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A

Original Issue

REV.

DESCRIPTION

19-FEB-08

KIDDE

RZ

JN

DATE

EXEC.

REV.

APPR.

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

REVISION:

PISCO PLANT EPC 12


BLOCK 56 CAMISEA EXPANSION PROJECT
TITLE:

SKZZ-66025 DATA BOOK

Per Corp. S.A.


INGENIERIA DE PROYECTO
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..

SCALE

DOCUMENT Nr:

Revision

1155-01-90-T0-8015101-DM1

REPLACE:

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

A
Page 1 of 4

INDICE DATA BOOK DE EQUIPOS


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

2. 4BWC3-A-MOR ILBP PROPORTIONING MODULE

3. SKID MOUNTED ILBP PROPORTIONING SYSTEM

4. 1000 GAL. FIBERGLASS FOAM LIQUID STORAGE TANK

5. 2 IN. PRESSURE VACUUM VENT

6. FLEXIBLE CONNECTORS

7. NATIONAL FOAM SEALER OIL

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.
3.5.5.
3.5.6.

Wiring Schematic WS750-308


Field Connections FC750-306
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 FOAM
AER-O-LITE 3% AFFF
FOAM CONCENTRATE

SKZZ-66025

N a tio n a l F o a m

1.1

1.2

Section 3. HAZARDS IDENTIFICATION


Potential Health Effects
Inhalation
Vapors 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.
Ingestion
Not 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


Inhalation
No 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.
Ingestion
Swallowing 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: >200F
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
Concentrate
Stop 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.
Storage
Recommended storage environment is between 20F (-7C) and 120F (49C). 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 Controls
Special ventilation is not required.
Personal Protective Equipment
Respiratory
Recommended 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 Clothing
Rubber 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 @ 25C

Freezing Point:

12F (-11C)

Odor:

Mild, pleasant

Form:

Liquid

Color:

Straw yellow

Section 10. STABILITY AND REACTIVITY


Chemical Stability
Stable.
Incompatibility, Materials to Avoid
Avoid 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
Ingestion
This material was not toxic when administered to Wistar Albino rats at an acute oral dose of
5g/kg body weight.
Eye
Animal testing indicates this material is a primary eye irritant when tested undiluted on New
Zealand Albino Rabbits.
Skin
Animal testing indicates this material is not a primary skin irritant when tested undiluted on New
Zealand Albino Rabbits.
Inhalation
No 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

400,000 mg/kg

Concentrate

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.
Concentrate
Do 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 Solution
Aer-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
Foams 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 INFORMATION
Canadian 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
Flammability 0
Reactivity 0

D2B

ADDITIONAL INFORMATION
Revision Summary
5/3/96 ........... 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

GFGV.EX1734
Foam Liquid Concentrates
Page Bottom

Foam Liquid Concentrates


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
Aer-O-Lite, nominal 3 percent Aqueous Film Forming Foam, +20 F minimum storage and use temperature. Hydrocarbon fuels only.
Foam concentrates for use with the following equipment:
AER-O-LITE, 3 PERCENT
PROPORTIONERS-BALANCED PRESSURE VALVES WITH CONTROLLERS

Controller
Size In.

Description
National, 1-1/2 in. Model 1.5 BPRV

National, 2 in. Model 2.0 BPRV

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

National, 2 in. Model 2.0 PRV or 2.0 PRV MOR

Last Updated on 2006-11-27

Orifice
Size In.

Flow GPM

0.203

60-225

0.500

106-1564

0.703

106-2968

0.500

106-1564

0.703

106-2968

1.250

850-4209

0.203

60-225

0.500

106-1564

0.703

106-2968

0.500

106-1564

0.703

106-2968

1.250

850-4209

Copyright 2008 Underwriters Laboratories Inc.

1.3.1

SECTION 2:
4BWC3-A-MOR ILBP
PROPORTIONING MODULE

SKZZ-66025

N a tio n a l F o a m

2.1

2.2

GFGV.EX1734
Foam Liquid Concentrates
Page Bottom

Foam Liquid Concentrates


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
Aer-O-Lite, nominal 3 percent Aqueous Film Forming Foam, +20 F minimum storage and use temperature. Hydrocarbon fuels only.
Foam concentrates for use with the following equipment:
AER-O-LITE, 3 PERCENT
PROPORTIONERS-BALANCED PRESSURE VALVES WITH CONTROLLERS

Controller
Size In.

Description
National, 1-1/2 in. Model 1.5 BPRV

National, 2 in. Model 2.0 BPRV

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

National, 2 in. Model 2.0 PRV or 2.0 PRV MOR

Last Updated on 2006-11-27

Orifice
Size In.

Flow GPM

0.203

60-225

0.500

106-1564

0.703

106-2968

0.500

106-1564

0.703

106-2968

1.250

850-4209

0.203

60-225

0.500

106-1564

0.703

106-2968

0.500

106-1564

0.703

106-2968

1.250

850-4209

Copyright 2008 Underwriters Laboratories Inc.

2.3.1

2.4

TABLE OF CONTENTS
Text

Page

Table of Contents ........................................................................................................................... i - ii


Warning-Failure to Read Manual ...................................................................................................... iii
Safety Information ............................................................................................................................. iii
NF Red Alert Fire Emergency Service ............................................................................................. iii

CHAPTER 1 - INTRODUCTION

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

CHAPTER 2 - INSTALLATION

2-1.

2-2.

Cautions and Notes for In-Line Balanced Pressure Proportioning System ................................
Recommended Materials of Construction .....................................................................................
A. With Synthetic Based Polar Solvent/AFFF & Conventional AFFF Foam Concentrates .....
B. Protein Based Foam Concentrates .........................................................................................
Figure 2-1 In-Line Balanced Pressure Proportioner Module
3" to 8" Wafer Style with Manual Override ......................................................................
Figure 2-2 In-Line Balanced Pressure Proportioner Module
3" to 8" Wafer Style without Manual Override .................................................................
Figure 2-3 In-Line Balanced Pressure Proportioner Module
2" to 8" Flanged Style ........................................................................................................
Installation and Start-Up: ILBP Module .........................................................................................
A. Off Loading ...............................................................................................................................
B. Installation .................................................................................................................................
C. Operating Requirements ..........................................................................................................

2-1
2-2
2-2
2-2
2-3
2-4
2-5
2-6
2-6
2-6
2-7

CHAPTER 3 - OPERATING PROCEDURES

3-1.

-i-

Minimum Inlet Pressure Requirements .........................................................................................


Figure 3-1 NF Ratio Controller Minimum Inlet Pressure vs. Solution Flow Chart ...............
Figure 3-2 Operating Schematic Drawing RCW Style ILBP Module With Manual Override .............................................................
Figure 3-3 Operating Schematic Drawing RCW Style ILBP Module Without Manual Override ........................................................
Figure 3-4 Operating Schematic Drawing RCF Style ILBP Module With Manual Override...............................................................

3-1
3-1
3-2
3-3
3-4

12/98

TABLE OF CONTENTS

Text

3-2.
3-3.
3-4.

Page

ILBP Module Operation .................................................................................................................. 3-5


ILBP Module Manual Override (Manual Regulation) .................................................................... 3-5
Shutdown ......................................................................................................................................... 3-6

CHAPTER 4 - INSPECTION AND MAINTENANCE

4-1.
4-2.
4-3.
4-4.
4-5.
4-6.
4-7.
4-8.

Inspection and Maintenance ..........................................................................................................


Testing After System Maintenance................................................................................................
Annual Testing ................................................................................................................................
Table 4-1 Recommended Inspection & Maintenance Schedule ...........................................
General ............................................................................................................................................
Water Powered Ball Valves ...........................................................................................................
Electrically Actuated Valves ..........................................................................................................
Control System ................................................................................................................................
Flushing - ILBP Module ..................................................................................................................
A. ILBP Module With Diaphragm Valve Manual Override Capability .......................................
B. ILBP Module Without Diaphragm Valve Manual Override Capability ..................................

4-1
4-1
4-1
4-2
4-2
4-2
4-3
4-3
4-4
4-4
4-4

CHAPTER 5 - TROUBLESHOOTING

5-1.
5-2.
5-3.
5-4.
5-5.
5-6.
5-7.

Troubleshooting ..............................................................................................................................
Table 5-1 Troubleshooting .......................................................................................................
No Proportioning .............................................................................................................................
Low Percent of Proportioning .........................................................................................................
High Percent of Proportioning ........................................................................................................
No Flow at Discharge Device(s) ....................................................................................................
Low Flow at Discharge Device(s) ..................................................................................................
No Operation ...................................................................................................................................

5-1
5-1
5-1
5-2
5-3
5-4
5-4
5-4

APPENDIX - FACTORY MUTUAL APPROVALS

A-1.
A-2.
A-3.

12/98

Universal Gold 3% .......................................................................................................................... A-1


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

- ii -

SAFETY INFORMATION

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

SAFETY INFORMATION
The International Safety Alert Symbol - is used with one of the following signal words to alert operating
personnel to the potential for death, personal injury or damage to equipment or property.
DANGER: indicates an extremely hazardous situation which, if not avoided, will result
in death or serious injury to the operator or major property damage.
WARNING: indicates a potentially hazardous situation which, if not avoided, can result
in 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 fully
understand the DANGER, WARNING, CAUTION and NOTE procedures by which hazards are to be reduced or
eliminated. Personnel must become thoroughly familiar with all aspects of safety and equipment prior to operation
or 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 thoroughly
trained and kept thoroughly trained in the functions they are expected to perform.

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

CALL LIONVILLE, PA 610-363-1400

- iii -

6/00

CHAPTER 1 - INTRODUCTION
The ILBP Module is a complete, self-contained unit,
assembled and tested at the factory. The unit is supplied
with no finish and is suitable for either horizontal or
vertical mounting.
The principle of operation of the ILBP Module is
based on the use of a modified venturi proportioner
called a ratio controller. With this type of proportioner,
water passes thru a jet (venturi) at the inlet of the ratio
controller, creating a reduced pressure area on the discharge side of the jet. This reduction in pressure creates
a pressure differential across the foam concentrate orifice and causes injection of foam concentrate into the
water 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 increases, thereby increasing the pressure differential across
the foam concentrate orifice. A proportionate increase in
foam concentrate injection will occur with an increase in
the water flow thru the ratio controller due to the increased pressure differential. As both the water and foam
concentrate flow into the common reduced pressure area,
it is necessary only to maintain identical water and foam
concentrate pressures at the inlets of the ratio controller.
A diaphragm valve (pressure control valve) automatically adjusts the foam concentrate inlet pressure to
correspond to the water inlet pressure. Pressure sensing
lines lead from the foam concentrate line upstream of the
ratio controller and from the water inlet to the ratio

controller to the diaphragm valve.


NF diaphragm valves, as previously mentioned, are
available in two versions. One version does not have
manual override capability. This version does not allow
manual regulation of foam concentrate inlet presssure in
the event of a diaphragm valve failure. The other version
does have manual override capability, which allows
manual regulation of the foam concentrate inlet pressure.
Pressure is adjusted by the operator by manually opening
the diaphragm valve (thru use of the Manual Override
Knob) and regulating the foam concentrate supply valve
(Valve "V") while watching the duplex gauge for system
balance. The duplex gauge monitors balancing of foam
concentrate and water pressures on a single gauge. Foam
concentrate pressure is indicated by the red pointer and
water pressure is indicated by the black pointer. When
the red pointer is directly aligned with the black pointer,
both pointing in the same direction, the system is balancing. Diaphragm valves that do not have manual override
capability also do not have a duplex gauge to monitor
pressure balance.
A National Foam ILBP Module is just one component of an In-Line Balanced Pressure Proportioning
System. This type of foam proportioning system consists
of one or more ILBP Modules, a foam concentrate pump,
a pressure sustaining valve and a foam concentrate
storage tank. An ILBP System requires a fire water
supply system for the module(s).

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

1-1

Foam Concentrate Supply Pressure Gauge

Foam Concentrate Supply Valve

The appropriate lengths of pipe and fittings to join these components into a single
package called an In-Line Balanced Pressure Proportioning Module.
12/98

CHAPTER 2 - INST
ALL
ATION
INSTALL
ALLA

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 those
specified 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 and
maintaining a foam fire protection system, or the replacement of equipment and/or components of an existing
system, 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 design
requirements provided to National Foam. Any changes to the area(s) of coverage or additions of other products
could exceed the design parameters of the foam equipment. Contact NF Engineering Dept. for questions regarding
changes 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 and
maintenance, and refilling of this system to read and understand this entire manual before using the
equipment.

NOTE: COMPONENTS FOR AN IN-LINE BALANCED PRESSURE PROPORTIONING SYSTEM


Products manufactured by NF are warranted free of defects in materials and workmanship for twelve
months from the date of purchase. NF will pass on to the system owner, as far as it is able to do, the benefit
of 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 makes
no warranty, either expressed or implied and assumes no responsibility on the engineering and design of
such systems.

12/98

2-1

INSTALLATION

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.

A. With Synthetic Based Polar Solvent/AFFF and


Conventional AFFF Foam Concentrates
1. Piping:






Brass or Bronze (Note: All foam concentrate 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 foam
concentrate

B. With Protein-Based Foam Concentrates

1. Piping:


2. Valves:


2. Valves:


Brass or Bronze. Cast brass valves fitted


with stainless steel (304L or 316 grades) or
brass trim are acceptable. Teflon seats and
packing are preferable for foam concentrate
service. EPT (EPDM), Buna-N or Viton are
also acceptable seal materials for use with
NF foam concentrates.
Stainless Steel 304L or 316 grades

3. Storage Tanks:




2-2

Stainless Steel 304L or 316 grades


High Density Cross Linked Polyethylene
Fiberglass with isophthalic based polyester
and an internal layer (50-100 mils minimum)
of vinyl ester resin in contact with foam
concentrate

Same materials as Synthetic Based Polar


Solvent/AFFF and Conventional AFFF Foam
Concentrate with the exception of stainless
steel
Black steel pipe and malleable iron fittings

Brass or Bronze. Cast brass valves fitted


with stainless steel (304L or 316 grades) or
brass trim are acceptable. Teflon seats and
packing are preferable for foam concentrate
service. EPT (EPDM), Buna-N or Viton are
also acceptable seal materials for use with
NF foam concentrates.

3. Storage Tanks:



Steel
Same materials as Synthetic Based Polar
Solvent/AFFF and Conventional AFFF Foam
Concentrate with the exception of stainless
steel.

12/98

12/98

2-3

850(3218)

0.3(.02)
0.3(.02)

5000(18927)

*4000(15141)

0.3(.02)

0.3(.02)

0.3(.02)

0.3(.02)

MIN. FLOW

20(1.37)

20(1.37)

19.5(1.34)

19.5(1.34)

19.5(1.34)

10.5(.72)

MAX. FLOW

PRESSURE LOSS **
PSI (BAR)

Percent Proportioning

"C" Contractor Model

Ratio Controller Style - "W" Wafer Style

"B"

Material of Construction - "B" Brass

Controller Pipe Size

FOAM CONCENTRATE
INLET CONNECTION

"C"

PRESSURE GAUGE

FOAM CONCENTRATE
SUPPLY VALVE "V"
(NORMALLY CLOSED)

P/A/U

"E"

FOAM
CONCENTRATE
FLUSH-OUT
VALVE "R"

WATER FLUSH-OUT
VALVE "P"

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

22-11/16(576)

"G"
(Ref.)

164(74)

MATERIALS OF CONSTRUCTION
Component Description
Material
Diaphragm Valve
Brass & Stainless Steel
Ratio Controller
Brass
Ball Valve
Brass & Stainless Steel
with Teflon Seals
Pipe and Fittings
Brass
Hose
Braided Stainless Steel
over Teflon Tube

DUPLEX GAUGE
WATER FLUSH-OUT
VALVE "M"

DUPLEX GAUGE
FOAM CONCENTRATE
FLUSH-OUT VALVE "N"

DUPLEX GAUGE

11(279)

FIGURE 2-1
IN-LINE BALANCED PRESSURE PROPORTIONER MODULE
3" - 8" WAFER STYLE WITH MANUAL OVERRIDE

Manual Override

150# ANSI BOLTED


FLANGES BY OTHERS
(SAME NOMINAL PIPE SIZE
AS RATIO CONTROLLER)

Foam Concentrate
- P - Protein
- U - Universal
- UG - Universal Gold
- A - AFFF

MOR

"D"
"F"

SOLUTION
FLOW

SCH. 40 PIPING BY OTHERS


(SAME NOMINAL SIZE
AS RATIO CONTROLLER)

BUSHING
CHECK VALVE

MANUAL OVERRIDE KNOB


(NORMALLY IN FULLY
OPEN POSITION)

MODEL NUMBER IDENTIFICATION

"A"

FLOW

WATER

BODY
DRAIN PLUG

DIAPHRAGM
BALANCING
VALVE

2-1/2(64)

164(74)

22-11/16(576)
11(279)

2-1/2(64)

1-3/4(44)

2(51)

12-1/4(311)

22(559)
1-3/4(44)

109(49)

21-15/16(557)

10-3/8(264)

2-3/8(60)

1-5/8(41)

2(51)

11-9/16(294)

21-7/8(556)

2(51)

94(43)

21-1/8(537)

10-3/8(264)

2-3/8(60)

1-5/8(41)

1-1/2(38)

11-1/8(283)

18-7/8(479)

12-9/16(319)

84(38)

20-1/8(511)

8-1/32(204)

1-31/32(50)

1-7/32(31)

1-1/2(38)

10-1/8(257)

19-1/4(489)

23-3/8(594)

74(34)

19-3/4(502)

4-13/16(122)

1-11/16(43)

1-3/16(30)

1-1/2(38)

APPROX.
WEIGHT
LBS (KGS)

9-3/4(248)

TABLE OF DIMENSIONS
INCHES (MILLIMETERS)
D
E

19-9/16(497)

* - 8 INCH PROPORTIONER RESTRICTED TO 4000 GPM (15141 LPM) FOR 6% PROPORTIONING.


** -ALL DATA BASED ON 3% PROPORTIONING, FOR 6% MULTIPLY BY 1.19.

6%

*8

2500(9463)

850(3218)

300(1136)

6%

1% & 3%

*8

2500(9463)

300(1136)

1% & 3%

1200(4542)

150 (568)

1%, 3% & 6%

450(1703)

70(265)

3% & 6%

3% SYSTEM
SOLUTION CAPACITIES **
GPM (LPM)
MINIMUM
MAXIMUM

NOMINAL
PERCENTAGE
PIPE
SIZE

SPECIFICATIONS

1-11/16(43)

4-13/16(122)

15-3/8(391)

74(34)

WEIGHT
LBS (KGS)

SPECIFICATIONS

1-3/16(30)

84(38)

TABLE OF DIMENSIONS
INCHES (MILLIMETERS)
D
E

B
1-1/2(38)

94(43)

70(265)

450(1703)
0.3(.02)

PRESSURE LOSS **
PSI (BAR)

3% & 6%
1200(4542)

NOMINAL
PERCENTAGE
PIPE
SIZE
9-3/4(248)

15-3/4(400)

109(49)

19-9/16(497)

16-3/4(425)

164(74)

10.5(.72)

8-1/32(204)

17-5/8(448)

MAX. FLOW

1-31/32(50)

10-3/8(264)

18-5/16(465)

0.3(.02)

1-7/32(31)

2-3/8(60)

11(279)

10-3/8(264)

MIN. FLOW

3
150 (568)
19.5(1.34)

3% SYSTEM
SOLUTION CAPACITIES **
GPM (LPM)
MINIMUM
MAXIMUM

1-1/2(38)

2-3/8(60)

10-1/8(257)

1-5/8(41)

2-1/2(64)

19-1/4(489)

1%, 3% & 6%

0.3(.02)

20(1.37)

19.5(1.34)

19.5(1.34)

4
2500(9463)
0.3(.02)

1-1/2(38)

300(1136)

0.3(.02)

11-1/8(283)

1% & 3%
2500(9463)

18-7/8(479)

5000(18927)

1-5/8(41)

300(1136)

1-3/4(44)

850(3218)

2(51)

6%

2(51)

1% & 3%

12-1/4(311)

11-9/16(294)

*8

22(559)

164(74)

21-7/8(556)

18-5/16(465)
2-1/2(64)

11(279)
1-3/4(44)

23-3/8(594)

2(51)

0.3(.02)

"F"

"D"

WATER FLUSH-OUT
VALVE "P"
FOAM
CONCENTRATE
FLUSH-OUT
VALVE "R"

Component Description
Diaphragm Valve
Ratio Controller
Ball Valve
Pipe and Fittings
Hose

"G"

(Ref.)

Material
Brass & Stainless Steel
Brass
Brass & Stainless Steel
with Teflon Seals
Brass
Braided Stainless Steel
over Teflon Tube

FIGURE 2-2
IN-LINE BALANCED PRESSURE PROPORTIONER MODULE
3" - 8" WAFER STYLE WITHOUT MANUAL OVERRIDE

150# ANSI BOLTED


FLANGES BY OTHERS
(SAME NOMINAL PIPE SIZE
AS RATIO CONTROLLER)

SOLUTION
FLOW

SCH. 40 PIPING BY OTHERS


(SAME NOMINAL SIZE
AS RATIO CONTROLLER)

BUSHING CHECK VALVE

"E"
P/A/U
Foam Concentrate
- P - Protein
- U - Universal
- UG - Universal Gold
- A - AFFF
2-1_2-2.P65 (2/98)
ILBP2-2.DSF

MATERIALS OF CONSTRUCTION

* - 8 INCH PROPORTIONER RESTRICTED TO 4000 GPM (15141 LPM) FOR 6% PROPORTIONING.


** -ALL DATA BASED ON 3% PROPORTIONING, FOR 6% MULTIPLY BY 1.19.

12-9/16(319)

*4000(15141)
20(1.37)

850(3218)

"A"

FLOW

WATER

BODY
DRAIN PLUG

MODEL NUMBER IDENTIFICATION

DIAPHRAGM BALANCING VALVE

6%

"B"

FOAM CONCENTRATE SUPPLY VALVE "V"


(NORMALLY CLOSED)

*8

PRESSURE GAUGE

"C"
FOAM CONCENTRATE
INLET CONNECTION

Controller Pipe Size


Material of Construction - "B" Brass

Ratio Controller Style - "W" Wafer Style


"C" Contractor Model
Percent Proportioning

12/98

2-4

12/98

2-5

0.3(.02)

*5000(18927)

850(3218)

* 8*
3-1/2(89)

3-1/16(78)

3(76)
22(559)
23-3/4(603)
26-1/4(667)

6" 150#
FLAT FACE
8" 150#
FLAT FACE

13-1/2(343)

12-3/4(324)

F1/4

Brass
Brass

Brass
Braided Stainless Steel

Ratio Controller
Pipe

Pittings (Pipe)
Hose

over Teflon Tube

Brass & Stainless Steel


Brass & Teflon

Diaphragm Valve
Ball Valve

Component Description Material

MATERIALS OF CONSTRUCTION

RCF2-3.DSF
RCF2-3.P65

FOAM CONCENTRATE
SUPPLY
"H"

PRESSURE GAUGE

FOAM CONCENTRATE SUPPLY VALVE "V"


(NORMALLY CLOSED)

A1/4

WATER
FLOW

DIAPHRAGM BALANCING VALVE

B
C

"D" FLANGE
PER ANSI B16.5

DRAIN/FLUSH-OUT
VALVES - TYPICAL
5 PLACES

12(305)

12(305)

12(305)

12-3/4(324)

12-3/4(324)

G1/4

12-3/4(324)

11(279)

9-1/2(241)

8(203)

7-1/2(191)

2 NPT

2 NPT

1-1/2 NPT

1-1/2 NPT

1-1/2 NPT

220(100)

145(66)

110(50)

90(41)

75(34)

WEIGHT
LBS (KGS)

FIGURE 2-3
IN-LINE BALANCED PRESSURE PROPORTIONER MODULE
2" - 8" FLANGED STYLE

FLOW

SOLUTION

- DUPLEX GAUGE RED NEEDLE - FOAM


BLACK NEEDLE - WATER
DUAL SCALE ENGLISH
AND METRIC

MANUAL OVERRIDE HANDWHEEL


(NORMALLY IN FULL OPEN POSITION)

E1/4

20-1/2(521)

4" 150#
FLAT FACE

6-1/2(165)
10(254)

19-3/4(502)

3" 150#
FLAT FACE

D
2" 150#
FLAT FACE

TABLE OF DIMENSIONS
INCHES (MILLIMETERS)

9-5/8(244)

* - 8 INCH PROPORTIONER RESTRICTED TO 4000 GPM (15141 LPM) FOR 6% PROPORTIONING.


** - ALL DATA BASED ON 3% INJECTION, FOR PRESSURE LOSSES FOR 6% INJECTION, MULTIPLY BY 1.19.

18-1/4(464)

18-11/16(475)

19.5(1.34)

0.3(.02)

2500(9463)

300(1136)

6
20(1.37)

15-1/4(387)

0.3(.02)

2(51)

16-1/4(413)

10.5(.72)
19.5(1.34)

0.3(.02)

450(1703)

1200(4542)

70(265)

150 (568)

2-9/16(65)

15-11/16(398)

14(.97)

0.5 .03)

180(681)

PRESSURE LOSS**
PSI (BAR)
MINIMUM MAXIMUM

30(114)

SOLUTION CAPACITIES
PSI (BAR)
MINIMUM
MAXIMUM

NOMINAL
PIPE
SIZE

SPECIFICATIONS

INSTALLATION

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 be
chained or locked in the open position or equipped with tamper alarm switch(es) which are monitored by a
supervisory panel alarm.
The major concern is the possibility that any manually operated valve(s) in the foam solution line to the
hazard(s) could inadvertently be left in the closed position during a fire condition, which would prevent the foam
solution 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
is not properly secured in the lifting device, damage to
the module or injury to personnel could result.

1. To avoid damage, the module should be left in its


shipping carton or crate until time of installation into
foam system.
2. Use a nylon lifting strap, secured around the ratio
controller 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 and
connect the foam concentrate supply piping to
the module. ILBP modules can be mounted in
either a horizontal or vertical orientation.
2. All interconnecting piping to and from the ILBP
Module (that is - foam concentrate supply piping, watermain piping and foam solution piping)
must be self-supporting so as to eliminate any
load on the module itself.
3. To facilitate future service/removal of the ratio
controller, the installer should provide a spool
piece upstream of the ratio controller. See Chart
below for minimum spool piece lengths.

2-6

Ratio Controller

Minimum Spool Length

3" .......................................... 8"


4" ........................................ 10"
6" ........................................ 12"
8" ........................................ 14"

(203)
(254)
(305)
(356)

4. Each proportioner module requires 5 diameters of


straight unobstructed upstream and downstream
watermain piping to obtain proper flow through the
ratio controller.
CAUTION:
The ILBP Module requires a stable, uniform
water flow at the inlet to the ratio controller to
insure proper proportion ing during all rated
flow conditions.

12/98

INSTALLATION

5. Regarding only RCF style ILBP modules:


A check valve must be placed in the foam concentrate line directly upstream of each
proportioner module.

9. Check that the system is properly installed according


to design with all necessary valves, correct pipe
sizes, discharge devices and discharge device locations, and is installed in compliance with local codes.

6. Regarding only ILBP Module(s) that have a


diaphragm valve with manual override capability: If the module is used with an Automatic
Zone Foam Concentrate Supply Valve, the
Manual Foam Concentrate Supply Valve "V" is
still required for manual override pressure regulation. Refer to Operating Schematic Dwg. Fig.
3-1 or Fig. 3-3 for valve locations and normal
stand-by position.

10. Hydrostatically test piping in accordance with procedures outlined in the latest edition of the applicable
section of NFPA.

7. Cycle all valves to insure freedom of movement


and that they open and close properly.
8. For NF recommended components - valves,
strainers, gauges and connections, and their location in the system, refer to the Operating
Schematic Drawing Fig. 3-1, 3-2 or 3-3.

11. Flush the foam concentrate piping before introducing foam concentrate into the foam system.
12. Follow the procedures outlined in Section 2-2., C.
Installation, Item Nos. 7 and 8. Refer to System
Flushing procedures outlined in Sect. 4-15.
13. Place all valves to their normal stand-by position.
See Normal Stand-By Valve Position Chart on Operating Schematic Dwg. Fig. 3-1, 3-2 or 3-3.
14. Perform the applicable testing after installation procedures as recommended by the latest edition of
NFPA 11.

C. Operating Requirements:
by position for automatic balancing. To place in
the normal stand-by position: rotate the
manual override handle in the counter-clockwise direction until fully open.

1. Foam concentrate pressure to the ILBP Module


inlet must exceed water pressure inlet by at least
30 psi (2.0 Bar) unless otherwise approved by
NF Engineering Department.
2. ILBP Module maximum working pressure - 200
psi(13.7 Bar).
3. Regarding only ILBP Module(s) that have a
diaphragm valve with manual override capability:

12/98

The Manual Override Handwheel on the


diaphragm valve must be in the normal stand-

Check the appropriate sensing line valve(s)


(Valves "J", "L" or "K") to insure that it is in the
proper stand-by position (Normally Open).

4. Insure that all valves are in their normal stand-by


position before operating the proportioning system.
See Normal Stand-By Valve Position Chart on Operating Schematic Dwg. Fig. 3-1, 3-2 or 3-3.

2-7

CHAPTER 3 - OPERA
TING PROCEDURES
OPERATING

3-1.

MINIMUM INLET PRESSURE REQUIREMENTS


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

W A T E R IN L E T P R E S S U R E (P S I/B A R )

B A R /P S I

3 " R C F /R C W

2 " R C T

6 .9 /1 0 0
6 .2 /9 0

4 " R C F /R C W

6 " R C F /R C W

8 " R C F /R C W

5 .5 /8 0
4 .8 /7 0
4 .1 /6 0
3 .4 /5 0
2 .7 /4 0
2 .0 6 /3 0

G P M
L P M

1 .3 /2 0

6 0
2 2 7

8 0
3 0 3

1 0 0
3 7 9

2 0 0
7 5 7

4 0 0
1 5 1 4

6 0 0
2 2 7 1

S O L U T IO N F L O W

8 0 0
3 0 2 8

1 0 0 0
3 7 8 5

2 0 0 0
7 5 7 1

4 0 0 0
1 5 1 4 1

(G P M /L P M )

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

12/98

3-1

FIG. 3-2 OPERATING SCHEMATIC DRAWING

NORMAL STAND-BY VALVE POSITION CHART


RCW IN-LINE BALANCED PRESSURE PROPORTIONING MODULE W/MOR

LEGEND
FOAM CONCENTRATE LINE

VALVE DESCRIPTION
WATER SENSING LINE SHUT-OFF VALVE
TO DIAPHRAGM VALVE
DUPLEX GAUGE WATER FLUSH-OUT
DUPLEX GAUGE FOAM CONC. FLUSH-OUT
DIAPHRAGM VALVE WATER FLUSH-OUT
DIAPHRAGM VALVE CONC. FLUSH-OUT
FOAM CONCENTRATE SUPPLY VALVE
BODY DRAIN PLUG

SENSING LINE
WATER LINE
RCW RATIO CONTROLLER
BALL VALVE (N.O.)
BALL VALVE (N.C.)

DESIGNATION
L
M
N
P
R
V

POSITION
MANUAL
AUTO.
OPEN
OPEN
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED

CLOSED
CLOSED
CLOSED
OPEN
OPEN
CLOSED

AUTOMATED VALVE W/MANUAL


OVERRIDE
D

DUPLEX GAUGE
P

PRESSURE GAUGE

MANUAL OVERRIDE
HANDWHEEL

DIAPHRAGM VALVE

M
N
R

P
V

ILBP MODULE
SCHEMATIC
- TYPICAL -

SEE NOTE NO. 1

BODY
DRAIN
PLUG

FO
A
LU M
TIO
N

SO

SEE NOTE NO. 2

NOTES:
The schematics shown are typical installations and
may not reflect actual equipment furnished.

SEE NOTE NO. 3


CO

1. Valve "V" - Normally CLOSED for systems using


no automatic foam concentrate valve(s).
- Normally OPEN for systems using an
automatic 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


RCW ILBP MODULE WITH MANUAL OVERRIDE

3-2

FO
AM
EN
SU TRA
T
PP
LY E

NC

WATER PUMP
(IF REQUIRED)
MAIN WATER
SUPPLY VALVE

WA
SU TER
PP
LY

MOD3-1.DSF
LGND3-1.DSF

12/98

FIG. 3-3 OPERATING SCHEMATIC DRAWING

NORMAL STAND-BY VALVE POSITION CHART


RCW IN-LINE BALANCED PRESSURE PROPORTIONING MODULE WITHOUT/MOR

LEGEND
FOAM CONCENTRATE LINE

POSITION
DESIGNATION MANUAL
AUTO.
P
CLOSED
CLOSED
R
CLOSED
OPEN
V
CLOSED
OPEN
CLOSED
CLOSED

VALVE DESCRIPTION
DIAPHRAGM VALVE WATER FLUSH-OUT
DIAPHRAGM VALVE CONC. FLUSH-OUT
FOAM CONCENTRATE SUPPLY VALVE
BODY DRAIN PLUG

SENSING LINE
WATER LINE
RCW RATIO CONTROLLER
BALL VALVE (N.O.)
BALL VALVE (N.C.)
AUTOMATED VALVE W/MANUAL
OVERRIDE
P

PRESSURE GAUGE
DIAPHRAGM VALVE

P
V

ILBP MODULE
SCHEMATIC
- TYPICAL -

SEE NOTE NO. 1

BODY
DRAIN
PLUG

FO
A
LU M
TIO
N

SO

SEE NOTE NO. 2

SEE NOTE NO. 3

NOTES:

CO

SU

The schematics shown are typical installations and


may not reflect actual equipment furnished.
1. Valve "V" - Normally CLOSED for systems using
no automatic foam concentrate valve(s).
- Normally OPEN for systems using an
automatic foam concentrate valve(s).
2. Position of Zone Foam Concentrate Valve.
Automatic valve optional.

FO
AM
EN
TR
PP ATE
LY

NC

WATER PUMP
(IF REQUIRED)
MAIN WATER
SUPPLY VALVE

WA
SU TER
PP
LY

3. Position of Zone Water Supply Valve.


Automatic valve optional.
Manual valve required if automatic valve not supplied.

MOD3-2.DSF
LGND3-2.DSF

12/98

FIG. 3-3 OPERATING SCHEMATIC DRAWING


RCW ILBP MODULE WITHOUT MANUAL OVERRIDE

3-3

FIG. 3-4 OPERATING SCHEMATIC DRAWING

NORMAL STAND-BY VALVE POSITION CHART


RCF IN-LINE BALANCED PRESSURE PROPORTIONING MODULE W/MOR

LEGEND
FOAM CONCENTRATE LINE

VALVE DESCRIPTION
WATER SENSING LINE SUPPLY VALVE
WATER SENSING LINE SHUT-OFF VALVE
TO DIAPHRAGM VALVE
FOAM CONCENTRATE SENSING LINE
SHUT-OFF VALVE TO DIAPHRAGM VALVE
DUPLEX GAUGE WATER FLUSH-OUT
DUPLEX GAUGE FOAM CONC. FLUSH-OUT
DIAPHRAGM VALVE WATER FLUSH-OUT
DIAPHRAGM VALVE CONC. FLUSH-OUT
FOAM CONCENTRATE SUPPLY VALVE
LOWER PETCOCK ON DIAPHRAGM VALVE

SENSING LINE
WATER LINE
RCF RATIO CONTROLLER
BALL VALVE (N.O.)
BALL VALVE (N.C.)
AUTOMATED VALVE W/MANUAL
OVERRIDE

POSITION
DESIGNATION MANUAL
AUTO.
J
OPEN
OPEN
L
OPEN
OPEN
K

OPEN

OPEN

M
N
P
R
V
W

CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED

CLOSED
CLOSED
CLOSED
OPEN
OPEN
CLOSED

CHECK VALVE
D

DUPLEX GAUGE
P

PRESSURE GAUGE

MANUAL OVERRIDE
HANDWHEEL

DIAPHRAGM VALVE

M
N
K

P
V

ILBP MODULE
SCHEMATIC
- TYPICAL SO

SEE NOTE NO. 1

FO
A
LU M
TIO
N

SEE NOTE NO. 4

NOTES:
SEE NOTE NO. 2

The schematics shown are typical installations and


may not reflect actual equipment furnished.
1. Valve "V" - Normally CLOSED for systems using
no automatic foam concentrate valve(s).
- Normally OPEN for systems using an
automatic foam concentrate valve(s).

SEE NOTE NO. 3


CO

SU

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

MOD3-3.DSF
LGND3-3.DSF

3-4

FO
AM
EN
TR
PP ATE
LY

NC

WATER PUMP
(IF REQUIRED)
MAIN WATER
SUPPLY VALVE

WA
SU TER
PP
LY

FIG. 3-4 OPERATING SCHEMATIC DRAWING


RCF ILBP MODULE WITH MANUAL OVERRIDE

12/98

OPERATING PROCEDURES

3-2.

ILBP MODULE OPERATION

NOTE: Refer to Operating Schematic Drawing Fig. 32, 3-3 or 3-4 for valve location, designation
and normal stand-by position.
1. Verify that all valves on the proportioning system
are 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 the
metering valve(s) at the appropriate ILBP Module(s).
NOTE: The metering valve is for regulating the
foam concentrate injection (percentage) into the system only , and does not have shut-off capability. For
positive foam concentrate shut-off, a separate valve
must be used along with the metering valve.
5. Open water supply valve to the desired ILBP
module(s).

3-3.

6. Open foam concentrate supply Valve "V" to the


desired ILBP module(s).
7. Open any required zone valves downstream of the
desired ILBP module(s).
8. Regarding only ILBP Module(s) that have a diaphragm valve with manual override capability:


Verify that pointers on the duplex gauge are


balancing; if not, follow procedures in Sect.3-3.,
ILBP Module Manual Override (Manual Regulation).

9. Observe the discharge pressure gauge at the foam


concentrate pump discharge to insure that the system
is operating at design pressure. If system is not
operating at design pressure, refer to the system
manual regulation section of the foam concentrate
pump system operating and maintenance manual. If
the foam concentrate pump system is provided by
NF, refer O. & M. Manual part number 1298-99362, Sect. 3-3.B., Pump and Pressure Sustaining Valve
Module.

ILBP MODULE MANUAL OVERRRIDE (MANUAL REGULATION)

NOTE: The instructions below, apply only to ILBP Module Diaphragm Valves with manual
override capability. These instructions do not apply to Diaphragm Valves which do not
have manual overrride capability.
NOTE: Used only when system will not balance automatically.

1. Close foam concentrate supply Valve "V".

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

2. Close water sensing shutoff Valve "L".


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

12/98

5. Slowly open foam concentrate supply Valve "V"


until duplex gauge indicates system balance. Keep
adjusting valve as required to maintain system balance.

3-5

OPERATING PROCEDURES

3-4.

SHUTDOWN

1. Shut down the foam concentrate pump.

output devices that were operated.

2. Close the foam concentrate supply Valve "V" at the


ILBP module(s) being operated.

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


supply.

WARNING:
Only after the fire is out and the danger of reignition
has passed, shall consideration be given to flushing
and draining the system. Follow the appropriate
Flushing Instructions which follow in this manual
after it is determined that it would be safe to flush
and drain the system.

4. Return all valves to their normal stand-by position.


See Normal Stand-by Valve Position Chart on
Operating Schematic Dwg. Fig. 3-2, 3-3 or 3-4.

3. Flush the foam solution system.


NOTE: If the system has a water powered foam
concentrate supply Valve "V", the cylinder water
pressure supply valve in the water line supplying
pressure to the water powered ball valve operating
cylinder must be closed before any flushing operation.
a. Make sure Valve "V" at the ILBP module(s)
being operated is closed.
b. Flow water through the system and allow water
to run until clean clear water issues from the

3-6

5. Replenish supply of foam concentrate. If the tank is


empty, it shall be inspected to determine if cleaning
is warranted before refilling. If cleaning is judged
necessary, refer to manufacturer's instructions. If
storage tank is provided by NF - refer to NF Storage
Tank Installation, Cleaning & Filling Instruction
Manual P/N: 1298-9933-7 for recommendations.
CAUTION:
Only foam concentrate of the type listed on the
tank nameplate shall be used to replenish the tank.
Mixing of different types or brands of foam
concentrate could cause failure of the system.
6. Replace all frangible components such as glass diaphragms, rupture discs, etc., in foam lines or foam
making devices.

12/98

CHAPTER 4 - INSPECTION AND MAINTENANCE

4-1.

INSPECTION AND MAINTENANCE


See Table 4-1 for recommended inspection and maintenance procedures. These procedures and
recommended intervals are based on normal operating conditions and may have to be modified to meet
the existing conditions.
WARNING:
The intervals in this chapter are a general recommendation; some environmental conditions
may 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 instruction
sheet 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 modify
system components, component parts, operating devices or equipment, the system must be tested to
insure 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 discussed
immediately with the manufacturer. Regular service contracts are recommended. The goal of this
inspection and testing shall be to ensure that the system is in full operating condition, and that it will
remain in that condition until the next inspection. The inspection report, with recommendations, shall
be filed with the owner. Between the regular service contract inspections or tests, the system shall
be inspected by competent personnel following an approved schedule.

6/00

4-1

INSPECTION & MAINTENANCE

TABLE 4-1 - RECOMMENDED INSPECTION & MAINTENANCE SCHEDULE

WARNING:
The following recommendations are based on normal operating conditions. Due to environmental or
other conditions unique to your system, the frequency of some inspecton and maintenance procedures
may 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

START
AFTER
UP
OPERATION WEEKLY MONTHLY

SEMIANNUAL ANNUAL

OTHER

4-4. GENERAL
1. Check all valves to insure that they are in the
normal stand-byposition. See Operating
Schematic Dwg. Fig. 3-2, 3-3 or 3-4.
2. Check that Manual Override Handwheel is in the
normal stand-by position for automatic
balancing. 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.

AFTER
ALL
MAINT.
PROCEDURES

4-5. WATER POWERED BALL VALVES


1. Cycle the valve(s) either manually or thru control
panel. If applicable,cycle the valve(s) using the
solenoid 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.

4-2

12/98

INSPECTION & MAINTENANCE

TABLE 4-1 - RECOMMENDED INSPECTION & MAINTENANCE SCHEDULE


DESCRIPTION

START
AFTER
UP
OPERATION WEEKLY MONTHLY

SEMIANNUAL ANNUAL

OTHER

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 valves
are cycled, Valve "V" must be closed.
When automated valves are cycled, the
main 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.

12/98

4-3

INSPECTION & MAINTENANCE - FLUSHING

4-8.

FLUSHING - ILBP MODULE


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

A. ILBP Module with


Diaphragm Valve Manual Override Capability:

B. ILBP Module without


Diaphragm Valve Manual Override Capability:

1. Open all ILBP Module sensing line drains and


flush-out points (Valves M, N, P, R and W).

1. Open all ILBP Module drains, flush-out points


(Valves P and R).

2. Turn manual override knob down (clockwise)


until it contacts stop.

2. Close Foam Concentrate Supply Valve "V" on


the ILBP Module.

3. Close Foam Concentrate Supply Valve "V" on


the ILBP Module.

3. The ILBP Module will be flushed thru the foam


solution piping. Flushing must be done thru zone
discharge devices or thru foam solution piping
drains (with zone foam solution discharge valves
closed).

4. The ILBP Module will be flushed thru the foam


solution piping. Flushing must be done thru zone
discharge devices or thru foam solution piping
drains (with zone foam solution discharge valves
closed).
5. Establish a water flow thru the foam concentrate
system until the water flows clear at all flush
points and drains.
NOTE: Flushing of the ILBP Module can be
performed at system shutdown when flowing
water thru the system. Refer to Sect. 3-4., Shutdown, for correct procedures.

4. Establish a water flow thru the foam concentrate


system until the water flows clear at all flush
points and drains.
NOTE: Flushing of the ILBP Module can be
performed at system shutdown when flowing
water thru the system. Refer to Sect. 3-4., Shutdown, for correct procedures.
5. After the water runs clear, shut off water supply
then drain the ILBP Module and zone piping.

6. After the water runs clear, shut off water supply


then drain the ILBP Module and zone piping.
NOTE: Remove diaphragm valve body drain
plug.
7. Turn manual override knob up (counter-clockwise) until it contacts stop for normal automatic
balancing operation.

NOTE: Remove diaphragm valve body drain


plug.
6.

Return all valves to their normal stand-by position (reinstall body drain plug). Refer to Normal
Stand-By Valve Position Chart on Operating
Schematic Dwg. Fig. 3-3.

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

4-4

12/98

CHAPTER 5 - TROUBLESHOOTING

5-1.

TROUBLESHOOTING
See Table 5-1 for Troubleshooting Problems, Possible Causes and Corrective Actions. These procedures
cover problems that may be experienced during normal operations. Although these recommendations cover
most problems that are experienced there are some situations that may occur which are not covered in these
instructions. Please contact National Foam's Engineering Department for problems that cannot be resolved
thru the use of this manual.
NOTE: Refer to individual instruction manuals or sheets for additional information on system components
and discharge devices.

TABLE 5-1 TROUBLESHOOTING


PROBLEM

5-2. No
Proportioning

POSSIBLE CAUSE

Automatic Foam Concentrate Zone Valve

CORRECTIVE ACTION

Check that wiring is installed to actuator.


Closed.(Electrically actuated)
Check that signal from control system is
available at valve actuator. If voltage is not
present, check control system.
If signal is present at actuator, use manual
override to cycle valve. If valve cycles manually, 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 the
valve is jammed. Remove valve, determine
and correct reason for jam. See actuator data.

Automatic valve actuator does not function


properly.(Electric or hydraulic actuation)

See manufacturers troubleshooting data.

Automatic Foam Concentrate Zone Valve


Closed.(Water Powered Ball Valve)

Check that cylinder water pressure supply


valve is fully open.
Check that quick release pull pin is not
removed from clevis. Reinsert pin thru
clevis and valve handle.

12/98

5-1

TROUBLESHOOTING

TABLE 5-1 TROUBLESHOOTING


PROBLEM

POSSIBLE CAUSE

No Proportioning
continued

5-3. Low
Percent of
Proportioning

CORRECTIVE ACTION

Check Drain/Vent valve on strainer for clogging which shuts off water supply to cylinder.
Open Drain/Vent valve on strainer, vent and
flush any debris blocking water supply.
Diaphragm Valve Foam Concentrate FlushOut Valve "R" open or partially open.

If provided, duplex gauge will show foam


concentrate pressure lower than water
pressure. Check to insure all flush valves
are closed.

Drain valve(s) or connection(s) in foam


concentrate piping open or partially open.

If provided, duplex gauge will show foam


concentrate pressure lower than water
pressure. Check to insure all drain valves
are closed.

Control system not functioning properly.

Check wiring for correct interconnection and


proper connections. See control system
manual.

Concentrate not compatible with the system.

Use correct concentrate. Drain and clean


tank before filling with new concentrate.

Ratio controller operating below minimum


inlet pressure.

Increase water pressure. Contact NF


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 Instruction Manual, P/N: 1298-9933-7.

Foam Concentrate Discharge Valve "D" and/


or Foam Concentrate Supply Valve "V"
partially closed.

Fully open valve(s). If more than one ILBP


Module is supplied by the foam concentrate
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


open.

Fully open valve. Determine cause and


correct.

Automatic Foam Concentrate Zone Valve


opens slowly.(Water powered ball valve)

Cylinder water pressure supply valve


partially open. Fully open valve.
Tighten Drain/Vent valve on cylinder strainer.
Snug with wrench to insure closure to rated
pressure.
Drain/Vent valve clogged, obstructing water
supply to cylinder. Open Drain/Vent valve on
strainer and vent. Flush any debris blocking
water supply.

5-2

12/98

TROUBLESHOOTING

TABLE 5-1 TROUBLESHOOTING


PROBLEM

Low Percent of
Proportioning
continued

POSSIBLE CAUSE

CORRECTIVE ACTION

Water pressure exceeds the design limits of


the system. System requires more capacity
than pump is capable of producing.

Adjust pressure to proportioner to be within


the flow and pressure limits of the system.

Drain valves in foam concentrate piping


open or partially open. If provided, duplex
gauge will show foam concentrate pressure
lower than water pressure.

Check to insure all drain valves are closed.

Control system not functioning properly.

See control system manual. Check wiring for


correct interconnection.
Check wiring for proper connections.

5-4. High
Percent of
Proportioning

12/98

Diaphragm valve not functioning properly.


If provided, duplex gauge will not show
balance.

Check water sensing lines for blockage.


Make sure that there are no air pockets in
water sensing lines.

Diaphragm Valve Water Flush-Out "P" open.

Fully close flush-out valve.

Foam concentrate incompatible with system


design.

Use only foam concentrates the system was


designed for. Contact NF Engineering Dept.
if you desire to change foam concentrates.

Incorrect orifice diameter or adjustment.

Contact NF Engineering Dept. for instructions


on checking orifice and adjustment settings.

Water flow too high. Exceeds capability


of foam concentrate pump.

Too many discharge devices in operation or


pressure too high. Check design and correct
to stay within limits of system.

Ratio controller operating below minimum


inlet pressure.

Increase water pressure. Contact NF


Engineering Dept. for recommendations.
Refer to Fig. 3-5, Minimum Inlet Pres. Req.

Diaphragm valve not functioning properly.


If provided, duplex gauge will not show
balance.

Check foam concentrate sensing lines for


blockage. Make sure that there are no air
pockets in foam concentrate sensing lines.

Foam concentrate sensing line blocked.

Remove line and clear blockage.

Diaphragm Valve Foam Concentrate


Flush-Out Valve "R" open.

Fully close flush-out valve.

Foam concentrate incompatible with system


design.

Use only foam concentrate the system was


designed for. Contact NF Engineering Dept.
if you desire to change foam concentrates.
5-3

TROUBLESHOOTING

TABLE 5-1 TROUBLESHOOTING


PROBLEM

High Percent of
Proportioning
continued

POSSIBLE CAUSE

CORRECTIVE ACTION

Incorrect orifice diameter or adjustment.

Contact NF Engineering Dept. for instructions


on checking orifice and adjustment settings.

Water flow too low for ratio controller.

Check system pressure. If low, find and


correct problem.
Blockage in solution line or valves not
completely open. Check solution line and
correct.
Discharge device blocked. Check devices
and correct problem.

5-5. No Flow
at Discharge
Device(s)

5-6. Low Flow


at Discharge
Device(S)

Water supply valve closed.

Open valve. If automated, find reason and


correct.

Fire pump did not start.

Determine the cause and correct the problem.

Blockage in the water supply or foam


solution discharge line.

Find the cause of the blockage and correct.

Manual valves in solution piping shut or


blockage in line.

Check line for blockage or open manual


valves.

System pressure too low.

Check inlet pressure and correct for proper


operation.

Fire pumps did not start.

Determine reason and correct.

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

5-7. No
Operation

5-4

Zone valve did not open completely.

Valve jammed, determine reason and correct.

Power failure.

Check power source and correct problem.

Control system not functioning properly.

Check wiring for correct interconnection and


proper connections. See control system
manual.

Foam concentrate storage tank empty.

Fill tank.

Failure of water supply system.

Check water supply and correct problem.

12/98

APPENDIX - F
ACTOR
Y MUTU
AL APPRO
VALS
FACTOR
ACTORY
MUTUAL
APPROV
Factory Mutual Research and Engineering is a non-profit independent research and testing organization. FM tests
and 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 gives
detailed information on the approved products, as well as the operational parameters of the approval. In the case of
foam proportioning systems, the parameters are the minimum and maximum foam solution flows and the foam
concentrates for which the proportioner is approved.
The following foam concentrates, along with the particular In-Line Balanced Pressure (ILBP) Proportioning System
components and discharge device(s) listed under the foam concentrate, constitute an FM Approved foam system. An
approved system must consist of a foam concentrate, ILBP Proportioning system and discharge device(s).
A-1.

d. Ethers

Universal Gold - 3% Alcohol Resistent AFFF

Viking Model M
17/32" Upright and Pendent

A. In-Line Balanced Pressure Proportioning Systems:


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

Viking Model M
1/2" Upright
Grinnell Model F950
1/2" Upright and Pendent

4" BWC3 - UG
4" BWC3 - UG-MOR

e. Hydrocarbons

6" BWC3 - UG
6" BWC3 - UG-MOR

Viking Model M
17/32" Large Orifice Upright

B. Foam Discharge Devices:

Viking Model M
1/2" Upright

1. Sprinklers - listed by the fuel group for which


they are approved (for application rates see
Factory Mutual Approval Guide):

Grinnell Model F950


1/2" Upright and Pendent
Grinnell Model B-1
Foam/Water
3/8" Orifice Pendent

a. Alcohols
Viking Model M
17/32" Upright

2. Nozzles

Viking Model M
1/2" Upright

Model JS-10
Model JS-10B

Grinnell Model F950


1/2" Upright and Pendent

Model PC-31A

b. Ketones
Viking Model M
17/32" Upright

MCS-9 Type A

Viking Model M
1/2" Upright

MCS-33 Type A
MCS-55 Type A

Grinnell Model F950


1/2" Upright and Pendent
c. Esters
Viking Model M
17/32" Upright
Viking Model M
1/2" Upright
Grinnell Model F950
1/2" Upright and Pendent

12/98

3. Foam Chambers

MCS-17 Type A

A-2.

Aer-O-Lite - 3% AFFF
A. In-Line Balanced Pressure Proportioning Systems:
1. ILBP Proportioner Models - for flow ranges see
Factory Mutual Approval Guide:

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

A-1

APPENDIX - FACTORY MUTUAL APPROVALS

APPENDIX

FACTORY MUTUAL APPROVALS CONTINUED

B. Foam Discharge Devices:


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:
Viking Model M
17/32" Upright
Viking Model M
1/2" Upright
Grinnell Model F950
1/2" Upright and Pendent
A-3.

Aer-O-Water 3EM -3% AFFF


A. In-Line Balanced Pressure Proportioning Systems:
1. ILBP Proportioner Models - for flow ranges see
Factory Mutual Approval Guide:
4" BWC3 - A
4" BWC3 - A-MOR
6" BWC3 - A
6" BWC3 - A-MOR
B. Foam Discharge Devices:
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 A
1/2" Upright and Pendent
Grinnell F950
1/2" Upright and Pendent

A-2

12/98

NOTES

Na
tional F
oam
National
Foam

FOAM SOLUTION PROFESSIONALS


180 Sheree Boulevard, Suite 3900 P.O. Box 695 Exton, PA 19341-0695 USA
Telephone: 610-363-1400 Fax: 610-524-9073
www.Kidde-Fire.com

SECTION 3:
SKID MOUNTED ILBP
PROPORTIONING SYSTEM

SKZZ-66025

N a tio n a l F o a m

3.1

3.2

TABLE OF CONTENTS

TABLE OF CONTENTS

Text

Page

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

CHAPTER 1 - INTRODUCTION

1-1.
1-2.
1-3.

NF Red Alert Fire Emergency Service ..........................................................................................


Warning-Failure to Read Manual ...................................................................................................
Safety Information ..........................................................................................................................
General Description ........................................................................................................................
General Notes .................................................................................................................................

1-1
1-2
1-1
1-2
1-3

CHAPTER 2 - INSTALLATION

2-1.

2-2.

2-3.

2-4.

2-5.

6/05

Cautions, Warning and Note for In-Line Balanced Pressure Proportioning System .................. 2-1
Recommended Materials of Construction ..................................................................................... 2-2
A. With Synthetic Based Polar Solvent/AFFF & Conventional AFFF Foam Concentrates ..... 2-2
B. 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 ........................................................................................................ 2-5
Installation and Start-Up: In-Line Balanced Pressure Proportioning Skid Pak .......................... 2-6
A. Site Selection ............................................................................................................................ 2-6
B. Off Loading ............................................................................................................................... 2-6
C. Installation ................................................................................................................................. 2-6
Installation and Start-Up: ILBP Module ......................................................................................... 2-8
A. Off Loading ............................................................................................................................... 2-8
B. Installation ................................................................................................................................. 2-9
C. Operating Requirements ........................................................................................................ 2-10
Installation and Start-Up: Pump and Pressure Sustaining Valve
Supplied as Loose Components ............................................................................................ 2-10
A. Foam Concentrate Pump ....................................................................................................... 2-10
B. Pressure Sustaining Valve ..................................................................................................... 2-11
C. General System ...................................................................................................................... 2-11
D. Foam Concentrate Jockey Pump .......................................................................................... 2-12
Testing After Installation .............................................................................................................. 2-12

-i-

TABLE OF CONTENTS

Text

Page

CHAPTER 3 - OPERATING PROCEDURES

3-1.
3-2.

3-3.

3-4.

Figure 3-1 Operating Schematic Drawing ILBP Module With Manual Override and RCW Ratio Controller ....................................
Figure 3-2 Operating Schematic Drawing ILBP Module Without Manual Override and RCW Ratio Controller ...............................
Figure 3-3 Operating Schematic Drawing ILBP Module With Manual Override and RCF Ratio Controller .....................................
Minimum Inlet Pressure Requirements .........................................................................................
Figure 3-4 NF Ratio Controller Minimum Inlet Pressure vs. Solution Flow Chart ...............
Operation of System .......................................................................................................................
A. Manual System Operation .......................................................................................................
B. Automatic System Operation ...................................................................................................
Manual System Override (Manual Regulation) .............................................................................
A. ILBP Module .............................................................................................................................
B. Pump and Pressure Sustaining Valve Module .......................................................................
Shutdown .........................................................................................................................................
A. Manual System Shutdown .......................................................................................................
B. Automatic System Shutdown ...................................................................................................

3-1
3-2
3-3
3-4
3-4
3-5
3-5
3-5
3-6
3-6
3-6
3-6
3-6
3-7

CHAPTER 4 - INSPECTION AND MAINTENANCE


4-1.
4-2.
4-3.
4-4.
4-5.
4-6.
4-7.
4-8.
4-9.
4-10.
4-11.
4-12.
4-13.
4-14.
4-15.

6/00

Inspection and Maintenance ..........................................................................................................


Testing After System Maintenance................................................................................................
Annual Testing ................................................................................................................................
Table 4-1 Recommended Inspection & Maintenance Schedule ...........................................
Total System ...................................................................................................................................
Strainers ..........................................................................................................................................
Foam Concentrate Pump ...............................................................................................................
Electrically Actuated Valves ..........................................................................................................
Water Powered Ball Valves ...........................................................................................................
Pneumatically Actuated Valves .....................................................................................................
Pressure Vacuum Vent ...................................................................................................................
Foam Concentrate Storage Tank...................................................................................................
Foam Concentrate ..........................................................................................................................
Control System ................................................................................................................................
Flushing - Pump and Pressure Sustaining Valve Module ............................................................
Flushing - ILBP Module ..................................................................................................................
A. ILBP Module With Diaphragm Valve Manual Override Capability .......................................
B. ILBP Module Without Diaphragm Valve Manual Override Capability ..................................

4-1
4-1
4-1
4-2
4-2
4-3
4-3
4-4
4-4
4-4
4-5
4-5
4-5
4-5
4-6
4-7
4-7
4-7

- ii -

TABLE OF CONTENTS

Text

Page

CHAPTER 5 - TROUBLESHOOTING
5-1.
5-2.
5-3.
5-4.
5-5.
5-6.
5-7.

Troubleshooting ..............................................................................................................................
Table 5-1 Troubleshooting .......................................................................................................
No Proportioning .............................................................................................................................
Low Percent of Proportioning .........................................................................................................
High Percent of Proportioning ........................................................................................................
No Flow at Discharge Device(s) ....................................................................................................
Low Flow at Discharge Device(s) ..................................................................................................
No Operation ...................................................................................................................................

5-1
5-1
5-1
5-3
5-5
5-6
5-6
5-6

ILBP SYSTEM_9936-2E.PMD
6/05

6/05

- iii -

CHAPTER 1 - INTRODUCTION

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

CALL LIONVILLE, PA 610-363-1400

WARNING:
This manual has been prepared as an aid and guide for personnel involved in the installation, operation and
maintenance of a NF In-Line Balanced Pressure Proportioning System. All instructions must be read and
understood thoroughly before attempting any installation, operation or maintenance to this equipment. Failure
to 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 operating
personnel to the potential for death, personal injury or damage to equipment or property.
DANGER: indicates an extremely hazardous situation which, if not avoided, will result
in death or serious injury to the operator or major property damage.
WARNING: indicates a potentially hazardous situation which, if not avoided, can result
in 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 fully
understand the DANGER, WARNING, CAUTION and NOTE procedures by which hazards are to be reduced or
eliminated. Personnel must become thoroughly familiar with all aspects of safety and equipment prior to operation
or 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 thoroughly
trained and kept thoroughly trained in the functions they are expected to perform.
6/00

1-1

INTRODUCTION

1-2.

GENERAL DESCRIPTION

The National foam In-Line Balanced Pressure Proportioning System is designed to inject foam concentrate
into the water supply at the correct percentage at multiple injection points. This type of foam proportioning
system consists of one or more In-Line Balanced Pressure Proportioning Modules (ILBP), a foam concentrate
pump, a pressure sustaining valve and a foam concentrate storage tank.

The ILBP system is ideal where: water pressure varies


at the various injection points (ILBP Module), a wide
range of flows are required or, the ability to selectively
run foam solution or water to individual discharge devices is required. The ILBP system will automatically
and accurately provide proportioned foam solution over
a wide range of flows and pressures. All discharge
devices can be switched from foam flow to water flow,
water flow to foam flow, or shut down completely
without affecting the correct operation of the other
discharge devices.

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 single
package called an In-Line Balanced Pressure Proportioning Module.

The ILBP Module is a complete, self-contained unit,


assembled and tested at the factory. The unit is supplied
with no finish and is suitable for either horizontal or
vertical mounting.
The principle of operation of the ILBP Module is
based on the use of a modified venturi proportioner
called a ratio controller. With this type of proportioner,
water passes thru a jet (venturi) at the inlet of the ratio
controller, creating a reduced pressure area on the discharge side of the jet. This reduction in pressure creates
a pressure differential across the foam concentrate orifice and causes injection of foam concentrate into the
water 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
6/00

increases, thereby increasing the pressure differential


across the foam concentrate orifice. A proportionate
increase in foam concentrate injection will occur with an
increase in the water flow thru the ratio controller due to
the increased pressure differential. As both the water and
foam concentrate flow into the common reduced pressure
area, it is necessary only to maintain identical water and
foam concentrate pressures at the inlets of the ratio
controller.
A diaphragm valve (pressure control valve) automatically adjusts the foam concentrate inlet pressure to
correspond to the water inlet pressure. Pressure sensing
lines lead from the foam concentrate line upstream of the
ratio controller and from the water inlet to the ratio
controller to the diaphragm valve.

1-2

INTRODUCTION

NF diaphragm valves, as previously mentioned, are


available in two versions. One version does not have
manual override capability. This version does not allow
manual regulation of foam concentrate inlet presssure in
the event of a diaphragm valve failure. The other version
does have manual override capability, which allows
manual regulation of the foam concentrate inlet pressure.
Pressure is adjusted by the operator by manually opening
the diaphragm valve (thru use of the Manual Override
Knob) and regulating the foam concentrate supply valve
(Valve "V") while watching the duplex gauge for system
balance. The duplex gauge monitors balancing of foam
concentrate and water pressures on a single gauge. Foam
concentrate pressure is indicated by the red pointer and
water pressure is indicated by the black pointer. When
the red pointer is directly aligned with the black pointer,
both pointing in the same direction, the system is balancing. Diaphragm valves that do not have manual override
capability also do not have a duplex gauge to monitor
pressure balance.
An In-Line Balanced Pressure Proportioning System
utilizes a positive displacement foam concentrate pump,
which transfers foam concentrate from a storage tank to
each ILBP Module thru a foam concentrate main.

1-3.

A pressure sustaining valve in the foam concentrate


pump return line maintains constant pressure in the foam
concentrate main at all design flow rates. When pressure
in the foam concentrate main exceeds design, foam
concentrate is passed thru the pressure sustaining valve
back to the foam concentrate storage tank until system
design pressure is reestablished in the main. Manual
regulation of foam concentrate discharge pressure in the
main in the event of pressure sustaining valve failure is
possible thru the use of the bypass line and the Manual
Concentrate Regulating Valve. By adjusting the manual
regulating valve and reading the foam concentrate discharge pressure gauge, the foam concentrate design
discharge pressure can be maintained.
An ILBP System requires a fire water supply system
for the module(s).

GENERAL NOTES

1. All correspondence relating to this system shall refer to


the sales order number, file number and user name and
location.
2. Before installation is begun, the final plans and design
data should be presented to the authorities having
jurisdiction.
3. National Foam recommends that those individuals
charged with designing, installing, operating, testing
and maintaining a foam fire protection system, or the
replacement of equipment and/or components of an
existing system, 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.
4. National Foam concentrates must be maintained and
stored within certain specified temperatures, containers and conditions. Failure to follow National Foams

6/00

Some ILBP Systems also utilize a foam concentrate


jockey pump along with the main foam concentrate
pump. The jockey pump maintains pressure in the foam
concentrate lines to insure prompt foam solution supply
when the foam system is actuated. Pressure is maintained
by the use of an adjustable differential pressure switch low limit actuates the jockey pump and high limit shuts
it down.

guidelines regarding these concentrates can compromise their effectiveness. Refer to NF Storage Tank
Installation, Cleaning & Filling Instruction Manual P/
N:1298-9933-7 for recommendations.
5. The foam system provided is based on specific design
requirements, that is, products(s) being protected and
area(s) of coverage. The design requirements may or
may not have been provided to National Foam. Any
changes to the area(s) of coverage or additions of other
products could exceed the design parameters of the
system. Contact NF Engineering Dept. for questions
regarding changes to design.
6. Before operating the system, the foam concentrate
pump should be serviced in accordance with the
manufacturers installation and maintenance sheets and
the recommended start-up procedures outlined in this
manual.

1-3

INTRODUCTION

7. In accordance with the requirements of NFPA 11,


National Foam recommends that the system be inspected and tested by qualified personnel. Testing shall
meet the approval of the authority having jurisdiction,
and as a minimum, shall be as outlined in NFPA 11 to
insure that the system has been properly installed and
will function as intended.
8. All electrical installations and equipment must conform
to the provisions of the National Electrical Code and
also all local codes.
WARNING:
Judgement must be used in applying foams to hot oils,
burning asphalts or burning liquids which are above
the boiling point of water. Intermittent foam operation should be used to prevent violent frothing and
slop-over of the tank contents.
Foam is a conductor and shall not be used on energized electrical equipment fires.
Foams are not suitable extinguishing agents for fires
involving gases, liquefied gases with boiling points
below ambient temperatures such as butane, butadiene, propane, etc., or cryogenic liquids.

6/00

1-4

CHAPTER 2 - INST
ALL
ATION
INSTALL
ALLA

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 those
specified 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 NFPA
standards

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 entire
manual before using the equipment.

NOTE: COMPONENTS FOR


AN IN-LINE BALANCED PRESSURE PROPORTIONING SYSTEM
Products manufactured by NF are warranted free of defects in materials and workmanship for
twelve months from the date of purchase. NF will pass on to the system owner, as far as it is
able to do, the benefit of 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 makes no warranty, either expressed or implied and assumes no responsibility on
the engineering and design of such systems.

6/00

2-1

INSTALLATION

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.

A. With Synthetic Based Polar Solvent/AFFF and


Conventional AFFF Foam Concentrates
1. Piping:

Brass or Bronze (Note: All foam concentrate 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 foam
concentrate

B. With Protein-Based Foam Concentrates

1. Piping:

2. Valves:

2. Valves:

Brass or Bronze. Cast brass valves fitted


with stainless steel (304L or 316 grades) or
brass trim are acceptable. Teflon seats and
packing are preferable for foam concentrate
service. EPT (EPDM), Buna-N or Viton are
also acceptable seal materials for use with
NF foam concentrates.
Stainless Steel 304L or 316 grades

6/00

Stainless Steel 304L or 316 grades


High Density Cross Linked Polyethylene
Fiberglass with isophthalic based polyester
and an internal layer (50-100 mils minimum)
of vinyl ester resin in contact with foam
concentrate

Brass or Bronze. Cast brass valves fitted


with stainless steel (304L or 316 grades) or
brass trim are acceptable. Teflon seats and
packing are preferable for foam concentrate
service. EPT (EPDM), Buna-N or Viton are
also acceptable seal materials for use with
NF foam concentrates.

3. Storage Tanks:

3. Storage Tanks:

Same materials as Synthetic Based Polar


Solvent/AFFF and Conventional AFFF Foam
Concentrate with the exception of stainless
steel
Black steel pipe and malleable iron fittings

Steel
Same materials as Synthetic Based Polar
Solvent/AFFF and Conventional AFFF Foam
Concentrate with the exception of stainless
steel.

2-2

6/00

2-3

850(3218)

850(3218)

0.3(.02)
0.3(.02)

5000(18927)

*4000(15141)

0.3(.02)

0.3(.02)

0.3(.02)

0.3(.02)

MIN. FLOW

20(1.37)

20(1.37)

19.5(1.34)

19.5(1.34)

19.5(1.34)

10.5(.72)

MAX. FLOW

PRESSURE LOSS **
PSI (BAR)

"B"

Percent Proportioning

"C" Contractor Model

Ratio Controller Style - "W" Wafer Style

Material of Construction - "B" Brass

Controller Pipe Size

FOAM CONCENTRATE
INLET CONNECTION

"C"

PRESSURE GAUGE

FOAM CONCENTRATE
SUPPLY VALVE "V"
(NORMALLY CLOSED)

P/A/U

"E"

FOAM
CONCENTRATE
FLUSH-OUT
VALVE "R"

WATER FLUSH-OUT
VALVE "P"

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

22-11/16(576)

"G"
(Ref.)

164(74)

MATERIALS OF CONSTRUCTION
Component Description
Material
Diaphragm Valve
Brass & Stainless Steel
Ratio Controller
Brass
Ball Valve
Brass & Stainless Steel
with Teflon Seals
Pipe and Fittings
Brass
Hose
Braided Stainless Steel
over Teflon Tube

DUPLEX GAUGE
WATER FLUSH-OUT
VALVE "M"

DUPLEX GAUGE
FOAM CONCENTRATE
FLUSH-OUT VALVE "N"

DUPLEX GAUGE

11(279)

FIGURE 2-1
IN-LINE BALANCED PRESSURE PROPORTIONER MODULE
3" - 8" WAFER STYLE WITH MANUAL OVERRIDE

Manual Override

150# ANSI BOLTED


FLANGES BY OTHERS
(SAME NOMINAL PIPE SIZE
AS RATIO CONTROLLER)

Foam Concentrate
- P - Protein
- U - Universal
- UG - Universal Gold
- A - AFFF

MOR

"D"
"F"

SOLUTION
FLOW

SCH. 40 PIPING BY OTHERS


(SAME NOMINAL SIZE
AS RATIO CONTROLLER)

BUSHING
CHECK VALVE

MANUAL OVERRIDE KNOB


(NORMALLY IN FULLY
OPEN POSITION)

MODEL NUMBER IDENTIFICATION

"A"

WATER
FLOW

BODY
DRAIN PLUG

DIAPHRAGM
BALANCING
VALVE

2-1/2(64)

164(74)

22-11/16(576)
11(279)

2-1/2(64)

1-3/4(44)

2(51)

12-1/4(311)

22(559)
1-3/4(44)

109(49)

21-15/16(557)

10-3/8(264)

2-3/8(60)

1-5/8(41)

2(51)

11-9/16(294)

21-7/8(556)

2(51)

94(43)

21-1/8(537)

10-3/8(264)

2-3/8(60)

1-5/8(41)

1-1/2(38)

11-1/8(283)

18-7/8(479)

12-9/16(319)

84(38)

20-1/8(511)

8-1/32(204)

1-31/32(50)

1-7/32(31)

1-1/2(38)

10-1/8(257)

19-1/4(489)

23-3/8(594)

74(34)

19-3/4(502)

4-13/16(122)

1-11/16(43)

1-3/16(30)

1-1/2(38)

APPROX.
WEIGHT
LBS (KGS)

9-3/4(248)

TABLE OF DIMENSIONS
INCHES (MILLIMETERS)
D
E

19-9/16(497)

* - 8 INCH PROPORTIONER RESTRICTED TO 4000 GPM (15141 LPM) FOR 6% PROPORTIONING.


** -ALL DATA BASED ON 3% PROPORTIONING, FOR 6% MULTIPLY BY 1.19.

6%

*8

2500(9463)

300(1136)

6%

1% & 3%

*8

2500(9463)

300(1136)

1% & 3%

1200(4542)

150 (568)

1%, 3% & 6%

450(1703)

70(265)

3% & 6%

3% SYSTEM
SOLUTION CAPACITIES **
GPM (LPM)
MINIMUM
MAXIMUM

NOMINAL
PERCENTAGE
PIPE
SIZE

SPECIFICATIONS

6/00

2-4

"C" FOAM
CONCENTRATE
INLET
CONNECTION

"B"

0.3(.02)

*4000(15141)

Percent Proportioning

"C" Contractor Model

"A"

WATER
FLOW

BODY
DRAIN PLUG

P/A/U

"F"

"D"

SCH. 40 PIPING
BY OTHERS
(SAME NOMINAL
SIZE AS RATIO
CONTROLLER)

1-3/4(44)

18-5/16(465)

164(74)

"G"

Pipe and Fittings


Hose

Component Description
Diaphragm Valve
Ratio Controller
Ball Valve

Material
Brass & Stainless Steel
Brass
Brass & Stainless Steel
with Teflon Seals
Brass
Braided Stainless Steel
over Teflon Tube

MATERIALS OF CONSTRUCTION

(Ref.)

FIGURE 2-2
IN-LINE BALANCED PRESSURE PROPORTIONER MODULE
3" - 8" WAFER STYLE WITHOUT MANUAL OVERRIDE

150# ANSI BOLTED


FLANGES BY OTHERS
(SAME NOMINAL PIPE SIZE
AS RATIO CONTROLLER)

FOAM
CONCENTRATE
FLUSH-OUT
VALVE "R"

WATER
FLUSH-OUT
VALVE "P"

SOLUTION
FLOW

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

Foam Concentrate
- P - Protein
- U - Universal
- UG - Universal Gold
- A - AFFF

"E"

2(51)

* - 8 INCH PROPORTIONER RESTRICTED TO 4000 GPM (15141 LPM) FOR 6% PROPORTIONING.


** -ALL DATA BASED ON 3% PROPORTIONING, FOR 6% MULTIPLY BY 1.19.

12-9/16(319)

BUSHING CHECK VALVE

23-3/8(594)

11(279)

164(74)

11(279)

2-1/2(64)

1-3/4(44)

2(51)
2-1/2(64)

109(49)

17-5/8(448)
18-5/16(465)

10-3/8(264)

2-3/8(60)

1-5/8(41)

2(51)

12-1/4(311)

22(559)

11-9/16(294)

21-7/8(556)

94(43)

16-3/4(425)

10-3/8(264)

2-3/8(60)

1-5/8(41)

1-1/2(38)

11-1/8(283)

18-7/8(479)

84(38)

15-3/4(400)

8-1/32(204)

1-31/32(50)

1-7/32(31)

1-1/2(38)

10-1/8(257)

19-1/4(489)

74(34)

15-3/8(391)

4-13/16(122)

1-11/16(43)

1-3/16(30)

1-1/2(38)

9-3/4(248)

19-9/16(497)

WEIGHT
LBS (KGS)
G

TABLE OF DIMENSIONS
INCHES (MILLIMETERS)
D
E

DIAPHRAGM
BALANCING VALVE

20(1.37)

20(1.37)

19.5(1.34)

19.5(1.34)

19.5(1.34)

10.5(.72)

MODEL NUMBER IDENTIFICATION

Ratio Controller Style - "W" Wafer Style

Material of Construction - "B" Brass

Controller Pipe Size

0.3(.02)

5000(18927)

0.3(.02)

0.3(.02)

0.3(.02)

0.3(.02)

MAX. FLOW

PRESSURE LOSS **
PSI (BAR)
MIN. FLOW

FOAM CONCENTRATE SUPPLY


VALVE "V" (NORMALLY CLOSED)

850(3218)

850(3218)

PRESSURE
GAUGE

6%

*8

2500(9463)

300(1136)

6%

1% & 3%

*8

2500(9463)

300(1136)

1% & 3%

1200(4542)

150 (568)

1%, 3% & 6%

450(1703)

70(265)

3% & 6%

3% SYSTEM
SOLUTION CAPACITIES **
GPM (LPM)
MINIMUM
MAXIMUM

NOMINAL
PERCENTAGE
PIPE
SIZE

SPECIFICATIONS

6/00

2-5

0.3(.02)

*5000(18927)

850(3218)

* 8*
3-1/2(89)

3-1/16(78)

3(76)
22(559)
23-3/4(603)
26-1/4(667)

6" 150#
FLAT FACE
8" 150#
FLAT FACE

13-1/2(343)

12-3/4(324)

F1/4

Brass
Brass

Brass
Braided Stainless Steel

Ratio Controller
Pipe

Pittings (Pipe)
Hose

over Teflon Tube

Brass & Stainless Steel


Brass & Teflon

Diaphragm Valve
Ball Valve

Component Description Material

MATERIALS OF CONSTRUCTION

RCF2-3.DSF
RCF2-3.P65

FOAM CONCENTRATE
SUPPLY
"H"

PRESSURE GAUGE

FOAM CONCENTRATE SUPPLY VALVE "V"


(NORMALLY CLOSED)

A1/4

WATER
FLOW

DIAPHRAGM BALANCING VALVE

B
C

"D" FLANGE
PER ANSI B16.5

DRAIN/FLUSH-OUT
VALVES - TYPICAL
5 PLACES

G1/4

12-3/4(324)

11(279)

9-1/2(241)

8(203)

7-1/2(191)

12-3/4(324)

12-3/4(324)

12(305)

12(305)

12(305)

2 NPT

2 NPT

1-1/2 NPT

1-1/2 NPT

1-1/2 NPT

220(100)

145(66)

110(50)

90(41)

75(34)

WEIGHT
LBS (KGS)

FIGURE 2-3
IN-LINE BALANCED PRESSURE PROPORTIONER MODULE
2" - 8" FLANGED STYLE

FLOW

SOLUTION

- DUPLEX GAUGE RED NEEDLE - FOAM


BLACK NEEDLE - WATER
DUAL SCALE ENGLISH
AND METRIC

MANUAL OVERRIDE HANDWHEEL


(NORMALLY IN FULL OPEN POSITION)

E1/4

20-1/2(521)

4" 150#
FLAT FACE

6-1/2(165)
10(254)

19-3/4(502)

3" 150#
FLAT FACE

D
2" 150#
FLAT FACE

TABLE OF DIMENSIONS
INCHES (MILLIMETERS)

9-5/8(244)

* - 8 INCH PROPORTIONER RESTRICTED TO 4000 GPM (15141 LPM) FOR 6% PROPORTIONING.


** - ALL DATA BASED ON 3% INJECTION, FOR PRESSURE LOSSES FOR 6% INJECTION, MULTIPLY BY 1.19.

18-1/4(464)

18-11/16(475)

19.5(1.34)

0.3(.02)

2500(9463)

300(1136)

6
20(1.37)

15-1/4(387)

0.3(.02)

2(51)

16-1/4(413)

10.5(.72)
19.5(1.34)

0.3(.02)

450(1703)

1200(4542)

70(265)

150 (568)

2-9/16(65)

15-11/16(398)

14(.97)

0.5 .03)

180(681)

PRESSURE LOSS**
PSI (BAR)
MINIMUM MAXIMUM

30(114)

SOLUTION CAPACITIES
PSI (BAR)
MINIMUM
MAXIMUM

NOMINAL
PIPE
SIZE

SPECIFICATIONS

INSTALLATION

2-2.

INSTALLATION AND START-UP:


IN-LINE BALANCED PRESSURE PROPORTIONING SKID PAK

NOTE: Refer to your particular ILBP proportioning


system skid pak outline drawing for as-built dimensions
and the location of various system components.
A. Site Selection:
1. The module shall be located on a flat and level
surface large enough to support the entire skid
frame.
2. The preferred base is concrete.

4. A relief valve has been installed in the foam concentrate discharge line downstream of the Foam Concentrate Discharge Valve "D" and discharge check
valve, with the relief valve discharge piped to the
foam concentrate return line downstream of the
pressure sustaining valve. This valve is intended to
relieve excess foam concentrate discharge line pressure. The relief valve is preset at the factory and
needs no adjustment.
5. Flush the foam concentrate piping before introducing foam concentrate into the foam system.

B. Off Loading:
1. Do not move the module using piping or installed
equipment as a lifting device. Use a crane or
other suitable lifting apparatus to move the module. Lift with a fork truck from the underside of
the module frame.
C. Installation:
1. The skid shall be suitably anchored to eliminate
vibration and movement. Level and shim as
necessary. NF recommends a clear distance of 2
ft. (0.6096 m) on the pump end and 3 ft. (0.9144
m) on the drive end be allowed by the installer to
facilitate service/removal of the pump and motor.
2. All interconnecting piping to and from the module must be self-supported. Plastic foam concentrate storage tanks must have flexible connection
fittings installed between the tank and proportioning equipment to eliminate stress imposed by
the piping and to eliminate vibration.
3. NF hydrostatically tests all skid units before
they leave our factory. However, due to vibration and handling experienced during transit, the
tightness of joints and connections on the skid
cannot be guaranteed. Therefore, NF recommends that the installer hydrostatically test the
skid piping in accordance with procedures outlined in the latest edition of the applicable section
of NFPA, before introducing foam concentrate
into the system.

6/05

6. Flush the Pump and Pressure Sustaining Module


before introducing foam concentrate into the system.
Refer to Chapter 4, Sect. 4-14 for flushing procedures.
7. Flush the water lines and all foam solution lines. The
foam solution lines shall be flushed at or above
design flow rates. The flushing shall be done prior to
installing any foam makers, sprinklers or nozzles.
NOTE: In order to remove foreign materials that
may have entered during installation, water supply
mains, both underground and aboveground, shall be
flushed thoroughly at the maximum practicable rate
of flow before connection is made to system piping.
The minimum rate of flow for flushing shall not be
less than the water demand rate of the system, as
determined by the system design. The flow shall be
continued for a sufficient time to ensure thorough
cleaning. Disposal of flushing water must be suitably arranged. All foam system piping shall be
flushed after installation, using its normal water
supply with foam-forming materials shut off, unless
the hazard cannot be subjected to water flow. Where
flushing cannot be accomplished, pipe interiors shall
be carefully visually examined for cleanliness during
installation.
8. After flushing, remove all strainer screens and clean.
Reinstall screens after cleaning.
NOTE: Proportioning system strainer mesh shall
have 1/4" openings for Universal foam concentrates
and 1/8" openings for all other foam concentrates.

2-6

INSTALLATION

9. Check that the system is properly installed according


to design with all necessary valves, correct pipe
sizes, discharge devices and discharge device locations and is installed in compliance with local codes.
10. Service foam concentrate pump before installation
into the system. Service pump, reducer and motor
in accordance with the manufacturers recommendations. Be sure that the reducer is filled with oil and
the pump and motor are lubricated. The pump body
is coated with a petroleum based rust preventative
for protection during shipment. The pump drain plug
must be removed, any excess liquid drained and the
plug reinstalled. The pump must then be flushed
with mineral spirits for approximately five (5) minutes and then drained. Finally, it must be flushed
with water. Always rotate the pump by hand to be
sure it turns freely before start up. Never start up the
pump when it is dry. (This applies to jockey pump
also).
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 motor


shafts to insure they are within the coupling
manufacturers recommended tolerances. (This applies to jockey pump also).
12. Check the foam concentrate pump motor and controller to insure it is wired properly. (This applies to
jockey pump also).
13. Check the motor rotation to insure it is running in the
correct direction to allow proper foam concentrate
pump rotation. "Bump" run the motor(and pump) by
alternately actuating the "ON" and "OFF" buttons
until the direction of rotation is determined. Correct
if necessary. (This applies to jockey pump also).

14. If the pump is driven by a gasoline or diesel engine,


refer to the manufacturers installation and start-up
instructions prior to using the pump.
15. If the foam concentrate pump is driven by a gasoline
or diesel engine, anti-vibration connections must be
installed in the foam concentrate line on both the inlet
and outlet sides of the pump. Also, anti-vibration
fittings must be installed on the foam concentrate
pump base if the base is skid mounted.
16. Cycle all valves to insure freedom of movement and
that they open and close properly.
17. Place all valves in their stand-by position. Refer to
Normal Stand-By Valve Position Chart on Operating Schematic Dwg. Fig. 3-1, 3-2 or 3-3.
18. It may be desirable to install shutoff valves between
the foam concentrate storage tank and the flexible
connections in addition to Valves A & B, which may
be on the module. These valves will be useful if the
foam concentrate piping has to be broken for repairs
between the tank and module. The shutoff valves can
be closed, thereby eliminating the need to drain the
tank before making repairs.
19. Install, clean and fill the foam concentrate storage
tank in accordance with the manufacturer's recommended procedures. NOTE: Regarding NF Storage
Tanks - Refer to NF Storage Tank Installation,
Cleaning & Filling Instruction Manual, P/N: 12989933-7 for recommendations.
20. Fill the foam concentrate piping with foam concentrate.
21. If applicable, check the foam concentrate pump
relief valve for proper installation. See manufacturers
instructions. (This applies to jockey pump also).
22. Run a foam concentrate pump relief valve pressure
setting check as follows (This applies to jockey
pump also):
a. Starting with all valves in their normal stand-by
position, close Valves "D" and "E" and open
Valve "C".
continued on next page

6/05

2-7

INSTALLATION

b. Start foam concentrate pump - concentrate will


recirculate back to foam concentrate storage
tank.
c. Slowly close Valve "C" and observe the pointer
on the pressure gauge until it shows a sudden
decrease. This will indicate opening of relief
valve. Adjust setting if required. Refer to the
Foam Concentrate Pump Outline Assembly
Drawing for relief valve pressure setting.
d. Return all valves to their normal stand-by position.
23. Run a pressure sustaining valve pressure setting
check as follows:

2-3.

a. Starting with all valves in their normal stand-by


position, close Valve "D".
b. Start foam concentrate pump - concentrate will
recirculate back to foam concentrate storage
tank.
c. Observe the pointer on the pressure gauge for
proper system operating pressure. Adjust setting, if required, according to the manufacturer's
instructions or recommendations.
24. Place all valves in their normal stand-by position.
See Normal Stand-By Valve Position Chart on Operating Schematic Dwg. Fig. 3-1, 3-2 or 3-3. Proceed with full system test as described in Section 25, Testing After Installation, in this manual.

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 be
chained or locked in the open position or equipped with tamper alarm switch(es) which are monitored by a
supervisory panel alarm.
The major concern is the possibility that any manually operated valve(s) in the foam solution line to the
hazard(s) could inadvertently be left in the closed position during a fire condition, which would prevent the foam
solution 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 is
not properly secured in the lifting device, damage to the module or injury to personnel could result.
1. To avoid damage, the module should be left in
its shipping carton or crate until time of installation into foam system.

2. Use a nylon lifting strap, secured around the ratio


controller body, to move or mount the module.

continued on next page

6/05

2-8

INSTALLATION

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 and
connect the foam concentrate supply piping to
the module. ILBP modules can be mounted in
either a horizontal or vertical orientation.
2. All interconnecting piping to and from the ILBP
Module (that is - foam concentrate supply piping, watermain piping and foam solution piping)
must be self-supporting so as to eliminate any
load on the module itself.
3. To facilitate future service/removal of the ratio
controller, the installer should provide a spool
piece upstream of the ratio controller. See Chart
below 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
of straight unobstructed upstream and downstream watermain piping to obtain proper flow
through the ratio controller.
CAUTION:
The ILBP Module requires a stable, uniform
water flow at the inlet to the ratio controller to
insure proper proportion ing during all rated
flow conditions.

6. Regarding only ILBP Module(s) that have a diaphragm valve with manual override capability:
If the module is used with an Automatic Zone Foam
Concentrate Supply Valve, the Manual Foam Concentrate Supply Valve "V" is still required for manual
override pressure regulation. Refer to Operating
Schematic Dwg. Fig. 3-1 or Fig. 3-3 for valve
locations and normal stand-by position.
7. Cycle all valves to insure freedom of movement and
that they open and close properly.
8. For NF recommended components - valves, strainers, gauges and connections, and their location in the
system, refer to the Operating Schematic Drawing
Fig. 3-1, 3-2 or 3-3.
9. Check that the system is properly installed according
to design with all necessary valves, correct pipe
sizes, discharge devices and discharge device locations, and is installed in compliance with local codes.
10. Hydrostatically test piping in accordance with procedures outlined in the latest edition of the applicable
section of NFPA.
11. Flush the foam concentrate piping before introducing foam concentrate into the foam system.
12. Follow the procedures outlined in Section 2-2., C.
Installation, Item Nos. 7 and 8. Refer to System
Flushing procedures outlined in Sect. 4-15.

5. Regarding only RCF style ILBP modules:


A check valve must be placed in the foam concentrate line directly upstream of each
proportioner module.

6/05

13. Place all valves to their normal stand-by position.


See Normal Stand-By Valve Position Chart on Operating Schematic Dwg. Fig. 3-1, 3-2 or 3-3. Proceed with full system test as described in Section 25, Testing After Installation in this manual.

2-9

INSTALLATION

C. Operating Requirements:
1. Foam concentrate pressure to the ILBP Module
inlet must exceed water pressure inlet by at least
30 psi (2.0 Bar) unless otherwise approved by
NF Engineering Department.
2. ILBP Module maximum working pressure - 200
psi(13.7 Bar).
3. Regarding only ILBP Module(s) that have a
diaphragm valve with manual override capability:

The Manual Override Handwheel on the diaphragm valve must be in the normal stand-by

position for automatic balancing. To place in the


normal stand-by position: rotate the manual
override handle in the counter-clockwise direction until fully open.

Check the appropriate sensing line valve(s)


(Valves "J", "L" or "K") to insure that it is in the
proper stand-by position (Normally Open).

4. Insure that all valves are in their normal stand-by


position before operating the proportioning system.
See Normal Stand-By Valve Position Chart on Operating Schematic Dwg. Fig. 3-1, 3-2 or 3-3.

2-4. INSTALLATION AND START-UP: PUMP AND PRESSURE SUSTAINING VALVE


SUPPLIED AS LOOSE COMPONENTS
NOTE: When equipment is supplied as loose components, refer to the individual component's manual for
installation instructions. For questions regarding these components, contact NF Engineering Dept.
For NF recommended components - valves, strainers, gauges, pumps and connections and their
location 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 the
maximum system design requirements. To ensure positive injection, the discharge pressure
rating at design discharge capacity shall be sufficiently in excess of the maximum water pressure likely under any condition at the point of
injection of the concentrate.
2. The foam concentrate pump shall be mounted as
near to and level with, or lower than, the bottom
of the foam concentrate tank.
3. The module shall be located on a flat and level
surface large enough to support the entire skid
frame. The preferred base is concrete.

6/05

4. The foam concentrate pump shall be suitably anchored to eliminate vibration and movement. Level
and 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 pump
relief valve for proper installation. See manufacturer's
instructions.
7. Run a foam concentrate pump relief valve pressure
setting check as described in Section 2-2., C. Installation, Item No. 22. NOTE: NF foam concentrate
pump relief valves are factory set at 200 psi (standard). For a relief valve pressure setting other than
standard, refer to the pump outline drawing or contact NF Engineering.

2-10

INSTALLATION

B. Pressure Sustaining Valve:


1. Refer to manufacturer's instructions before attempting to install the Pressure Sustaining Valve
into your system.
2. The Pressure Sustaining Valve can be mounted
in either a horizontal or vertical orientation.
3. The Pressure Sustaining Valve shall be mounted
as near as possible to the foam concentrate pump
and storage tank.

4. Install a Pressure Sustaining Valve bypass line as


illustrated in Fig. 3-1, 3-2 or 3-3. In the event of a
Pressure Sustaining Valve failure, the bypass line
must have a manual foam concentrate regulating
valve to allow manual regulation of the foam concentrate discharge pressure to the foam concentrate
main.
5. Run a pressure sustaining valve pressure setting
check as described in Section 2-2., C. Installation,
Item No. 23.

C. General System:
1. A check valve (customer supplied) must be
installed in the foam concentrate piping main
downstream of the Pump and Pressure Sustaining Module foam concentrate discharge connection. Refer to Operating Schematic Dwg. Fig.31 or 3-2 for location.
2. A 3/4" relief valve is required in the foam
concentrate piping main. The relief valve shall be
installed downstream of the check valve referred to
in item 1. The discharge from the relief valve shall
be piped to the foam concentrate return line downstream of the pressure sustaining valve. Refer to
Operating Schematic Dwg. Fig. 3-1, 3-2 or 3-3 for
location in the system.
3. All interconnecting piping to and from the components must be self-supported. Plastic foam
concentrate storage tanks must have flexible
connection fittings installed between the tank
and proportioning equipment to eliminate stress
imposed by the piping and to eliminate vibration.
4. Hydrostatically test piping in accordance with
procedures outlined in the latest edition of the
applicable section of NFPA.
5. Follow the procedures outlined in Section 2-2.,
C. Installation, Item Nos. 5 thru 9. Refer to
System Flushing procedures outlined in Sect. 414.

6/05

6. Refer to Sect. 2-2.C., item 18 - When the system is


supplied as loose components, it may be desirable to
position Valves A and B at the foam concentrate
storage tank, between the tank and the flexible connections. This may eliminate the need for Valves A
and B plus shutoff valves in the suction and return
piping. However, the need for Valves A and B in
place of tank shutoff valves will have to be evaluated
on an individual system design basis. For questions
or problems, contact NF Engineering Dept.
7. Install, clean and fill the foam concentrate storage
tank in accordance with the manufacturer's recommended procedures. NOTE: Regarding NF Storage
Tanks - Refer to NF Storage Tank Installation,
Cleaning & Filling Instruction Manual, P/N: 12989933-7 for recommendations.
8. Fill the foam concentrate piping with foam concentrate.
9. Cycle all manual and automatic valves to insure
freedom of movement and that they open and close
properly.
10. Place all valves in their normal stand-by position.
See Normal Stand-By Valve Position Chart on Operating Schematic Drawing Fig. 3-1, 3-2 or 3-3.
Proceed with full system test as described in Sect. 25, Testing After Installation, in this manual.

2-11

INSTALLATION

D. Foam Concentrate Jockey Pump:

1. Refer to Operating Schematic Drawing Fig. 3-1,


3-2 or 3-3 for location of jockey pump and
pressure switches in the system.
2. Refer to Sect. 2-4.A. - Foam Concentrate Pump,
and follow installation instructions items 2 thru
5.

2-5.

CAUTION:
The pressure switch must have the high limit
jockey pump shutoff point set below the system
design discharge pressure.

TESTING AFTER INSTALLATION

1. The completed system shall be tested by qualified personnel to meet the approval of the authority having jurisdiction. These tests shall be adequate to determine that the system has been
properly installed, and will function as intended.
2. Foam systems shall be examined visually to
determine that they have been properly installed.
They shall be inspected for such items as conformity with installation plans; continuity of piping; removal of temporary blinds; accessibility
of valves; controls, and gages; and proper installation of vapor seals, where applicable. Devices
shall be checked for proper identification and
operating instructions.
3. Before acceptance, all operating devices and
equipment shall be tested for proper function.
4. A full scale test shall be run after the system is

6/05

3. Install the adjustable differential pressure switch.


Set the desired high and low pressure limits on the
pressure switch. Refer to manufacturer's instructions.

installed and prior to acceptance of the system.The


test run shall include running water to each discharge
device to insure that proper pressures and flow rates
can be achieved and to insure there is no blockage.
Then foam solution shall be run to the devices
protecting the greatest single hazard and to the
device with the lowest flow rate. The foam test shall
last a minimum of 1 minute (actual injection time) to
insure the proportioning system has stabilized before
taking samples. At this time, the quality of the foam
shall be observed and the foam solution concentration shall be checked by refractive index or conductivity method. The foam test shall be run for each
ratio controller when multiple proportioners are
present in the system. See NFPA 11 for detailed
procedures.
5. After completion of acceptance tests, the system
shall be flushed and restored to operational condition.

2-12

6/00

3-1

DESIGNATION

MANUAL

MANUAL FOAM CONC. REGULATING VALVE

FOAM CONCENTRATE DISCHARGE VALVE

FOAM CONCENTRATE PRESSURE

FLUSH-OUT CONNECTION

STRAINER FLUSH-OUT

B2

FOAM CONCENTRATE TANK SUCTION

CLOSED

OPEN

CLOSED

CLOSED

CLOSED

CLOSED

OPEN

OPEN

CLOSED

OPEN

OPEN

DUPLEX GAUGE FOAM CONC. FLUSH-OUT

DIAPHRAGM VALVE WATER FLUSH-OUT

DIAPHRAGM VALVE CONC. FLUSH-OUT

FOAM CONCENTRATE SUPPLY VALVE

WATER LINE

PRESSURE SUSTAINING VALVE

CHECK VALVE

OVERRIDE

AUTOMATED VALVE W/MANUAL

BALL VALVE (N.C.)

BALL VALVE (N.O.)

RCW RATIO CONTROLLER

SENSING LINE

FOAM CONCENTRATE LINE

COMPONENTS PROVIDED BY NF

LEGEND

BODY DRAIN PLUG

DUPLEX GAUGE WATER FLUSH-OUT

TO DIAPHRAGM VALVE

WATER SENSING LINE SHUT-OFF VALVE

CLOSED

OPEN

OPEN

CLOSED

CLOSED

CLOSED

OPEN

OPEN

OPEN

CLOSED

CLOSED

CLOSED

CLOSED

OPEN

OPEN

CLOSED

OPEN

OPEN

AUTO.

PRESSURE SWITCH

Closed

Open

Open

Wet
System

OU
ND

CO
MP

GA
UG
E

(M

AUXILIARY
FOAM CONCENTRATE
PUMP
(OPTIONAL)

ANTI-VIBRATION
FLEXIBLE COUPLING

BODY
DRAIN
PLUG

NT
OU

SEE NOTE NO. 6

B2

B1

SEE NOTE NO. 4

SEE NOTE NO. 5

PRESSURE
GAUGE

FIG3-123.P65
FIG3-1.DSF

SEE NOTE NO. 4

PRIMARY
FOAM CONCENTRATE
PUMP

WA
SU TER
PP
LY

MAIN WATER
SUPPLY VALVE

WATER PUMP
(IF REQUIRED)

SEE NOTE NO. 2

SEE NOTE NO. 1

PRESSURE
SUSTAINING
VALVE

MANUAL OVERRIDE
HANDWHEEL

JOCKEY PUMP
(OPTIONAL)

T)
RU
ST
NINU
O
D

R
TE
AR
ST

SEE NOTE NO. 3

FIG. 3-1 OPERATING SCHEMATIC DRAWING


RCW ILBP MODULE WITH MANUAL OVERRIDE

Closed

Closed

Zone Water Valve(s)


Zone Foam Conc. Valve(s)

Closed

Dry
System

FIELD
CONNECTIONS
(Typical)

System Water Main Valve(s)

Field Piping

FLEXIBLE
EXPANSION JOINT

SO FOA
LU M
TIO
N

DRAIN CONNECTION

FILL CONNECTION

INSPECTION HATCH

PRESSURE VACUUM VENT

ILBP MODULE
SCHEMATIC
- TYPICAL -

FOAM CONCENTRATE STORAGE TANK

6. Location of "D" Valve with auxiliary foam concentrate pump.

5. Standard location of "D" Valve (no auxiliary foam conc.


pump).

4. Supplied with Auxiliary Foam Concentrate Pump only.

3. Position of Zone Water Supply Valve.


Automatic valve optional.
Manual valve required if automatic valve not supplied.

2. Position of Zone Foam Concentrate Valve.


Automatic valve optional.

1. Valve "V" - Normally CLOSED for systems using no


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

The schematics shown are typical installations and may not


reflect actual equipment furnished.

NOTES:

FLUSH-OUT CONNECTION

FLUSH-IN CONNECTION

DIAPHRAGM VALVE

COMPOUND GAUGE

PRESSURE GAUGE

DUPLEX GAUGE

STRAINER

RELIEF VALVE

CLOSED

CLOSED

CLOSED

CLOSED

CLOSED

CLOSED

OPEN

IN-LINE BALANCED PRESSURE PROPORTIONING MODULE

(AUXILIARY PUMP)

(PRIMARY PUMP)

B1

FOAM CONCENTRATE TANK SUCTION

DRAIN VALVES

FLUSH-IN CONNECTION

SUSTAINING VALVE SHUT-OFF VALVE

FOAM CONCENTRATE TANK SUCTION

FOAM CONCENTRATE TANK RETURN

PUMP AND PRESSURE SUSTAINING VALVE MODULE

VALVE DESCRIPTION

POSITION

NORMAL STAND-BY VALVE POSITION CHART

6/00

3-2

DESIGNATION

MANUAL

FOAM CONCENTRATE TANK SUCTION

MANUAL FOAM CONC. REGULATING VALVE

FOAM CONCENTRATE DISCHARGE VALVE

FOAM CONCENTRATE PRESSURE

FLUSH-OUT CONNECTION

STRAINER FLUSH-OUT

B2

FOAM CONCENTRATE TANK SUCTION

CLOSED

OPEN

CLOSED

CLOSED

CLOSED

CLOSED

OPEN

OPEN

CLOSED

OPEN

OPEN

DIAPHRAGM VALVE CONC. FLUSH-OUT

FOAM CONCENTRATE SUPPLY VALVE

WATER LINE

PRESSURE SUSTAINING VALVE

CHECK VALVE

OVERRIDE

AUTOMATED VALVE W/MANUAL

BALL VALVE (N.C.)

BALL VALVE (N.O.)

RCW RATIO CONTROLLER

SENSING LINE

FOAM CONCENTRATE LINE

COMPONENTS PROVIDED BY NF

LEGEND

BODY DRAIN PLUG

DIAPHRAGM VALVE WATER FLUSH-OUT

CLOSED

OPEN

CLOSED

CLOSED

OPEN

OPEN

CLOSED

CLOSED

CLOSED

CLOSED

OPEN

OPEN

CLOSED

OPEN

OPEN

AUTO.

PRESSURE SWITCH

Closed

Open

Open

Wet
System

B
S

AU
GE

MP
OU
ND
G

CO

AUXILIARY
FOAM CONCENTRATE
PUMP
(OPTIONAL)

BODY
DRAIN
PLUG

P
V

SEE NOTE NO. 6

B2

B1

SEE NOTE NO. 4

SEE NOTE NO. 5

PRESSURE
GAUGE

FIG3-123.P65
FIG3-2.DSF

SEE NOTE NO. 4

PRIMARY
FOAM CONCENTRATE
PUMP

WA
SU TER
PP
LY

MAIN WATER
SUPPLY VALVE

WATER PUMP
(IF REQUIRED)

SEE NOTE NO. 2

SEE NOTE NO. 1

PRESSURE
SUSTAINING
VALVE

JOCKEY PUMP
(OPTIONAL)

)
UT
TR
I-S
UN
ON
D
TE

R
TE
AR
ST

N
OU
(M

ANTI-VIBRATION
FLEXIBLE COUPLING

SEE NOTE NO. 3

FIG. 3-2 OPERATING SCHEMATIC DRAWING


RCW ILBP MODULE WITHOUT MANUAL OVERRIDE

Closed

Closed

Zone Water Valve(s)


Zone Foam Conc. Valve(s)

Closed

Dry
System

FIELD
CONNECTIONS
(Typical)

DRAIN CONNECTION

FILL CONNECTION

INSPECTION HATCH

PRESSURE VACUUM VENT

System Water Main Valve(s)

Field Piping

FLEXIBLE
EXPANSION JOINT

SO FOA
LU M
TIO
N

ILBP MODULE
SCHEMATIC
- TYPICAL -

FOAM CONCENTRATE STORAGE TANK

6. Location of "D" Valve with auxiliary foam concentrate pump.

5. Standard location of "D" Valve (no auxiliary foam conc.


pump).

4. Supplied with Auxiliary Foam Concentrate Pump only.

3. Position of Zone Water Supply Valve.


Automatic valve optional.
Manual valve required if automatic valve not supplied.

2. Position of Zone Foam Concentrate Valve.


Automatic valve optional.

1. Valve "V" - Normally CLOSED for systems using no


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

The schematics shown are typical installations and may not


reflect actual equipment furnished.

NOTES:

FLUSH-OUT CONNECTION

FLUSH-IN CONNECTION

DIAPHRAGM VALVE

COMPOUND GAUGE

PRESSURE GAUGE

DUPLEX GAUGE

STRAINER

RELIEF VALVE

CLOSED

CLOSED

CLOSED

CLOSED

IN-LINE BALANCED PRESSURE PROPORTIONING MODULE

(AUXILIARY PUMP)

(PRIMARY PUMP)

B1

FOAM CONCENTRATE TANK SUCTION

DRAIN VALVES

FLUSH-IN CONNECTION

SUSTAINING VALVE SHUT-OFF VALVE

FOAM CONCENTRATE TANK RETURN

PUMP AND PRESSURE SUSTAINING VALVE MODULE

VALVE DESCRIPTION

POSITION

NORMAL STAND-BY VALVE POSITION CHART

6/00

3-3

DESIGNATION

MANUAL

FOAM CONCENTRATE TANK SUCTION

MANUAL FOAM CONC. REGULATING VALVE

FOAM CONCENTRATE DISCHARGE VALVE

FOAM CONCENTRATE PRESSURE

STRAINER FLUSH-OUT

B2

CLOSED

OPEN

CLOSED

CLOSED

CLOSED

CLOSED

OPEN

OPEN

CLOSED

OPEN

OPEN

WATER SENSING LINE SHUT-OFF VALVE

FOAM CONCENTRATE SENSING LINE

DUPLEX GAUGE FOAM CONC. FLUSH-OUT

DIAPHRAGM VALVE WATER FLUSH-OUT

DIAPHRAGM VALVE CONC. FLUSH-OUT

FOAM CONCENTRATE SUPPLY VALVE

LOWER PETCOCK ON DIAPHRAGM VALVE

WATER LINE

PRESSURE SUSTAINING VALVE

CHECK VALVE

OVERRIDE

AUTOMATED VALVE W/MANUAL

BALL VALVE (N.C.)

BALL VALVE (N.O.)

RCF RATIO CONTROLLER

SENSING LINE

FOAM CONCENTRATE LINE

COMPONENTS PROVIDED BY NF

LEGEND

DUPLEX GAUGE WATER FLUSH-OUT

SHUT-OFF VALVE TO DIAPHRAGM VALVE

TO DIAPHRAGM VALVE

WATER SENSING LINE SUPPLY VALVE

CLOSED

OPEN

CLOSED

CLOSED

CLOSED

CLOSED

OPEN

OPEN

OPEN

OPEN

OPEN

CLOSED

CLOSED

CLOSED

CLOSED

OPEN

OPEN

CLOSED

OPEN

OPEN

AUTO.

PRESSURE SWITCH

Closed

Closed

Closed

Dry
System

Closed

Open

Open

Wet
System

FIELD
CONNECTIONS
(Typical)

CO
MP
OU
ND
GA
UG
E

AUXILIARY
FOAM CONCENTRATE
PUMP
(OPTIONAL)

SEE NOTE NO. 7

JOCKEY PUMP
(OPTIONAL)

B2

B1

SEE NOTE NO. 5

SEE NOTE NO. 6

PRESSURE
GAUGE

FIG3-123.P65
FIG3-3.DSF

SEE NOTE NO. 5

PRIMARY
FOAM CONCENTRATE
PUMP

WA
SU TER
PP
LY

MAIN WATER
SUPPLY VALVE

WATER PUMP
(IF REQUIRED)

SEE NOTE NO. 2

SEE NOTE NO. 4

SEE NOTE NO. 1

PRESSURE
SUSTAINING
VALVE

MANUAL OVERRIDE
HANDWHEEL

T)
RU
ST
NINU
O
D
TE

R
TE
AR
ST

N
OU
(M

ANTI-VIBRATION
FLEXIBLE COUPLING

SEE NOTE NO. 3

FIG. 3-3 OPERATING SCHEMATIC DRAWING


ILBP MODULE WITH MOR & RCF RATIO CONTROLLER

Zone Foam Conc. Valve(s)

Zone Water Valve(s)

System Water Main Valve(s)

Field Piping

FLEXIBLE
EXPANSION JOINT

SO FOA
LU M
TIO
N

DRAIN CONNECTION

FILL CONNECTION

INSPECTION HATCH

PRESSURE VACUUM VENT

ILBP MODULE
SCHEMATIC
- TYPICAL -

FOAM CONCENTRATE STORAGE TANK

7. Location of "D" Valve with auxiliary foam concentrate pump.

6. Standard location of "D" Valve (no auxiliary foam conc.


pump).

5. Supplied with Auxiliary Foam Concentrate Pump only.

4. A check valve must be installed in the foam concentrate line


directly upstream of each proportioner module.

3. Position of Zone Water Supply Valve.


Automatic valve optional.
Manual valve required if automatic valve not supplied.

2. Position of Zone Foam Concentrate Valve.


Automatic valve optional.

1. Valve "V" - Normally CLOSED for systems using no


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

The schematics shown are typical installations and may not


reflect actual equipment furnished.

NOTES:

FLUSH-OUT CONNECTION

FLUSH-IN CONNECTION

DIAPHRAGM VALVE

COMPOUND GAUGE

PRESSURE GAUGE

DUPLEX GAUGE

STRAINER

RELIEF VALVE

CLOSED

CLOSED

CLOSED

CLOSED

CLOSED

CLOSED

OPEN

OPEN

OPEN

IN-LINE BALANCED PRESSURE PROPORTIONING MODULE

(AUXILIARY PUMP)

FOAM CONCENTRATE TANK SUCTION

(PRIMARY PUMP)

FOAM CONCENTRATE TANK SUCTION

B1

FLUSH-OUT CONNECTION

DRAIN VALVES

FLUSH-IN CONNECTION

SUSTAINING VALVE SHUT-OFF VALVE

FOAM CONCENTRATE TANK RETURN

PUMP AND PRESSURE SUSTAINING VALVE MODULE

VALVE DESCRIPTION

POSITION

NORMAL STAND-BY VALVE POSITION CHART

CHAPTER 3 - OPERA
TING PROCEDURES
OPERATING

3-1.

MINIMUM INLET PRESSURE REQUIREMENTS


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

BAR/PSI

WATER INLET PRESSURE (PSI/BAR)

3" RCF/RCW

2" RCT

6.9/100
6.2/90

4" RCF/RCW

6" RCF/RCW

8" RCF/RCW

5.5/80
4.8/70
4.1/60
3.4/50
2.7/40

2.06/30

1.3/20
60
GPM
227
LPM

80
303

100
379

200
757

400
1514

600
2271

800 1000
3028 3785

2000
7571

4000
15141

SOLUTION FLOW (GPM/LPM)

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

6/00

3-4

OPERATING PROCEDURES

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 for
valve location, designation and normal stand-by position.
1. Verify that all valves on the proportioning system are in their normal stand-by position.

6. Open foam concentrate supply Valve "V" to the


desired ILBP module(s).

2. Start water pump (if required).

7. Open any required zone valves downstream of the


desired ILBP module(s).

3. Start foam concentrate pump.


4. If applicable - Set the desired percentage on the
metering valve(s) at the appropriate ILBP
Module(s).
NOTE: The metering valve is for regulating
the foam concentrate injection (percentage) into
the system only , and does not have shut-off
capability. For positive foam concentrate shutoff, a separate valve must be used along with the
metering valve.
5. Open water supply valve to the desired ILBP
module(s).

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

Verify that pointers on the duplex gauge are


balancing; if not, follow procedures under Manual
System Override (ILBP module) Sect. 3-3.A.

9. Observe the discharge pressure gauge on the pump


and pressure sustaining module to insure that the
system is operating at design pressure. If system is
not operating at design pressure, refer to Manual
System Override (Pump and Pressure Sustaining
Module) 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 for
valve location, designation and normal stand-by position.
Upon initiation of automatic start sequence, the following should occur:
NOTE: If applicable - Before actuating the system, set the desired percentage on the metering
valve(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 ILBP
Module(s) opens.

6/00

4. Zone concentrate discharge valve opens.


NOTE: Water powered zone concentrate valve(s),
if supplied, will actuate when water supply is initiated to zone.
5. Appropriate zone valves downstream of desired ILBP
Module(s) open.
6. If system fails to respond to automatic operation,
follow Manual Operation Procedures Sect 3-2.A.

3-5

OPERATING PROCEDURES

3-3.

MANUAL SYSTEM OVERRRIDE (MANUAL REGULATION)

NOTE: The instructions in sub-section A. below, apply only to ILBP Module Diaphragm Valves with manual
override capability. These instructions do not apply to Diaphragm Valves which do not have manual
overrride capability.
A. ILBP Module:
NOTE: Used only when system will not balance
automatically.

B. Pump & Pressure Sustaining Valve Module:


1. Open Valve "C".
2. Close Valve "E".

1. Close foam concentrate supply Valve "V".


2. Close water sensing shutoff Valve "L".
3. Verify adequate foam concentrate pressure on
foam concentrate supply pressure gauge.
4. Turn manual override knob clockwise until it
contacts a stop and will not travel further.

3. Slowly close Valve "C" until system design pressure is indicated on the discharge pressure gauge.
CAUTION:
An operator must remain stationed at the pump
and pressure sustaining module while the pressure is manually controlled to adjust for variations in pressure.

5. Slowly open foam concentrate supply Valve "V"


until duplex gauge indicates system balance.
Keep adjusting valve as required to maintain
system balance.

3-4.

SHUTDOWN

A. Manual System Shutdown:


1. Shut down the foam concentrate pump.
2. Close the foam concentrate supply Valve "V" at
the ILBP module(s) being operated.
WARNING:
Only after the fire is out and the danger of reignition
has passed, shall consideration be given to flushing and draining the system. Follow the appropriate Flushing Instructions which follow in this
manual after it is determined that it would be safe
to flush and drain the system.
3. Flush the foam solution system.
NOTE: If the system has a water powered foam
concentrate supply Valve "V", the cylinder water

6/00

pressure supply valve in the water line supplying


pressure to the water powered ball valve operating
cylinder must be closed before any flushing operation.
a. Make sure Valve "V" at the ILBP module(s)
being operated is closed.
b. Flow water through the system and allow water
to run until clean clear water issues from the
output devices that were operated.
c. Close the water supply valve(s). Shut off water
supply.
4. Return all valves to their normal stand-by position.
See Normal Stand-by Valve Position Chart on Operating Schematic Dwg. Fig. 3-1, 3-2 or 3-3.
3-6

OPERATING PROCEDURES

5. Replenish supply of foam concentrate. If the


tank is empty, it shall be inspected to determine
if cleaning is warranted before refilling. If
cleaning is judged necessary, refer to
manufacturer's instructions. If storage tank is
provided by NF - refer to NF Storage Tank
Installation, Cleaning & Filling Instruction
Manual P/N: 1298-9933-7 for recommendations.

CAUTION:
Only foam concentrate of the type listed on the
tank nameplate shall be used to replenish the tank.
Mixing of different types or brands of foam concentrate could cause failure of the system.
6. Replace all frangible components such as glass diaphragms, rupture discs, etc., in foam lines or foam
making devices.

B. Automatic System Shutdown:


Upon system shutdown, the following sequence should occur.

1. Shutdown the foam concentrate pump.


2. Close the Zone Foam Concentrate Valve to the
ILBP module(s) (if appropriate).
NOTE: Water powered foam concentrate
valves do not reset automatically and must be
reset manually.
WARNING:
Only after the fire is out and the danger of
reignition has passed shall consideration be
given to flushing and draining the system.
Follow the appropriate Flushing Instructions
which follow in this manual after it is determined that it would be safe to flush and drain
the system.
3. Flush the foam solution system.
NOTE: If the system has a water powered
foam concentrate supply Valve "V", the cylinder
water pressure supply valve in the water line
supplying pressure to the water powered ball
valve operating cylinder must be closed before
any flushing operation.
a. Make sure that the Zone Foam Concentrate
Valve to the ILBP module(s) being operated
is closed.

6/00

b. Flow water through the system and allow water


to run until clean clear water issues from the
output devices that were operated.
c. Close the water supply valve(s). Shut off water
supply.
4. Return all valves to their normal stand-by position.
Refer to Normal Stand-by Valve Position Chart on
Operating Schematic Dwg. Fig. 3-1, 3-2 or 3-3.
5. Replenish supply of foam concentrate. If the tank is
empty, it shall be inspected to determine if cleaning
is warranted before refilling. If cleaning is judged
necessary, refer to manufacturer's instructions.
Ifstorage tank is provided by NF - refer to NF
Storage Tank Installation, Cleaning & Filling Instruction Manual P/N: 1298-9933-7 for recommendations.
CAUTION:
Only foam concentrate of the type listed on the
tank nameplate shall be used to replenish the tank.
Mixing of different types or brands of foam concentrate could cause failure of the system.
6. Replace all frangible components such as glass diaphragms, rupture discs, etc., in foam lines or foam
making devices.

3-7

CHAPTER 4 - INSPECTION AND MAINTENANCE

4-1.

INSPECTION AND MAINTENANCE


See Table 4-1 for recommended inspection and maintenance procedures. These procedures and recommended
intervals are based on normal operating conditions and may have to be modified to meet the existing
conditions.
WARNING:
The intervals in this chapter are a general recommendation; some environmental conditions may dictate
such 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 thru
the 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, actuators
etc.) refer to that particular component's operating and maintenance manual or instruction sheet 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 modify system
components, component parts, operating devices or equipment, the system must be tested to insure 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 discussed immediately with
the manufacturer. Regular service contracts are recommended. The goal of this inspection and testing shall
be to ensure that the system is in full operating condition, and that it will remain in that condition until the
next inspection. The inspection report, with recommendations, shall be filed with the owner. Between the
regular service contract inspections or tests, the system shall be inspected by competent personnel following
an approved schedule.

6/00

4-1

INSPECTION & MAINTENANCE

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

TABLE 4-1 - RECOMMENDED INSPECTION & MAINTENANCE SCHEDULE

NOTE: The following recommendations are based on normal operating conditions. Due to environmental or other
conditions unique to your system, the frequency of some inspecton and maintenance procedures may 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
4-4. TOTAL SYSTEM
1. Check all valves to insure that they are in the
normal stand-byposition. See Operating
Schematic Dwg. Fig. 3-1, 3-2 or 3-3.
2. Check that Manual Override Handwheel is in the
normal stand-by position for automatic
balancing. 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 fire
pumps 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 this
manual.
9. Cycle manual valves where practical.

6/00

START
AFTER
UP
OPERATION WEEKLY MONTHLY

SEMIANNUAL ANNUAL

OTHER

AFTER
ALL
MAINT.
PROCEDURES

AFTER
MAINTENANCE
TO PIPING

4-2

INSPECTION & MAINTENANCE

TABLE 4-1 - RECOMMENDED INSPECTION & MAINTENANCE SCHEDULE


DESCRIPTION
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 is
circulated, 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. STRAINERS
Foam Concentrate Line and Sensing Line
Strainers:
1. Remove screen, clean and inspect and
reassemble.
Total System:
1. Remove screens, check, clean and reinstall.
4-6. FOAM CONCENTRATE PUMP
1. 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 or
overheating 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 for
relief valve setting procedures. Refer to Pump
Outline 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, recirculate
foam concentrate back to storage tank.

6/00

START
AFTER
UP
OPERATION WEEKLY MONTHLY

SEMIANNUAL ANNUAL

AFTER
FLOW TEST
(PER NFPA)

AFTER
FLOW TEST
(PER NFPA)

MFR. RECOM.

OTHER

MFR. RECOM.

MFR. RECOM.

4-3

INSPECTION & MAINTENANCE

TABLE 4-1 - RECOMMENDED INSPECTION & MAINTENANCE SCHEDULE


DESCRIPTION
4-7. ELECTRICALLY ACTUATED VALVES
1. Cycle valve(s) - Valve(s) may be cycled from
control panel or by manual override at valve.

START
AFTER
UP
OPERATION WEEKLY MONTHLY

SEMIANNUAL ANNUAL

OTHER

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

2.
3.
4.
4-8.
1.

When automated valves are cycled, the


main water supply valve must be closed.
Cycle valve(s) from the control panel to insure
proper operation from control.
Check supervision of control circuit.
Check for leakage past valve seat.
WATER POWERED BALL VALVES
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:

3.
4.
5.
4-9.
1.

2.
3.
4.
5.
6.

6/00

When water powered ball valves are cycled,


Valve "V" must be closed.
Check supervision of circuit if solenoid release is
provided.
Make sure that the quick release pin is securely
positioned thru the clevis.
Make sure the drain/vent valve is fully closed.
PNEUMATICALLY ACTUATED VALVES
Cycle the valve(s) - Valve(s) may be cycled
from control panel or by manual override at
valve.
WARNING:
When water powered ball valves are cycled,
Valve "V" must be closed.
When automated valves are cycled, the
main water supply valve must be closed.
Cycle Valve(s) from the control panel to insure
proper operation from control.
Check supervision of control circuit.
Check air supply.
Check low air supply alarm.
Check for leakage past valve seat.

4-4

INSPECTION & MAINTENANCE

TABLE 4-1 - RECOMMENDED INSPECTION & MAINTENANCE SCHEDULE


DESCRIPTION

START
AFTER
UP
OPERATION WEEKLY MONTHLY

4-10. PRESSURE VACUUM VENT


1. Inspect the pressure vacuum vent to insure that
the poppets move freely, the screens are clean
and there is no other dirt or blockage.
2. Service pressure vacuum vent. Refer to NF
Storage Tank Installation, Cleaning & Filling
Instruction Manual P/N: 1298-9933-7 for
recommendations for NF supplied tanks.
4-11. FOAM CONCENTRATE STORAGE TANK
1. Check the level of concentrate in the tank. Refer

to NF Storage Tank Installation, Cleaning &


Filling Instruction Manual P/N: 1298-9933-7 for
recommendations for NF supplied tanks.
2. Check pressure vacuum vent in accordance with
maintenance instructions outlined in this Section
4-10 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 CONCENTRATE


1. Check that storage temperature is within
acceptable limits. Refer to NF Storage Tank
Installation, Cleaning & Filling Instruction
Manual P/N: 1298-9933-7 for recommended
temperatures 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 NF
Storage Tank Installation, Cleaning & Filling
Instruction Manual P/N: 1298-9933-7 for
sampling instructions.
3. Circulate foam concentrate.
CAUTION:
The foam concentrate dischargeValve(s) "D"
must be closed to prevent loss of foam
concentrate.
4-13. 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.

6/00

SEMIANNUAL ANNUAL

OTHER

4-5

INSPECTION & MAINTENANCE - FLUSHING

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 foam
concentrate, or if the foam concentrate piping has to be broken for repairs. Flushing is not a normal shutdown
procedure and is not necessary after Foam Concentrate Pump and Pressure Sustaining Valve Module
operation.
CAUTION:
If the tank is full of foam concentrate, the tank suction Valve "B" and return Valve "A" must be closed
to prevent dilution of the foam concentrate.
If the system has a water powered foam concentrate discharge valve, the cylinder water pressure supply
valve in the water line supplying pressure to the water powered ball valve operating cylinder, must be
closed before any flushing operation.

1. Close foam concentrate tank supply Valve "B"


and tank return Valve "A".
2. Close concentrate discharge Valve(s) "D". If
Valve(s) "D" is automated electrically, de-energize the valve at the control panel. A water
powered foam concentrate discharge valve does
not close automatically, it must be closed and
reset manually.
3. Open Valve "C".
4. Attach hose from water supply to Flush-In Connection "S" .

Momentarily close Valve "E" to allow water to


flush through the relief valve. Open Valve "E".
Repeat this procedure two or three times.

8. Stop concentrate pump, open Strainer Flush-Out


Connection "U" and then close Flush-In Connection
"S".
9. Let system drain through Strainer Flush-Out Connection "U" and Flush-Out Connection "T"; then
close Flush-Out Connection "T" and Strainer FlushOut Connection "U".
10. Remove lower plug in concentrate pump, allow to
drain, replace plug.

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


6. Open water supply valve.
7. Start foam concentrate pump.

6/00

Close Valve "C" once to force flush water


through pressure sustaining valve, then open
Valve "C".

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


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

4-6

INSPECTION & MAINTENANCE - FLUSHING

4-15. FLUSHING - ILBP MODULE


NOTE: Flushing of the ILBP Module is to be done at Module installation into the system, prior to
refilling a depleted tank, changing type of foam concentrate, or if the foam concentrate piping has to
be broken for repairs. Flushing is not a normal shutdown procedure and is not necessary after ILBP
Module operation.
A. ILBP Module with
Diaphragm Valve Manual Override Capability:

B. ILBP Module without


Diaphragm Valve Manual Override Capability:

1. Open all ILBP Module sensing line drains and


flush-out points (Valves M, N, P, R and W).

1. Open all ILBP Module drains, flush-out points


(Valves P and R).

2. Turn manual override knob down (clockwise)


until it contacts stop.

2. Close Foam Concentrate Supply Valve "V" on


the ILBP Module.

3. Close Foam Concentrate Supply Valve "V" on


the ILBP Module.

3. The ILBP Module will be flushed thru the foam


solution piping. Flushing must be done thru zone
discharge devices or thru foam solution piping
drains (with zone foam solution discharge valves
closed).

4. The ILBP Module will be flushed thru the foam


solution piping. Flushing must be done thru zone
discharge devices or thru foam solution piping
drains (with zone foam solution discharge valves
closed).
5. Establish a water flow thru the foam concentrate
system until the water flows clear at all flush
points and drains.
NOTE: Flushing of the ILBP Module can be
performed at system shutdown when flowing
water thru the system. Refer to Sect. 3-4, Shutdown, for correct procedures.

4. Establish a water flow thru the foam concentrate


system until the water flows clear at all flush
points and drains.
NOTE: Flushing of the ILBP Module can be
performed at system shutdown when flowing
water thru the system. Refer to Sect. 3-4, Shutdown, for correct procedures.
5. After the water runs clear, shut off water supply
then drain the ILBP Module and zone piping.

6. After the water runs clear, shut off water supply


then drain the ILBP Module and zone piping.
NOTE: Remove diaphragm valve body drain
plug.
7. Turn manual override knob up (counter-clockwise) until it contacts stop for normal automatic
balancing operation.

NOTE: Remove diaphragm valve body drain


plug.
6.

Return all valves to their normal stand-by position (reinstall body drain plug). Refer to Normal
Stand-By Valve Position Chart on Operating
Schematic Dwg. Fig. 3-2.

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

6/00

4-7

CHAPTER 5 - TROUBLE SHOOTING


5-1.

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

NOTE: Refer to individual instruction manuals or sheets for additional information on


system components and discharge devices.

TABLE 5-1 TROUBLESHOOTING


PROBLEM

5-2. No
Proportioning

POSSIBLE CAUSE

CORRECTIVE ACTION

Tank Return Valve "A" and Tank Suction


Valve B at foam concentrate tank not open.

Check valve position on tank to insure that


they are fully open. Open valve(s) if closed.

Foam Concentrate Discharge Valve "D"


and/or Foam Concentrate Supply Valve "V"
not open.

Fully open appropriate valve(s). (Normal


stand-by position is closed)

Automatic Foam Concentrate Zone Valve


Closed.(Electrically actuated)

Check that wiring is installed to actuator.

Check that signal from control system is


available at valve actuator. If voltage is not
present, check control system.
If signal is present at actuator, use manual
override to cycle valve. If valve cycles manually, 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 the
valve is jammed. Remove valve, determine
and correct reason for jam. See actuator data.
Automatic valve actuator does not function
properly.(Electric or hydraulic actuation)

6/00

See manufacturers troubleshooting data.

5-1

TROUBLESHOOTING

TABLE 5-1 TROUBLESHOOTING


PROBLEM

No Proportioning
continued

POSSIBLE CAUSE

Automatic Foam Concentrate Zone Valve


Closed.(Water Powered Ball Valve)

CORRECTIVE ACTION

Check that cylinder water pressure supply


valve is fully open.
Check that quick release pull pin is not
removed from clevis. Reinsert pin thru
clevis and valve handle.
Check Drain/Vent valve on strainer for clogging which shuts off water supply to cylinder.
Open Drain/Vent valve on strainer, vent and
flush any debris blocking water supply.

Foam concentrate pump not running.

Check that power is available and correct


voltage is available to all three motor legs.
Check that wiring is complete to the pump.
Check that all disconnect switches and circuit
breakers are closed, and fuses are in
satisfactory condition.
Pump couplings disconnected at reducer or
pump.
Reducer jammed or damaged; determine
cause and correct.
Pump jammed. Determine cause and correct.
See manufacturers data.

6/00

Foam concentrate pump running wrong


direction.

Reverse rotation of foam concentrate pump.

Foam pump relief valve set too low.


Duplex gauge will show foam concentrate
pressure lower than water pressure. Pressure
in foam concentrate line will probably pulse.

Foam concentrate allowed to bypass thru


relief valve at pressure lower than water
pressure on supply line to ratio controller.
Reset pump relief valve. Contact NF Eng. Dept.

Manual Foam Concentrate Regulating Valve


"C" open or partially open.

Check that manual regulating valve is closed


completely.

Diaphragm Valve Foam Concentrate FlushOut Valve "R" open or partially open.

If provided, duplex gauge will show foam


concentrate pressure lower than water
pressure. Check to insure all flush valves are
closed.

5-2

TROUBLESHOOTING

TABLE 5-1 TROUBLESHOOTING


PROBLEM

No Proportioning
continued

5-3. Low
Percent of
Proportioning

6/00

POSSIBLE CAUSE

CORRECTIVE ACTION

Drain valve(s) or connection(s) in foam


concentrate piping open or partially open.

If provided, duplex gauge will show foam


concentrate pressure lower than water
pressure. Check to insure all drain valves are
closed.

Control system not functioning properly.

Check wiring for correct interconnection and


proper connections. See control system
manual.

Concentrate not compatible with the system.

Use correct concentrate. Drain and clean


tank before filling with new concentrate.

Strainer clogged. High vacuum reading on


compound gauge and pump will probably
be very noisy due to cavitation.

Blow down, remove strainer screen


and clean.

Pump suction strainer mesh size too small.

Replace with proper size strainer.

Water pressure too high. Pump can not build


sufficient pressure to overcome water
pressure.

Reduce water pressure to system limitations.


Reset pump relief valve 25 psi higher than
water pressure, provided pump motor has
sufficient horsepower to drive pump at
higher pressure rating.

Ratio controller operating below minimum


inlet pressure.

Increase water pressure. Contact NF


Engineering Dept. for recommendations.
Refer to Fig. 3-4, Minimum Inlet Pres. Req.

Pressure Sustaining Valve setting too low.

Reset to correct pressure. Follow procedures


in Sect. 2-2.C., item 23 for checking the
valve set pressure. Refer to manufacturers
instructions for resetting.

Foam concentrate storage tank empty.

Fill tank. Refer to NF Storage Tank Instruction Manual, P/N: 1298-9933-7.

Tank Suction Valve "B" at foam concentrate


tank partially closed. Pump should be noisy
due to cavitation. Also compound gauge will
indicate high vacuum.

Check valve position. Normal stand-by


position is fully open.

Foam Concentrate Discharge Valve "D" and/


or Foam Concentrate Supply Valve "V"
partially closed.

Fully open valve(s). If more than one ILBP


Module is supplied by the foam concentrate
main, be sure that Valve(s) "V" or zone
valve(s) of ILBP Module(s) not required, are
closed.
5-3

TROUBLESHOOTING

TABLE 5-1 TROUBLESHOOTING


PROBLEM

Low Percent of
Proportioning
continued

POSSIBLE CAUSE

CORRECTIVE ACTION

Foam Concentrate Zone Valve(s) not fully


open.

Fully open valve. Determine cause and


correct.

Automatic Foam Concentrate Zone Valve


opens slowly.(Water powered ball valve)

Cylinder water pressure supply valve


partially open. Fully open valve.
Tighten Drain/Vent valve on cylinder strainer.
Snug with wrench to insure closure to rated
pressure.
Drain/Vent valve clogged, obstructing water
supply to cylinder. Open Drain/Vent valve on
strainer and vent. Flush any debris blocking
water supply.

Foam concentrate pump not operating to


capacity.

Loss of phase to motor.


Low voltage to motor.
Check pump end clearance.
Check for damage to vanes and pushrods.
See manufacturers data.

Foam Concentrate Regulating Valve "C"


partially open.

Check that Valve "C" is completely closed.

Water pressure exceeds the design limits of


the system. System requires more capacity
than pump is capable of producing.

Adjust pressure to proportioner to be within


the flow and pressure limits of the system.

Flush-In Connection "S" open or partially


open. If provided, duplex gauge will show
foam concentrate pressure lower than water
pressure.

Check to insure all flush connections are


closed.

Drain valves in foam concentrate piping


open or partially open. If provided, duplex
gauge will show foam concentrate pressure
lower than water pressure.

Check to insure all drain valves are closed.

Control system not functioning properly.

See control system manual. Check wiring for


correct interconnection.
Check wiring for proper connections.

6/00

5-4

TROUBLESHOOTING

TABLE 5-1 TROUBLESHOOTING


PROBLEM

Low Percent of
Proportioning
continued

5-4. High
Percent of
Proportioning

6/00

POSSIBLE CAUSE

CORRECTIVE ACTION

Foam concentrate strainer at Flush-Out


Connection "U" clogged. High vacuum
reading on compound gauge and pump will
probably be very noisy due to cavitation.

Remove strainer screen and clean.

Diaphragm valve not functioning properly.


If provided, duplex gauge will not show
balance.

Check water sensing lines for blockage.


Make sure that there are no air pockets in
water sensing lines.

Diaphragm Valve Water Flush-Out "P" open.

Fully close flush-out valve.

Foam concentrate incompatible with system


design.

Use only foam concentrates the system was


designed for. Contact NF if you desire to
change foam concentrates.

Incorrect orifice diameter or adjustment.

Contact NF Engineering Dept. for instructions


on checking orifice and adjustment settings.

Water flow too high. Exceeds capability


of foam concentrate pump.

Too many discharge devices in operation or


pressure too high. Check design and correct
to stay within limits of system.

Ratio controller operating below minimum


inlet pressure.

Increase water pressure. Contact NF


Engineering Dept. for recommendations.
Refer to Fig. 3-5, Minimum Inlet Pres. Req.

Pressure Sustaining Valve setting too low.

Reset to correct pressure. Follow procedures


in Sect. 2-2.C., item 23 for checking the
valve set pressure. Refer to manufacturers
instructions for resetting.

Tank Return Valve "A" at foam concentrate


tank not open.

Check valve position to insure that


Valve "A" is open. Open valve if closed.

Diaphragm valve not functioning properly.


If provided, duplex gauge will not show
balance.

Check foam concentrate sensing lines for


blockage. Make sure that there are no air
pockets in foam concentrate sensing lines.

Foam concentrate sensing line blocked.

Remove line and clear blockage.

Diaphragm Valve Foam Concentrate


Flush-Out Valve "R" open.

Fully close flush-out valve.

Foam concentrate incompatible with system


design.

Use only foam concentrate the system was


designed for. Contact NF if you desire to
change foam concentrates.
5-5

TROUBLESHOOTING

TABLE 5-1 TROUBLESHOOTING


PROBLEM

High Percent of
Proportioning
continued

POSSIBLE CAUSE

CORRECTIVE ACTION

Incorrect orifice diameter or adjustment.

Contact NF Engineering Dept. for instructions


on checking orifice and adjustment settings.

Water flow too low for ratio controller.

Check system pressure. If low, find and


correct problem.
Blockage in solution line or valves not
completely open. Check solution line and
correct.
Discharge device blocked. Check devices
and correct problem.

5-5. No Flow
at Discharge
Device(s)

5-6. Low Flow


at Discharge
Device(S)

Water supply valve closed.

Open valve. If automated, find reason and


correct.

Fire pump did not start.

Determine the cause and correct the problem.

Blockage in the water supply or foam


solution discharge line.

Find the cause of the blockage and correct.

Manual valves in solution piping shut or


blockage in line.

Check line for blockage or open manual


valves.

System pressure too low.

Check inlet pressure and correct for proper


operation.

Fire pumps did not start.

Determine reason and correct.

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

5-7. No
Operation

6/00

Zone valve did not open completely.

Valve jammed, determine reason and correct.

Power failure.

Check power source and correct problem.

Control system not functioning properly.

Check wiring for correct interconnection and


proper connections. See control system
manual.

Foam concentrate storage tank empty.

Fill tank.

Failure of water supply system.

Check water supply and correct problem.

5-6

Na
tional F
oam
National
Foam

FOAM SOLUTION PROFESSIONALS


180 Sheree Boulevard, Suite 3900 P.O. Box 695 Exton, PA 19341-0695 USA
Telephone: 610-363-1400 Fax: 610-524-9073
www.Kidde-Fire.com

3.3.1

3.3.2

3.3.3

INSTALLATION AND MAINTENANCE MANUAL


FOR NEMA LOW VOLTAGE ELECTRIC MOTORS

INSTALLATION AND MAINTENANCE MANUAL


FOR NEMA LOW VOLTAGE ELECTRIC MOTORS

Contents

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
3

INSTALLATION AND MAINTENANCE MANUAL


FOR NEMA LOW VOLTAGE ELECTRIC MOTORS

INSTALLATION AND MAINTENANCE MANUAL


FOR NEMA LOW VOLTAGE ELECTRIC MOTORS

1. Introduction

his manual covers all the three-phase


and single-phase asynchronous squirrelcage 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.

INSTALLATION AND MAINTENANCE MANUAL


FOR NEMA LOW VOLTAGE ELECTRIC MOTORS

2. Basic Instructions

2.1 Safety Instructions


All personnel involved with electrical installations, either
handling, lifting, operation and maintenance, should be wellinformed 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 Delivery
Prior 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.

bearing surfaces thereby removing the protective lm 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 machines 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 40C test voltage in
applied during one minute.

2.3 Storage
Motors 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

Insulation resistance Rm is obtained by the formula:


Rm = Vn + 1
Where: Rm - minimum recommended insulation resistance in
M W with winding at 40C
Vn - rated machine voltage in kV
In case the test is carried out at a temperature other than 40C,
the value must be corrected to 40C using an approximated
curve of insulation resistance v.s temperature of the winding
with the aid of Figure 2.1; its possible verify that resistance
practically doubles every 10C that insulating temperature is
lowered.

INSTALLATION AND MAINTENANCE MANUAL


FOR NEMA LOW VOLTAGE ELECTRIC MOTORS

Example:
Ambient temperature = 50C
Motor winding resistence at 50C = 1.02 M W
Correction to 40C
R 40C = R 50C x K 50C
R 40 C = 1.02 x 1.3
R 40 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 5C per hour and the temperature of the winding
should not exceed 105C. 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 (C)
R40 C = Rt x Kt 40 C
Figure 2.1.

INSTALLATION AND MAINTENANCE MANUAL


FOR NEMA LOW VOLTAGE ELECTRIC MOTORS

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.

Where:
F1 and F2
g
G
Tmax
A

Lateral stress (Lb)


Force of gravity (32.18 ft/s2)
Weight of motor (Lb)
Maximum torque (Lb . Ft)
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 Rails
When 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.

3.1 Mechanical Aspects


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

3.1.1 Foundation
The 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 Tmx/A)

After the alignment, the rails are fixed.


Figure 3.2 - Positioning of slide rails for motor alignment

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

Figure 3.1 - Base stresses


7

INSTALLATION AND MAINTENANCE MANUAL


FOR NEMA LOW VOLTAGE ELECTRIC MOTORS

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.

exially - Figure 3.5.


Figure 3.5 - Alignment with dial gauges
Thus, 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

Figure 3.3 - Motor mounted on a concrete base with foundation


studs
3.1.3 Alignment
The 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

INSTALLATION AND MAINTENANCE MANUAL


FOR NEMA LOW VOLTAGE ELECTRIC MOTORS

3.1.4 Coupling
Figure 3.8a - Pulley extractor
a) Direct Coupling
Direct 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 coupling

b) Gear Coupling

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.

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 Coupling


Belt 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 80C is recommended, or alternatively, the devices
illustrated in Figure 3.8 may be employed.

Figure 3.9 - Correct positioning of pulley on the shaft

Figure 3.8 - Pulley mounting device

INSTALLATION AND MAINTENANCE MANUAL


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

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 3.10 - 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).

Figure 3.11 - Belt tensions

Table 1 - Minimum pitch diameter of pulleys


Ball bearings
Frame
140
W 180
180
W 210
210
W 250
250
280
320
360

Bearing
6205-Z
6206-Z
6307-Z
6308-Z
6308-Z
6309 C3
6309 C3
6311 C3
6312 C3
6314 C3

Size X Inches
0.79
1.7
3.03
1.69

1.57
1.85
3.23
1.81
2.86
2.90
4.37
4.41

2.36
2
3.46
1.93
3.00
3.06
4.54
4.59
5.08
7.44
8.73

3.15

3.94

4.72

3.16
3.22
4.72
4.77
5.19
7.76
9.00

4.92
4.97
5.47
7.94
9.28

5.65
8.18
9.57

Ball Bearing
Frame

400
440
500
5008
580

Important:

Poles

Bearing

II

6314 C3

IV-VI-VII

6314 C3

II

6314 C3

IV-VI-VIII

6319 C3

II

6314 C3

IV-VI-VIII

6319 C3

II

6314 C3

IV-VI-VIII

6322 C3

II

6314 C3

IV-VI-VIII

6322 C3

Roller Bearing

Size X Inches
1.97

3.15

4.33

5.51

7.3

7.62

7.94

8.24

11.75
23.54
44.66
57

12.16
24.34
45.79
58

12.61
25.12
46.98
59

Bearing

Size X Inches
1.97

4.33

5.51

6.69

8.27

NU 316

4.13

4.31

4.49

4.67

4.85

NU 319

4.02

4.17

4.32

4.47

4.62

4.82

NU 319

6.52

6.73

6.95

7.17

7.39

7.67

NU 322

8.73

8.95

9.96

11.34

12.87

14.82

NU 322

10.72

10.91

11.11

11.31

11.50

11.76

13.08
25.87
48.23
60

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)
10

3.15

INSTALLATION AND MAINTENANCE MANUAL


FOR NEMA LOW VOLTAGE ELECTRIC MOTORS

Nema 56 Motors

Saw Arbor Motors


Radial Force (Lbf)

Frame

Distance X

Poles

56A
56B
56D

1,18

II

88

59

IV

88

59

II

88

59

IV

86

59

II

127

70

IV

141

70

80 LMS

II

355

80 MMS

II

359

80 SMS

II

357

427

555

90 LMS

II
IV

Table 3 - Maximum acceptable axial load (Lbf)


IP55 Totally Enclosed Motors - 60Hz
Position / Construction Form

F
R
A
M
E

140
W 180
180
W 210
210
W 250
250
280
320
360
400
440
500
5008

II
103
108
149
196
189
282
273
355
374
890
877
842
769
791

IV
141
145
207
264
257
372
368
480
498
1,181
1,148
1,303
1,250
1624

VI
167
180
249
326
315
443
436
551
588
1,144
1,347
1,563
1,481
1909

VIII
187
202
286
368
357
485
485
624
668
1,323
1,521
1,821
1,728
2137

II
112
154
269
329
324
471
463
621
703
890
877
842
769
791

IV
152
209
370
447
443
620
615
826
930
1,181
1,148
1,303
1,250
1624

VI
185
255
443
544
533
734
727
959
1,091
1,375
1,347
1,563
1,481
1909

VIII
207
286
500
610
599
811
813
1,082
1,232
1,552
1,521
1,821
1,728
2137

II
99
94
136
176
160
240
220
275
266
745
705
568
355
728

IV
132
130
189
238
220
317
310
388
366
985
890
884
721
1548

VI
158
165
229
297
275
394
379
427
432
1,144
1,060
1,109
844
1808

VIII
178
183
266
339
310
414
421
502
511
1,323
1,241
1,488
1,190
2029

II
105
141
253
310
295
430
410
540
597
745
705
568
355
728

IV
143
194
352
421
405
564
557
736
793
985
890
884
721
1548

VI
174
240
421
518
493
685
672
838
937
1,144
1,060
1,109
844
1808

VIII
198
269
480
582
553
743
749
961
1,078
1,323
1,241
1,488
1,109
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 - 60Hz


Position / 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

11

INSTALLATION AND MAINTENANCE MANUAL


FOR NEMA LOW VOLTAGE ELECTRIC MOTORS

The maximum radial load for each frame are determined, by


graphs.
INSTRUCTIONS ON HOW TO USE THE GRAPHS
1 - 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 : 145T
Fr
: 110Lb
X
: 2 inches
1 - Mark the distance X
2 - Find out line N = 3600 for bearing
Based
on the above, this bearing withstands a radial load of 130 Lb.

12

INSTALLATION AND MAINTENANCE MANUAL


FOR NEMA LOW VOLTAGE ELECTRIC MOTORS

13

INSTALLATION AND MAINTENANCE MANUAL


FOR NEMA LOW VOLTAGE ELECTRIC MOTORS

14

INSTALLATION AND MAINTENANCE MANUAL


FOR NEMA LOW VOLTAGE ELECTRIC MOTORS

Note: For frames 600 and above, consult your engineering


representative.
15

INSTALLATION AND MAINTENANCE MANUAL


FOR NEMA LOW VOLTAGE ELECTRIC MOTORS

3.2 Electrical Aspects


3.2.1 Feed System
Proper 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
rating

5min

15min

30 at
60min

Continuous

Short (operating valves,


activating contacts etc)

1.10

1.20

1.50

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

0.85

0.85

0.90

1.40

Cyclic (rolling mills,


mining machines etc)

0.85

0.90

0.95

1.40

Variable

1.10

1.20

1.50

2.00

Duty
Classification

16

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 = 52.5A
b) Closest value on table 6:55A
c) Minimum gauge: 6 AWG

3.2.2 Starting of Electric Motor


Induction motors can be started by the following methods:

Direct Starting
Whenever 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 Directon-Line (DoL) starting.

INSTALLATION AND MAINTENANCE MANUAL


FOR NEMA LOW VOLTAGE ELECTRIC MOTORS
Table 4 - Wire and cable gauges for single-phase motor installation (voltage drop < 5%) (in conduits)
Supply Voltage
115
230
460
575

Distance of motor from distribution centre (feet)


34
69
138
170

51
102
204
250

69
138
276
338

85
170
340
420

102
204
408
501

137
274
548
670

14
14
12
12
10
8
6
4
2

14
14
12
12
10
8
6
4
2

14
14
12
12
10
8
6
4
2

14
14
12
10
8
8
6
4
2

14
12
12
10
8
6
6
4
2

14
12
10
8
6
6
4
2
2

Current (A)
5
10
15
20
30
40
55
70
95

171
342
684
840

205
410
820
1010

240
480
960
1181

273
546
1092
1342

308
616
1232
1515

342
684
1368
1680

428
856
1712
2105

514
1028
2056
2530

12
8
6
6
4
2
1/0
1/0
2/0

12
8
6
4
2
2
1/0
2/0
3/0

10
8
6
4
2
2
1/0
2/0
3/0

10
6
4
4
2
1/0
1/0
2/0
4/0

8
6
2
2
1/0
2/0
2/0
2/0
250M

Cable gauge (conductor)


14
10
8
8
6
4
4
2
1/0

12
10
8
6
6
4
2
2
1/0

12
10
6
6
4
2
2
1/0
1/0

Table 5 - Wire and cable gauges for three-phase motor installation - aerial conductors with 25cm spacing (voltage drop < 5%)
Supply Voltage
115
230
460
575

Distance of motor from distribution centre (feet)


51
102
204
250

69
138
276
338

85
170
340
420

102
204
408
501

137
274
547
670

171
342
684
840

Current (A)
15
20
30
40
55
70
100
130
175
225
275
320

205
410
820
1010

240
480
960
1181

273
546
1092
1342

308
616
1232
1515

342
684
1368
1680

428
856
1712
2105

514
1028
2056
2530

685
1370
2740
3350

8
6
4
2
2
1/0
4/0
------

8
6
4
2
1/0
2/0
4/0
------

6
4
2
2
2/0
3/0
-------

6
4
2
1/0
3/0
--------

4
2
1/0
2/0
---------

Cable gauge (conductor)


14
14
14
12
10
8
6
4
2
1/0
2/0
3/0

14
14
12
10
10
8
6
4
2
1/0
2/0
3/0

14
12
10
10
8
6
4
4
2
1/0
2/0
3/0

12
12
8
8
8
6
4
2
1/0
2/0
4/0
4/0

12
10
8
8
6
4
2
1/0
2/0
3/0
---

10
10
8
6
4
2
2
1/0
3/0
----

10
8
6
4
4
2
1/0
2/0
-----

10
8
6
4
2
2
2/0
4/0
-----

8
8
4
4
2
1/0
3/0
------

Table 6 - Wire and cable gauges for three-phase motor installation (voltage drop < 5%) (in conduits)
Supply Voltage
115
230
460
575

Distance of motor from distribution centre (feet)


85
170
340
420

102
204
408
501

120
240
480
590

137
274
548
670

171
342
684
840

Current (A)
15
20
30
40
55
70
95
125
145
165
195
215
240
265
280
320

205
410
820
1010

240
480
960
1181

273
546
1092
1342

308
616
1232
1515

342
684
1368
1680

428
856
1712
2105

514
1028
2056
2530

8
6
4
4
2
1/0
1/0
2/0
3/0
3/0
4/0
250M
300M
350M
400M
500M

6
6
4
2
2
1/0
1/0
3/0
3/0
4/0
250M
250M
300M
350M
400M
500M

6
6
4
2
1/0
1/0
2/0
3/0
4/0
4/0
250M
300M
300M
350M
400M
500M

6
4
2
2
1/0
2/0
3/0
4/0
250M
250M
300M
350M
400M
500M
400M
500M

4
4
2
1/0
1/0
2/0
4/0
250M
300M
350M
350M
400M
500M
500M
---

Cable gauge (conductor)


12
12
10
8
6
4
2
1/0
2/0
3/0
4/0
250M
300M
350M
400M
500M

12
10
8
8
6
4
2
1/0
2/0
3/0
4/0
250M
300M
350M
400M
500M

12
10
8
6
6
4
2
1/0
2/0
3/0
4/0
250M
300M
350M
400M
500M

10
10
8
6
4
4
2
1/0
2/0
3/0
4/0
250M
300M
350M
400M
500M

10
8
6
6
4
2
2
1/0
2/0
3/0
4/0
250M
300M
350M
400M
500M

8
8
6
4
4
2
1/0
1/0
2/0
3/0
4/0
250M
300M
350M
400M
500M

8
6
6
4
2
2
1/0
2/0
2/0
3/0
4/0
250M
300M
350M
400M
500M

Note: The above indicated values are orientative. For guaranteed values, contact the Local Power Company.
17

INSTALLATION AND MAINTENANCE MANUAL


FOR NEMA LOW VOLTAGE ELECTRIC MOTORS

There are DOL starter assemblies available combining a threepole 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 autotransformer) 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 starting
It is fundamental to star-delta starting that the three-phase motor
has the necessary numbers of leads for both connections:
6 leads for Y/
or 12 leads for YY/
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 Protection

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


100
The 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 clients
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-up
3.3.1 Preliminary Inspection
Before 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.;

Motor circuits have, in principle, two types of protection: motor


18

c) Ascertain that voltage and frequency correspond to those

INSTALLATION AND MAINTENANCE MANUAL


FOR NEMA LOW VOLTAGE ELECTRIC MOTORS
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
Causes of
overheating
Fuse only

Fuse and
thermal
protector

Protection
with
probe
thermistor
in motor

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
19

INSTALLATION AND MAINTENANCE MANUAL


FOR NEMA LOW VOLTAGE ELECTRIC MOTORS

CONNECTION DIAGRAMS
a) Direct starting
POWER NETWORK

c) Auto-transformer starting
POWER NETWORK

20

b) Star-Delta starting
POWER NETWORK

INSTALLATION AND MAINTENANCE MANUAL


FOR NEMA LOW VOLTAGE ELECTRIC MOTORS

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;

21

INSTALLATION AND MAINTENANCE MANUAL


FOR NEMA LOW VOLTAGE ELECTRIC MOTORS
Table 11 - Bearing specications by type of motor
Bearings
Mounting

143 T
145 T
182 T
184 T
W 182 T
W 184 T
213 T
215 T
W 213 T
W 215 T
254 T
256 T
W 254 T
W 256 T
284 T and TS
286 T and TS
324 T and TS
326 T and TS
364 T and TS
365 T and TS
404 T
404 TS
405 T
405 TS
444 T
444 TS
445 T
445 TS
447 T
447 TS
449 T
449 TS
504 T
504 TS
505 T
505 TS
5008 T
5008TS
586 T
586 TS
587 T
587 TS
Saw Arbor
motor
frame
80 S MS
80 M MS
80 L MS
90 L MS

22

Rear (O.D.E.)
6202 Z
6202 Z
6202 Z
6202 Z /
6203 Z

ALL FORMS

B48 and C48


56 and A56
B56 and C56
D56 and
F56H/G56H

Front (D.E.)
Open drip proof motors
6203 Z
6203 Z
6203 Z
6204 Z

Totally enclosed fan cooled motors


6205 ZZ
6205 ZZ
6307 ZZ
6307 ZZ
6206 ZZ
6206 ZZ
6308 ZZ
6308 ZZ
6308 ZZ
6308 ZZ
6309-C3
6309-C3
6309-C3
6309-C3
6311-C3
6311-C3
6312-C3
6312-C3
6314-C3
6314-C3
NU 316-C3
6314-C3
NU 316-C3
6314-C3
NU 319-C3
6314-C3
NU 319-C3
6314-C3
NU 319-C3
6314-C3
NU 322-C3
6314-C3
NU 319-C3
6314-C3
NU 319-C3
6314-C3
NU 322-C3
6314-C3
NU 322-C3
6314-C3
NU 322-C3
6314-C3
ALL FORMS

Frames

6204 ZZ
6204 ZZ
6206 ZZ
6206 ZZ
6205 ZZ
6205 ZZ
6207 ZZ
6207 ZZ
6207 ZZ
6207 ZZ
6209 Z-C3
6209 Z-C3
6209 Z-C3
6209 Z-C3
6211 Z-C3
6211 Z-C3
6212 Z-C3
6212 Z-C3
6314-C3
6314-C3
6314-C3
6314-C3
6314-C3
6414-C3
6316-C3
6314-C3
6316-C3
6314-C3
6316-C3
6314-C3
6319-C3
6314-C3
6316-C3
6314-C3
6316-C3
6314-C3
6319-C3
6314-C3
6319-C3
6314-C3
6319-C3
6314-C3

Bearings

ODP Motors
Nema-T
frames
E143/5T
F143/5T
182 T
184 T
213/5T
254 T
256 T
284 T
284 TS
286 T
286 TS
324 T
324 TS
326 T
326 TS
364 T
364 TS
365 T
365 TS
404 T
404 TS
405 T
405 TS
444 T
444 TS
445 T
445 TS

IEC

B3

Rear (O.D.E.)
6207 ZZ
6207 ZZ
6207 ZZ
6208 ZZ

Front (D.E.)
6205 ZZ
6205 ZZ
6206 ZZ
6202 ZZ
6208 ZZ
6309 Z-C3
6309 Z-C3
6311 Z-C3
6311 Z-C3
6311 Z-C3
6311 Z-C3
6312 Z-C3
6312 Z-C3
6312 Z-C3
6312 Z-C3
6314 C3
6314 C3
6314 C3
6314 C3
NU 316 C3
6314 C3
NU 316 C3
6314 C3
NU 319 C3
6314 C3
NU 319 C3
6314 C3

Rear (O.D.E.)
6204 ZZ
6204 ZZ
6205 ZZ
6205 ZZ
6206 ZZ
6209 Z-C3
6209 Z-C3
6211 Z-C3
6211 Z-C3
6211 Z-C3
6211 Z-C3
6212 Z-C3
6212 Z-C3
6212 Z-C3
6212 Z-C3
6314 C3
6314 C3
6314 C3
6314 C3
6314 C3
6314 C3
6314 C3
6314 C3
6316 C3
6314 C3
6316 C3
6314 C3

Bearings
Mounting

frame
63
71
80
90 S - L
100 L
112 M
132 S - M
160 M - L
180 M - L
200 M - L
225 S/M
250 S/M
280 S/M
315 S/M

Mounting
Front (D.E.)
6307 ZZ
6307 ZZ
6307 ZZ
6308 ZZ

Bearings
Mounting

HORIZONTAL MOUNTING ONLY

NEMA

355 M/L

Front (D.E.)
Rear (O.D.E.)
Totally enclosed fan cooled motors
6201 ZZ
6201 ZZ
6203 ZZ
6202 ZZ
6204 ZZ
6203 ZZ
6205 ZZ
6204 ZZ
6206 ZZ
6205 ZZ
6307 ZZ
6206 ZZ
6308 ZZ
6207 ZZ
6309-C3
6209 Z-C3
6211 Z-C3
B3
6311-C3
6312-C3
6212 Z-C3
6314-C3
6314-C3
6314-C3
6314-C3
6314-C3
6314-C3
6316-C3
6316-C3
6314-C3
6314-C3
6319-C3
6316-C3
6314-C3
6314-C3
NU 322-C3
6319-C3

INSTALLATION AND MAINTENANCE MANUAL


FOR NEMA LOW VOLTAGE ELECTRIC MOTORS
Table 12 - Bearing lubrication intervals and amount of grease
1 - SINGLE-ROW FIXED BALL BEARINGS
Lubrication intervals (running hours)
Bearings

II Pole

IV Pole
60Hz
1800
rpm

50Hz
1500
rpm

VI Pole
60Hz
1200
rpm

50Hz
1000
rpm

VIII Pole
60Hz
900
rpm

50Hz
750
rpm

X Pole
60Hz
720
rpm

50Hz
600
rpm

XII Pole

Characteristics
Ref.

60Hz
3600
rpm

50Hz
3000
rpm

60Hz
600
rpm

50Hz Amount
500 of grease
rpm
(oz)

6200

12500

13800

6201

11700

13000

16600

18400

6202

10500

11900

15400

17100

19500

0,07

6203

9800

11200

14500

16200

18500

0,11

6204

8700

10100

13300

14800

17100

19100

6205

8000

9400

12600

14100

16200

18200

19300

6206

7300

8700

12000

13400

15400

17200

18300

6207

6600

8100

11400

12700

14500

16300

17300

19200

0,25

0,07
0,07

0,14

> 20000

0,14
0,18

6208

5900

7400

10800

12000

13700

15300

16300

18200

0,29

6209

5300

6900

10400

11600

13400

15000

16000

17800

0,29

6210

4900

6400

9700

11000

12900

14600

15600

17300

0,32

6211

4300

5900

9500

10900

12700

14400

15300

17000

0,39

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

6305

8000

9400

12600

14100

16200

18200

0,14
19300

0,21
0,25

6306

7300

8700

12000

13400

15400

17200

18300

6307

6600

8100

11400

12700

14500

16300

17300

19200

6308

5900

7400

10800

12000

13700

15300

16300

18200

18600

6309

5300

6900

10400

11600

13400

15000

16000

17800

18200

19900

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

6312

3800

5400

9300

10300

12400

14300

15200

16500

16800

18200

18200

0,75

6313

3100

4900

8900

10100

12200

14000

14800

16100

16400

17900

17900

19700

0,86

6314

1100

2000

4100

5000

5900

6500

6900

7600

7700

8600

8600

9600

0,96

> 20000

0,32
0,39
0,46

6315

1000

1800

4400

5000

5600

6300

6700

7600

7900

8900

8900

9900

1,07

6316

700

1600

4100

4700

5700

6500

6800

7500

7700

8500

8500

9500

1,22

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.

23

INSTALLATION AND MAINTENANCE MANUAL


FOR NEMA LOW VOLTAGE ELECTRIC MOTORS
Table 13 - Bearing lubrication intervals and amount of grease
2 - CYLINDRICAL ROLLER BEARINGS
Lubrication intervals (running hours)
Bearings

II Pole

IV Pole

VI Pole

X Pole

XII Pole

60Hz
3600
rpm

50Hz
3000
rpm

60Hz
1800
rpm

50Hz
1500
rpm

60Hz
1200
rpm

50Hz
1000
rpm

60Hz
900
rpm

50Hz
750
rpm

60Hz
720
rpm

50Hz
600
rpm

60Hz
600
rpm

50Hz Amount
500 of grease
rpm
(oz)

NU309

2800

4000

8300

9500

10700

11800

12500

14100

14500

16300

16300

18200

0,46

NU310

2400

3600

7900

9100

10300

11400

12200

13700

14000

15800

15800

17700

0,54

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

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

Characteristics
Ref.

NU315

900

2900

3800

4500

5100

5500

6200

6300

7100

7100

7900

1,07

NU316

800

2800

3600

4400

5000

5400

6100

6200

7000

7000

7800

1,22

NU317

600

2600

3500

4300

4900

5300

6000

6100

6900

6900

7700

1,32

NU318

2100

3300

4300

4900

5300

5900

6000

6700

6700

7500

1,47

NU319

2300

3200

4100

4700

5100

5800

6000

6700

6700

7500

1,61

NU320

2000

3000

4000

4700

5000

5700

5900

6600

6600

7300

1,82

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.

24

VIII Pole

INSTALLATION AND MAINTENANCE MANUAL


FOR NEMA LOW VOLTAGE ELECTRIC MOTORS

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 Cleanliness
Motors 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.

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 Grease


Correct 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 200C.
This grease should never be mixed with sodium or calcium
based greases.
GREASES FOR MOTOR BEARINGS

4.2 Lubrication
Proper 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 70C.
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 Lubrication


WEG motors are supplied with sufficient grease for a long

For operating temperatures from - 20 to 130C


Frame

Supplier

Grease

Temperature range

143T-215T
254T to 586/7

Esso
Shell

Alvania R3
Unirex N2

-20 to 130C
-30 to 165C

Substitutes
Supplier

Grease

Temperature Range

Mobil
ESSO
Atlantic
Texaco
Molikote
Inisilkon

Mobilith SHC100
Beacon 2
Litholine 2
Multifak 2
BG 20
L5012

-40 to 177C
-20 to 130C
-20 to 130C
-20 to 130C
-45 to 180C
-20 to 200C

Note: When changing lubricant, please follow manfacturers


instructions

4.2.3 Lubricating Instructions


a) Frame 140T to 210T motors
Frame 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.
25

INSTALLATION AND MAINTENANCE MANUAL


FOR NEMA LOW VOLTAGE ELECTRIC MOTORS
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 Motors


Motors 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 wellknown 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

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 Bearings


The 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
of the bearing case and hence into the motor.
Figure 4.1 - Bearings and lubrication system

26

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.

INSTALLATION AND MAINTENANCE MANUAL


FOR NEMA LOW VOLTAGE ELECTRIC MOTORS

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 Steps

4.4.1 Objective
In 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 Precautions

Dismantle 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 motors 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 WINDINGS
This 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.

IMPREGNATION
Protect 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.
ASSEMBLY
Inspect 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.
TESTING
Rotate 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 BOX
Prior 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
340B resin
Ground quartz

50 parts
50 parts
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.

27

INSTALLATION AND MAINTENANCE MANUAL


FOR NEMA LOW VOLTAGE ELECTRIC MOTORS

5. Malfunctioning

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 Failures


Owing 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 40C.
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 Turns


A 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 Failures

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 phases


This 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 phases


Probable cause 1
Motor 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 2
Motor 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 3
The 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 4
Failures 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 shaft
e) load torque vs. speed during acceleration and braking.

a) One burnt winding phase


This failure arises when a motor runs wired in delta and current

28

The continuous effort exerted by the rotor during intermittent

INSTALLATION AND MAINTENANCE MANUAL


FOR NEMA LOW VOLTAGE ELECTRIC MOTORS

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.

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 Drives


5.1.3 Rotor Failures
If 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 Failures


Bearing 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.

The 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 Alignment
Damage 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.

5.1.5 Shaft Fractures


Although 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.

29

INSTALLATION AND MAINTENANCE MANUAL


FOR NEMA LOW VOLTAGE ELECTRIC MOTORS

5.2 Troubleshooting chart


FAILURE
Motor fails to start

PROBABLE CAUSE
1.No voltage supply
2. Low voltage supply
3. Wrong control connections
4. Loose connection at some
terminal lug
5. Overload

High noise level

1. Unbalance
2.
3.
4.
5.
6.

Distorted shaft
Incorrect alignment
Uneven air gap
Dirt in the air gap
Extraneous matter stuck between
fan and motor casing
7. Loose motor foundation
8. Worn bearings

Overheating of bearings

1. Excessive grease
2.
3.
4.
5.

Excessive axial or radial strain on belt


Deformed shaft
Rough bearing surface
Loose or poorly fitted motor end
shields
6. Lack of grease
7. Hardened grease cause locking of
balls
8. Foreign material in grease

Intense bearing vibration

1. Unbalanced rotor
2. Dirty or worn bearing
3. Bearing rings too tight on shaft
and/or bearing housing
4. Extraneous solid particles in
bearing

Overheating of motor

1. Obstructed cooling system


2. Overload
3. Incorrect voltages and frequecies
4. Frequent inversions
5. Rotor dragging on stator
6. Unbalanced electrical load
(burnt fuse, incorrect control)

30

CORRECTIVE MEASURES
Check feed connections to control system and from this to motor.
Check voltage supply and ascertain that voltage remains
within 10% of the rated voltage shown on the motor nameplate.
Compare connections with the wiring diagram on the
motor nameplate.
Tighten all connections.
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.
Vibrations can be eliminated by balancing rotor. If load is
coupled directly to motor shaft, the load can be unbalanced.
Shaft key bent; check rotor balance and eccentricity.
Check motor aligment with machine running.
Check shaft for warping or bearing wear.
Dismantle motor and remove dirt or dust with jet of dry air.
Dismantle motor and clean. Remove trash or debris from
motor vicinity.
Tighten all foundation studs. If necessary, realign motor.
Check lubrication. Replace bearing if noise is excessive
and continuous.
Remove grease bleeder plug and run motor until excess
grease is expelled.
Reduce belt tension.
Have shaft straightened and check rotor balance.
Replace bearings before they damage shaft.
Check end shields for close fit and tightness around circumference.
Add grease to bearing.
Replace bearings.
Flush out housings and relubricate.
Balance rotor statically and dynamically.
If bearing rings are in perfect condition, clean and
relubricate the bearing, otherwise, replace bearing.
Before altering shaft or housing dimensions, it is advisable
to ascertain that bearing dimensions correspond to
manufacturers specifications.
Take bearing apart and clean. Reassemble only if rotating
and support surfaces are unharmed.
Clean and dry motor; inspect air vents and windings periodically.
Check application, measuring voltage and current under
normal running conditions.
Compare values on motor nameplate with those of mains
supply. Also check voltage at motor terminals under full load.
Exchange motor for another that meets needs.
Check bearing wear and shaft curvature.
Check for unbalanced voltages or operation under
single-phase condition.

INSTALLATION AND MAINTENANCE MANUAL


FOR NEMA LOW VOLTAGE ELECTRIC MOTORS

6. Spare Parts and


Component Terminology

THREE-PHASE MOTORS IP55 NEMA Frames 140T - W180T - 180T - 210T and W210T

Part Nr.
1
2
3
4
5
6
7
8
9
10
11
12

Description
Terminal box cover
Terminal box cover fixing bolt
Terminal box cover gasket
Terminal box fixing bolt
Terminal box fixing washer
Terminal box grounding lug
Terminal box
Frame grounding lug
Terminal box oring gasket
Fan cover
Fan cover fixing bolt
Fan

Part Nr.

Description

13
14
15
16
17
18
19
20
21
22
23
24

VRing
Non-drive end endshield fixing bolt
Non-drive end endshield washer
Non-drive endshield
Spring washer
Non-drive bearing
Fan fixing pin
Wound stator
Rotor / shaft assembly
Nameplate fixing rivet
Nameplate
Frame

Part Nr.
25
26
27
28
29
33
31

Description
Shaft key
Drive end bearing
Drive endshield
Drive endshield washer
Drive end endshield fixing bolt
VRing
Drain plug

THREE-PHASE MOTORS IP55 NEMA Frames 250T - W250T - 280T and 320T

Part Nr.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Description
Terminal box cover
Terminal box cover fixing bolt
Terminal box cover gasket
Terminal box fixing bolt
Terminal box fixing washer
Terminal box grounding lug
Terminal box
Frame grounding lug
Terminal box oring gasket
Fan cover
Fan cover washer
Fan cover fixing bolt
Fan
Non-drive end bearing cap bolt
VRing

Part Nr.

Description

16
17
18
19
20
21
22
23
24
25
26
27
28
29

Non-drive end endshield fixing bolt


Non-drive end bearing cap washer
Non-drive end grease nipple
Non-drive end grease nipple cover
Non-drive end endshield washer
Non-drive endshield
Spring washer
Non-drive end bearing
Non-drive end bearing cap
Fan fixing pin
Wound stator
Rotor and shaft
Eyebolt
Nameplate fixing rivet

Part Nr.
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44

Description
Nameplate
Frame
Shaft key
Drive end bearing cap
Drive end bearing
Drive andshield
Drive end grease nipple cover
Drive endshield washer
Drive end endshield fixing bolt
Drive end bearing cap washer
VRing
Drive end bearing cap fixing bolt
Drain plug
Non-drive and grease relief
Drive end grease relief

31

INSTALLATION AND MAINTENANCE MANUAL


FOR NEMA LOW VOLTAGE ELECTRIC MOTORS

THREE-PHASE MOTORS IP55 NEMA T Frames 360T - 400T - 440T - 500T and 580T

Part Nr.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

32

Description
Terminal box cover
Terminal box cover fixing bolt
Terminal box cover washer
Terminal box cover gasket
Terminal box fixing bolt
Terminal box fixing washer
Terminal box grounding lug
Terminal box
Frame grounding lug
Terminal box oring gasket
Nameplate fixing rivet
Nameplate
Eyebolt
Fan cover
Fan cover washer
Fan cover fixing bolt
Fan fixing ring

Part Nr.

Description

18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33

Fan
Non-drive end bearing cap bolt
VRing
Non-drive end bearing cap washer
Non-drive end endshield fixing bolt
Non-drive end endshield washer
Non-drive end grease nipple
Non-drive end grease nipple cover
Non-drive enshield
Bearing cap
Non-drive bearing
Internal non-drive end bearing cap
Fan fixing key
Wound stator
Rotor / shaft assembly
Frame

Part Nr.
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49

Description
Shaft key
Internal drive end bearing cap
Drive end bearing
Drive endshield
Drive end grease nipple cover
Drive endshield washer
Pre-load spring
Drive end endshield fixing bolt
External drive end bearing cap
Drive end bearing cap washer
VRing
Drive end bearing cap fixing bolt
Drain plug
External non-drive end bearing cap
Non drive end grease relief
Non-drive end grease relief

INSTALLATION AND MAINTENANCE MANUAL


FOR NEMA LOW VOLTAGE ELECTRIC MOTORS

THREE-PHASE MOTORS NEMA 56 Frames A56 - B56 - D56 - F56H and G56H

Part Nr.
1
2
3
4
5
6
7

Description
Sticker
Terminal box cover fixing bolt
Terminal box cover
Grounding lug
Through bolt fastening nut
Non-drive endshield
Spring washer

Part Nr.
8
9
10
11
12
13

Description
Non-drive end bearing
Wound stator
Rotor / shaft assembly
Frame
Through bolt
Shaft key

Part Nr.

Description

14
15
16
17

Fan
Drive end bearing fastening washer
Drive end bearing
Drive endshield

SINGLE-PHASE MOTORS NEMA 56 Frames B48 - C48 - C56 - A56 - B56 - D56 - F56H - G56H

Part Nr.
1
2
3
4
5
6
7
8
9
10
11

Note:

Description
Sticker
Capacitor cover fixing bolt
Terminal box cover fixing bolt
Terminal box cover
Grounding lug
Through bolt fastening nut
Non-drive endshield
Spring washer
Non-drive and bearing
Non-drive and bearing fastening
washer
Stationary switch

Part Nr.

Description

Part Nr.

12
13
14

Stationary switch fastening bolt


Centrifugal switch
Rubber ring for lead passing hole to
capacitor
Capacitor cover
Capacitor
Wound stator
Rotor / shaft assembly
Frame
Through bolt
Shaft key
Fan

23
24
25
26
27

15
16
17
18
19
20
21
22

Description
Drive end bearing fastening washer
Drive end bearing
Drive endshield
Overload thermal protector fixing ring
Overload thermal protector

For F56H and G56H frame motors: 1) Part nr. 2 = 3 pieces; 2) Part nr. 15 and 16 = 2 pieces

33

INSTALLATION AND MAINTENANCE MANUAL


FOR NEMA LOW VOLTAGE ELECTRIC MOTORS

NOTES:

34

INSTALLATION AND MAINTENANCE MANUAL


FOR NEMA LOW VOLTAGE ELECTRIC MOTORS

NOTES:

35

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.

WEG Electric Motors Corp.


2100 Brighton-Henrietta Townline Road
Rochester NY 14623
PHONE: 716-240-1000
FAX: 716-240-1034

3.4.1

Curvde # 80428SDF
Issue Date: August 1999

PUMP WATER HP VERSUS DISCHARGE PRESSURE


EDWARDS MODEL 80-428 STANDARD DUTY
9.00
1800 RPM
1500 RPM
1200 RPM
1000 RPM

8.00
7.00

HORSEPOWER

6.00
5.00
4.00
3.00
2.00
1.00
0.00
5

50

100

150

200

DISCHARGE PRESSURE (PSI)

PUMP WATER FLOW VERSUS DISCHARGE PRESSURE


EDWARDS MODEL 80-428 STANDARD DUTY
60

DISCHARGE FLOW (GPM)

50

40

30

20
1800 RPM
1500 RPM
1200 RPM
1000 RPM

10

0
5

50

100

150

200

DISCHARGE PRESSURE (PSI)

2439 SE STUBB ST.


MILWAUKIE, OR, USA 97222

PH: 503/659-4198
FX: 503/659-4696

EMAIL: edwards_info@pentairpump.com
WEBSITE: www.edwardsmfg.com
3.4.2

GKWT.EX5231
Pumps, Foam Concentrate
Page Bottom

Pumps, Foam Concentrate


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
rpm

Pressure Range
psi

Max 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

1000-1800

40-200

400

150-332SDF

1000-1800

40-200

400

150-338SDF

1000-1800

40-200

400

150-344SDF

1000-1800

40-200

400

150-348SDF

1000-1800

40-200

400

160-324HDF

1000-1800

200-300

550

3.4.3.1

160-332HDF

1000-1800

200-300

550

160-338HDF

1000-1800

200-300

550

160-344HDF

1000-1800

200-300

550

160-348HDF

1000-1800

200-300

550

300-360SDF

1000-1800

40-200

400

300-368SDF

1000-1800

40-200

400

300-372SDF

1000-1800

40-200

400

300-388SDF

1000-1800

40-200

400

300-360HDF

1000-1800

200-300

550

300-368HDF

1000-1800

200-300

550

300-372HDF

1000-1800

200-300

550

300-388HDF

1000-1800

200-300

550

300-388HDF-AG

1000-1800

200-300

550

400-092HDF

1000-1800

40-300

550

400-112HDF

1000-1800

40-300

550

400-128HDF

1000-1800

40-200

400

400-140HDF

1000-1800

40-200

400

The maximum viscosity of foam concentrate intended for use with these pumps is 2700 cps.
Last Updated on 2006-02-14
Questions?

Notice of Disclaimer

Page Top

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 nonmisleading 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."

3.4.4

Contents

Safety

General Precautions . . . . . . . . . . . . . . iii


Warnings and Cautions . . . . . . . . . . . . iii

Inspection . . . . . . . . . . . . . . . . . . . . . . 3-1
Unpacking . . . . . . . . . . . . . . . . . . . . . . 3-1
Repacking . . . . . . . . . . . . . . . . . . . . . . 3-1
Storage . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Installation. . . . . . . . . . . . . . . . . . . . . . 3-2

Warnings . . . . . . . . . . . . . . . . . . . . . . . . iii
Cautions . . . . . . . . . . . . . . . . . . . . . . . . . iv

Clean Pump . . . . . . . . . . . . . . . . . . . . . 3-2


Mount Pump. . . . . . . . . . . . . . . . . . . . . 3-2
Prepare Foundation . . . . . . . . . . . . . . . 3-4
Level Pump Skid . . . . . . . . . . . . . . . . . 3-5
Grout Pump Skid . . . . . . . . . . . . . . . . . 3-5
Check Driver Rotation . . . . . . . . . . . . . 3-6
Align Couplings . . . . . . . . . . . . . . . . . . 3-7
Piping . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Strainers . . . . . . . . . . . . . . . . . . . . . . . 3-10
Overpressure Protection . . . . . . . . . . 3-10

General
Introduction . . . . . . . . . . . . . . . . . . . . 1-1
Pump Specifications . . . . . . . . . . . . . 1-2

Maintenance
Consumable Materials . . . . . . . . . . . . 2-1
Lubrication . . . . . . . . . . . . . . . . . . . . . 2-2
Troubleshooting . . . . . . . . . . . . . . . . . 2-2
Removal . . . . . . . . . . . . . . . . . . . . . . . 2-3
Disassembly . . . . . . . . . . . . . . . . . . . . 2-4
General Practice . . . . . . . . . . . . . . . . . 2-4
Disassembly Procedure . . . . . . . . . . . . 2-4

Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-6
Inspection . . . . . . . . . . . . . . . . . . . . . . 2-7
Repair and Replacement . . . . . . . . . . 2-7
Assembly . . . . . . . . . . . . . . . . . . . . . . 2-8

Installation

Pre-Startup Checks . . . . . . . . . . . . . 3-11

Parts
Warranty

General Practice . . . . . . . . . . . . . . . . . 2-8


Assembly Procedure . . . . . . . . . . . . . . 2-8

Replacement. . . . . . . . . . . . . . . . . . . 2-12

Safety

General Precautions
The following are general safety precautions not related to any specific procedure. Personnel must understand and apply these precautions during both operation and maintenance 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 deenergize 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 precautions while working with the chemicals used in cleaning agents.

Warnings and Cautions


The 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 personal injury.

iii

Edwards Model 80-428 Pump

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.

Cautions
Do not hammer on pump endcase. This will cause gasket sealing surface damage, 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 assembly 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 installing 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 connecting piping to pump.

iv

General

Introduction
pump
(Figure
a standard-duty
high-speed
gearThe Edwards Model
Model 80-428
80 pump
(Figure
1-1)1-1)
is a is
standard-duty
high-speed
gear-driven
driven positive-displacement
with gear-type
The casing,
liners, and
positive-displacement
rotary rotary
pump pump
with gear-type
rotors.rotors.
The pump
is self-priming.
rotors arerotary
bronze.
The drive
and idler rotor
shafts
are stainless steel.
pump
fitted
Edwards
pumps
are available
in many
configurations.
WhileThe
they
mayislook
with lip
seals,
andbeissignificant
self-priming.
alike,
there
may
differences from one pump to another. Differences
include construction material, sealing method, rotor type, etc.
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 construction material, sealing method, rotor type, etc. This manual covers only one configuration, 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

1070_0001c.cdr

Figure
Edwards
Model
80 Pump
Figure
1-1. 1-1.
Edwards
Model
80-428
Pump

1-1

Maintenance

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.
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 construction material, sealing method, rotor type, etc. This manual covers only one configuration, 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 available tools.

Consumable Materials
Cleaning materials, lubricants, and other products needed during pump maintenance
are listed in Table 2-1.
Table 2-1. Consumable Materials
Item

Nomenclature

Specification

Common Name

Lint-Free Cloth

MIL-C-85043

Dry Cleaning Solvent

Emery Cloth

Anti-Seize Compound

Nevr Seize

Red Loctite

PermaLoc HH-120

High-Tack Gasket Spray

Loctite, Permatex

Acetone, Brake
Cleaner
220 Grit

3M, Anderson,
Sandvik, Mirka

2-1

Edwards Model 80-428 Pump

Table 2-1. Consumable Materials (Continued)


Item
7

General Purpose Grease

Zerk fittings do not


have check balls.
This prevents bearings from being
over-greased.
Excess grease will
run out of the fitting when pump is
in operation.

Nomenclature

Lapping Compound

Specification
MIL-G-18709

Common Name

NLGI #2

Chevron Ulti-Plex,
Shell Retina LC

D51804, 180 Grit


Silicon Carbide

Felpro Clover
Brand

Lubrication
To 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 180F, contact
EMI
for for
recommended
lubrication
interval
for your
application.
Pentair
recommended
lubrication
interval
for your
application.

Table 2-2.
2-2. Model
Model 80-428
80 Lubrication
Schedule
Table
Lubrication
Schedule
Item

Interval

Amount of Grease

Bearings

6,000 Hours

0.25 Ounce

Timing Gears

6,000 Hours

1.00 Ounce

Troubleshooting
Table 2-3 provides assistance in diagnosing and correcting malfunctions that may occur
during normal operation.
Table 2-3. Troubleshooting
Trouble
1.

The pump has


heat-treated steel
timing gears,
which can be very
noisy when operated above 900
rpm. This is a normal condition, and
does not require
maintenance
action.

2-2

2.

Pump does
not turn

Excessive
Noise

Probable Cause

Remedial Action

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.

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 10in. Hg in most cases.
Contact EMI for the exact
reading for your
application.

Maintenance

Table 2-3. Troubleshooting (Continued)


Trouble

3.

4.

Excessive
vibration

Reduced flow

Probable Cause

Remedial Action

2c. Worn or damaged


bearing(s).

2c. Repair or replace pump.

3a. Loose or misaligned


coupling.

3a. Tighten, align, or replace


coupling.

3b. Cavitation.

3b. Check suction piping with


a vacuum gauge. Gauge
should read less than 10in. Hg in most cases.
Contact EMI for the exact
reading for your
application.

3c. Worn or damaged


bearing(s).

3c. Repair or replace pump.

4a. Clogged suction screen.

4a. Clean or replace screen.

4b. Cavitation.

4b. Check suction piping with


a vacuum gauge. Gauge
should read less than 10in. Hg in most cases.
Contact EMI for the exact
reading for your
application.

4c. Pump liners and/or


rotors worn or damaged.

4c. Repair or replace pump.

4d. Low pump speed

4d. Increase pump speed.

Removal
To avoid injury, always de-energize the input driver and lock-out or red-tag the
controller. Let the pump cool before removing.
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 components 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.

2-3

Edwards Model 80-428 Pump

Disassembly
General Practice
1. 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 construction 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 Procedure
The pump can be
reassembled into
several configurations 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 during 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 misalignment during
removal.

2-4

Remove machine
four machine
screws
(4, Figure
nuts (3),
timing
gear
1. Remove
screws
(4, Figure
4-1), 4-1),
nuts four
(3), timing
gear
cover
(2),cover
and (2),
and cover
gasket
Discard
gasket.
cover
gasket
(5). (5).
Discard
gasket.
2. Remove idler timing gear locknut (9).
3. Fabricate timing gear puller plate as shown in Figure 2-2.
.

Use shaft protector between puller tip and shaft face to prevent distortion of
shaft center.
Install timing gear puller
NCon
x 1-3/4-in.
Grade
8 cap
4. Install
puller plate
plate with
with two
cap 5/16
screws
idler timing
gear
(12,screws
Figureon
idler timing
gear (12, puller,
Figure pull
4-1).on
Using
jaw-type
puller,
on the gear
puller
4-1).
Using jaw-type
the gear
puller
platepull
to remove
the idler
timing
plate to
remove
idler timing
gear.
Repeat
procedure
for drive timing gear (11).
gear.
Repeat
procedure
for the
drive
timing
gear (11).
5. Remove Woodruff key (10) from drive shaft.
Remove machine
four machine
screws
(7), four
nuts (3),
front
(6), and
cover(5).
gasket
(5).
6. Remove
screws
(7), nuts
(3), front
cover
(6),cover
and cover
gasket
Discard
Discard gasket.
gasket.
7. Remove front cover seal (8) from front cover (6). Discard seal.
8. Remove
(13) from
endcases
(17).
Remove setscrews
four setscrews
(13) from
two endcases
(17).
9. Remove
bearing
adjusting
nuts
(14)
from
endcases
(17).
Remove four bearing adjusting nuts (14) from two endcases
(17).
10. Remove
cap screws
screws (18),
(18), nuts
2 nuts
(3),
andwashers
10 washers
timing
endcase
Remove8cap
(3),
and
(19) (19)
fromfrom
timing
geargear
endcase
(17).
(17).
Do not hammer on pump endcase. This will cause gasket sealing surface damage, resulting in leaks.
Use shaft protector between puller tip and shaft face to prevent distortion of
shaft center.
11. Using jaw-type puller, remove timing gear endcase (17) and pump body gasket (21).
Discard gasket.

Maintenance

UPPER DRIVE

SUCTION
PORT

DISCHARGE
PORT

DISCHARGE
PORT

RIGHT HAND
ROTATION

LEFT HAND
ROTATION

LOWER DRIVE

SUCTION
PORT

SUCTION
PORT

DISCHARGE
PORT

LEFT HAND
ROTATION

RIGHT HAND
ROTATION

1070_0002a.cdr

NOTE: ALL ROTATIONS ARE VIEWED FROM PUMP SHAFT END.


EMI USES THE FOLLOWING NOTATION FOR PUMP IDENTIFICATION:
UR
UL
LR
LL

= UPPER SHAFT RIGHT HAND ROTATION


= UPPER SHAFT LEFT HAND ROTATION
= LOWER SHAFT RIGHT HAND ROTATION
= LOWER SHAFT LEFT HAND ROTATION

Figure 2-1. Pump Configuration Diagram

2-5

Edwards Model 80-428 Pump

1
THRU
3/8 HOLES
(2 PLACES)

5/16 x 1-3/4 NC GRADE 8


CAP SCREWS (2 PLACES)

1-5/8
3/4
4
1-1/2
1070_0003b.cdr

Figure 2-2. Timing-Gear Puller Plate Fabrication Diagram

12. Remove
Remove8cap
(3),
and
washers
(19) (19)
fromfrom
timing
geargear
endcase
(17).
capscrews
screws (18),
(18), nuts
2 nuts
(3),
and
10 washers
timing
endcase
(17).
13. Using jaw-type puller, remove drive endcase (17) and pump body gasket (21). Discard gasket.
Never hammer directly on pump drive shaft. This will cause the rotor assembly to become misaligned, resulting in incorrect internal clearances. Also,
hammering on the shaft ends may damage the shaft centers.

and hardwood
hardwoodblock,
block,tap
tappump
pumpdrive
driveshaft
shafttotoremove
removeidler
idler
and
14. Using hammer and
and
drive
drive
assemblies
(2324)
and
24)two
and
liners
(22).
rotor rotor
assemblies
(23 and
and
liners
(22).
15. Using hammer and hardwood
liners
pump
body
hardwood block,
block, remove
remove other
other two
liners
(22)(22)
fromfrom
pump
body
(27).
(27).
If damaged,
damaged, remove four
(26) from
pump
16. If
studsstuds
(26) from
pump
bodybody
(27).(27).
Using hammer and brass
bearings
fourseals
grease
seals
17. Using
brass drift,
drift, remove
removefour
ball ball
bearings
(15)(15)
andand
grease
(16)
from
(16) from(17).
two endcases (17).
endcases
18. Using hammer and brass
lip seals
two endcases
(17).
brass drift,
drift, remove
remove four
lip seals
(20)(20)
fromfrom
endcases
(17).
19. If damaged or plugged,
grease
fittings
(1) from
two endcases
plugged, remove
remove two
grease
fittings
(1) from
endcases
(17). (17).
20. If damaged or plugged, remove grease fittings (1) from timing gear cover (2).

Cleaning
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.
1. Use dry cleaning solvent (2, Table 2-1) to clean parts. Do not use gasoline for
cleaning parts.

2-6

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 moistened 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 damaging 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 individual passages.
7. Buff bearing adjusting nut threads (14, Figure 4-1) with a wire brush.

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.

Inspection
1. 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 rotation, 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 Replacement


1. 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) counterbore surfaces and inside diameter of pump body (27).

Take special care to


keep gasket surfaces flat and
smoothly finished
to prevent leakage.

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.

2-7

Edwards Model 80-428 Pump

Assembly
General Practice
1. 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 recommend 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 gaskets 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.
If rotors are worn,
replace both rotor
assemblies.

Assembly Procedure
Assemble Rotors and Liners
If removed,
removed, install
install studs
four studs
(26, Figure
in pump
using
red Loctite
1. If
(26, Figure
4-1) 4-1)
in pump
bodybody
(27) (27)
using
red Loctite
(5,
Table
2-1).
Remove
all all
traces
of of
redred
Loctite
after
installing
studs.
(5, Table
2-1).
Remove
traces
Loctite
after
installing
studs.
2. Install
Install liners
two liners
in pump
Make
liner
suction
faces
pump
2.
(22) (22)
in pump
bodybody
(27).(27).
Make
suresure
liner
suction
holehole
faces
pump
body suction
suction port
port as
as shown
shown in
in Figure 2-3.
body

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.

DISCHARGE
SIDE
SUCTION
HOLES

SUCTION
SIDE

1070_0017b.cdr

Figure 2-3. Liner Installation


Do not rotate rotor assemblies until bearings have been installed and adjusted.
Damage to rotors and liners may occur.

2-8

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.
InstallSeals
Seals(if pump has lip seals)
Install

and outside
outside diameters
diametersof
offour
lip seals
(20,(20,
Figure
4-1)4-1)
withwith
red red
1. Lightly coat bores and
lip seals
Figure
Loctite (5, Table 2-1).
Do not use excessive force when installing seals. This could damage the seals,
causing them to leak. Use approved tools available from Pentair.
EMI.

2.
seals
(20, Figure
4-1) in
seal
boresbores
of endcases
(17). Press
allseals
the
2. Install
Install lip
four
lip seals
(20, Figure
4-1)
in seal
of two endcases
(17).seals
Press
way
to
the
bottom
of
the
bore
as
shown
in
Figure
2-4.
We
recommend
using
an
all the way to the bottom of the bore as shown in Figure 2-4. We recommend using
arbor
press
to seat
thethe
seals.
Installation
tools
are
available
an arbor
press
to seat
seals.
Installation
tools
are
availablefrom
fromPentair.
EMI.
Pre-lubricate grease
four grease
(16) with
approved
grease
(7, Table
3. Pre-lubricate
sealsseals
(16) with
approved
grease
(7, Table
2-1).2-1).
Install grease
four grease
Figure
in two endcases
(17)
with sealing
lip facing
4. Install
sealsseals
(16, (16,
Figure
4-1) 4-1)
in endcases
(17) with
sealing
lip facing
toward counterbore
counterbore in
in endcase.
toward

CAP SCREW

BODY GASKET

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.

BODY

ENDCASE
LINER

SEAL
INSTALLATION
CONE

ROTOR
ASSEMBLY

SEAL

1070_0004a.cdr

Figure 2-4. Single Lip Seal Installation

2-9

Edwards Model 80-428 Pump

Install Endcases
1. Install new pump body gasket (21) to each side of the body (27).

Seals must be
installed in endcases before installing endcases.

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 running the nut and washer up against liners.
3. Check that seals (20) have been installed in endcases (17) before proceeding with
endcase installation.
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.

We highly
highly recomrecommend
you seal
use
mend you use
seal
installation
installation
cones
cones
on thefrom
rotor
(available
shafts
EMI) during
on the rotor
installation
of the
shafts during
endcases.
installation of the
endcases.

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.
5.
6.
7.

Install cap
8 cap
screws
(18),
10 washers
and 2(3)
nuts
and tighten
finger-tight.
Install
screws
(18),
washers
(19), (19),
and nuts
and(3)
tighten
finger-tight.
Remove large washer and nut (3) from timing-gear end of pump body (27).
Carefully install other endcase (17) over idler and drive rotor assemblies (23 and
24). Use caution not to damage seals (20).
Install cap
8 cap
screws
(18),
10 washers
and 2(3)
nuts
and tighten
finger-tight.
8. Install
screws
(18),
washers
(19),(19),
and nuts
and(3)
tighten
finger-tight.
Install Bearings

1. Pack
(15) with
approved
grease
(7, Table
2-1).2-1).
Pack ball
four bearings
ball bearings
(15) with
approved
grease
(7, Table
Support ends of shafts axially with a jaw puller on the endcase when installing 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.

Bearing
Bearinginstallation
installatools
are available
tion tools
are availfrom
able Pentair.
from EMI.

2. Using
Using aa bearing
bearing seating sleeve,
bearings
Figure
on both
2.
sleeve, install
install two
ballball
bearings
(15,(15,
Figure
4-1)4-1)
on both
ends of
of idler
idler and
and drive rotor assemblies (23
ends
(23 and
and 24).
24). Make
Makesure
sureball
ballbearings
bearingsare
seated
on shoulders
of shafts
withwith
loading
grooves
facing
center
of pump.
are
seated
on shoulders
of shafts
loading
grooves
facing
center
of the pump.
Using criss-cross
criss-cross pattern, tighten
screws
(18)
lb-ft.
3. Using
tighten 16
capcap
screws
(18)
to to
12 12
to to
1515
lb-ft.
4.
Using
criss-cross
pattern,
tighten
nuts
(3)
to
8
to
10
lb-ft.
4. Using criss-cross pattern, tighten four nuts (3) to 8 to 10 lb-ft.
Adjust Rotor Clearance

The rotors must be


centered between
the liners.

2-10

1. Install
adjusting
nutsnuts
(14)(14)
on endcases
(17), leaving
about 1/2-turn
short
Install bearing
four bearing
adjusting
on two endcases
(17), leaving
about 1/2-turn
of
bearing
contact.
short
of bearing
contact.
2. On idler rotor assembly (23) tighten one bearing adjusting nut (14) until rotor contacts liner (22). Install dial indicator on opposite end of shaft as shown in Figure 25 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.)

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.
.

Do not overtighten bearing adjusting nut setscrews. Excessive bearing preload


may result, causing bearing damage.
6. Tighten the setscrews (13) enough to secure the bearing adjusting nuts (14) in endcase (17).
7. Repeat steps 2 through 6 for drive rotor assembly (24) bearings.

ENDCASE

USE NUT AND BOLT


TO SUPPORT DIAL INDICATOR

SECURE TO BOLT

DIAL INDICATOR
ROTOR SHAFT
1070_0018a.cdr

Figure 2-5. Rotor Clearance Adjustment


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).
To avoid injury, always use suitable protective gear. The timing gear is hot!

2. If possible, preheat drive timing gear (11, Figure 4-1) to 450F and install with Woodruff 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).

2-11

Edwards Model 80-428 Pump

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
Apply light coat of approved grease
grease (7,
(7, Table
Table 2-1)
2-1) to
to front
front cover
cover gasket
gasketsurface
surfaceand
and
install
new
gasket
(5,
Figure
4-1),
front
cover
(6),
four
machine
screws
(7),
four
install
gasket (5, Figure 4-1), front cover (6), machine screws (7), andand
nuts
(3).
nuts (3).machine
Tighten screws
machine
to lb-ft.
12 to 15 lb-ft.
Tighten
toscrews
12 to 15
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
Apply light
light coat
coat of
of approved
approved grease (7, Table
5.
Table 2-1)
2-1) to
to timing
timing gear
gearcover
coversealing
sealingsurface andand
install
newnew
gasket
(5, Figure
4-1),4-1),
timing
geargear
cover
(2), (2),
fourmachine
machine
surface
install
gasket
(5, Figure
timing
cover
screws (4),
(3). Tighten
screws
to 15 lb-ft.
screws,
andand
nutsfour
(3).nuts
Tighten
machinemachine
screws to
12 toto
1512
lb-ft.
Lubricate Bearings
If removed,
removed, install two
grease
fittings
(1)each
in each
endcase
twofittings
grease fit1. If
grease
fittings
(1) in
endcase
(17)(17)
andand
grease
(1)
tings
(1) in
timing
gear
in
timing
gear
cover
(2).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 bearings have been previously packed.

Replacement
1. 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 misalignment. Correct any problems.

2-12

Installation

Inspection
EMI pumps
are are
shipped
suitably
protected
to prevent
damage
in transit
fromfrom
normal
Pentair
pumps
shipped
suitable
protected
to prevent
damage
in transit
normal
handling. When
Whenreceived,
received,inspect
inspectthe
theshipment
shipmentimmediately:
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 Pentair
EMI of damage
to contents
not not
a fault
of the
carrier,
or inorthe
of shortof damage
to contents
a fault
of the
carrier,
in event
the event
of
ages.
shortages.

Unpacking
Care 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.

Repacking
1. Using suitable lifting device, lift pump and place on pallet.
2. Secure pump to pallet.
3. Install protective material.

Storage
If 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.

3-1

Edwards Model 80-428 Pump

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.

Installation
The pump can be installed wherever adequate space exists to connect piping and perform 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 Pump
To 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 Pump
Install 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.
.

PUMP

DRIVER

SKID BASE
1070_0019a.cdr

Figure 3-1. Typical Pump Skid

3-2

Installation

NOTES
14.375

7.75

8
5.0
3.75
2.75

2.25

0.625

4.5

5.9375

1070_0006d.cdr

Figure 3-2. Edwards Model 80-428 Dimensions

6.25
3.13
2.50

2.50
CL PUMP

CL PUMP

0.38 HOLES

1.14
2.28

1070_0007c.cdr

Figure 3-3. Edwards Model 80-428 Mounting Bolt Locations

3-3

Edwards Model 80-428 Pump

Prepare Foundation
The 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 concrete.
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.
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.

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 aggregate) into form. Leave surface rough for anchoring grout.

FOUNDATION
FORM

TEMPLATE FOR HOLDING


FOUNDATION FORM BOLTS
FOUNDATION
BOLT ASSEMBLY
20 TIMES
DIAMETER
OF FOUNDATION
BOLTS

4 - 6'' LONGER
THAN PUMP
SKID BASE

4 - 6'' WIDER
THAN PUMP
SKID BASE

1070_0010a.cdr

Figure 3-4. Typical Foundation Form

3-4

Installation

PUT WASTE
AROUND BOLT
BEFORE POURING
CONCRETE

1/2
TEMPLATE
LEAVE SURFACE
ROUGH TO
ANCHOR GROUT

SLEEVE
5

1.5

WASHER
1/4
2
3

1070_0011a.cdr

Figure 3-5. Typical Foundation Bolt Configuration

Level Pump Skid


1. Before pump skid is set on foundation, clean underside of skid base and top of foundation.
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 Skid


The 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.

A small spirit level


should be used in
leveling the pump.
Surfaces for determining level in
order of preference
are the pump
flange faces, the
pump shaft, projections of machined
surfaces on the base
and, finally, the
surface of the base.

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.

3-5

Edwards Model 80-428 Pump

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 drying 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.

FINISH
GROUTING

1/4
BASE

ALLOW
1/2 TO 3/4
FOR LEVELING

GROUT
LEAVE
LEVELING
WEDGES OR
SHIMS IN
PLACE

WOOD
FRAME
CLEAN AND
WET DOWN
TOP OF
FOUNDATION

1070_0012a.cdr

Figure 3-6. Leveling and Grouting Diagram


Since alignment
follows the rotation check, we recommend the pump
and driver be separated during the
rotation check.

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 directional 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.

3-6

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 offset 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
manufacturers literature for specific allowable limits. Any improvement in alignment
beyond the coupling manufacturers minimum specification will extend pump, mechanical 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.

ANGULAR

PARALLEL

For applications
where pumps are
operated at elevated
temperatures, final
alignment may not
be possible at operating 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 vertical allowance of
0.001 inch per inch
of pump shaft
height above the
base per 150F
(65C) should be
added to the height
of the driver shaft.

ANGULAR AND PARALLEL


1070_0013a.cdr

Figure 3-7. Types of Coupling Misalignment


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 manufacturers recommendations.
3. Adjust shims under driver or adjust driver location in horizontal plane.

3-7

Edwards Model 80-428 Pump

FEELER
GAUGE
1070_0014a.cdr

Figure 3-8. Checking for Angular Coupling Misalignment


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.

STRAIGHT
EDGE

SECURE
TO SHAFT
DIAL
INDICATOR

OR
1070_0015a.cdr

Figure 3-9. Checking for Parallel Coupling 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.

3-8

Installation

USE DIAL
INDICATOR
FOR PARALLEL
ALIGNMENT

SECURE BRACKET
TO COUPLING HALF

USE INSIDE MICROMETER FOR


ANGULAR ALIGNMENT

1070_0016a.cdr

Figure 3-10. Checking for Spacer Coupling Misalignment

Piping
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 connecting piping to pump.
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, precluding contact with adjacent piping and equipment. Pipe strains or stresses transmitted 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. Expansion 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 preferred 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 velocities, the fluid viscosity at the lowest pumping temperature, the length of the piping sys-

3-9

Edwards Model 80-428 Pump

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 manufacturers Engineering Manual or the Hydraulic Institutes
Engineering Data Book.
Do not install 45or 90-degree fittings at the pump
suction port. When
possible, provide 10
pipe diameters of
straight pipe at the
suction port.

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 highvacuum starting.

Strainers
With 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 probable 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 vacuum 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 notation 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 foreign material in the system is most likely to collect in the strainer.

Overpressure Protection
Overpressurization of the pump can cause equipment failure, resulting in personal injury.

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.

3-10

Installation

RECOMMENDED
BYPASS FLOW

SUPPLY
TANK

PRESSURE
RELIEF
VALVE

NPT
BUSHING

NOT RECOMMENDED

PIPE TEE

TO SYSTEM
SUCTION PORT
DISCHARGE PORT
ROTARY GEAR PUMP

1070_0005a.cdr

Figure 3-11. Pump By-pass Piping

Pre-Startup Checks
Inspection 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.

3-11

Parts

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.
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 construction material, sealing method, rotor type, etc. This manual covers only one configuration, 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.
3.

4.
5. Quantity needed.
Order replacement parts from:

Pentair
WaterNorth Aurora Operations
Edwards
Manufacturing
Inc.
800
Airport
Rd.
2441 SE Stubb St.
North
Aurora,
60542
Milwaukie,
ORIL,
97222
Phone: (630)
(503) 859-7000
659-4198
Phone:
FAX:
(503)
659-4696
FAX: (630) 859-7060
Internet: www.aurorapump.com
www.edwardsmfg.com
Internet:
E-Mail: parts@edwardsmfg.com

4-1

Edwards Model 80-428 Pump

1
9
5
12
14
15
17

16

3
18
19
1

11

20
21
13

3
19
13
22

23
27

24
10

26

21

19

22
18

20

10

5
6
7

19
3

8
13
17
16
15
14

Figure 4-1. Edwards


Edwards Model
Model 80-428
80 Pump
Exploded
ViewView
Pump
Exploded

4-2

1070_0008e.cdr

Parts

Figure &
Index No.

Part
Number

4-1-1
-2
-3
-4
-5
-6
-7
-8
-9
-10
-11
-12
-13
-14
-15
-16
-17
-18
-19
-20
-21
-22a
-22b
-23

1080428BBBS40S
0200032
0120022
0200038
0200070
0200082
0120002
0200072
0160004
0200002
0200057
0180004
0180002
0200034
0190002
0170004
0160006
0110004
0200006
0200020
0160050
0200080
0130202
0130202L
No Number

-23a

0140200

-23b

0150216

-24

No Number

-24a

0140200

-24b

0150018

-26
-27

0200014
0100012

Description

PUMP, Standard duty foam, all bronze with lip seals


Grease, 1/4-28
no check
ballno check ball
. FITTING, Grease,
short,
. COVER, Timing gear
. NUT, Hex, GR5, 1/4-20
. SCREW, Round/slot head, 1/4-20 X 2 in.
. GASKET, Cover
. COVER, Front
. SCREW, Round/slot head, 1/4-20 X 1 in.
. SEAL, Front cover
. LOCKNUT, Timing gear
. KEY, Woodruff, SS, 3/16 X 3/4 in.
. GEAR, Drive timing, straight bore
. GEAR, Idler timing, taper bore
. SETSCREW, Nylon tip, 5/16-18 X 5/16 in.
. NUT, Bearing adjusting
. BEARING, Ball
. SEAL, Grease
. ENDCASE
. SCREW, Cap, hex head, GR5, 1/4-20 X 3/4 in.
. WASHER, Flat, zinc, 1/4 SAE
. SEAL, Lip
. GASKET, Body
. LINER, Right hand
. LINER, Left hand
. ROTOR ASSEMBLY, Idler (Factory assembled from 23a and
23b.)
. .ROTOR, 80-428 (Cannot be ordered separately. Must be
ordered with 23b.)
. . SHAFT, Idler (Cannot be ordered separately. Must be
ordered with 23a.)
. ROTOR ASSEMBLY, Drive (Factory assembled from 24a
and 24b.)
. .ROTOR, 80-428 (Cannot be ordered separately. Must be
ordered with 24b.)
. . SHAFT, Drive (Cannot be ordered separately. Must be
ordered with 24a.)
. STUD, SS, 1/4-20 X 1.2 in.
. BODY, Pump

Units
Per
Assy

REF
5
1
12
4
2
1
4
1
1
2
1
1
4
4
4
4
2
16
20
4
2
2
2
1
1
1
1
1
1
4
1

4-3

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 startup, 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.

Warranty (8/99)

3.5.1

-CTS

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).

-EG
-EH
-EJ
-EK
-KH
-JR
-JT
-P
-PB
-PE
-PT

CIRCUIT BREAKER OPTION


-E
Intermediate withstand rating
85,000 Amperes RMS Sym at 200-240V
65,000 Amperes RMS Sym at 380-480V
25,000 Amperes RMS Sym at 550-600V

-HV
-LVA
-LW

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

-LY

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 SWITCHES
FTA975 - generator set emergency supply
FTA976 - 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)

Built in Low Suction Pressure Alarm Panel (Includes


selectable auto/manual reset, audible, visible and
remote alarms and mounted and wired pressure
switch)
Visible Relief Valve Discharge alarm
Contacts for remote indication, relief valve discharge
Built-in flow meter on alarm
Contacts for remote indication, flow meter on
Contacts for remote indication, common output for
any alarm
Visible jockey pump running indication
Audible and Visible jockey pump trouble indication
Built-in alarm system (Includes visible supervisory
voltage normal indication and audible pump operating, phase failure and phase reversal indication)
Built-in low system pressure visible alarm with
manual reset
Contacts for remote indication, low system pressure
Built-in alarm system, 220 VAC supervisory power
(Includes visible supervisory voltage normal
indication and audible pump operating, phase failure
and phase reversal indication)
Audible alarm device
Visible pump on demand alarm
Audible and visible pump on demand alarm (requires
(-HV))
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 Firetrol
representative 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


XXXGJSFUSPMDPN4BMFT0GGJDF$BSZ /$64"
PD750-20 (07-05-06)

$6&2

Specifications
Limited Service Fire Pump Controllers

Main Fire Pump Controller


The main fire 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, Standard 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 fire pump service.
Starting Method
The controller shall be of the combined manual
and automatic type designed for full voltage starting
of the fire pump motor having the horsepower, voltage, 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 Ratings)
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 Breaker
The controller shall include a thermal magnetic
circuit breaker. The circuit breaker shall be mechanically 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 fire 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 fluorescent, dot matrix

FTA750

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 opening 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 fire pump controller operator interface shall
be capable of displaying true RMS digital motor
voltage and current measurements for all three
phases simultaneously. Displays requiring pushbutton and selector switches to toggle between
phases or current and voltage shall not be accepted.
Voltage and current shall be measured by
True RMS technology to provide the most accurate
measurement for all sine waves, including nonsinusoidal 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
reflecting the value of the remaining time.
LED Visual Indicators
LED 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 Currents
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

3.5.2

Event Recording
Memory - The controller shall record all operational 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: flash drive,
thumb drive, memory stick, etc..) shall be provided.
The controller shall save all operational and alarm
events to the flash 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 flash disk utilized. The controller
shall have the capability to save settings and values
to the flash disk via the user interface.
Communications - The controller shall feature two
independent communications ports to allow connectivity 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 control of the fire 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.

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 addition, the controller shall have the capability to display
a preventative maintenance message for a service
inspection. The message text and frequency of occurrence 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 fire 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 fire pump controller software shall be automatically upgradable through the USB port by simply
inserting a flash disk with the new software. Fire pump
controllers that require laptop computers, handheld
equipment or specialized devices for software upgrades shall be prohibited.
The controller shall be a Firetrol brand.

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 field 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.

(919) 460-5200 www.firetrol.com Sales Office: Cary, NC 27512 USA


SP750-20 (06-08-07)

3.5.3

When the deluge valve contact opens, relay 1CR is


energized, closing its normally open contact to the 1M
contactor coil, and the motor runs.
When the deluge valve contact closes, relay 1CR is
de-energized, re-opening its normally open contact, deenergizing the 1M contactor, and the motor stops.
Shutdown Interlock Operation
The 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 the
pressure transducer, or the deluge valve. The controller
may be started manually by depressing the manual
START push button. See the specific starting operation
for more details.
Pump Motor Starting Sequence
Whenever relay 1CR is energized, its normally open
contact closes, allowing voltage to the coil of the motor
starting contactor. During full voltage starting the following
sequence occurs.
1CR normally open contact closes, energizing
contactor 1M . 1M connects motor terminals T1, T2,
and T3 to the power source. This starts the motor in the
full voltage configuration, in which the pump motor draws
100% of its normal inrush current and supplies 100% of
its normal starting torque.

Emergency Starting and Stopping


The controller is equipped with an emergency run
mechanism for use in the event of a coil burnout or other
electrical problem which would prevent normal starting
of the pump motor. The mechanism attempts to both
electrically and mechanically start the pump motor.
When the emergency run mechanism is utilized, a
e-run contact is closed, energizing 1M coil . This, in
effect, attempts to electrically start the pump motor.
The emergency run mechanism also manually
closes the 1M contactor, starting the motor. This will
run the motor as long as the main three phase power is
available.
If the pump motor is running via the emergency run
mechanism, DO NOT release the mechanism to stop
the motor. Place the circuit breaker handle in the off
position, then release the emergency run mechanism.
Releasing the mechanism while the motor is running
could result in damage to the motor or the motor
contactor.
Note: The emergency run mechanism is not intended
for, nor should it be used as a testing device. Its sole
purpose is to attempt to start the pump motor in the
event of a failure.


XXXGJSFUSPMDPN4BMFT0GGJDF$BSZ /$64"
SQ750-20 (04-12-07)

$6&2

3.5.4

3.5.5

QYZS.EX2662
Pump Controllers, Fire
Page Bottom

Pump Controllers, Fire


See General Information for Pump Controllers, Fire
ASCO POWER TECHNOLOGIES L P

EX2662

5625 DILLARD DR
CARY, NC 27511 USA
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 or
more 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 be
followed 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 be
followed 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, followed
by 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 by
additional suffixes.
Controllers are suitable for use as service equipment on circuits capable of delivering high fault currents: maximum ratings are
42,000 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 or
C, 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

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:

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

600

200,000

switches
Same as above when
provided with current
limiting devices (PCL)
Those controllers provided with transfer switches have withstand ratings on the normal side equal to those shown above at 240 and
480 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:

Circuit
Breaker

Rated
V

Short Circuit Current


RMS Symmetrical A

SEL

480

65,000

SED

600

14,000

SEL (with current

600

150,000

SEH

240

65,000

SEL

480

65,000

SEH

600

18,000

limiting device)

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
For operation with diesel generator (FTA-475).

Rated
V

Short Circuit Current


RMS Symmetrical A

All 975, any breaker

200-600 v

10,000

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

or molded case switch


For operation with second utility (FTA-976).

limiters - All HP
Cat. No. FTA-975 transfer switch assembly has the following short circuit rating:

Molded Case
Switch

Short Circuit
Current + RMS
Symmetrical A

Max
Rated V

SED

200-480

10,000

SED

550-600

10,000

+-When protected by an external circuit breaker rated 100 A maximum.


Cat. No. FTA-976 transfer switch assembly has the following short circuit rating:

Circuit
Breaker

Rated
V

Short Circuit Current


RMS Symmetrical A

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

++-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

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

Isolation
Voltage
Range

Withstand
Maximum
Rating RMS
Symmetrical
A

Circuit Breaker
MFR

Frame

Rating A

Rating
Code

200 240

ABB

S3NT

15-150

65,000

380 480

ABB

S3NT

15-150

25,000

550-600

ABB

S3NT

15-150

14,000

FTA750 Intermediate short-circuit rating

Isolation
Voltage
Range

Withstand
Maximum
Rating RMS
Symmetrical
A

Circuit Breaker
MFR

Frame

Rating A

Rating
Code

200 240

ABB

S3LT

15-150

85,000

380 480

ABB

S3LT

15-150

65,000

550-600

ABB

S3LT

15-150

25,000

FTA740 Standard short-circuit rating

Isolation
Voltage
Range
200 240

Circuit Breaker
MFR
ABB

Frame
S3LT-2

Rating A
15-150

Withstand
Maximum
Rating RMS
Symmetrical
A
10,000

Rating
Code
D

FTA740 Intermediate short-circuit rating

Isolation
Voltage
Range
200 240

Circuit Breaker
MFR
ABB

Frame
S3LT-2

Rating A
15-150

Withstand
Maximum
Rating RMS
Symmetrical
A
65,000

Rating
Code
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 by
a 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)

Withstand Rating RMS


Symmetrical Amperes

ASCO Transfer Switch


A

Cat. No.

200-480 V ac

When Used With External


Molded Case Circuit Breaker
(Maximum), A

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

Trademark and/or Tradename:

Last Updated on 2006-10-31


Questions?

Notice of Disclaimer

Page Top

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."

SECTION 4:
1000 GAL. FIBERGLASS
FOAM LIQUID STORAGE TANK

SKZZ-66025

N a tio n a l F o a m

4.1

SECTION 5:
2 IN. PRESSURE VACUUM VENT

SKZZ-66025

N a tio n a l F o a m

5.1

SECTION 6:
FLEXIBLE CONNECTORS

SKZZ-66025

N a tio n a l F o a m

6.1

SECTION 7:
NATIONAL FOAM SEALER OIL

SKZZ-66025

N a tio n a l F o a m

7.1

7.2

Section 3. HAZARDS IDENTIFICATION


Potential Health Effects
Inhalation
Not 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..
Ingestion
Not 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 Effects
No significant signs or symptoms indicative of any adverse health effects are expected to occur.
Carcinogenicity Information
No data available.

Section 4. FIRST AID MEASURES


Inhalation
No 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.
Ingestion
If 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.

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Section 5. FIRE FIGHTING MEASURES


Flammable Properties
Flash Point 445oF(224oC)
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 Spill
Stop 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.
Storage
Recommended storage environment is between 35F (2C) and 120F (49oC). Store product in
original shipping container or tanks designed for product storage.

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Section 8. EXPOSURE CONTROLS/PERSONAL PROTECTION


Engineering Controls
Use or store with adequate ventilation..
Personal Protective Equipment
Respiratory
Recommended exposure limits (OSHA-PEL and ACGIH-TLV) are noted below. The need for
respiratory protection should be evaluated by a qualified health specialist.
Protective Clothing
Rubber 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)
8 hr
5 mg/m3
3
10 mg/m
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

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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 Avoid
Avoid 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.
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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 Foams 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 requirements
of CERCLA.
OTHER REGULATORY INFORMATION
None

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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

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