HL Series Centrifugal Fire Pumps

Installation Instructions

Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Operational Limits .................................................................................... 2

Available Pump Models ........................................................................... 2

Installation Instructions ........................................................................... 3

Pump Lifting Points ................................................................................ 3

Pump Mounting ...................................................................................... 4

Pump Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Low Pressure Discharge ........................................................................ 5

High Pressure Discharge ....................................................................... 5

High Pressure Inlet Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

High Pressure Relief Valve .................................................................... 5

Read through the installation Thermal Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

instructions carefully before

installing your Waterous HL Series Fire Pump.

Piston Primers ....................................................................................... 6

Lubrication ............................................................................................. 7

Pedestal (Primer Housing) Fill and Drain ........................................... 7

K Series Transmission Fill and Drain . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Pump Water Drains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

NOTE: Instructions subject to change without notice Tachometer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Optional Items ...................................................................................... 10

Solenoid Valve for PIV (Priming Isolation Valve) . . . . . . . . . . . . . . . 10

RTP Foam Systems: ....................................................................... 11

Installed on Pump at Factory ....................................................... 11

Mounted Remotely from Pump .................................................... 11

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Final Checks ........................................................................................... 13

Lubrication ........................................................................................... 13

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

F-1031, Section 3032 (Rev: 9/5/17)

Waterous Company, 125 Hardman Avenue South, South St. Paul, Minnesota 55075 USA (651) 450-5000

www.waterousco.com

F−1031, Section 3032 Page 2 of 13

Introduction

This instruction covers the typical installation of any HL Series pump regardless of the model or intake and discharge.

General Description

The HL series are pedestal mounted fire pumps designed to operate in two modes:

Low Pressure Mode

Pump only low pressure water.

High Pressure Mode

Simultaneously pump low and high pressure water.

Three performance levels are available:

Before operating the HL pump, read the following instructions carefully.

Operational Limits

Maximum Low Pressure

Control the speed of the pump so that the maximum low pressure is limited to 17 bar.

Maximum High Pressure

The maximum high pressure is internally limited by the high pressure relief valve not to exceed 55 bar.

Maximum Angle of Inclination

The maximum angle of inclination for pump operation is 15 degrees.

Maximum Pump Speed

The pump has a maximum operating speed of 3450 rpm. Do not exceed this speed.

Maximum Priming Speed

When priming, the pump speed should be limited to 2600 rpm.

Low Pressure High Pressure Model Series

2000 L/min @ 10 bar 400 L/min @ 40 bar HL200

3000 L/min @ 10 bar 400 L/min @ 40 bar HL300

4000 L/min @ 10 bar 400 L/min @ 40 bar HL400

Available Pump Models

F−1031, Section 3032 Page 3 of 13

Installation

Pump Lifting Points

Direct Drive Models HL200D, HL300D, HL400D

Gear Drive Models HL200K, HL300K, HL400K

F−1031, Section 3032 Page 4 of 13

Pump Mounting

Select a mounting location that will make the pump and its accessories readily available for maintenance. Provide room around the pump for all intended piping, instrumentation and drive system.

Pump Mounting Flange

For mounting holes are located on the pump pedestal that are to be used to secure the pump to a mounting plate (plate not supplied by Waterous). The mounting plate should be designed with the four mounting holes (see diagram below for dimensions).

The plate should also provide clearance for the volute flange as identified in the diagram below.

Attach the pump to the mounting plate and secure to the vehicle with M16 bolts.

Driveline Connection

The pump mounting location should be such that the drive­ line shaft length and angles are in accordance with the drive­ line manufacturer's specification.

Connect the driveline to the companion flange provided on the pump input shaft. use appropriate fasteners and torque following the driveline manufacturer's specification.

NOTICE

Tighten fasteners to the following specifications: 176-190 • (130-140 lb-ft).

N m

Pump Mounting

F−1031, Section 3032 Page 5 of 13

NOTICE

Install a suitable 1/2 in. fitting and tube or hose as­ sembly and route to one of the following locations:

To the holding tank, vehicle tank or to atmosphere (ground).

Pump Intake

If piping is to be attached to the pump intake, provisions must be made to allow the removal of the pump intake adapter while the pump remains in the vehicle. This is necessary to provide access to the pump for repairs and maintenance.

Low Pressure Discharge

Any piping connected to the low pressure discharge open­ ings on the pump discharge manifold must be properly sup­ ported and secured.

High Pressure Discharge

Any piping connected to the high pressure discharge open­ ing on the pump discharge manifold must be suitable for high pressure and properly supported and secured.

High Pressure Inlet Strainer

Pump installation should provide access as this is a main­ tenance item.

High Pressure Relief Valve

Pump installation should provide access as this is a main­ tenance item.

Thermal Relief Valve

The valve is designed to discharge water if the temperature of the pump water reaches 49° C. The discharged water must be diverted away from the pump operator.

Installation of Components

NOTICE

The piping must not be restricted in any way.

NOTICE

A suitable strainer should be installed in each intake opening on the pump.

F−1031, Section 3032 Page 6 of 13

Clearance for Service

Piston Primers

Primer Discharge

The pump has (2) two automatic piston primers located on each side of the pump pedestal. Pump installation must provide 50 mm (2 in.) of space behind the primers to allow them to be removed for servicing.

During operation, the primers can discharge water. This wa­ ter exits through the primer discharge outlets. It is important that this water is not restricted in any way. Typically the water is discharged to the ground.

A suitable hose may be used to assist in directing the water to the ground, however, it is not recommended that any angled fittings be used as they will restrict the flow.

Piston Primers

NOTICE

The piping or hose must not be restricted in any way.

F−1031, Section 3032 Page 7 of 13

Lubrication

Models HL200 and HL300D

Pedestal (Primer Housing) Fill and Drain - HL200D, HL300D

Models HL200K, HL300K, HL300D, HL400D

Pedestal (Primer Housing) and K Series Transmission Fill and Drain

See next page for K Series Transmission requirements.

NOTICE

Pump installation must provide for access to the lubrication fills and drains.

F−1031, Section 3032 Page 8 of 13

Lubrication

Models HL200K, HL300K and HL400K Only

Transmission Mounted Vertically

NOTICE

Pump installation must provide for access to the lubrication fills and drains.

NOTICE

All piping, fittings and valves must be suitable for pres­ sures that are present in the low and high pressure stages.

Pump Water Drains

The pump is provided with two (2) 3/8 in. BSPT taps to allow water to be drained. Once is located on the low pressure stage volute and one on the high pressure stage volute.

The drains should be fitted with valves and piping. The pip­ ing should be routed to a suitable draining location.

Tachometer Connection

If Optional Control Panel was not furnished:

The pump includes a magnetic pick-up installed in the pump pedestal which allows a tachometer to be connected. A 10 meter cable is included with the pump which mates with the magnetic pick-up (Amphenol connector part no. MS3106A-10SL-4S).

Wire the cable to the tachometer. Note that the magnetic pick-up produces four pulses per revolution of the pump shaft.

If Optional Control Panel was furnished:

The tachometer is included in the control panel and the wir­ ing to the magnetic pick-up was completed at the factory.

Optional Items

F−1031, Section 3032 Page 9 of 13

Solenoid Valve for PIV (Priming Isolation Valve)

Drain Taps

Pump Water Drains

F-1031, Section 3032 Page 10 of 13

Solenoid Valve for PIV (Priming Isolation Valve)

2.750

69.85

1.188

30.16

MOUNTING FLANGE : 1.563 i

·'":f-

19.84

39.69

2X M4 MOUNTING HOLE

I SOLENOID DIMENSIONS

AllDIMENSIONS SHOWN INCH ) AS INCH/MILLIMETER (MILLIMETER

GROMMET TWO 16 OR 18

AWG WIRES

CONNECTOR

HOUSING

SOLENOID

VALVE TERMINAL

SCREWS

NOTE: SOLENOID IS NOT

POLARITY SENSITIVE SOLENOID WIRING

AIR INLET CONNECTOR ON PUMP

PRIMING ISOLATION VALVE IPIVI.

CONNECT 6mm TUBING TO

PUSH-ON FITTING

TO PTO ACTUATOR

PTO SWITCH

6mm TUBING 16 OR 18 AWG WIRE

PRIMING VAL VE SOLENOID,

REMOTELY MOUNT IN CHASSIS

ISEE DIMENSION AND WIRING DETAILS!

FROM CHASSIS

AIR SUPPLY

6mm TUBE X 1/4

BSP FITTINGS

IL:9561

F−1031, Section 3032 Page 11 of 13

RTP Foam System

(RTP Foam System is Optional)

Installed on Pump at Factory:

Install the Foam Suction Hose:

Install the barbed fitting in the tap located on the bottom of the Proportioner Valve.

Attach the hose and wand to the barbed fitting using the clamps provided.

Mounted Remotely from Pump:: See separate Installation Instructions F-1031, Section 2321.

RTP Foam System (Installed at Factory)

F−1031, Section 3032 Page 12 of 13

Control Panel

(Control Panel is Optional)

Complete Electrical Connections for the fol­ lowing:

• Tachometer / Hourmeter

• Pump Overheat Module

• Pump Engaged Module

Complete Electrical Connections and Tank Connections for the following:

• Optional Tank Level Monitors

Control Panel

F−1031, Section 3032 Page 13 of 13

Final Checks

Lubrication

Before operating the pump, add the lubricants specified below (see Pages 7 and 8 for fill locations.)

Models HL200D, HL300D and HL400D

Lubrication required for Pedestal (Primer Housing) Only

Pedestal (Primer Housing) Lubricant Capacity

SAE 10W-30 Motor Oil .95 Liter (1 Quart)

Models HL200K, HL300K and HL400K

Lubrication required for Pedestal (Primer Housing) and K Series Transmission

Pedestal (Primer Housing) Lubricant Capacity

SAE 10W-30 Motor Oil .95 Liter (1 Quart)

K Series Transmission Lubricant Capacity

SAE 80W-90 Gear Oil .95 Liter (1 Quart)

Testing Before operating the pump, check and verify all fasteners and connections (mounting, driveline, piping, etc.) are se­ cure.

To run the pump, follow instructions F-1031, Section 2408, HL Series Fire Pump Operation and Maintenance Instruc­ tions.

During the running of the pump, monitor for smoothness of operation, listen for unusual noises and check for leaks.

NOTICE

Failure to properly lubricate the pump may result in serious damage.

NOTICE

1. Capacities shown are approximate. Quantities listed vary based on ratio and /or mounting orientation.

2. Always fill to the marking on dipstick (pedestal) or bottom of the plug labeled “Oil Level” (K Series Transmission).

3. K Transmission breather may be removed and the hole used as the lubricant fill.

4. Synthetic oil substitutes are acceptable.