alert operatingpersonnel to the potential for death, personal injury or damage to equipment or property.

DANGER: indicates an extremely hazardous situation which, if not avoided, will resultin death or serious injury to the operator or major property damage.

WARNING: indicates a potentially hazardous situation which, if not avoided, can resultin serious injury, or death to the operator or major property damage.

CAUTION: indicates a potentially hazardous situation which, if not avoided, can resultin personal injury or property damage.

NOTE: indicates special instructions which are very important and must be followed.

It is the responsibility and duty of all personnel involved in the operating and maintenance of this equipment to fullyunderstand the DANGER, WARNING, CAUTION and NOTE procedures by which hazards are to be reduced oreliminated. Personnel must become thoroughly familiar with all aspects of safety and equipment prior to operationor maintenance of the equipment.

Operating and Maintenance Instructions and layouts shall be posted at control equipment with a second copy on file.All persons who may be expected to inspect, test, maintain or operate foam-generating apparatus shall be thoroughlytrained and kept thoroughly trained in the functions they are expected to perform.

- iii - 6/00

SAFETY INFORMATION

National FoamRed Alert Fire Emergency Service

National Foam’s Red Alert Emergency Service is a system set up to respond to an emergencysituation requiring foam, equipment or service and is available 24 hours a day, 365 days a year.

CALL LIONVILLE, PA 610-363-1400

1-1 12/98

controller to the diaphragm valve.

NF diaphragm valves, as previously mentioned, areavailable in two versions. One version does not havemanual override capability. This version does not allowmanual regulation of foam concentrate inlet presssure inthe event of a diaphragm valve failure. The other versiondoes have manual override capability, which allowsmanual regulation of the foam concentrate inlet pressure.Pressure is adjusted by the operator by manually openingthe diaphragm valve (thru use of the Manual OverrideKnob) and regulating the foam concentrate supply valve(Valve "V") while watching the duplex gauge for systembalance. The duplex gauge monitors balancing of foamconcentrate and water pressures on a single gauge. Foamconcentrate pressure is indicated by the red pointer andwater pressure is indicated by the black pointer. Whenthe red pointer is directly aligned with the black pointer,both pointing in the same direction, the system is balanc-ing. Diaphragm valves that do not have manual overridecapability also do not have a duplex gauge to monitorpressure balance.

A National Foam ILBP Module is just one compo-nent of an In-Line Balanced Pressure ProportioningSystem. This type of foam proportioning system consistsof one or more ILBP Modules, a foam concentrate pump,a pressure sustaining valve and a foam concentratestorage tank. An ILBP System requires a fire watersupply system for the module(s).

The ILBP Module is a complete, self-contained unit,assembled and tested at the factory. The unit is suppliedwith no finish and is suitable for either horizontal orvertical mounting.

The principle of operation of the ILBP Module isbased on the use of a modified venturi proportionercalled a ratio controller. With this type of proportioner,water passes thru a jet (venturi) at the inlet of the ratiocontroller, creating a reduced pressure area on the dis-charge side of the jet. This reduction in pressure createsa pressure differential across the foam concentrate ori-fice and causes injection of foam concentrate into thewater stream at this reduced pressure area.

As the water flow thru the ratio controller increases, thepressure reduction on the discharge side of the jet in-creases, thereby increasing the pressure differential acrossthe foam concentrate orifice. A proportionate increase infoam concentrate injection will occur with an increase inthe water flow thru the ratio controller due to the in-creased pressure differential. As both the water and foamconcentrate flow into the common reduced pressure area,it is necessary only to maintain identical water and foamconcentrate pressures at the inlets of the ratio controller.

A diaphragm valve (pressure control valve) automati-cally adjusts the foam concentrate inlet pressure tocorrespond to the water inlet pressure. Pressure sensinglines lead from the foam concentrate line upstream of theratio controller and from the water inlet to the ratio

A National Foam ILBP Module consists of the following major components:

● Ratio Controller

● Diaphragm Valve - with foam concentrate and water sensing lines

Two Versions

1. With Manual Override and Duplex Gauge

2. Without Manual Override and Duplex Gauge

● Foam Concentrate Supply Pressure Gauge

● Foam Concentrate Supply Valve

● The appropriate lengths of pipe and fittings to join these components into a singlepackage called an In-Line Balanced Pressure Proportioning Module.


CHAPTER 2 - INSTCHAPTER 2 - INSTCHAPTER 2 - INSTCHAPTER 2 - INSTCHAPTER 2 - INSTALLALLALLALLALLAAAAATIONTIONTIONTIONTION

CAUTION:Install the In-Line Balanced Pressure Proportioning Module in accordance with instructions in this manual.Variations may affect performance or cause system failure.

Customer modification or alteration of this equipment, or the use of replacement parts other than thosespecified by NF, may affect the performance of this equipment and may void the warranty.

NOTE: National Foam recommends that those individuals charged with designing, installing, operating, testing andmaintaining a foam fire protection system, or the replacement of equipment and/or components of an existingsystem, refer to the appropriate authority having jurisdiction for compliance with applicable standard(s), code(s)and regulation(s) for that particular type of system and its components.

NOTE: The design requirements for the foam equipment provided may or may not be based on specific designrequirements provided to National Foam. Any changes to the area(s) of coverage or additions of other productscould exceed the design parameters of the foam equipment. Contact NF Engineering Dept. for questions regardingchanges to design.

NOTE: READ ALL OPERATING INSTRUCTIONS BEFORE USING EQUIPMENT.It is the responsibility and duty of all personnel involved in the installation, operation, inspection andmaintenance, and refilling of this system to read and understand this entire manual before using theequipment.

NOTE: COMPONENTS FOR AN IN-LINE BALANCED PRESSURE PROPORTIONING SYSTEMProducts manufactured by NF are warranted free of defects in materials and workmanship for twelvemonths from the date of purchase. NF will pass on to the system owner, as far as it is able to do, the benefitof the manufacturer's warranty for those parts and components not manufactured by NF.

National Foam may supply components such as an ILBP Module, ratio controller, diaphragm valve,pump(s), gauges, controls etc. for use in new or refurbished in-line balanced pressure systems. NF makesno warranty, either expressed or implied and assumes no responsibility on the engineering and design ofsuch systems.

12/98 2-1

2-1. RECOMMENDED MATERIALS OF CONSTRUCTION

NOTE:1. The following recommenations are for materials which will be in contact with the foam concentrates.2. Type 304 and 316 stainless steel includes "L" grades.

CAUTION:Galvanized steel storage tanks or piping must never be used to contain any foam concentrates.

2-2 12/98

A. With Synthetic Based Polar Solvent/AFFF andConventional AFFF Foam Concentrates

1. Piping:

� Brass or Bronze (Note: All foam concen-trate lines on NF skid paks are Brass)

� Stainless Steel 304L or 316 grades� High Density Polyethylene� PVC� Fiberglass with isophthalic based polyester

and an internal layer (50-100 mils minimum)of vinyl ester resin in contact with foamconcentrate

2. Valves:

� Brass or Bronze. Cast brass valves fittedwith stainless steel (304L or 316 grades) orbrass trim are acceptable. Teflon seats andpacking are preferable for foam concentrateservice. EPT (EPDM), Buna-N or Viton arealso acceptable seal materials for use withNF foam concentrates.

� Stainless Steel 304L or 316 grades

3. Storage Tanks:

� Stainless Steel 304L or 316 grades� High Density Cross Linked Polyethylene� Fiberglass with isophthalic based polyester


B. With Protein-Based Foam Concentrates

1. Piping:

� Same materials as Synthetic Based PolarSolvent/AFFF and Conventional AFFF FoamConcentrate with the exception of stainlesssteel

� Black steel pipe and malleable iron fittings

2. Valves:

� Brass or Bronze. Cast brass valves fittedwith stainless steel (304L or 316 grades) orbrass trim are acceptable. Teflon seats andpacking are preferable for foam concentrateservice. EPT (EPDM), Buna-N or Viton arealso acceptable seal materials for use withNF foam concentrates.

3. Storage Tanks:

� Steel� Same materials as Synthetic Based Polar

Solvent/AFFF and Conventional AFFF FoamConcentrate with the exception of stainlesssteel.

INSTALLATION

12/98 2-3

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cent

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port

ioni

ng

P/A

/U

3% &

6%

1%, 3

% &

6%

1% &

3%

6%

1% &

3%

6%

19-9

/16(

497)

19-1

/4(4

89)

18-7

/8(4

79)

21-7

/8(5

56)

22(5

59)

23-3

/8(5

94)

9-3/

4(24

8)

10-1

/8(2

57)

11-1

/8(2

83)

11-9

/16(

294)

12-1

/4(3

11)

12-9

/16(

319)

1-1/

2(38

)

1-1/

2(38

)

1-1/

2(38

)

2(51

)

2(51

)

2(51

)

1-3/

16(3

0)

1-7/

32(3

1)

1-5/

8(41

)

1-5/

8(41

)

1-3/

4(44

)

1-3/

4(44

)

1-11

/16(

43)

1-31

/32(

50)

2-3/

8(60

)

2-3/

8(60

)

2-1/

2(64

)

2-1/

2(64

)

4-13

/16(

122)

8-1/

32(2

04)

10-3

/8(2

64)

10-3

/8(2

64)

11(2

79)

11(2

79)

19-3

/4(5

02)

20-1

/8(5

11)

21-1

/8(5

37)

21-1

5/16

(557

)

22-1

1/16

(576

)

22-1

1/16

(576

)

3 4 6 6 *8 *8

SP

EC

IFIC

ATI

ON

S

TAB

LE O

F D

IME

NS

ION

SIN

CH

ES

(MIL

LIM

ETE

RS

)N

OM

INA

LPI

PES

IZE

74(3

4)

84(3

8)

94(4

3)

109(

49)

164(

74)

164(

74)

APP

RO

X.W

EIG

HT

LBS

(KG

S)

AB

CD

GF

E

10.5

(.72)

19.5

(1.3

4)

19.5

(1.3

4)

19.5

(1.3

4)

20(1

.37)

20(1

.37)

0.3(

.02)

0.3(

.02)

0.3(

.02)

0.3(

.02)

0.3(

.02)

0.3(

.02)

PR

ES

SU

RE

LO

SS

**P

SI (

BA

R)

MIN

. FLO

WM

AX

. FLO

W45

0(17

03)

1200

(454

2)

2500

(946

3)

2500

(946

3)

5000

(189

27)

*400

0(15

141)

70(2

65)

150

(568

)

300(

1136

)

300(

1136

)

850(

3218

)

850(

3218

)

3% S

YS

TEM

SO

LUTI

ON

CA

PA

CIT

IES

**G

PM

(LP

M)

MIN

IMU

MM

AX

IMU

M

FIG

UR

E 2

-1IN

-LIN

E B

AL

AN

CE

D P

RE

SSU

RE

PR

OPO

RT

ION

ER

MO

DU

LE

3" -

8" W

AFE

R S

TY

LE

WIT

H M

AN

UA

L O

VE

RR

IDE

MO

DEL

NU

MB

ER ID

ENTI

FIC

ATI

ON

3B

WC

3

2-1_

2-2.

P65

(2/9

8)IL

BP

2-1.

DS

F

* - 8

INC

H P

RO

PO

RTI

ON

ER

RE

STR

ICTE

D T

O 4

000

GP

M (1

5141

LP

M) F

OR

6%

PR

OP

OR

TIO

NIN

G.

** -A

LL D

ATA

BA

SE

D O

N 3

% P

RO

PO

RTI

ON

ING

, FO

R 6

% M

ULT

IPLY

BY

1.1

9.

PERC

ENTA

GE

MO

R

MA

TER

IALS

OF

CO

NS

TRU

CTI

ON

Com

pone

nt D

escr

iptio

nM

ater

ial

Dia

phra

gm V

alve

Bra

ss &

Sta

inle

ss S

teel

Rat

io C

ontr

olle

rB

rass

Bal

l Val

veB

rass

& S

tain

less

Ste

elw

ith T

eflo

n S

eals

Pip

e an

d Fi

tting

sB

rass

Hos

eB

raid

ed S

tain

less

Ste

elov

er T

eflo

n Tu

be

"D"

"A"

"F"

SOLU

TIO

NFL

OW

WA

TER

FLO

W

"B"

"C"

FOAM

CO

NC

EN

TRA

TEIN

LET

CO

NN

EC

TIO

N

FOAM

CO

NC

EN

TRA

TE S

UP

PLY

VA

LVE

"V"

(NO

RM

ALL

Y C

LOSE

D)

DIA

PHR

AG

MB

ALA

NC

ING

VAL

VE

PR

ESS

UR

E G

AUG

E

BO

DY

DR

AIN

PLU

G

BU

SHIN

GC

HE

CK

VA

LVE

150#

AN

SI B

OLT

EDFL

AN

GE

S B

Y O

THE

RS

(SA

ME

NO

MIN

AL

PIP

E S

IZE

AS

RA

TIO

CO

NTR

OLL

ER

)

SC

H. 4

0 P

IPIN

G B

Y O

THER

S(S

AM

E N

OM

INA

L S

IZE

AS

RAT

IO C

ON

TRO

LLER

)

WAT

ER

FLU

SH

-OU

TV

ALV

E "P

"

FOAM

CO

NC

EN

TRA

TEFL

US

H-O

UT

VAL

VE

"R"

"G"

(Ref

.)

"E"

MAN

UA

L O

VE

RR

IDE

KN

OB

(NO

RM

ALL

Y IN

FU

LLY

OP

EN

PO

SIT

ION

)

DU

PLE

X G

AU

GE

DU

PLE

X G

AU

GE

WAT

ER

FLU

SH

-OU

TV

ALV

E "M

"

DU

PLE

X G

AU

GE

FOAM

CO

NC

EN

TRA

TEFL

US

H-O

UT

VALV

E "

N"

"D"

"A"

"F"

SOLU

TION

FLOW

WA

TERFLO

W

"B"

"C"

FOA

M C

ON

CE

NTR

ATE

INLE

T CO

NN

EC

TION

FOA

M C

ON

CEN

TRA

TE SU

PPLY

VALVE

"V"

(NO

RM

ALLY C

LOSE

D)

DIA

PHR

AGM

BALA

NC

ING

VALVE

PRE

SSU

RE G

AUG

E

BOD

YD

RAIN

PLUG

BUS

HIN

G C

HEC

K VA

LVE

150# ANS

I BOLTED

FLANG

ES BY

OTH

ER

S(SA

ME N

OM

INA

L PIPE S

IZEAS

RATIO

CO

NTR

OLLE

R)

SCH

. 40 PIPING

BY O

THER

S(SA

ME N

OM

INA

L SIZEAS

RATIO

CO

NTR

OLLE

R)

WA

TER FLU

SH

-OU

TVA

LVE "P

"

FOA

MC

ON

CEN

TRATE

FLUSH

-OU

TVA

LVE "R

""G

"(R

ef.)

"E"

2-4 12/98

Controller P

ipe Size

Material of C

onstruction - "B" B

rassFoam

Concentrate

- P - P

roteinR

atio Controller S

tyle - "W" W

afer Style

- U - U

niversal- U

G - U

niversal Gold

"C" C

ontractor Model

- A - A

FFF

Percent P

roportioning

P/A

/U

3% &

6%

1%, 3%

& 6%

1% &

3%

6%

1% &

3%

6%

19-9/16(497)

19-1/4(489)

18-7/8(479)

21-7/8(556)

22(559)

23-3/8(594)

9-3/4(248)

10-1/8(257)

11-1/8(283)

11-9/16(294)

12-1/4(311)

12-9/16(319)

1-1/2(38)

1-1/2(38)

1-1/2(38)

2(51)

2(51)

2(51)

1-3/16(30)

1-7/32(31)

1-5/8(41)

1-5/8(41)

1-3/4(44)

1-3/4(44)

1-11/16(43)

1-31/32(50)

2-3/8(60)

2-3/8(60)

2-1/2(64)

2-1/2(64)

4-13/16(122)

8-1/32(204)

10-3/8(264)

10-3/8(264)

11(279)

11(279)

15-3/8(391)

15-3/4(400)

16-3/4(425)

17-5/8(448)

18-5/16(465)

18-5/16(465)

3466*8*8

SPECIFIC

ATIO

NS

TAB

LE O

F DIM

EN

SIO

NS

INC

HE

S (M

ILLIME

TER

S)

NO

MIN

AL

PIPESIZE

74(34)

84(38)

94(43)

109(49)

164(74)

164(74)

WEIG

HT

LBS

(KG

S)

AB

CD

GF

E

10.5(.72)

19.5(1.34)

19.5(1.34)

19.5(1.34)

20(1.37)

20(1.37)

0.3(.02)

0.3(.02)

0.3(.02)

0.3(.02)

0.3(.02)

0.3(.02)

PRESSU

RE LO

SS **P

SI (B

AR

)M

IN. FLO

WM

AX

. FLOW

450(1703)

1200(4542)

2500(9463)

2500(9463)

5000(18927)

*4000(15141)

70(265)

150 (568)

300(1136)

300(1136)

850(3218)

850(3218)

3% SYSTEM

SO

LUTIO

N C

AP

AC

ITIES

**G

PM (LPM

)M

INIM

UM

MAXIM

UM

PERCENTAGE

FIGU

RE

2-2IN

-LIN

E B

AL

AN

CE

D PR

ESSU

RE

PRO

POR

TIO

NE

R M

OD

UL

E3" - 8" W

AFE

R ST

YL

E W

ITH

OU

T M

AN

UA

L O

VE

RR

IDE

* - 8 INC

H P

RO

PO

RTIO

NE

R R

ES

TRIC

TED

TO 4000 G

PM

(15141 LPM

) FOR

6% P

RO

PO

RTIO

NIN

G.

** -ALL D

ATA

BA

SE

D O

N 3%

PR

OP

OR

TION

ING

, FOR

6% M

ULTIP

LY B

Y 1.19.

MA

TER

IALS

OF C

ON

STR

UC

TION

Com

ponent Description

Material

Diaphragm

Valve

Brass &

Stainless S

teelR

atio Controller

Brass

Ball V

alveB

rass & S

tainless Steel

with Teflon S

ealsP

ipe and FittingsB

rassH

oseB

raided Stainless S

teelover Teflon Tube

MO

DE

L NU

MB

ER

IDE

NTIFIC

ATIO

N

3B

WC

3

2-1_2-2.P65 (2/98)ILBP2-2.D

SF

12/98 2-5

2-9/

16(6

5)

2(51

)

3(76

)

3-1/

16(7

8)

3-1/

2(89

)

14(.9

7)

10.5

(.72)

19.5

(1.3

4)

19.5

(1.3

4)

20(1

.37)

2 3 4 6 8*

SPEC

IFIC

ATI

ON

S

*

MIN

IMU

M

PRES

SUR

E LO

SS**

PSI (

BA

R)

0.5

.03)

0.3(

.02)

0.3(

.02)

0.3(

.02)

0.3(

.02)

TAB

LE O

F D

IMEN

SIO

NS

INC

HES

(MIL

LIM

ETER

S)N

OM

INA

LPI

PESI

ZE

30(1

14)

70(2

65)

150

(568

)

300(

1136

)

850(

3218

)

180(

681)

450(

1703

)

1200

(454

2)

2500

(946

3)

*500

0(18

927)

SOLU

TIO

N C

APA

CIT

IES

PSI (

BA

R)

MIN

IMU

MM

AXI

MU

M

75(3

4)

90(4

1)

110(

50)

145(

66)

220(

100)

MA

XIM

UM

15-1

1/16

(398

)

16-1

/4(4

13)

15-1

/4(3

87)

18-1

1/16

(475

)

18-1

/4(4

64)

AB

9-5/

8(24

4)

6-1/

2(16

5)

10(2

54)

12-3

/4(3

24)

13-1

/2(3

43)

CD

WEI

GH

TLB

S (K

GS)

1-1/

2 N

PT

1-1/

2 N

PT

1-1/

2 N

PT

2 N

PT

2 N

PT

HG

12(3

05)

12(3

05)

12(3

05)

12-3

/4(3

24)

12-3

/4(3

24)

7-1/

2(19

1)

8(20

3)

9-1/

2(24

1)

11(2

79)

12-3

/4(3

24)

F

19-3

/4(5

02)

20-1

/2(5

21)

22(5

59)

23-3

/4(6

03)

26-1

/4(6

67)

E

6" 1

50#

FLA

T FA

CE

*- 8

INC

H P

RO

PO

RTI

ON

ER

RE

STR

ICTE

D T

O 4

000

GP

M (1

5141

LP

M) F

OR

6%

PR

OP

OR

TIO

NIN

G.

** -

ALL

DA

TA B

AS

ED

ON

3%

INJE

CTI

ON

, FO

R P

RE

SS

UR

E L

OS

SE

S F

OR

6%

INJE

CTI

ON

, MU

LTIP

LY B

Y 1

.19.

FIG

UR

E 2

-3IN

-LIN

E B

AL

AN

CE

D P

RE

SSU

RE

PR

OPO

RT

ION

ER

MO

DU

LE

2" -

8" F

LA

NG

ED

ST

YL

E

RC

F2-3

.DSF

RC

F2-3

.P65

MA

TER

IALS

OF

CO

NS

TRU

CTI

ON

Com

pone

nt D

escr

iptio

nM

ater

ial

Dia

phra

gm V

alve

Bra

ss &

Sta

inle

ss S

teel

Bal

l Val

veB

rass

& T

eflo

nR

atio

Con

trol

ler

Bra

ssP

ipe

Bra

ssP

ittin

gs (

Pip

e)B

rass

Hos

eB

raid

ed S

tain

less

Ste

elov

er T

eflo

n Tu

be

3" 1

50#

FLA

T FA

CE

4" 1

50#

FLA

T FA

CE

8" 1

50#

FLA

T FA

CE

2" 1

50#

FLA

T FA

CE

DIA

PH

RAG

M B

ALA

NC

ING

VAL

VE

FOA

M C

ON

CEN

TRA

TESU

PPLY

"H"

F±1/

4

WA

TER

FLO

W

"D" F

LAN

GE

PER

AN

SI B

16.5

SOLU

TIO

N

FLO

W

E±1/

4

DR

AIN

/FLU

SH-O

UT

VALV

ES

- TYP

ICAL

5 PL

ACE

S

- DU

PLE

X G

AUG

E -

RED

NEE

DLE

- FO

AM

BLAC

K N

EED

LE -

WA

TER

DU

AL S

CA

LE E

NG

LISH

AND

MET

RIC

MA

NU

AL O

VER

RID

E H

AND

WH

EEL

(NO

RM

ALLY

IN F

ULL

OPE

N P

OSI

TIO

N)

FOA

M C

ON

CEN

TRAT

E SU

PPLY

VAL

VE

"V"

(NO

RM

ALLY

CLO

SED

)

PRE

SSU

RE

GAU

GE

G±1

/4

B

CA±

1/4

2-6 12/98

2-2. INSTALLATION AND START-UP: ILBP MODULE

CAUTION:For proper piping sizes contact NF Engineering Department.

WARNING:In accordance with NFPA requirements for supervision of an Automated Foam Fire Protection System -manually operated valve(s) in the foam solution line from the proportioner to the discharge device(s) must bechained or locked in the open position or equipped with tamper alarm switch(es) which are monitored by asupervisory panel alarm.

The major concern is the possibility that any manually operated valve(s) in the foam solution line to thehazard(s) could inadvertently be left in the closed position during a fire condition, which would prevent the foamsolution from reaching the hazard(s) in the event of an automatic trip sequence.

A. Off Loading:

WARNING:Be sure the module is properly secured and balancedduring any lifting or moving procedure. If the moduleis not properly secured in the lifting device, damage tothe module or injury to personnel could result.

1. To avoid damage, the module should be left in itsshipping carton or crate until time of installation intofoam system.

2. Use a nylon lifting strap, secured around the ratiocontroller body, to move or mount the module.

B. Installation:

NOTE: Refer to Operating Schematic Drawing Fig. 3-1, 3-2 or 3-3.

1. Mount the module on the water piping main andconnect the foam concentrate supply piping tothe module. ILBP modules can be mounted ineither a horizontal or vertical orientation.

2. All interconnecting piping to and from the ILBPModule (that is - foam concentrate supply pip-ing, watermain piping and foam solution piping)must be self-supporting so as to eliminate anyload on the module itself.

3. To facilitate future service/removal of the ratiocontroller, the installer should provide a spoolpiece upstream of the ratio controller. See Chartbelow for minimum spool piece lengths.

Ratio Controller Minimum Spool Length

3" .......................................... 8" (203)4" ........................................ 10" (254)6" ........................................ 12" (305)8" ........................................ 14" (356)

4. Each proportioner module requires 5 diameters ofstraight unobstructed upstream and downstreamwatermain piping to obtain proper flow through theratio controller.

CAUTION:The ILBP Module requires a stable, uniformwater flow at the inlet to the ratio controller toinsure proper proportion ing during all ratedflow conditions.

INSTALLATION

5. Regarding only RCF style ILBP modules:A check valve must be placed in the foam con-centrate line directly upstream of eachproportioner module.

6. Regarding only ILBP Module(s) that have adiaphragm valve with manual override capabil-ity: If the module is used with an AutomaticZone Foam Concentrate Supply Valve, theManual Foam Concentrate Supply Valve "V" isstill required for manual override pressure regu-lation. Refer to Operating Schematic Dwg. Fig.3-1 or Fig. 3-3 for valve locations and normalstand-by position.

7. Cycle all valves to insure freedom of movementand that they open and close properly.

8. For NF recommended components - valves,strainers, gauges and connections, and their lo-cation in the system, refer to the OperatingSchematic Drawing Fig. 3-1, 3-2 or 3-3.

12/98 2-7

9. Check that the system is properly installed accordingto design with all necessary valves, correct pipesizes, discharge devices and discharge device loca-tions, and is installed in compliance with local codes.

10. Hydrostatically test piping in accordance with pro-cedures outlined in the latest edition of the applicablesection of NFPA.

11. Flush the foam concentrate piping before introduc-ing foam concentrate into the foam system.

12. Follow the procedures outlined in Section 2-2., C.Installation, Item Nos. 7 and 8. Refer to SystemFlushing procedures outlined in Sect. 4-15.

13. Place all valves to their normal stand-by position.See Normal Stand-By Valve Position Chart on Op-erating Schematic Dwg. Fig. 3-1, 3-2 or 3-3.

14. Perform the applicable testing after installation pro-cedures as recommended by the latest edition ofNFPA 11.

INSTALLATION

C. Operating Requirements:

1. Foam concentrate pressure to the ILBP Moduleinlet must exceed water pressure inlet by at least30 psi (2.0 Bar) unless otherwise approved byNF Engineering Department.

2. ILBP Module maximum working pressure - 200psi(13.7 Bar).

3. Regarding only ILBP Module(s) that have adiaphragm valve with manual override capabil-ity:

• The Manual Override Handwheel on thediaphragm valve must be in the normal stand-

by position for automatic balancing. To place inthe normal stand-by position: rotate themanual override handle in the counter-clock-wise direction until fully open.

• Check the appropriate sensing line valve(s)(Valves "J", "L" or "K") to insure that it is in theproper stand-by position (Normally Open).

4. Insure that all valves are in their normal stand-byposition before operating the proportioning system.See Normal Stand-By Valve Position Chart on Op-erating Schematic Dwg. Fig. 3-1, 3-2 or 3-3.

12/98 3-1

CHAPTER 3 - OPERACHAPTER 3 - OPERACHAPTER 3 - OPERACHAPTER 3 - OPERACHAPTER 3 - OPERATING PROCEDURESTING PROCEDURESTING PROCEDURESTING PROCEDURESTING PROCEDURES

3-1. MINIMUM INLET PRESSURE REQUIREMENTS

Since it is not uncommon for water inlet pressures to be quite low in some system applications, it isnecessary to determine that the minimum proportioning system inlet pressure is adequate to allowproper system operation. The curves in Fig. 3-1 indicate the minimum inlet pressure required relativeto the anticipated flow rate of the system. These curves apply to all proportioning systems whichutilize National Foam Model RCT, RCF or RCW ratio controllers.

FIGURE 3-1RATIO CONTROLLER MINIMUM INLET PRESSURE VS. SOLUTION FLOW CHART

� � � � � � �

� � � � � �

� � � � �

� � � �

� � � � �

� � � � � �

� � � � �

� � � �

� � � � � �

� � � � �

� � �

� � �

� �

� �

� � �

� � �

� �

� �

� � �

� � �

� � �

�

� � �

� � �

� � � �

� �

� � �

�

� � � �

� � � �

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

� � � � � � � � � � � � � � � � � � � � � � �

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WATERSUPPLY

WATER PUMP(IF REQUIRED)

MAIN WATERSUPPLY VALVE

SEE NOTE NO. 3

FOAMSOLUTION

V

SEE NOTE NO. 2

M

N

L

R P

P

D

ILBP MODULESCHEMATIC- TYPICAL -

SEE NOTE NO. 1

MANUAL OVERRIDEHANDWHEEL

BODYDRAINPLUG

FOAMCONCENTRATE

SUPPLY

3-2 12/98

NOTES:

The schematics shown are typical installations andmay not reflect actual equipment furnished.

1. Valve "V" - Normally CLOSED for systems usingno automatic foam concentrate valve(s).

- Normally OPEN for systems using anautomatic foam concentrate valve(s).

2. Position of Zone Foam Concentrate Valve.Automatic valve optional.

3. Position of Zone Water Supply Valve.Automatic valve optional.Manual valve required if automatic valve not supplied.

FIG. 3-2 OPERATING SCHEMATIC DRAWING

MOD3-1.DSFLGND3-1.DSF

LEGENDPOSITION

VALVE DESCRIPTION DESIGNATION MANUAL AUTO.WATER SENSING LINE SHUT-OFF VALVE L OPEN OPEN

TO DIAPHRAGM VALVEDUPLEX GAUGE WATER FLUSH-OUT M CLOSED CLOSEDDUPLEX GAUGE FOAM CONC. FLUSH-OUT N CLOSED CLOSEDDIAPHRAGM VALVE WATER FLUSH-OUT P CLOSED CLOSEDDIAPHRAGM VALVE CONC. FLUSH-OUT R CLOSED OPENFOAM CONCENTRATE SUPPLY VALVE V CLOSED OPENBODY DRAIN PLUG CLOSED CLOSED

NORMAL STAND-BY VALVE POSITION CHARTRCW IN-LINE BALANCED PRESSURE PROPORTIONING MODULE W/MOR

FIG. 3-2 OPERATING SCHEMATIC DRAWINGRCW ILBP MODULE WITH MANUAL OVERRIDE

P

D

FOAM CONCENTRATE LINE

SENSING LINE

WATER LINE

RCW RATIO CONTROLLER

BALL VALVE (N.O.)

BALL VALVE (N.C.)

AUTOMATED VALVE W/MANUALOVERRIDE

DUPLEX GAUGE

PRESSURE GAUGE

DIAPHRAGM VALVE

WATERSUPPLY



SEE NOTE NO. 3

FOAMSOLUTION

V

SEE NOTE NO. 2

R P

P


SEE NOTE NO. 1

BODYDRAINPLUG

FOAMCONCENTRATE

SUPPLY

12/98 3-3



NOTES:






POSITIONVALVE DESCRIPTION DESIGNATION MANUAL AUTO.

DIAPHRAGM VALVE WATER FLUSH-OUT P CLOSED CLOSEDDIAPHRAGM VALVE CONC. FLUSH-OUT R CLOSED OPENFOAM CONCENTRATE SUPPLY VALVE V CLOSED OPENBODY DRAIN PLUG CLOSED CLOSED

NORMAL STAND-BY VALVE POSITION CHARTRCW IN-LINE BALANCED PRESSURE PROPORTIONING MODULE WITHOUT/MORLEGEND

FIG. 3-3 OPERATING SCHEMATIC DRAWINGRCW ILBP MODULE WITHOUT MANUAL OVERRIDE

P


SENSING LINE

WATER LINE

RCW RATIO CONTROLLER

BALL VALVE (N.O.)

BALL VALVE (N.C.)


PRESSURE GAUGE

DIAPHRAGM VALVE

WATERSUPPLY



SEE NOTE NO. 3

FOAMSOLUTION J

V

SEE NOTE NO. 2

W

K

M

N

L

R P

P

D


SEE NOTE NO. 4

SEE NOTE NO. 1

MANUAL OVERRIDEHANDWHEEL

FOAMCONCENTRATE

SUPPLY

3-4 12/98

FIG. 3-4 OPERATING SCHEMATIC DRAWINGRCF ILBP MODULE WITH MANUAL OVERRIDE



NOTES:






4. A check valve must be installed in the foam concentrateline directly upstream of each proportioner module.

POSITIONVALVE DESCRIPTION DESIGNATION MANUAL AUTO.

WATER SENSING LINE SUPPLY VALVE J OPEN OPENWATER SENSING LINE SHUT-OFF VALVE L OPEN OPEN

TO DIAPHRAGM VALVEFOAM CONCENTRATE SENSING LINE K OPEN OPEN

SHUT-OFF VALVE TO DIAPHRAGM VALVEDUPLEX GAUGE WATER FLUSH-OUT M CLOSED CLOSEDDUPLEX GAUGE FOAM CONC. FLUSH-OUT N CLOSED CLOSEDDIAPHRAGM VALVE WATER FLUSH-OUT P CLOSED CLOSEDDIAPHRAGM VALVE CONC. FLUSH-OUT R CLOSED OPENFOAM CONCENTRATE SUPPLY VALVE V CLOSED OPENLOWER PETCOCK ON DIAPHRAGM VALVE W CLOSED CLOSED

NORMAL STAND-BY VALVE POSITION CHARTRCF IN-LINE BALANCED PRESSURE PROPORTIONING MODULE W/MORLEGEND

P

D


SENSING LINE

WATER LINE

RCF RATIO CONTROLLER

BALL VALVE (N.O.)

BALL VALVE (N.C.)


CHECK VALVE

DUPLEX GAUGE

PRESSURE GAUGE

DIAPHRAGM VALVE

12/98 3-5

3-2. ILBP MODULE OPERATION

NOTE: Refer to Operating Schematic Drawing Fig. 3-2, 3-3 or 3-4 for valve location, designationand normal stand-by position.

1. Verify that all valves on the proportioning systemare in their normal stand-by position.

2. Start water pump (if required).

3. Start foam concentrate pump.

4. If applicable - Set the desired percentage on themetering valve(s) at the appropriate ILBP Module(s).

NOTE: The metering valve is for regulating thefoam concentrate injection (percentage) into the sys-tem only , and does not have shut-off capability. Forpositive foam concentrate shut-off, a separate valvemust be used along with the metering valve.

5. Open water supply valve to the desired ILBPmodule(s).

6. Open foam concentrate supply Valve "V" to thedesired ILBP module(s).

7. Open any required zone valves downstream of thedesired ILBP module(s).

8. Regarding only ILBP Module(s) that have a dia-phragm valve with manual override capability:

� Verify that pointers on the duplex gauge arebalancing; if not, follow procedures in Sect.3-3.,ILBP Module Manual Override (Manual Regu-lation).

9. Observe the discharge pressure gauge at the foamconcentrate pump discharge to insure that the systemis operating at design pressure. If system is notoperating at design pressure, refer to the systemmanual regulation section of the foam concentratepump system operating and maintenance manual. Ifthe foam concentrate pump system is provided byNF, refer O. & M. Manual part number 1298-9936-2, Sect. 3-3.B., Pump and Pressure Sustaining ValveModule.

3-3. ILBP MODULE MANUAL OVERRRIDE (MANUAL REGULATION)

NOTE: The instructions below, apply only to ILBP Module Diaphragm Valves with manualoverride capability. These instructions do not apply to Diaphragm Valves which do nothave manual overrride capability.

NOTE: Used only when system will not balance automatically.

4. Turn manual override knob clockwise until it con-tacts a stop and will not travel further.

5. Slowly open foam concentrate supply Valve "V"until duplex gauge indicates system balance. Keepadjusting valve as required to maintain system bal-ance.

1. Close foam concentrate supply Valve "V".

2. Close water sensing shutoff Valve "L".

3. Verify adequate foam concentrate pressure on foamconcentrate supply pressure gauge.

OPERATING PROCEDURES

3-6 12/98

3-4. SHUTDOWN

1. Shut down the foam concentrate pump.

2. Close the foam concentrate supply Valve "V" at theILBP module(s) being operated.

WARNING:Only after the fire is out and the danger of reignitionhas passed, shall consideration be given to flushingand draining the system. Follow the appropriateFlushing Instructions which follow in this manualafter it is determined that it would be safe to flushand drain the system.

3. Flush the foam solution system.

NOTE: If the system has a water powered foamconcentrate supply Valve "V", the cylinder waterpressure supply valve in the water line supplyingpressure to the water powered ball valve operatingcylinder must be closed before any flushing opera-tion.

a. Make sure Valve "V" at the ILBP module(s)being operated is closed.

b. Flow water through the system and allow waterto run until clean clear water issues from the

output devices that were operated.

c. Close the water supply valve(s). Shut off watersupply.

4. Return all valves to their normal stand-by position.See Normal Stand-by Valve Position Chart onOperating Schematic Dwg. Fig. 3-2, 3-3 or 3-4.

5. Replenish supply of foam concentrate. If the tank isempty, it shall be inspected to determine if cleaningis warranted before refilling. If cleaning is judgednecessary, refer to manufacturer's instructions. Ifstorage tank is provided by NF - refer to NF StorageTank Installation, Cleaning & Filling InstructionManual P/N: 1298-9933-7 for recommendations.

CAUTION:Only foam concentrate of the type listed on thetank nameplate shall be used to replenish the tank.Mixing of different types or brands of foamconcentrate could cause failure of the system.

6. Replace all frangible components such as glass dia-phragms, rupture discs, etc., in foam lines or foammaking devices.



4-1. INSPECTION AND MAINTENANCE

See Table 4-1 for recommended inspection and maintenance procedures. These procedures andrecommended intervals are based on normal operating conditions and may have to be modified to meetthe existing conditions.

WARNING:The intervals in this chapter are a general recommendation; some environmental conditionsmay dictate such inspections and maintenance be performed at more frequent intervals.

For various proportioning system components (diaphragm valve, foam concentrate pump, valves,actuators etc.) refer to that particular component's operating and maintenance manual or instructionsheet for inspection and maintenance procedures.

4-2. TESTING AFTER SYSTEM MAINTENANCE

If during the course of normal system maintenance it becomes necessary to replace, repair or modifysystem components, component parts, operating devices or equipment, the system must be tested toinsure proper operation before being placed back into service.

4-3. ANNUAL TESTING

At least annually, all foam systems shall be thoroughly inspected and checked for proper operation.This shall include performance evaluation of the foam concentrate or premix solution quality or both.Deviation of results exceeding 10 percent from those recorded in acceptance testing shall be discussedimmediately with the manufacturer. Regular service contracts are recommended. The goal of thisinspection and testing shall be to ensure that the system is in full operating condition, and that it willremain in that condition until the next inspection. The inspection report, with recommendations, shallbe filed with the owner. Between the regular service contract inspections or tests, the system shallbe inspected by competent personnel following an approved schedule.

6/00 4-1

TABLE 4-1 - RECOMMENDED INSPECTION & MAINTENANCE SCHEDULE

WARNING:The following recommendations are based on normal operating conditions. Due to environmental orother conditions unique to your system, the frequency of some inspecton and maintenance proceduresmay need to be adjusted. Additional inspection and maintenance procedures may also be required.

NOTE: When performing inspection and maintence procedures which:a. require operation of the system or parts of the system,b. cause the system to be non-operational during the procedure,c. cause a trouble indication,

the system should be taken out of service and the proper authorities should be notified.

DESCRIPTION OTHERSEMI-

ANNUALMONTHLYWEEKLYAFTER

OPERATIONSTART

UP

AFTERALL

MAINT.PROCEDURES

ANNUAL

4-2 12/98

INSPECTION & MAINTENANCE

4-4. GENERAL

1. Check all valves to insure that they are in the ◆ ◆ ◆

normal stand-byposition. See OperatingSchematic Dwg. Fig. 3-2, 3-3 or 3-4.

2. Check that Manual Override Handwheel is in the ◆ ◆ ◆

normal stand-by position for automaticbalancing. Refer to Sect. 2-2.C., item 3.

3. Inspect system for physical damage and repair. ◆ ◆ ◆

4. Check the complete module, all valves, fittings ◆ ◆ ◆

& connections for leakage.5. Cycle manual valves where practical. ◆

6. Check flange bolts for tightness. ◆ ◆

7. Perform system testing after installation as ◆

described in the latest edition of NFPA 11.8. Check module for any external damage to the ◆ ◆

paint surfaces.

4-5. WATER POWERED BALL VALVES

1. Cycle the valve(s) either manually or thru control ◆ ◆

panel. If applicable,cycle the valve(s) using thesolenoid release.

WARNING:When water powered ball valves are cycled,Valve "V" must be closed.

2. Check supervision of circuit if solenoid release ◆ ◆

is provided.3. Make sure that the quick release pin is securely ◆ ◆

positioned thru the clevis.4. Make sure the drain/vent valve is fully closed. ◆ ◆





OPERATIONSTART

UP ANNUAL

12/98 4-3

4-6. ELECTRICALLY ACTUATED VALVES

1. Cycle valve(s) - Valve(s) may be cycled from ◆ ◆

control panel or by manual override at valve.

WARNING:When automated foam concentrate valvesare cycled, Valve "V" must be closed.

When automated valves are cycled, themain water supply valve must be closed.

2. Cycle valve(s) from the control panel to insure ◆ ◆

proper operation from control.3. Check supervision of control circuit. ◆

4. Check for leakage past valve seat. ◆ ◆ ◆

4-7. CONTROL SYSTEM

1. Check that proper indicators are present. See ◆ ◆

control panel data.2. Check supervision of all circuits. ◆ ◆

3. Check alarm operation. ◆ ◆

4. Check system operation. See control panel data. ◆ ◆

5. Check that all indicators illuminate. ◆ ◆

INSPECTION & MAINTENANCE - FLUSHING

4-4 12/98

4-8. FLUSHING - ILBP MODULE

NOTE: Flushing of the ILBP Module is to be done at Module installation into the system, prior torefilling a depleted tank, changing type of foam concentrate, or if the foam concentrate piping has tobe broken for repairs. Flushing is not a normal shutdown procedure and is not necessary after ILBPModule operation.

A. ILBP Module withDiaphragm Valve Manual Override Capability:

1. Open all ILBP Module sensing line drains andflush-out points (Valves M, N, P, R and W).

2. Turn manual override knob down (clockwise)until it contacts stop.

3. Close Foam Concentrate Supply Valve "V" onthe ILBP Module.

4. The ILBP Module will be flushed thru the foamsolution piping. Flushing must be done thru zonedischarge devices or thru foam solution pipingdrains (with zone foam solution discharge valvesclosed).

5. Establish a water flow thru the foam concentratesystem until the water flows clear at all flushpoints and drains.

NOTE: Flushing of the ILBP Module can beperformed at system shutdown when flowingwater thru the system. Refer to Sect. 3-4., Shut-down, for correct procedures.

6. After the water runs clear, shut off water supplythen drain the ILBP Module and zone piping.

NOTE: Remove diaphragm valve body drainplug.

7. Turn manual override knob up (counter-clock-wise) until it contacts stop for normal automaticbalancing operation.

8. Return all valves to their normal stand-by posi-tion (reinstall diaphragm valve body drain plug).Refer to Normal Stand-By Valve Position Charton Operating Schematic Dwg. Fig. 3-2 or 3-4.

B. ILBP Module withoutDiaphragm Valve Manual Override Capability:

1. Open all ILBP Module drains, flush-out points(Valves P and R).




NOTE: Flushing of the ILBP Module can beperformed at system shutdown when flowingwater thru the system. Refer to Sect. 3-4., Shut-down, for correct procedures.



6. Return all valves to their normal stand-by posi-tion (reinstall body drain plug). Refer to NormalStand-By Valve Position Chart on OperatingSchematic Dwg. Fig. 3-3.

5-2. No Automatic Foam Concentrate Zone Valve Check that wiring is installed to actuator.Proportioning Closed.(Electrically actuated)

Check that signal from control system isavailable at valve actuator. If voltage is notpresent, check control system.

If signal is present at actuator, use manualoverride to cycle valve. If valve cycles manu-ally, then valve actuator is probably bad.Remove actuator, check operation, if bad,repair or replace. If valve does not open,using manual override on actuator, then thevalve is jammed. Remove valve, determineand correct reason for jam. See actuator data.

Automatic valve actuator does not function See manufacturer’s troubleshooting data.properly.(Electric or hydraulic actuation)

Automatic Foam Concentrate Zone Valve Check that cylinder water pressure supplyClosed.(Water Powered Ball Valve) valve is fully open.

Check that quick release pull pin is notremoved from clevis. Reinsert pin thruclevis and valve handle.

12/98 5-1

PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION

TABLE 5-1 TROUBLESHOOTING


5-1. TROUBLESHOOTING

See Table 5-1 for Troubleshooting Problems, Possible Causes and Corrective Actions. These procedurescover problems that may be experienced during normal operations. Although these recommendations covermost problems that are experienced there are some situations that may occur which are not covered in theseinstructions. Please contact National Foam's Engineering Department for problems that cannot be resolvedthru the use of this manual.

NOTE: Refer to individual instruction manuals or sheets for additional information on system componentsand discharge devices.

No Proportioning Check Drain/Vent valve on strainer for clog-continued ging which shuts off water supply to cylinder.

Open Drain/Vent valve on strainer, vent andflush any debris blocking water supply.

Diaphragm Valve Foam Concentrate Flush- If provided, duplex gauge will show foamOut Valve "R" open or partially open. concentrate pressure lower than water

pressure. Check to insure all flush valvesare closed.

Drain valve(s) or connection(s) in foam If provided, duplex gauge will show foamconcentrate piping open or partially open. concentrate pressure lower than water

pressure. Check to insure all drain valvesare closed.

Control system not functioning properly. Check wiring for correct interconnection andproper connections. See control systemmanual.

Concentrate not compatible with the system. Use correct concentrate. Drain and cleantank before filling with new concentrate.

Ratio controller operating below minimum Increase water pressure. Contact NFinlet pressure. Engineering Dept. for recommendations.

Refer to Fig. 3-1, Minimum Inlet Pres. Req.

Foam concentrate storage tank empty. Fill tank. Refer to NF Storage Tank Instruc-tion Manual, P/N: 1298-9933-7.

5-3. Low Foam Concentrate Discharge Valve "D" and/ Fully open valve(s). If more than one ILBPPercent of or Foam Concentrate Supply Valve "V" Module is supplied by the foam concentrateProportioning partially closed. main, be sure Valve(s) "V" or zone valve(s)

of ILBP Module(s) not required, are closed.

Foam Concentrate Zone Valve(s) not fully Fully open valve. Determine cause andopen. correct.

Automatic Foam Concentrate Zone Valve Cylinder water pressure supply valveopens slowly.(Water powered ball valve) partially open. Fully open valve.

Tighten Drain/Vent valve on cylinder strainer.Snug with wrench to insure closure to ratedpressure.

Drain/Vent valve clogged, obstructing watersupply to cylinder. Open Drain/Vent valve onstrainer and vent. Flush any debris blockingwater supply.

5-2 12/98



TROUBLESHOOTING

Low Percent of Water pressure exceeds the design limits of Adjust pressure to proportioner to be withinProportioning the system. System requires more capacity the flow and pressure limits of the system.continued than pump is capable of producing.

Drain valves in foam concentrate piping Check to insure all drain valves are closed.open or partially open. If provided, duplexgauge will show foam concentrate pressurelower than water pressure.

Control system not functioning properly. See control system manual. Check wiring forcorrect interconnection.

Check wiring for proper connections.

Diaphragm valve not functioning properly. Check water sensing lines for blockage.If provided, duplex gauge will not show Make sure that there are no air pockets inbalance. water sensing lines.

Diaphragm Valve Water Flush-Out "P" open. Fully close flush-out valve.

Foam concentrate incompatible with system Use only foam concentrates the system wasdesign. designed for. Contact NF Engineering Dept.

if you desire to change foam concentrates.

Incorrect orifice diameter or adjustment. Contact NF Engineering Dept. for instructionson checking orifice and adjustment settings.

Water flow too high. Exceeds capability Too many discharge devices in operation orof foam concentrate pump. pressure too high. Check design and correct

to stay within limits of system.



5-4. High Diaphragm valve not functioning properly. Check foam concentrate sensing lines forPercent of If provided, duplex gauge will not show blockage. Make sure that there are no airProportioning balance. pockets in foam concentrate sensing lines.

Foam concentrate sensing line blocked. Remove line and clear blockage.

Diaphragm Valve Foam Concentrate Fully close flush-out valve.Flush-Out Valve "R" open.

Foam concentrate incompatible with system Use only foam concentrate the system wasdesign. designed for. Contact NF Engineering Dept.

if you desire to change foam concentrates.

12/98 5-3



TROUBLESHOOTING

High Percent of Incorrect orifice diameter or adjustment. Contact NF Engineering Dept. for instructionsProportioning on checking orifice and adjustment settings.continued

Water flow too low for ratio controller. Check system pressure. If low, find andcorrect problem.

Blockage in solution line or valves notcompletely open. Check solution line andcorrect.

Discharge device blocked. Check devicesand correct problem.

5-5. No Flow Water supply valve closed. Open valve. If automated, find reason andat Discharge correct.Device(s)

Fire pump did not start. Determine the cause and correct the problem.

Blockage in the water supply or foam Find the cause of the blockage and correct.solution discharge line.

Manual valves in solution piping shut or Check line for blockage or open manualblockage in line. valves.

5-6. Low Flow System pressure too low. Check inlet pressure and correct for properat Discharge operation.Device(S)

Fire pumps did not start. Determine reason and correct.

Partial blockage in water or foam solution line. Find blockage and remove.

Zone valve did not open completely. Valve jammed, determine reason and correct.

5-7. No Power failure. Check power source and correct problem.Operation


Foam concentrate storage tank empty. Fill tank.

Failure of water supply system. Check water supply and correct problem.

5-4 12/98



TROUBLESHOOTING

APPENDIX - FAPPENDIX - FAPPENDIX - FAPPENDIX - FAPPENDIX - FACTORACTORACTORACTORACTORY MUTUY MUTUY MUTUY MUTUY MUTUAL APPROAL APPROAL APPROAL APPROAL APPROVVVVVALSALSALSALSALS

A-1. Universal Gold - 3% Alcohol Resistent AFFF

A. In-Line Balanced Pressure Proportioning Systems:

1. ILBP Proportioner Models - for flow ranges seeFactory Mutual Approval Guide:

• 4" BWC3 - UG• 4" BWC3 - UG-MOR• 6" BWC3 - UG• 6" BWC3 - UG-MOR

B. Foam Discharge Devices:

1. Sprinklers - listed by the fuel group for which they are approved (for application rates seeFactory Mutual Approval Guide):

a. Alcohols

• Viking Model M17/32" Upright


• Grinnell Model F9501/2" Upright and Pendent

b. Ketones




c. Esters




d. Ethers

• Viking Model M17/32" Upright and Pendent



e. Hydrocarbons

• Viking Model M17/32" Large Orifice Upright



• Grinnell Model B-1Foam/Water3/8" Orifice Pendent

2. Nozzles

• Model JS-10• Model JS-10B• Model PC-31A

3. Foam Chambers

• MCS-9 Type A• MCS-17 Type A• MCS-33 Type A• MCS-55 Type A

A-2. Aer-O-Lite - 3% AFFF



• 4" BWC3 - A• 4" BWC3 - A-MOR• 6" BWC3 - A• 6" BWC3 - A-MOR

Factory Mutual Research and Engineering is a non-profit independent research and testing organization. FM testsand approves a wide variety of equipment, materials and services related to fire safety.

Each year FM publishes an Approval Guide listing all approved equipment, materials and services. This guide givesdetailed information on the approved products, as well as the operational parameters of the approval. In the case offoam proportioning systems, the parameters are the minimum and maximum foam solution flows and the foamconcentrates for which the proportioner is approved.

The following foam concentrates, along with the particular In-Line Balanced Pressure (ILBP) Proportioning Systemcomponents and discharge device(s) listed under the foam concentrate, constitute an FM Approved foam system. Anapproved system must consist of a foam concentrate, ILBP Proportioning system and discharge device(s).

12/98 A-1

APPENDIX - FACTORY MUTUAL APPROVALS CONTINUEDAPPENDIX - FACTORY MUTUAL APPROVALS CONTINUEDAPPENDIX - FACTORY MUTUAL APPROVALS CONTINUEDAPPENDIX - FACTORY MUTUAL APPROVALS CONTINUEDAPPENDIX - FACTORY MUTUAL APPROVALS CONTINUED


1. Water Powered Oscillating Monitors:

• Model HOM-2B-NA 100• Model HOM-2B-NA 200• Model HOM-2B-NA 300• Model HOM-2B-NA 400• Model HOM-2B-NA 500• Model HOM-4A-NA 1000

2. Sprinklers - for hydrocarbons only:




A-3. Aer-O-Water 3EM -3% AFFF



• 4" BWC3 - A• 4" BWC3 - A-MOR• 6" BWC3 - A• 6" BWC3 - A-MOR


1. Water Powered Oscillating Monitor:

• Model HOM-2B-NA 100• Model HOM-2B-NA 200• Model HOM-2B-NA 300• Model HOM-2B-NA 400• Model HOM-2B-NA 500• Model HOM-4A-NA 1000

2. Nozzles:

• Model JS-10• Model JS-10B

3. Sprinklers:

• Central Model A1/2" Upright and Pendent

• Grinnell F9501/2" Upright and Pendent

A-2 12/98

APPENDIX - FACTORY MUTUAL APPROVALS

NOTES

FOAM SOLUTION PROFESSIONALS180 Sheree Boulevard, Suite 3900 • P.O. Box 695 • Exton, PA 19341-0695 • USA

Telephone: 610-363-1400 • Fax: 610-524-9073www.Kidde-Fire.com

NaNaNaNaNational Ftional Ftional Ftional Ftional Foamoamoamoamoam�

SECTION 3:

SKID MOUNTED ILBPPROPORTIONING SYSTEM

� � � � � � � � � � �

�

SKZZ-66025

3.1

3.2

6/05 - i -

TABLE OF CONTENTS

Text Page

Table of Contents .......................................................................................................................... i - iii


NF Red Alert Fire Emergency Service .......................................................................................... 1-1Warning-Failure to Read Manual ................................................................................................... 1-2

1-1. Safety Information .......................................................................................................................... 1-11-2. General Description ........................................................................................................................ 1-21-3. General Notes ................................................................................................................................. 1-3

CHAPTER 2 - INSTALLATIONCHAPTER 2 - INSTALLATIONCHAPTER 2 - INSTALLATIONCHAPTER 2 - INSTALLATIONCHAPTER 2 - INSTALLATION

Cautions, Warning and Note for In-Line Balanced Pressure Proportioning System .................. 2-12-1. Recommended Materials of Construction ..................................................................................... 2-2

A. With Synthetic Based Polar Solvent/AFFF & Conventional AFFF Foam Concentrates ..... 2-2B. Protein Based Foam Concentrates ......................................................................................... 2-2• Figure 2-1 In-Line Balanced Pressure Proportioner Module

3" to 8" Wafer Style with Manual Override ...................................................................... 2-3• Figure 2-2 In-Line Balanced Pressure Proportioner Module

3" to 8" Wafer Style without Manual Override ................................................................. 2-4• Figure 2-3 In-Line Balanced Pressure Proportioner Module

2" to 8" Flanged Style ........................................................................................................ 2-52-2. Installation and Start-Up: In-Line Balanced Pressure Proportioning Skid Pak .......................... 2-6

A. Site Selection ............................................................................................................................ 2-6B. Off Loading ............................................................................................................................... 2-6C. Installation ................................................................................................................................. 2-6

2-3. Installation and Start-Up: ILBP Module ......................................................................................... 2-8A. Off Loading ............................................................................................................................... 2-8B. Installation ................................................................................................................................. 2-9C. Operating Requirements ........................................................................................................ 2-10

2-4. Installation and Start-Up: Pump and Pressure Sustaining ValveSupplied as Loose Components ............................................................................................ 2-10

A. Foam Concentrate Pump ....................................................................................................... 2-10B. Pressure Sustaining Valve ..................................................................................................... 2-11C. General System ...................................................................................................................... 2-11D. Foam Concentrate Jockey Pump .......................................................................................... 2-12

2-5. Testing After Installation .............................................................................................................. 2-12

TABLE OF CONTENTS

6/00 - ii -

CHAPTER 3 - OPERATING PROCEDURESCHAPTER 3 - OPERATING PROCEDURESCHAPTER 3 - OPERATING PROCEDURESCHAPTER 3 - OPERATING PROCEDURESCHAPTER 3 - OPERATING PROCEDURES

• Figure 3-1 Operating Schematic Drawing -ILBP Module With Manual Override and RCW Ratio Controller .................................... 3-1

• Figure 3-2 Operating Schematic Drawing -ILBP Module Without Manual Override and RCW Ratio Controller ............................... 3-2

• Figure 3-3 Operating Schematic Drawing -ILBP Module With Manual Override and RCF Ratio Controller ..................................... 3-3

3-1. Minimum Inlet Pressure Requirements ......................................................................................... 3-4• Figure 3-4 NF Ratio Controller Minimum Inlet Pressure vs. Solution Flow Chart ............... 3-4

3-2. Operation of System ....................................................................................................................... 3-5A. Manual System Operation ....................................................................................................... 3-5B. Automatic System Operation ................................................................................................... 3-5

3-3. Manual System Override (Manual Regulation) ............................................................................. 3-6A. ILBP Module ............................................................................................................................. 3-6B. Pump and Pressure Sustaining Valve Module ....................................................................... 3-6

3-4. Shutdown ......................................................................................................................................... 3-6A. Manual System Shutdown ....................................................................................................... 3-6B. Automatic System Shutdown ................................................................................................... 3-7


4-1. Inspection and Maintenance .......................................................................................................... 4-14-2. Testing After System Maintenance................................................................................................ 4-14-3. Annual Testing ................................................................................................................................ 4-1

• Table 4-1 Recommended Inspection & Maintenance Schedule ........................................... 4-24-4. Total System ................................................................................................................................... 4-24-5. Strainers .......................................................................................................................................... 4-34-6. Foam Concentrate Pump ............................................................................................................... 4-34-7. Electrically Actuated Valves .......................................................................................................... 4-44-8. Water Powered Ball Valves ........................................................................................................... 4-44-9. Pneumatically Actuated Valves ..................................................................................................... 4-44-10. Pressure Vacuum Vent ................................................................................................................... 4-54-11. Foam Concentrate Storage Tank................................................................................................... 4-54-12. Foam Concentrate .......................................................................................................................... 4-54-13. Control System................................................................................................................................ 4-54-14. Flushing - Pump and Pressure Sustaining Valve Module ............................................................ 4-64-15. Flushing - ILBP Module .................................................................................................................. 4-7

A. ILBP Module With Diaphragm Valve Manual Override Capability ....................................... 4-7B. ILBP Module Without Diaphragm Valve Manual Override Capability .................................. 4-7

Text Page

TABLE OF CONTENTS

6/05 - iii -


5-1. Troubleshooting .............................................................................................................................. 5-1• Table 5-1 Troubleshooting ....................................................................................................... 5-1

5-2. No Proportioning ............................................................................................................................. 5-15-3. Low Percent of Proportioning ......................................................................................................... 5-35-4. High Percent of Proportioning ........................................................................................................ 5-55-5. No Flow at Discharge Device(s) .................................................................................................... 5-65-6. Low Flow at Discharge Device(s) .................................................................................................. 5-65-7. No Operation ................................................................................................................................... 5-6

Text Page

ILBP SYSTEM_9936-2E.PMD6/05

TABLE OF CONTENTS


6/00 1-1

WARNING:This manual has been prepared as an aid and guide for personnel involved in the installation, operation andmaintenance of a NF In-Line Balanced Pressure Proportioning System. All instructions must be read andunderstood thoroughly before attempting any installation, operation or maintenance to this equipment. Failureto follow any instructions can result in personal injury and/or damage to this equipment.

1-1. SAFETY INFORMATION

The International Safety Alert Symbol - - is used with one of the following signal words to alert operatingpersonnel to the potential for death, personal injury or damage to equipment or property.

DANGER: indicates an extremely hazardous situation which, if not avoided, will resultin death or serious injury to the operator or major property damage.

WARNING: indicates a potentially hazardous situation which, if not avoided, can resultin serious injury, or death to the operator or major property damage.

CAUTION: indicates a potentially hazardous situation which, if not avoided, can result

in personal injury or property damage.

NOTE: indicates special instructions which are very important and must be followed.

It is the responsibility and duty of all personnel involved in the operating and maintenance of this equipment to fullyunderstand the DANGER, WARNING, CAUTION and NOTE procedures by which hazards are to be reduced oreliminated. Personnel must become thoroughly familiar with all aspects of safety and equipment prior to operationor maintenance of the equipment.

Operating and Maintenance Instructions and layouts shall be posted at control equipment with a second copy on file.All persons who may be expected to inspect, test, maintain or operate foam-generating apparatus shall be thoroughlytrained and kept thoroughly trained in the functions they are expected to perform.

National FoamRed Alert Fire Emergency Service

National Foam’s Red Alert Emergency Service is a system set up to respond to an emergency situationrequiring foam, equipment or service and is available 24 hours a day, 365 days a year.

CALL LIONVILLE, PA 610-363-1400

6/00 1-2

1-2. GENERAL DESCRIPTION

A National Foam ILBP Module consists of the following major components:

● Ratio Controller

● Diaphragm Valve - with foam concentrate and water sensing lines

Two Versions

1. With Manual Override and Duplex Gauge

2. Without Manual Override and Duplex Gauge

● Foam Concentrate Supply Pressure Gauge

● Foam Concentrate Supply Valve

● The appropriate lengths of pipe and fittings to join these components into a singlepackage called an In-Line Balanced Pressure Proportioning Module.

The National foam In-Line Balanced Pressure Pro-portioning System is designed to inject foam concentrateinto the water supply at the correct percentage at mul-tiple injection points. This type of foam proportioningsystem consists of one or more In-Line Balanced Pres-sure Proportioning Modules (ILBP), a foam concentratepump, a pressure sustaining valve and a foam concen-trate storage tank.

The ILBP system is ideal where: water pressure variesat the various injection points (ILBP Module), a widerange of flows are required or, the ability to selectivelyrun foam solution or water to individual discharge de-vices is required. The ILBP system will automaticallyand accurately provide proportioned foam solution overa wide range of flows and pressures. All dischargedevices can be switched from foam flow to water flow,water flow to foam flow, or shut down completelywithout affecting the correct operation of the otherdischarge devices.

increases, thereby increasing the pressure differentialacross the foam concentrate orifice. A proportionateincrease in foam concentrate injection will occur with anincrease in the water flow thru the ratio controller due tothe increased pressure differential. As both the water andfoam concentrate flow into the common reduced pressurearea, it is necessary only to maintain identical water andfoam concentrate pressures at the inlets of the ratiocontroller.

A diaphragm valve (pressure control valve) automati-cally adjusts the foam concentrate inlet pressure tocorrespond to the water inlet pressure. Pressure sensinglines lead from the foam concentrate line upstream of theratio controller and from the water inlet to the ratiocontroller to the diaphragm valve.

The ILBP Module is a complete, self-contained unit,assembled and tested at the factory. The unit is suppliedwith no finish and is suitable for either horizontal orvertical mounting.

The principle of operation of the ILBP Module isbased on the use of a modified venturi proportionercalled a ratio controller. With this type of proportioner,water passes thru a jet (venturi) at the inlet of the ratiocontroller, creating a reduced pressure area on the dis-charge side of the jet. This reduction in pressure createsa pressure differential across the foam concentrate ori-fice and causes injection of foam concentrate into thewater stream at this reduced pressure area.

As the water flow thru the ratio controller increases,the pressure reduction on the discharge side of the jet

INTRODUCTION

6/00 1-3

NF diaphragm valves, as previously mentioned, areavailable in two versions. One version does not havemanual override capability. This version does not allowmanual regulation of foam concentrate inlet presssure inthe event of a diaphragm valve failure. The other versiondoes have manual override capability, which allowsmanual regulation of the foam concentrate inlet pressure.Pressure is adjusted by the operator by manually openingthe diaphragm valve (thru use of the Manual OverrideKnob) and regulating the foam concentrate supply valve(Valve "V") while watching the duplex gauge for systembalance. The duplex gauge monitors balancing of foamconcentrate and water pressures on a single gauge. Foamconcentrate pressure is indicated by the red pointer andwater pressure is indicated by the black pointer. Whenthe red pointer is directly aligned with the black pointer,both pointing in the same direction, the system is balanc-ing. Diaphragm valves that do not have manual overridecapability also do not have a duplex gauge to monitorpressure balance.

An In-Line Balanced Pressure Proportioning Systemutilizes a positive displacement foam concentrate pump,which transfers foam concentrate from a storage tank toeach ILBP Module thru a foam concentrate main.

Some ILBP Systems also utilize a foam concentratejockey pump along with the main foam concentratepump. The jockey pump maintains pressure in the foamconcentrate lines to insure prompt foam solution supplywhen the foam system is actuated. Pressure is maintainedby the use of an adjustable differential pressure switch -low limit actuates the jockey pump and high limit shutsit down.

A pressure sustaining valve in the foam concentratepump return line maintains constant pressure in the foamconcentrate main at all design flow rates. When pressurein the foam concentrate main exceeds design, foamconcentrate is passed thru the pressure sustaining valveback to the foam concentrate storage tank until systemdesign pressure is reestablished in the main. Manualregulation of foam concentrate discharge pressure in themain in the event of pressure sustaining valve failure ispossible thru the use of the bypass line and the ManualConcentrate Regulating Valve. By adjusting the manualregulating valve and reading the foam concentrate dis-charge pressure gauge, the foam concentrate designdischarge pressure can be maintained.

An ILBP System requires a fire water supply systemfor the module(s).

1-3. GENERAL NOTES

1. All correspondence relating to this system shall refer tothe sales order number, file number and user name andlocation.

2. Before installation is begun, the final plans and designdata should be presented to the authorities havingjurisdiction.

3. National Foam recommends that those individualscharged with designing, installing, operating, testingand maintaining a foam fire protection system, or thereplacement of equipment and/or components of anexisting system, refer to the appropriate authority hav-ing jurisdiction for compliance with applicablestandard(s), code(s) and regulation(s) for that particu-lar type of system and its components.

4. National Foam concentrates must be maintained andstored within certain specified temperatures, contain-ers and conditions. Failure to follow National Foam’s

guidelines regarding these concentrates can compro-mise their effectiveness. Refer to NF Storage TankInstallation, Cleaning & Filling Instruction Manual P/N:1298-9933-7 for recommendations.

5. The foam system provided is based on specific designrequirements, that is, products(s) being protected andarea(s) of coverage. The design requirements may ormay not have been provided to National Foam. Anychanges to the area(s) of coverage or additions of otherproducts could exceed the design parameters of thesystem. Contact NF Engineering Dept. for questionsregarding changes to design.

6. Before operating the system, the foam concentratepump should be serviced in accordance with themanufacturer’s installation and maintenance sheets andthe recommended start-up procedures outlined in thismanual.

INTRODUCTION

6/00 1-4

7. In accordance with the requirements of NFPA 11,National Foam recommends that the system be in-spected and tested by qualified personnel. Testing shallmeet the approval of the authority having jurisdiction,and as a minimum, shall be as outlined in NFPA 11 toinsure that the system has been properly installed andwill function as intended.

8. All electrical installations and equipment must conformto the provisions of the National Electrical Code andalso all local codes.

WARNING:Judgement must be used in applying foams to hot oils,burning asphalts or burning liquids which are abovethe boiling point of water. Intermittent foam opera-tion should be used to prevent violent frothing and“slop-over” of the tank contents.

Foam is a conductor and shall not be used on ener-gized electrical equipment fires.

Foams are not suitable extinguishing agents for firesinvolving gases, liquefied gases with boiling pointsbelow ambient temperatures such as butane, butadi-ene, propane, etc., or cryogenic liquids.

INTRODUCTION

CHAPTER 2 - INSTCHAPTER 2 - INSTCHAPTER 2 - INSTCHAPTER 2 - INSTCHAPTER 2 - INSTALLALLALLALLALLAAAAATIONTIONTIONTIONTION

CAUTION:Install the In-Line Balanced Pressure Proportioning System in accordance with instructions in this manual.Variations may affect performance or cause system failure.

Customer modification or alteration of this equipment, or the use of replacement parts other than thosespecified by NF, may affect the performance of this equipment and may void the warranty.

WARNING:National Foam, Inc. recommends the system be inspected and tested in accordance with applicable NFPAstandards

NOTE: READ ALL OPERATING INSTRUCTIONS BEFORE USING EQUIPMENT.It is the responsibility and duty of all personnel involved in the installation, operation,inspection and maintenance, and refilling of this system to read and understand this entiremanual before using the equipment.

NOTE: COMPONENTS FORAN IN-LINE BALANCED PRESSURE PROPORTIONING SYSTEMProducts manufactured by NF are warranted free of defects in materials and workmanship fortwelve months from the date of purchase. NF will pass on to the system owner, as far as it isable to do, the benefit of the manufacturer's warranty for those parts and components notmanufactured by NF.

National Foam may supply components such as an ILBP Module, ratio controller, diaphragmvalve, pump(s), gauges, controls etc. for use in new or refurbished in-line balanced pressuresystems. NF makes no warranty, either expressed or implied and assumes no responsibility onthe engineering and design of such systems.

6/00 2-1

2-1. RECOMMENDED MATERIALS OF CONSTRUCTION

NOTE:1. The following recommenations are for materials which will be in contact with the foam concentrates.2. Type 304 and 316 stainless steel includes "L" grades.

CAUTION:Galvanized steel storage tanks or piping must never be used to contain any foam concentrates.

6/00 2-2

A. With Synthetic Based Polar Solvent/AFFF andConventional AFFF Foam Concentrates

1. Piping:

● Brass or Bronze (Note: All foam concen-trate lines on NF skid paks are Brass)

● Stainless Steel 304L or 316 grades● High Density Polyethylene● PVC● Fiberglass with isophthalic based polyester


2. Valves:

● Brass or Bronze. Cast brass valves fittedwith stainless steel (304L or 316 grades) orbrass trim are acceptable. Teflon seats andpacking are preferable for foam concentrateservice. EPT (EPDM), Buna-N or Viton arealso acceptable seal materials for use withNF foam concentrates.

● Stainless Steel 304L or 316 grades

3. Storage Tanks:

● Stainless Steel 304L or 316 grades● High Density Cross Linked Polyethylene● Fiberglass with isophthalic based polyester


B. With Protein-Based Foam Concentrates

1. Piping:

● Same materials as Synthetic Based PolarSolvent/AFFF and Conventional AFFF FoamConcentrate with the exception of stainlesssteel

● Black steel pipe and malleable iron fittings

2. Valves:

● Brass or Bronze. Cast brass valves fittedwith stainless steel (304L or 316 grades) orbrass trim are acceptable. Teflon seats andpacking are preferable for foam concentrateservice. EPT (EPDM), Buna-N or Viton arealso acceptable seal materials for use withNF foam concentrates.

3. Storage Tanks:

● Steel● Same materials as Synthetic Based Polar

Solvent/AFFF and Conventional AFFF FoamConcentrate with the exception of stainlesssteel.

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2-2. INSTALLATION AND START-UP:IN-LINE BALANCED PRESSURE PROPORTIONING SKID PAK

6/05 2-6

NOTE: Refer to your particular ILBP proportioningsystem skid pak outline drawing for as-built dimensionsand the location of various system components.

A. Site Selection:

1. The module shall be located on a flat and levelsurface large enough to support the entire skidframe.

2. The preferred base is concrete.

B. Off Loading:

1. Do not move the module using piping or installedequipment as a lifting device. Use a crane orother suitable lifting apparatus to move the mod-ule. Lift with a fork truck from the underside ofthe module frame.

C. Installation:

1. The skid shall be suitably anchored to eliminatevibration and movement. Level and shim asnecessary. NF recommends a clear distance of 2ft. (0.6096 m) on the pump end and 3 ft. (0.9144m) on the drive end be allowed by the installer tofacilitate service/removal of the pump and mo-tor.

2. All interconnecting piping to and from the mod-ule must be self-supported. Plastic foam concen-trate storage tanks must have flexible connectionfittings installed between the tank and propor-tioning equipment to eliminate stress imposed bythe piping and to eliminate vibration.

3. NF hydrostatically tests all skid units beforethey leave our factory. However, due to vibra-tion and handling experienced during transit, thetightness of joints and connections on the skidcannot be guaranteed. Therefore, NF recom-mends that the installer hydrostatically test theskid piping in accordance with procedures out-lined in the latest edition of the applicable sectionof NFPA, before introducing foam concentrateinto the system.

4. A relief valve has been installed in the foam concen-trate discharge line downstream of the Foam Con-centrate Discharge Valve "D" and discharge checkvalve, with the relief valve discharge piped to thefoam concentrate return line downstream of thepressure sustaining valve. This valve is intended torelieve excess foam concentrate discharge line pres-sure. The relief valve is preset at the factory andneeds no adjustment.


6. Flush the Pump and Pressure Sustaining Modulebefore introducing foam concentrate into the system.Refer to Chapter 4, Sect. 4-14 for flushing proce-dures.

7. Flush the water lines and all foam solution lines. Thefoam solution lines shall be flushed at or abovedesign flow rates. The flushing shall be done prior toinstalling any foam makers, sprinklers or nozzles.

NOTE: In order to remove foreign materials thatmay have entered during installation, water supplymains, both underground and aboveground, shall beflushed thoroughly at the maximum practicable rateof flow before connection is made to system piping.The minimum rate of flow for flushing shall not beless than the water demand rate of the system, asdetermined by the system design. The flow shall becontinued for a sufficient time to ensure thoroughcleaning. Disposal of flushing water must be suit-ably arranged. All foam system piping shall beflushed after installation, using its normal watersupply with foam-forming materials shut off, unlessthe hazard cannot be subjected to water flow. Whereflushing cannot be accomplished, pipe interiors shallbe carefully visually examined for cleanliness duringinstallation.

8. After flushing, remove all strainer screens and clean.Reinstall screens after cleaning.

NOTE: Proportioning system strainer mesh shallhave 1/4" openings for Universal foam concentratesand 1/8" openings for all other foam concentrates.

INSTALLATION

9. Check that the system is properly installed accordingto design with all necessary valves, correct pipesizes, discharge devices and discharge device loca-tions and is installed in compliance with local codes.

10. Service foam concentrate pump before installationinto the system. Service pump, reducer and motorin accordance with the manufacturer’s recommenda-tions. Be sure that the reducer is filled with oil andthe pump and motor are lubricated. The pump bodyis coated with a petroleum based rust preventativefor protection during shipment. The pump drain plugmust be removed, any excess liquid drained and theplug reinstalled. The pump must then be flushedwith mineral spirits for approximately five (5) min-utes and then drained. Finally, it must be flushedwith water. Always rotate the pump by hand to besure it turns freely before start up. Never start up thepump when it is dry. (This applies to jockey pumpalso).

WARNING:For Petroleum Based Rust Preventative -• Refer to Material Safety Data Sheet• Avoid contact with strong oxidizing agents• May cause skin and eye irritation• Inhalation of mist may cause irritation of nasal

and respiratory passages• Swallowing may cause mouth and

gastrointestinal irritation• Dispose of rust preventative according to

MSDS guidelines

11. Check the alignment of the pump, reducer and motorshafts to insure they are within the couplingmanufacturer’s recommended tolerances. (This ap-plies to jockey pump also).

12. Check the foam concentrate pump motor and con-troller to insure it is wired properly. (This applies tojockey pump also).

13. Check the motor rotation to insure it is running in thecorrect direction to allow proper foam concentratepump rotation. "Bump" run the motor(and pump) byalternately actuating the "ON" and "OFF" buttonsuntil the direction of rotation is determined. Correctif necessary. (This applies to jockey pump also).

6/05 2-7

14. If the pump is driven by a gasoline or diesel engine,refer to the manufacturer’s installation and start-upinstructions prior to using the pump.

15. If the foam concentrate pump is driven by a gasolineor diesel engine, anti-vibration connections must beinstalled in the foam concentrate line on both the inletand outlet sides of the pump. Also, anti-vibrationfittings must be installed on the foam concentratepump base if the base is skid mounted.

16. Cycle all valves to insure freedom of movement andthat they open and close properly.

17. Place all valves in their stand-by position. Refer toNormal Stand-By Valve Position Chart on Operat-ing Schematic Dwg. Fig. 3-1, 3-2 or 3-3.

18. It may be desirable to install shutoff valves betweenthe foam concentrate storage tank and the flexibleconnections in addition to Valves A & B, which maybe on the module. These valves will be useful if thefoam concentrate piping has to be broken for repairsbetween the tank and module. The shutoff valves canbe closed, thereby eliminating the need to drain thetank before making repairs.

19. Install, clean and fill the foam concentrate storagetank in accordance with the manufacturer's recom-mended procedures. NOTE: Regarding NF StorageTanks - Refer to NF Storage Tank Installation,Cleaning & Filling Instruction Manual, P/N: 1298-9933-7 for recommendations.

20. Fill the foam concentrate piping with foam concen-trate.

21. If applicable, check the foam concentrate pumprelief valve for proper installation. See manufacturer’sinstructions. (This applies to jockey pump also).

22. Run a foam concentrate pump relief valve pressuresetting check as follows (This applies to jockeypump also):

a. Starting with all valves in their normal stand-byposition, close Valves "D" and "E" and openValve "C".

continued on next page

INSTALLATION

b. Start foam concentrate pump - concentrate willrecirculate back to foam concentrate storagetank.

c. Slowly close Valve "C" and observe the pointeron the pressure gauge until it shows a suddendecrease. This will indicate opening of reliefvalve. Adjust setting if required. Refer to theFoam Concentrate Pump Outline AssemblyDrawing for relief valve pressure setting.

d. Return all valves to their normal stand-by posi-tion.

23. Run a pressure sustaining valve pressure settingcheck as follows:

6/05 2-8

a. Starting with all valves in their normal stand-byposition, close Valve "D".

b. Start foam concentrate pump - concentrate willrecirculate back to foam concentrate storagetank.

c. Observe the pointer on the pressure gauge forproper system operating pressure. Adjust set-ting, if required, according to the manufacturer'sinstructions or recommendations.

24. Place all valves in their normal stand-by position.See Normal Stand-By Valve Position Chart on Op-erating Schematic Dwg. Fig. 3-1, 3-2 or 3-3. Pro-ceed with full system test as described in Section 2-5, Testing After Installation, in this manual.

2-3. INSTALLATION AND START-UP: ILBP MODULE

CAUTION:For proper piping sizes contact NF Engineering Department.

WARNING:In accordance with NFPA requirements for supervision of an Automated Foam Fire Protection System -manually operated valve(s) in the foam solution line from the proportioner to the discharge device(s) must bechained or locked in the open position or equipped with tamper alarm switch(es) which are monitored by asupervisory panel alarm.

The major concern is the possibility that any manually operated valve(s) in the foam solution line to thehazard(s) could inadvertently be left in the closed position during a fire condition, which would prevent the foamsolution from reaching the hazard(s) in the event of an automatic trip sequence.

A. Off Loading:

WARNING:Be sure the module is properly secured and balanced during any lifting or moving procedure. If the module isnot properly secured in the lifting device, damage to the module or injury to personnel could result.

continued on next page

1. To avoid damage, the module should be left inits shipping carton or crate until time of installa-tion into foam system.

2. Use a nylon lifting strap, secured around the ratiocontroller body, to move or mount the module.

INSTALLATION

1. Mount the module on the water piping main andconnect the foam concentrate supply piping tothe module. ILBP modules can be mounted ineither a horizontal or vertical orientation.

2. All interconnecting piping to and from the ILBPModule (that is - foam concentrate supply pip-ing, watermain piping and foam solution piping)must be self-supporting so as to eliminate anyload on the module itself.

3. To facilitate future service/removal of the ratiocontroller, the installer should provide a spoolpiece upstream of the ratio controller. See Chartbelow for minimum spool piece lengths.

Ratio Controller Minimum Spool Length

3" ------------------------ 8" (203)4" ----------------------- 10"(254)6" ----------------------- 12"(305)8" ----------------------- 14"(356)

4. Each proportioner module requires 5 diametersof straight unobstructed upstream and down-stream watermain piping to obtain proper flowthrough the ratio controller.

CAUTION:The ILBP Module requires a stable, uniformwater flow at the inlet to the ratio controller toinsure proper proportion ing during all ratedflow conditions.

5. Regarding only RCF style ILBP modules:

A check valve must be placed in the foam con-centrate line directly upstream of eachproportioner module.

B. Installation:

NOTE: Refer to Operating Schematic Drawing Fig. 3-1, 3-2 or 3-3.

6/05 2-9


If the module is used with an Automatic Zone FoamConcentrate Supply Valve, the Manual Foam Con-centrate Supply Valve "V" is still required for manualoverride pressure regulation. Refer to OperatingSchematic Dwg. Fig. 3-1 or Fig. 3-3 for valvelocations and normal stand-by position.

7. Cycle all valves to insure freedom of movement andthat they open and close properly.

8. For NF recommended components - valves, strain-ers, gauges and connections, and their location in thesystem, refer to the Operating Schematic DrawingFig. 3-1, 3-2 or 3-3.

9. Check that the system is properly installed accordingto design with all necessary valves, correct pipesizes, discharge devices and discharge device loca-tions, and is installed in compliance with local codes.

10. Hydrostatically test piping in accordance with pro-cedures outlined in the latest edition of the applicablesection of NFPA.


12. Follow the procedures outlined in Section 2-2., C.Installation, Item Nos. 7 and 8. Refer to SystemFlushing procedures outlined in Sect. 4-15.

13. Place all valves to their normal stand-by position.See Normal Stand-By Valve Position Chart on Op-erating Schematic Dwg. Fig. 3-1, 3-2 or 3-3. Pro-ceed with full system test as described in Section 2-5, Testing After Installation in this manual.

INSTALLATION

6/05 2-10

C. Operating Requirements:

1. Foam concentrate pressure to the ILBP Moduleinlet must exceed water pressure inlet by at least30 psi (2.0 Bar) unless otherwise approved byNF Engineering Department.

2. ILBP Module maximum working pressure - 200psi(13.7 Bar).

3. Regarding only ILBP Module(s) that have adiaphragm valve with manual override capabil-ity:

• The Manual Override Handwheel on the dia-phragm valve must be in the normal stand-by

position for automatic balancing. To place in thenormal stand-by position: rotate the manualoverride handle in the counter-clockwise direc-tion until fully open.

• Check the appropriate sensing line valve(s)(Valves "J", "L" or "K") to insure that it is in theproper stand-by position (Normally Open).

4. Insure that all valves are in their normal stand-byposition before operating the proportioning system.See Normal Stand-By Valve Position Chart on Op-erating Schematic Dwg. Fig. 3-1, 3-2 or 3-3.

2-4. INSTALLATION AND START-UP: PUMP AND PRESSURE SUSTAINING VALVESUPPLIED AS LOOSE COMPONENTS

NOTE: When equipment is supplied as loose components, refer to the individual component's manual forinstallation instructions. For questions regarding these components, contact NF Engineering Dept.For NF recommended components - valves, strainers, gauges, pumps and connections and theirlocation in the system - refer to Operating Schematic Drawing Fig. 3-1, 3-2 or 3-3.

A. Foam Concentrate Pump:

1. Pumps shall have adequate capacities to meet themaximum system design requirements. To en-sure positive injection, the discharge pressurerating at design discharge capacity shall be suf-ficiently in excess of the maximum water pres-sure likely under any condition at the point ofinjection of the concentrate.

2. The foam concentrate pump shall be mounted asnear to and level with, or lower than, the bottomof the foam concentrate tank.

3. The module shall be located on a flat and levelsurface large enough to support the entire skidframe. The preferred base is concrete.

4. The foam concentrate pump shall be suitably an-chored to eliminate vibration and movement. Leveland shim as necessary.

5. Follow the procedures outlined in Section 2-2., C.Installation, Item No. 10 thru 15.

6. If applicable, check the foam concentrate pumprelief valve for proper installation. See manufacturer'sinstructions.

7. Run a foam concentrate pump relief valve pressuresetting check as described in Section 2-2., C. Instal-lation, Item No. 22. NOTE: NF foam concentratepump relief valves are factory set at 200 psi (stan-dard). For a relief valve pressure setting other thanstandard, refer to the pump outline drawing or con-tact NF Engineering.

INSTALLATION

6/05 2-11

4. Install a Pressure Sustaining Valve bypass line asillustrated in Fig. 3-1, 3-2 or 3-3. In the event of aPressure Sustaining Valve failure, the bypass linemust have a manual foam concentrate regulatingvalve to allow manual regulation of the foam concen-trate discharge pressure to the foam concentratemain.

5. Run a pressure sustaining valve pressure settingcheck as described in Section 2-2., C. Installation,Item No. 23.

B. Pressure Sustaining Valve:

1. Refer to manufacturer's instructions before at-tempting to install the Pressure Sustaining Valveinto your system.

2. The Pressure Sustaining Valve can be mountedin either a horizontal or vertical orientation.

3. The Pressure Sustaining Valve shall be mountedas near as possible to the foam concentrate pumpand storage tank.

C. General System:

1. A check valve (customer supplied) must beinstalled in the foam concentrate piping maindownstream of the Pump and Pressure Sustain-ing Module foam concentrate discharge connec-tion. Refer to Operating Schematic Dwg. Fig.3-1 or 3-2 for location.

2. A 3/4" relief valve is required in the foamconcentrate piping main. The relief valve shall beinstalled downstream of the check valve referred toin item 1. The discharge from the relief valve shallbe piped to the foam concentrate return line down-stream of the pressure sustaining valve. Refer toOperating Schematic Dwg. Fig. 3-1, 3-2 or 3-3 forlocation in the system.

3. All interconnecting piping to and from the com-ponents must be self-supported. Plastic foamconcentrate storage tanks must have flexibleconnection fittings installed between the tankand proportioning equipment to eliminate stressimposed by the piping and to eliminate vibration.

4. Hydrostatically test piping in accordance withprocedures outlined in the latest edition of theapplicable section of NFPA.

5. Follow the procedures outlined in Section 2-2.,C. Installation, Item Nos. 5 thru 9. Refer toSystem Flushing procedures outlined in Sect. 4-14.

INSTALLATION

6. Refer to Sect. 2-2.C., item 18 - When the system issupplied as loose components, it may be desirable toposition Valves A and B at the foam concentratestorage tank, between the tank and the flexible con-nections. This may eliminate the need for Valves Aand B plus shutoff valves in the suction and returnpiping. However, the need for Valves A and B inplace of tank shutoff valves will have to be evaluatedon an individual system design basis. For questionsor problems, contact NF Engineering Dept.

7. Install, clean and fill the foam concentrate storagetank in accordance with the manufacturer's recom-mended procedures. NOTE: Regarding NF StorageTanks - Refer to NF Storage Tank Installation,Cleaning & Filling Instruction Manual, P/N: 1298-9933-7 for recommendations.

8. Fill the foam concentrate piping with foam concen-trate.

9. Cycle all manual and automatic valves to insurefreedom of movement and that they open and closeproperly.

10. Place all valves in their normal stand-by position.See Normal Stand-By Valve Position Chart on Op-erating Schematic Drawing Fig. 3-1, 3-2 or 3-3.Proceed with full system test as described in Sect. 2-5, Testing After Installation, in this manual.

D. Foam Concentrate Jockey Pump:

1. Refer to Operating Schematic Drawing Fig. 3-1,3-2 or 3-3 for location of jockey pump andpressure switches in the system.

2. Refer to Sect. 2-4.A. - Foam Concentrate Pump,and follow installation instructions items 2 thru5.

6/05 2-12

3. Install the adjustable differential pressure switch.Set the desired high and low pressure limits on thepressure switch. Refer to manufacturer's instruc-tions.

CAUTION:The pressure switch must have the high limitjockey pump shutoff point set below the systemdesign discharge pressure.

2-5. TESTING AFTER INSTALLATION

1. The completed system shall be tested by quali-fied personnel to meet the approval of the author-ity having jurisdiction. These tests shall be ad-equate to determine that the system has beenproperly installed, and will function as intended.

2. Foam systems shall be examined visually todetermine that they have been properly installed.They shall be inspected for such items as confor-mity with installation plans; continuity of pip-ing; removal of temporary blinds; accessibilityof valves; controls, and gages; and proper instal-lation of vapor seals, where applicable. Devicesshall be checked for proper identification andoperating instructions.

3. Before acceptance, all operating devices andequipment shall be tested for proper function.

4. A full scale test shall be run after the system is

INSTALLATION

installed and prior to acceptance of the system.Thetest run shall include running water to each dischargedevice to insure that proper pressures and flow ratescan be achieved and to insure there is no blockage.Then foam solution shall be run to the devicesprotecting the greatest single hazard and to thedevice with the lowest flow rate. The foam test shalllast a minimum of 1 minute (actual injection time) toinsure the proportioning system has stabilized beforetaking samples. At this time, the quality of the foamshall be observed and the foam solution concentra-tion shall be checked by refractive index or conduc-tivity method. The foam test shall be run for eachratio controller when multiple proportioners arepresent in the system. See NFPA 11 for detailedprocedures.

5. After completion of acceptance tests, the systemshall be flushed and restored to operational condi-tion.

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SUR

EG

AUG

E

SEE

NO

TE N

O. 4

PRIM

ARY

FOAM

CO

NC

ENTR

ATE

PUM

P

SEE

NO

TE N

O. 4

AUXI

LIAR

YFO

AM C

ON

CEN

TRAT

EPU

MP

(OPT

ION

AL)

SEE

NO

TE N

O. 5

SEE

NO

TE N

O. 6 D

BODY

DR

AIN

PLU

G

P

P

D

SEE

NO

TE N

O. 1

6/00 3-1

FIG

3-12

3.P6

5FI

G3-

1.D

SF

FIG

. 3-1

OPE

RA

TIN

G S

CH

EM

AT

IC D

RA

WIN

GR

CW

IL

BP

MO

DU

LE

WIT

H M

AN

UA

L O

VE

RR

IDE

LEG

EN

D

NOTE

S:

The

sche

mat

ics

show

n ar

e ty

pica

l ins

talla

tions

and

may

not

refle

ct a

ctua

l equ

ipm

ent f

urni

shed

.

1.Va

lve "V

" -No

rmal

ly CL

OSED

for s

yste

ms u

sing

noau

tom

atic

foam

conc

entra

te va

lve(s

).-

Norm

ally

OPEN

for s

yste

ms u

sing

anau

tom

atic

foam

conc

entra

te va

lve(s

).

2.Po

sitio

n of

Zon

e Fo

am C

once

ntra

te V

alve

.Au

tom

atic

valve

optio

nal.

3.Po

sitio

n of

Zon

e W

ater

Sup

ply V

alve

.Au

tom

atic

valve

optio

nal.

Man

ual v

alve

requ

ired

if aut

omat

ic va

lve n

ot su

pplie

d.

4.Su

pplie

d wi

th A

uxilia

ry F

oam

Con

cent

rate

Pum

p only

.

5.St

anda

rd lo

catio

n of

"D" V

alve

(no

auxil

iary

foam

conc

.pu

mp)

.

6.Lo

catio

n of

"D" V

alve

with

aux

iliary

foam

conc

entra

te p

ump.

CO

MPO

NEN

TS P

RO

VID

ED B

Y N

F

FOAM

CO

NC

ENTR

ATE

LIN

E

SEN

SIN

G L

INE

WAT

ER L

INE

RC

W R

ATIO

CO

NTR

OLL

ER

BALL

VAL

VE (N

.O.)

BALL

VAL

VE (N

.C.)

AUTO

MAT

ED V

ALVE

W/M

ANU

ALO

VER

RID

E

CH

ECK

VALV

E

PRES

SUR

E SU

STAI

NIN

G V

ALVE

REL

IEF

VALV

E

STR

AIN

ER

DU

PLEX

GAU

GE

PRES

SUR

E G

AUG

E

CO

MPO

UN

D G

AUG

E

DIA

PHR

AGM

VAL

VE

FLU

SH-IN

CO

NN

ECTI

ON

FLU

SH-O

UT

CO

NN

ECTI

ON

PRES

SUR

E SW

ITC

H

PD

C

POSI

TION

VALV

E D

ESCR

IPTI

ONDE

SIGN

ATIO

NM

ANUA

LAU

TO.

PU

MP

AN

D P

RE

SS

UR

E S

US

TAIN

ING

VA

LVE

MO

DU

LEFO

AM C

ONCE

NTRA

TE T

ANK

RET

URN

AOP

ENOP

ENFO

AM C

ONCE

NTRA

TE T

ANK

SUC

TION

BOP

ENOP

ENMA

NUAL

FOA

M C

ONC.

REG

ULAT

ING

VAL

VEC

CLOS

EDCL

OSED

FOAM

CON

CENT

RATE

DIS

CHAR

GE V

ALVE

DOP

ENOP

ENFO

AM C

ONCE

NTRA

TE P

RESS

URE

EOP

ENOP

ENSU

STAI

NING

VAL

VE S

HUT-

OFF

VAL

VEFL

USH-

IN C

ONNE

CTIO

NS

CLOS

EDCL

OSED

FLUS

H-OU

T C

ONNE

CTIO

NT

CLOS

EDCL

OSED

STRA

INER

FLU

SH-O

UTU

CLOS

EDCL

OSED

DRAI

N V

ALVE

SCL

OSED

CLOS

EDFO

AM C

ONCE

NTRA

TE T

ANK

SUC

TION

B1OP

ENOP

EN(P

RIMA

RY P

UMP)

FOAM

CON

CENT

RATE

TAN

K S

UCTI

ONB2

CLOS

EDOP

EN(A

UXILI

ARY

PUM

P)IN

-LIN

E B

ALA

NC

ED

PR

ES

SU

RE

PR

OP

OR

TIO

NIN

G M

OD

ULE

WAT

ER S

ENSI

NG L

INE

SHU

T-OF

F V

ALVE

LOP

ENOP

ENTO

DIA

PHRA

GM V

ALVE

DUPL

EX G

AUGE

WAT

ER F

LUSH

-OUT

MCL

OSED

CLOS

EDDU

PLEX

GAU

GE F

OAM

CON

C. F

LUSH

-OUT

NCL

OSED

CLOS

EDDI

APHR

AGM

VAL

VE W

ATER

FLU

SH-O

UTP

CLOS

EDCL

OSED

DIAP

HRAG

M V

ALVE

CON

C. F

LUSH

-OUT

RCL

OSED

OPEN

FOAM

CON

CENT

RATE

SUP

PLY

VAL

VEV

CLOS

EDOP

ENBO

DY D

RAIN

PLU

GCL

OSED

CLOS

ED

NO

RM

AL

STA

ND

-BY

VA

LVE

PO

SITI

ON

CH

AR

T

Dry

Wet

Fiel

d P

ipin

gSy

stem

Syst

em

Sys

tem

W

ater

M

ain

Val

ve(s

)C

lose

dO

pen

Zone

Wat

er V

alve

(s)

Clo

sed

Ope

n

Zone

Foa

m C

onc.

Val

ve(s

)C

lose

dC

lose

d

S

U

FIEL

DC

ON

NEC

TIO

NS

(Typ

ical

)CO

MPO

UND

GAU

GE

STAR

TER

(MO

UNTE

DO

NUN

I-STR

UT)

WAT

ERSU

PPLY

ANTI

-VIB

RAT

ION

FLEX

IBLE

CO

UPL

ING

B2

B1

D

E

C

T

A

B

PRES

SUR

ESU

STAI

NIN

GVA

LVE

WAT

ER P

UM

P(IF

REQ

UIR

ED)

JOC

KEY

PUM

P(O

PTIO

NAL

)

MAI

N W

ATER

SUPP

LY V

ALVE

SEE

NO

TE N

O. 3

FOAM

SOLU

TIO

N

V

SEE

NO

TE N

O. 2

RP

FOAM

CO

NC

ENTR

ATE

STO

RAG

E TA

NK

PRES

SUR

E VA

CU

UM

VEN

T

INSP

ECTI

ON

HAT

CH

FILL

CO

NN

ECTI

ON

DR

AIN

CO

NN

ECTI

ON

FLEX

IBLE

EXPA

NSI

ON

JO

INT

ILB

P M

OD

ULE

SCH

EMAT

IC- T

YPIC

AL

-

PRES

SUR

EG

AUG

E

SEE

NO

TE N

O. 4

PRIM

ARY

FOAM

CO

NC

ENTR

ATE

PUM

P

SEE

NO

TE N

O. 4

AUXI

LIAR

YFO

AM C

ON

CEN

TRAT

EPU

MP

(OPT

ION

AL)

SEE

NO

TE N

O. 5

SEE

NO

TE N

O. 6 D

BODY

DR

AIN

PLU

G

P

C

P

P

SEE

NO

TE N

O. 1

6/00 3-2

FIG

. 3-2

OPE

RA

TIN

G S

CH

EM

AT

IC D

RA

WIN

GR

CW

IL

BP

MO

DU

LE

WIT

HO

UT

MA

NU

AL

OV

ER

RID

E

LEG

EN

D

NOTE

S:

The

sche

mat

ics

show

n ar

e ty

pica

l ins

talla

tions

and

may

not

refle

ct a

ctua

l equ

ipm

ent f

urni

shed

.

1.Va

lve "V

" -No

rmal

ly CL

OSED

for s

yste

ms u

sing

noau

tom

atic

foam

conc

entra

te va

lve(s

).-

Norm

ally

OPEN

for s

yste

ms u

sing

anau

tom

atic

foam

conc

entra

te va

lve(s

).

2.Po

sitio

n of

Zon

e Fo

am C

once

ntra

te V

alve

.Au

tom

atic

valve

optio

nal.

3.Po

sitio

n of

Zon

e W

ater

Sup

ply V

alve

.Au

tom

atic

valve

optio

nal.

Man

ual v

alve

requ

ired

if aut

omat

ic va

lve n

ot su

pplie

d.

4.Su

pplie

d wi

th A

uxilia

ry F

oam

Con

cent

rate

Pum

p only

.

5.St

anda

rd lo

catio

n of

"D" V

alve

(no

auxil

iary

foam

conc

.pu

mp)

.

6.Lo

catio

n of

"D" V

alve

with

aux

iliary

foam

conc

entra

te p

ump.

FIG

3-12

3.P6

5FI

G3-

2.D

SF

CO

MPO

NEN

TS P

RO

VID

ED B

Y N

F

FOAM

CO

NC

ENTR

ATE

LIN

E

SEN

SIN

G L

INE

WAT

ER L

INE

RC

W R

ATIO

CO

NTR

OLL

ER

BALL

VAL

VE (N

.O.)

BALL

VAL

VE (N

.C.)

AUTO

MAT

ED V

ALVE

W/M

ANU

ALO

VER

RID

E

CH

ECK

VALV

E

PRES

SUR

E SU

STAI

NIN

G V

ALVE

REL

IEF

VALV

E

STR

AIN

ER

DU

PLEX

GAU

GE

PRES

SUR

E G

AUG

E

CO

MPO

UN

D G

AUG

E

DIA

PHR

AGM

VAL

VE

FLU

SH-IN

CO

NN

ECTI

ON

FLU

SH-O

UT

CO

NN

ECTI

ON

PRES

SUR

E SW

ITC

H

PD

C

POSI

TION

VALV

E D

ESCR

IPTI

ONDE

SIGN

ATIO

NM

ANUA

LAU

TO.

PU

MP

AN

D P

RE

SS

UR

E S

US

TAIN

ING

VA

LVE

MO

DU

LEFO

AM C

ONCE

NTRA

TE T

ANK

RET

URN

AOP

ENOP

ENFO

AM C

ONCE

NTRA

TE T

ANK

SUC

TION

BOP

ENOP

ENMA

NUAL

FOA

M C

ONC.

REG

ULAT

ING

VAL

VEC

CLOS

EDCL

OSED

FOAM

CON

CENT

RATE

DIS

CHAR

GE V

ALVE

DOP

ENOP

ENFO

AM C

ONCE

NTRA

TE P

RESS

URE

EOP

ENOP

ENSU

STAI

NING

VAL

VE S

HUT-

OFF

VAL

VEFL

USH-

IN C

ONNE

CTIO

NS

CLOS

EDCL

OSED

FLUS

H-OU

T C

ONNE

CTIO

NT

CLOS

EDCL

OSED

STRA

INER

FLU

SH-O

UTU

CLOS

EDCL

OSED

DRAI

N V

ALVE

SCL

OSED

CLOS

EDFO

AM C

ONCE

NTRA

TE T

ANK

SUC

TION

B1OP

ENOP

EN(P

RIMA

RY P

UMP)

FOAM

CON

CENT

RATE

TAN

K S

UCTI

ONB2

CLOS

EDOP

EN(A

UXILI

ARY

PUM

P)IN

-LIN

E B

ALA

NC

ED

PR

ES

SU

RE

PR

OP

OR

TIO

NIN

G M

OD

ULE

DIAP

HRAG

M V

ALVE

WAT

ER F

LUSH

-OUT

PCL

OSED

CLOS

EDDI

APHR

AGM

VAL

VE C

ONC.

FLU

SH-O

UTR

CLOS

EDCL

OSED

FOAM

CON

CENT

RATE

SUP

PLY

VAL

VEV

CLOS

EDOP

ENBO

DY D

RAIN

PLU

GCL

OSED

CLOS

ED

NO

RM

AL

STA

ND

-BY

VA

LVE

PO

SITI

ON

CH

AR

T

Dry

Wet

Fiel

d P

ipin

gSy

stem

Syst

em

Sys

tem

W

ater

M

ain

Val

ve(s

)C

lose

dO

pen

Zone

Wat

er V

alve

(s)

Clo

sed

Ope

n

Zone

Foa

m C

onc.

Val

ve(s

)C

lose

dC

lose

d

S

U

FIEL

DC

ON

NEC

TIO

NS

(Typ

ical

)CO

MPO

UND

GAU

GE

STAR

TER

(MO

UNTE

DO

NUN

I-STR

UT)

WAT

ERSU

PPLY

ANTI

-VIB

RAT

ION

FLEX

IBLE

CO

UPL

ING

B2

B1

D

E

C

T

A

B

PRES

SUR

ESU

STAI

NIN

GVA

LVE

WAT

ER P

UM

P(IF

REQ

UIR

ED)

JOC

KEY

PUM

P(O

PTIO

NAL

)

MAI

N W

ATER

SUPP

LY V

ALVE

SEE

NO

TE N

O. 3

FOAM

SOLU

TIO

N

V

SEE

NO

TE N

O. 2

M

N

L RP

FOAM

CO

NC

ENTR

ATE

STO

RAG

E TA

NK

PRES

SUR

E VA

CU

UM

VEN

T

INSP

ECTI

ON

HAT

CH

FILL

CO

NN

ECTI

ON

DR

AIN

CO

NN

ECTI

ON

FLEX

IBLE

EXPA

NSI

ON

JO

INT

ILB

P M

OD

ULE

SCH

EMAT

IC- T

YPIC

AL

-

MAN

UAL

OVE

RR

IDE

HAN

DW

HEE

L

PRES

SUR

EG

AUG

E

SEE

NO

TE N

O. 5

PRIM

ARY

FOAM

CO

NC

ENTR

ATE

PUM

P

SEE

NO

TE N

O. 5

AUXI

LIAR

YFO

AM C

ON

CEN

TRAT

EPU

MP

(OPT

ION

AL)

SEE

NO

TE N

O. 6

SEE

NO

TE N

O. 7 D

K

JW

SEE

NO

TE N

O. 4

P

C

P

P

D

SEE

NO

TE N

O. 1

6/00 3-3

FIG

3-12

3.P6

5FI

G3-

3.D

SF

FIG

. 3-3

OPE

RA

TIN

G S

CH

EM

AT

IC D

RA

WIN

GIL

BP

MO

DU

LE

WIT

H M

OR

& R

CF

RA

TIO

CO

NT

RO

LL

ER

NOTE

S:

The

sche

mat

ics

show

n ar

e ty

pica

l ins

talla

tions

and

may

not

refle

ct a

ctua

l equ

ipm

ent f

urni

shed

.

1.Va

lve "V

" -No

rmal

ly CL

OSED

for s

yste

ms u

sing

noau

tom

atic

foam

conc

entra

te va

lve(s

).-

Norm

ally

OPEN

for s

yste

ms u

sing

anau

tom

atic

foam

conc

entra

te va

lve(s

).

2.Po

sitio

n of

Zon

e Fo

am C

once

ntra

te V

alve

.Au

tom

atic

valve

optio

nal.

3.Po

sitio

n of

Zon

e W

ater

Sup

ply V

alve

.Au

tom

atic

valve

optio

nal.

Man

ual v

alve

requ

ired

if aut

omat

ic va

lve n

ot su

pplie

d.

4.A

chec

k val

ve m

ust b

e in

stal

led

in th

e fo

am co

ncen

trate

line

dire

ctly

upst

ream

of e

ach

prop

ortio

ner m

odul

e.

5.Su

pplie

d wi

th A

uxilia

ry F

oam

Con

cent

rate

Pum

p only

.

6.St

anda

rd lo

catio

n of

"D" V

alve

(no

auxil

iary

foam

conc

.pu

mp)

.

7.Lo

catio

n of

"D" V

alve

with

aux

iliary

foam

conc

entra

te p

ump.

POSI

TION

VALV

E D

ESCR

IPTI

ONDE

SIGN

ATIO

NM

ANUA

LAU

TO.

PU

MP

AN

D P

RE

SS

UR

E S

US

TAIN

ING

VA

LVE

MO

DU

LEFO

AM C

ONCE

NTRA

TE T

ANK

RET

URN

AOP

ENOP

ENFO

AM C

ONCE

NTRA

TE T

ANK

SUC

TION

BOP

ENOP

ENMA

NUAL

FOA

M C

ONC.

REG

ULAT

ING

VAL

VEC

CLOS

EDCL

OSED

FOAM

CON

CENT

RATE

DIS

CHAR

GE V

ALVE

DOP

ENOP

ENFO

AM C

ONCE

NTRA

TE P

RESS

URE

EOP

ENOP

ENSU

STAI

NING

VAL

VE S

HUT-

OFF

VAL

VEFL

USH-

IN C

ONNE

CTIO

NS

CLOS

EDCL

OSED

FLUS

H-OU

T C

ONNE

CTIO

NT

CLOS

EDCL

OSED

STRA

INER

FLU

SH-O

UTU

CLOS

EDCL

OSED

DRAI

N V

ALVE

SCL

OSED

CLOS

EDFO

AM C

ONCE

NTRA

TE T

ANK

SUC

TION

B1OP

ENOP

EN(P

RIMA

RY P

UMP)

FOAM

CON

CENT

RATE

TAN

K S

UCTI

ONB2

CLOS

EDOP

EN(A

UXILI

ARY

PUM

P)IN

-LIN

E B

ALA

NC

ED

PR

ES

SU

RE

PR

OP

OR

TIO

NIN

G M

OD

ULE

WAT

ER S

ENSI

NG L

INE

SUP

PLY

VAL

VEJ

OPEN

OPEN

WAT

ER S

ENSI

NG L

INE

SHU

T-OF

F V

ALVE

LOP

ENOP

ENTO

DIA

PHRA

GM V

ALVE

FOAM

CON

CENT

RATE

SEN

SING

LIN

EK

OPEN

OPEN

SHUT

-OFF

VAL

VE T

O D

IAPH

RAGM

VAL

VEDU

PLEX

GAU

GE W

ATER

FLU

SH-O

UTM

CLOS

EDCL

OSED

DUPL

EX G

AUGE

FOA

M C

ONC.

FLU

SH-O

UTN

CLOS

EDCL

OSED

DIAP

HRAG

M V

ALVE

WAT

ER F

LUSH

-OUT

PCL

OSED

CLOS

EDDI

APHR

AGM

VAL

VE C

ONC.

FLU

SH-O

UTR

CLOS

EDCL

OSED

FOAM

CON

CENT

RATE

SUP

PLY

VAL

VEV

CLOS

EDOP

ENLO

WER

PET

COCK

ON

DIA

PHRA

GM V

ALVE

WCL

OSED

CLOS

ED

NO

RM

AL

STA

ND

-BY

VA

LVE

PO

SITI

ON

CH

AR

T

Dry

Wet

Fiel

d P

ipin

gSy

stem

Syst

em

Sys

tem

W

ater

M

ain

Val

ve(s

)C

lose

dO

pen

Zone

Wat

er V

alve

(s)

Clo

sed

Ope

n

Zone

Foa

m C

onc.

Val

ve(s

)C

lose

dC

lose

d

LEG

EN

D

PD

C

CO

MPO

NEN

TS P

RO

VID

ED B

Y N

F

FOAM

CO

NC

ENTR

ATE

LIN

E

SEN

SIN

G L

INE

WAT

ER L

INE

RC

F R

ATIO

CO

NTR

OLL

ER

BALL

VAL

VE (N

.O.)

BALL

VAL

VE (N

.C.)

AUTO

MAT

ED V

ALVE

W/M

ANU

ALO

VER

RID

E

CH

ECK

VALV

E

PRES

SUR

E SU

STAI

NIN

G V

ALVE

REL

IEF

VALV

E

STR

AIN

ER

DU

PLEX

GAU

GE

PRES

SUR

E G

AUG

E

CO

MPO

UN

D G

AUG

E

DIA

PHR

AGM

VAL

VE

FLU

SH-IN

CO

NN

ECTI

ON

FLU

SH-O

UT

CO

NN

ECTI

ON

PRES

SUR

E SW

ITC

H

6/00 3-4

CHAPTER 3 - OPERACHAPTER 3 - OPERACHAPTER 3 - OPERACHAPTER 3 - OPERACHAPTER 3 - OPERATING PROCEDURESTING PROCEDURESTING PROCEDURESTING PROCEDURESTING PROCEDURES

3-1. MINIMUM INLET PRESSURE REQUIREMENTS

Since it is not uncommon for water inlet pressures to be quite low in some system applications, it isnecessary to determine that the minimum proportioning system inlet pressure is adequate to allowproper system operation. The curves in Fig. 3-4 indicate the minimum inlet pressure required relativeto the anticipated flow rate of the system. These curves apply to all proportioning systems whichutilize National Foam Model RCT, RCF or RCW ratio controllers.

FIGURE 3-4RATIO CONTROLLER MINIMUM INLET PRESSURE VS. SOLUTION FLOW CHART

6.9/100BAR/PSI

6.2/905.5/80

4.8/70

4.1/60

3.4/50

2.7/40

2.06/30

1.3/20GPMLPM

60227

80303

100379

200757

4001514

6002271

8003028

10003785

20007571

400015141

3" RCF/RCW 4" RCF/RCW 6" RCF/RCW 8" RCF/RCW2" RCT

SOLUTION FLOW (GPM/LPM)

WAT

ER IN

LET

PRES

SUR

E (P

SI/B

AR)

6/00 3-5

3-2. OPERATION OF SYSTEM

A. Manual System Operation (No Automated Valves):

NOTE: Refer to Operating Schematic Drawing Fig. 3-1, 3-2 or 3-3 forvalve location, designation and normal stand-by position.

1. Verify that all valves on the proportioning sys-tem are in their normal stand-by position.

2. Start water pump (if required).


4. If applicable - Set the desired percentage on themetering valve(s) at the appropriate ILBPModule(s).

NOTE: The metering valve is for regulatingthe foam concentrate injection (percentage) intothe system only , and does not have shut-offcapability. For positive foam concentrate shut-off, a separate valve must be used along with themetering valve.

5. Open water supply valve to the desired ILBPmodule(s).

6. Open foam concentrate supply Valve "V" to thedesired ILBP module(s).

7. Open any required zone valves downstream of thedesired ILBP module(s).


● Verify that pointers on the duplex gauge arebalancing; if not, follow procedures under ManualSystem Override (ILBP module) Sect. 3-3.A.

9. Observe the discharge pressure gauge on the pumpand pressure sustaining module to insure that thesystem is operating at design pressure. If system isnot operating at design pressure, refer to ManualSystem Override (Pump and Pressure SustainingModule) Sect. 3-3.B.

B. Automatic System Operation (Automated Systems Only):

NOTE: Refer to Operating Schematic Drawing Fig. 3-1, 3-2 or 3-3 forvalve location, designation and normal stand-by position.

Upon initiation of automatic start sequence, the following should occur:

4. Zone concentrate discharge valve opens.

NOTE: Water powered zone concentrate valve(s),if supplied, will actuate when water supply is initi-ated to zone.

5. Appropriate zone valves downstream of desired ILBPModule(s) open.

6. If system fails to respond to automatic operation,follow Manual Operation Procedures Sect 3-2.A.

NOTE: If applicable - Before actuating the sys-tem, set the desired percentage on the meteringvalve(s) at the appropriate ILBP Module(s).

1. Main water supply valve will initiate.

2. Foam concentrate pump starts.

3. Zone water supply valve to the desired ILBPModule(s) opens.


6/00 3-6

3-3. MANUAL SYSTEM OVERRRIDE (MANUAL REGULATION)

NOTE: The instructions in sub-section A. below, apply only to ILBP Module Diaphragm Valves with manualoverride capability. These instructions do not apply to Diaphragm Valves which do not have manualoverrride capability.

A. ILBP Module:

NOTE: Used only when system will not balanceautomatically.

1. Close foam concentrate supply Valve "V".

2. Close water sensing shutoff Valve "L".

3. Verify adequate foam concentrate pressure onfoam concentrate supply pressure gauge.

4. Turn manual override knob clockwise until itcontacts a stop and will not travel further.

5. Slowly open foam concentrate supply Valve "V"until duplex gauge indicates system balance.Keep adjusting valve as required to maintainsystem balance.

B. Pump & Pressure Sustaining Valve Module:

1. Open Valve "C".

2. Close Valve "E".

3. Slowly close Valve "C" until system design pres-sure is indicated on the discharge pressure gauge.

CAUTION:An operator must remain stationed at the pumpand pressure sustaining module while the pres-sure is manually controlled to adjust for varia-tions in pressure.

3-4. SHUTDOWN

A. Manual System Shutdown:

1. Shut down the foam concentrate pump.

2. Close the foam concentrate supply Valve "V" atthe ILBP module(s) being operated.

WARNING:Only after the fire is out and the danger of reignitionhas passed, shall consideration be given to flush-ing and draining the system. Follow the appropri-ate Flushing Instructions which follow in thismanual after it is determined that it would be safeto flush and drain the system.


NOTE: If the system has a water powered foamconcentrate supply Valve "V", the cylinder water

pressure supply valve in the water line supplyingpressure to the water powered ball valve operatingcylinder must be closed before any flushing opera-tion.

a. Make sure Valve "V" at the ILBP module(s)being operated is closed.

b. Flow water through the system and allow waterto run until clean clear water issues from theoutput devices that were operated.


4. Return all valves to their normal stand-by position.See Normal Stand-by Valve Position Chart on Oper-ating Schematic Dwg. Fig. 3-1, 3-2 or 3-3.


6/00 3-7

5. Replenish supply of foam concentrate. If thetank is empty, it shall be inspected to determineif cleaning is warranted before refilling. Ifcleaning is judged necessary, refer tomanufacturer's instructions. If storage tank isprovided by NF - refer to NF Storage TankInstallation, Cleaning & Filling InstructionManual P/N: 1298-9933-7 for recommendations.

CAUTION:Only foam concentrate of the type listed on thetank nameplate shall be used to replenish the tank.Mixing of different types or brands of foam con-centrate could cause failure of the system.


1. Shutdown the foam concentrate pump.

2. Close the Zone Foam Concentrate Valve to theILBP module(s) (if appropriate).

NOTE: Water powered foam concentratevalves do not reset automatically and must bereset manually.

WARNING:Only after the fire is out and the danger ofreignition has passed shall consideration begiven to flushing and draining the system.Follow the appropriate Flushing Instructionswhich follow in this manual after it is deter-mined that it would be safe to flush and drainthe system.


NOTE: If the system has a water poweredfoam concentrate supply Valve "V", the cylinderwater pressure supply valve in the water linesupplying pressure to the water powered ballvalve operating cylinder must be closed beforeany flushing operation.

a. Make sure that the Zone Foam ConcentrateValve to the ILBP module(s) being operatedis closed.

b. Flow water through the system and allow waterto run until clean clear water issues from theoutput devices that were operated.


4. Return all valves to their normal stand-by position.Refer to Normal Stand-by Valve Position Chart onOperating Schematic Dwg. Fig. 3-1, 3-2 or 3-3.

5. Replenish supply of foam concentrate. If the tank isempty, it shall be inspected to determine if cleaningis warranted before refilling. If cleaning is judgednecessary, refer to manufacturer's instructions.Ifstorage tank is provided by NF - refer to NFStorage Tank Installation, Cleaning & Filling In-struction Manual P/N: 1298-9933-7 for recommen-dations.

CAUTION:Only foam concentrate of the type listed on thetank nameplate shall be used to replenish the tank.Mixing of different types or brands of foam con-centrate could cause failure of the system.


B. Automatic System Shutdown:

Upon system shutdown, the following sequence should occur.



4-1. INSPECTION AND MAINTENANCE

See Table 4-1 for recommended inspection and maintenance procedures. These procedures and recommendedintervals are based on normal operating conditions and may have to be modified to meet the existingconditions.

WARNING:The intervals in this chapter are a general recommendation; some environmental conditions may dictatesuch inspections and maintenance be performed at more frequent intervals.

CAUTION:When cycling automated valves, make sure the main water valve, Foam Concentrate Suction Valve "B"and Return Valve "A" are closed. After cycling, return all valves to their normal stand-by position.

The Foam Concentrate Discharge Valve(s) "D" must be closed when circulating foam concentrate thruthe proportioning system to prevent loss of foam concentrate. Refer to Operating Schematic Dwg. Fig.3-1, 3-2 or 3-3.

For various proportioning system components (diaphragm valve, foam concentrate pump, valves, actuatorsetc.) refer to that particular component's operating and maintenance manual or instruction sheet for inspectionand maintenance procedures.

4-2. TESTING AFTER SYSTEM MAINTENANCE

If during the course of normal system maintenance it becomes necessary to replace, repair or modify systemcomponents, component parts, operating devices or equipment, the system must be tested to insure properoperation before being placed back into service.

4-3. ANNUAL TESTING

At least annually, all foam systems shall be thoroughly inspected and checked for proper operation. This shallinclude performance evaluation of the foam concentrate or premix solution quality or both. Deviation ofresults exceeding 10 percent from those recorded in acceptance testing shall be discussed immediately withthe manufacturer. Regular service contracts are recommended. The goal of this inspection and testing shallbe to ensure that the system is in full operating condition, and that it will remain in that condition until thenext inspection. The inspection report, with recommendations, shall be filed with the owner. Between theregular service contract inspections or tests, the system shall be inspected by competent personnel followingan approved schedule.

6/00 4-1

6/00 4-2


WARNING:The intervals in this chapter are a general recommendation; some environmental conditions may dictatesuch inspections and maintenance be performed at more frequent intervals.


NOTE: The following recommendations are based on normal operating conditions. Due to environmental or otherconditions unique to your system, the frequency of some inspecton and maintenance procedures may need to beadjusted. Additional inspection and maintenance procedures may also be required.

NOTE: When performing inspection and maintence procedures which:a. require operation of the system or parts of the system,b. cause the system to be non-operational during the procedure,c. cause a trouble indication,

the system should be taken out of service and the proper authorities should be notified.



OPERATIONSTART

UP

AFTERALL

MAINT.PROCEDURES

ANNUAL

AFTERMAINTENANCE

TO PIPING

4-4. TOTAL SYSTEM1. Check all valves to insure that they are in the ◆ ◆ ◆

normal stand-byposition. See OperatingSchematic Dwg. Fig. 3-1, 3-2 or 3-3.

2. Check that Manual Override Handwheel is in the ◆ ◆ ◆

normal stand-by position for automaticbalancing. Refer to Sect. 2-3.C., item 3.

3. Inspect system for physical damage and repair. ◆ ◆ ◆

4. Check the complete system, all valves, fittings & ◆ ◆ ◆

connections for leakage.5. Perform normal maintenance and inspection of the ◆

fire water supply system to insure that the firepumps will be operational when required.

6. Perform the system testing after installation as ◆

prescribed in Sect. 2-5 of this manual.7. Perform annual system test as prescribed in ◆

Sect. 4-3 of this manual.8. Flush and drain the concentrate system. See ◆

Flushing instructions Sect. 4-14 & 4-15 of thismanual.

9. Cycle manual valves where practical. ◆


6/00 4-3

AFTERFLOW TEST(PER NFPA)

MFR. RECOM.

MFR. RECOM.

MFR. RECOM.

AFTERFLOW TEST(PER NFPA)




OPERATIONSTART

UP ANNUAL

10. Circulate the foam concentrate. ◆ ◆

CAUTION:The foam concentrate discharge Valve(s) "D"must be closed to prevent loss of foam concentrate.

NOTE: When the foam concentrate iscirculated, verify gauges are functioning.

11. Check flange bolts for tightness. ◆ ◆

12. Check system for any external damage to the ◆ ◆

paint surfaces.13. Check the Pressure Sustaining Valve pressure ◆ ◆

setting. See Sect. 2-2.C., item 23. Refer to mfg's.data for valve setting procedures.

4-5. STRAINERSFoam Concentrate Line and Sensing LineStrainers:

1. Remove screen, clean and inspect and ◆ ◆

reassemble.Total System:

1. Remove screens, check, clean and reinstall. ◆ ◆

4-6. FOAM CONCENTRATE PUMP1. Service pump and motor. ◆

2. Check alignment of the pump, reducer and motor. ◆ ◆

See Manufacturer's data for details.3. Lubricate pump, reducer and motor in accordance ◆ ◆

with manufacturers instructions.4. Check pumps, motors, reducers, diesel and ◆ ◆ ◆

gasoline engines for proper oil level.5. Check that proper voltage is available to pump ◆ ◆

motor.6. Check motor for proper rotation. Rotate pump by ◆ ◆

hand to insure freedom of movement.7. Run pump to insure proper operation. Check for ◆ ◆

leakage, excessive noise or vibration oroverheating in the pump, reducer and motor.

8. Check that pump will supply adequate pressure to ◆ ◆

supply system.9. Check relief valve for proper operation. See ◆ ◆

Sect. 2-2.C., item 22. Refer to mfg's. data forrelief valve setting procedures. Refer to PumpOutline Assembly for the proper pressure setting.

10. Service diesel or gasoline engine driver.11. Run engine exclusive of pump. ◆

NOTE: If no clutch is provided, recirculatefoam concentrate back to storage tank.


6/00 4-4




OPERATIONSTART

UP ANNUAL

4-7. ELECTRICALLY ACTUATED VALVES1. Cycle valve(s) - Valve(s) may be cycled from ◆ ◆

control panel or by manual override at valve.

WARNING:When automated foam concentrate valvesare cycled, Valve "V"must be closed.


2. Cycle valve(s) from the control panel to insure ◆ ◆

proper operation from control.3. Check supervision of control circuit. ◆


4-8. WATER POWERED BALL VALVES1. Cycle the valve(s) either manually or thru control ◆ ◆

panel.WARNING:

When water powered ball valves are cycled,Valve "V" must be closed.

2. If applicable, cycle the valve(s) using the solenoid ◆ ◆

release.WARNING:

When water powered ball valves are cycled,Valve "V" must be closed.

3. Check supervision of circuit if solenoid release is ◆ ◆

provided.4. Make sure that the quick release pin is securely ◆ ◆

positioned thru the clevis.5. Make sure the drain/vent valve is fully closed. ◆ ◆

4-9. PNEUMATICALLY ACTUATED VALVES1. Cycle the valve(s) - Valve(s) may be cycled ◆ ◆

from control panel or by manual override atvalve.

WARNING:When water powered ball valves are cycled,Valve "V" must be closed.


2. Cycle Valve(s) from the control panel to insure ◆ ◆

proper operation from control.3. Check supervision of control circuit. ◆ ◆

4. Check air supply. ◆ ◆

5. Check low air supply alarm. ◆ ◆



6/00 4-5




OPERATIONSTART

UP ANNUAL

4-10. PRESSURE VACUUM VENT1. Inspect the pressure vacuum vent to insure that ◆

the poppets move freely, the screens are cleanand there is no other dirt or blockage.

2. Service pressure vacuum vent. Refer to NF ◆

Storage Tank Installation, Cleaning & FillingInstruction Manual P/N: 1298-9933-7 forrecommendations for NF supplied tanks.

4-11. FOAM CONCENTRATE STORAGE TANK1. Check the level of concentrate in the tank. Refer ◆ ◆

to NF Storage Tank Installation, Cleaning &Filling Instruction Manual P/N: 1298-9933-7 forrecommendations for NF supplied tanks.

2. Check pressure vacuum vent in accordance with ◆ ◆

maintenance instructions outlined in this Section4-10 of this manual.

3. Check for rust, corrosion, leakage, and weak ◆

spots or other physical damage.4. Check poly tank bulkhead fittings for leakage. ◆ ◆

4-12. FOAM CONCENTRATE1. Check that storage temperature is within ◆

acceptable limits. Refer to NF Storage TankInstallation, Cleaning & Filling InstructionManual P/N: 1298-9933-7 for recommendedtemperatures for NF foam concentrates.

2. Sample foam concentrate and submit sample to ◆

foam manufacturer to be tested for sedimentation,corrosion, dilution or contamination. Refer to NFStorage Tank Installation, Cleaning & FillingInstruction Manual P/N: 1298-9933-7 forsampling instructions.

3. Circulate foam concentrate. ◆

CAUTION:The foam concentrate dischargeValve(s) "D"must be closed to prevent loss of foamconcentrate.

4-13. CONTROL SYSTEM1. Check that proper indicators are present. See ◆ ◆

control panel data.2. Check supervision of all circuits. ◆ ◆

3. Check alarm operation. ◆ ◆

4. Check system operation. See control panel data. ◆ ◆

5. Check that all indicators illuminate. ◆ ◆

6/00 4-6

4-14. FLUSHING - PUMP AND PRESSURE SUSTAINING VALVE MODULE

NOTE: Flushing is to be done only prior to start-up, prior to refilling a depleted tank, changing type of foamconcentrate, or if the foam concentrate piping has to be broken for repairs. Flushing is not a normal shutdownprocedure and is not necessary after Foam Concentrate Pump and Pressure Sustaining Valve Moduleoperation.

CAUTION:If the tank is full of foam concentrate, the tank suction Valve "B" and return Valve "A" must be closedto prevent dilution of the foam concentrate.

If the system has a water powered foam concentrate discharge valve, the cylinder water pressure supplyvalve in the water line supplying pressure to the water powered ball valve operating cylinder, must beclosed before any flushing operation.

1. Close foam concentrate tank supply Valve "B"and tank return Valve "A".

2. Close concentrate discharge Valve(s) "D". IfValve(s) "D" is automated electrically, de-ener-gize the valve at the control panel. A waterpowered foam concentrate discharge valve doesnot close automatically, it must be closed andreset manually.

3. Open Valve "C".

4. Attach hose from water supply to Flush-In Con-nection "S" .

5. Attach hose to Flush-Out Connection "T".

6. Open water supply valve.


● Close Valve "C" once to force flush waterthrough pressure sustaining valve, then openValve "C".

● Momentarily close Valve "E" to allow water toflush through the relief valve. Open Valve "E".Repeat this procedure two or three times.

8. Stop concentrate pump, open Strainer Flush-OutConnection "U" and then close Flush-In Connection"S".

9. Let system drain through Strainer Flush-Out Con-nection "U" and Flush-Out Connection "T"; thenclose Flush-Out Connection "T" and Strainer Flush-Out Connection "U".

10. Remove lower plug in concentrate pump, allow todrain, replace plug.

12. Open all low point drains, allow to drain. Closedrains.

13. Return all valves to their normal stand-by position.Refer to Normal Stand-By Position Chart on Oper-ating Schematic Dwg. Fig. 3-1, 3-2 or 3-3.


6/00 4-7

4-15. FLUSHING - ILBP MODULE

NOTE: Flushing of the ILBP Module is to be done at Module installation into the system, prior torefilling a depleted tank, changing type of foam concentrate, or if the foam concentrate piping has tobe broken for repairs. Flushing is not a normal shutdown procedure and is not necessary after ILBPModule operation.

A. ILBP Module withDiaphragm Valve Manual Override Capability:

1. Open all ILBP Module sensing line drains andflush-out points (Valves M, N, P, R and W).

2. Turn manual override knob down (clockwise)until it contacts stop.




NOTE: Flushing of the ILBP Module can beperformed at system shutdown when flowingwater thru the system. Refer to Sect. 3-4, Shut-down, for correct procedures.



7. Turn manual override knob up (counter-clock-wise) until it contacts stop for normal automaticbalancing operation.

8. Return all valves to their normal stand-by posi-tion (reinstall diaphragm valve body drain plug).Refer to Normal Stand-By Valve Position Charton Operating Schematic Dwg. Fig. 3-1 or 3-3.

B. ILBP Module withoutDiaphragm Valve Manual Override Capability:

1. Open all ILBP Module drains, flush-out points(Valves P and R).




NOTE: Flushing of the ILBP Module can beperformed at system shutdown when flowingwater thru the system. Refer to Sect. 3-4, Shut-down, for correct procedures.



6. Return all valves to their normal stand-by posi-tion (reinstall body drain plug). Refer to NormalStand-By Valve Position Chart on OperatingSchematic Dwg. Fig. 3-2.


5-2. No Tank Return Valve "A" and Tank Suction Check valve position on tank to insure thatProportioning Valve “B” at foam concentrate tank not open. they are fully open. Open valve(s) if closed.

Foam Concentrate Discharge Valve "D" Fully open appropriate valve(s). (Normaland/or Foam Concentrate Supply Valve "V" stand-by position is closed)not open.

Automatic Foam Concentrate Zone Valve Check that wiring is installed to actuator.Closed.(Electrically actuated)

Check that signal from control system isavailable at valve actuator. If voltage is notpresent, check control system.

If signal is present at actuator, use manualoverride to cycle valve. If valve cycles manu-ally, then valve actuator is probably bad.Remove actuator, check operation, if bad,repair or replace. If valve does not open,using manual override on actuator, then thevalve is jammed. Remove valve, determineand correct reason for jam. See actuator data.

Automatic valve actuator does not function See manufacturer’s troubleshooting data.properly.(Electric or hydraulic actuation)

6/00 5-1



CHAPTER 5 - TROUBLE SHOOTINGCHAPTER 5 - TROUBLE SHOOTINGCHAPTER 5 - TROUBLE SHOOTINGCHAPTER 5 - TROUBLE SHOOTINGCHAPTER 5 - TROUBLE SHOOTING

5-1. TROUBLESHOOTING

See Table 5-1 for Troubleshooting Problems, Possible Causes and Corrective Actions. These procedurescover problems that may be experienced during normal operations. Although these recommendations covermost problems that are experienced there are some situations that may occur which are not covered in theseinstructions. Please contact National Foam's Engineering Department for problems that cannot be resolvedthru the use of this manual.

NOTE: Refer to individual instruction manuals or sheets for additional information onsystem components and discharge devices.

No Proportioning Automatic Foam Concentrate Zone Valve Check that cylinder water pressure supplycontinued Closed.(Water Powered Ball Valve) valve is fully open.

Check that quick release pull pin is notremoved from clevis. Reinsert pin thruclevis and valve handle.

Check Drain/Vent valve on strainer for clog-ging which shuts off water supply to cylinder.Open Drain/Vent valve on strainer, vent andflush any debris blocking water supply.

Foam concentrate pump not running. Check that power is available and correctvoltage is available to all three motor legs.

Check that wiring is complete to the pump.Check that all disconnect switches and circuitbreakers are closed, and fuses are insatisfactory condition.

Pump couplings disconnected at reducer orpump.

Reducer jammed or damaged; determinecause and correct.

Pump jammed. Determine cause and correct.

See manufacturer’s data.

Foam concentrate pump running wrong Reverse rotation of foam concentrate pump.direction.

Foam pump relief valve set too low. Foam concentrate allowed to bypass thruDuplex gauge will show foam concentrate relief valve at pressure lower than waterpressure lower than water pressure. Pressure pressure on supply line to ratio controller.in foam concentrate line will probably pulse. Reset pump relief valve. Contact NF Eng. Dept.

Manual Foam Concentrate Regulating Valve Check that manual regulating valve is closed"C" open or partially open. completely.

Diaphragm Valve Foam Concentrate Flush- If provided, duplex gauge will show foamOut Valve "R" open or partially open. concentrate pressure lower than water

pressure. Check to insure all flush valves areclosed.

6/00 5-2



TROUBLESHOOTING

No Proportioning Drain valve(s) or connection(s) in foam If provided, duplex gauge will show foamcontinued concentrate piping open or partially open. concentrate pressure lower than water

pressure. Check to insure all drain valves areclosed.


Concentrate not compatible with the system. Use correct concentrate. Drain and cleantank before filling with new concentrate.

Strainer clogged. High vacuum reading on Blow down, remove strainer screencompound gauge and pump will probably and clean.be very noisy due to cavitation.

Pump suction strainer mesh size too small. Replace with proper size strainer.

Water pressure too high. Pump can not build Reduce water pressure to system limitations.sufficient pressure to overcome water Reset pump relief valve 25 psi higher thanpressure. water pressure, provided pump motor has

sufficient horsepower to drive pump athigher pressure rating.



Pressure Sustaining Valve setting too low. Reset to correct pressure. Follow proceduresin Sect. 2-2.C., item 23 for checking thevalve set pressure. Refer to manufacturer’sinstructions for resetting.

Foam concentrate storage tank empty. Fill tank. Refer to NF Storage Tank Instruc-tion Manual, P/N: 1298-9933-7.

5-3. Low Tank Suction Valve "B" at foam concentrate Check valve position. Normal stand-byPercent of tank partially closed. Pump should be noisy position is fully open.Proportioning due to cavitation. Also compound gauge will

indicate high vacuum.

Foam Concentrate Discharge Valve "D" and/ Fully open valve(s). If more than one ILBPor Foam Concentrate Supply Valve "V" Module is supplied by the foam concentratepartially closed. main, be sure that Valve(s) "V" or zone

valve(s) of ILBP Module(s) not required, areclosed.

6/00 5-3



TROUBLESHOOTING

Low Percent of Foam Concentrate Zone Valve(s) not fully Fully open valve. Determine cause andProportioning open. correct.continued

Automatic Foam Concentrate Zone Valve Cylinder water pressure supply valveopens slowly.(Water powered ball valve) partially open. Fully open valve.

Tighten Drain/Vent valve on cylinder strainer.Snug with wrench to insure closure to ratedpressure.

Drain/Vent valve clogged, obstructing watersupply to cylinder. Open Drain/Vent valve onstrainer and vent. Flush any debris blockingwater supply.

Foam concentrate pump not operating to Loss of phase to motor.capacity.

Low voltage to motor.

Check pump end clearance.

Check for damage to vanes and pushrods.See manufacturer’s data.

Foam Concentrate Regulating Valve "C" Check that Valve "C" is completely closed.partially open.

Water pressure exceeds the design limits of Adjust pressure to proportioner to be within the system. System requires more capacity the flow and pressure limits of the system.than pump is capable of producing.

Flush-In Connection "S" open or partially Check to insure all flush connections areopen. If provided, duplex gauge will show closed.foam concentrate pressure lower than waterpressure.

Drain valves in foam concentrate piping Check to insure all drain valves are closed.open or partially open. If provided, duplexgauge will show foam concentrate pressurelower than water pressure.

Control system not functioning properly. See control system manual. Check wiring forcorrect interconnection.

Check wiring for proper connections.

6/00 5-4



TROUBLESHOOTING

Low Percent of Foam concentrate strainer at Flush-Out Remove strainer screen and clean.Proportioning Connection "U" clogged. High vacuumcontinued reading on compound gauge and pump will

probably be very noisy due to cavitation.

Diaphragm valve not functioning properly. Check water sensing lines for blockage.If provided, duplex gauge will not show Make sure that there are no air pockets inbalance. water sensing lines.

Diaphragm Valve Water Flush-Out "P" open. Fully close flush-out valve.

Foam concentrate incompatible with system Use only foam concentrates the system wasdesign. designed for. Contact NF if you desire to

change foam concentrates.

Incorrect orifice diameter or adjustment. Contact NF Engineering Dept. for instructionson checking orifice and adjustment settings.

Water flow too high. Exceeds capability Too many discharge devices in operation orof foam concentrate pump. pressure too high. Check design and correct

to stay within limits of system.



Pressure Sustaining Valve setting too low. Reset to correct pressure. Follow proceduresin Sect. 2-2.C., item 23 for checking thevalve set pressure. Refer to manufacturer’sinstructions for resetting.

5-4. High Tank Return Valve "A" at foam concentrate Check valve position to insure thatPercent of tank not open. Valve "A" is open. Open valve if closed.Proportioning

Diaphragm valve not functioning properly. Check foam concentrate sensing lines forIf provided, duplex gauge will not show blockage. Make sure that there are no airbalance. pockets in foam concentrate sensing lines.

Foam concentrate sensing line blocked. Remove line and clear blockage.

Diaphragm Valve Foam Concentrate Fully close flush-out valve.Flush-Out Valve "R" open.

Foam concentrate incompatible with system Use only foam concentrate the system wasdesign. designed for. Contact NF if you desire to

change foam concentrates.

6/00 5-5



TROUBLESHOOTING

High Percent of Incorrect orifice diameter or adjustment. Contact NF Engineering Dept. for instructionsProportioning on checking orifice and adjustment settings.continued

Water flow too low for ratio controller. Check system pressure. If low, find andcorrect problem.

Blockage in solution line or valves notcompletely open. Check solution line andcorrect.

Discharge device blocked. Check devicesand correct problem.

5-5. No Flow Water supply valve closed. Open valve. If automated, find reason andat Discharge correct.Device(s)

Fire pump did not start. Determine the cause and correct the problem.

Blockage in the water supply or foam Find the cause of the blockage and correct.solution discharge line.

Manual valves in solution piping shut or Check line for blockage or open manualblockage in line. valves.

5-6. Low Flow System pressure too low. Check inlet pressure and correct for properat Discharge operation.Device(S)

Fire pumps did not start. Determine reason and correct.

Partial blockage in water or foam solution line. Find blockage and remove.

Zone valve did not open completely. Valve jammed, determine reason and correct.

5-7. No Power failure. Check power source and correct problem.Operation


Foam concentrate storage tank empty. Fill tank.

Failure of water supply system. Check water supply and correct problem.

6/00 5-6



TROUBLESHOOTING

FOAM SOLUTION PROFESSIONALS180 Sheree Boulevard, Suite 3900 • P.O. Box 695 • Exton, PA 19341-0695 • USA

Telephone: 610-363-1400 • Fax: 610-524-9073www.Kidde-Fire.com

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3.3.1

3.3.2

3.3.3

INSTALLATION AND MAINTENANCE MANUALFOR NEMA LOW VOLTAGE ELECTRIC MOTORS

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1 - Introduction 03

2 - Basic Instructions ..........................................................05 2.1 Safety Instructions.......................................................05 2.2 Delivery .....................................................................05 2.3 Storage .....................................................................05 2.3.1 Drying the Windings ....................................06

3 - Installation 07 3.1 Mechanical Aspects ..................................................07 3.1.1 Foundation...................................................07 3.1.2 Types of bases ............................................07 3.1.3 Alignment.....................................................08 3.1.4 Coupling ......................................................09 3.1.5 Bearing Load (Stresses on the bearings) ....10 3.2 Electrical Aspects......................................................16 3.2.1 Feed System ...............................................16 3.2.2 Starting of Electric Motors ...........................16 3.2.3 Motor Protection ..........................................18 3.3 Start-up19 3.3.1 Preliminary Inspection .................................19 3.3.2 The First Start-up.........................................21 3.3.3 Operation.....................................................21 3.3.4 Stopping ......................................................21

4 - Maintenance.....................................................................25 4.1 Cleanliness ...............................................................25 4.2 Lubrication ................................................................25 4.2.1 Periodical Lubrication ..................................25 4.2.2 Quality and Quantity of Grease ...................25 4.2.3 Lubricating Instructions................................25 4.2.4 Replacement of Bearings ............................26 4.3 Air Gap Checking......................................................26 4.4 Explosion Proof Motor Repair Steps.........................27 4.4.1 Objective......................................................27 4.4.2 Repair Procedure and Precautions .............27 4.4.3 Miscellaneous Recommendations...............27

5 - Malfunctioning ..............................................................28 5.1 Standard Three-phase Motor Failures......................28 5.1.1 Short Circuits Between Turns ......................28 5.1.2 Winding Failures..........................................28 5.1.3 Rotor Failures ..............................................29 5.1.4 Bearing Failures ..........................................29 5.1.5 Shaft Fractures ............................................29 5.1.6 Unbalanced V-Belt Drives............................29 5.1.7 Damage Arising from Poorly Fitted Transmission Parts or Improper Motor Alignment ...........................29 5.2 Troubleshooting Chart ..............................................30

6 - Spare Parts and Component Terminology ...................31

Contents


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This manual covers all the three-phase and single-phase asynchronous squirrel-cage induction motors, from 140T to 580T frame sizes.

The motors described in this manual are subject to continuous improvement and all information is subject to change without notice.For further details, please consult WEG.


1. Introduction


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2. Basic Instructions

2.1 Safety InstructionsAll personnel involved with electrical installations, either handling, lifting, operation and maintenance, should be well-informed and up-to-date concerning the safety standards and principles that govern the work and carefully follow them. Before work commences, it is the responsibility of the person in charge to ascertain that these have been duly complied with and to alert his personnel of the inherent hazards of the job in hand.It is recommended that these tasks be undertaken only by qualified personnel and they should be instructed to:· avoid contact with energized circuits or rotating parts,· avoid by-passing or rendering inoperative any safeguards or

protective devices,· avoid extended exposure in close proximity to machinery with

high noise levels,· use proper care and procedures in handling, lifting, installing,

operating and maintaining the equipment, and· follow consistently any instructions and product

documentation supplied when they do such work.Before initiating maintenance procedures, be sure that all power sources are disconnected from the motor and accessories to avoid electric shock.Fire fighting equipment and notices concerning first aid should not be lacking at the job site; these should be visible and accessible at all times.

2.2 DeliveryPrior to shipment, motors are factory-tested and balanced. They are packed in boxes or bolted to a wooden base.Upon receipt, we recommend careful handling and a physical examination for damage which may have occurred during transportation.In the event of damage and in order to guaranty insurance coverage, both the nearest WEG sales office and the carrier should be notified without delay.

2.3 StorageMotors should be raised by their eyebolts and never by their shafts. It is important that high rating three-phase motors be raised by their eyebolts. Raising and lowering must be steady and joltless, otherwise bearings may be harmed.When motors are not immediately installed, they should be stored in their normal upright position in a dry even temperature place, free of dust, gases and corrosive atmosphere. Other objects should not be placed on or against them.Motors stored over long periods are subject to loss of insulation resistance and oxidation of bearings.

Bearings and lubricant deserve special attention during prolonged periods of storage. Depending on the length and conditions of storage it may be necessary to regrease or change rusted bearings. The weight of the rotor in an inactive motor tends to expel grease from between the

bearing surfaces thereby removing the protective film that impedes metal-to-metal contact. As a preventive measure against the formation of corrosion by contact, motors should not be stored near machines which cause vibrations, and every 3 month their shafts should be rotated manually.

Insulation resistance fluctuates widely with temperature and humidity variations and the cleanliness of components. When a motor is not immediately put into service it should be protected against moist, high temperatures and impurities, thus avoiding damage to insulation resistance.If the motor has been in storage more than six month or has been subjected to adverse moisture conditions, it is best to check the insulation resistance of the stator winding with a megohmeter.If the resistance is lower than ten megohms the windings should be dried in one of the two following ways:1) Bake in oven at temperatures not exceeding 194 degrees F

until insulation resistance becomes constant.2) With rotor locked, apply low voltage and gradually increase

current through windings until temperature measured with thermometer reaches 194 degrees F. Do not exceed this temperature.

If the motor is stored for an extensive period, the rotor must be periodically rotated.Should the ambient conditions be very humid, a periodical inspection is recommended during storage. It is difficult to prescribe rules for the true insulation resistance value of a machine as resistance varies according to the type, size and rated voltage and the state of the insulation material used, method of construction and the machine’s insulation antecedents. A lot of experience is necessary in order to decide when a machine is ready or not to be put into service. Periodical records are useful in making this decision.

The following guidelines show the approximate values that can be expected of a clean and dry motor, at 40°C test voltage in applied during one minute.

Insulation resistance Rm is obtained by the formula:Rm = Vn + 1

Where: Rm - minimum recommended insulation resistance in M W with winding at 40°C

Vn - rated machine voltage in kV

In case the test is carried out at a temperature other than 40°C, the value must be corrected to 40°C using an approximated curve of insulation resistance v.s temperature of the winding with the aid of Figure 2.1; it’s possible verify that resistance practically doubles every 10°C that insulating temperature is lowered.


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Example:

Ambient temperature = 50°CMotor winding resistence at 50°C = 1.02 M W Correction to 40°C

R 40°C = R 50°C x K 50°C

R 40º C = 1.02 x 1.3

R 40º C = 1.326 M W

The minimum resistence Rm will be: Rm = Vn + 1 Rm = 0.440 + 1 Rm = 1.440 M W

On new motors, lower values are often attained due to solvents present in the insulating varnishes that later evaporate during normal operation. This does not necessarily mean that the motor is not operational, since insulating resistance will increase after a period of service. On motors which have been in service for a period of time much larger values are often attained. A comparison of the values recorded in previous tests on the same motor under similar load, temperature and humidity conditions, serves as a better indication of insulation condition than that of the value derived from a single test. Any substantial or sudden reduction is suspect and the cause determined and corrective action taken.Insulation resistance is usually measured with a MEGGER.In the event that insulation resistance is inferior to the values derived from the above formula, motors should be subjected to a drying process.

This operation should be carried out with maximum care, and only by qualified personnel. The rate of temperature rise should not exceed 5°C per hour and the temperature of the winding should not exceed 105°C. An overly high final temperature as well as a fast temperature increase rate can each generate vapour harmful to the insulation.Temperature should be accurately controlled during the drying process and the insulation resistance measured at regular intervals.During the early stages of the drying process, insulation resistance will decrease as a result of the temperature increase, but the resistance will increase again when the insulation becomes dryer.The drying process should be extended until sucessive measurements of insulation resistance indicate that a constant value above the minimum acceptable value has been attained. It is extremely important that the interior of the motor be well ventilated during the drying operation to ensure that the dampness is really removed.

Heat for drying can be obtained from outside sources (an oven), energization of the space heater (optional), or introducing a current through the actual winding of the motor being dried.

Winding Temperature (ºC)R40 ºC = Rt x Kt 40 ºC

Figure 2.1.


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3. Installation

Electric machines should be installed in order to allow an easy access for inspection and maintenance. Should the surrounding atmosphere be humid, corrosive or contain flammable substances or particles, it is essential to ensure an adequate degree of protection.The installation of motors in environments where there are vapours, gases or dusts, flammable or combustible materials, subject to fire or explosion, should be undertaken according to appropriate and governing codes, such as NEC Art. 500 (National Electrical Code) and UL-674 (Underwriters Laboratories, Inc.) Standards.Under no circumstances can motors be enclosed in boxes or covered with materials which may impede or reduce the free circulation of ventilating air. Machines fitted with external ventilation should be at least 50cm from the wall to permit the passage of air.The opening for the entry and exit of air flow should never be obstructed or reduced by conductors, pipes or other objects.The place of installation should allow for air renewal at a rate of 700 cubic feet per minute for each 75 HP motor capacity.

3.1 Mechanical Aspects

3.1.1 FoundationThe motor base must be levelled and as far as possible free of vibrations. A concrete foundation is recommended for motors over 100 HP. The choice of base will depend upon the nature of the soil at the place of erection or of the floor capacity in the case of buildings. When dimensioning the motor base, keep in mind that the motor may occasionally be run at a torque above that of the rated full load torque.Based upon Figure 3.1, foundation stresses can be calculated by using the following formula:

F1 = 0.2247 (0.009 x g x G - 213 Tmáx/A)

F2 = 0.2247 (0.009 x g x G + 213 Tmax/A )

Figure 3.1 - Base stresses

Where:

F1 and F2 - Lateral stress (Lb)g - Force of gravity (32.18 ft/s2)G - Weight of motor (Lb)Tmax - Maximum torque (Lb . Ft)A - Obtained from the dimensional drawing of the

motor (in)Sunken bolts or metallic base plates should be used to secure the motor to the base.

3.1.2 Types of Bases

a) Slide RailsWhen motor drive is by pulleys the motor should be mounted on slide rails and the lower part of the belt should be pulling. The rail nearest the drive pulley is positioned in such a manner that the adjusting bolt be between the motor and the driven machine. The other rail should be positioned with the bolt in the opposite position, as shown in Figure 3.2.The motor is bolted to the rails and set on the base. The drive pulley is aligned such that its center is on a plane with the center of the driven pulley and the motor shaft and that of the machine be parallel.

The belt should not be overly stretched, see Figure 3.11.

After the alignment, the rails are fixed.Figure 3.2 - Positioning of slide rails for motor alignment


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b) Foundation Studs Very often, particularly when drive is by flexible coupling the motor is anchored directly to the base with foundation studs. It is recommended that shim plates of approximately 0.8 inches be used between the foundation studs and the feet of the motor for replacement purposes. These shim plates are useful when exchanging one motor for another of larger shaft height due to variations allowed by standard tolerances. Foundation studs should neither be painted nor rusted as both interfere with to the adherence of the concrete, and bring about loosening.After accurate alignment and levelling of the motor, the foundation studs are cemented and their screws tightened to secure the motor.

Figure 3.3 - Motor mounted on a concrete base with foundation studs3.1.3 AlignmentThe electric motor should be accurately aligned with the driven machine, particularly in cases of direct coupling. An incorrect alignment can cause bearing failure vibrations and even shaft rupture.The best way to ensure correct alignment is to use dial gauges placed on each coupling half, one reading radially and the other

exially - Figure 3.5.Figure 3.5 - Alignment with dial gaugesThus, simultaneous readings are possible and allow for checking for any parallel (Figure 3.6a) and concentricity deviations (Figure 3.6b) by rotating the shafts one turn.Gauge readings should not exceed 0.02 inches. If the installer is sufficiently skilled, he can obtain alignment with feeler gauges and a steel ruler, providing that the couplings are perfect and

centered - Figure 3.6c.

Figure 3.6a - Deviation from parallel

Figure 3.6b - Deviation from concentricity

Figure 3.6c - Alignment with a steel ruler


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3.1.4 Coupling

a) Direct CouplingDirect coupling is always preferable due to its lower cost, space economy, no belt slippage and lower accident risk.In the case of speed ratio drives, it is also common to use a direct coupling with a reducer (gear box).

CAUTION: Carefully align the shaft ends using, whenever feasible, a flexible coupling.

Figure 3.7 - A type of direct couplingb) Gear Coupling

Poorly aligned gear couplings are the cause of jerking motions which bring about the vibration of the actual drive and vibrations within the motor.Therefore, due care must be given to perfect shaft alignment: exactly parallel in the case of straight gears, and at the correct angle for bevel or helical gears.Perfect gear engagement can be checked by the insertion of a strip of paper on which the teeth marks will be traced after a single rotation.

c) Belt and Pulley CouplingBelt coupling is most commonly used when a speed ratio is required.Assembly of Pulleys: To assemble pulleys on shaft ends with a keyway and threaded end holes the pulley should be inserted halfway up the keyway merely by manual pressure.On shafts without threaded end holes the heating of the pulley to about 80°C is recommended, or alternatively, the devices illustrated in Figure 3.8 may be employed.

Figure 3.8 - Pulley mounting device

Figure 3.8a - Pulley extractor

Hammers should be avoided during the fitting of pulleys and bearings. The fitting of bearings with the aid of hammers leaves blemishes on the bearing races. These initially small flaws increase with usage and can develop to a stage that completely impairs the bearing.The correct positioning of a pulley is shown in Figure 3.9.

Figure 3.9 - Correct positioning of pulley on the shaft


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RUNNING: To avoid needless radial stresses on the bearings it is imperative that shafts are parallel and the pulleys perfectly aligned. (Figure 3.10).

Figure 3.10 - Correct pulley alignment

Laterally misaligned pulleys, when running, transmit alternating knocks to the rotor and can damage the bearing housing. Belt slippage can be avoided by applying a resin (rosin for example).Belt tension should be sufficient to avoid slippage during operation (Figure 3.11).

Pulleys that are too small should be avoided; these cause shaft flexion because belt traction increases in proportion to a decrease in the pulley size. Table 1 determines minimum pulley diameters, and Tables 2 and 3 refer to the maximum stresses acceptable on motor bearings up to frame 580. Beyond frame size 600, an analysis should be requested from the WEG engineering.

Figure 3.11 - Belt tensions

Table 1 - Minimum pitch diameter of pulleys

Ball bearings

Frame Size X Inches Bearing 0.79 1.57 2.36 3.15 3.94 4.72 140 6205-Z 1.7 1.85 2 W 180 6206-Z 3.03 3.23 3.46 180 6307-Z 1.69 1.81 1.93 W 210 6308-Z 2.86 3.00 3.16 210 6308-Z 2.90 3.06 3.22 W 250 6309 C3 4.37 4.54 4.72 4.92 250 6309 C3 4.41 4.59 4.77 4.97 280 6311 C3 5.08 5.19 5.47 5.65 320 6312 C3 7.44 7.76 7.94 8.18 360 6314 C3 8.73 9.00 9.28 9.57 Ball Bearing Roller Bearing Frame Poles Size X Inches Size X Inches Bearing Bearing 1.97 3.15 4.33 5.51 1.97 3.15 4.33 5.51 6.69 8.27 II 6314 C3 7.3 7.62 7.94 8.24 - - - - - - 400 IV-VI-VII 6314 C3 NU 316 4.13 4.31 4.49 4.67 4.85 - II 6314 C3 11.75 12.16 12.61 13.08 - - - - - - 440 IV-VI-VIII 6319 C3 NU 319 4.02 4.17 4.32 4.47 4.62 4.82 II 6314 C3 23.54 24.34 25.12 25.87 - - - - - - 500 IV-VI-VIII 6319 C3 NU 319 6.52 6.73 6.95 7.17 7.39 7.67 II 6314 C3 44.66 45.79 46.98 48.23 - - - - - - 5008 IV-VI-VIII 6322 C3 NU 322 8.73 8.95 9.96 11.34 12.87 14.82 II 6314 C3 57 58 59 60 - - - - - - 580 IV-VI-VIII 6322 C3 NU 322 10.72 10.91 11.11 11.31 11.50 11.76 Important: 1) Peripheral speeds for solid grey cast iron pulleys FC 200 is V = 115 ft/s 2) Use steel pulleys when peripheral speed is higher than 115 ft/s 3) V-belt speed should not exceed 115 ft/s.Table 2 - Maximum acceptable radial load (Lbf)


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Nema 56 Motors Saw Arbor Motors Radial Force (Lbf) 80 LMS II - 355 - Frame Distance X 80 MMS II - 359 - Poles 1 1,18 2 80 SMS II - 357 - II 88 - 59 II 427 - 56A 90 LMS IV 88 - 59 IV - 555 - II 88 - 59 56B IV 86 - 59 II 127 - 70 56D IV 141 - 70

Table 3 - Maximum acceptable axial load (Lbf)IP55 Totally Enclosed Motors - 60Hz

Position / Construction Form

F R A M E II IV VI VIII II IV VI VIII II IV VI VIII II IV VI VIII 140 103 141 167 187 112 152 185 207 99 132 158 178 105 143 174 198 W 180 108 145 180 202 154 209 255 286 94 130 165 183 141 194 240 269 180 149 207 249 286 269 370 443 500 136 189 229 266 253 352 421 480 W 210 196 264 326 368 329 447 544 610 176 238 297 339 310 421 518 582 210 189 257 315 357 324 443 533 599 160 220 275 310 295 405 493 553 W 250 282 372 443 485 471 620 734 811 240 317 394 414 430 564 685 743 250 273 368 436 485 463 615 727 813 220 310 379 421 410 557 672 749 280 355 480 551 624 621 826 959 1,082 275 388 427 502 540 736 838 961 320 374 498 588 668 703 930 1,091 1,232 266 366 432 511 597 793 937 1,078 360 890 1,181 1,144 1,323 890 1,181 1,375 1,552 745 985 1,144 1,323 745 985 1,144 1,323 400 877 1,148 1,347 1,521 877 1,148 1,347 1,521 705 890 1,060 1,241 705 890 1,060 1,241 440 842 1,303 1,563 1,821 842 1,303 1,563 1,821 568 884 1,109 1,488 568 884 1,109 1,488 500 769 1,250 1,481 1,728 769 1,250 1,481 1,728 355 721 844 1,190 355 721 844 1,109 5008 791 1624 1909 2137 791 1624 1909 2137 728 1548 1808 2029 728 1548 1808 2029 580 679 1,406 1,649 1,865 679 1,406 1,649 1,865 033 474 549 597 033 474 549 597

Open Motors - NEMA 56 Frames - 60HzPosition / Construction Form

F R A M E II IV II IV II IV II IV 56 A 68 90 83 112 63 85 79 108 56 B 66 90 81 110 63 83 77 105 56 D 63 88 105 145 59 81 101 138


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The maximum radial load for each frame are determined, by graphs.

INSTRUCTIONS ON HOW TO USE THE GRAPHS1 - Maximum radial load on shaft.2 - Maximum radial load on bearings.

Where: X - Half of pulley width (inches) Fr- Maximum radial load in relation to the diameter and

pulley width.

Example:Verify whether a 2HP motor, II Pole, 60Hz withstands a radial load of 110Lb, considering a pulley width of 4 inches.

Frame : 145TFr : 110LbX : 2 inches

1 - Mark the distance X2 - Find out line N = 3600 for bearing Based on the above, this bearing withstands a radial load of 130 Lb.


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Note: For frames 600 and above, consult your engineering representative.


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3.2 Electrical Aspects

3.2.1 Feed SystemProper electric power supply is very important. The choice of motor feed conductors, whether branch or distribution circuits, should be based on the rated current of the motors as per NFPA-70 Standard article 430.Tables 4, 5 and 6 show minimum conductor gauges sized according to maximum current capacity and maximum voltage drop in relation to the distance from the distribution center to the motor, and to the type of installation (Overhead or in ducts).

To determine the conductor gauge proceed as follows:

a) Determine the current by multiplying the current indicated on the motor nameplate by 1.25 and then locate the resulting value on the corresponding table.If the conductor feeds more than one motor, the value to be sought on the table should be equal 1.25 times the rated current of the largest motor plus the rated current of the other motors.In the case of variable speed motors, the highest value among the rated currents should be considered.When motor operation is intermittent, the conductors should have a current carrying capacity equal or greater, to the product of the motor rated current times the running cycle factor shown on Table 7.

Table 7 - Running cycle factor

Motor short time 5min 15min 30 at Conti- Duty rating 60min nuous Classification

Short (operating valves, 1.10 1.20 1.50 - activating contacts etc)

Intermittent (passenger or 0.85 0.85 0.90 1.40 freight elevators, tools, pumps, rolling bridges etc)

Cyclic (rolling mills, 0.85 0.90 0.95 1.40 mining machines etc)

Variable 1.10 1.20 1.50 2.00

b) Locate the rated voltage of the motor and the feed network distance in the upper part of the corresponding table. The point of intersection of the distance column and the line referring to current will indicate the minimum required gauge of the conductor.

Example:Size the conductors for a 15 HP, three-phase, 230V, 42A, motor located 200 feet from the main supply with cables laid in conduits.

a) Current to be located: 1.25 x 42A = 52.5Ab) Closest value on table 6:55Ac) Minimum gauge: 6 AWG

3.2.2 Starting of Electric MotorInduction motors can be started by the following methods:

Direct StartingWhenever possible a three-phase motor with a squirrel cage rotor should be started directly at full supply voltage by means of a contactor (Connection diagram a). This method is called Direct-on-Line (DoL) starting.


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Table 4 - Wire and cable gauges for single-phase motor installation (voltage drop < 5%) (in conduits)Supply Voltage Distance of motor from distribution centre (feet)

115 34 51 69 85 102 137 171 205 240 273 308 342 428 514 230 69 102 138 170 204 274 342 410 480 546 616 684 856 1028 460 138 204 276 340 408 548 684 820 960 1092 1232 1368 1712 2056 575 170 250 338 420 501 670 840 1010 1181 1342 1515 1680 2105 2530

Current (A) Cable gauge (conductor)

5 14 14 14 14 14 14 14 12 12 12 12 10 10 8 10 14 14 14 14 12 12 10 10 10 8 8 8 6 6 15 12 12 12 12 12 10 8 8 6 6 6 6 4 2 20 12 12 12 10 10 8 8 6 6 6 4 4 4 2 30 10 10 10 8 8 6 6 6 4 4 2 2 2 1/0 40 8 8 8 8 6 6 4 4 2 2 2 2 1/0 2/0 55 6 6 6 6 6 4 4 2 2 1/0 1/0 1/0 1/0 2/0 70 4 4 4 4 4 2 2 2 1/0 1/0 2/0 2/0 2/0 2/0 95 2 2 2 2 2 2 1/0 1/0 1/0 2/0 3/0 3/0 4/0 250M

Table 5 - Wire and cable gauges for three-phase motor installation - aerial conductors with 25cm spacing (voltage drop < 5%)

Supply Voltage Distance of motor from distribution centre (feet)

115 51 69 85 102 137 171 205 240 273 308 342 428 514 685 230 102 138 170 204 274 342 410 480 546 616 684 856 1028 1370 460 204 276 340 408 547 684 820 960 1092 1232 1368 1712 2056 2740 575 250 338 420 501 670 840 1010 1181 1342 1515 1680 2105 2530 3350


15 14 14 14 12 12 10 10 10 8 8 8 6 6 4 20 14 14 12 12 10 10 8 8 8 6 6 4 4 2 30 14 12 10 8 8 8 6 6 4 4 4 2 2 1/0 40 12 10 10 8 8 6 4 4 4 2 2 2 1/0 2/0 55 10 10 8 8 6 4 4 2 2 2 1/0 2/0 3/0 -- 70 8 8 6 6 4 2 2 2 1/0 1/0 2/0 3/0 -- -- 100 6 6 4 4 2 2 1/0 2/0 3/0 4/0 4/0 -- -- -- 130 4 4 4 2 1/0 1/0 2/0 4/0 -- -- -- -- -- -- 175 2 2 2 1/0 2/0 3/0 -- -- -- -- -- -- -- -- 225 1/0 1/0 1/0 2/0 3/0 -- -- -- -- -- -- -- -- -- 275 2/0 2/0 2/0 4/0 -- -- -- -- -- -- -- -- -- -- 320 3/0 3/0 3/0 4/0 -- -- -- -- -- -- -- -- -- --

Table 6 - Wire and cable gauges for three-phase motor installation (voltage drop < 5%) (in conduits)

Supply Voltage Distance of motor from distribution centre (feet)

115 85 102 120 137 171 205 240 273 308 342 428 514 230 170 204 240 274 342 410 480 546 616 684 856 1028 460 340 408 480 548 684 820 960 1092 1232 1368 1712 2056 575 420 501 590 670 840 1010 1181 1342 1515 1680 2105 2530


15 12 12 12 10 10 8 8 8 6 6 6 4 20 12 10 10 10 8 8 6 6 6 6 4 4 30 10 8 8 8 6 6 6 4 4 4 2 2 40 8 8 6 6 6 4 4 4 2 2 2 1/0 55 6 6 6 4 4 4 2 2 2 1/0 1/0 1/0 70 4 4 4 4 2 2 2 1/0 1/0 1/0 2/0 2/0 95 2 2 2 2 2 1/0 1/0 1/0 1/0 2/0 3/0 4/0 125 1/0 1/0 1/0 1/0 1/0 1/0 2/0 2/0 3/0 3/0 4/0 250M 145 2/0 2/0 2/0 2/0 2/0 2/0 2/0 3/0 3/0 4/0 250M 300M 165 3/0 3/0 3/0 3/0 3/0 3/0 3/0 3/0 4/0 4/0 250M 350M 195 4/0 4/0 4/0 4/0 4/0 4/0 4/0 4/0 250M 250M 300M 350M 215 250M 250M 250M 250M 250M 250M 250M 250M 250M 300M 350M 400M 240 300M 300M 300M 300M 300M 300M 300M 300M 300M 300M 400M 500M 265 350M 350M 350M 350M 350M 350M 350M 350M 350M 350M 500M 500M 280 400M 400M 400M 400M 400M 400M 400M 400M 400M 400M 400M -- 320 500M 500M 500M 500M 500M 500M 500M 500M 500M 500M 500M --

Note: The above indicated values are orientative. For guaranteed values, contact the Local Power Company.


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There are DOL starter assemblies available combining a three-pole contactor, a bimetal relay (overload protection device), and a fuse (short circuit protection on branch circuit). DOL starting is the simplest method, only feasible however, when the locked rotor current (LRC) does not influence the main electric supply lines.Initial locked rotor current (LRC) in induction motors reach values six to eight times the value of the full load current. During starting by the DOL method, starting current can reach these high levels. The main electrical supply should be rated sufficiently, such that during the starting cycle no supply disturbance to others on the power network is caused by the voltage drop in the main supply.This can be achieved under one of the following situations: a) The rated main supply current is high enough for the locked

rotor current not to be proportionally high;b) Motor locked rotor current is low with no effect on the

networks.c) The motor is started under no-load conditions with a short

starting cycle and, consequently, a low locked rotor current with a transient voltage drop tolerable to other consumers.

Starting with a compensating switch (auto-transformer starting)Should direct on line starting not be possible, either due to restrictions imposed by the power supply authority or due to the installation itself, reduced voltage indirect starting methods can be employed to lower the locked rotor current. The single line connection diagram (C) shows the basic components of a compensating switch featuring a transformer (usually an auto-transformer) with a series of taps corresponding to the different values of the reduced voltage. Only three terminals of the motor are connected to the switch, the other being interconnected as per diagram, for the indicated voltage.

Star-Delta startingIt is fundamental to star-delta starting that the three-phase motor has the necessary numbers of leads for both connections:

6 leads for Y/Δor 12 leads for YY/ΔΔ

All the connections for the various voltages are made through terminals in the terminal box in accordance with the wiring diagram that accompanies the motor. This diagram may be shown on the nameplate or in the terminal box.The star-delta connection is usually used only in low-voltage motors due to normally available control and protection devices. In this method of starting the locked rotor current is approximately 30% of the original LRC. The locked rotor torque is reduced proportionally as well. For this reason, it is very important before deciding to use star-delta starting to verify if the reduced locked rotor torque in “STAR” connection is enough to accelerate the load.

3.2.3 Motor ProtectionMotor circuits have, in principle, two types of protection: motor

overload, locked rotor and protection of branch circuit from short circuits. Motors in continuous use should be protected from overloading by means of a device incorporated into the motor, or by an independent device, usually a fixed or adjustable thermal relay equal or less than to the value derived from multiplying the rated feed current at full load by:

- 1.25 for motors with a service factor equal or superior to 1.15 or;

- 1.15 for motors with service factor equal to 1.0.

Some motors are optionally fitted with overheating protective detectors (in the event of overload, locked rotor, low voltage, inadequate motor ventilation) such as a thermostat (thermal probe), thermistor (PTC), RTD type resistance which dispense with independent devices.

THERMOSTAT (THERMAL PROBE): bimetallic thermal detectors with normally closed silver contacts. These open at pre-determined temperatures. Thermostats are series connected directly to the contactor coil circuit by two conductors.

THERMISTORS: Semi-conductor heat detectors positive temperature coeficient (PTC) that sharply change their resistance upon reaching a set temperature. Thermistors, depending upon the type, are series or parallel-connected to a control unit that cuts out the motor feed, or actuates an alarm system, in response to the thermistors reaction.

Resistance temperature detectors (RTD) - PT 100The resistance type heat detector (RTD) is a resistance element usually manufactured of copper or platinum.The RTD operates on the principle that the electrical resistance of a metallic conductor varies linearly with the temperature. The detector terminals are connected to a control panel, usually fitted with a temperature gauge, a test resistance and a terminal changeover switch.Subject to the desired degree of safety and the client’s specification, three (one per phase) or six (two per phase) protective devices can be fitted to a motor for the alarm stems, circuit breaker or combined alarm and circuit breaker, with two leads from the terminal box to the alarm or circuit breaker system and four for the combined system (alarm and circuit breaker).Table 9 compares the two methods of protection.

3.3 Start-up3.3.1 Preliminary InspectionBefore starting a motor for the first time, it will be necessary to:a) Remove all locking devices and blocks used in transit and

check that the motor rotates freely;

b) Check that the motor is firmly secured and that coupling elements are correctly mounted and aligned.;

c) Ascertain that voltage and frequency correspond to those


19

indicated on the nameplate. Motor performance will be satisfactory with main supply voltage fluctuation within ten per cent of the value indicated on the nameplate or a frequency fluctuation within five per cent or, yet, with a combined voltage and frequency variance within ten per cent;

d) Check that connections are in accordance with the connection diagram shown on the nameplate and be sure that all terminal screws and nuts are tight;

e) Check the motor for proper grounding. Providing that there are no specifications calling for ground-insulated installation, the motor must be grounded in accordance with prevalent standard for grounding electrical machines. The screw identified by the symbol should be used for this purpose.

This screw is generally to be found in the terminal box or on one foot of the frame;

f) Check that motor leads connecting with the mains, as well as the control wires and the overload protection device, are in accordance with Nema Standards;

g) If the motor has been stored in a damp place, or has been stopped for some time, measure the insulating resistance as recommended under the item covering storage instructions;

h) Start the motor uncoupled to ascertain that it is turning in the desired direction. To reverse the rotation of a three-phase motor, invert two terminal leads of the mains supply.

High voltage motors bearing an arrow on the frame indicating rotation direction can only turn in the direction shown;

Table 9 - Comparison between motor protection system

Current-based Protection protection with Causes of probe overheating Fuse and thermistor Fuse only thermal in motor protector

1. Overload with 1.2 times rated current

2. Duty cycles S1 to S8 IEC 34, EB 120

3. Brakings, reversals and frequent starts

4. Operating with more than 15 starts p/hour

5. Locked rotor

6. Fault on one phase

7. Execessive voltage fluctuation

8. Frequency fluctuation on main supply

9. Excessive ambient temperature

10. External heating caused by bearings, belts, pulleys etc.

11. Obstructed ventilation

Caption: unprotected

partially protected

totally protected


20

a) Direct startingPOWER NETWORK

c) Auto-transformer startingPOWER NETWORK

CONNECTION DIAGRAMS

b) Star-Delta startingPOWER NETWORK


21

3.3.2 The First Start-up

Three-Phase Motor with Cage Rotor

After careful examination of the motor, follow the normal sequence of starting operations listed in the control instructions for the initial start-up.

3.3.3 Operation

Drive the motor coupled to the load for a period of at least one hour while watching for abnormal noises or signs of overheating.Compare the line current with the value shown on the nameplate.Under continuous running conditions without load fluctuations this should not exceed the rated current times the service factor, also shown on the nameplate.All measuring and control instruments and apparatus should be continuously checked for anomalies, and any irregularities corrected.

3.3.4 Stopping

Warning:

To touch any moving part of a running motor, even though disconnected, is a danger to life and limb.

a) Three-phase motor with cage rotor: Open the stator circuit switch. With the motor at a complete

stop, reset the auto-transformer, if any, to the “start” position;


22

HO

RIZ

ON

TAL

MO

UN

TIN

G O

NLY

ODP Motors Bearings Nema-T Mounting frames Front (D.E.) Rear (O.D.E.) E143/5T 6205 ZZ 6204 ZZ F143/5T 6205 ZZ 6204 ZZ 182 T 6206 ZZ 6205 ZZ 184 T 6202 ZZ 6205 ZZ 213/5T 6208 ZZ 6206 ZZ 254 T 6309 Z-C3 6209 Z-C3 256 T 6309 Z-C3 6209 Z-C3 284 T 6311 Z-C3 6211 Z-C3 284 TS 6311 Z-C3 6211 Z-C3 286 T 6311 Z-C3 6211 Z-C3 286 TS 6311 Z-C3 6211 Z-C3 324 T 6312 Z-C3 6212 Z-C3 324 TS 6312 Z-C3 6212 Z-C3 326 T 6312 Z-C3 6212 Z-C3 326 TS 6312 Z-C3 6212 Z-C3 364 T 6314 C3 6314 C3 364 TS 6314 C3 6314 C3 365 T 6314 C3 6314 C3 365 TS 6314 C3 6314 C3 404 T NU 316 C3 6314 C3 404 TS 6314 C3 6314 C3 405 T NU 316 C3 6314 C3 405 TS 6314 C3 6314 C3 444 T NU 319 C3 6316 C3 444 TS 6314 C3 6314 C3 445 T NU 319 C3 6316 C3 445 TS 6314 C3 6314 C3

IEC Bearings Mounting frame Front (D.E.) Rear (O.D.E.)

Totally enclosed fan cooled motors 63 6201 ZZ 6201 ZZ 71 6203 ZZ 6202 ZZ 80 6204 ZZ 6203 ZZ 90 S - L 6205 ZZ 6204 ZZ 100 L 6206 ZZ 6205 ZZ 112 M 6307 ZZ 6206 ZZ 132 S - M 6308 ZZ 6207 ZZ 160 M - L 6309-C3 6209 Z-C3 180 M - L B3 6311-C3 6211 Z-C3 200 M - L 6312-C3 6212 Z-C3 225 S/M 6314-C3 6314-C3 250 S/M 6314-C3 6314-C3 280 S/M 6314-C3 6314-C3 6316-C3 6316-C3 315 S/M 6314-C3 6314-C3 6319-C3 6316-C3 355 M/L 6314-C3 6314-C3 NU 322-C3 6319-C3

ALL

FOR

MS

Table 11 - Bearing specifications by type of motor

NEMA Bearings Mounting Frames Front (D.E.) Rear (O.D.E.)

Open drip proof motors B48 and C48 6203 Z 6202 Z 56 and A56 6203 Z 6202 Z B56 and C56 6203 Z 6202 Z D56 and 6204 Z 6202 Z / F56H/G56H 6203 Z

Totally enclosed fan cooled motors 143 T 6205 ZZ 6204 ZZ 145 T 6205 ZZ 6204 ZZ 182 T 6307 ZZ 6206 ZZ 184 T 6307 ZZ 6206 ZZ W 182 T 6206 ZZ 6205 ZZ W 184 T 6206 ZZ 6205 ZZ 213 T 6308 ZZ 6207 ZZ 215 T 6308 ZZ 6207 ZZ W 213 T 6308 ZZ 6207 ZZ W 215 T 6308 ZZ 6207 ZZ 254 T 6309-C3 6209 Z-C3 256 T 6309-C3 6209 Z-C3 W 254 T 6309-C3 6209 Z-C3 W 256 T 6309-C3 6209 Z-C3 284 T and TS 6311-C3 6211 Z-C3 286 T and TS 6311-C3 6211 Z-C3 324 T and TS 6312-C3 6212 Z-C3 326 T and TS 6312-C3 6212 Z-C3 364 T and TS 6314-C3 6314-C3 365 T and TS 6314-C3 6314-C3 404 T NU 316-C3 6314-C3 404 TS 6314-C3 6314-C3 405 T NU 316-C3 6314-C3 405 TS 6314-C3 6414-C3 444 T NU 319-C3 6316-C3 444 TS 6314-C3 6314-C3 445 T NU 319-C3 6316-C3 445 TS 6314-C3 6314-C3 447 T NU 319-C3 6316-C3 447 TS 6314-C3 6314-C3 449 T NU 322-C3 6319-C3 449 TS 6314-C3 6314-C3 504 T NU 319-C3 6316-C3 504 TS 6314-C3 6314-C3 505 T NU 319-C3 6316-C3 505 TS 6314-C3 6314-C3 5008 T NU 322-C3 6319-C3 5008TS 6314-C3 6314-C3 586 T NU 322-C3 6319-C3 586 TS 6314-C3 6314-C3 587 T NU 322-C3 6319-C3 587 TS 6314-C3 6314-C3

Saw Arbor Bearings motor Mounting frame Front (D.E.) Rear (O.D.E.) 80 S MS 6307 ZZ 6207 ZZ 80 M MS 6307 ZZ 6207 ZZ 80 L MS 6307 ZZ 6207 ZZ 90 L MS 6308 ZZ 6208 ZZ

ALL

FO

RM

S

B3


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Table 12 - Bearing lubrication intervals and amount of grease

1 - SINGLE-ROW FIXED BALL BEARINGS Lubrication intervals (running hours)

Bearings II Pole IV Pole VI Pole VIII Pole X Pole XII Pole

60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz Amount Characteristics 3600 3000 1800 1500 1200 1000 900 750 720 600 600 500 of grease Ref. rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm (oz) 6200 12500 13800 0,07 6201 11700 13000 16600 18400 0,07 6202 10500 11900 15400 17100 19500 0,07 6203 9800 11200 14500 16200 18500 0,11 6 6204 8700 10100 13300 14800 17100 19100 > 20000 0,14 2 6205 8000 9400 12600 14100 16200 18200 19300 0,14 6206 7300 8700 12000 13400 15400 17200 18300 0,18 S 6207 6600 8100 11400 12700 14500 16300 17300 19200 0,25 E 6208 5900 7400 10800 12000 13700 15300 16300 18200 0,29 R 6209 5300 6900 10400 11600 13400 15000 16000 17800 0,29 I 6210 4900 6400 9700 11000 12900 14600 15600 17300 0,32 E 6211 4300 5900 9500 10900 12700 14400 15300 17000 0,39 S 6212 3800 5400 9300 10300 12400 14300 15200 16500 0,46 6213 3100 4900 8900 10100 12200 14000 14800 16100 0,50 6214 1100 2000 4100 5000 5900 6500 6900 7600 0,54 6215 1000 1800 4400 5000 5600 6300 6700 7600 0,61 6216 700 1600 4100 4700 5700 6500 6800 7500 0,68

6304 8700 10100 13300 14800 17100 19100 0,14 6305 8000 9400 12600 14100 16200 18200 19300 0,21 6306 7300 8700 12000 13400 15400 17200 18300 > 20000 0,25 6307 6600 8100 11400 12700 14500 16300 17300 19200 0,32 6308 5900 7400 10800 12000 13700 15300 16300 18200 18600 0,39 6 6309 5300 6900 10400 11600 13400 15000 16000 17800 18200 19900 0,46 3 6310 4900 6400 9700 11000 12900 14600 19500 17300 17700 19500 19500 0,54 6311 4300 5900 9500 10900 12700 14400 15300 17000 17400 19000 19000 0,64 S 6312 3800 5400 9300 10300 12400 14300 15200 16500 16800 18200 18200 0,75 E 6313 3100 4900 8900 10100 12200 14000 14800 16100 16400 17900 17900 19700 0,86 R 6314 1100 2000 4100 5000 5900 6500 6900 7600 7700 8600 8600 9600 0,96 I 6315 1000 1800 4400 5000 5600 6300 6700 7600 7900 8900 8900 9900 1,07 E 6316 700 1600 4100 4700 5700 6500 6800 7500 7700 8500 8500 9500 1,22 S 6317 800 1300 3900 4700 5600 6300 6700 7400 7500 8300 8300 9300 1,32 6318 - 1000 3800 4600 5500 6200 6600 7200 7400 8200 8200 9100 1,47 6319 - 800 3700 4500 5400 6100 6500 7100 7300 8000 8000 8900 1,61 6320 - - 3600 4300 5300 6000 6300 7000 7100 7900 7900 8800 1,82 6321 - - 3400 4200 5100 5800 6200 6800 7000 7800 7800 8700 2,00 6322 - - 3100 4000 5000 5700 6100 6700 6900 7700 7700 8600 2,14

1) Lubrication periodicity valid for NLG 1 and lithium based bearing lubricant.2) Bearings for motors of X and XII poles - Lubrication Intervals > 20,000.


24

Table 13 - Bearing lubrication intervals and amount of grease

2 - CYLINDRICAL ROLLER BEARINGS Lubrication intervals (running hours)

Bearings II Pole IV Pole VI Pole VIII Pole X Pole XII Pole

60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz Amount Characteristics 3600 3000 1800 1500 1200 1000 900 750 720 600 600 500 of grease Ref. rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm (oz) NU309 2800 4000 8300 9500 10700 11800 12500 14100 14500 16300 16300 18200 0,46 N NU310 2400 3600 7900 9100 10300 11400 12200 13700 14000 15800 15800 17700 0,54 U NU311 2000 3200 7400 8700 10000 11000 11800 13300 13600 15400 15400 17200 0,64 NU312 1600 2700 6900 8300 9600 10700 11400 12800 13200 14900 14900 16800 0,75 3 NU313 1500 2500 6600 8100 9400 10500 11200 12700 13000 14700 14700 16500 0,86 NU314 700 1100 3100 3900 4600 5200 5500 6200 6400 7200 7200 8100 0,96 NU315 - 900 2900 3800 4500 5100 5500 6200 6300 7100 7100 7900 1,07 S NU316 - 800 2800 3600 4400 5000 5400 6100 6200 7000 7000 7800 1,22 E NU317 - 600 2600 3500 4300 4900 5300 6000 6100 6900 6900 7700 1,32 R NU318 - - 2100 3300 4300 4900 5300 5900 6000 6700 6700 7500 1,47 I NU319 - - 2300 3200 4100 4700 5100 5800 6000 6700 6700 7500 1,61 E NU320 - - 2000 3000 4000 4700 5000 5700 5900 6600 6600 7300 1,82 S NU321 - - 1900 2800 4000 4600 4900 5600 5700 6500 6500 7200 2,00 NU322 - - 1900 2600 3900 4400 4800 5500 5600 6400 6400 7100 2,14

1) Lubrication periodicity valid for NLG 1 and 2 lithium based bearing lubricant.


25

4. Maintenance

A well-designed maintenance program for electric motors can be summed up as: periodical inspection of insulation levels, temperature rise, wear, bearing lubrication and the occasional checking of fan air flow. Inspection cycles depend upon the type of motor and the conditions under which it operates.

4.1 CleanlinessMotors should be kept clean, free of dust, debris and oil. Soft brushes or clean cotton rags should be used for cleaning. A jet of compressed air should be used to remove non-abrasive dust from the fan cover and any accumulated grime from the fan and cooling fins.Oil or damp impregnated impurities can be removed with rags soaked in a suitable solvent.Terminal boxes fitted to motors with IP55 protection should be cleaned; their terminals should be free of oxidation, in perfect mechanical condition, and all unused space dust-free.Motors with IPW 55 protection are recommended for use under unfavourable ambient conditions.

4.2 LubricationProper lubrication extends bearing life.

Lubrication Maintenance Includes:a) Attention to the overall state of the bearings;b) Cleaning and lubrication;c) Critical inspection of the bearings.

Motor noise should be measured at regular intervals of one to four months. A well-tuned ear is perfectly capable of distinguishing unusual noises, even with rudimentary tools such as a screw driver, etc., without recourse to sophisticated listening aids or stethescopes that are available on the market.A uniform hum is a sign that a bearing is running perfectly. Bearing temperature control is also part of routine maintenance. The temperature of bearings lubricated as recommended under item 4.2.2 should not exceed 70°C.Constant temperature control is possible with the aid of external thermometers or by embedded thermal elements. WEG motors are normally equipped with grease lubricated ball or roller bearings.Bearings should be lubricated to avoid metallic contact of the moving parts, and also for protection against corrosion and wear. Lubricant properties deteriorate in the course of time and mechanical operation: furthermore, all lubricants are subject to contamination under working conditions.For this reason lubricants must be renewed and any lubricant consumed needs replacing from time to time.

4.2.1 Periodical LubricationWEG motors are supplied with sufficient grease for a long

period. Lubrication intervals, the amount of grease and the type of bearing used in frames 140T to 580T are to be found in Tables 11, 12 and 13.Lubrication intervals depend upon the size of the motor, speed, working conditions and the type of grease used.

4.2.2 Quality and Quantity of GreaseCorrect lubrication is important!Grease must be applied correctly and in sufficient quantity as both insufficient or excessive greasing are harmful.Excessive greasing causes overheating brought about by the greater resistance encountered by the rotating parts and, in particular, by the compacting of the lubricant and its eventual loss of lubricating qualities.This can cause seepage with the grease penetrating the motor and dripping on the coils.A lithium based grease is commonly used for the lubrication of electric motor bearings as it has good mechanical stability, is insoluble in water and has a drip point of approximately 200°C.This grease should never be mixed with sodium or calcium based greases.

GREASES FOR MOTOR BEARINGSFor operating temperatures from - 20 to 130°C

Frame Supplier Grease Temperature range 143T-215T Esso Alvania R3 -20 to 130ºC 254T to 586/7 Shell Unirex N2 -30 to 165ºC

Substitutes

Supplier Grease Temperature Range Mobil Mobilith SHC100 -40 to 177ºC ESSO Beacon 2 -20 to 130ºC Atlantic Litholine 2 -20 to 130ºC Texaco Multifak 2 -20 to 130ºC Molikote BG 20 -45 to 180ºC Inisilkon L5012 -20 to 200ºCNote: When changing lubricant, please follow manfacturers instructions

4.2.3 Lubricating Instructions

a) Frame 140T to 210T motorsFrame 140T to 210T size motors are not fitted with grease nipples. Lubrication is carried out during periodical overhauls when the motor is taken apart.

Cleaning and Lubrication of Bearings

With the motor dismantled and without extracting the bearings from the shaft, all existing grease should be removed and the bearings cleaned with Diesel oil, kerosene or other solvent, until thoroughly clean.


26

running Refill the spaces between the balls or rollers and the bearing cages with grease immediately after washing. Never rotate bearings in their dry state after washing.For inspection purposes apply a few drops of machine oil. During these operations maximum care and cleanliness is recommended to avoid the penetration of any impurities or dust that could harm the bearings. Clean all external parts prior to reassembly.

b) Frame 360T to 580T MotorsMotors above 360T frame size are fitted with regreasable bearing system.The lubrication system from this frame size upwards was designed to allow the removal of all grease from the bearing races through a bleeder outlet which at the same time impedes the entry of dust or other contaminants harmful to the bearing.This outlet also prevents injury to the bearings from the well-known problem of over-greasing. It is advisable to lubricate while the motor is running, to allow the renewal of grease in the bearing case.Should this procedure not be possible because of rotating parts in the proximity of the nipple (pulleys, coupling sleeves, etc.) that are hazardous to the operator the following procedure should be followed:- Inject about half the estimated amount of grease and run the motor at full speed for approximately a minute; switch off the motor and inject the remaining grease.The injection of all the grease with the motor at rest could cause penetration of a portion of the lubricant through the internal seal

of the bearing case and hence into the motor.Figure 4.1 - Bearings and lubrication system

Nipples must be clean prior to introduction of grease to avoid entry of any alien bodies into the bearing.For lubricating use only a manual grease gun.

Bearing Lubrication Steps

1. Cleanse the area around the grease nipples with clean cotton fabric.

2. With the motor running, add grease with a manual grease gun until the lubricant commences to be expelled from the bleeder outlet, or until the quantity of grease recommended in Tables 12 or 13 has been applied.

3. Allow the motor to run long enough to eject all excess grease.

4.2.4 Replacement of BearingsThe opening of a motor to replace a bearing should only be carried out by qualified personnel.Damage to the core after the removal of the bearing cover can be avoided by filling the gap between the rotor and the stator with stiff paper of a proper thickness.Providing suitable tooling is employed, disassembly of a bearing is not difficult.The extractor grips should be applied to the sidewall of the inner ring to be stripped, or to an adjacent part.To ensure perfect functioning and to prevent injury to the bearing parts, it is essential that the assembly be undertaken under conditions of complete cleanliness and by competent personnel.New bearings should not be removed from their packages until the moment of assembly.Prior to fitting a new bearing, ascertain that the shaft has no

rough edges or signs of hammering.Figure 4.2 - A bearing extractor

During assembly bearings cannot be subjected to direct blows.The aid used to press or strike the bearing should be applied to the inner ring.


27

4.3 Air Gap Checking (Large Rating Open Motors)

Upon the completion of any work on the bearings check the gap measurement between the stator and the rotor using the appropriate gazes.The gap variation at any two vertically opposite points must be less than 10% of the average gap measurement.

4.4 Explosion Proof Motor Repair Steps4.4.1 ObjectiveIn view of the heavy liability associated with burning of motors of this type, this product has been designed and manufactured to high technical standards, under rigid controls. In addition, in many areas it is required that explosion proof motors ONLY be repaired by licensed personnel or in licensed facilities authorized to do this type of work.

The following general procedures, safeguards, and guidelines must be followed in order to ensure repaired explosion proof motors operate as intended.

4.4.2 Repair Procedure and PrecautionsDismantle the damaged motor with appropriate tools without hammering and/or pitting machined surfaces such as enclosure joints, fastening holes, and all joints in general.The position of the fan cover should be suitably marked prior to removal so as to facilitate reassembly later on.Examine the motor’s general condition and, if necessary, disassemble all parts and clean them with kerosene. Under no circumstances should scrapers, emery papers or tools be used that could affect the dimensions of any part during cleaning.

Protect all machined parts against oxidation by applying a coating of vaseline or oil immediately after cleaning.

STRIPPING OF WINDINGSThis step requires great care to avoid knocking and/or denting of enclosure joints and, when removing the sealing compound from the terminal box, damage or cracking of the frame.

IMPREGNATIONProtect all frame threads by inserting corresponding bolts, and the joint between terminal box and frame, by coating it with a non-adhesive varnish (ISO 287 - ISOLASIL).Protective varnish on machined parts should be removed soon after treating with impregnating varnish. This operation should be carried out manually without using tools.

ASSEMBLYInspect all parts for defects, such as cracks, joint incrustations, damaged threads and other potential problems.Assemble using a rubber headed mallet and a bronze bushing after ascertaining that all parts are perfectly fitted.Bolts should be positioned with corresponding spring washers and evenly tightened.

TESTINGRotate the shaft by hand while examining for any drag problems on covers or fastening rings.Carry out running tests as for standard motors.

MOUNTING THE TERMINAL BOXPrior to fitting the terminal box all cable outlets on the frame should be sealed with a sealing compound (Ist layer) and an Epoxy resin (ISO 340) mixed with ground quartz (2nd layer) in the following proportions:

340A resin 50 parts 340B resin 50 parts Ground quartz 100 parts

Drying time for this mixture is two hours during which the frame should not be handled and cable outlets should be upwards.When dry, see that the outlets and areas around the cables are perfectly sealed.Mount the terminal box and paint the motor.

4.4.3 Miscellaneous Recommendations• Any damaged parts (cracks, pittings in machined surfaces,

defective threads) must be replaced and under no circumstances should attempts be made to recover them.

• Upon reassembling explosion proof motors IPW55 the substitution of all seals is mandatory.

• Should any doubts arise, consult WEG.


28

Most malfunctions affecting the normal running of electric motors can be prevented by maintenance and the appropriate precautions.While ventilation, cleanliness and careful maintenance are the main factors ensuring long motor life, a further essential factor is the prompt attention to any malfunctioning as signalled by vibrations, shaft knock, declining insulation resistance, smoke or fire, sparking or unusual slip ring or brush wear, sudden changes of bearing temperatures.When failures of an electric or mechanical nature arise, the first step to be taken is to stop the motor and subsequent examination of all mechanical and electrical parts of the installation.In the event of fire, the installation should be isolated from the mains supply, which is normally done by turning off the respective switches.In the event of fire within the motor itself, steps should be taken to restrain and suffocate it by covering the ventilation vents. To extinguish a fire, dry chemical or C02 extinguishers should be used - never water.

5.1 Standard Three-Phase Motor FailuresOwing to the widespread usage of asynchronous three-phase motors in industry which are more often repaired in the plant workshops, there follows a summary of possible failures and their probable causes, detection and repairs.Motors are generally designed to Class B or F insulation and for ambient temperatures up to 40°C.Most winding defects arise when temperature limits, due to current overload, are surpassed throughout the winding or even in only portions thereof. These defects are identified by the darkening or carbonizing of wire insulation.

5.1.1 Short Circuits Between TurnsA short circuit between turns can be a consequent of two coinciding insulation defects, or the result of defects arising simultaneously on two adjacent wires. As wires are randomly tested, even the best quality wires can have weak spots. Weak spots can, on occasion, tolerate a voltage surge of 30% at the time of testing for shorting between turns, and later fail due to humidity, dust or vibration.Depending on the intensity of the short, a magnetic hum becomes audible.In some cases, the three-phase current imbalance can be so insignificant that the motor protective device fails to react. A short circuit between turns, and phases to ground due to insulation failure is rare, and even so, it nearly always occurs during the early stages of operation.

5.1.2 Winding Failuresa) One burnt winding phaseThis failure arises when a motor runs wired in delta and current

5. Malfunctioning fails in one main conductor.Current rises from 2 to 2.5 times in the remaining winding with a simultaneous marked fall in speed. If the motor stops, the current will increase from 3.5 to 4 times its rated value.In most instances, this defect is due to the absence of a protective switch, or else the switch has been set too high.

b) Two burnt winding phasesThis failure arises when current fails in one main conductor and the motor winding is star-connected. 0ne of the winding phases remains currentless while the others absorb the full voltage and carry an excessive current.The slip almost doubles.

c) Three burnt winding phasesProbable cause 1Motor only protected by fuses; an overload on the motor will be the cause of the trouble.Consequently, progressive carbonizing of the wires and insulation culminate in a short circuit between turns, or a short against the frame occurs.A protective switch placed before the motor would easily solve this problem.

Probable cause 2Motor incorrectly connected. For example: A motor with windings designed for 230/400V is connected through a star-delta switch to 400V connection.The absorted current will be so high that the winding will burn out in a few seconds if the fuses or a wrongly set protective switch fail to react promptly.

Probable cause 3The star-delta switch is not commutated and the motor continues to run for a time connected to the star under overload conditions.As it only develops 1/3 of its torque, the motor cannot reach rated speed. The increased slip results in higher ohmic losses arising from the Joule effect. As the stator current, consistent with the load, may not exceed the rated value for the delta connection, the protective switch will not react.Consequent to increased winding and rotor losses the motor will overheat and the winding burn out.

Probable cause 4Failures from this cause arise from thermal overload, due to too many starts under intermittent operation or to an overly long starting cycle. The perfect functioning of motor operating under these conditions is only assured when the following values are heeded:a) number of starts per hour;b) starting with or without load;c) mechanical brake or current inversion;d) acceleration of rotating masses connected to motor shafte) load torque vs. speed during acceleration and braking.

The continuous effort exerted by the rotor during intermittent


29

starting brings about heavier losses which provoke overheating.Under certain circumstances with the motor idle there is a possibility that the stator winding is subjected to damage as a result of the heating of the motor. In such a case, a slip ring motor is recommended as a large portion of the heat (due to rotor losses) is dissipated in the rheostat.

5.1.3 Rotor FailuresIf a motor running under load conditions produces a noise of varying intensity and decreasing frequency while the load is increased, the reason, in most cases, will be an unsymmetrical rotor winding.In squirrel-cage motors the cause will nearly always be a break in one or more of the rotor bars; simultaneously, periodical stator current fluctuations may be recorded. As a rule, this defect appears only in molded or die cast aluminum cages.Failures due to spot heating in one or another of the bars in the rotor stack are identified by the blue coloration at the affected points.Should there be failures in various contiguous bars, vibrations and shuddering can occur as if due to an unbalance, and are often interpreted as such. When the rotor stack acquires a blue or violet coloration, it is a sign of overloading.This can be caused by overly high slip, by too many starts or overlong starting cycles. This failure can also arise from insufficient main voltage.

5.1.4 Bearing FailuresBearing damage is a result of overloading brought about by an overly taut belt or axial impacts and stresses.Underestimating the distance between the drive pulley and the driven pulley is a common occurrence.The arc of contact of the belt on the drive pulley thus becomes inadmissibly small and thereby belt tension is insufficient for torque transmission.In spite of this it is quite usual to increase belt tension in order to attain sufficient drive.Admittably, this is feasible with the latest belt types reinforced by synthetic materials.However, this practice fails to consider the load on the bearing and the result is bearing failure within a short time.Additionally there is the possibility of the shaft being subjected to unacceptably high loads when the motor is fitted with a pulley that is too wide.

5.1.5 Shaft FracturesAlthough bearings traditionally constitute the weaker part, and the shafts are designed with wide safety margins, it is not beyond the realm of possibility that a shaft may fracture by fatigue from bending stress brought about by excessive belt tension.In most cases, fractures occur right behind the drive end bearing.

As a consequence of alternating bending stress induced by a rotating shaft, fractures travel inwards from the outside of the shaft until the point of rupture is reached when resistance of the remaining shaft cross-section no longer suffices.Avoid additional drilling the shaft (fastening screw holes) as such operations tend to cause stress concentration.

5.1.6 Unbalanced V-Belt DrivesThe substitution of only one of a number of other parallel belts on a drive is frequently the cause of shaft fractures, as well as being malpractice.Any used, and consequently stretched belts retained on the drive, especially those closest to the motor, while new and unstretched belts are placed on the same drive turning farther from the bearing, can augment shaft stress.

5.1.7 Damage Arising from Poorly Fitted Transmission Parts or Improper

Motor AlignmentDamage to bearing and fracture in shafts often ensue from inadequate fitting of pulleys, couplings or pinions. There parts “knock” when rotating. The defect is recognized by the scratches that appear on the shaft or the eventual scalelike flaking of the shaft end.Keyways with edges pitted by loosely fitted keys can also bring about shaft failures.Poorly aligned couplings cause knocks and radial and axial shaking to shaft and bearings.Within a short while these malpractices cause the deterioration of the bearings and the enlargement of the bearing cover bracket located on the drive end side.Shaft fracture can occur in more serious cases.


30

5.2 Troubleshooting chart

FAILURE PROBABLE CAUSE CORRECTIVE MEASURES

Motor fails to start 1.No voltage supply • Check feed connections to control system and from this to motor. 2. Low voltage supply • Check voltage supply and ascertain that voltage remains within 10% of the rated voltage shown on the motor nameplate. 3. Wrong control connections • Compare connections with the wiring diagram on the motor nameplate. 4. Loose connection at some • Tighten all connections. terminal lug 5. Overload • Try to start motor under no-load conditions. If it starts, there may be an overload condition or a blocking of the starting mechanism. Reduce load to rated load level and increase torque.

High noise level 1. Unbalance • Vibrations can be eliminated by balancing rotor. If load is coupled directly to motor shaft, the load can be unbalanced. 2. Distorted shaft • Shaft key bent; check rotor balance and eccentricity. 3. Incorrect alignment • Check motor aligment with machine running. 4. Uneven air gap • Check shaft for warping or bearing wear. 5. Dirt in the air gap • Dismantle motor and remove dirt or dust with jet of dry air. 6. Extraneous matter stuck between • Dismantle motor and clean. Remove trash or debris from fan and motor casing motor vicinity. 7. Loose motor foundation • Tighten all foundation studs. If necessary, realign motor. 8. Worn bearings • Check lubrication. Replace bearing if noise is excessive and continuous.

Overheating of bearings 1. Excessive grease • Remove grease bleeder plug and run motor until excess grease is expelled. 2. Excessive axial or radial strain on belt • Reduce belt tension. 3. Deformed shaft • Have shaft straightened and check rotor balance. 4. Rough bearing surface • Replace bearings before they damage shaft. 5. Loose or poorly fitted motor end • Check end shields for close fit and tightness around circumference. shields 6. Lack of grease • Add grease to bearing. 7. Hardened grease cause locking of • Replace bearings. balls 8. Foreign material in grease • Flush out housings and relubricate.

Intense bearing vibration 1. Unbalanced rotor • Balance rotor statically and dynamically. 2. Dirty or worn bearing • If bearing rings are in perfect condition, clean and relubricate the bearing, otherwise, replace bearing. 3. Bearing rings too tight on shaft • Before altering shaft or housing dimensions, it is advisable and/or bearing housing to ascertain that bearing dimensions correspond to manufacturer’s specifications. 4. Extraneous solid particles in • Take bearing apart and clean. Reassemble only if rotating bearing and support surfaces are unharmed.

Overheating of motor 1. Obstructed cooling system • Clean and dry motor; inspect air vents and windings periodically. 2. Overload • Check application, measuring voltage and current under normal running conditions. 3. Incorrect voltages and frequecies • Compare values on motor nameplate with those of mains supply. Also check voltage at motor terminals under full load. 4. Frequent inversions • Exchange motor for another that meets needs. 5. Rotor dragging on stator • Check bearing wear and shaft curvature. 6. Unbalanced electrical load • Check for unbalanced voltages or operation under (burnt fuse, incorrect control) single-phase condition.


31

6. Spare Parts and Component Terminology

THREE-PHASE MOTORS IP55 NEMA - Frames 140T - W180T - 180T - 210T and W210T

THREE-PHASE MOTORS IP55 NEMA - Frames 250T - W250T - 280T and 320T

Part Nr. Description 1 Terminal box cover 2 Terminal box cover fixing bolt 3 Terminal box cover gasket 4 Terminal box fixing bolt 5 Terminal box fixing washer 6 Terminal box grounding lug 7 Terminal box 8 Frame grounding lug 9 Terminal box o’ring gasket 10 Fan cover 11 Fan cover fixing bolt 12 Fan

Part Nr. Description 13 V’Ring 14 Non-drive end endshield fixing bolt 15 Non-drive end endshield washer 16 Non-drive endshield 17 Spring washer 18 Non-drive bearing 19 Fan fixing pin 20 Wound stator 21 Rotor / shaft assembly 22 Nameplate fixing rivet 23 Nameplate 24 Frame

Part Nr. Description 25 Shaft key 26 Drive end bearing 27 Drive endshield 28 Drive endshield washer 29 Drive end endshield fixing bolt 33 V’Ring 31 Drain plug

Part Nr. Description 1 Terminal box cover 2 Terminal box cover fixing bolt 3 Terminal box cover gasket 4 Terminal box fixing bolt 5 Terminal box fixing washer 6 Terminal box grounding lug 7 Terminal box 8 Frame grounding lug 9 Terminal box o’ring gasket 10 Fan cover 11 Fan cover washer 12 Fan cover fixing bolt 13 Fan 14 Non-drive end bearing cap bolt 15 V’Ring

Part Nr. Description 16 Non-drive end endshield fixing bolt 17 Non-drive end bearing cap washer 18 Non-drive end grease nipple 19 Non-drive end grease nipple cover 20 Non-drive end endshield washer 21 Non-drive endshield 22 Spring washer 23 Non-drive end bearing 24 Non-drive end bearing cap 25 Fan fixing pin 26 Wound stator 27 Rotor and shaft 28 Eyebolt 29 Nameplate fixing rivet

Part Nr. Description 30 Nameplate 31 Frame 32 Shaft key 33 Drive end bearing cap 34 Drive end bearing 35 Drive andshield 36 Drive end grease nipple cover 37 Drive endshield washer 38 Drive end endshield fixing bolt 39 Drive end bearing cap washer 40 V’Ring 41 Drive end bearing cap fixing bolt 42 Drain plug 43 Non-drive and grease relief 44 Drive end grease relief


32

THREE-PHASE MOTORS IP55 NEMA T - Frames 360T - 400T - 440T - 500T and 580T

Part Nr. Description 1 Terminal box cover 2 Terminal box cover fixing bolt 3 Terminal box cover washer 4 Terminal box cover gasket 5 Terminal box fixing bolt 6 Terminal box fixing washer 7 Terminal box grounding lug 8 Terminal box 9 Frame grounding lug 10 Terminal box o’ring gasket 11 Nameplate fixing rivet 12 Nameplate 13 Eyebolt 14 Fan cover 15 Fan cover washer 16 Fan cover fixing bolt 17 Fan fixing ring

Part Nr. Description 18 Fan 19 Non-drive end bearing cap bolt 20 V’Ring 21 Non-drive end bearing cap washer 22 Non-drive end endshield fixing bolt 23 Non-drive end endshield washer 24 Non-drive end grease nipple 25 Non-drive end grease nipple cover 26 Non-drive enshield 27 Bearing cap 28 Non-drive bearing 29 Internal non-drive end bearing cap 30 Fan fixing key 31 Wound stator 32 Rotor / shaft assembly 33 Frame

Part Nr. Description 34 Shaft key 35 Internal drive end bearing cap 36 Drive end bearing 37 Drive endshield 38 Drive end grease nipple cover 39 Drive endshield washer 40 Pre-load spring 41 Drive end endshield fixing bolt 42 External drive end bearing cap 43 Drive end bearing cap washer 44 V’Ring 45 Drive end bearing cap fixing bolt 46 Drain plug 47 External non-drive end bearing cap 48 Non drive end grease relief 49 Non-drive end grease relief


33

Part Nr. Description 1 Sticker 2 Terminal box cover fixing bolt 3 Terminal box cover 4 Grounding lug 5 Through bolt fastening nut 6 Non-drive endshield 7 Spring washer

Part Nr. Description 1 Sticker 2 Capacitor cover fixing bolt 3 Terminal box cover fixing bolt 4 Terminal box cover 5 Grounding lug 6 Through bolt fastening nut 7 Non-drive endshield 8 Spring washer 9 Non-drive and bearing 10 Non-drive and bearing fastening

washer 11 Stationary switch

THREE-PHASE MOTORS NEMA 56 - Frames A56 - B56 - D56 - F56H and G56H

SINGLE-PHASE MOTORS NEMA 56 - Frames B48 - C48 - C56 - A56 - B56 - D56 - F56H - G56H

Part Nr. Description 8 Non-drive end bearing 9 Wound stator 10 Rotor / shaft assembly 11 Frame 12 Through bolt 13 Shaft key

Part Nr. Description 12 Stationary switch fastening bolt 13 Centrifugal switch 14 Rubber ring for lead passing hole to

capacitor 15 Capacitor cover 16 Capacitor 17 Wound stator 18 Rotor / shaft assembly 19 Frame 20 Through bolt 21 Shaft key 22 Fan

Note: For F56H and G56H frame motors: 1) Part nr. 2 = 3 pieces; 2) Part nr. 15 and 16 = 2 pieces

Part Nr. Description 23 Drive end bearing fastening washer 24 Drive end bearing 25 Drive endshield 26 Overload thermal protector fixing ring 27 Overload thermal protector

Part Nr. Description 14 Fan 15 Drive end bearing fastening washer 16 Drive end bearing 17 Drive endshield


34

NOTES:


35

NOTES:

WEG Electric Motors Corp.2100 Brighton-Henrietta Townline Road

Rochester NY 14623PHONE: 716-240-1000

FAX: 716-240-1034

THE FOLLOWING INSTALLATION AND MAINTENANCE MANUALS ARE AVAILABLE

Low and High Voltage Large Motors Induction, Slip Ring, H Line, M Line, A Line

DC Motors

Tacho Generator Dynamo

Generators “GTA” Line

YOU CAN REQUEST THE ABOVE MANUALS FROM YOUR NEAREST WEG SALES OFFICE.

3.4.1

Curvde # 80428SDFIssue Date: August 1999

PUMP WATER HP VERSUS DISCHARGE PRESSUREEDWARDS MODEL 80-428 STANDARD DUTY

0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

8.00

9.00

5 50 100 150 200

DISCHARGE PRESSURE (PSI)

HO

RSE

POW

ER

1800 RPM1500 RPM1200 RPM1000 RPM

PUMP WATER FLOW VERSUS DISCHARGE PRESSUREEDWARDS MODEL 80-428 STANDARD DUTY

0

10

20

30

40

50

60

5 50 100 150 200

DISCHARGE PRESSURE (PSI)

DIS

CH

AR

GE

FLO

W (G

PM)

1800 RPM1500 RPM1200 RPM1000 RPM

2439 SE STUBB ST.MILWAUKIE, OR, USA 97222

PH: 503/659-4198FX: 503/659-4696

EMAIL: [email protected]: www.edwardsmfg.com

3.4.2

Pumps, Foam Concentrate

GKWT.EX5231 Pumps, Foam Concentrate

Page Bottom

See General Information for Pumps, Foam Concentrate

EDWARDS, MEMBER OF PENTAIR PUMP GROUP EX5231

800 AIRPORT RD

NORTH AURORA, IL 60542 USA

Model Size, In.Speed Range

rpmPressure Range

psiMax Working Pressure psi

20-412SDF 1-1/2 1000-1800 40-200 400

20-414SDF 1-1/2 1000-1800 40-200 400

20-416SDF 1-1/2 1000-1800 40-200 400

20-418SDF 1-1/2 1000-1800 40-200 400

20-420SDF 1-1/2 1000-1800 40-200 400

20-412HDF 1-1/2 1000-1800 200-300 550

20-414HDF 1-1/2 1000-1800 200-300 550

20-416HDF 1-1/2 1000-1800 200-300 550

20-418HDF 1-1/2 1000-1800 200-300 550

20-420HDF 1-1/2 1000-1800 200-300 550

80-424SDF 1-1/2 1000-1800 40-200 400

80-428SDF 1-1/2 1000-1800 40-200 400

80-432SDF 1-1/2 1000-1800 40-200 400

80-440SDF 1-1/2 1000-1800 40-200 400

80-424HDF 1-1/2 1000-1800 200-300 550

80-428HDF 1-1/2 1000-1800 200-300 550

80-432HDF 1-1/2 1000-1800 200-300 550

80-440HDF 1-1/2 1000-1800 200-300 550

150-324SDF 2 1000-1800 40-200 400

150-332SDF 2 1000-1800 40-200 400

150-338SDF 2 1000-1800 40-200 400

150-344SDF 2 1000-1800 40-200 400

150-348SDF 2 1000-1800 40-200 400

160-324HDF 2 1000-1800 200-300 550

3.4.3.1

The maximum viscosity of foam concentrate intended for use with these pumps is 2700 cps.

Copyright © 2008 Underwriters Laboratories Inc.®

The appearance of a company's name or product in this database does not in itself assure that products so identified have been manufactured under UL's Follow-Up Service. Only those products bearing the UL Mark should be considered to be Listed and covered under UL's Follow-Up Service. Always look for the Mark on the product.

UL permits the reproduction of the material contained in the Online Certification Directory subject to the following conditions: 1. The Guide Information, Designs and/or Listings (files) must be presented in their entirety and in a non-misleading manner, without any manipulation of the data (or drawings). 2. The statement "Reprinted from the Online Certifications Directory with permission from Underwriters Laboratories Inc." must appear adjacent to the extracted material. In addition, the reprinted material must include a copyright notice in the following format: "Copyright © 2008 Underwriters Laboratories Inc.®"

160-332HDF 2 1000-1800 200-300 550

160-338HDF 2 1000-1800 200-300 550

160-344HDF 2 1000-1800 200-300 550

160-348HDF 2 1000-1800 200-300 550

300-360SDF 3 1000-1800 40-200 400

300-368SDF 3 1000-1800 40-200 400

300-372SDF 3 1000-1800 40-200 400

300-388SDF 3 1000-1800 40-200 400

300-360HDF 3 1000-1800 200-300 550

300-368HDF 3 1000-1800 200-300 550

300-372HDF 3 1000-1800 200-300 550

300-388HDF 3 1000-1800 200-300 550

300-388HDF-AG 3 1000-1800 200-300 550

400-092HDF 4 1000-1800 40-300 550

400-112HDF 4 1000-1800 40-300 550

400-128HDF 4 1000-1800 40-200 400

400-140HDF 4 1000-1800 40-200 400

Last Updated on 2006-02-14

Questions? Notice of Disclaimer Page Top

3.4.4

i

Contents

Safety

General Precautions . . . . . . . . . . . . . . iiiWarnings and Cautions . . . . . . . . . . . . iii

Warnings . . . . . . . . . . . . . . . . . . . . . . . . iiiCautions . . . . . . . . . . . . . . . . . . . . . . . . . iv

1 General

Introduction . . . . . . . . . . . . . . . . . . . . 1-1Pump Specifications . . . . . . . . . . . . . 1-2

2 Maintenance

Consumable Materials . . . . . . . . . . . . 2-1Lubrication . . . . . . . . . . . . . . . . . . . . . 2-2Troubleshooting . . . . . . . . . . . . . . . . . 2-2Removal . . . . . . . . . . . . . . . . . . . . . . . 2-3Disassembly . . . . . . . . . . . . . . . . . . . . 2-4

General Practice . . . . . . . . . . . . . . . . . 2-4Disassembly Procedure . . . . . . . . . . . . 2-4

Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-6Inspection . . . . . . . . . . . . . . . . . . . . . . 2-7Repair and Replacement . . . . . . . . . . 2-7Assembly . . . . . . . . . . . . . . . . . . . . . . 2-8

General Practice . . . . . . . . . . . . . . . . . 2-8Assembly Procedure . . . . . . . . . . . . . . 2-8

Replacement. . . . . . . . . . . . . . . . . . . 2-12

3 Installation

Inspection . . . . . . . . . . . . . . . . . . . . . .3-1Unpacking . . . . . . . . . . . . . . . . . . . . . .3-1Repacking . . . . . . . . . . . . . . . . . . . . . .3-1Storage . . . . . . . . . . . . . . . . . . . . . . . .3-1Installation. . . . . . . . . . . . . . . . . . . . . .3-2

Clean Pump . . . . . . . . . . . . . . . . . . . . . 3-2Mount Pump. . . . . . . . . . . . . . . . . . . . . 3-2Prepare Foundation . . . . . . . . . . . . . . . 3-4Level Pump Skid . . . . . . . . . . . . . . . . . 3-5Grout Pump Skid . . . . . . . . . . . . . . . . . 3-5Check Driver Rotation . . . . . . . . . . . . . 3-6Align Couplings . . . . . . . . . . . . . . . . . . 3-7Piping . . . . . . . . . . . . . . . . . . . . . . . . . 3-9Strainers . . . . . . . . . . . . . . . . . . . . . . . 3-10Overpressure Protection . . . . . . . . . . 3-10

Pre-Startup Checks . . . . . . . . . . . . . 3-11

4 Parts

Warranty

iii

Safety

General PrecautionsThe following are general safety precautions not related to any specific procedure. Per-sonnel must understand and apply these precautions during both operation and main-tenance of the pump.

Do Not Operate Pump Without Ear Protection. The pump has heat-treated steel timing gears, which can be very noisy when operated above 900 rpm.

Be Aware of High Heat When Unit Is Running. Both operating and maintenance personnel must observe all safety precautions at all times. To avoid injury, always de-energize the input power sources and lock-out or red-tag the controller. Let the pump cool before handling.

Be Aware of Chemical Hazards. Maintenance personnel must observe all safety pre-cautions while working with the chemicals used in cleaning agents.

Warnings and CautionsThe following warnings and cautions relate to specific procedures in this manual. They are repeated here for emphasis.

Warnings

Do not perform maintenance using this manual if the model number on the pump is not 80-428 or the serial number is not ________________. Performing maintenance using the wrong manual could result in pump failure or personal injury.

To avoid injury, always de-energize the input driver and lock-out or red-tag the controller. Let the pump cool before removing.

To avoid injury, always use suitable protective gear. The timing gear is hot!

Overpressurization of the pump can cause equipment failure, resulting in per-sonal injury.

iv

Edwards Model 80-428 Pump

Cautions

Do not order parts using this manual if the model number on the pump is not 80-428 or the serial number is not ________________. Using parts ordered from the wrong manual could result in pump failure or personal injury.

Do not hammer on pump endcase. This will cause gasket sealing surface dam-age, resulting in leaks.

Use shaft protector between puller tip and shaft face to prevent distortion of shaft center.

Never hammer directly on pump drive shaft. This will cause the rotor assem-bly to become misaligned, resulting in incorrect internal clearances. Also, hammering on the shaft ends may damage the shaft centers.

Never dip or soak packings, rubber, plastic, or teflon parts in “dry” cleaning solvent. Wipe with clean, lint-free cloth. Solvent can react with material and result in severe damage or destruction of parts.

Do not use excessive force when installing seals. This could damage the seals, causing them to leak. Use approved tools available from EMI.

Do not rotate rotor assemblies until bearings have been installed and adjusted. Damage to rotors and liners may occur.

Make sure liners fit into counterbore on endcase, and that they can be fully seated into the endcase counterbore without using excessive force. Damage to endcases and liners could occur.

Support ends of shafts axially with a jaw puller on the endcase when install-ing ball bearings to avoid damaging liners and rotors. The jaw puller should be used on the shaft end opposite the end where the bearing is being installed. Use a shaft protector to avoid damaging shaft center.

Do not overtighten bearing adjusting nut setscrews. Excessive bearing preload may result, causing bearing damage.

Rotary pumps have close running clearances. Thus, clean piping is a must. Dirt, grit, weld bead or scale, flushed from an unclean piping system, will damage and may stall the pump. Flush the system thoroughly before connect-ing piping to pump.

1-1

General 1

IntroductionThe Edwards Model 80-428 pump (Figure 1-1) is a standard-duty high-speed gear-driven positive-displacement rotary pump with gear-type rotors. The casing, liners, and rotors are bronze. The drive and idler rotor shafts are stainless steel. The pump is fitted with lip seals, and is self-priming.

Edwards rotary pumps are available in many configurations. While they may look alike, there may be significant differences from one pump to another. Differences include con-struction material, sealing method, rotor type, etc. This manual covers only one config-uration, which is defined by a model number and a serial number. Check the name plate on the pump to make sure the model number is 80-428 and the serial number is ________________. If the numbers do not match, contact EMI

Figure 1-1. Edwards Model 80-428 Pump

1070_0001c.cdr

The Edwards Model 80 pump (Figure 1-1) is a standard-duty high-speed gear-drivenpositive-displacement rotary pump with gear-type rotors. The pump is self-priming.Edwards rotary pumps are available in many configurations. While they may lookalike, there may be significant differences from one pump to another. Differencesinclude construction material, sealing method, rotor type, etc.

Figure 1-1. Edwards Model 80 Pump

2-1

Maintenance 2

l

Edwards rotary pumps are available in many configurations. While they may look alike, there may be significant differences from one pump to another. Differences include con-struction material, sealing method, rotor type, etc. This manual covers only one config-uration, which is defined by a model number and a serial number. Check the name plate on the pump to make certain the model number is 80-428 and the serial number is ________________. If the numbers do not match, contact EMI.

Most pump repairs can be performed by maintenance personnel using normally avail-able tools.

Consumable MaterialsCleaning materials, lubricants, and other products needed during pump maintenance are listed in Table 2-1.

Do not perform maintenance using this manual if the model number on the pump is not 80-428 or the serial number is not ________________. Performing maintenance using the wrong manual could result in pump failure or personal injury.

Table 2-1. Consumable Materials

Item Nomenclature Specification Common Name

1 Lint-Free Cloth MIL-C-85043

2 “Dry” Cleaning Solvent Acetone, Brake Cleaner

3 Emery Cloth 220 Grit 3M, Anderson, Sandvik, Mirka

4 Anti-Seize Compound “Nev’r Seize”

5 Red Loctite PermaLoc HH-120

6 High-Tack Gasket Spray Loctite, Permatex

2-2


LubricationTo ensure a long service life, the pump should be lubricated routinely with approved grease (7, Table 2-1). If the pump is operating under normal loads and temperatures, use the intervals defined in Table 2-2. If the pump is operating at over 180°F, contact EMI for recommended lubrication interval for your application.

TroubleshootingTable 2-3 provides assistance in diagnosing and correcting malfunctions that may occur during normal operation.

7 General Purpose Grease MIL-G-18709

NLGI #2

Chevron Ulti-Plex, Shell Retina LC

8 Lapping Compound D51804, 180 Grit Silicon Carbide

Felpro “Clover” Brand

Table 2-2. Model 80-428 Lubrication Schedule

Item Interval Amount of Grease

Bearings 6,000 Hours 0.25 Ounce

Timing Gears 6,000 Hours 1.00 Ounce

Table 2-3. Troubleshooting

Trouble Probable Cause Remedial Action

1. Pump does not turn

1a. Seized pump. 1a. Repair or replace pump.

1b. Faulty or misaligned coupling.

1b. Replace or realign coupling.

1c. Damaged or missing shaft key.

1c. Replace key.

2. Excessive Noise

2a. Loose or misaligned coupling.

2a. Tighten, align, or replace coupling.

2b. Cavitation. 2b. Check suction piping with a vacuum gauge. Gauge should read less than 10-in. Hg in most cases. Contact EMI for the exact reading for your application.

Table 2-1. Consumable Materials (Continued)

Item Nomenclature Specification Common Name

Zerk fittings do not have check balls. This prevents bear-ings from being over-greased. Excess grease will run out of the fit-ting when pump is in operation.

The pump has heat-treated steel timing gears, which can be very noisy when oper-ated above 900 rpm. This is a nor-mal condition, and does not require maintenance action.

Table 2-2. Model 80 Lubrication Schedule

Pentair for recommended lubrication interval for your application.

2-3

Maintenance

Removal

1. Before removing pump, refer to troubleshooting chart (Table 2-3) to determine if the problem is actually the pump.

2. Ensure adequate clearance exists for removal of pump. Disassemble adjacent com-ponents as required for adequate working clearance.

3. Before removal, clean exterior parts to remove accumulated dirt, grease, or foreign material.

4. Apply tags to identify parts of similar configuration to ensure correct installation.

2c. Worn or damaged bearing(s).

2c. Repair or replace pump.

3. Excessive vibration

3a. Loose or misaligned coupling.

3a. Tighten, align, or replace coupling.


3c. Worn or damaged bearing(s).


4. Reduced flow 4a. Clogged suction screen. 4a. Clean or replace screen.


4c. Pump liners and/or rotors worn or damaged.


4d. Low pump speed 4d. Increase pump speed.

To avoid injury, always de-energize the input driver and lock-out or red-tag the controller. Let the pump cool before removing.

Table 2-3. Troubleshooting (Continued)

Trouble Probable Cause Remedial Action

2-4


Disassembly

General Practice1. Keep work area as clean as possible to avoid contamination of internal parts.2. Replace gaskets, packings, and seals removed during repair. Replace all keys, spring

washers, and like items during assembly.3. When removing gaskets, packings, or seals, do not use a metal tool to pry, pick, or

scrape. Doing this could scratch sealing surfaces. Use wood or plastic scrapers to remove gasket material.

4. Before disassembly of any component, study exploded view illustration (Figure 4-1). Pay particular attention to relationship of internal parts. Being familiar with con-struction will speed up disassembly and help avoid improper assembly.

5. To prevent moisture or foreign material from entering open components, install protective plugs or covers as soon as practical after disassembly. Wrap parts in clean paper or clean lint-free cloths (1, Table 2-1).

6. Remove only the parts requiring repair or replacement. Do not disassemble pump any further than necessary to complete needed repairs.

Disassembly Procedure1. Remove four machine screws (4, Figure 4-1), four nuts (3), timing gear cover (2),

and cover gasket (5). Discard gasket.2. Remove idler timing gear locknut (9).3. Fabricate timing gear puller plate as shown in Figure 2-2..

4. Install timing gear puller plate with two 5/16 NC x 1-3/4-in. Grade 8 cap screws on idler timing gear (12, Figure 4-1). Using jaw-type puller, pull on the gear puller plate to remove idler timing gear. Repeat procedure for drive timing gear (11).

5. Remove Woodruff key (10) from drive shaft.6. Remove four machine screws (7), four nuts (3), front cover (6), and cover gasket (5).

Discard gasket.7. Remove front cover seal (8) from front cover (6). Discard seal.8. Remove four setscrews (13) from two endcases (17).9. Remove four bearing adjusting nuts (14) from two endcases (17).10. Remove 8 cap screws (18), 2 nuts (3), and 10 washers (19) from timing gear endcase

(17).

11. Using jaw-type puller, remove timing gear endcase (17) and pump body gasket (21). Discard gasket.


Do not hammer on pump endcase. This will cause gasket sealing surface dam-age, resulting in leaks.


The pump can be reassembled into several configura-tions as shown in Figure 2-1. Before disassembling the pump, circle the configuration that matches the pump being repaired. This will be an invaluable aid dur-ing reassembly.

When removing the endcases, use two pullers, or alternate one puller between shafts.

The endcase may be pulled off each shaft about 1/8 in. at a time. Alternate the puller between shafts to avoid mis-alignment during removal.

1. Remove machine screws (4, Figure 4-1), nuts (3), timing gear cover (2), andcover gasket (5). Discard gasket.

4. Install timing gear puller plate with cap screws on idler timing gear (12, Figure4-1). Using jaw-type puller, pull on the gear puller plate to remove the idler timinggear. Repeat procedure for the drive timing gear (11).

6. Remove machine screws (7), nuts (3), front cover (6), and cover gasket (5). Discardgasket.

8. Remove setscrews (13) from endcases (17).9. Remove bearing adjusting nuts (14) from endcases (17).10. Remove cap screws (18), nuts (3), and washers (19) from timing gear endcase (17).

2-5

Maintenance

Figure 2-1. Pump Configuration Diagram

DISCHARGEPORT

SUCTIONPORT

SUCTIONPORT

SUCTIONPORT

UPPER DRIVE

LOWER DRIVE

DISCHARGEPORT

DISCHARGEPORT

LEFT HANDROTATION

LEFT HANDROTATION

RIGHT HANDROTATION

RIGHT HANDROTATION

1070_0002a.cdr

NOTE: ALL ROTATIONS ARE VIEWED FROM PUMP SHAFT END.

EMI USES THE FOLLOWING NOTATION FOR PUMP IDENTIFICATION:

UR = UPPER SHAFT – RIGHT HAND ROTATIONUL = UPPER SHAFT – LEFT HAND ROTATIONLR = LOWER SHAFT – RIGHT HAND ROTATIONLL = LOWER SHAFT – LEFT HAND ROTATION

2-6


12. Remove 8 cap screws (18), 2 nuts (3), and 10 washers (19) from timing gear endcase (17).

13. Using jaw-type puller, remove drive endcase (17) and pump body gasket (21). Dis-card gasket.

14. Using hammer and hardwood block, tap pump drive shaft to remove idler and drive rotor assemblies (23 and 24) and two liners (22).

15. Using hammer and hardwood block, remove other two liners (22) from pump body (27).

16. If damaged, remove four studs (26) from pump body (27).17. Using hammer and brass drift, remove four ball bearings (15) and four grease seals

(16) from two endcases (17).18. Using hammer and brass drift, remove four lip seals (20) from two endcases (17).19. If damaged or plugged, remove two grease fittings (1) from two endcases (17).20. If damaged or plugged, remove grease fittings (1) from timing gear cover (2).

Cleaning

1. Use “dry” cleaning solvent (2, Table 2-1) to clean parts. Do not use gasoline for cleaning parts.

Figure 2-2. Timing-Gear Puller Plate Fabrication Diagram

Never hammer directly on pump drive shaft. This will cause the rotor assem-bly to become misaligned, resulting in incorrect internal clearances. Also, hammering on the shaft ends may damage the shaft centers.

Never dip or soak packings, rubber, plastic, or teflon parts in “dry” cleaning solvent. Wipe with clean, lint-free cloth. Solvent can react with material and result in severe damage or destruction of parts.

4’’

1-5/8’’

1’’THRU

3/4’’

5/16’’ x 1-3/4’’ NC GRADE 8CAP SCREWS (2 PLACES)

3/8’’ HOLES(2 PLACES)

1-1/2’’

1070_0003b.cdr

12. Remove cap screws (18), nuts (3), and washers (19) from timing gear endcase (17).

14. Using hammer and hardwood block, tap pump drive shaft to remove idler anddrive rotor assemblies (23 and 24) and liners (22).

15. Using hammer and hardwood block, remove other liners (22) from pump body (27).

16. If damaged, remove studs (26) from pump body (27).17. Using hammer and brass drift, remove ball bearings (15) and grease seals (16) from

endcases (17).18. Using hammer and brass drift, remove lip seals (20) from endcases (17).19. If damaged or plugged, remove grease fittings (1) from endcases (17).

2-7

Maintenance

2. After soaking parts in “dry” cleaning solvent, deposits may be washed away by flushing or spraying. Where necessary, use soft-bristled, non-metallic brush moist-ened in solvent.

3. Except for bearings, dry parts using filtered, compressed air after cleaning.4. Unless otherwise noted, do not use metal scrapers, wire brushes, abrasive wheels,

or compounds when cleaning parts.

5. Place ball or roller bearings in basket and suspend in container of “dry” cleaning solvent overnight. If necessary, use soft-bristled brush to remove caked grease and chips. Avoid rotating bearing before solid particles are removed to prevent damag-ing balls and races. After cleaning, dry bearings with low-pressure compressed air.

6. Check all passages and cavities for cleanliness and freedom from foreign material. Use wire brush or pressurized spray gun and “dry” cleaning solvent to clean indi-vidual passages.

7. Buff bearing adjusting nut threads (14, Figure 4-1) with a wire brush.

Inspection1. Check that rotor assemblies and liners are free of radial scoring and heat damage

(usually indicated by blue discoloration).2. Check all surfaces in contact with gaskets, packings, or seals for nicks, burrs, or

scratches that may damage new parts during assembly.3. Visually check castings or weldments for cracks.4. Check bearings for rusted or pitted balls, races, or cage. Check balls and races for

brinelling, abrasions, and discoloration. Excluding defects that may cause bearing binding or misalignment, nicks or gouges outside race load areas are not cause for rejection. Bearings shall be rejected for cuts or grooves parallel to ball or roller rota-tion, or for fatigue pits (not minor machine marks or scratches).

5. Check all screws, nuts, fittings, and tapped holes for distortion and for stripped or corroded threads.

Repair and Replacement1. Using fine file or 220 grit emery cloth (3, Table 2-1), remove nicks, burrs, or

scratches from surfaces in contact with gaskets, packings, or seals.2. Using 220 grit emery cloth, remove any buildup on endcase (17, Figure 4-1) coun-

terbore surfaces and inside diameter of pump body (27).3. Using 220 grit emery cloth or flat file, deburr all edges of pump parts, especially the

end covers (2 and 6) and endcases (17).4. Repair of cracked castings and weldments is not authorized. Replace cracked or

damaged parts.5. Replace all damaged screws, nuts, and fittings. Repair minor damage to tapped

holes with same size tap. Do not change size or thread type. Replace all self-locking fasteners.

Always replace bearings whenever possible. If new bearings are not available you may clean and inspect the bearings. The bearings may be reused if they are not damaged.

Take special care to keep gasket sur-faces flat and smoothly finished to prevent leakage.

2-8


Assembly

General Practice1. Remove any protective coatings from new parts.2. Lubricate bearings with same type of lubricant normally used in pump or as

directed in specific repair procedure.3. Lubricate lip of oil seals with lubricant specified in specific procedure. Install oil

seals, with lip facing out, by applying an even force to outer edge of seal. We recom-mend using an arbor press to seat the seals.

4. Coat both sides of gaskets with high-tack spray (6, Table 2-1). Be sure all old gas-kets and sealant are removed from parts before installing new ones.

5. Hand-thread cap screws into parts until snug, then tighten in criss-cross pattern to final torque. Install all cap screws, nuts, and fasteners using anti-seize compound (4, Table 2-1) unless otherwise indicated in specific procedure.

Assembly Procedure

Assemble Rotors and Liners

1. If removed, install four studs (26, Figure 4-1) in pump body (27) using red Loctite (5, Table 2-1). Remove all traces of red Loctite after installing studs.

2. Install two liners (22) in pump body (27). Make sure liner suction hole faces pump body suction port as shown in Figure 2-3.

Figure 2-3. Liner Installation

Do not rotate rotor assemblies until bearings have been installed and adjusted. Damage to rotors and liners may occur.

If rotors are worn, replace both rotor assemblies.

The suction port of pump body is stamped “Suction” and the discharge port is stamped “Discharge.” There are holes drilled in the suction side of the liners.

1070_0017b.cdr

D

D

S

S

DISCHARGESIDE

SUCTIONSIDE

SUCTIONHOLES

1. If removed, install studs (26, Figure 4-1) in pump body (27) using red Loctite (5,Table 2-1). Remove all traces of red Loctite after installing studs.

2. Install liners (22) in pump body (27). Make sure liner suction hole faces pumpbody suction port as shown in Figure 2-3.

2-9

Maintenance

3. Install idler rotor assembly (23, ) in pump body (27) and into liner (22). Make sure threaded end of rotor shaft is away from drive end of pump.

4. Install drive rotor assembly (24) in pump body (27) and into liner (22). Make sure drive rotor shaft is in correct position (Figure 2-1) and short end of rotor shaft is away from drive end of pump.

5. Install second set of liners (22, Figure 4-1) in pump body (27). Make sure suction holes face pump body suction port.

Install Seals

1. Lightly coat bores and outside diameters of four lip seals (20, Figure 4-1) with red Loctite (5, Table 2-1).

2. Install four lip seals (20, Figure 4-1) in seal bores of two endcases (17). Press seals all the way to the bottom of the bore as shown in Figure 2-4. We recommend using an arbor press to seat the seals. Installation tools are available from EMI.

3. Pre-lubricate four grease seals (16) with approved grease (7, Table 2-1).4. Install four grease seals (16, Figure 4-1) in two endcases (17) with sealing lip facing

toward counterbore in endcase.

Do not use excessive force when installing seals. This could damage the seals, causing them to leak. Use approved tools available from EMI.

Figure 2-4. Single Lip Seal Installation

Lip seals have two lips on one side and one lip on the other side. The side with two lips must face toward pump body as shown in Figure 2-4.

1070_0004a.cdr

SEALINSTALLATIONCONE

SEAL

ROTORASSEMBLY

LINER

ENDCASE

CAP SCREW BODY GASKET BODY

Install Seals (if pump has lip seals)

1. Lightly coat bores and outside diameters of lip seals (20, Figure 4-1) with redLoctite (5, Table 2-1).

2. Install lip seals (20, Figure 4-1) in seal bores of endcases (17). Press seals all theway to the bottom of the bore as shown in Figure 2-4. We recommend using anarbor press to seat the seals. Installation tools are available from Pentair.

3. Pre-lubricate grease seals (16) with approved grease (7, Table 2-1).4. Install grease seals (16, Figure 4-1) in endcases (17) with sealing lip facing

toward counterbore in endcase.

Pentair.

2-10


Install Endcases

1. Install new pump body gasket (21) to each side of the body (27).2. Install large flat washer and nut (3) on one of the studs (26) on timing-gear end of

pump body (27). The outside diameter of the washer must overlap the liners (22) to prevent the liners and rotors from being displaced during installation of the drive endcase. Make sure liners are protruding at least 0.2 in. from the body before run-ning the nut and washer up against liners.

3. Check that seals (20) have been installed in endcases (17) before proceeding with endcase installation.

4. Starting with the drive end, carefully install endcase over idler and drive rotor assemblies (23 and 24). Use caution not to damage seals (20).

5. Install 8 cap screws (18), 10 washers (19), and 2 nuts (3) and tighten finger-tight.6. Remove large washer and nut (3) from timing-gear end of pump body (27).7. Carefully install other endcase (17) over idler and drive rotor assemblies (23 and

24). Use caution not to damage seals (20).8. Install 8 cap screws (18), 10 washers (19), and 2 nuts (3) and tighten finger-tight.

Install Bearings

1. Pack four ball bearings (15) with approved grease (7, Table 2-1).

2. Using a bearing seating sleeve, install two ball bearings (15, Figure 4-1) on both ends of idler and drive rotor assemblies (23 and 24). Make sure ball bearings are seated on shoulders of shafts with loading grooves facing center of pump.

3. Using criss-cross pattern, tighten 16 cap screws (18) to 12 to 15 lb-ft.4. Using criss-cross pattern, tighten four nuts (3) to 8 to 10 lb-ft.

Adjust Rotor Clearance

1. Install four bearing adjusting nuts (14) on two endcases (17), leaving about 1/2-turn short of bearing contact.

2. On idler rotor assembly (23) tighten one bearing adjusting nut (14) until rotor con-tacts liner (22). Install dial indicator on opposite end of shaft as shown in Figure 2-5 and zero indicator.

3. Loosen previously tightened bearing adjusting nut (14). Tighten opposing bearing adjusting nut until rotor just contacts the other liner and note reading. This is the total clearance.

4. Loosen adjusting nut tightened in step 3 and tighten opposing adjusting nut until dial indicator reading is half the total clearance reading obtained in step 3. (for example, if the total clearance is 0.006 in., adjust for reading of 0.003 in.)

Make sure liners fit into counterbore on endcase, and that they can be fully seated into the endcase counterbore without using excessive force. Damage to endcases and liners could occur.

Support ends of shafts axially with a jaw puller on the endcase when install-ing ball bearings to avoid damaging liners and rotors. The jaw puller should be used on the shaft end opposite the end where the bearing is being installed. Use a shaft protector to avoid damaging shaft center.

Seals must be installed in end-cases before install-ing endcases.

We highly recom-mend you use seal installation cones (available from EMI) on the rotor shafts during installation of the endcases.

Bearing installa-tion tools are avail-able from EMI.

The rotors must be centered between the liners.

5. Install cap screws (18), washers (19), and nuts (3) and tighten finger-tight.

8. Install cap screws (18), washers (19), and nuts (3) and tighten finger-tight.

1. Pack ball bearings (15) with approved grease (7, Table 2-1).

2. Using a bearing seating sleeve, install ball bearings (15, Figure 4-1) on bothends of idler and drive rotor assemblies (23 and 24). Make sure ball bearingsare seated on shoulders of shafts with loading grooves facing center of the pump.

3. Using criss-cross pattern, tighten cap screws (18) to 12 to 15 lb-ft.4. Using criss-cross pattern, tighten nuts (3) to 8 to 10 lb-ft.

1. Install bearing adjusting nuts (14) on endcases (17), leaving about 1/2-turn shortof bearing contact.

We highlyrecommend you useseal installationcones on the rotorshafts duringinstallation of theendcases.

Bearing installationtools are availablefrom Pentair.

2-11

Maintenance

5. Slowly tighten adjusting nut opposing adjusting nut tightened during step 4 until slight opposite dial indicator needle movement is observed. Do not overtighten.

.

6. Tighten the setscrews (13) enough to secure the bearing adjusting nuts (14) in end-case (17).

7. Repeat steps 2 through 6 for drive rotor assembly (24) bearings.

Install Timing Gears

1. Using a lapping compound (8, Table 2-1), lap taper of idler timing gear (12, Figure 4-1) to idler rotor shaft (23), then clean both surfaces with a clean rag and “dry” cleaning solvent (2, Table 2-1).

2. If possible, preheat drive timing gear (11, Figure 4-1) to 450°F and install with Woo-druff key (10) on drive rotor shaft (24). Position gear about 0.175 to 0.200 inch from face of endcase (17). We recommend using shims for accurate positioning.

3. Cool drive timing gear (11) with compressed air. Do not quench gear with liquid.4. After drive timing gear has cooled to ambient temperature, insert piece of 0.004- to

0.006-in. shim stock between rotors from the discharge port for lash adjustment. Shim should feed into pump between rotors when drive rotor is turned in normal direction of rotation.

5. Install idler timing gear (12) on idler shaft (23). Remove all lash between timing gears in direction of rotation by turning idler timing gear until gear meshes fully with drive timing gear (11).

Do not overtighten bearing adjusting nut setscrews. Excessive bearing preload may result, causing bearing damage.

Figure 2-5. Rotor Clearance Adjustment

To avoid injury, always use suitable protective gear. The timing gear is hot!

1070_0018a.cdr

USE NUT AND BOLTTO SUPPORT DIAL INDICATOR

SECURE TO BOLT

ENDCASE

DIAL INDICATOR

ROTOR SHAFT

2-12


6. After all lash has been removed, hold idler timing gear (11) in place while seating gear by lightly tapping it with a bearing seating sleeve.

7. Apply anti-seize compound (4, Table 2-10) to timing gear locknut (9, Figure 4-1) threads and install locknut on idler shaft. Wedge a piece of nylon or rawhide between rotors to prevent rotation, and tighten locknut to 90 lb-ft.

8. Remove shim stock and rotate drive rotor (24) in direction of rotation. The drive rotor should rotate idler rotor (23) freely with no contact between rotors.

Install End Covers

1. Apply light coat of approved grease (7, Table 2-1) to rubber surface of new front cover seal (8, Figure 4-1).

2. Install front cover seal (8) in front cover (6) with seal lips pointed toward inside of cover. We recommend using an arbor press to seat the seal.

3. Apply light coat of approved grease (7, Table 2-1) to front cover gasket surface and install new gasket (5, Figure 4-1), front cover (6), four machine screws (7), and four nuts (3). Tighten machine screws to 12 to 15 lb-ft.

4. Fill timing gear cover (2) with about three 1/2-in. beads of approved grease (7, Table 2-1) around inside perimeter of cover.

5. Apply light coat of approved grease (7, Table 2-1) to timing gear cover sealing sur-face and install new gasket (5, Figure 4-1), timing gear cover (2), four machine screws (4), and four nuts (3). Tighten machine screws to 12 to 15 lb-ft.

Lubricate Bearings

1. If removed, install two grease fittings (1) in each endcase (17) and two grease fit-tings (1) in timing gear cover (2).

2. Using grease gun, lubricate pump bearings with approved grease (7, Table 2-1) through endcase grease fittings. Usually five to six pumps is sufficient when bear-ings have been previously packed.

Replacement1. Be sure pump is oriented in same position as removed.2. Check all identifying tags for correct connection of all lines and hoses.3. Operate pump and inspect for proper adjustment, leaks, vibration, noise, or mis-

alignment. Correct any problems.

.

3. Apply light coat of approved grease (7, Table 2-1) to front cover gasket surface andinstall new gasket (5, Figure 4-1), front cover (6), machine screws (7), and nuts (3).Tighten machine screws to 12 to 15 lb-ft.

5. Apply light coat of approved grease (7, Table 2-1) to timing gear cover sealingsurface and install new gasket (5, Figure 4-1), timing gear cover (2), machinescrews, and nuts (3). Tighten machine screws to 12 to 15 lb-ft.

1. If removed, install grease fittings (1) in each endcase (17) and grease fittings (1)in timing gear cover (2).

3-1

Installation 3

InspectionEMI pumps are shipped suitably protected to prevent damage in transit from normal handling. When received, inspect the shipment immediately:

1. Check for damage to the packaging or crating and note it on the bill of lading. 2. Check for shipment shortages against the bill of lading. 3. Report shortages to the carrier and note them on the bill of lading.4. Notify EMI of damage to contents not a fault of the carrier, or in the event of short-

ages.

UnpackingCare must be taken when removing the pump from the shipping pallet. Remove pump as follows:

1. Remove all protective material.2. Remove all bolts securing pump to pallet.3. Using suitable lifting device, lift pump from packing case.4. Inspect equipment for proper lubrication prior to entering service.

Repacking1. Using suitable lifting device, lift pump and place on pallet.2. Secure pump to pallet.3. Install protective material.

StorageIf the pump will not be installed immediately after receipt and inspection, the pump should be repackaged and placed in suitable storage:

1. Inspect protective coatings on unpainted surfaces. (Do not disturb coatings.)2. If protective coatings are damaged or if unpainted surfaces are not coated, apply

rust inhibiting protective coating to surfaces.

Pentair pumps are shipped suitable protected to prevent damage in transit from normalhandling. When received, inspect the shipment immediately:

4. Notify Pentair of damage to contents not a fault of the carrier, or in the event ofshortages.

3-2


3. Leave plastic or gasket-type port covers in place. 4. If pump comes wrapped with protective material, rewrap pump. 5. Store in clean, dry location.

InstallationThe pump can be installed wherever adequate space exists to connect piping and per-form maintenance. The pump must be installed in compliance with regulatory body codes (national, state, and local) in effect at the time of installation. In cases where a code conflicts with the following instructions, the code shall prevail.

Clean PumpTo ensure that test fluids and/or preservatives do not contaminate the fluid to be pumped, do the following:

1. Flush pump thoroughly before it is placed in service. The flushing media must be compatible with the pump and seal materials.

2. Remove rust-inhibiting coatings on unpainted exterior surfaces with dry-cleaning solvent (2, Table 2-3).

3. Cover ports and other openings until ready to install piping.

Mount PumpInstall pump on skid base along with the driver as shown in Figure 3-1. See Figure 3-2 for pump dimensions. and Figure 3-3 for mounting bolt locations..

Figure 3-1. Typical Pump Skid

1070_0019a.cdr

DRIVER

SKID BASE

PUMP

3-3

Installation

Figure 3-2. Edwards Model 80-428 Dimensions

Figure 3-3. Edwards Model 80-428 Mounting Bolt Locations

1070_0006d.cdr

7.75’’

4.5’’0.625’’

5.0’’

3.75’’2.75’’

5.9375’’

2.25’’

8’’

14.375’’

0.38’’ HOLES 1070_0007c.cdr

CL PUMP

CL PUMP

6.25’’

3.13’’

2.50’’2.50’’

1.14’’

2.28’’

NOTES

3-4


Prepare FoundationThe foundation absorbs any vibration, strains, or shock, while providing a permanent, rigid support for the pump skid.

1. Construct a foundation form that is 4 to 6 inches longer and wider than the skid base. The foundation form height should be about twenty times the diameter of the foundation bolts. See Figure 3-4 for a typical foundation form.

2. Make templates to position and hold foundation bolts in place while pouring con-crete.

3. Fasten templates to foundation form.4. Place form where pump is to be located.5. Cut four 1.5-inch inside-diameter pipe sleeves 5 inches long.6. Assemble foundation bolts as shown in Figure 3-5 and attach them to template.

Foundation bolts should extend about 2 to 2.5 inches above top of form.

7. Pour a concrete mix of 1:2:4 ratio by volume (cement, fine aggregate, coarse aggre-gate) into form. Leave surface rough for anchoring grout.

Figure 3-4. Typical Foundation Form

Allow a cure time for the concrete of at least 14 days prior to operation of the pump. A cure time of 28 days is preferred.

1070_0010a.cdr

TEMPLATE FOR HOLDINGFOUNDATION FORM BOLTS

FOUNDATIONFORM

FOUNDATIONBOLT ASSEMBLY

20 TIMESDIAMETEROF FOUNDATIONBOLTS

4 - 6'' WIDERTHAN PUMPSKID BASE

4 - 6'' LONGERTHAN PUMPSKID BASE

3-5

Installation

Level Pump Skid1. Before pump skid is set on foundation, clean underside of skid base and top of foun-

dation. 2. Remove waste from pipe sleeves around foundation bolts. 3. Set leveling pads, either tapered wedge or flat shim plate, adjacent to foundation

bolts. Pads should be 1/2 to 3/4 inch total height for grouting as shown in Figure 3-6.

4. Lower pump skid over foundation bolts to rest on leveling pads.

5. Adjust height of leveling pads until base is level and supported at all leveling pad locations.

6. Tighten foundation-bolt nuts finger tight. 7. Double-check level of pump skid.

Grout Pump SkidThe purpose of grouting is to prevent lateral shifting of the skid base, not to take up irregularities in the foundation.

1. Construct wood frame around foundation as shown in Figure 3-6. Set height of the frame to create desired thickness of finished grout.

2. Prepare grout mix of 1:2 ratio by volume (Portland cement and fine sand) with just enough water to obtain creamy consistency and allow free flow under base.

Figure 3-5. Typical Foundation Bolt Configuration

1070_0011a.cdr

5’’

2’’

1/4’’

1/2’’

3’’

WASHER

1.5’’

SLEEVE

TEMPLATE

PUT WASTE AROUND BOLTBEFORE POURINGCONCRETE

LEAVE SURFACEROUGH TO ANCHOR GROUT

A small spirit level should be used in leveling the pump. Surfaces for deter-mining level in order of preference are the pump flange faces, the pump shaft, projec-tions of machined surfaces on the base and, finally, the surface of the base.

3-6


3. Wet top of foundation prior to grouting. 4. Pour grout between frame and skid base.5. Puddle grout as poured, working as much as possible under skid base and into

sleeves around foundation bolts. Ideally, complete space under skid base should be filled to height of grout around skid base.

6. After grout is poured, keep covered with wet burlap for 48 hours to effect slow dry-ing and prevent cracking.

7. When grout is set sufficiently, remove frame and finish grout as desired.8. Tighten foundation-bolt nuts 72 hours after grouting.

Check Driver Rotation

The direction of pump rotation is either clockwise (CW) or counterclockwise (CCW) when viewed from the shaft end of the pump. Pump rotation is specified by a direc-tional arrow designation on the pump as shown in Figure 2-1.

Most pump drivers are induction motors, and direction of rotation is dependent on the connection of the three-phase wire connection. Some drivers, such as unidirectional motors, engines, and turbines, must be carefully checked to ensure that driver direction of rotation matches the pump.

1. Remove coupling safety guards. 2. Remove covers, then remove chain, gear, or steel grid connecting coupling halves.3. Flex member couplings require loosening of coupling setscrew on one half, sliding

coupling half back on shaft, and removing flex member.

Figure 3-6. Leveling and Grouting Diagram

1070_0012a.cdr

1/4’’FINISHGROUTING BASE

GROUT

LEAVELEVELINGWEDGES ORSHIMS INPLACE

CLEAN ANDWET DOWNTOP OFFOUNDATION

WOODFRAME

ALLOW1/2’’ TO 3/4’’FOR LEVELING

Since alignment follows the rota-tion check, we rec-ommend the pump and driver be sepa-rated during the rotation check.

3-7

Installation

4. Start and stop the driver while observing driver shaft rotation. Driver rotation must be same as pump rotation.

Align Couplings

The alignment of the pump and motor or engine driver must be checked before startup. Maximum angular offset in the two coupling halves is 1 degree; maximum parallel off-set is 0.015 inch. To align the pump and motor, loosen the mounting bolts, align the two components, and tighten the bolts.

Couplings are intended to provide a mechanically flexible connection for two shaft ends. Additionally, they provide limited shaft end float (for mechanical movement or thermal expansion) and, within prescribed limits, angular and parallel misalignment of shafts. Couplings are not intended to compensate for major angular or parallel misalignment. The allowable misalignment varies with the type of coupling. Refer to the coupling manufacturer’s literature for specific allowable limits. Any improvement in alignment beyond the coupling manufacturer’s minimum specification will extend pump, mechan-ical seal or packing, coupling, and driver service life by reducing bearing loads and wear.

Misalignment of the pump and driver shafts may be angular (shaft axes concentric but not parallel), parallel (shaft axes parallel but not concentric), or a combination of the two, as shown in Figure 3-7.

Flexible coupling types in general use are chain, gear, steel grid, and flex member. For aligning the pump and driver shafts, remove the coupling cover, then remove chain, gear, steel grid, or flex member connecting the coupling halves.

Checking for Angular Misalignment. To check angular misalignment:

1. Insert feeler gauge between coupling halves as shown in Figure 3-8. 2. Rotate complete coupling 1/4 turn, 1/2 turn, and 3/4 turn, checking spacing

between coupling halves at same location on coupling as in original spacing check. Checking the difference in spacing between coupling halves without rotating the complete coupling may result in an error because coupling faces are sometimes not machined or they may not be square with the centerline of the shaft. The variation in spacing should not exceed the manufacturer’s recommendations.

3. Adjust shims under driver or adjust driver location in horizontal plane.

Figure 3-7. Types of Coupling Misalignment

For applications where pumps are operated at elevated temperatures, final alignment may not be possible at oper-ating temperature. In this instance, proper allowance should be made for the increase in pump shaft height due to thermal expansion. As a “rule of thumb” (for cast iron or steel pumps), a ver-tical allowance of 0.001 inch per inch of pump shaft height above the base per 150°F (65°C) should be added to the height of the driver shaft.

1070_0013a.cdr

ANGULAR PARALLEL ANGULAR AND PARALLEL

3-8


Checking for Parallel Misalignment. To check parallel misalignment:

1. Attach dial indicator as shown in Figure 3-9. 2. With dial indicator secured to pump or driver shaft, rotate both shafts together,

noting dial indicator readings through one complete revolution. 3. Adjust shims under driver. Only when absolutely necessary should shims be

adjusted or added under pump. 4. If a dial indicator is not available, an alternate check may be made by using a

straightedge, as shown in Figure 3-9.

5. Recheck for angular misalignment, which may have resulted when correcting for parallel misalignment.

Checking for Spacer Coupling Misalignment. Spacer-type couplings may be checked for angular and parallel misalignment by the same methods described above, with some minor differences. After the spacer has been removed, the distance between coupling halves requires minor changes to the procedure. For the angular misalignment check, an inside micrometer replaces the feeler gauge. For the parallel misalignment check, a bracket should be attached to one coupling half to support the dial indicator as shown in Figure 3-10.

Figure 3-8. Checking for Angular Coupling Misalignment

Figure 3-9. Checking for Parallel Coupling Misalignment

1070_0014a.cdr

FEELERGAUGE

1070_0015a.cdr

STRAIGHTEDGESECURE

TO SHAFT

DIALINDICATOR

OR

3-9

Installation

.

Piping

Piping should be installed on supports independent of the pump. Supports must be capable of carrying the mass of the pipe, insulation, and the fluid carried. Supports may be hangers or stands that respectively carry the mass from above or below. Clamps or brackets may be used to secure piping to existing columns. Supports must allow for free movement of the piping caused by thermal expansion or contraction. Supports should be installed at intervals such that piping load is uniformly and amply supported, pre-cluding contact with adjacent piping and equipment. Pipe strains or stresses transmit-ted to the pump by improper piping support systems may cause pump distortion, wear or binding of the rotary members, and excessive power requirements.

Piping systems containing expansion joints must be so designed that the expansion joint is not exposed to motion greater than that for which the joint is designed. Expan-sion joints or flexible connectors should not be used to compensate for misaligned piping.

Threaded joints should be coated with compounds compatible with but not soluble in the liquid handled. Care must be taken with Teflon-taped joints to prevent shredded pieces of Teflon from entering the piping system. Piping should start at the pump, working toward the source of supply and the point of discharge. Shutoff valves and unions are recommended to facilitate future inspection and repair. Reducers are pre-ferred to bushings when a change in pipe size is necessary. Unnecessary restrictions in the pipeline should be avoided, including elbows, sharp bends, globe or angle valves, and restricted-type plug valves.

Pipe size must take into account the required capacity, minimum or maximum veloci-ties, the fluid viscosity at the lowest pumping temperature, the length of the piping sys-

Figure 3-10. Checking for Spacer Coupling Misalignment

Rotary pumps have close running clearances. Thus, clean piping is a must. Dirt, grit, weld bead or scale, flushed from an unclean piping system, will damage and may stall the pump. Flush the system thoroughly before connect-ing piping to pump.

1070_0016a.cdrUSE INSIDE MICROMETER FOR

ANGULAR ALIGNMENT

USE DIALINDICATORFOR PARALLELALIGNMENT

SECURE BRACKETTO COUPLING HALF

3-10


tem including valves, strainers, and other restrictions, and the elevation of the pump with reference to supply and discharge points. Friction or line losses may be calculated by referring to the manufacturer’s Engineering Manual or the Hydraulic Institute’s Engineering Data Book.

Inlet Piping. Inlet piping should normally be equal to or one size larger than the pump inlet port connection. Viscous liquids may require larger inlet piping. Absolute air tightness of the inlet line is a must. Pumps operating with a static suction lift should have the inlet piping sloping gradually upward to the pump. On a long, horizontal run, keep the horizontal piping below the liquid level when possible. Piping should go around obstacles that are encountered rather than over them. Piping over an obstacle creates an air pocket, thereby making priming difficult.

Outlet Piping. Outlet piping should be sized to produce the desired discharge pressure. At the outlet port, the piping should have a vertical rise of about five pipe diameters to prevent gas or air pockets in the pump and act as a fluid seal within the pump on high-vacuum starting.

StrainersWith but a few exceptions, a pump should not be installed without strainer protection. Foreign matter may be large enough or of sufficient volume to jam a pump with proba-ble damage to both pump and drive equipment. Smaller matter passing through the pump will cause rapid pump wear and premature pump failure.

Strainers should be of ample size to prevent an excessive vacuum condition at the pump. Generally, the net area of the strainer screen should be three to five times the area of the inlet pipe. The required net area is dependent on the flow rate and the liquid viscosity. Strainer basket design must include capability of operation under high vac-uum without collapsing.

Install the strainer in the inlet piping near the pump, making certain it is located where it may be readily serviced. The strainer must be installed according to arrows or nota-tion designating direction of flow. Provide a vacuum or compound gauge before and after the strainer to determine when cleaning is required.

For continuous pumping, a bypass (including valving) should be piped around the strainer to permit cleaning. Alternately, two strainers in parallel or a duplex strainer may be used.

Check the strainer frequently when the pump is first started. This is the time that for-eign material in the system is most likely to collect in the strainer.

Overpressure Protection

The pump is capable of building infinite pressure. A pressure relief valve should be installed in the discharge side of the piping as shown in Figure 3-11. The relief valve discharge should be piped back to the supply tank. If it is routed directly to the suction side of the pump, the recirculation will cause excessive heat buildup. This will cause expansion between close-tolerance parts, which will result in galling or binding in the pump.

Overpressurization of the pump can cause equipment failure, resulting in per-sonal injury.

Do not install 45- or 90-degree fit-tings at the pump suction port. When possible, provide 10 pipe diameters of straight pipe at the suction port.

3-11

Installation

Pre-Startup ChecksInspection checks are essential to avoid operational difficulties and ensure trouble-free startup. Listed below are several items that need to be checked before the pump is started:

1. Inspect all piping for undue stress and strain on the pump.2. Flush and leak test all piping before connecting to pump. 3. Fully open inlet and outlet valves. Pump must not be started with throttled or

closed inlet or outlet valves.4. Close all drain valves.5. Check wiring diagrams for proper connections for voltage and rotation. Proper

rotation is indicated by an arrow on the pump. Disconnect driver coupling and start driver momentarily to ensure correct rotation.

6. Before reconnecting driver coupling, turn pump shaft to be sure it rotates freely.7. Reconnect driver coupling and replace guard. Make certain all other guards are in

place.8. For relief valves that can be installed for either direction of rotation, make certain

that valve is installed properly for desired rotation.9. Install pressure and vacuum gauges for checking startup conditions.

Figure 3-11. Pump By-pass Piping

1070_0005a.cdr

SUPPLYTANK

SUCTION PORT

ROTARY GEAR PUMP

DISCHARGE PORT

TO SYSTEM

PIPE TEE

PRESSURERELIEFVALVE

NOT RECOMMENDEDNPTBUSHING

RECOMMENDEDBYPASS FLOW

4-1

Parts 4

Edwards rotary pumps are available in many configurations. While they may look alike, there may be significant differences from one pump to another. Differences include con-struction material, sealing method, rotor type, etc. This manual covers only one config-uration, which is defined by a model number and a serial number. Check the name plate on the pump to make certain the model number is 80-428 and the serial number is ________________. If the numbers do not match, contact EMI.

When ordering parts, please provide:

1. Model number from pump name plate.

2. Serial number from pump name plate.

3. Part number of part from parts list.

4. Name of part from parts list.

5. Quantity needed.

Order replacement parts from:

Edwards Manufacturing Inc.2441 SE Stubb St.Milwaukie, OR 97222

Phone: (503) 659-4198FAX: (503) 659-4696Internet: www.edwardsmfg.comE-Mail: [email protected]

Do not order parts using this manual if the model number on the pump is not 80-428 or the serial number is not ________________. Using parts ordered from the wrong manual could result in pump failure or personal injury.

3.4.

Pentair Water- North Aurora Operations800 Airport Rd.North Aurora, IL, 60542

Phone: (630) 859-7000FAX: (630) 859-7060Internet: www.aurorapump.com

4-2


Figure 4-1. Edwards Model 80-428 Pump Exploded View

1070_0008e.cdr

20

21

3

1615

1412

59

12 4

119

18

17

22

10

24

23

1018

3

1

19

26

2227

13

319

13

20

21

8

76

5

14

15

16

1713

319

11

Figure 4-1. Edwards Model 80 Pump Exploded View

Parts

4-3

Figure &Index No.

PartNumber

Description

Units

Per

Assy

4-1- 1080428BBBS40S PUMP, Standard duty foam, all bronze with lip seals REF- 1 0200032 . FITTING, Grease, 1/4-28 short, no check ball 5- 2 0120022 . COVER, Timing gear 1- 3 0200038 . NUT, Hex, GR5, 1/4-20 12- 4 0200070 . SCREW, Round/slot head, 1/4-20 X 2 in. 4- 5 0200082 . GASKET, Cover 2- 6 0120002 . COVER, Front 1- 7 0200072 . SCREW, Round/slot head, 1/4-20 X 1 in. 4- 8 0160004 . SEAL, Front cover 1- 9 0200002 . LOCKNUT, Timing gear 1-10 0200057 . KEY, Woodruff, SS, 3/16 X 3/4 in. 2-11 0180004 . GEAR, Drive timing, straight bore 1-12 0180002 . GEAR, Idler timing, taper bore 1-13 0200034 . SETSCREW, Nylon tip, 5/16-18 X 5/16 in. 4-14 0190002 . NUT, Bearing adjusting 4-15 0170004 . BEARING, Ball 4-16 0160006 . SEAL, Grease 4-17 0110004 . ENDCASE 2-18 0200006 . SCREW, Cap, hex head, GR5, 1/4-20 X 3/4 in. 16-19 0200020 . WASHER, Flat, zinc, 1/4 SAE 20-20 0160050 . SEAL, Lip 4-21 0200080 . GASKET, Body 2-22a 0130202 . LINER, Right hand 2-22b 0130202L . LINER, Left hand 2-23 No Number . ROTOR ASSEMBLY, Idler (Factory assembled from 23a and

23b.)1

-23a 0140200 . .ROTOR, 80-428 (Cannot be ordered separately. Must be ordered with 23b.)

1

-23b 0150216 . . SHAFT, Idler (Cannot be ordered separately. Must be ordered with 23a.)

1

-24 No Number . ROTOR ASSEMBLY, Drive (Factory assembled from 24a and 24b.)

1

-24a 0140200 . .ROTOR, 80-428 (Cannot be ordered separately. Must be ordered with 24b.)

1

-24b 0150018 . . SHAFT, Drive (Cannot be ordered separately. Must be ordered with 24a.)

1

-26 0200014 . STUD, SS, 1/4-20 X 1.2 in. 4-27 0100012 . BODY, Pump 1

. FITTING, Grease, no check ball

Warranty (8/99)

WARRANTY

WARRANTY: Seller warrants equipment (and its component parts) of its own manufacture against defects in materials and workmanship under normal use and service for one (1) year from the date of installation or start-up, or for eighteen (18) months after the date of shipment, whichever occurs first. Seller does not warrant accessories or components that are not manufactured by Seller; however, to the extent possible, Seller agrees to assign to Buyer its rights under the original manufacturer's warranty, without recourse to Seller. Buyer must give Seller notice in writing of any alleged defect covered by this warranty (together with all identifying details, including the serial number, the type of equipment, and the date of purchase) within thirty (30) days of the discovery of such defect during the warranty period. No claim made more than 30 days after the expiration of the warranty period shall be valid.

Guarantees of performance and warranties are based on the use of original equipment manufactured (OEM) replacement parts. Seller assumes no responsibility or liability if alterations, non-authorized design modifications and/or non-OEM replacement parts are incorporated If requested by Seller, any equipment (or its component parts) must be promptly returned to Seller prior to any attempted repair, or sent to an authorized service station designated by Seller, and Buyer shall prepay all shipping expenses. Seller shall not be liable for any loss or damage to goods in transit, nor will any warranty claim be valid unless the returned goods are received intact and undamaged as a result of shipment. Repaired or replaced material returned to customer will be shipped F.O.B., Seller's factory. Seller will not give Buyer credit for parts or equipment returned to Seller, and will not accept delivery of any such parts or equipment, unless Buyer has obtained Seller's approval in writing.

The warranty extends to repaired or replaced parts of Seller's manufacture for ninety (90) days or for the remainder of the original warranty period applicable to the equipment or parts being repaired or replaced, whichever is greater. This warranty applies to the repaired or replaced part and is not extended to the product or any other component of the product being repaired.

Repair parts of its own manufacture sold after the original warranty period are warranted for a period of one (1) year from shipment against defects in materials and workmanship under normal use and service. This warranty applies to the replacement part only and is not extended to the product or any other component of the product being repaired.

Seller may substitute new equipment or improve part(s) of any equipment judged defective without further liability. All repairs or services performed by Seller, which are not covered by this warranty, will be charged in accordance with Seller's standard prices then in effect. THIS WARRANTY IS THE SOLE WARRANTY OF SELLER AND SELLER HEREBY EXPRESSLY DISCLAIMS AND BUYER WAIVES ALL OTHER WARRANTIES EXPRESSED, IMPLIED IN LAW OR IMPLIED IN FACT, INCLUDING ANY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Seller's sole obligation under this warranty shall be, at its option, to repair or replace any equipment (or its component parts) which has a defect covered by this warranty, or to refund the purchase price of such equipment or part. Under the terms of this warranty, Seller shall not be liable for (a) consequential, collateral, special or liquidated losses or damages; (b) equipment conditions caused by normal wear and tear, abnormal conditions of use, accident, neglect, or misuse of said equipment; (c) the expense of, and loss or damage caused by, repairs or alterations made by anyone other than the Seller; (d) damage caused by abrasive materials, chemicals, scale deposits, corrosion, lightning, improper voltage, mishandling, or other similar conditions; (e) any loss, damage, or expense relating to or resulting from installation, removal or reinstallation of equipment; (f) any labor costs or charges incurred in repairing or replacing defective equipment or parts, including the cost of reinstalling parts that are repaired or replaced by Seller; (g) any expense of shipment of equipment or repaired or replacement parts; or (h) any other loss, damage or expense of any nature.

3.5.1

PD750-20 (07-05-06)

SPECIAL ENCLOSURES-T NEMA Type 3R (IEC IP14), Painted Steel-E NEMA Type 4 (IEC IP56), Painted Steel-F NEMA Type 4X (IEC IP56), #304 Stainless Steel,

Natural Finish**-FXP NEMA Type 4X (IEC IP56), #304 Stainless Steel,

Painted Finish-FD NEMA Type 4X (IEC IP56), #316 Stainless Steel,

Natural Finish**-FDB NEMA Type 4X (IEC IP56), 12 Gauge, Seam

Welded, #316 Stainless Steel, Polished and Brushed Finish

-FDP NEMA Type 4X (IEC IP56), #316 Stainless Steel Painted Finish

-G NEMA Type 12 (IEC IP52), Painted Steel** Natural Finish (Visible surface blemishes, weld burns and grinding marks).

CIRCUIT BREAKER OPTION-E Intermediate withstand rating

85,000 Amperes RMS Sym at 200-240V65,000 Amperes RMS Sym at 380-480V25,000 Amperes RMS Sym at 550-600V

ANTI-CONDENSATION SPACE HEATERS-H 120 Volt Space Heater-J 120 Volt Space Heater With Thermostat-K 120 Volt Space Heater With Humidistat-L 240 Volt Space Heater-M 240 Volt Space Heater With Thermostat-N 240 Volt Space Heater With Humidistat

PRESSURE TRANSDUCERS-B 0-600 psi (0-42.25 bar) Pressure Transducer for

Fresh Water Service-C 0-300 psi (0-21.1 bar) Pressure Transducer for Sea

Water, Foam or Copper Corrosive Service-D 0-600 psi (0-42.25 bar) Pressure Transducer for Sea

Water, Foam or Copper Corrosive Service

AUTOMATIC POWER TRANSFER SWITCHESFTA975 - generator set emergency supplyFTA976 - second utility emergency supply(Refer to publication SD975-20)

ALARMS-AC Extra contacts (normally open & normally closed) for

remote indication, pump operating-AF Audible and Visible low pump room temperature alarm-AG Built-in reservoir low alarm-AH Audible low suction pressure alarm-AM Contacts for remote indication, pump fail to start-AV Contacts for remote indication, low pump room

temperature-AW Contacts for remote indication, reservoir low-AY Contacts for remote indication, low suction pressure-AZ Low pump room temperature switch, mounted and wired-BW Extra contacts for remote indication,

phase failure/phase reversal-BY Contacts for remote indication, pump overload-COM Visible low suction pressure alarm, Manual

reset only (Includes reset push-button, initiating pressure switch not included)

-CTS Built in Low Suction Pressure Alarm Panel (Includes selectable auto/manual reset, audible, visible and remote alarms and mounted and wired pressure switch)

-EG Visible Relief Valve Discharge alarm-EH Contacts for remote indication, relief valve discharge-EJ Built-in flow meter on alarm-EK Contacts for remote indication, flow meter on-KH Contacts for remote indication, common output for

any alarm-JR Visible jockey pump running indication-JT Audible and Visible jockey pump trouble indication-P Built-in alarm system (Includes visible supervisory

voltage normal indication and audible pump operating, phase failure and phase reversal indication)

-PB Built-in low system pressure visible alarm with manual reset

-PE Contacts for remote indication, low system pressure-PT Built-in alarm system, 220 VAC supervisory power

(Includes visible supervisory voltage normal indication and audible pump operating, phase failure and phase reversal indication)

-HV Audible alarm device-LVA Visible pump on demand alarm-LW Audible and visible pump on demand alarm (requires

(-HV))-LY Contacts for remote indication, pump on demand

(requires (-LVA) or (-LW))

MISCELLANEOUS-DZ Test push-button and solenoid valve*-ED Load shed circuits-PY Motor space heater output contacts-S Tropicalization-ZPA Customized, annual service display message (when

factory programmed or programmed by Firetrolrepresentative during start-up)

-ZPN 5150 Ethernet Connectivity Module (Allows users to monitor limited controller status via a single computer or over a computer network)

-ZPM Serial Modbus RTU Communications Protocol (Allows users to monitor all aspects of the controller status via a RS485 communications network (system integration required). (Includes RS485 to twisted pair breakout module, optical isolation module (4000 ft. range), DC power supply and customer connection terminal blocks).

Export packaging (Wooden crating to conform to IPPC Standards)

*Weekly Test Timer - Standard

Main Fire Pump ControllerThe main fi re pump controller shall be a factory

assembled, wired and tested unit and shall conform to all the requirements of the latest edition of NFPA 20, Standard for the Installation of Stationary Pumps for Fire Protection and NFPA 70, National Electrical Code. The controller shall be listed by Underwriters Laboratories, Inc., in accordance with UL218, Stan-dard for Fire Pump Controllers, CSA, and Canadian Standards Association CSA-C22.2, Standard for Industrial Control Equipment (cULus), approved by Factory Mutual and approved by the City of New York for fi re pump service.

Starting Method The controller shall be of the combined manual and automatic type designed for full voltage starting of the fi re pump motor having the horsepower, volt-age, phase and frequency rating shown on the plans and drawings. The controller components shall be housed in a NEMA Type 2 (IEC IP11) drip-proof, wall mounted enclosure.

Withstand Ratings (Short Circuit Current Rat-ings)

All controller components shall be front mounted, wired and front accessible for maintenance. The minimum withstand rating of the controller shall not be less than: 65,000 Amperes RMS Sym. at 200-240V 25,000 Amperes RMS Sym. at 380-480V 14,000 Amperes RMS Sym. at 550-600V

If the available fault current of the system exceeds these ratings, the controller shall be available with a withstand rating as shown below: 85,000 Amperes RMS Sym. at 200-240V 65,000 Amperes RMS Sym. at 380-480V 25,000 Amperes RMS Sym. at 550-600V

Circuit BreakerThe controller shall include a thermal magnetic

circuit breaker. The circuit breaker shall be mechani-cally interlocked so that the enclosure door cannot be opened with the handle in the ON position except by a hidden tool operated defeater mechanism. The circuit breaker shall be capable of being padlocked in the OFF position for installation and maintenance safety, and shall also be capable of being locked in the ON position without affecting the tripping characteristics of the circuit breaker. The controller door shall have a locking type handle and three point cam and roller vault type hardware. The controller shall be suitable for use as service equipment.

Operator Interface The fi re pump controller shall feature an operator interface with user keypad. The interface shall monitor and display motor operating conditions, including all alarms, events, and pressure conditions. All alarms, events, and pressure conditions shall be displayed with a time and date stamp. The display shall be a 2-line, 20-character, vacuum fl uorescent, dot matrix

type designed to allow easy viewing from all angles and in all light conditions. The display and interface shall be NEMA rated for Type 2, 3R, 4, 4X, and 12 protection and shall be fully accessible without open-ing the controller door. The display and user interface shall utilize multiple levels of password protection for system security. A minimum of 3 password levels shall be provided. The display shall be capable of being programmed for any language.

Ammeter/Voltmeter The fi re pump controller operator interface shall be capable of displaying true RMS digital motor voltage and current measurements for all three phases simultaneously. Displays requiring push-button and selector switches to toggle between phases or current and voltage shall not be accept-ed.

Voltage and current shall be measured by True RMS technology to provide the most accurate measurement for all sine waves, including non-sinusoidal waveforms. Average responding meters will not be accepted.

Digital Status/Alarm Messages The digital display shall indicate text messages for the status and alarm conditions of:• Motor On • Sequential Start Time • Minimum Run Time • Local Start / Off Delay Time • Remote Start• Fail to Start • System Battery Low• Under Voltage • Over Voltage• Low Suction Pressure • Over Frequency • Emergency Start • Motor Over 320% • Drive Not Installed • Motor Overload • Disk Error • Pressure Error • Disk Near Full

The Sequential Start Timer and Minimum Run Timer/Off Delay Timer shall be displayed as numeric values refl ecting the value of the remaining time.

LED Visual IndicatorsLED indicators, visible with the door closed, shall

indicate:• Power On • Emerg. Isolating Switch Open• Pump Running • Low System Pressure• Alarm • Transfer Switch Normal• Deluge Open • Transfer Switch Emergency• Phase Failure • Phase Reversal• Interlock On

Data Logging The digital display shall monitor the system and log the following data:• Motor Calls/Starts • Elapsed Motor Run Time• Elapsed Power On Time • Maximum Run Cur-rents• Minimum Voltages • Minimum Run Currents• Maximum Voltages • Last Motor Run Time• Last Phase Failure • Last Start Currents• Last Phase Reversal • Min/Max Frequency• Min/Max Pressure

Specifi cationsLimited Service Fire Pump Controllers • FTA750

3.5.2

(919) 460-5200 • www.firetrol.com • Sales Office: Cary, NC 27512 USA

Event RecordingMemory - The controller shall record all opera-

tional and alarm events to system memory. All events shall be time and date stamped and include an index number. The system memory shall have the capability of storing 3000 events and allow the user access to the event log via the user interface. The user shall have the ability to scroll through the stored messages in groups of 1, 10, or 100.

USB Host Controller - The controller shall have a built-in USB Host Controller. A USB port capable of accepting a USB Flash Memory Disk (aka: fl ash drive, thumb drive, memory stick, etc..) shall be provided. The controller shall save all operational and alarm events to the fl ash memory on a daily basis. Each saved event shall be time and date stamped. The total amount of historical data saved shall solely depend on the size of the fl ash disk utilized. The controller shall have the capability to save settings and values to the fl ash disk via the user interface.

Communications - The controller shall feature two independent communications ports to allow connec-tivity to computers, modems, or building management systems.

Solid State Pressure Transducer The controller shall be supplied with a solid state pressure transducer with a range of 0-300 psi (0-20.7 bar) ±1 psi. The solid state pressure switch shall be used for both display of the system pressure and con-trol of the fi re pump controller. Systems using analog pressure devices or mercury switches for operational control will not be accepted. The START, STOP and SYSTEM PRESSURE shall be digitally displayed and adjustable through the user interface. The pressure transducer shall be mounted inside the controller to prevent accidental damage. The pressure transducer shall be directly pipe mounted to a bulkhead pipe coupling without any other supporting members. Field connections shall be made externally at the controller coupling to prevent distortion of the pressure switch element and mechanism.

Operation A digitally set On Delay (Sequential Start) timer shall be provided as standard. Upon a call to start, the user interface shall display a message indicating the remaining time value of the On Delay timer. The controller shall be fi eld programmable for manual stop automatic stop. If set for automatic stopping, the controller shall allow the user to select either a Minimum Run Timer or an Off Delay Timer. Both timers shall be programmable through the user interface.

A nonadjustable restart delay timer shall be provided to allow the residual voltage of the motor to decay prior to restarting the motor. At least 2 seconds, but no more than 3 seconds, shall elapse between stopping and restarting the pump motor. A weekly test timer shall be provided as standard. The controller shall have the ability to program the time, date, and frequency of the weekly test. In addi-tion, the controller shall have the capability to display a preventative maintenance message for a service inspection. The message text and frequency of oc-currence shall be programmable through the user interface. A Lamp Test feature shall be included. The user interface shall also have the ability to display the status of the system inputs and outputs. The controller shall not start the fi re pump motor under a single-phase condition. If the motor is already running when a phase loss occurs, the controller shall continue to run the motor, but still display a Phase Failure alarm. The fi re pump controller software shall be auto-matically upgradable through the USB port by simply inserting a fl ash disk with the new software. Fire pump controllers that require laptop computers, handheld equipment or specialized devices for software up-grades shall be prohibited. The controller shall be a Firetrol brand.

SP750-20 (06-08-07)

3.5.3

When the deluge valve contact opens, relay 1CR isenergized, closing it’s normally open contact to the 1Mcontactor coil, and the motor runs.

When the deluge valve contact closes, relay 1CR isde-energized, re-opening it’s normally open contact, de-energizing the 1M contactor, and the motor stops.

Shutdown Interlock OperationThe shutdown interlock, if used, is a normally open,

closed to interlock contact wired to terminals 1 and 10.When the interlock contact is closed, relay 1CR

cannot be energized by inputs to the MarkII from thepressure transducer, or the deluge valve. The controllermay be started manually by depressing the manualSTART push button. See the specific starting operationfor more details.

Pump Motor Starting SequenceWhenever relay 1CR is energized, it’s normally open

contact closes, allowing voltage to the coil of the motorstarting contactor. During full voltage starting the followingsequence occurs.

1CR normally open contact closes, energizingcontactor 1M . 1M connects motor terminals T1, T2,and T3 to the power source. This starts the motor in thefull voltage configuration, in which the pump motor draws100% of its normal inrush current and supplies 100% ofits normal starting torque.

Emergency Starting and StoppingThe controller is equipped with an emergency run

mechanism for use in the event of a coil burnout or otherelectrical problem which would prevent normal startingof the pump motor. The mechanism attempts to bothelectrically and mechanically start the pump motor.

When the emergency run mechanism is utilized, ae-run contact is closed, energizing 1M coil . This, ineffect, attempts to electrically start the pump motor.

The emergency run mechanism also manuallycloses the 1M contactor, starting the motor. This willrun the motor as long as the main three phase power isavailable.

If the pump motor is running via the emergency runmechanism, DO NOT release the mechanism to stopthe motor. Place the circuit breaker handle in the offposition, then release the emergency run mechanism.Releasing the mechanism while the motor is runningcould result in damage to the motor or the motorcontactor.Note: The emergency run mechanism is not intendedfor, nor should it be used as a testing device. Its solepurpose is to attempt to start the pump motor in theevent of a failure.

SQ750-20 (04-12-07)

3.5.4

3.5.5

Pump Controllers, Fire

Combined manual and automatic type controllers for internal combustion engines driving centrifugal fire pumps, Model FTA-1100 followed by A or B, followed by -A, followed by 12 or 24, followed by L or N, followed by N or P, may be followed by one ormore suffix letters. Model FTA-1100 followed by A, F or R, followed by L or N, followed by 12 or 24, followed by N or P, may befollowed by one or more suffix letters.

Cat. No. FTA-1100 followed by D or M, followed by L or N, followed by 12 or 24, followed by N or P.

Cat. No. FTA1100 followed by E, followed by L or N, followed by 12 or 24, followed by N or P, with or without modification or optional suffix letters.

Model FTA-1100 followed by J, -HW or -HX, followed by L or N, followed by 12 or 24, followed by P or N.

Manual controller-wound rotor type, Cat. No. FTA-1750 followed by A, B, C, D, E, F, G, H, J or K, followed by 15-400, followed by A, B, C, F or H, followed by additional suffixes.

Cat. No. FTA1100-P followed by L or N, followed by 12 or 24, followed by N or P.

Manual controllers, Cat. No. FTA1000 (across the line), FTA1250 (part winding*), FTA1300, (wye-delta open transition*), FTA1350(wye-delta closed transition*), FTA1500 (primary resistor*), FTA1800 (autotransformer*) and FTA1900 (electronic soft start*), followed C, followed by D, E, F, G or K, followed by 2 or 3 digit number 15 to 700, followed by A, B, C, F or H, may be followed by additional suffixes. (*Emergency manual operator provides full voltage across the line starting).

Automatic controllers, Cat. No FTA1000 (across the line), FTA1250 (part winding*), FTA1300 (wye-delta open transition*), FTA1350(wye-delta closed transition*), FTA1500 (primary resistor*), FTA1800 (autotransformer*) and FTA1900 (electronic soft start*), followed by A or B, followed by D, E, F, G or K, followed by 2 or 3 digit number 15 to 700, followed by A, B, C, F or H, may befollowed by additional suffixes. (*Emergency manual operator provides full voltage across the line starting).

Variable Speed Pressure Limiting Fire Pump Controllers Cat. No. FTA followed by 3100, 3110, 3120, followed by A, B or C, followedby M, N, P, Q or R, followed by two or three numbers from 15 to 400 followed by A, AZ, B, BZ, C, F, FZ, H or HH, maybe followed byadditional suffixes.

Controllers are suitable for use as service equipment on circuits capable of delivering high fault currents: maximum ratings are42,000 amps at 200-600 v (D), 200,000 aperes at 200-600 v (E, F, G) or 200,000 amps at 200-600 v (K) with current limiting (K).

Controllers rated 15-250 hp, 200-800 v (H); 15-300 hp, 220-240 v (A), 15-500 hp, 380-415 v (F); 15-600 hp, 440-480 v (B); and 15-700 hp, 550-600 v (C), three-phase, 50/60 hz (cps).

Controllers may be provided with a power transfer switch compartment, Cat. No. FTA900 (generator alternate source) or FTA901 (generator alternate source with bypass-isolation switch, followed by BL or Cat. No FTA950 (utility alternate source) or FTA951(utility alternate source with bypass-isolation switch), followed by B, followed by D, E, F, G or K; either catalog number followed by 100, 150, 260, 400, 600, 800 or 1000 (amp rating) followed by A, B, C, F or H, may be followed by additional suffixes. Fault current rating on normal side is same as fire pump controller. Fault current rating on emergency side is dependent upon the external circuit breaker (FTA900, FTA901) or the same as the fire pump controller rating D, E, F, G or K (FTA950, FTA951 ).

Foam concentrate fire pump controller, Cat. No. FTA followed by 1000, 1250, 1300, 1350, 1500, 1800 or 1900, followed by A, B orC, followed by D, E, F, G, K, M, N, P, Q or R, followed by 03 through 700, followed by A, AZ, B, BZ, C, F, FZ, H or HZ, may be

QYZS.EX2662Pump Controllers, Fire

Page Bottom

See General Information for Pump Controllers, Fire

ASCO POWER TECHNOLOGIES L P EX2662

5625 DILLARD DR

CARY, NC 27511 USA

3.5.6

followed by KL or LL.

The above foam concentrate fire pump controllers may be provided with transfer switch assembly, Cat. No. FTA900, FTA901, FTA950 or FTA951, followed by suffix letters and numbers.

All of the above controllers are suitable for use on circuits capable of delivering high fault currents. The withstand ratings are as follows:

Those controllers provided with transfer switches have withstand ratings on the normal side equal to those shown above at 240 and480 v. The emergency side of the transfer switch, if protected by an additional circuit located within the controller, has withstand ratings shown above at 240 and 480 v. If the circuit breaker protecting the emergency side is not supplied with the controller, the withstand rating for the emergency side will be dependent upon the ratings of the transfer switch and external circuit breaker provided.

Foam concentrate fire pump controller, Cat. No. FTA-740 or -750 followed by A, B or C, followed by A, B or H, followed by 10 or 30, followed by A, B, C, E, F, H or T, followed by **, LK, LKA, LL or LLA. The above foam concentrate controllers may be provided with transfer switch assembly. Cat. No. FTA-975 or -976 followed by suffix letters and numbers.

All of the above controllers are suitable for use on circuits capable of delivering high fault currents. The withstand ratings are as follows:

Above limited service controllers may be provided with transfer switch assembly, Cat. Nos. FTA-975 or -976; followed by suffix letters and numbers.

Circuit Breaker

Rated V

Short Circuit Current RMS Symmetrical A

SEL 150 amp, 240 42,000

SFL 250 amp, 480 30,000

600 22,000

SGL 400 amp, 240 42,000

SGL 600 amp 480 30,000

SEL, SFL, SGL, 600 22,000

when provided with 480 150,000

SEL, SFL, SGL isolation 600 22,000

switches

Same as above when 600 200,000

provided with current

limiting devices (PCL)

Circuit Breaker

Rated V


SEL 480 65,000

SED 600 14,000

SEL (with current 600 150,000

limiting device)

SEH 240 65,000

SEL 480 65,000

SEH 600 18,000

Circuit Breaker

Rated V


For operation with diesel generator (FTA-475).

Cat. No. FTA-975 transfer switch assembly has the following short circuit rating:

+-When protected by an external circuit breaker rated 100 A maximum.

Cat. No. FTA-976 transfer switch assembly has the following short circuit rating:

++-With current limiting device.

Cat. No. FTA, followed by 1000, 1250, 1300, 1350, 1500, 1800 or 1900, followed by A, B or C, followed by M, N, P, Q or R, followed by two or three numbers from 03 to 700, followed by A, AZ, B, BZ, C, F, FZ, H or HZ, may be followed by additional suffixes.

Cat. Nos. FTA900A or FTA901A, followed by L or M, followed by three or four digit number 100 to 1000, followed by A, AZ, B, BZ, C, F, FZ, H or HZ, may be followed by additional suffixes.

Cat. No. FTA950A or FTA951A, followed by A, AZ, B, BZ, C, F, FZ, H or HZ, may be followed by additional suffixes; Model AS-2001.

Remote alarm panels for use with this manufacturer's controllers - Cat. Nos. FTA-200A, -B, -F and -G.

Fire pump controllers, Cat. Nos. FTA-1750 followed by C, followed by M, N, P, Q or R, followed by 15-400, followed by A, AZ, B, BZ, C, F, FZ, H or HH, followed by additional suffixes.

Stand alone automatic power transfer switches, Cat. No. FTA902A or FTA903A, followed by L, followed by three or four digit number 100 to 1000 incl., followed by A, AZ, B, BZ, C, F, FZ, H or HH, followed by a two or three digit number from 03 to 700 incl.,followed by HP, may be followed by additional suffixes.

Cat. No. FTA952A or FTA953A, followed by M, N, P, Q or R, followed by three or four digit number 100 to 1000 incl., followed by A, AZ, B, BZ, C, F, FZ, H or HH, followed by a two or three digit number from 03 to 700 incl., followed by HP, ay be followed by

All 975, any breaker 200-600 v 10,000

or molded case switch

For operation with second utility (FTA-976).

SED 3-20 HP 220-240 10,000

25-30 HP 220-240 18,000

SED All HP 480 14,000

SEL All HP 480 14,000

All HP 200-240 18,000

SEL with PCL current 200-480 150,000

limiters - All HP

Molded Case Switch

Max Rated V

Short Circuit Current + RMS Symmetrical A

SED 200-480 10,000

SED 550-600 10,000

Circuit Breaker

Rated V


SED 3-20 HP 200-240 10,000

SED 25-30 HP 200-240 18,000

SED 380-600 14,000

SEL++ 600 150,000

SEH 550-600 18,000

additional suffixes.

Cat. Nos. FTA followed by 750, followed by A, B or C, followed by D or E, followed by two numbers from 03 to 30, followed by A, AZ,B, BZ, C, F, FZ, H or HH, may be followed by additional suffixes.

Cat. Nos. FTA followed by 740, followed by A, B or C, followed by D or E, followed by two numbers from 03 to 10, followed by E, EZ, T, or TT, may be followed by additional suffixes.

Cat. Nos. FTA followed by 975 or 976, followed by A followed by L, D or E, followed by two numbers from 100 to 150, followed by A, AZ, B, BZ, C, F, FZ, H or HH, may be followed by additional suffixes.

These controllers are suitable for use on circuits capable of delivering high fault currents. The withstand ratings are determined by the circuit breaker used except for those controllers provided with transfer switches in which case the ratings are determined by the circuit breaker and transfer switch.

Withstand ratings of the controller are dependent upon the circuit breaker as indicated below:

FTA750 Standard short-circuit rating

FTA750 Intermediate short-circuit rating

FTA740 Standard short-circuit rating

FTA740 Intermediate short-circuit rating

Isolation Voltage Range

Circuit Breaker

Withstand Maximum

Rating RMS Symmetrical

ARating CodeMFR Frame Rating A

200 240 ABB S3NT 15-150 65,000 D

380 480 ABB S3NT 15-150 25,000 D

550-600 ABB S3NT 15-150 14,000 D


Circuit Breaker

Withstand Maximum



200 240 ABB S3LT 15-150 85,000 E

380 480 ABB S3LT 15-150 65,000 E

550-600 ABB S3LT 15-150 25,000 E


Circuit Breaker

Withstand Maximum



200 240 ABB S3LT-2 15-150 10,000 D


Circuit Breaker

Withstand Maximum



200 240 ABB S3LT-2 15-150 65,000 E

The above ratings also apply to the normal side of the transfer switch. They also apply to the emergency side when it is protected bya circuit breaker of the same type. If the emergency side is not protected by an additional circuit breaker within the power transfer switch compartment, the following ratings apply to the emergency side. The external circuit breaker must have an interrupting rating at least equal to those shown.

WITHSTAND RATINGS EMERGENCY SIDE (UNITS WITH FIRE PUMP POWER TRANSFER SWITCH)

Trademark and/or Tradename: ,

Copyright © 2008 Underwriters Laboratories Inc.®

The appearance of a company's name or product in this database does not in itself assure that products so identified have been manufactured under UL's Follow-Up Service. Only those products bearing the UL Mark should be considered to be Listed and coveredunder UL's Follow-Up Service. Always look for the Mark on the product.

UL permits the reproduction of the material contained in the Online Certification Directory subject to the following conditions: 1. The Guide Information, Designs and/or Listings (files) must be presented in their entirety and in a non-misleading manner, without anymanipulation of the data (or drawings). 2. The statement "Reprinted from the Online Certifications Directory with permission from Underwriters Laboratories Inc." must appear adjacent to the extracted material. In addition, the reprinted material must include a copyright notice in the following format: "Copyright © 2008 Underwriters Laboratories Inc.®"

ASCO Transfer SwitchWithstand Rating RMS Symmetrical Amperes

When Used With External Molded Case Circuit Breaker

(Maximum), AA Cat. No. 200-480 V ac 550-600 V ac

100 as described 22,000 10,000 150

104 as described 22,000 10,000 150

150 as described 22,000 10,000 225

Last Updated on 2006-10-31

Questions? Notice of Disclaimer Page Top

SECTION 4:

1000 GAL. FIBERGLASSFOAM LIQUID STORAGE TANK

� � � � � � � � � � �

�

SKZZ-66025

4.1

SECTION 5:

2 IN. PRESSURE VACUUM VENT

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�

SKZZ-66025

5.1

SECTION 6:

FLEXIBLE CONNECTORS

� � � � � � � � � � �

�

SKZZ-66025

6.1

SECTION 7:

NATIONAL FOAM SEALER OIL

� � � � � � � � � � �

�

SKZZ-66025

7.1

7.2

Section 3. HAZARDS IDENTIFICATION

Potential Health Effects

InhalationNot a hazard in normal industrial use.

Skin Contact No irritation is expected from short-term exposure

Eye Contact No irritation is expected from short-term exposure..

IngestionNot a hazard in normal industrial use. Small amounts swallowed during normal handling operations are not likely to cause injury; swallowing large amounts may produce a cathartic (laxative) effect and may cause irritation to the digestive tract. Aspiration into lungs will cause lipoid pneumonia.

Additional Health EffectsNo significant signs or symptoms indicative of any adverse health effects are expected to occur.

Carcinogenicity InformationNo data available.

Section 4. FIRST AID MEASURES

InhalationNo specific treatment is necessary since this material is not likely to be hazardous by inhalation. If exposed to excessive levels of airborne mists, remove to fresh air. Seek medical attention if effects occur.

Skin Contact In case of skin contact, immediately flush skin with copious amounts of water for at least 15 minutes. Launder clothing before re-use. If irritation occurs, obtain medical attention.

Eye Contact In case of eye contact, immediately flush eyes with copious amounts of water for 15-30 minutes. Retract eyelids often to ensure thorough rinsing. Contact a physician if irritation persists.

IngestionIf swallowed, give victim plenty of milk or water to drink. Do not induce vomiting. Never administer anything by mouth to an unconscious person. Seek medical attention.

NMS#950 Page 2 of 7 10/01/07

Section 5. FIRE FIGHTING MEASURES

Flammable Properties Flash Point – 445 F(224 C)o o

Fire and Explosion Hazards Slightly combustible when heated above its flash point. This material will release flammable vapors which can burn in the open or be explosive in confined spaces if exposed to an ignition source. Keep away from extreme heat and open flame.

Extinguishing Media Dry chemical, carbon dioxide, or foam.

Special Fire Fighting Instructions Do not enter any enclosed or confined fire space without proper protective equipment such as self-contained breathing apparatus. Cool tanks and containers exposed to fire with water. Notify appropriate authorities if liquid enters sewer/waterways.

Section 6. ACCIDENTAL RELEASE MEASURES

Safeguards (Personnel) NOTE: Review FIRE FIGHTING MEASURES and HANDLING (Personnel) sections before proceeding with clean-up. Use appropriate Personal Protective Equipment during clean-up.

Accidental Release Measures

Small Spill Absorb liquid on paper, vermiculite, floor absorbent or other absorbent material.

Large SpillStop spill at source, dike area to prevent spreading. Pump liquid to salvage tank. Remaining liquid may be taken up on sand, clay, earth, floor absorbent or other absorbent material and shoveled into containers.

Section 7. HANDLING AND STORAGE

Handling (Personnel) Avoid contact with eyes, skin or clothing. Avoid ingestion or inhalation. Rinse skin and eyes thoroughly in case of contact. Review HAZARDS and FIRST AID sections.

StorageRecommended storage environment is between 35°F (2°C) and 120°F (49oC). Store product in original shipping container or tanks designed for product storage.

NMS#950 Page 3 of 7 10/01/07

Section 8. EXPOSURE CONTROLS/PERSONAL PROTECTION

Engineering ControlsUse or store with adequate ventilation..

Personal Protective Equipment

RespiratoryRecommended exposure limits (OSHA-PEL and ACGIH-TLV) are noted below. The need for respiratory protection should be evaluated by a qualified health specialist.

Protective ClothingRubber or PVC gloves recommended.

Eye Protection Safety glasses, face shield or chemical splash goggles must be worn when possibility exists for eye contact. Contact lenses should not be worn. Eye wash facilities are recommended.

Other Hygienic Practices Use good personal hygiene practices. Wash hands before eating, drinking, smoking, or using toilet facilities. Promptly remove soiled clothing and wash thoroughly before re-use.

Exposure Guidelines

Exposure Limits Mineral Oil Mist

PEL(OSHA)5 mg/m3 8 hr. TLV (ACGIH) 5 mg/m3 8 hr 10 mg/m3 15 min.

Section 9. PHYSICAL AND CHEMICAL PROPERTIES

Physical Data

Boiling Point: 6000F

Vapor Pressure: < 0.1 mm Hg @ 70oF

Vapor Density: Not applicable

Melting Point: Not applicable

Evaporation Rate: <1 (Butyl Acetate = 1.0)

Solubility in Water: Negligible

NMS#950 Page 4 of 7 10/01/07

pH: 7.0

Specific Gravity: 0.88 @ 60oF

Odor: Odorless

Form: Liquid

Color: Colorless

Section 10. STABILITY AND REACTIVITY

Chemical Stability Stable.

Incompatibility, Materials to AvoidAvoid extreme heat and flame. Avoid strong acids and oxidizers such as liquid chlorine and oxygen.

Polymerization Will not occur.

Section 11. TOXICOLOGICAL INFORMATION

No data available. This is a food grade product and is not expected to present a significant hazard under anticipated conditions of use.

Section 12. ECOLOGICAL INFORMATION

Ecotoxicological Information Aquatic Toxicity No data available.

Environmental Fate

BOD5 No data available

COD No data available

Section 13. DISPOSAL CONSIDERATIONS

Maximize product recovery for reuse or recycling. If product is introduced into a waste water treatment facility, Biological and Chemical Oxygen demand will likely increase. Spill material is biodegradable if gradually exposed to microorganisms. Potential treatment and disposal methods include land farming, incineration, and land disposal if permitted. Disposal should be made in accordance with federal, state and local regulations.

NMS#950 Page 5 of 7 10/01/07

NOTE: As a service to our customers, National Foam has approvals in place with disposal facilities throughout the U.S. for waste water treatment of our foam liquid concentrates and foam solutions. If required, National Foam, Inc. can also provide information on the disposal of drums used for shipping our concentrates. Please contact National Foam’s Risk Management Administrator at (610) 363-1400 for additional information.

Section 14. TRANSPORTATION INFORMATION

Shipping Information Proper Shipping Name: Not a D.O.T. “Hazardous Material” National Motor Freight Code: 69160 Sub 0 Hazard Class: Not Regulated

UN Number: Not Regulated

Section 15. REGULATORY INFORMATION

U.S. Federal Regulations

Toxic Substances Control Act (TSCA) All components of this product are listed in the TSCA inventory.

Superfund Amendments and Reauthorization Act of 1986 (SARA), Title III

Section 302/304 There are no components of this material with known CAS numbers which are on the Extremely Hazardous Substances (EHS) list.

Section 311 & 312 This material does not contain any components which are classified as health and/or physical hazards according to Section 311 & 312:

Section 313 This material does not contain any components which are subject to Section 313 reporting requirements.

COMPREHENSIVE ENVIRONMENTAL RESPONSE, COMPENSATION, AND LIABILITY ACT (CERCLA) this material does not contain any components which are subject to the reporting requirementsof CERCLA.

OTHER REGULATORY INFORMATIONNone

NMS#950 Page 6 of 7 10/01/07

STATE REGULATIONS

PENNSYLVANIA RIGHT-TO-KNOW HAZARDOUS SUBSTANCES LIST

PA Hazardous Substances present at levels greater than 1%: None

Section 16. OTHER INFORMATION

NFPA Rating

Health 0 Flammability 0 Reactivity 0

ADDITIONAL INFORMATION

Preparation Date/Revision Number .......................10/01/07

The information contained herein is furnished without warranty either expressed or implied. This data sheet is not a part of any contract of sale. The information contained herein is believed to be correct or is obtained from sources believed to be generally reliable. However, it is the responsibility of the user of these materials to investigate, understand and comply with federal, state and local guidelines and procedures for safe handling and use of these materials. National Foam, Inc. shall not be liable for any loss or damage arising directly or indirectly from the use of this product and National Foam, Inc. assumes no obligation or liabilities for reliance on the information contained herein or omissions herefrom.

October 1, 2007

NMS#950 Page 7 of 7 10/01/07

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