Attachment 59 - Section J.59 TANK AND PUMP SYSTEM

Attachment 59 Section J.59

TANK AND PUMP SYSTEM (Manual) – FMTPS002 – Darley – 10.17.16

TANK AND PUMP SYSTEM

-FMTPS002-

FEMA

Place of manufacture:

Ohler Pumps – A Division of W.S. Darley 501 Maple Street Janesville, Iowa 50647

Phone: 319-987-2121 Fax: 319-987-2161

Web: www.ohlerpumps.com Email: KurtBond@darley.com

Darley headquarters:

W.S. Darley

325 Spring Lake Drive Itasca, Il 60143

Web: www.darley.com Email: RobertBond@darley.com http://www.ohlerpumps.com/ http://www.darley.com/

Document Revision History:

This document may change over time to continually improve its use. This table tracks the revisions and changes made to this document since the initial release.

Date Sections revised Revision explanation

10.17.16 Insulating water hose connection Added this section to the manual

Table of Contents Packaged items

Terms and definitions

System Overview

Handling and Storage instructions

Handling instructions – Forklift

Lifting instructions

Periodic storage maintenance instructions

Long term storage instructions

Shipping Instructions

Installation Preparation

Site preparation

TPS mounting instructions

Ventilation instructions

Alarm Bar Installation

Water hose connection instructions

Pre-connection to MHU

CONNECTING HOSE TO MHU

CONNECTING HEAT TRACE TO MHU

Electrical connection instructions

Water tank filling/ low pressure test instructions

Final TPS setup/high pressure test instructions

Insulating water hose to MHU connection

Installing sprinkler cover plates

Operating information

Master control panel use and information

PLC information

Manual Self-Test Information

Automatic self-test information

To disable automatic self-test

Bypass valve test

Operational requirements

Decommissioning instructions

De-activation

Pre-deactivation testing

Disconnection from MHU

Electrical disconnection

Alarm Bar Removal

Initial draining

Water disconnection/final draining:

Maintenance/Troubleshooting

Maintenance instructions

Removal of pump/motor

Removal of Pump and Panel Base Assembly

Troubleshooting

Appendix A

FM00025 - Exploded pump drawings

Wiring diagrams

Flow diagrams

Misc. Drawings

Warranty information

Appendix B

Monthly maintenance checks

Packaged items

Box 1 of 5

(1) 1-1/2” Galvanized 90o elbow

(1) 1-1/2” Galvanized 45o elbow

(2) 1-1/2” Galvanized close nipples

(2) 1-1/2” Galvanized unions

(1) Pipe thread tape

Box 2 of 5

(4) Tie down brackets

(1) PVC flange

Flange bolts and hardware

(5) 16-inch strips of insulation sealing tape and 30 feet of aluminum tape

(2) Heat trace caps

Box 3 of 5

(2) SCH 40 6-inch PVC 45 elbows

Box 4 of 5

(2) SCH 40 6-inch PVC 90 elbows

Box 5 of 5

(2) SCH 40 6-inch PVC 90 elbows

TPS discharge hose (pre-connected to pump)

TPS power chord (pre-connected to control panel)

(1) 6 foot or (2) 4 foot sections of 6-inch PVC pipe

(1) 6-foot section of hose insulation

Red storage container items (fastened to door)

(1) Manual

(1) Decommissioning checklist

(1) Manufacturers test sheet

Alarm bar (fastened to wall)

Terms and definitions TPS – Tank and Pump System

Interim Storage – Six months or less

Long Term Storage –Beyond six months

MHU – Manufactured Housing Units

TPS enclosure - The ridged housing that protects the TPS from weather, tampering and provides freeze protection

DST – Daylight Savings Time

CST – Central Standard Time

Temp – Temperature

W.S. Darley & Company - Darley

Fire alarm – Red alarm on the alarm bar

Maintenance alarm – White alarm on alarm bar

Power button – Green light on the alarm bar

MRT – Minimum Run Time

PLC – Programmable Logic Controller

PSI – Pounds per Square Inch

GPM – Gallons Per Minute

DLY – Delay

SEC – Seconds

MRT – Minimum Run Time

ALM – Alarm

TEMP – Temperature

DIFF – Difference

System FLT – System Fault

System Overview The Darley Tank and Pump System (TPS) has been manufactured and designed for use with manufactured housing units (MHU). It is attached to the MHU sprinkler system and is in standby mode until there is a sprinkler system demand. Upon demand, the Darley TPS is designed to flow a minimum of 30 GPM @ 40 PSI

(see Operational Requirements section for maximum sprinkler head information). With a 290-gallon tank, the system can run for a minimum of nine minutes while flowing 30 GPM before needing an additional water supply. In addition, the TPS is equipped with automatic self-testing and manual self-testing features to ensure the entire system is working properly in the event of a sprinkler system demand.

The TPS has a compact yet sturdy frame construction to withstand outside conditions and to allow for multiple deployments. Its dimensions are as follows:

Length: 90” Width: 66” Height: 92” Weight (dry): 2,100 lbs.

The system has been designed with a "fire alarm" (red) that will sound when the fire sprinkler system is running. It also contains a "maintenance alarm" (white) that sounds when the internal temperature of the system drops below 40°F, when the hose temperature drops below 40°F, when the battery voltage drops below 25.8 Volts (only applicable if A/C power is available), or when the battery voltage gets above 31 Volts.

Both alarms are equipped with strobe lights to provide a visual indication that the alarm is sounding. The alarms will also sound in the event of a failed automatic self-test or manual self-test (Phase I pump test only).

The TPS has a freeze protection system that includes fully insulated walls, ceiling and floor, heat tape, building temperature sensor, hose temperature sensor, hose insulation and an internal heater to allow these units to be deployed in cold temperature conditions without freezing (minimum temperature of -35 degrees

Fahrenheit (35°F below zero or -37.3°C)).

The system has also been equipped with a vent in the door to allow cool air to enter and warm air to exit the building in the event of extreme temperatures. This vent is insulated from the factory, but can be removed if the circumstances require.

The system also has a battery backup. The battery backup ensures that the controls, memory and alarms all continue to function for a minimum of 12 hours if the main power to the TPS is lost. This ensures that if the interior temperature of the building falls below 40F the alarm will go off, while still keeping the ability to snooze this alarm. In the event of loss of power, the green light on the front of the TPS will not be glowing.

Also note that the pump will not function if the main power is lost.

The PLC has a removable memory microSD card that stores event history. This provides the ability to download performance information to see if there was a sprinkler demand and review its performance.

Handling and Storage instructions Note: The Darley TPS should only be stored in an upright position (fork lift access at the bottom). Failure to store upright will result damage to the TPS.

Handling instructions – Forklift

Caution: When handling with a fork lift, be sure to use standard lifting precautions!

Caution: System should not be moved when water is in the tank. See "Draining Instructions" for proper draining of the TPS.

Note: Before moving TPS, make sure all exterior items are fastened to enclosure and are not at risk of damage.

1) This system has been designed with fork lift access. These can be found on the left and right side of the system perpendicular to the door (Fig. 1).

2) Slide forks into slots, making sure forks are properly spaced to prevent any side tipping.

3) Tip forks back to make sure center of gravity is centered on forks.

4) Slowly lift and move the TPS to desired location.

Fig. 1 – Fork lift slots

Lifting instructions

Caution: When lifting the TPS, be sure to use standard lifting precautions. Failure to do so could result in damage or serious injury.

Caution: System should not be moved when water is in the tank. See "Draining Instructions" for proper draining of the TPS.

Note: Before moving TPS, make sure to check that the total weight of the TPS falls within lifting capacity of the spreader bars being used (see system overview for weight specifications). Spreader bars will need to be a minimum of 51” in width and 72” in length (Fig. 2). A 4–point spreader bar is recommended to lift the TPS

(See Fig.3).

Fig. 2 – Top lifting slings

Fig. 3 – Spreader bar example

Lift strap requirements:

1,600 lbs. vertical lift capacity (will need one for each corner)

Minimum of 1” straps

Please follow the steps below to ensure safety when lifting:

This system has been designed with lift hooks. These are located on the roof in all four corners.

Make sure all straps are equally attached to ensure parallel lifting. Failure to do so could result in damage to the TPS.

Slowly lift and move the TPS to desired location.

Upon lowering the TPS at its desired location, be sure to slowly lower the unit on a flat and firm surface. Continue to lower TPS until it is set firmly on ground and there is slack in the straps.

Periodic storage maintenance instructions

If proper care is taken to drain the TPS completely, no periodic maintenance is required during storage.

Long term storage instructions

For long term storage, make sure there is no residual water in the TPS system. Follow draining procedures on

Page 52 in the decommissioning section to drain system properly.

Shipping Instructions Note: If shipping in a container, take note of the height restrictions of the sourced container.

1) Lift the TPS from the side and load it onto the truck/container.

2) If loading in a container, enter through the door opening very carefully, taking extra care not to hit the top of the unit and cause undue damage.

3) Move containers into place (Fig. 4).

a. 40-foot containers can fit up to 7 units.

b. 20-foot containers can fit up to 3 units.

Fig. 4 – Container shipment

4) The TPS has been fitted with four tie downs for strapping the TPS in place. Use these when strapping the system down (Fig. 5).

Fig. 5 – Tie downs

40’ container

7 per trailer

20’ container

3 per trailer

Installation Preparation

Site preparation

Note: Please follow the "FEMA Site Preparation Guide" for proper site preparation.

Steps to complete for proper installation:

TPS mounting

Alarm bar installation

Water hose connection o Pre-connection o Hose to MHU o Heat trace to MHU

Electrical connection

Water tank fill/low pressure test

Final TPS setup/high pressure test

Insulating water hose to MHU connection

Sprinkler covers installed

TPS mounting instructions

1) Move TPS into position (see handling instructions).

2) Slowly lower TPS onto gravel.

3) Verify the ground does not shift while setting into place.

a. If shifting occurs, remove TPS and repack the base or set a pad to prevent settling.

4) Find the (4) four manufactured roof rack brackets located in Box 2 of 5.

5) Set the roof brackets into position at approximately 6” from the front on each side and 6 inches from the back on each side (Fig. 6).

Fig. 6 – Roof brackets

6) Install anchors (not included) per manufacturer’s instructions.

7) Slide strapping material (not included) through roof brackets and attach to anchors per manufacturer’s instructions.

8) Tighten strapping material to proper tension so that the TPS is firmly anchored to the ground.

9) Continue the install by moving to the alarm/light bar installation section.

Caution: The interior of the TPS building can reach very high temperatures in hot conditions. In order to combat this, follow the "Ventilation instructions" section.

Ventilation instructions

Caution: In humid conditions, turn the LED light on the inside of the TPS on and leave it on. This allows the humidity inside of the master control panel to be minimized.

Note: By default, the vent in the door is plugged and insulated. This insulation should ONLY be removed in the following conditions:

Local daytime temperatures are above 65F AND

Overnight temperatures are above 40F.

If both above conditions are met, follow the below steps to remove the vent cover.

1) Locate the vent plug on the inside of the door (Fig. 7).

2) Rotate all four clips on the door so the plug can easily be removed (Fig. 8).

3) Gently pull the plug away from the door and place in a safe location inside of the building.

To replace the plug:

1) Gently slide plug back into hole in door (Fig. 7).

2) Rotate all four clips so the plug is secured to the door.

Fig. 7 - Door vent plug

Fig. 8 – Clips rotated

Alarm Bar Installation

Note: Alarm bar is located on the inside of the TPS to protect from shipping damages (Fig. 9).

Fig. 9 – Stored alarm bar location

1) Remove Alarm bar from inside of TPS by opening the face of the alarm box and unscrewing from wall.

a. Use these screws for mounting to the front of the TPS.

2) Remove electric cap from the plug on the front of the TPS and place inside alarm box (Fig. 10).

3) Open the alarm box so you can see inside of the box (Fig. 10).

4) Align the square hole on the box with the plug flange on the back of the TPS (Fig. 11).

Fig. 10 – Electric cap and storage location

5) Use the (4) four provided screws to attach the Alarm bar to the Front of the TPS (Fig. 11).

Fig. 11 – Alarm bar alignment and attachment with screws

6) Screw the electric plug from the alarm box to the TPS plug.

7) Tighten plug down by twisting the outer ring until tight (Fig. 12).

Fig. 12 – Alarm bar electric plug attachment and final installed location

Water hose connection instructions

Caution: The TPS hose is shipped with a protective cap on the end of the hose that connects to the MHU.

The cap should not be removed until just before connecting to the MHU. Leave this cap in place to prevent debris that might plug the sprinkler from getting into the hose.

Pre-connection to MHU

Note: The TPS has been equipped with a 6” PVC flange, which is to be used for direct bury purposes, located in Box 2 of 5.

1) Find the location where the TPS will connect to the MHU sprinkler system.

2) Identify which side of the system the hose will need to exit in order for the most direct route to the

MHU.

3) Dig a trench to protect the water hose assembly and the electric cable. The trench must be not less than 24 inches deep, and 7 inches wide. The trench should reach from the edge of the prepared base for the TPS to underneath the MHU, inside the skirting.

4) Unscrew the appropriate interior cover from the wall (Fig. 13).

a. Note that both interior covers are pre-installed. You may need to unscrew both and place the hose covers on the correct side.

b. Place screws in a safe location for later use in re-mounting these cover plates.

Fig. 13 – Screws on interior cover plates

5) Remove interior plates and insulation from the wall (Fig. 14).

Fig. 14 – Removal of interior plate and insulation

6) Unbolt the exterior cover plate wing nuts (Fig. 15).

Fig. 15 – Removal of exterior cover plate wing nuts

7) Once cover plate is completely unbolted, allow cover plate to drop and come to a rest on the base.

8) Place wing nuts back on the bolts of the cover plate so they are not lost (Fig. 16).

Fig. 16 – Re-applying wing nuts on cover plate

9) Using a pipe wrench (not provided), loosen the union located on the discharge manifold so you can rotate the discharge hose to point in the correct direction (Fig. 17).

Fig. 17 – Loosening interior union

10) Feed hose through the 12” x 12” opening.

11) Feed the power cable through the 12" x 12" opening.

12) Feed both the power cable and hose through the 6” PVC flange (located in Box 2 of 5), up to the base of the TPS (Fig. 18).

Fig. 18 – Feeding cable and hose through 6” flange

13) Inside of the TPS, verify the hose is pointing directly out of the 12" x 12" opening.

14) Inside of the TPS, verify the power cord is located so as to not interfere with draining or installation

(Fig. 19).

Fig. 19 – Hose pointing toward exit and cable run

15) Using a pipe wrench (not provided), tighten the union.

16) Fold the (2) two exterior half cover plates in, (1) one at a time, placing the power cord in the small cutout at the top of the hose hole (Fig. 20 and 21).

a. Verify the cover plates sit flush to one another with no overlaps.

Fig. 20 – Power cable in small notch of cover plates

Fig. 21 – Exterior cover plates closed

17) Run the PVC flange the rest of the way up to the cover plates (Fig. 22).

Fig. 22 – PVC flange mounted, exterior view

18) Place four ¼” size bolts and washers through the four openings in the cover plates.

19) On the inside of the TPS, tighten the wing nuts on the (4 )four bolts as tight as you can get them by hand (Fig. 23).

Fig. 23 – PVC flange mounted, interior view

20) Slide (2) two interior half cover plates and insulation back into the 12" x 12" opening, placing the power cord in the small cutout at the top of the hose hole.

21) Using the (4) four screws provided from Step 5, screw the cover plates back to the building (Fig. 24).

a. If you needed to remove the solid cover plate, replace that as well in this step so both sides are covered and insulated.

Fig. 24 – Interior cover plates re-installed

22) Cut the 6” PVC pipe to keep the 90° PVC pipe elbow as close to the side of the TPS as possible.

a. The PVC pipe should run to the ground just barely touching the edge of the ABS pad, wood frame, or hard surface prepared base.

23) Measure and cut the vertical section of 6” PVC pipe to length as shown in Fig. 25, Fig. 26 and Fig. 27.

24) Cut a second length of PVC pipe to encase the cable and hose where it exits the trench under the

MHU.

a. The exit pipe should extend above the surface of the ground not less than eight inches.

25) Slip the PVC elbows (found in Boxes 3, 4 and 5 of 5), and pipe over the MHU end of the electric cable and the water hose assembly.

a. Test fit the PVC pipe, make adjustments as necessary. If the pipe is not snug fitting, glue the

PVC parts together; otherwise, glue is not necessary.

26) Lay the water hose assembly and electric cable in the trench. Be sure to remove any sharp rocks or debris that could cut into the cable.

27) Position the PVC pipe around the hose and cable at the MHU end of the trench. This pipe must extend above grade not less than eight inches to protect the cable from rodents.

28) Extend the hose assembly to the point of connection under the MHU. Lay the excess hose neatly on ground inside the skirting underneath the MHU.

29) Proceed to the next step in the installation – Connecting Hose to MHU.

Fig. 25

Fig. 26

Fig. 27

CONNECTING HOSE TO MHU

1) Remove the protective pipe caps from the sprinkler drain pipe and from the sprinkler riser pipe on the underside of the MHU.

a. Lay the caps nearby under the MHU so that they can be re‐used during decommissioning.

2) Remove the protective cap from the end of the hose assembly.

3) Identify the proper fittings to allow the flexible hose to be connected to the MHU (Fig. 28).

a. See included TPS PARTS KIT in Box 1 of 5.

b. Note that the union is the item that will allow rotation of the fittings, so this should be the last item connecting the MHU to the TPS.

Fig. 28

4) Locate the pipe tape in the "TPS to MHU Parts Kit" (Box 1 of 5).

5) Thoroughly clean all male and female threads to remove any debris.

6) While keeping the edge of the tape parallel to the face of the male fitting, wrap the tape in the direction of the thread spiral (Fig. 29).

Fig. 29

7) Use two to four revolutions of tape.

8) Rip or tear off any excess and use finger to gently press tape into threads.

9) Continue with fitting connections until you are ready to connect the flexible hose to MHU.

10) Prepare male fitting on hose with thread tape.

11) Attach hose to MHU.

12) Finish hose installation by verifying all connections are tight.

13) Proceed to the next step in the installation – Connecting heat trace to MHU.

CONNECTING HEAT TRACE TO MHU

Note: No heat trace comes with the MHU. Two pull tapes are installed between the sprinkler riser pipe and the insulation above the belly board (Fig. 30). Heat trace cable from the TPS will be run from the end of the insulated hose assembly into the MHU using one of the pull tapes. (The second pull tape is a spare.)

Fig. 30 – Pull tabs

1) Fish the heat trace cable from the end of the insulated hose assembly into the MHU. Use the pull tapes provided with the home, or an electrician’s fish tape, to fish the new heat trace cable into position.

a. The heat trace cable must be located directly against the pipe under the pipe insulation (Fig.

31).

2) Cleanly cut the end of the heat trace cable 12 – 16 inches above the floor of the water heater closet.

3) Install a new End Seal (located in Box 2 of 5) onto the cut end of the heat trace cable.

4) Install aluminum tape (located in Box 2 of 5) along the heat trace.

5) Fill the trench and tamp the soil lightly. Be sure no rocks or sharp edges are in contact with the electric cable.

6) Proceed to the next step in the installation – Electrical connection instructions.

Fig. 31 – Heat trace to MHU

Electrical connection instructions

Caution: Make sure the power switch on the master panel inside the TPS is in the “OFF” position before attaching the electrical connection.

Notes: The mechanical interlock installed on the rear of the MHU is shipped from the factory set up to be locked in the OFF position. (Note: In the event of an incident, we instruct the Fire Department to cut off the lock with bolt cutters to switch the TPS power off.)

1) Cut an opening through the skirt directly below the cable connection.

2) Work the connector and cable over and through the skirt.

3) Extend the electric cable to the point of connection (Fig. 32).

4) Loosen and remove the protective cover on the bottom of the mechanical interlock assembly. The cover is attached to the interlock, and simply swings back and away once it has been unscrewed.

5) Insert the plug from the TPS cable into the receptacle on the bottom of the mechanical interlock.

The plug can only be inserted one way; look at the tabs on the plug and the receptacle and align them. Once properly aligned, the plug can be easily inserted.

Note: The mechanical interlock is designed so that the connection can only be put together when the switch is in the "Off" position. This is an important safety feature.

6) Tighten the locking ring on the plug assembly, securing the plug and cord to the interlock.

7) Leave the switch on the mechanical interlock in the "OFF" position for now.

8) Switch the 240V/30A circuit breaker inside the MHU main electric panel that supplies power to the mechanical interlock/TPS to the "ON" position.

9) Proceed to the next step in the installation – Water tank filling/low pressure test instructions.

Fig. 32

Water tank filling/ low pressure test instructions

Caution: If local ambient temperature is expected to fall below 40°F during installation, water should not be added to the system until electrical connection has been made for proper freeze protection.

1) Connect garden hose from water supply source to the TPS.

2) Open garden hose valve on TPS (Fig. 33) and water supply valve from water source to turn water on.

Fig. 33 – Tank fill valve in open position

3) Verify the 1.5” discharge hose valve to allow water to fill the system (Fig. 34).

Fig. 34 – Discharge valve in open position

4) Let the discharge hose get pressure from the water supply pressure.

5) Check that the pipe cap on the sprinkler drain line underneath the MHU has been removed from the drain line. If the drain pipe still has a cap on it, remove the cap. (The cap is there to prevent insects from getting into the drain pipe during storage and transport.)

6) Open the sprinkler drain valve inside the MHU slightly.

7) Allow water to flow from the garden hose into the sprinkler system in the home. When water begins to flow out of the sprinkler drain line onto the ground beneath the MHU, close the sprinkler drain valve inside the MHU, and allow the water to flow into the pipes in the home.

8) Allow the hose to pressurize for 10 minutes and stabilize.

9) Record the pressure shown on the pressure gauge.

a. Starting pressure: __________

10) Wait (1) one hour and then record the pressure shown on the pressure gauge.

a. Ending pressure: __________

11) There should be no drop in pressure readings over that test period. If the pressure is lower after the test, look carefully for leaks.

a. Pressure drop (Starting minus ending): ___________

12) Locate all water connection points and verify no leaks have occurred.

a. If there are any leaks in the system plumbing:

i. Turn off water supply.

ii. You may need to completely drain the pump.

iii. Disconnect leaky fitting(s).

iv. Follow procedures above to re-tape and connect fitting(s).

v. Repeat the water tank filling/low pressure test instructions from Step 1.

13) Once all leaks have been fixed, open the "bypass valve" to allow water into the tank (Fig. 35).

Fig. 35 – Bypass valve in open position

14) Move the end of the "overflow" hose out of the door to protect overflow water from entering the building.

15) Allow water to fill the tank until water is near the "Max fill – 290 gallons" line.

a. Note: During this step, periodically check the connection points on the system to verify no leaks have occurred.

16) Place overflow hose back inside the building in a safe location.

17) Close the bypass valve from Step 13.

18) Turn water supply off and close garden hose valve from Step 2.

19) Disconnect water supply (garden hose) hose from TPS.

20) Proceed to the next step in the installation – Final TPS setup/high pressure test.

Final TPS setup/high pressure test instructions

Note: For the monthly maintenance checks, follow the steps outlined in Appendix B.

1) Verify the suction valves is open (Fig. 41).

2) Verify the discharge valve is open (Fig. 42).

3) Verify the tank fill and bypass valves are closed (Fig. 43).

4) Turn the mechanical interlock on the MHU to the "ON" position.

5) Cut the lock-out zip-tie from the master control "ON" switch.

a. Place the "lock-out" tag inside the red box on the door for use in decommissioning.

6) Turn the master control panel to the "ON" position (Fig. 36).

a. There will be approx. 15 seconds of loading time for the program to load.

b. After program loads, if the pressure is below 50 PSI, the pump will start and run for the minimum run time set (default is 120 seconds).

i. DO NOT PROCEED until the pump has stopped running.

Fig. 36 – Master control panel in the "ON" position

7) Press the test button (Fig. 37). This will start the automatic test, which will last approximately four minutes

Fig. 37 – Test button

8) Wait for the pump to run through its test procedure (see "Manual self-test" instructions section for a description of what is occurring) (Fig. 38).

Fig. 38 – Phase I testing (pump test)

a. Record pressure of the system when self-test valve is open: __________

b. Verify the fire alarm (red) strobe is active when solenoid valve is open.

c. Record pressure of the system when the self-test valve has closed: __________

d. If any point of this test fails, see Troubleshooting section.

9) Pump will automatically shut down when Phase I pump test is complete.

a. Record pressure of the system after Phase I is complete: __________

10) System will then move to Phase II Heater test and run the heater for 30 seconds (Fig. 39).

Fig. 39 – Phase II testing (heater test)

a. Verify the heater is on and warm by feeling the air from the bottom heater vent (Fig. 62).

i. If no warm air is produced, see Troubleshooting section.

b. No alarm will sound during this test.

11) System will then move to Phase III Heat trace test and run for 90 seconds (Fig. 40).

Fig. 40 – Phase III testing (heat trace test)

a. Verify the heat trace is on by grabbing the heat trace and verifying you feel a change in temperature (Fig. 63).

i. If heat trace does not get warm, see Troubleshooting section.

b. No alarm will sound during this test.

12) Following a successful test, there will be no active alarm and the pump will be off. The unit will be ready for standard use. The system is ready for operation by verifying all loose items in the TPS have been safely placed in a location that will not interfere with pumping or electrical operation.

13) Close the front door and lock deadbolt, making sure the deadbolt is correctly locked to prevent unwanted entry into the TPS.

14) Give the master key (included with the TPS) to the proper authorities.

15) Proceed to the next step of the installation – Insulating water hose connection.

Fig. 41 – Open suction valve

Fig. 42 – Open discharge valve

Fig. 43 – Closed bypass and tank fill valves

Insulating water hose to MHU connection

1) Verify the connection between the end of the TPS hose assembly and the sprinkler riser has no leaks.

2) Verify heat trace tape has been applied.

3) Install insulation around the connection.

4) Ensure that the entire pipe and hose are insulated.

5) Securely fasten all insulation with tape (located in Box 2 of 5).

Installing sprinkler cover plates

1) Sprinkler cover plates are shipped inside a box in the refrigerator of the MHU with other parts that will be used in this step.

a. NOTE: Please be sure your hands are clean, or use clean gloves. We don’t want to dirty the clean white Cover Plate.

2) At each sprinkler, do the following:

a. NOTE: Do NOT install a cover plate on the sprinkler inside the water heater closet.

3) Remove the brightly colored plastic Protective Cap from the sprinkler by unscrewing it counterclockwise to remove it from the Sprinkler Support Cup (Fig. 44).

Fig. 44 – Plastic protective cap

a. NOTE: Inside the water heater closet, removing the protective cap is all that is required. No cover plate should be installed on this sprinkler.

4) Gently insert the Cover Plate/Retainer Assembly into the Sprinkler Support Cup, and screw the Cover

Plate/Retainer Assembly clockwise into the Sprinkler Support Cup until its flange just comes in contact with the Decoshield, wall or ceiling. Finger tight is all that is required. Some minor alignment may be needed (Fig. 45).

a. Note: The Cover Plate/Retainer Assembly is a precision manufactured device. If you need to force it into place, something is wrong.

b. Note: There is a small gap between the white cover plate and the copper‐colored retaining cup. This gap is important for the proper operation of the sprinkler; leave the gap!

5) At this point, the TPS install is complete.

Fig. 45

Operating information Caution: Do not start the pump until it has been completely filled with water. Dry operation could cause irreparable damage to the mechanical seal.

Note: The system has been pre-tested to verify conformance to FEMA specifications. For test data, see conformance test sheet included with each system.

Master control panel use and information

The control panel is equipped with (1) one test button, (1) one DC voltage gauge, (1) one amperage gauge, (1) one Master "ON" switch, and (1) one PLC display.

Fig. 46 – Master control panel

The test button controls the manual self-test function (see manual self-test section on Page 44).

The DC voltage gauge displays the voltage charge on the batteries. This should read between 25-30 volts. If the reading is below 25.8 volts, see Troubleshooting section.

The DC Amperes gauge displays the amps the system is using off of the batteries.

Master ‘ON’ switch

Test button

PLC display screen

Amperage gauge

DC voltage gauge

PLC information

PLC terms and definitions PLC – Programmable Logic Controller

PSI – Pounds per Square Inch

GPM – Gallons Per Minute

DLY – Delay

SEC – Seconds

MRT – Minimum Run Time

ALM – Alarm

TEMP – Temperature

DIFF – Difference

DST – Daylight Savings Time

CST – Central Standard Time

System FLT – System Fault

Note: The PLC/master control panel is pre-programmed from the factory and does NOT require any adjustments in the field.

The PLC home screen displays the room temperature, hose temperature, pump pressure, and calculated* pump flow (Fig. 47). By pressing the right and left arrows, you can navigate through the several screens on the PLC. Below is an image and description of each screen.

*The calculated pump flow is based off 10 performance points on the pump curve. This value changes in intervals of 4-6 GPM, meaning the displayed flow rate is "projected" flow, not a calibrated flow reading.

Steps for changing a setting (if applicable):

1) Locate the setting that needs changed.

2) Hit the "OK" button to enter "Edit mode" to adjust that setting.

a. Note the character that is being changed is underlined.

3) While in "Edit mode," press the "up" and "down" arrows to change that character.

4) While in "Edit mode," press the "left" and "right" arrows to move to the next character.

5) Once all adjustments have been made, hit "OK" to exit "Edit mode."

Fig. 47 – Screen 1: Home screen

*Nothing is adjustable on this screen*

Fig. 48 – Screen 2: Password screen

*Enter the password on this screen to change "locked" settings on other screens*

Fig. 49 – Screen 3: Pump start pressure, start delay, reset pressure, and reset delay settings

*START (PSI) adjusts the pressure that turns the pump on. START DLY (SEC) adjusts the delay the pump takes before turning on when falling below start pressure. RESET (PSI) adjusts the pressure the pump turns off at.

RESET DLY (SEC) adjusts the delay that the pump turns off after going over the reset pressure. *

Fig. 50 – Screen 4: Minimum run time, restart delay screen, counters, and software version screen

*MIN RUN DLY (SEC) adjusts the minimum run time (MRT) the pump will run when demand is lost. RESTART

DLY (SEC) adjusts how long the pump waits after that minimum run time before starting again. CLEAR

COUNTERS displays the number of times the statistics on screen 55 have been cleared. SOFTWARE VERSION is the version that the program is running on. *

Fig. 51 – Screen 5: Heater and heat trace settings

*ROOM HEAT ON adjusts the temperature that the room heater turns on. ROOM HEAT OFF adjusts the temperature that the room heater turns off. PIPE HEAT ON adjusts the temperature that the heat trace turns

on. PIPE HEAT OFF adjusts the temperature the heat trace turns off. *

Fig. 52 – Screen 6: Heater/Heat trace alarm settings

*HEATER ALARM SETTINGS adjusts at what temperature the alarms go off. *

Fig. 53 – Screen 7: Automatic self-test date and time settings

*TEST DAY (0-6) adjusts the date the automatic self-test runs (0=Sunday, 1=Monday, 2=Tuesday, 3=

Wednesday, 4=Thursday, 5=Friday, and 6=Saturday). TEST HOUR (0-23) adjusts the hour the automatic self-test turns on. TEST MINUTE (0-59) adjusts the minutes the automatic self-test turns on. *

Fig. 54 – Screen 8: Phase 1 test pressure settings

*STATIC PSI adjusts the minimum pressure the pump must be before starting the self-test. RECOVERY PSI adjusts the minimum pressure the pump must get to in order to pass the Phase I test. *

Fig. 55 – Screen 9: Automatic self-test Phase II heater settings and automatic self-test Phase III heat trace settings

*TEST TIME (SEC) adjusts the length of time the test lasts in seconds. TEMP DIFF adjusts the temperature increase that is needed in order to pass the test. *

Fig. 56 – Screen 10: Clock settings

*DST adjusts if daylight savings time is off or to the USA DST. Date is formatted as "Day of week, year/month/day." Once changes have been made, you will need to go to the "update" field and hit "OK."*

Fig. 57 – Screen 11: Run time information

*POWER ON displays the hours the system has been turned on. RUN TIME displays the minutes the pump has run. RM HEATER displays the minutes the room heater has run. HT HEATER displays the minutes the heat trace has run. *

Fig. 58 – Screen 12: Test statistics

*AUTO TESTS displays the number of times the automatic self-test has run. MANUAL TESTS displays the number of times the manual test has run. The other items display the number of times that each phase has failed. *

Fig. 59 – Screen 13: Alarm and snooze statistics

*This screen shows the number of times each alarm has sounded and the number of times each has been snoozed/silenced. *

Fig. 60 – Screen 14: Change password settings

*This screen allows the user to change the service or factory passwords. *

Testing information:

The system has a minimum run-time of 120 seconds. This design will allow the pump to continue running to meet any low sprinkler pump demand without turning off. There is also a (2) two second delay restart to prevent any damage to the pump/electrical by excessive thermal shock.

When “Test Enable Jumper” is installed (factory default) an automatic test will occur once a week.

Automatic self-test is set to begin every Wednesday at 1:30 pm CST, but can be modified by a technician.

Manual self-test is available 24/7.

Minimum run timer is NOT active during a manual self-test or automatic self-test.

When in test mode the pump will run until pressure reaches the reset pressure setting (default is 85

PSI).

If a fault occurs during the test, the test is terminated and alarm activated (see Troubleshooting section).

In the event of a failed test, if a pump demand is encountered (sprinkler demand) the pump will start and meet the system demand.

Alarm information

If Maintenance (white) alarm and/or Pump Run (red) alarms are going off, to reset, the cycling of power is needed.

There is a “Snooze” button located on the outside of the TPS below the alarm box. This button will silence the Fire Alarm (red) alarm for (1) hour and the Maintenance Alarm (white) for (12) hours.

Manual Self-Test Information

Note: For monthly maintenance checks, follow procedures in Appendix B.

Pressing the test button runs the system through three test phases to help ensure all major components in the system are functioning properly (Pump, room heater, and heat trace). See below for information on each test phase. If any point of the "manual self-test" fails, see Troubleshooting section.

Phase I: Pump Test Sequence (same as the automatic self-test) (Fig. 38):

When a manual self-test is started, the system verifies the pressure is above 70 PSI, signifying there is not a significant leak in the system.

The test valve will open and confirm pressure drops, signifying the valve has opened.

o If pressure does not drop within two seconds, the test fails and an alarm is tripped, signifying the valve did not open or is blocked.

Test valve will open for 20 seconds, in which pressures should be between 30-85 PSI, signifying the pump responded to system demand and water is flowing through test loop.

The test valve will close and confirm the pressure recovers to above 70 PSI.

o If pressure does not recover to above 70 PSI within five seconds, the valve did not close or there is a leak somewhere, tripping the alarm.

If this test fails, an "FLT" sign will be displayed on the screen next to the system operating pressure, signifying this is the step that failed (Fig. 61).

Fig. 61 – Pump fault

Phase II: Room Heater test

During manual self-test mode, the room heater will start and run for 30 seconds, allowing the technician to feel the warm air blowing from the heater signifying the heater is working (Fig. 62).

After 30 seconds, the system moves to the heat trace test.

NO alarm is activated for this test. It is the discretion of the technician to verify the heater is working.

Fig.62 – Feeling the heater blowing warm air

Phase III: Heat trace test

During the manual self-test mode, the heat trace will turn on for 90 seconds, allowing the technician to feel the orange heat trace getting warm (Fig.63).

When the 90 seconds has completed, the automatic self-test is over.

NO alarm is activated for this test. It is the discretion of the technician to verify the heat trace is working.

Fig.63 – Feeling warm heat trace

Automatic self-test information

The automatic self-test is set to begin every Wednesday at 1:30 pm CST. If any point of the "manual self-test" fails, see Troubleshooting section.

Phase I: Pump Test Sequence (same as the manual self-test):

When a manual self-test is started, the system verifies the pressure is above 70 PSI, signifying there is not a significant leak in the system.

The test valve will open and confirm pressure drops, signifying the valve has opened.

o If pressure does not drop within two seconds, the test fails and an alarm is tripped, signifying the valve did not open or is blocked.

Test valve will open for 20 seconds, in which pressures should be between 30-85 PSI, signifying the pump responded to system demand and water is flowing through test loop.

The test valve will close and confirm the pressure recovers to above 70 PSI.

o If pressure does not recover to above 70 PSI within five seconds, the valve did not close or there is a leak somewhere, tripping the alarm.

If this test fails, an "FLT" sign will be displayed on the screen next to the system operating pressure and the alarm will sound, signifying this is the step that failed (Fig.61).

Phase II: Room Heater test

If room temperature is already above 65F, no heat test will be conducted and the system will move to the heat trace test.

If room temperature is between 45F and 65F, heater will start and will look for the temperature of the building to increase by one degree in a five-minute period.

If the heater is already on, no test will be held and the system will move to the heat trace test.

If the test fails, an "FLT” sign with be displayed on the screen next to the room temperature and alarm will sound, signifying this is the step that failed.

Phase III: Heat trace test

If hose temperature is already above 65F, no heat trace test will be conducted and the system test will be finished.

If hose temperature is below 65F, heat trace will start and will look for the temperature of the hose to increase by .2 degrees in a 30-minute period.

If the test fails, an "FLT” sign with be displayed on the screen next to the hose temperature and alarm will sound, signifying this is the step that failed.

To disable automatic self-test

Caution: It is not recommended that the automatic self-test be disabled. If the circumstances require the automatic self-test to be disabled, follow the below instructions.

1) Open the Master Control Panel by turning the Master control switch to "OFF."

2) Unscrew the latch screws by turning them ¼ turn counterclockwise and open the door.

3) Remove the yellow wire that is connecting ports (9) and (10) on the gray terminal block (Fig.64).

Fig.64 – Disconnecting yellow jumper wire

4) Close the door and turn the 1/4" turn screws to latch the door.

5) Verify the door is latched correctly by gently pulling on the top and bottom corners (Fig.65).

6) Turn master control switch to "ON" to place the system back in "ready mode."

Fig.65 – Door properly latched

Bypass valve test

Note: All testing should be done through the "self-test" button. In the event that the button or solenoid valve is not functioning, the bypass valve can be used in the following procedure to verify pump performance.

1) Open the "Bypass valve" fully.

a. Water will flow from the pump and back into the tank.

b. This will sound the Fire Alarm (red).

2) While the pump is running, record pressure shown on the controller display screen or pressure gauge.

a. Pump running pressure: __________

3) Slowly turn the "Bypass valve" to the closed position.

a. The alarm should stop sounding and strobing.

b. The pump will run for the minimum run time set (default is 120 seconds).

4) After the pump stops, record the pressure shown on the controller display screen or pressure gauge

(you should use the same method you used in Step 2):

a. Pump static pressure: __________

5) If the pump holds pressure above 70 PSI, the test is complete.

a. If test fails, see Troubleshooting section

Operational requirements

Power supply requirements: 30 Amp, 240V / 1 Phase / 60 Hz Water tank capacity: 290 gallons Maximum pump performance: 35 GPM @ 40 PSI Maximum sprinkler heads based on flow of sprinkler head:

Sprinklers rated for 8 GPM, the TPS could provide design flow rates to 4 sprinkler heads

Sprinklers rated for 10gpm, the TPS could provide design flow rates to 3 sprinkler heads

Sprinklers rated for 11gpm, the TPS could provide design flow rates to 3 sprinkler heads

Sprinklers rated for 12gpm, the TPS could provide design flow rates to 2 sprinkler heads, and 11 gpm to a third head

Sprinklers rated for 15gpm, the TPS could provide design flow rates to 2 sprinkler heads

Sprinklers rated for 16gpm, the TPS could provide design flow rates to 2 sprinkler heads

Sprinklers rated for 17gpm, the TPS could provide design flow rates to 2 sprinkler heads

Decommissioning instructions If proper care is taken to decommission the TPS, the system is designed to be deployed multiple times.

Follow all below steps to allow for multiple deployments with minimal issues.

Caution: If temperature is below 40 degrees Fahrenheit, decommissioning should not take place due to possible freezing occurring in drain lines. If possible, wait until temperature rises above 40 degrees

Fahrenheit and proceed. If temperatures will not rise above this mark, proceed with extreme caution, taking care not to allow hoses or water in tank to freeze.

De-activation

Prior to deactivating, follow the below steps to ensure the system is running as expected before deactivation.

Pre-deactivation testing

1) Verify the master control is set to the "ON" position.

2) Perform the manual self-test feature by pressing the black button on the control panel.

a. Follow Steps 4-9 on the Final TPS setup/high pressure test section on Page 32

3) While test is running, do a final inspection of all water connection points to verify no leaks have occurred.

4) Verify everything in the TPS is working properly.

5) Fill out the TPS Decommissioning Checklist located inside the Red box attached to the inside of the door.

6) After approximately five minute have passed, the Manual Self-Test should be complete.

a. Note: If the manual Self-Test has failed during any portion of the testing time, fill out the

Decommissioning Checklist as to where the test failed and continue with the decommissioning process. The Decommissioning Checklist should be placed back in the Red box on the backside of the TPS door.

7) Verify there are no leaks inside the TPS or at the MHU connection points.

8) Once complete, move on to the Electrical disconnection section to continue the de-commissioning process.

Disconnection from MHU

Electrical disconnection

1) Put the Master Control lever in the “OFF” position. (Fig.66).

Fig.66 – Master control switch in "OFF" position

2) Replace the lockout placard and zip-tie by lifting the white latch and sliding through the hole.

3) Turn the switch on the mechanical interlock to the "OFF" position (Fig.67).

4) Loosen the locking ring on the plug assembly.

5) Gently pull plug out of socket to disconnect electrical.

6) Replace the protective cover on the bottom of the mechanical interlock by tightening the protective cover to the receptacle.

Fig.67 – Mechanical switch in off position

Alarm Bar Removal

Note: Remove the Alarm bar on the front of the TPS to protect from shipping damages.

1) Loosen the (2) two screws located on the face of the Alarm bar (Fig.68).

Fig.68 – Two screws on face of alarm bar

2) Lower the door of the Alarm bar so you have access to the plug located inside.

3) Unscrew the electrical plug inside the Alarm bar.

4) Carefully remove the Alarm bar by removing the (4) four screws holding it to the TPS.

a. Be sure to leave the screws with the Alarm bar so they can be used for re-securing inside the

TPS.

5) Find the Electrical Cap inside the Alarm bar box and secure to the plug that is attached to the building (Fig.69).

Fig.69 – Electrical cap stored and connected

6) Carefully place the Alarm bar back on the inside of the TPS.

a. Use the (4) four screws used to mount the TPS and secure the Alarm bar to the inside of the

TPS to the right of the door on the wall (Fig.70).

Fig.70 – Stored alarm bar

b. This is to ensure that the Alarm bar is secured safely to the wall to reduce the risk of damage during shipment.

7) Tighten the (2) two screws on the door of the Alarm bar.

8) Once these steps are complete, you can move to the Shipping preparation checklist.

Initial draining

Prior to draining, disassemble any and all anchors from the TPS. Place roof brackets back inside the TPS for safe storage and shipment.

Warning: Make sure electrical disconnection was done properly (follow electrical disconnection section).

1) Roll both of the clear reinforced drain hoses out of the door to a safe draining location (up to two feet away).

a. Make sure the hoses are routed along the floor to make sure unit is drained completely.

b. If further drain hose length is needed, you will need to use hose barbs and hose extensions

(not supplied).

2) Open the drain valve inside of the TPS that is connected to the end of the tank drain hose (Fig.71).

Fig.71 – Drain valve open

3) Allow to drain until minimal water is running out.

4) Open the pump drain cock on the backside of the pump (Fig.72).

Fig.72 – Pump drain cock

5) Leave the drain hoses through the door exit and proceed to the water disconnection section.

Water disconnection/final draining:

1) Using the proper wrenches, disconnect the hose and all associated fittings from the MHU.

2) Drain all excess water from the discharge hoses.

3) Loosen the pipe union on the inside of the TPS on the pump discharge side.

4) Route the hose back through the hose exit doors on the side of the TPS.

5) Roll the hose back up and place in the TPS in front of the pump and behind the door (Fig.73).

Fig.73 – Hose placed back inside TPS

6) Tighten the pipe union on the inside of the TPS on the pump discharge side to ensure the connection does not come apart during shipment.

7) Place forklift on the right side (when standing in front of the TPS, facing the alarms).

8) Slide forks approximately (8) eight inches inside the fork pockets on the base of the TPS (Fig.74).

9) Lift the corner of the TPS approximately 6-8 inches off of the ground (Fig.74).

Fig.74 – Forks inside of pockets and lifted approx. 8 inches

10) Allow to drain until no more water is exiting through the drain hoses.

11) Lower TPS back to level ground.

12) Place all drain hoses back inside the TPS.

13) Place all other miscellaneous items back inside the TPS for shipment.

Maintenance/Troubleshooting Caution: Before any maintenance is done to the TPS, make sure that the electrical supply is disconnected. Be sure to reconnect power once maintenance has been completed to ensure proper function of the TPS.

Maintenance instructions

Periodic cleaning of the pump should be done on an as-needed basis. Follow the below steps to clean the pump:

1) Remove the clean out port plug located below the inlet port (Fig.75).

Fig.75 – Clean out port

2) Insert a thin device (such as an ice pick or bradawl) and gently move it in a "push and pull" motion to…