Attachment 60 - Section J.60 General Air Products Tank and Pump System for FEMA - Installation Operation and Maintenance Manual Revision BB_004.pdf

Attachment 60 Section J.60

General Air Products Tank and Pump System for FEMA

– Installation, Operation and Maintenance Manual, Revision BB_004

1 Version 2, Rev BB_004, 11/30/16

Tank & Pump System for FEMA

Installation, Operation and Maintenance Manual

Revision BB_004

For Technical Support, Call 1-800-345-8207

Unit Serial Number: _____________________________________

Installation Date:

2 Version 2, Rev BB_004, 11/30/16

Table of Contents

Section 1 - Safety & Warnings

1.1 - Unpacking

1.2 - General Safety Information

Section 2 - System Description

Section 3 - Installation Instructions

3.1 - Initial Inspection

3.2 - Rigging & Moving

3.3 – Storage

3.4 - Location & Installation

3.5 – Water Pipe & Electrical Connections

3.6 – Water Tank Filling Instructions

3.7 – Alarm Battery Backup Connection

Section 4 - Start-Up Checklist

4.1 – TPS Start-Up Instructions and Checklist

Section 5 - Air Bleeding the System (if required)

Section 6 – Alarm Reset Instructions

Section 7 – Tank Topping Off and Tank Drain Instructions

Section 8 – Trouble Shooting Guide

Wiring Diagrams

NOTE: The FEMA Site Preparation and Installation Guide for Manufactured Housing Unit Fire Sprinkler Systems with Tank and Pump System should be used in conjunction with this TPS Operation, Installation, and Maintenance manual.

IMPORTANT: ALL INFORMATION SUBJECT TO CHANGE WITHOUT

NOTICE. Consult factory for the most up to date version of this manual - 1-800-345-8207.

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Section 1 – Safety & Warnings

1.1 Unpacking

1. After unpacking the unit, carefully inspect for any damage that may have occurred during transit. Make sure to tighten fittings, bolts, etc., before putting unit into service. Do not operate unit if damaged during shipping, handling or use.

1.2 General Safety Information

1. Read all manuals included with this product carefully. Be thoroughly familiar with the controls and the proper use of the equipment prior to putting into operation.

2. Periodic inspection and test of this equipment is required.

3. Check all fasteners for proper tightness.

4. Use a backup wrench when adjusting any water piping on the tank or pumping unit.

Section 2 – System Description

This TPS unit is a heated weather proof enclosure with a pump and tank package inside specifically designed for installation with a FEMA MHU with fire sprinklers installed.

The tank holds a given volume of water to be supplied to the sprinklers if they activate.

The pump will turn on if the pressure, sensed by the pressure switch, drops to the lower set point. As long as the water pressure in the fire sprinkler system is above the lower set point, the pump will not turn ON.

Section 3 – Installation Instructions

3.1 Initial Inspection

When the TPS is ready to be installed, all equipment should be inspected for damage or shortages during shipment.

3.2 Rigging and Moving

The TPS can be moved with either lifting forks or with a spreader bar using the installed lifting lugs located at the top of the TPS.

Please note center of gravity locators on each side of the TPS when lifting.

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The TPS is designed to be lifted using the fork lift channels or the lifting lugs located on each corner at the top of the TPS. Take special care not to bump, hit, or otherwise stress the lifting channels or lifting lugs during the lifting and positioning of the TPS. See Figures 4 and 5 for the designated lifting points.

Lifting devices (straps, cables, chains) should be rated at 4,000 lbs. total or 1,000 lbs. per lifting point. The TPS dry weight is 2,100 lbs.

Figure 6: Lifting Lug Location and Hold Dow Strap Location

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3.3 Storage Instructions

Storage when TPS is “New” – Vent plugs may be removed or left installed. NO special instructions or periodic maintenance is required.

Storage after decommissioning – Follow tank draining instructions in Section 7 to ensure there is no water in the tank or piping.

3.4 Location & Installation - The TPS must be installed on a level surface with proper hold down strapping per FEMA specifications (reference Figure 6). The location of the TPS at the installation site should be determined first to ensure the electric cable and water hose will reach the MHU connection points.

3.5 Water Pipe and Electrical Connections

3.5.1 Water Pipe and Electrical Assembly Outside TPS:

3.5.1.1 There are two locations available for water hose entry to the TPS on either side of the door. Choose the best single entry location and follow the following instructions.

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3.5.1.2 Measure and cut the supplied 6” PVC pipe and determine what elbow fittings are required to attach to the TPS. Install the supplied 6” PVC elbows and pipe over the water hose end that has the four (4) electrical connectors. Supplied 6” PVC parts are: • (4) 90° elbows, • (2) 45° elbows, • (1) piece of pipe, 6 feet long.

The PVC fittings and cut pipe should be fitted over the water hose loosely for assembly after water hose is connected inside the TPS (see following example and reference Section 3.5.2.3 before proceeding)

3.5.1.3 Electrical connectors on end of water hose must be inserted through the TPS wall in the order shown in 3.4.1.1, #3 illustration. The water hose end with union threaded fitting and 45 degree metal elbow is the last item to be inserted. The outer insulation of the water pipe must be inserted through the TPS wall and extend inside the TPS approximately 1”-3” past the interior wall.

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Next, install Vent Plugs inside TPS when outside temperature is below 40 degrees F.

Leave Vent Plugs out when above 40 degrees F to provide ventilation inside TPS.

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3.5.1.4 Install the Alarm Bar (shipped inside the TPS) to the outside wall opposite door.

NOTE: This operation takes two (2) people to install correctly.

Alarm Bar after Installation and Power is ON:

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3.5.1.4.1 One person should hold the alarm bar while the second person connects the yellow cord assembly. Align the connector and push together. Then screw the black metal connector together to secure the two yellow cords.

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3.5.4.1.2 After you have securely connected the yellow cord, hook the top of the alarm bar to the pre-installed metal hooks located on the rear outside wall. After you hook the Alarm Bar to the two hooks, let the bottom section rest against the TPS wall.

3.5.4.1.3 Fasten the Alarm Bar bottom section to the wall using the tamper resistant screw installed in the threaded hole in the wall. You will need to use the supplied tool to remove the screw first, then secure the bottom section to the wall using the screw just removed.

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3.5.2 Water Pipe & Electrical Connections Inside the TPS:

3.5.2.1 Water Hose Connection – Connect the water hose to the union on the water pump discharge manifold to the water hose threaded end and tighten.

First find the blue or black washer supplied in zip lock bag. Now install the gasket onto the water hose end as shown here (NOTE: Washer may be Blue or Black):

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Align the water hose end to the union as shown here.

Tighten union using standard pipe wrenches. Use a backup wrench on the water hose end to keep it from turning.

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3.5.2.2 Electrical Connections –

1) Connect all four (4) electrical connectors attached to the water hose to the side of the control panel per the following illustration:

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2) Attach the heat trace splice kit to the plastic bracket.

3) Check Heater setting below water pump. Dial should be between 2 and 3 at the 12 O’clock position.

4) Connect power cord connector to MHU Power Box and turn ON.

3.5.2.3 Water Hose Installation Instructions - Connect Water Hose to MHU Fire Sprinkler riser pipe using supplied union and fittings and use the following FEMA supplied information from MHU Technical Bulletin 2016-7 (with minor edits specific to the General TPS model) to install the water hose correctly .

Heat Trace Splice Kit Bracket

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The following water hose installation instructions are provided from

FEMA MHU Technical Bulletin 2016-7:

Background:

The TPS installation guides and manuals require that the hose and electric wire connecting the TPS to the MHU be buried in a trench at least 24 inches deep between the TPS and the MHU skirting.

Buried installation is called for to protect against rodent attack, to prevent a tripping hazard, to eliminate a potential playground, and for aesthetic reasons.

A number of recent installations have been made by encasing the hose and wire in the 6 inch PVC pipe included with the TPS and making an unsupported aerial run of pipe between the TPS and the MHU skirting. Figure 1 shows some of these installations, each of which is deficient in one or more regards.

Burial remains the preferred installation method. In some circumstances, aboveground installations may be acceptable. This Bulletin provides the technical requirements for above-ground installations, and describes the circumstances where above-ground installations may be acceptable.

Discussion:

Figure 2 illustrates the required below-grade installation for the TPS hose and wire assemblies that is founded in the TPS Installation Manuals. Note that the PVC pipe rests on the bottom of the 24 inch deep trench, providing support to the pipe above grade in the event someone steps onto the pipe.

Where digging the trench is impossible or impractical due to hard surface such as asphalt, concrete, paver stones, rocks, etc., an above-ground installation is acceptable.

Note: Some minor edits have been made to the illustrations to make them specific to the General TPS model.

Alternative Installation:

When site conditions preclude underground installation of the TPS hose/wire, above-ground installation should be provided in accordance with the instructions below. The following safety requirements must be provided for all above-ground installations:

• All exposed portions of the hose/wire assemblies must be fully encased in 6 inch diameter schedule 40 PVC pipe and fittings. A limited supply of pipe and fittings is supplied with the

TPS. If this supply is insufficient to completely encase the hose/wire assemblies, additional pipe and/or fittings must be procured locally. Only the portion of the hose/wire assemblies that are visible need to be enclosed in PVC pipe; inside the skirting, beneath the MHU, the hose and wire do not need to be enclosed in PVC pipe.

• The PVC pipe must be supported with piers or stands that will support a 200 lb. load imposed at the top of the pier or stand. Refer to the schematic diagram in Figure 3.

o Vertical supports or piers must be provided so that there is not more than 36 inches between supports.

o The pipe must be secured so that it cannot move vertically or horizontally if lawn maintenance equipment or an individual runs into it or climbs on it.

• The pipe may be installed directly on the ground as shown in Figure 4.

o If laid on the ground, the pipe must be securely staked down at 36 inch intervals to prevent lateral movement or lifting if lawn maintenance equipment or an individual runs into it or attempts to lift it.

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• The opening in the skirting must be made in a good and workmanlike manner. There shall not be more than ¼ inch gap between the outside wall of the pipe and the skirt, all the way around the pipe.

The PVC pipe does not need to be plumb or level for the TPS to function properly. It is, however, desirable that the pipe be level for aesthetic reasons.

The TPS above is located too close to the MHU.

The pipe is not supported. The opening in the skirt is professionally done.

In the installation above, the opening in the skirt is poorly done and should be repaired. Also in this installation, the pipe is not supported and the electric wire is taped to the underside of the PVC pipe; the wire should be inside the pipe for proper protection.

Although not explicitly stated, the TPS installation guides do not intend that an existing hard surface pad be cut out to bury the hose assembly. In the installation at left, burial of the hose and pipe is not recommended due to the concrete surface, so an above-ground installation is appropriate.

This installation would be acceptable if the TPS hose/pipe were structurally supported as described in this Bulletin.

Figure 1. Examples of improper TPS installation.

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The following illustrations show how the water hose should be installed. The preferred method is to bury the water hose 24 inches below grade as illustrated in figure 2.

Figure 2. Preferred/Standard\ TPS Installation Method.

Note:

There are two additional approved methods of installation when appropriate to the site conditions as follow:

Trench

Tank and Pump System

TPS) (

ABS Pads, Wood Frame w/Gravel or Hard

Surface Base

Grade

AC Power

(Black cable with Orange

Band @ plug)

TPS Skid / Base

Heat Trace

Cable

(Black or

Orange

Cable w/

Yel Band @ plug)

24 “minimum depth of trench for NEC compliance

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Tank and Pump

System

) TPS (

ABS Pads, Wood Frame w/Gravel or Hard Surface Base

Grade

AC Power

(Black cable with Orange

Band @ plug)

TPS Skid / Base

Heat Trace

Cable (Black or

Orange Cable w/ Yel Band@ plug) Skirt

MHU

Secure pipe to ground at 36 inches on center. Secure at the skirt, at TPS end, and every 36 inches between. Attachment must prevent lateral movement if pipe is kicked hard, as well as lifting. Stake may be located inside the skirt if visible for inspection.

May also be done with 90° elbows Gap between pipe and skirt shall not notnot exceed ¼ inch.

Figure 3. Aerial Installation showing supporting piers.

Figure 4. Installation with pipe on grade.

Tank and Pump

System

TPS ( )

ABS Pads, Wood Frame w/Gravel or Hard Surface Base

Grade

Pier

AC Power

(Black cable with Orange

Band @ plug)

TPS Skid / Base

Heat Trace Cable

(Black or

Orange Cable w/ Yel Band @ plug) Skirt

MHU

Pier

Pier 1 not more than 7 inches from outside surface of TPS enclosure.

Pier 2 not more than 3 inches from skirting. Pier 2 may be located inside the skirting if it is visible for inspection.

Install additional piers as needed to provide supporting piers 36 inches on center or less.

Securely attach pipe to piers with

UV and weather resistant material.

Gap between pipe and skirt shall not exceed ¼ inch.

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3.6 Water Tank Filling Instructions – CAUTION and NOTE: If local ambient temperature falls below 40°F, DO NOT FILL with water unless electric power is connected and confirmed to be working.

Make sure all four (4) ball valves are CLOSED before proceeding (see illustration for locations). Connect garden hose female end to a clean potable water supply. Connect the other end (Male) of garden hose to Fill Connection inside the TPS, Tank Isolation Valve and Water Hose Valve should remain Closed during tank filling.

Next, Open System Test Valve, turn on water (see illustration below), then open System Fill Valve slowly. Fill until tank water level is up to return test line inlet connection at the top of the tank. Close System Fill Valve and then System Test Valve. Keep garden hose connected.

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3.7 Alarm Battery Backup Connection -

1. Connect Batteries for Alarm Battery Backup:

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Section 4 – TPS Start-Up Instructions and Checklist

4.1 MHU-TPS System Start-Up Checklist

1. Ensure the insulated water pipe assembly is connected to the MHU and TPS with connections tight.

2. Ensure the electrical cord is connected to the MHU and all electrical connections are connected correctly and MHU power switch is ON.

3. Ensure the water tank is filled with water – leave garden hose connected.

4. Ensure both System Fill Valve and System Test Valve inside TPS are in the closed position. Open the Water Hose Valve. The Tank Isolation Valve is Closed.

NOTE: Illustration is for valve identification and location ONLY.

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5. Open test/drain valve inside the MHU to allow air to escape from the sprinkler piping system when filling with water.

6. Open System Fill Valve in TPS (garden hose will fill sprinkler pipe through water hose going to MHU) – System Test Valve and Tank Isolation Valve are Closed. Water Hose Valve is Open. This will fill the sprinkler piping in the MHU.

Note: Illustration is for valve location only – NOT valve position (Open/Closed)

7. Close the test/drain valve inside MHU when water is present and coming out of the test/drain pipe on the outside of the MHU at a steady stream.

8. Fill until pressure gauge is steady.

9. Close System Fill Valve in TPS and disconnect garden hose. Some pressure will be present in the sprinkler system and will register on the pressure gauge.

10. Ensure Test and System Fill Valves inside TPS are closed. Open Tank Isolation

Valve. Water Hose Valve remains Open (see illustration for valve location).

11. Open Bleeder Valve until water comes out of valve. Hand tighten bleeder valve.

12. Turn the electrical rotary disconnect (located on control panel enclosure above water pump) to the ON position. This will power up the TPS. NOTE: The water pump might run if water pressure inside the sprinkler system is low. If the water pump runs, it will run for a minimum of 2 minutes. While pump is running, the

24 Version 2, Rev BB_004, 11/30/16 alarm strobe will flash. The water pump should run for 2 minutes only – if it runs longer than 2 minutes or cycles ON and OFF, a leak is present. If excess run time is observed, please call 1-800-345-8207 immediately.

13. The electric circuit tester should be plugged into Circuit 2 receptacle when shipped from the factory. The two lights should show as shown below when power is on. If the two lights do not show as indicated, an electrical issue is present and must be fixed before proceeding with the installation and start up.

14. Remove the electric circuit tester from Circuit 2 and insert into Circuit 1. The two lights should show as shown. If not, an electrical issue is present and must be fixed before proceeding with the installation and start up.

15. Remove electric circuit tester and keep inside TPS Control Panel or Document Holder.

16. Monitor TPS for 5 minutes to ensure the water pump is not running. If the pump cycles ON, check for water leaks.

17. Open System Test Valve to ensure water is flowing back to tank. There should be ripples on the water surface inside the tank to indicate water flow. If no water flow is detected with the water pump running, see section 5 below.

18. Leave System Test Valve open for 10 seconds maximum. Note: While pump is running, the alarm strobe will flash. Close Test Valve. Note: Water pump will run for 2 minutes after starting even with Test Valve closed. Note: If pump runs longer than 15 seconds and pressure is too low, the alarm horn will sound and the strobe will flash.

19. Ensure Test and System Fill Valves are in the Closed position. Suction and Water Hose Valves should be in the OPEN position. (see illustration in step 4)

20. Check water level in tank. Top off if necessary (refer to Section 3.5 Tank Filling). After filling make sure Discharge and Tank Isolation Valves are OPEN and System Fill Valve and Test Valve are closed.

21. Ensure the Power ON green light is illuminated on the alarm bar outside the TPS. Note: There is an Alarm Mute button below the green power light.

Should one of the alarms go off, pressing the mute button will silence the horn, but the strobe will continue to flash. You must cycle power to the TPS and disconnect the battery wire for 5 seconds to reset the horn/strobe after alarm activation. The mute button will silence the low temperature horn (white) for 12 hours and the water flow horn (red) for 1 hour. You should NOT experience an audible alarm during startup.

22. TPS is now in service.

Electric Circuit Tester

Circuit 1

Circuit 2

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Section 5 – Air Bleeding the Water Pump System –

If water pump motor runs but has no water flow or pressure, perform the following procedure:

When first filling up the sprinkler system, ensure that all of the air is bled out of the pump and piping. The pump is supplied with a Bleeder Valve on the piping manifold

(see illustration below) that allows the pump casing to be vented. Loosen the Bleeder

Valve by hand to allow air to escape. Once the pump casing is filled with water, tighten the Bleeder Valve by hand ONLY.

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Section 6 – Alarm Reset Instructions

1. Turn Power Switch to OFF position.

2. Open Control Panel door. Remove lower Yellow wire off battery terminal. Wire will be labeled “Yellow Wire”. Temperature controller displays in upper left of control panel will go out.

3. Connect Yellow Wire back to the battery terminal.

4. Close Control Panel door.

5. Turn Power Switch ON.

6. Alarms have now been reset.

Section 7 – Tank Top-Off and Drain Instructions

1. Turn TPS Power Off by switching the power disconnect switch to the OFF position.

2. To Top Off water level in tank, Refer to Section 3.5 and follow instructions. After filling, turn Tank Isolation Valve and Water Hose Valve ON. Turn Power Switch On.

3. To Drain Tank, place drain hose outside TPS and open drain valve.

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Section 8 - Trouble Shooting Guide

Symptom Possible Causes Corrective Action

Power ON – no response

Electricity to MHU is not ON

Circuit breaker at MHU is OFF

Electric Power Cord is not connected to MHU or switch is

OFF

Ensure Power is on at MHU

Turn Circuit Breaker ON

Check MHU connection and switch setting

Power ON -water pump does not rotate

Circuit breaker inside control panel has tripped Water pressure is above 40 PSIG

Reset circuit breaker

Nothing – Pressure switch activates at 40 PSIG

Water Pump Motor won’t turn

OFF

System water pressure is below 62 PSIG. Pressure must be above 62 PSIG for motor to turn

OFF

Pump ran more than 2 minutes

There is water flowing

Ensure Bypass valve is closed

Turn Power off, disconnect battery, reconnect, turn power ON

White Alarm Activates

Temperature of water pipe or inside temperature of TPS is too low

Check to make sure heater is ON and is set at 2-3 on the dial

Ensure vent plugs are installed in 3 vent openings

Red Alarm Activates

Water Pump has turned ON for more than 15 seconds

System Test Valve has been opened. Wait 2 minutes and Alarm should reset. If not, follow Alarm Reset Instruction in Section 6.

If a sprinkler head has not activated, air may need to be bled from pump (see Section 5)

Alarm Bar power light is not ON

Connection is not correct Check connection under Alarm Bar

Cannot fill tank with a garden hose connected

Ball valves are not in correct position

For Top-Off, System Pressure is greater than garden hose connection

Check ball valve position (see Section 3.5)

Make sure Power Switch is OFF when Toping Off

For Technical Support, Call 1-800-345-8207.

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Control Panel Internal Schematic

1) Circuit Breakers –Switch “UP” position is ON and color indicator below switch is RED when ON (Green when OFF and down).

2) Dwyer Heat Trace Controller has a digital read out showing the actual water hose temperature. A small Yellow/Green indicator light will turn ON when Heat Trace is activated.

Circuit Breakers – Qty (5)

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WIRING DIAGRAMS

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General Air Products, Inc.

118 Summit Drive

Exton, PA 19341

P: 610-524-8950

F: 610-524-8965