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Diesel Engine Fire Pump Controllers

Instructions

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Effective October 2007

Table of Contents

1. INSTALLATION AND MOUNTING ................................................................................................................1

2. ELECTRICAL CONNECTIONS .......................................................................................................................1

2.1 WIRE SIZES ...................................................................................................................................................1

3. SYSTEM PRESSURE CONNECTION ..............................................................................................................2

4. MAIN DISPLAY PANEL ....................................................................................................................................2

4.1 LCD DISPLAY ...............................................................................................................................................24.2 ANNUNCIATORS .........................................................................................................................................24.3 MAIN SWITCH .............................................................................................................................................24.4 FUNCTION (F1,F2,F3) AND MENU KEYS ................................................................................................24.5 SILENCE AND RESET BUTTON ................................................................................................................24.6 LAMP TEST BUTTON ..................................................................................................................................24.7 TIME/PRINT BUTTON .................................................................................................................................2

5. OPERATION OF CONTROLLER ....................................................................................................................3

5.1 OFF MODE ....................................................................................................................................................35.2 MANUAL MODE ..........................................................................................................................................35.3 AUTO MODE .................................................................................................................................................35.4 STOP MODES ................................................................................................................................................35.5 WEEKLY TEST TIMER ................................................................................................................................35.6 TEST MODE ..................................................................................................................................................45.7 RUN PERIOD TIMER ...................................................................................................................................45.8 SEQUENTIAL START TIMER ....................................................................................................................4

6. PROGRAMMING OF THE MAIN CONTROLLER .....................................................................................4

6.1 TO PROGRAM THE CONTROLLER ..........................................................................................................46.2 PROGRAM DESCRIPTIONS .......................................................................................................................4

6.2.1 Change Date ...............................................................................................................................................56.2.2 Change Time ...............................................................................................................................................56.2.3 Weekly Timer ..............................................................................................................................................56.2.4 Run Period Timer ........................................................................................................................................56.2.5 Language ....................................................................................................................................................56.2.6 Pressure Transmitter ..................................................................................................................................56.2.7 Pressure Start Point ....................................................................................................................................56.2.8 Pressure Stop Point ....................................................................................................................................56.2.9 Low Suction Shutdown ................................................................................................................................56.2.10 Printer Deviation ........................................................................................................................................66.2.11 Current Pressure .........................................................................................................................................66.2.12 Sequential Start ...........................................................................................................................................66.2.13 Stop Mode ...................................................................................................................................................66.2.14 AC Failure Start ..........................................................................................................................................66.2.15 Print Routine ...............................................................................................................................................66.2.16 Print Status .................................................................................................................................................66.2.17 Select Mode or Press Menu ........................................................................................................................6

7. ALARM SIGNALS (ANNUNCIATOR PANEL) ..............................................................................................6

7.1 BATTERY FAILURE ....................................................................................................................................67.2 CHARGER FAILURE ...................................................................................................................................67.3 ENGINE RUN ................................................................................................................................................67.4 ENGINE OVERSPEED .................................................................................................................................67.5 FAIL TO START ............................................................................................................................................67.6 FUEL SPILL ...................................................................................................................................................77.7 HIGH ENGINE TEMPERATURE ................................................................................................................77.8 LOW / HIGH FUEL .......................................................................................................................................7

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7.9 LOW OIL PRESSURE ...................................................................................................................................77.10 LOW / HIGH RESERVOIR ...........................................................................................................................77.11 LOW ROOM TEMPERATURE ....................................................................................................................7

8. BATTERY CHARGERS .....................................................................................................................................7

9. OPERATING TEMPERATURE ........................................................................................................................9

10. SYSTEM OVERPRESSURE – PLD .................................................................................................................10

11. ELECTRONIC STARTING ENGINES – ECM .............................................................................................10

12. INITIAL START UP ..........................................................................................................................................11

12.1 AUTOMATIC START TEST ......................................................................................................................1112.2 MANUAL START TEST .............................................................................................................................1212.3 TEST START TEST .....................................................................................................................................1212.4 WEEKLY EXERCISER TEST ....................................................................................................................12

13. FIELD FAILURE ALARM SIMULATION ....................................................................................................13

13.1 CHARGER FAILURE .................................................................................................................................1313.2 BATTERY FAILURE ..................................................................................................................................1313.3 LOW OIL PRESSURE .................................................................................................................................1313.4 HIGH ENGINE TEMPERATURE ..............................................................................................................1313.5 ENGINE FAIL TO START ..........................................................................................................................1313.6 ENGINE OVERSPEED ...............................................................................................................................1313.7 OTHER ALARMS (PUMP ROOM ALARMS) ..........................................................................................13

14. PRINTER – RECORDER INSTRUCTIONS ..................................................................................................14

14.1 OPERATING PROCEDURE .......................................................................................................................1414.2 SELF TEST FUNCTION .............................................................................................................................1414.3 PAPER LOADING .......................................................................................................................................1414.4 PRINT MODES ............................................................................................................................................15

14.4.1 Auto Print ..................................................................................................................................................1514.4.2 Manual Print .............................................................................................................................................15

14.5 PRINT STATUS ...........................................................................................................................................1514.6 PRINTER DEVIATION ...............................................................................................................................1514.7 REPLACEMENT PAPER TYPE .................................................................................................................16

APPENDIX A ..........................................................................................................................................................19

APPENDIX B ANNUNCIATOR ALARMS ..........................................................................................................20

APPENDIX C PRINTER ‘EVENT’ MESSAGES ................................................................................................21

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Installation & Maintenance Manual for Diesel Engine

Fire Pump Controller In order to familiarize yourself with the FD100 Diesel Controller, please read this instruction manual thoroughly and carefully. Retain the manual for future reference.

1. Installation and MountingCarefully unpack the diesel controller and inspectthoroughly.The controller should be located as close as ispractical to the engine it controls and shall bewithin sight of the diesel engine and batteries,preferably ten feet or less.The FD100 controller is designed for wallmounting using the mounting brackets on the topand bottom of the unit. The controller is not free-standing and must be bolted securely to a wall. Refer to the dimension drawing (Figure #3) in thismanual for dimensional data.The enclosure should be mounted with fasteningdevices capable of supporting 105lbs/48kg.

2. Electrical ConnectionsAll electrical connections should meet national andlocal electrical codes and standards. The controller should be located or so protectedthat it will not be damaged by water escaping frompumps or pump connections. Current carryingparts of controllers shall be a minimum of12 inches (305 mm) above the floor level.• Verify all data on the nameplate such as

catalog number, polarity of grounding, ACline, battery voltage and system pressure.

• Inspect all electrical connections, componentsand wiring for any visible damage and correctas necessary. Ensure that all electricalconnections are tightened before beingenergized.

• Refer to the appropriate field connectiondrawing affixed to the enclosure door, for allwiring information pertaining to the incomingAC power supply, batteries and engine wiring.

• Install necessary conduit using proper methodsand tools.

• Terminals 1 through 12, located on the lowerterminal block, are for interconnection to therespective terminals on the diesel engineterminal block.

• Incoming AC line voltage is clearly markedL,N and GD (ground) located on the lowerterminal block.

• Terminals 16 through 31, located on the lowerterminal block, are for interconnection of allremote alarm functions.*Do not apply an AC voltage to these terminals. Dry contact rating only.

• Terminals 39 through 134, located on theRelay Board, are for connection of all outputrelay functions. These terminals are of the pull-apart variety for ease of wiring.

• Input terminals on controller card are rated for30 VDC.

2.1 Wire Sizes• For control wiring, use #14 AWG wire for all

electrical connections except batteryconnections.

• For battery connection, terminals 6, 7, 8 and11, use the following:

#10 AWG: 0' to 25' (7.62 m)# 8 AWG: 25' to 50' (15.2 m)

NOTE: All field connections and AC wiring must bebrought into the enclosure through the lowerright or bottom right side ONLY (refer to labelaffixed inside enclosure),

*OTHERWISE WARRANTY IS VOID.*

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3. System Pressure ConnectionThe FD100 is supplied with a Pressure Transmitteror, as an option, a Pressure Switch. The controlleris provided with a 1/4" NPT female systempressure connection located on the bottom,external side of the enclosure. The connectionshould be installed as per NFPA, pamphlet No. 20. The “TEST” drain connection, located to the left ofthe system pressure connection, should be piped toa drain or to waste.

The main controller panel interfaces with either thepressure transmitter or the optional pressureswitch. The controller must be programmed for theappropriate device.Using the standard pressure transmitter, the actualpressure is displayed on the top right hand cornerof the LCD display. Precise start and stop pressureset points can be programmed into the controllervia the membrane switches. Pressure readings arealso displayed on the printer during alarmsituations or pressure deviations.With the Pressure Switch option, the LCD willdisplay “OK” if the pressure is satisfied, and“LOW”, if the contacts on the pressure switchchange state. The printer will indicate “LowPressure” on the paper display when the pressuredrops below the set point.

4. Main Display PanelThe main display panel located inside theenclosure, behind the breakable glass panel, servesmany operator interface functions (refer to Figure#1 for the main display panel layout):• LCD Display• Annunciators• Main Switches• Ammeter and Voltmeter for Each Battery• Pressure Indicator• Programming Functions 4.1 LCD DisplayThe LCD display located on the bottom of the maindisplay panel indicates both the voltage and currentreading of each battery as well as the systempressure, in PSI. The LCD display is also used while programmingthe diesel controller.

4.2 AnnunciatorsThe alarm and status indicators are located in thetop portion of the main display panel and willilluminate only if the situation occurs. The indicators are color coded to signify theurgency of the alarm: GREEN: Normal Running ConditionRED: Critical AlarmYELLOW: Supervisory Alarm4.3 Main Switch Four membrane switches labeled AUTO,MANUAL, TEST and OFF, each equipped with anLED indicator, are clearly marked for easyoperation of the controller. 4.4 Function (F1,F2,F3) and MENU KeysThere are four membrane switches, F1, F2, F3 andMENU which are dedicated to programming thecontroller. Refer to section 6 for programming ofthe controller.4.5 Silence and Reset Button Used to silence and/or reset prescribed alarms asper NFPA Pamphlet No. 20. 4.6 Lamp Test Button When depressed, the LED’s will illuminatesequentially, row by row. This function can beutilized at any time during the operation of thediesel controller. 4.7 Time/Print ButtonThis button toggles between two functions. Wheninitially depressed the LCD display will indicate:

When depressed again, the controller will promptthe user to hold the button for 3 seconds (at whichtime an audible tone is heard) after which thestored event and alarm messages will betransmitted to the printer. This is only applicablewhen the ‘Print Routine’ is set for Manual Print,otherwise the data is sent directly to the printerwithout user intervention. Refer to Section 14. The“Time/Print” key is not functional when thecontroller is in the OFF mode.

NOTE: Water lines to the drain valve and pressure switchmust be free from dirt and contamination.

TOP: Actual date and time BOTTOM: Weekly Test Timer, date and

time.BOTTOM:RIGHT

Quantity of messages stored inmemory.

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5. Operation of Controller

5.1 OFF ModeIn the OFF position the controller prevents theengine from starting and resets the followingalarms:• Overspeed• Charger Failure• Battery Failure• Fail to Start• Low Oil Pressure• High Engine TemperatureThe OFF position will silence all alarms.Three (3) sets of alarm contacts are provided toindicate that the controller is in the “OFF” mode.The contacts are rated for 10 A @ 220 VAC / 32VDC. Terminals 120 to 128.5.2 Manual ModeThis position allows the starting of the enginesusing the manual crank buttons, Crank #1 andCrank #2, located below the main display panel.For added cranking capacity, both Crank buttonscan be depressed simultaneously.The engine can be stopped by the ‘Local Stop’pushbutton or by placing the controller in the OFFmode. The engine will automatically stop in thecase of an OVERSPEED condition.All alarms, except for “FAIL TO START”, areactive in the MANUAL mode.

Three (3) sets of alarm contacts are provided toindicate that the controller is in the “MANUAL”mode. The contacts are rated for 10 A @ 220 VAC/ 32 VDC. Terminals 63 to 71.5.3 AUTO ModePlacing the controller in the AUTO modeilluminates the “SWITCH IN AUTO” annunciator.The controller is now ready to start the engine in anemergency situation.

A drop in pressure, ‘Remote Start’ signal, a signalfrom the ‘Deluge Valve’ or Weekly Test Timer willinitiate the “attempt to start” cycle. This cycleconsists of 6 crank periods of 15 seconds durationseparated by 5 rest periods of 15 seconds duration.Battery 1 and Battery 2 are alternated for eachcrank cycle. In the event that one battery isinoperative or missing, the controller will lock-inon the remaining battery during the crankingsequence. Once the engine is running, thecontroller will stop all further cranking.5.4 Stop ModesThe Stop Mode is programmable for either‘Manual Stop’ or ‘Auto Stop’ (see Figure #2). Notethat the engine can be stopped at any time byplacing the controller in the OFF position orautomatically in case of an OVERSPEEDcondition.Manual Stop Mode: the engine will continue torun until the ‘Local Stop’ or ‘Remote Stop’pushbutton is depressed, providing all startingcauses have been eliminated.

Auto Stop Mode: the engine will continue to rununtil the running period timer (RPT) has timed out(factory set at 30 minutes) and all starting causeshave been eliminated. 5.5 Weekly Test TimerEach diesel controller is equipped with a WeeklyTest Timer, 24 hour clock, to automaticallyexercise the engine once a week. The controllerinitiates the starting sequence by opening the drainvalve resulting in a simulated system pressure loss.The drain valve is automatically closed once thecontroller receives an “ENGINE RUN” signal. Theengine will continue to run for a minimum of 30minutes or for the duration of the RPT setting,whichever is greater. “Weekly Test Started” will beindicated on the hard copy printout.In the event that the engine is inoperative at thetime the Weekly Test is to be initiated, the WeeklyTest will commence immediately after the engine isput in service. This ensures that the engine isexercised at least once a week for the timespecified as per NFPA Pamphlet No. 20.In order to protect the engine, during the WeeklyTest sequence, an OVERSPEED condition, LOWOIL PRESSURE or HIGH ENGINE TEMP alarmwill automatically shutdown the engine.

Before accessing any mode, you must return tothe OFF mode.

CAUTION: Only depress Crank #1 or Crank#2 pushbuttons with controller in the‘MANUAL’ mode. Do not depress the crank pushbuttons in anyother mode or while engine is running. Doing socan result in serious damage to the engine.

NOTE: When the controller starts in this mode there is a 15second time delay in which the ‘Local Stop’pushbutton will have no effect.

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5.6 TEST ModePlacing the controller in the TEST position initiatesa starting sequence by opening the drain valveresulting in a pressure loss. The controller will startthe engine in the automatic mode.The TEST sequence can be terminated by puttingthe controller in the OFF mode, otherwise theSTOP mode prevails as programmed.All alarms are active in the test mode. In order toprotect the engine, in the test mode, anOVERSPEED condition, LOW OIL PRESSUREor HIGH ENGINE TEMP alarm will automaticallyshutdown the engine. 5.7 Run Period TimerThe Run Period Timer (RPT) performs theautomatic stopping function in a Fire PumpController after a start initiated by the pressuretransmitter during automatic operation. The purpose of the RPT is to ensure that the engineis not subjected to frequent starts in response to thepressure. Refer to Section 6 for programming ofthe RPT. 5.8 Sequential Start TimerThe Sequential Start Timer is standard in all dieselfire pump controllers.“The controller for each unit of multiple pumpunits operating in parallel shall incorporate asequential timing device to prevent any one motorfrom starting simultaneously with any other motor.If water requirements call for more than onepumping unit to operate, the units shall start atintervals of 5 to 10 seconds. Failure of a leadingmotor to start shall not prevent subsequentpumping units from starting” – NFPA, Pamphlet20, Chapter 7.The sequential start timer (SST) delays the startingof a fire pump in response to the pressure switch.It does not delay a pushbutton or emergency handlestart.With a SST in each controller, any pump may beselected as the lead pump by appropriate setting ofthe timers. If the lead pump restores the pressure inless than the time delays applied to the lag pumps,then the lag pumps will not start.In addition, the provision of a sequential starttimer, set to a few seconds delay, will prevent thelead pump controller from responding tomomentary hydraulic transient pressure loss whichwould otherwise start the fire pump unnecessarily.The SST can be programmed from 0 – 300seconds. Typically, each pump should be delayed

by 10 seconds from the pump ahead of it. Ifhydraulic transients are a problem, all timers canbe adjusted for a few seconds extra time delay.

6. Programming of the Main Controller

The LCD display will prompt the programmer withdata and allow the operator to modify the programusing a combination of the MENU key and threefunction keys; F1, F2 and F3. The displayedparameter value indicates the present setting of thecontroller. Located above the F1, F2 & F3 keys aredesignated symbols and/or words describing theirfunction. The function keys are used to increase,decrease or accept preset values.

6.1 To Program The ControllerPlace the controller in the ‘OFF’ mode and depressthe MENU key, followed by the F3 key. Figure #2illustrates the sequence in which the operator isprompted for each parameter. To move to the nextparameter, press the MENU key. Note that movingfrom one parameter to the next does not affect thevalue of the parameter currently displayed. F1 and F2 are used to change the value while F3 isused to enter the value into memory or accept thepresent value and proceed to the next parameter.For example, if the parameter displayed is“CHANGE DATE”, press the MENU key three (3)times to access the “RUN PERIOD TIMER”parameter and press F3 to change the time. F1increases the count, F2 decreases the count and F3enters the selected value into memory and proceedsto the next parameter.PROGRAMMABLE RANGES

Run Period Timer: 1-60 minsPressure (Start/Stop): 1-500 PSIPressure Deviation: 1-100 PSIAC Failure Delay: 0-300 secSequential Start Timer: 0-300 secLow Suction Shutdown YES or NO6.2 Program DescriptionsRefer to Appendix A attached .

>> The controller is programmablein the ‘OFF’ mode only

<<

While programming, a Function key or theMENU key must be depressed within a 60 secondtime period, otherwise the controller will returnto the initial prompt.

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6.2.1 Change Date

Factory set, however, this parameter allows theuser to set the current date.6.2.2 Change TimeFactory set, however, this parameter allows theuser to set the current time.6.2.3 Weekly TimerThis function allows the user to set the controller toautomatically start and stop the engine once perweek. Select the day and time (24-hour clock) forthe engine to run. Once selected, choose the runtime desired, in minutes. The engine will nowstart once per week as programmed. The enginewill run for a minimum of 30 minutes or for theduration of the RPT setting, whichever isgreater.You can view the status of the Weekly Test date bydepressing the TIME/PRINT button twice. 6.2.4 Run Period TimerTo activate the RPT, the STOP MODE functionmust be ‘Set for Automatic’ (see below in thissection). When the engine is started in response tothe pressure switch, it will continue to run for theduration of the RPT, in minutes. Once timed out, ifno further starting causes prevail, the engine willautomatically stop. If the engine is started manually the RPT has noaffect and the engine must be stopped manually.If the STOP MODE function is ‘Set for Manual’,the RPT does not affect the operation of thecontroller and becomes inoperative.The timing range for the RPT is: 1-60 mins

6.2.5 LanguageThe language can be selected for either English,Spanish or French.6.2.6 Pressure TransmitterWhen selected as YES, the controller will startbased on the signal from the pressure transmitter. When selected as NO, the engine will start whenthe controller detects a contact closure betweenterminals 31+11.For both starting conditions above, the SequentialStart Timer is activated when selected.

6.2.7 Pressure Start PointThe value programmed determines at whatpressure the controller will initiate a start commandto the engine.The pressure range is: 1-500 PSIFactory default: 1 PSI6.2.8 Pressure Stop PointThe value programmed determines at whatpressure the system must reach before thecontroller will STOP the engine, either manuallyvia the STOP pushbutton or automatically via theRPT timer. If the actual pressure does not exceedthe STOP pressure value, the engine will continueto run.The pressure range is: 1-500 PSIFactory default: 100 PSI6.2.9 Low Suction ShutdownThis function monitors a contact closure betweenterminals 29+11. If shutdown is disabled, the LCDdisplay will show low suction and the engine willcontinue to run.If shutdown is enabled, to prevent the controllerfrom responding to momentary hydraulic transientpressure loss (which would otherwise shut downthe engine unnecessarily), a time delay must beprogrammed to ensure a steady state.The shutdown time delay is selectable between 0 -30 seconds. Upon detecting a steady state contactclosure, the engine will turn off. The reset mode of the engine is user selectable. ForAUTOMATIC reset, a time delay between 0 - 30seconds is selected, after which the controllerobserves the input for a true signal, and if true, willnot allow the engine to restart. If false, thecontroller will function as normal and respond to astart signal.If MANUAL reset is selected, the RESETpushbutton must be depressed to reset thecontroller. If the situation continues to exist, thecontroller will not restart the engine and the alarmwill reappear.The LCD display will indicate ‘Low SuctionShutdown’ in both situations.

NOTE: that the RPT timer must be reset to thirty (30)minutes when the controller is placed in service.

NOTE: NFPA 20, Section 2-9.9, specifically prohibits theinstallation of any device in the suction piping thatwill restrict starting or stopping of the fire pump.Eaton Corporation assumes no liability when thisfunction is used.

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6.2.10 Printer DeviationThis value determines how often to print systempressure fluctuations as programmed by the user.In effect, it performs as a chart recorder. For example, if 10 PSI is programmed, each timethe system pressure fluctuates by 10 PSI, up ordown, the actual pressure is recorded in memoryand printed, tagged with a date and time. Thismethod avoids continual, time-based printing ofunnecessary pressure values.6.2.11 Current PressureAllows the user to view the actual pressure duringprogramming of the Diesel Controller.6.2.12 Sequential StartThis parameter allows programming of a startdelay after a start request. To bypass the start delay,set the parameter to zero.The programmable range is:0-300 sec6.2.13 Stop ModeIf ‘Set for Manual’, once started, the engine MUSTbe stopped manually by depressing the STOPpushbutton located on the flange, regardless of thestarting cause. If ‘Set for Auto’, the RPT becomesoperative.6.2.14 AC Failure StartIf ‘Enabled’, the controller will automatically startupon the loss of AC power. There will be a non-adjustable delay of 30 seconds before the ACfailure is detected. An additional delay can be set ifdesired. Time range is between 0 & 300 seconds. If‘disabled’ AC power failure will have no affect onthe starting of the engine.6.2.15 Print RoutineIf selected for Auto, the messages will printimmediately without any user intervention.If selected for Manual, the messages will be storedin the controller’s memory and will print once theTIME/PRINT key is pushed and held for 3seconds.To avoid paper build up inside the enclosure, it isrecommended that the print mode be selected as‘MANUAL’ during normal operation of thecontroller. 6.2.16 Print StatusIf selected as ‘NO’, a Status report will not printwhen exiting the programming menu. If selected as‘YES’, after exiting the program mode, andpressing the Time/Print button for 3 seconds, theprogrammed parameters and selected controller

readings will be printed. This is most helpfulduring and after commissioning of the Fire PumpController. A sample status printout is shown insection 14.6.2.17 Select Mode or Press MenuIf programming of the unit is complete pressing themode keys will put the controller back intooperation.

7. Alarm Signals (Annunciator Panel)

Each FD100 Diesel Controller is equipped with allthe alarms as shown in Appendix A. Unusedalarms can be activated at any time. Refer to theschematic supplied with the FD100 for alarmconnections.Refer to Appendix A: “Annunciator Alarms”affixed inside the enclosure, which describes eachalarm, method of resetting, associated terminalreference number, common trouble alarm and printout. Section 14 describes the “Print Mode”.7.1 Battery FailureThere are two annunciators on the alarm panel for,“Battery #1 Failure” and “Battery #2 Failure”. Thealarm is activated during the cranking cycle whenthe controller detects a weak or discharged battery,i.e. 67% of rated voltage, or less, or whenever abattery cable is disconnected.7.2 Charger FailureThere are two annunciators on the alarm panel for,“Charger #1 Failure” and “Charger #2 Failure”.The alarm is activated when the supply power tothe charger is lost or when the chargermalfunctions (alarm contacts are fed into thecontroller from the charging unit). The enginecontinues to run. To avoid nuisance power failures,a 20 second delay is built in to the charger failurealarm actuation circuit.7.3 Engine RunThis annunciator illuminates when the controllerreceives a running signal from the diesel engine.7.4 Engine OverspeedAn “Engine Overspeed” alarm will shutdown theengine regardless of the start condition – in allmodes. The signal is sent from the engine to thecontroller.7.5 Fail To StartAfter 6 cranking attempts, three attempts perbattery, the “Fail To Start” annunciator will

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illuminate. Attention to the diesel and itsassociated equipment is required immediately.7.6 Fuel SpillIndicates that the relief valve has been manuallyopened. This will cause a start of the engine oncethe pressure drops below the set value.7.7 High Engine TemperatureIndicates that the coolant temperature in the waterjackets is extremely hot. The over temperatureswitch on the engine signals the controller. Theengine continues to run in the AUTO andMANUAL modes. In the “TEST” mode and duringthe weekly test cycle the engine will shutdown. 7.8 Low / High Fuel

(When Fuel Level Switch Wired)

Indicates that the engine fuel supply is low / high.The engine continues to run.7.9 Low Oil PressureThe controller has an inherent delay to bypass thelow oil pressure alarm during engine start up. Afterthe delay, should the engine receive a ‘Low OilPressure’ signal, the controller will initiate analarm. The engine will continue to run in the‘AUTO’ and ‘MANUAL’ mode. In the ‘TEST’mode and during the weekly test cycle this alarmwill automatically shutdown the engine. Thissituation will result in serious engine damage ifkept running. 7.10 Low / High ReservoirIndicates that the water reservoir level is low /high. (Signal supplied by others)7.11 Low Room Temperature

(When Thermostat Installed)

Should a “Low Room Temperature” alarm occurthe engine will continue to run. 1 Software versions before V2.91 have a ReliefValve Discharge alarm instead of the Fuel spillalarm.2 Software versions prior to V2.91 have an audiblealarm for Low / High Fuel which followed theinput signal from the fuel tank.

8. Battery ChargersBattery chargers are independent chargersproducing a maximum of 10 amps each at full rate.Each battery charger is fully electronic and willprotect itself by shutting down during a continuedshort circuit.

The maximum current draw that the chargers willdraw when operating at 100% charging rate is:12 Volt System 24 Volt System1.6 amps - 120V 3.2 amps - 120V0.8 amps - 240V 1.6 amps - 240VThree Step Charge

The three steps are referred to as Bulk mode,Overcharge Mode and Float mode.Bulk In Bulk mode, a current of 10 Amps is deliveredinto the battery until the voltage reaches 2.4 Voltsper cell for Lead Acid Batteries. (14.4 Volts for a12 Volt battery). At this point, the battery hasrecovered approximately 90% of its capacity.When the charger senses this state, it switches tothe Overcharge mode.The battery charger LCD display will indicate“BULK” while in this mode. The bulk mode charging may take up to 24 hoursdepending on the battery capacity and the level towhich it was discharged.Overcharge In the Overcharge mode, the voltage on the batteryis held at 14.4 Volts and the current into the batterydeclines. This mode is maintained until the currentinto the battery declines to 1.5 Amps. At thismoment, the battery is approximately 99% chargedand the charger will change to Float Mode.The battery charger LCD display will indicate“OVER” as well as the battery voltage and thedelivered current.The overcharge mode charging may take up to 12hours depending on the battery capacity and thelevel to which it was discharged.FloatIn Float Mode, the charger maintains the batteryvoltage at 2.23 Volts per cell for a lead acid battery(13.4 Volts for a 12 Volt battery). Once Bulk andOvercharge modes are completed, the charger willmaintain the battery charge in Float mode byregulating to 13.3V. If the charger cannot maintainthe battery capacity while in Float mode, thecharger will begin a new charging sequence byentering Bulk mode.

The battery chargers incorporate a three stepcharge to guarantee the fastest charge times whileoptimizing battery life.

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The battery charger LCD display will indicate"FLT" as well as the battery voltage and thedelivered current.Charger Failure AlarmA single Form C relay output will activate if thecharger fails during a charge cycle due to any ofthe following conditions:Maximum battery charger output voltage has beenexceeded.1

Battery charger output voltage is greater than themaximum battery voltage threshold.1

Battery charger output voltage is less than theminimum battery voltage threshold.1

Battery charger output voltage is greater than thebattery charge mode maximum voltage threshold.2

Battery charger output voltage is less than thebattery charge mode minimum voltage threshold.2

Loss of AC power. The Charger Failure Alarm relay is normallyenergized and utilizes the Normally Open contactto signal the alarm condition. When there is afailure, the relay de-energizes.Dead Cell AlarmA single Form C relay output will activate if thebattery fails during a charge cycle due to any of thefollowing conditions:Battery charger output current is greater than themaximum battery current threshold.1

Battery charger output current is greater than thebattery charge mode maximum current threshold.2

Battery charger output current is less than thebattery charge mode minimum current threshold.2

Loss of AC power. The Dead Cell Alarm relay is normally energizedand utilizes the Normally Open contact to signalthe alarm condition. When there is a failure, therelay de-energizes.Note: The Dead Cell Alarm relay is not providedand must be ordered separately.Charger Shut DownThe charger will automatically shut down if thereis no load connected to the output or if there is ashort on the load side of the charger. In addition,

the charger will not operate if a battery isconnected incorrectly or if the wrong voltage ofbattery is connected. AC Input Fuse ProtectionThe AC Supply is protected by a 5 amp fuse whichwill blow in case of a breakdown of the charger.This fuse will not blow as a result of overloading ofthe charger since the electronics will shutdown thecharger in this event before the fuse blows. LCD DisplayA 1 line by 16 character LCD display on the frontof each charger will alternately show:Charging Amps; Voltage; AlarmsAs well, error messages will be displayedaccording to the conditions that exist. “NO BATTERY” is displayed if no battery isattached to the charger.“BATTERY ERROR” is displayed if a battery isconnected to the charger but the voltage is notwithin the minimum and maximum thresholds forthe selected battery type.“ERROR, RECOVERING” is displayed if themaximum battery charger output voltage (31.4V)has been exceeded.“VOLTAGE ERROR” is displayed if a chargingtest fails during a charge cycle due to any of thefollowing conditions:Battery charger output voltage is greater than themaximum battery voltage threshold.1

Battery charger output voltage is less than theminimum battery voltage threshold.1

Battery charger output voltage is greater than thebattery charge mode maximum voltage threshold.2

Battery charger output voltage is less than thebattery charge mode minimum voltage threshold.2

“TEMPERATURE ERROR” is displayed if atemperature error is detected.Temperature errors:Internal temperature is greater than the maximumambient temperature.External temperature is greater than the maximumbattery temperature. If the external temperatureprobe is not connected (terminal P2) the internaltemperature is used in its place.Note: The ambient and battery maximumtemperature threshold are both 60°C.1 - Refer to Appendix A: Table 1

2 - Refer to Appendix A: Table 2

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“CURRENT ERROR” is displayed if a batterytest has failed during a charge cycle due to any ofthe following conditions:Battery charger output current is greater than themaximum battery current threshold.1

Battery charger output current is greater than thebattery charge mode maximum current threshold.2

Battery charger output current is less than thebattery charge mode minimum current threshold.Charger Setup: Lead Acid / Ni CadDIP switches on the charger can be used to select anumber of options including battery type andvoltage as well as Forced Charging. Optionscurrently supported for the charger include 12 or24 Volt Lead Acid and NiCad Batteries. Lead AcidTo select 12Volt battery charge cycle with LeadAcid batteries set all DIP switches to the OFFposition.

To select 24Volt battery charger cycle with LeadAcid batteries, set DIP switch 3 to the ON positionand all other DIP switches to the OFF position.

NiCadTo select 12Volt battery charger with NiCadbatteries, set DIP switch 6 to the ON position andall other DIP switches to the OFF position.

To select 24Volt battery charger cycle with NiCadbatteries, set DIP switches 3 and 6 to the ON

position and all other DIP switches to the OFFposition.

Forced ChargingThere is provision for the battery chargers toprovide a forced charge to the batteries.The Forced Charge function will only activateimmediately after applying power to the chargerwith DIP Switch 8 in the ON position and a batteryconnected.When the charger is in the forced charge mode, itwill attempt to recover a battery by delivering10 amps. If the battery does not reach theminimum battery voltage (8 volts for a 12 voltsystem; 18 volts for a 24 volt system) within 5minutes, the recovery attempt will terminate. Oncethe battery reaches it's minimum battery voltage,the normal charge sequence will commence.Forced charging will only occur once per batterycharger power cycle.

Installation / MountingTwo chargers are direct mounted to the back pan.A retrofit kit consisting of a retrofit mountingplate, single battery charger and wire connectionterminals is available for retro-fitting previousmodels. Refer to the Renewal Parts ListPL05805008K.SpecificationsVoltage Input: 90 - 240VAC - Auto detectVoltage Output: 12 - 24VDC-DIP switch selectableHertz: Operates on 50 / 60HzOperating Temperature: 0 to 55 degrees C

9. Operating TemperatureThe operating temperature range of the FD100 is:-20°C to 55°C.

1 - Refer to Appendix A: Table 12 - Refer to Appendix A: Table 2

1ON

OFF

2 3 4 5 6 7 8

12 Volt - Lead Acid12 Volt Lead Acid

ON

OFF

1ON

OFF

2

3

4 5 6 7 8

24 Volt - Lead Acid24 Volt Lead Acid

ON

OFF

1ON

OFF

2 3 4 5

6

7 8

12 Volt - NiCa d12 Volt - NiCad

ON

OFF

1ON

OFF

2

3

4 5

6

7 8

24 Volt - NiCad24 Volt - NiCad

ON

OFF

1 1

1 1

ON ON

ON ON

OFF OFF

OFF OFF

2 2

2 2

3 3

3 3

4 4

4 4

5 5

5 5

6

6

6

6

7 7

7 7

8

12 Volt - Lead Acid 12 Volt - NiCa d

24 Volt - Lead Acid 24 Volt - NiCa d

8

88

24 Volt - NiCadON

OFF

12 Volt - NiCadON

OFF

12 Volt Lead AcidON

OFF

24 Volt Lead AcidON

OFF

IM05805016K


10. System Overpressure – PLDAll FD100 diesel engine controllers conform toNFPA - Section 12.4.1.3 (8) - System overpressurefor engines equipped with pressure limitingcontrols. Separate visible and audible indicatorswill activate once the pressure reaches 115 percentof total rated head (pressure).When the PLD option is requested, a visible alarmlight and an additional pressure switch are added tothe controller. The diesel controller horn will soundif system overpressure is present.

11. Electronic Starting Engines – ECM

The FD100 diesel engine fire pump controllers arecompatible with NFPA20 - Section 12.4.1.3 forengines with ECM (Electronic Control Module)controls.Separate visible indicators and audible alarms areprovided for the conditions - ECM Selector Switchin Alternate and Fuel Injection Malfunction.When the ECM option is requested, two pilot lightsand relay contacts are added to the controller inorder to meet the requirements.The FD100 terminal strip will be provided withtwo additional terminals as follows:Terminal Number 301 - ECM Selector Switch inAlternateTerminal Number 302 - Fuel Injection Malfunction

IM05805016K Page 11


12. Initial Start Up1. Ensure that circuit breakers CB1 and CB2 are in the OFF (0) position.

2. Ensure that AC power is supplied to terminals L and N, and GD is grounded.

3. Connect engine batteries to the controller, terminals 6,8 and 11. If batteries are connected in wrong polarity the battery voltage will read zero.

Note that terminals 6A and 8A are for factory use only and NOT for external connections.

4. Turn circuit breakers CB1 and CB2 ON (“1” position).

5. Turn printer ON after CB1 and/or CB2 have been turned ON.

6. Pressure (start) is factory preset at 1 PSI.

7. Place the controller in the ‘OFF’ mode by depressing the “OFF” button.

8. Ensure that the Diesel is programmed to user’s specifications. Refer to section 6 in this manual. Refer to STATUS printout for factory set parameters.

12.1 Automatic Start Test

Test printer while in Auto mode as per Section 14 of manual.

Depress the “AUTO” button.LED on “AUTO” button will light and Annunciator “Switch in Auto” will illuminate.Ensure that water pressure is available and the LCD display on the Display Panel isreading the system pressure, in PSI.Decrease water pressure. Controller will begin its cranking cycle.Should the engine fail to start after 6 crank and rest cycles, the audible alarm willsound and the “Fail To Start” annunciator will illuminate. Depress “OFF” button tosilence alarm.When engine starts, “Engine Run” annunciator illuminates.Increase water pressure above programmed STOP point. Press the stop pushbutton onthe enclosure. If the pressure is satisfied, the engine will stop.ORIf STOP mode is programmed for “Auto-Stop”, engine will stop after Run PeriodTimer times out and pressure is satisfied. RPT is programmed by the user, factory setat 30 minutes.If Sequential Timer is > 0 seconds, automatic start will be delayed by the number ofseconds programmed.

If AC Power Failure is ENABLED, automatic start will be delayed by the number ofseconds programmed upon a power failure.

IM05805016K


12.2 Manual Start Test

12.3 Test Start Test

12.4 Weekly Exerciser Test

Depress the “Manual” button. The LED on the button will illuminate.Fuel Solenoid relay will change state.Press Crank No.1 pushbutton. Engine cranks and starts, “Engine Run” annunciatorilluminates.Press “OFF” button. Wait for engine to stop. Push “Manual” button then press CrankNo.2 pushbutton. Engine cranks and starts, “Engine Run” annunciator illuminates.Press “OFF” button. Engine will stop.

Depress the “Test” button. LED on button will illuminate.Drain Valve Solenoid will energize and reduce pressure. Controller will start engineautomatically. “Engine Run” annunciator illuminates.Press “OFF” button. Engine will stop.

NOTE: Engine will stop if Low Oil Pressure, High Water Temp orOverspeed alarms are detected.

Depress “OFF” button.To test the Weekly Exerciser, preprogram the controller to initiate the test at a timesuitable to the user.Depress “AUTO” button.At programmed time and date the drain valve solenoid will open. When the pressuredrops below the start PSI value, engine will start, “Engine Run” annunciator willilluminate, and drain valve solenoid will close.Press “OFF” button. Engine will stop.Reprogram Weekly Exerciser for normal operation.

NOTE: Engine will stop if Low Oil Pressure, High Water Temp orOverspeed alarms are detected.

IM05805016K Page 13


13. Field Failure Alarm SimulationEnsure that CB1 and/or CB2 are in the ON positionprior to applying power to the printer (refer tonameplate above printer).Ensure that both CB1 and CB2 are in the ONposition and that there is AC power to the chargers.Place the controller in either the AUTO orMANUAL mode.

13.1 Charger FailureRemove AC power to the diesel controller panel.After a delay of 30 seconds, the alarm will soundand both Charger #1 Failure and Charger #2Failure indicating LED's will display. Or, jumper11 & 22, 11 & 23; [ 11 is Battery (negative)].After test, reapply AC power to continue testing ofother alarms. To reset alarm go to OFF mode andthen back into AUTO or MANUAL mode.13.2 Battery FailureTurn OFF CB1. Alarm will sound and BatteryFailure #1 will indicate in the display.To reset alarm go to OFF mode and then back intoAUTO or MANUAL mode.Turn ON CB1 and turn CB2 OFF. Alarm willsound and Battery Failure #2 will indicate in thedisplay. Reset alarms as per above.

13.3 Low Oil PressureJumper 4 & 11. Alarm will sound and indicate onthe display. To silence alarm, controller must be inthe OFF mode. If the engine is wired to the paneland the engine itself is NOT running, the LOW OILPRESSURE alarm will automatically alarm afterthe 15 second delay, with terminals 2 and 11jumpered.13.4 High Engine TemperatureJumper 5 & 11. Alarm will sound and indicate ondisplay. To silence alarm, controller must be in theOFF mode. Note that the LOW OIL PRESSURE

alarm will also indicate if terminal 4 is wired fromthe engine to the panel and the engine is notphysically running.13.5 Engine Fail to Start(ALL ENGINES EXCEPT CATERPILLAR)1. Disconnect field wires #9 & #10 on Fire Pump

Controller & initiate automatic start (Place controller in TEST mode). Note that actual engine will not crank thus reducing wear and tear on its starters and batteries.

Caterpillar Engines: Install a wire jumper between terminals 1 & 12 and initiate automatic start.

2. Allow pressure to drop and begin cranking sequence.

3. Wait 180 seconds to allow for 3 cranks per battery (15 seconds cranking, 15 seconds rest, 6 times).

4. Alarm will sound and Fail To Start indicator will display. To silence alarm, place controller in the OFF mode.

13.6 Engine OverspeedMechanically close speed switch relay on thediesel engine or jumper 3 & 11. Alarm will sound,Engine Overspeed indicator will display, and thefuel stop relay will energize.To silence alarm, place controller in the OFFmode.13.7 Other Alarms (Pump Room Alarms)To test pump room alarms, such as Low Fuel, LowRoom Temp etc., place a jumper between terminal11 and the corresponding alarm terminal input.

NOTE: – For all engine alarms, the Engine Trouble Alarmrelay will energize.– Do not put an AC voltage on these contacts.

NOTE: Do not turn off both CB1 and CB2 simultaneously.Otherwise power will be lost to the controller card.

NOTE: For the following tests, while controller is in theAUTO or MANUAL mode, place a JUMPERbetween terminal 2 & 11. This will give anENGINE RUN signal to the controller. Or, you canrun the engine.

NOTE: There is an inherent 15 second delay for detectingalarms after an ENGINE RUN signal.

NOTE: The Pump Room Trouble relay will also activate.

IM05805016K


14. Printer – Recorder InstructionsThe microprocessor-controlled printer is suppliedas standard with all Diesel Fire Pump Controllers.Mounted inside the enclosure the printer-recorderprovides a hard copy status report of all alarms,events, voltage, system pressure, weekly test timerand programmed parameters of the controller. Eachalarm printout is stamped with the time and datethat can be used as a trouble-shooting tool todetermine start-up causes and exact times of allevents.

14.1 Operating ProcedureThe printer-recorder is shipped from the factorywith two rolls of paper.

The functions of operating controls are as follows:

14.2 Self Test FunctionTo activate self-test feature, press and hold the feedbutton then turn the power on. To stop the self-testbefore the end of the message, power down theprinter.

14.3 Paper LoadingRemove printer chassis from enclosure by turningthe latch counter clockwise. Pull out chassis until itstops. Install the paper spindle into a new roll of thermalpaper. Position the roll of paper so that it will feedfrom the top, then place the roll and spindle intothe paper support brackets, making certain that thepaper is level. It is recommended that square andclean cut edge is used for entry of paper into theprinter mechanism – scissor cut preferred.To load paper, turn on the power. Now feed the cutedge of the paper into the guide until the paperstops. Press feed button, paper will advance as longas button is held. Feed paper until lead edge linesup with paper cutter. At this time it is recommended that a self-test beperformed to ensure that the paper is installedcorrectly, (thermal side up) and that it is feedingproperly.In the event of a paper jam condition do not forcethe paper into the unit, or try to pry the paper out ofthe unit, this may damage the thermal printmechanism. Disconnect primary power andinterface cable before servicing the unit. Carefullyremove paper with a set of tweezers, or a small pairof needle nose pliers. If the paper cannot becleared, remove the face plate by removing the fivePhilips head screws and nuts holding the face plate.This will allow access to the printer mechanism.Once paper is cleared from the mechanism, re-assemble the unit. At this time, re-load paper.

Caution must be taken while inside the controllerto avoid electrical shocks.

Control FunctionL.E.D. Indicates ‘power on’ when green and

‘paper out’ when orange.Switch Power off in down position. Power

on in up position.Latch To secure main body of the printer to

mounting enclosure.

NOTE: Do not remove jumpers inside of printer

IM05805016K Page 15


14.4 Print ModesWhile in the MENU mode, the ‘PRINTROUTINE’ can be set up for either ‘Auto’ or‘Manual’.14.4.1 Auto Print

Messages will print directly to the printer as theevent or alarm occurs.

14.4.2 Manual Print The event and alarm messages are stored inmemory until the ‘Time/Print’ key is depressed, atwhich time all stored data is printed. The controllerwill store up to 1024 messages on a First In-FirstOut basis. To print the stored data hold the ‘Time/Print’ key for 3 seconds or more. DO NOTREMOVE POWER FROM PRINTER UNTIL ALLMESSAGES ARE PRINTED, OTHERWISEINFORMATION WILL BE LOST.14.5 Print StatusWhen programmed as YES, the printer will printthe “STATUS” of the controller upon exiting theprogram mode and only after selecting AUTO,MANUAL or TEST mode on the main switch. 14.6 Printer DeviationIs used to determine how often to print systempressure fluctuations, in PSI, as programmed bythe user.For example, if 10 PSI is programmed, each timethe system pressure varies by 10 PSI or greater, theactual pressure, date and time will be printed on theprintout display (if a Mercoid Pressure Switch issupplied this parameter has no effect).The programming of the print mode is detailed inSection 6.

“STATUS” Printout

Alarm & Message Printout

*DO NOT LEAVE IN THIS MODE*

IM05805016K


14.7 Replacement Paper TypeThe printer-recorder uses a thermographic printingpaper on a 2-3/4" diameter roll which is 2-1/4"wide and having a plastic core with a 7/16" hole.Suitable paper is available at most office-supplystores. See list below depicting the office supplystores and their respective catalog number for thepaper.

NON-TAPED ENDED ROLLSWILSONS: LAB CR722TAPED ENDED ROLLSSTAPLES: 14485GRAND & TOY: 7767000OFFICE DEPOT: 302-232

NOTE: If the end of the paper roll is taped, extra cautionmust be taken when the colored stripe appears –indicating the paper is running out. At this pointturn the printer off and replace the roll. Note thatone or two messages may be lost as a result.

IM05805016K Page 17


FIGURE #1

1

1

5

4

HIGHENGINETEMP.

OFF

BATTERY#2

FAILURE

MENUF3

PrintTime

LOWOIL

PRESSURE

SWITCHIN

AUTO

FAILTO

START

HIGHFUEL

LOWROOMTEMP.

LOWFUEL

TEST

AMPS

ENGINERUN

HIGHRESERVOIR

AUTO

VOLTS

MANUAL

BATTERY#1

FAILURE

CHARGER#2

FAILURE

CHARGER#1

FAILURE

BATT. #1

BATT. #2

TestLamp

F2F1

Silence Reset

ENGINEOVERSPEED

LOWRESERVOIR

PSI / BAR

FUELSPILL

CB1 CRANK #1 CRANK #2 CB2

NOTES:1. LED'S ARE LIT TO INDICATE WHICH MODE THE CONTROLLER IS IN.2. CONNECT BOTH BATTERIES FIRST THEN CLOSE BOTH BREAKERS.3. TIME/PRINT TOGGLES BETWEEN TWO FUNCTIONS. WHEN IN PRINT FUNCTION TAKE INSTRUCTION FROM LCD DISPLAY. (HOLD BUTTON FOR AT LEAST 3 SEC. THEN PRINTER WILL PRINT ANY AVAILABLE INFORMATION

4. FOR DETAIL AND SET UP REFER TO OPERATING MANUAL5. TO MANUALLY START THE DIESEL, DEPRESS THE "OFF" MODE SWITCH THEN THE MAUAL MODE SWITCH. PRESS CRANK #1 OR CRANK #2 OR BOTH TILL DIESEL IS STARTED.

LCD DISPLAY

NOTES:1. LED'S ARE LIT TO INDICATE WHICH MODE THE

CONTROLLER IS IN.2. CONNECT BOTH BATTERIES FIRST THEN CLOSE BOTH

BREAKERS.3. TIME/PRINT TOGGLES BETWEEN TWO FUNCTIONS. WHEN

IN PRINT FUNCTION TAKE INSTRUCTION FROM LCD DISPLAY. (HOLD BUTTON FOR AT LEAST 3 SEC. THEN PRINTER WILL PRINT ANY AVAILABLE INFORMATION

4. FOR DETAIL AND SET UP REFER TO OPERATING MANUAL5. TO MANUALLY START THE DIESEL, DEPRESS THE "OFF"

MODE SWITCH THEN THE MAUAL MODE SWITCH. PRESS CRANK #1 OR CRANK #2 OR BOTH TILL DIESEL IS STARTED.

IM05805016K


FIGURE #2

F2

F2

F2

MENU

MENU

MENU

MENU

MENU

MENU

MENU

MENU

MENU

MENU

F3

F3

F3

F3

F1

F1

F2

F2

F3

F3

F3

F3

F3

F3

F3

F1

F3

F3

F3

F3

F3

F3

F3

F1

F1

F1

F1

F1

F1

F1

F2

F2

F3

F3

F2 F3

F1

F2

F2

F3

F3

F2

F2

F3

F3

F1

MENU

MENU

MENU

MENU

MENU

MENU

MENU

MENU

F1

F3

F3

F3

F1

F3

F3

F3

F3

F3

F3

F3

F3

F3

F3

F3

F1

F1

F1

F1

F1

F1

F1

F3F2

F2 F3

F2 F3

F2

F2

F3

F3

F2

F2

F3

F3

F1

F1

F3F3

F3

F2

F1

F3

F1 F2 F3 F1

F3 F3

F3 F3

F2 F3 F1

F2

F2 F3

F1

F1

F3

F2 F3

F2 F3 F1

F1 F2

F3

F2 F3

F3

F3

F3

F3F3

F3

F2F1 F3

F2

F2

F3

F3

F1 F2 F3

F3 F3

F2 F3 F1 F2 F3

F3

MENU

F3 F3

MENUF1 F2 F3

F3

F1 F2 F3

7REV. 3A13358H01

OFF

SELECT MODEOR PRESS MENU

SELECT MENUCATEGORIES

LANGUAGEENGLISH

CHANGE DATE10/28/98

CHANGE TIME15:35

WEEKLY TIMERMON 07:05

RUN PERIOD TIMER30 MINS.

PRESS TRANSMITTERYES

PRESS. START PT.100 PSI

PRESS. STOP PT.110 PSI

FUT#1 FUNCTIONINPUT=OUTPUT

FUT#2 FUNCTIONINPUT=OUTPUT

LOW SUCN SHUTDOWNDISABLE

OVERPRESSUREDISABLE

PRINTR DEVIATION10 PSI

CURRENT PRESSURE97 PSI

SEQUENTIAL START0 SEC.

STOP MODEAUTO

AC FAILURE STARTDISABLE

PRINT ROUTINEMANUAL

PRINT STATUSNO

SELECT MODE OR PRESS MENU

INCREASE COUNT UNLESS OTHERWISE SHOWN

DECREASE COUNT UNLESS OTHERWISE SHOWN

INCREASE COUNT

LANG: ENGLISH

YEAR: 98

HOUR: 15

DAY: MON

RPT (MINUTES):30

PRES. TRANS: YES

START: 100 PSI

STOP: 110 PSI

INPUT=OUTPUT

INPUT=OUTPUT

OVER PRESS.DIS.

LOW SUCN: DISABLE

P. DEV: 10 PSI

NEXTMENU

SST (SEC): 0

STOP MODE: AUTOAUTO MAN

AC FAIL: DISABLEENA.DIS.

PRINT IN:MNAULAUTO MAN.

PRINT STATUS: NOYES NO

MONTH: 10

MINUTES: 35

HOUR: 7

NEXTMENU

NEXTMENU

NEXTMENU

NEXTMENU

OR

OR

SHTDWN DELAY: 5S

OVER PRES. 350

NEXTMENU

NEXTMENU

NEXTMENU

AC FAILURE DEALY15 SEC

NEXTMENU

NEXTMENU

DATE: 28

NEXTMENU

MINUTES: 5

NEXTMENU

RESET MODE: AUTO

NEXTMENU

DELAY (SEC): 15

NEXTMENU

NEXTMENU

AUTO DELAY: 105

NEXTMENU

NEXTMENU

NEXTMENU

LANG: ITALIANLANG: SPANISHLANG: GERMANLANG: FRANCAIS

BATTERY FAILURETEST MODEAUTO MODEAC POWER FAILUREFAIL TO STARTLOW PRESS. STARTLOW OIL PRESSUREHIGH ENGINE TEMPLOW FUELENGINE OVERSPEED

BATTERY FAILURETEST MODEAUTO MODEAC POWER FAILUREFAIL TO STARTLOW PRESS. STARTLOW OIL PRESSUREHIGH ENGINE TEMPLOW FUELENGINE OVERSPEED

**WARNING**NFPA 20 SPECIFICALLY PROHIBITS THE INSTALLATION OF ANY DEVICE IN THE SUCTION PIPING WHICH WILL RESTRICT STARTING OR STOPPING OF THE FIREPUMP (SEE NFPA20 PARA 2-9.9) CUTLER-HAMMER, DIV. OF EATON YAL LTD. ASSUMES NO LIABILITY WHEN LOW SUCTION SHUTDOWN IS ENABLED IN THE FIRMWARE OF THE FIRE PUMP CONTROLLER.

OR

IM05805016K Page 19


APPENDIX A:

Table 1:

Threshold 12V Battery 24V Battery

Min. Typ. Max Min. Typ. Max

Charger Output Voltage 31.4 V 31.4 V

Charger Output Current 11 A 11 A

Battery Voltage 8.0V 18.0V 18.0 V 31.4 V

Ambient Temperature 60°C 60°C

Table 2:

Threshold 12V Battery 24V Battery

Bulk Overcharge Float Bulk Overcharge Float

Min Max Min Max Min Max Min Max Min Max Min Max

Charger Output Voltage 14.4 V 14.4 V 12.4V 14.4 V 28.8V 28.8V 25.8 27.8V

Charger Output Current 9.0A 10.0 A 10.0 A 2.0 A 9.0A 10.0 A 10.0 A 2.0 A

IM05805016K


APPENDIX B: ANNUNCIATOR ALARMSA

larm

Term

inal

Ref

. No.

Aud

ible

Ala

rmSi

lenc

ed B

y :

Ann

unci

ator

* R

eset

By:

Com

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#1

/ #2

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/APl

acin

g C

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olle

rin

the

“OFF

” M

ode

Pres

sing

RES

ET

On

Con

trol

ler P

anel

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p R

oom

PRT

Pres

sing

RES

ETO

nC

ontr

olle

r Pan

el

MM

/DD

/YR

, HH

/MM

/SS

Bat

tery

#X

Failu

re

**m

ode*

*

Cha

rger

#1

/ #2

Failu

re22

/ 23

Plac

ing

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ler

in th

e“O

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e

Pres

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RES

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TPr

essi

ng R

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On

Con

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anel

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, HH

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Cha

rger

#X

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mod

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Engi

ne

Ove

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ed3

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in th

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e

Plac

ing

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trol

ler i

n th

e “O

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e,R

eset

ting

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d Sw

itch

on D

iese

l

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neET

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the

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” M

ode

MM

/DD

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, HH

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/SS

Engi

ne O

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peed

**m

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*

Fail

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N/A

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ing

Con

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in th

e“O

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e

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in th

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ler

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Hig

h En

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p**

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Low

Fue

lO

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igh

Fuel

16 17

Pres

sing

SIL

ENC

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nC

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el

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ing

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ler

in th

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lem

MM

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(or H

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Oil

Pres

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4Pl

acin

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rin

the

“OFF

” M

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in th

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Plac

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in th

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MM

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, HH

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Low

Oil

Pres

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**m

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*Lo

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voir

Or

Hig

h R

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voir

18 19

Pres

sing

SIL

ENC

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nC

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RES

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(or H

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Res

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m

Tem

pera

ture

21Pr

essi

ng S

ILEN

CE

On

Con

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ler P

anel

Pres

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RES

ETO

nC

ontr

olle

r Pan

elPu

mp

Roo

mPR

TPr

essi

ng R

ESET

On

Con

trol

ler P

anel

MM

/DD

/YR

, HH

/MM

/SS

Low

Roo

m T

emp

**m

ode*

** A

larm

s ar

e no

t res

etta

ble

if co

nditi

on c

ontin

ues

to e

xist

.PA

GE

2 O

F 3

** M

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** re

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to M

ain

Switc

h M

ode

- AU

TO, M

AN

UA

L, T

EST

3A14

093H

01-C

IM05805016K Page 21


APPENDIX C: PRINTER ‘EVENT’ MESSAGES

Message Description of Message Message ** Print Out

Cranking Battery #1 or #2Indicates which battery the controller is cranking during an “attempt to start” cycle. This message will not print in the manual mode.

MM/DD/YR, HH/MM/SSCranking Battery #X

**mode**

Drain Valve OpenedIn the “TEST” mode or when initiating the weekly test timer this message prints to indicate the actual time that the drain valve has opened.

MM/DD/YR, HH/MM/SSDrain Valve Opened

**mode**

Deluge Valve OpenIndicates that the engine was requested to start due to the Deluge Valve being activated.

MM/DD/YR, HH/MM/SSDeluge Valve Open

**mode**

Engine RunPrints after the controller receives an “Engine Run” signal from the diesel engine.

MM/DD/YR, HH/MM/SSEngine Run

**mode**

Engine StoppedPrints after the diesel engine has stopped as indicated by the “Engine Run” contacts.

MM/DD/YR, HH/MM/SSEngine Stopped

**mode**

Fuel Solenoid ClosedAny time the fuel solenoid is de-activated, after a manual stop for example, this message will print.

MM/DD/YR, HH/MM/SSFuel Solenoid Close

**mode**

Fuel Solenoid OpenAny time the fuel solenoid is activated, prior to cranking for example, this message will print.

MM/DD/YR, HH/MM/SSFuel Solenoid Open

**mode**

Low PressureThis message is printed when the controller is called upon to start the diesel engine as a result of low system pressure.

MM/DD/YR, HH/MM/SSLow Pressure

**mode**

Manual Stop RequestIndicates that the Local STOP pushbutton has been depressed to initiate an engine shutdown.

MM/DD/YR, HH/MM/SSManual Stop Request

**mode**

Pressure = XXX PSIPressure reading will print if the deviation in pressure exceeds the amount, in PSI, as programmed in to the controller by the user.

MM/DD/YR, HH/MM/SSPressure = XXXPSI

**mode**

* Pressure StartFuture #2 relay will energize once the pressure is less than the programmed Pressure Start Point and the engine starts. Can be enabled or disabled.

MM/DD/YR, HH/MM/SSPressure Start

**mode**

Remote Start RequestIndicates that the engine was called upon to start due to someone pressing the “Remote Start” pushbutton.

MM/DD/YR, HH/MM/SSRemote Start Request

**mode**

RPT Time OutAfter the Weekly Test Timer or Running Period Timer expires (if STOP Mode is programmed for Auto) this message will print.

MM/DD/YR, HH/MM/SSRPT Timed Out

**mode**

Weekly Test StartedThis is the actual time that the Weekly Test Timer is called upon to start. The engine will continue to run for 30 minutes after the time indicated.

MM/DD/YR, HH/MM/SSWeekly Test Started

**mode**

* Not Available on software versions V2.91 or earlier** Mode ** refers to Main Switch Mode - AUTO, MANUAL, TEST

IM05805016K


FIGURE #3

2

4

3

5

6

89

7

-

114.33 [364]

29.72 [755]

22.17 [563]

33.97 [863]

10.00 [254]

2.00 [51]

18.00 [457]

53.97 [1371]

18.00 [457]

10.56 [268]

35.97 [914]

1.23 [31]

6.64 [169]

6.03 [153]

13.29 [337] 3.32 [84]

1.13 [29]

5.75 [146] 8.48 [215]

1.37 [35]

CRANK # 1CB1 CRANK # 2 CB2 CRANK # 1CB1 CRANK # 2 CB2

DimensionsStandard Enclosure - Type NEMA 2, 12

NOTES:1. All enclosures finished in FirePump red.2. Cable entrance bottom only.3. Standard enclosure type NEMA 2, 124. Enclosure made from #14 gauge(0.75) HR. Steel.

Dimensions in Inches and [millimeters].

Approx. WeightLbs. (Kg)

105(48

N. Y. C.APPROVED

1 - AUDIBLE ALARM2 - DIESEL MEMBRANE3 - CRANK BUTTONS4 - MAIN CIRCUIT BREAKERS5 - LOCKABLE HANDLES6 - STOP BUTTON7 - DVS DISCHARGE PIPE8 - PIPING ENTRANCE 1/4" NPT - FEMALE9 - CABLE ACCESS (BOTTOM ONLY)

IM05805016K Page 23


FIGURE #4

3A

15

56

4

76

{123

P15{

P1250

97

{{

REV.3

90{

8788

89

8. 9291

9395

9496

43{

4039

8.

4142

4544

4648

4749

8.

{

P14

10098

99102

101103

8.

107105

104106

8.

109108

110

5753

5152

5554

5660{8.

5859

6261

116{

111112

114113

115119

8. 117118

121120

122

69{64

6365

8.

6766

6872

7071

7473

75

P13

8.

126124

125128

127129

8.

133{

131130

132134

7977

7881

8082

86{8.

8483

858.

35

212

43

56A

6

378A

89

1110

1120

4

1111

11

11211

11

30117

16302

1918

2623

2221

2524

2928

2731

30N

3836

37L

LN

GD

FIELD

CO

NN

EC

TION

TER

MIN

AL B

LOC

K

FIELD

CO

NN

EC

TION

TER

MIN

AL B

LOC

KS

FOR

AU

X. C

ON

TAC

TS (R

ELAY

CA

RD

)

FIELD

CO

NN

EC

TION

TER

MIN

AL B

LOC

KS

FOR

AU

X. CO

NTA

CTS

(RE

LAY C

AR

D)

FUTU

RE

#1

PUM

P RO

OM

TRO

UB

LEFU

TUR

E #2

MA

NU

AL M

OD

E

FUEL STO

P

CR

AN

K O

N B

AT.#2

ENG

INE

TRO

UBLE

ALAR

M

ENG

INE

RU

NC

OM

MO

N A

LAR

MD

RA

IN VA

LVE

S

OLE

NO

ID

OFF M

OD

E

CR

AN

K O

N B

AT.#1

FUEL&WATER SOLENOID VALVECRANK TERMINATION SW.(ENGINE RUN)

OVERSPEED SW.OIL PRESSURE SW.

ENGINE WATER TEMP SW.BATTERY #1 INPUT

(FACTORY USE ONLY)ENGINE ALT. CIRCUIT (IF REQ.)

BATTERY #2 INPUT(+)(FACTORY USE ONLY)

BATTERY #1 CRANKBATTERY #2 CRANK

BATTERIES(–)

FUEL SOLENOIDECM IN ALTERNATIVEFUEL MALFUNCTION

LOW FUELHIGH FUELLOW RES.HIGH RES.

FUEL SPILLLOW ROOM TEMP.CHARGER #1 FAIL (C)CHARGER #2 FAIL (C)

PROOF PRESSURE SW. (IF USED)

INTERLOCKLOCAL STOP

REMOTE STARTLOW FOAM LEVEL

DELUGE VALVE (REMOVE JUMPER IF USED)

REMOTE START (REMOVE JUMPER IF USED)

CHARGER #2(–)TO BATTERIES (–)(11)TO BATTERIES (–)(11)

CHARGER #1(–)

CUST. 90-240VAC LINE

CUST. 90-240VAC NEUTRALENCLOSURE GROUND

GR

OU

ND

TO

EN

CLO

SU

RE

NO

TES

:1.

ALL A

LAR

M C

ON

TAC

TS AR

E R

ATED AT 10A

MP

S 220VAC

1/3HP

R

ESISTIV

E LOA

D O

NLY.

2. TH

IS C

ON

NE

CTIO

N D

IAG

RA

M IS S

UITA

BLE FOR

THE FO

LLOW

ING

D

IESEL EN

GIN

ES:

C

LARK

E - DE

TRO

IT DIE

SEL - ALLIS

ON

, MO

DELS

:

DD

FP-O

3DT, D

DFP

-L3DT, D

DFP

-T3DT, JD

FP-O

6WA

, JDFP

-O6W

R,

D

DFP

-T6FA, D

DFP

-O6FA, D

DFP

-O6FH

, DD

FP-L8FA

, DD

FP-O

8FA,

D

DFP

-O8FH

, DD

FP-12FH

, PD

FP-L4YN

, PD

FP-L4Y

T, PD

FP-O4YT,

P

DFP-L6Y

N, P

DFP-L6Y

T, PD

FP-O6YT, P

DFP-L6Y

W, PD

FP-J6Y

T,

PD

FP-K6YT, PDFP

-O6Y

R, V

MFP-04H

N, VM

FP-04H

T, VMFP

-06HT.

C

UM

MIN

S D

IES

EL E

NG

INE

S IN

C., M

OD

ELS:

4BT3.9F, 6BTA5.9, 6B

TA5.9-F1, 6B

TA5.9-F2, 6BTA

5.9-F3,

6BTA5.9-F4, 6CTA8.3F, N

-495-F, N-855-F, N

T-495-F,

NT-855-F3, N

T-855-F4, NT-855-F5, N

T-855-F6, NTA

-855-F,

NTTA-855-F, V-378-F1, V-378-F2, V-504-F1, V-504-F2,

V

T1-710-F, VT-28F.

CATE

RP

ILLAR

INC

., MO

DE

LS:

3208-D

INA

, 3208-DIT, 3306B

-DIT, 3306B

-DITA

, 3406B-D

IT,

3406B-D

ITA, 3408B

-DITA

, 3412-DIT, 3412-D

ITA, 3508-DITA

,

3512-DITA, 3516-D

ITA.

3. C

ON

TAC

T FACTO

RY

FOR

FIELD

CO

NN

EC

TION

DR

AWIN

GS

OF

DIE

SEL ENG

INE

S NO

T LISTED

ABO

VE.

4. TH

IS C

ON

NE

CTIO

N D

IAG

RA

M IS S

UITA

BLE FOR

DIE

SEL ENG

INE

S EQ

UIP

PED

WITH

ELE

CTR

ON

IC STAR

TING

MO

DU

LES. (O

ption - ECM

m

ust be specified - otherwise the controller w

ill be supplied without

terminals 301 and 302.).

5. O

N C

ATER

PILLA

R E

NG

INE

S, TE

RM

INA

L #12 IS U

SE

D FO

R TH

E FU

EL

SO

LEN

OID

. 6.

ON

CATE

RP

ILLAR

EN

GIN

ES

, TER

MIN

AL #1 IS N

OT U

SE

D E

XC

EPT

WH

EN

A R

AW W

ATER

VALVE

IS USE

D.

7. A

FTER

1987, MO

ST E

NG

INE

S D

ID N

OT R

EQ

UIR

E TH

E U

SE

OF

TER

MIN

AL #7. IF R

EQ

UIR

ED

, CO

NTA

CT TH

E FA

CTO

RY.

8. AVA

ILAB

LE FO

R C

US

TOM

ER

CO

NN

EC

TION

S. S

EE

NO

TE 1. FO

R

RATIN

GS

. 9.

EATO

N C

OR

PO

RATIO

N A

SS

UM

ES

NO

LIABILITY

WH

EN

LOW

SUC

TION

S

HU

TDO

WN

IS U

SE

D. S

EE

THE

LATES

T ED

ITION

OF N

FPA20 FO

R

RE

STR

ICTIO

NS

.

10. FOR

TERM

INA

LS 1 TO

12, SEE

DIE

SEL M

AN

UFA

CTU

RE

R'S

WIR

ING

D

IAG

RA

M.

WATE

R S

YSTEM

CO

NN

EC

TION

B

OTTO

M O

F THE

CE

LL WITH

1/4" N

PT–FEM

ALE

RE

CO

MM

EN

DE

D

WIR

E S

IZE(AW

G)

TER

MIN

AL N

o.

NU

MBE

R O

F FEET(M

ETER

S)

FRO

M C

ON

TRO

LLER

TO TH

E

DIES

EL’S TER

MIN

AL BLOC

KS

TRA

ND

ED

#141-5,9,10,16-38,L,N

N.A

.S

TRA

ND

ED

#1439-134

N.A

.S

TRA

ND

ED

#10G

DN

.A.

STR

AN

DE

D #10

6,7,8,110' TO

25'(7.62)S

TRA

ND

ED

#86,7,8,11

25' TO 50'(7.62-15.24)

IM05805016K


FIGURE #5

71 5 6432

21

312

45

66A

78

8A9

1111

1011

1111

11

CB

1C

B2

129 10 118

-+ -+

115

DV

S

6540

39

PRT

F1

4643

4142

4544

4847

4951

5052

P1

2

F2 5956

5455

5857

5361

6062

6463

P7P5

90ERC

MM

CFS

7169

6768

7066

7473

7577

7672

P1

3

C2

8482

8081

8378

7988

8786

8985

ETA

9695

9392

9491

101100

99102

9798

P1

4

CA

109108

106105

107103

104114

112113

110111

C3

C2

C1

C4

OM

C

121P1

5

119118

120116

117127

125126

122123

124

C1

134132

131133

128129

130

N2

N1

P16

3535

P7

31P1

129

3028

27

P10

2226

2524

34

523

218

2021

1917

16+

J3

J1

8A6A

33 32348A P66A

+-

P3

P2

38 37 36

38 3637

P4

+ -

DV

S

3022

1617

1819

2021

2624

2325

2827

2931

3536

3738

LL

NN

GD

B4

--

B6

LN

6A8A

+

++

++

B6

--

B4

NL

LOW FUELHIGH FUELLOW RES.HIGH RES.

FUEL SPILLLOW ROOM TEMP.

CHARGER #1 FAILURECHARGER #2 FAILURE

ENGINE RUNHIGH ENGINE TEMP.

LOW OIL PRESS.OVERSPEED

FUTURE #1FUTURE #2

INTERLOCKLOCAL STOP

REMOTE STARTLOW SUCTION

DELUGE VALVE STARTMERCOID SW INPUT

INPUT (BROWN)COMMON (BLUE)OUTPUT (WHITE)

TO TERMINAL BLOCKS(CABLE P4)

USE TWO CABLES ON 24V CONTROLLERS

FOR

CAT

ER

PIL

LAR

EN

GIN

ES

AN

D N

EW

ER

E

MI E

NG

INE

S O

NLY

RE

MO

VE

BO

TH J

UM

PE

RS

J1

AN

D J

3 (C

AR

D 5

D15

229H

01 V

ER

4.0

& A

BO

VE

PR

ES

SU

RE

TR

AN

SM

ITTE

R

TO T

ER

MIN

AL

BLO

CK

S(C

AB

LE P

11)

NO

TE:

1.C

ON

TAC

TS A

RE

RAT

ED

FO

R 1

0 A

MP

ER

ES

AT

120

V.2.

PU

MP

HO

US

E T

RO

UB

LE C

ON

TAC

T M

US

T C

LOS

E F

OR

ALA

RM

.3.

DC

GR

OU

ND

IS IS

OLA

TED

FR

OM

CA

BIN

ET

GR

OU

ND

.4.

RE

FER

TO

CO

NTR

OLL

ER

NA

ME

PLA

TE F

OR

PR

OP

ER

PO

WE

R S

UP

PLY

RE

QU

IRE

ME

NTS

. TH

IS D

IES

EL

CO

NTR

OLL

ER

DR

AWS

15A

MP

S M

AX

.5.

FOR

CAT

ER

PIL

LER

EN

GIN

ES

ON

LY.

6.A

FTE

R 1

987,

MO

ST

EN

GIN

E D

ID N

OT

RE

QU

IRE

TH

E U

SE

OF

TER

MIN

AL

#7. C

ON

SU

LT T

HE

FA

CTO

RY

FO

R M

OR

E D

ETA

ILS

IF R

EQ

UIR

ED

.

WIR

ING

NO

TES

:1

U

NLE

SS

OTH

ER

WIS

E N

OTE

D A

LL W

IRIN

G T

O B

E T

EW

#14

AW

G|–

>--

> TE

W #

16 A

WG

. (1.

29 M

M)

----

----

-- C

US

TOM

ER

CO

NN

EC

TIO

NS

- S

EE

WIR

ING

LA

BLE

FO

R S

IZE

S

RIB

BO

N C

ABLE

TO P

LAS

TIC

M

EM

BR

AN

E

CO

NTR

OLL

ER

PA

D

RIBBON CABLE RIBBON CABLE

TO ANNUNCIATOR CARD (CABLE P3)

TO P7 ON RELAY CARD (CABLE P7)

TO P

RIN

TER

(CA

BLE

P2)

CO

NTR

OLL

ER C

AR

D

PU

MP

RO

OM

TR

OU

BLE

FUTU

RE

#1FU

TUR

E #

2M

AN

UA

L M

OD

EFU

EL

STO

PG

RA

NK

ON

BAT

. #2

EN

GIN

E R

UN

EN

GIN

E T

RO

UB

LE A

LAR

MC

OM

MO

N A

LAR

MD

RA

IN V

ALV

E S

OL.

OFF

MO

DE

CR

AN

K O

N B

AT. #

1

RE

LAY

CA

RD

TO P

.B. O

N F

AC

E P

LATE

(C

AB

LE P

5)

TO C

ON

TRO

LLE

R C

AR

D

(CA

BLE

P7)

CR

AN

K #

1C

RA

NK

#2 G

RO

UN

D T

O

EN

CLO

SU

RE

TO C

ON

TRO

LLE

R

CA

RD

(CA

BLE

P4)

TO C

ON

TRO

LLE

R C

AR

D

(CA

BLE

P11

)

TO C

ON

TRO

LLE

R C

ARD

(C

ABLE

P4)

USE

TW

O

CA

BLE

S O

N 2

4V

CO

NTR

OLL

ER

S

CO

MM

UN

ICAT

ION

(C

AB

LE P

2)

TO C

ON

TRO

LLE

R

CA

RD

(CA

BLE

P1

1)

PR

INTE

R

AC

PO

WE

R S

UP

PLY

15

A M

AX

IMU

M

THIS

CO

NTR

OL

IS N

EG

ATIV

E G

RO

UN

D

GROUNDNEUTRALLINE

MERCOID SW. INPUT

DELUTE VALVE START

LOW SUCTION

REMOTE START

INTERLOCK

FUTURE #2

FUTURE #1

LOW ROOM TEMP.

FUEL SPILL

HIGH RES.

LOW RES.

HIGH FUEL

LOW FUEL BAT

TER

Y IS

OLA

TOR

SE

E N

OTE

5

DIESEL ENGINE

FUE

L &

WAT

ER

SO

LEN

OID

VAL

VE

ENG

INE

RU

N S

W.

OV

ER

SPE

ED

SW

.

OIL

PR

ESS

UR

E S

W.

EN

GIN

E W

ATE

R T

EM

P. S

W.

BAT

TER

Y #

1 IN

PU

T(+)

EN

GIN

E A

LT. C

IRC

UIT

(IF R

EQ

.)

BAT

TER

Y #2

INP

UT

(+)

BAT

TER

Y #

1 C

RA

NK

BAT

TER

Y #

2 C

RA

NK

BATT

ER

IES

(–)

FUE

L S

OLE

NO

ID

LOC

AL

STO

P P

.B.

BAT

TER

Y

CH

ARG

ER

#2

BAT

TER

Y

CH

AR

GE

R #

1

CA

BLE

SU

PP

LIED

BY

P

RIN

TER

MAN

UFA

CTU

RE

R

IM05805016K Page 25


Diesel Commissioning ListRead Completely Before Proceeding With Start Up

Sign-Off

Physical Inspection

Inspect for Enclosure DamageInspect for Component Damage within EnclosureController Free of Debris (Inside and Outside Controller)All Packing Material is Removed from Controller (i.e.- behind pressure switch)All Components are Secure within EnclosureAll Moving Parts are Allowed to Move Freely

-Push Buttons-Door Handles-Roller Breakers (CB1 & CB2)-Outer Door

Wiring Inspection

Ensure that cicuit breakers CB1 and CB2 are in the OFF (0) position. Inspect all Wiring to and from Controller

-All field connections and incoming wiring must be brought into the enclosure through the bottom right sideONLY

Compare rating nameplates on controller and engine.All Electrical Connections are tightAll Wiring to and from Controller is Correct

-Field Connections (Remote Starters, Fuel Level Switch, etc)-Engine Connections: (Terminal #)#1 - Fuel & Water Solenoid Valve#2 - Engine Run Sw.#3 - Overspeed Sw.#4 - Oil Pressure Sw.#5 - Engine Water Temp. Sw.#6 - Battery #1 Input (+) (If connected to the wrong polarity the battery voltage will read 0)#7 - Engine Alt. Circuit (If Required)#8 - Battery #2 Input (+) (If connected to the wrong polarity the battery voltage will read 0)#9 - Battery #1 Crank#10 - Battery #2 Crank#11 - Batteries (-)#12 - Fuel Solenoid (Caterpillar engines only)* Ensure battery wire is sized per the following Chart: (Terminals 6, 8 and 11)

#10 AWG: 0' to 25' (7.62 m) #8 AWG: 25' to 50' (15.2 m)

Note: Ensure that the negative ground (Terminal #11) is making a good connection in the controller, engine controlbox, on the engine block and at the batteries.

IM05805016K


Immediately Before Initial Start-Up

Check Pressure Transmitter Connections-Ensure Sensing Line is connected to pump discharge-Check for leaks from Pressure Transmitter to incoming sensing line.

If using a Caterpillar engine remove jumpers J1 & J3 from the controller board.Ensure that AC power is supplied to terminals L and N, and GD is grounded to earth.Ensure battery chargers are set to the AUTO ModeEnsure printer is in the 'OFF' position

Diesel Configuration Checklist

Turn circuit breakers CB1 & CB2 ON ("I" Position)Turn printer ON after CB1 and/or CB2 have been turned ONPlace the controller in the 'OFF' mode by depressing the "OFF" buttonEnter the diesel programming menu, a flowchart is provided on the Diesel door and in the instruction manualChange Date & TimeSet Weekly Run Timer - This cannot be set for less than 30 minutesSet Run Period TimerSet Pressure Start PointSet Pressure Stop PointSet Pressure Deviation (Default value is 10 PSI)Set Sequential Start Timer (If required)Set Stop Mode to either Manual or AutomaticEnable/Disable AC Failure StartSet Print Routine to Automatic (This will be set back to manual when testing is finished)Set "Print Status Report" to YES.

Operational Check

Press "Lamp Test" Button on the Diesel display board to make sure all lights are operational

Note: To switch between modes the controller must be switched into the 'OFF' mode first.

Automatic Start TestPlace the controller in the 'AUTO' mode by depressing the "AUTO" button

- Annunciator "Switch in Auto" will illuminateDecrease the water pressure to below the controller 'Start Point'

- The controller will begin its cranking cycle- When the engine starts "Engine Run" will illuminate

Increase the water pressure to above the controller 'Stop Point'Press the Stop pushbutton on the enclosure

Note: The stop pushbutton will not work when the controller is programmed for auto stop on controllers withfirmware Version 4.4 and lower. Controllers with version 4.6 or higher will stop regardless of what stop mode isprogrammed providing the pressure stop point has been reached and a 15 second fixed time delay has elapsed.

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Manual Start TestPlace the controller in the 'MANUAL' mode by depressing the "MANUAL" button

- Fuel Solenoid relay will change statePress the 'Crank #1' pushbutton

- The controller will attempt to crank off Battery #1- When the engine starts "Engine Run" will illuminate

Press the "OFF" button to stop the engineOnce the engine stops, press the "MANUAL" button to return to 'MANUAL' modePress the 'Crank #2' pushbutton

- The controller will attempt to crank off Battery #2- When the engine starts "Engine Run" will illuminate

Press the "OFF" button to stop the engine

Test Start TestPlace the controller in the 'TEST' mode by depressing the "TEST" button

- Drain Valve Solenoid will energize and reduce pressure- controller will start automatically- When the engine starts "Engine Run" will illuminate


Weekly Exerciser TestProgram the Weekly Timer to a time suitable to run the testPlace the controller in the 'AUTO' mode by depressing the "AUTO" button

- At the programmed date and time the drain valve solenoid will open and the pressure will drop- The engine will run for a minimum of 30 minutes or for the duration of the RPT setting, whichever is greater

Reprogram the Weekly Timer for normal operation

Controller Function TestsOverspeedPlace the controller in the 'AUTO' mode by depressing the "AUTO" button (Optional)

-Start the controller either by jumpering remote start (Terminal #11 & #28) or by dropping the pressure -Press the 75% verify button on the speed switch in the engine control box, the engine should stop and thecontroller should give an overspeed alarm

Press the "OFF" button to reset the alarms

Low Oil Pressure / High Engine TempPlace the controller in the 'AUTO' mode by depressing the "AUTO" button

-Start the controller either by jumpering remote start (Terminal #11 & #28) or by dropping the pressure -Place a jumper between Terminals #4 & #11, the 'Low Oil Pressure' light should illuminate-Place a jumper between Terminals #5 & #11, the 'High Engine Termperature' light should illuminate


IM05805016K


Battery #1 Failure / Battery #2 FailurePlace the controller in the 'MANUAL' mode by depressing the "MANUAL" button

-Disconnect one of the leads going to battery #1-'Battery #1 Failure' should illuminate after 3 minutes-Reconnect Battery #1

Press the "OFF" button to reset the alarmsPlace the controller in the 'MANUAL' mode by depressing the "MANUAL" button

-Disconnect one of the leads going to battery #2-'Battery #2 Failure' should illuminate after 3 minutes-Reconnect Battery #2


Charger #1 Failure / Charger #2 FailurePlace the controller in the 'MANUAL' mode by depressing the "MANUAL" button

-Disconnect AC power going to the controller-'Charger #1 Failure' and ' Charger #2 Failure' should illuminate after 3 minutes-Reconnect AC power


Fail to StartPlace the controller in the 'AUTO' mode by depressing the "AUTO" button

-Disconnect leads #9 & #10 going to the controller-Start the controller either by jumpering remote start (Terminal #11 & #28) or by dropping the pressure -After the controller goes through its cranking cycles 'Fail to Start' should illuminate-Reconnect #9 & #10


Optional AlarmsPlace the controller in the 'MANUAL' mode by depressing the "MANUAL" buttonTest Alarm Conditions with a Jumper Between Terminal #11 and … (If condition is used)

#16 - Low Fuel#17 - High Fuel#18 - Low Reservoir#19 - High Reservoir#20 - Fuel Spill#21 - Low Room Temperature#25 - Future #2#24 - Future #2#25 - Interlock (with jumper in engine should never start)#29 - Low SuctionNote: To clear the above alarms, press the "OFF" button

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Starting ConditionsTest Starting Conditions with a Jumper Between Terminal #11 and …

#28 - Remote Start (The engine will start)#30 - Deluge Valve Start (The engine will start)#31 - Mercoid Switch Input (The engine will start)Note: To stop the engine, press the "OFF" button

Diesel Configuration Checklist

Confirm all settings below…Date & TimeWeekly Run Timer Run Period TimerPressure Start PointPressure Stop PointLow Pressure AlarmPressure DeviationSequential Start Timer (If required)Enable/Disable Manual Stop as per requirementsEnable/Disable AC Failure Start (If Required)Print Routine (When finished at site set to 'Manual')Set "Print Status Report" to YES.

Note: Press and hold the 'F3' button for 3 seconds in order to print a status report on controllers with firmwareversion 4.6 or higher.

Before Leaving Site

Test printer by printing Status Report - and keep for your records.Dump all printer messages contained in the memory.(Hit time/print button for 3 seconds while printing - hold the reset button on printer until memory iscleared).

EATONCutler-Hammer2256 29th Street NE #10Calgary, Alberta, T1Y 7G4CanadaTel: 403-717-2000Fax: 403-717-0567www.chfire.com

© 2007 Eaton CorporationAll Rights ReservedPrinted in CanadaPublication No.: IM05805016KOctober 2007

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