MANUAL FOR

AUTOMATIC DIESEL ENGINE

CONTROL PANEL

OPERATION & MAINTENANCE MANUAL

Table Of Contents.

1. General Arrangement of the panel ......... 3

2. General .............................................. 4

3. Safety .................................................. 4

4. Transport and Storage ............................4

5. Installation ...........................................5

6. Operating Principle ................................ 5

7. Product Info & Type Key ...................... 5

8. Description of Product Accessories ..........5

9. Quick Start Guide …………………………………… 6

10. Scope of Supply.……………………….…………… 7

11. Mounting ………………………………………………….8

12. Functional Description of panel ………………8

13. Fittings…………………………………………………….11

14. Commissioning ……………………………………….11

15. Faults ………………………………………………………11

16. DO’s and DON’Ts …………………………………….12

OPERATION & MAINTENANCE MANUAL

Fig 1

OPERATION & MAINTENANCE MANUAL

1. General. damages. Lack of care may lead to problems such as
failure of important pump or machinery functions,
Installation and commissioning by qualified and danger to persons from electrical, mechanical and
trained personals only. bacteriological influences, material damage.

1.1 About this document.

2.4 Safety Precautions for the operator.
These installation and operating instructions are an Regulations for the prevention of accidents must be
integral part of the unit. They must be kept readily followed. Directives issued by the local Electricity
available at the place where the unit is installed. Strict supply companies are to be observed.
adherence to these instructions is a precondition for
the proper use and correct operation of the unit. These
2.5 Installation and commissioning of system. If
installation and operating instructions correspond to
system is going to be commissioned after six months
the relevant version of the unit and the underlying
from the date of dispatch, revalidation of the system
safety standards valid at the time of going to print.
is required. Revalidation to be done through Wilo
authorized service personnel before commissioning
2. Safety.
system.
Read these instructions carefully before installing and
starting up. Pay special attention to the points
3. Transport and storage.
regarding safety of the equipment for the intermediate
or final user.
3.1 When the equipment is delivered, check that it
has not been damaged in transit. If any defects are
2.1. Symbols in the instructions. found, please inform supplier.

Safety instruction: If not followed, could cause injury The equipment must be transported by means of
for person. authorized load carriers. Stability of the load must be
ensured. Transport straps or ropes must be secured to
the existing transport lugs or taken round the base
frame. The pipes will not withstand loads and should
not be used to secure loads in transit.

Electrical safety instructions. If not followed could

cause injury to the person. ATTENTION!

ATTENTION!
Loading of the pipes in transit can result in leaks.

If the delivered equipment is to be

Safety instruction: If not followed could cause
installed later, store it in a dry place and protect
damages for the equipment and its operating.
it from impacts and all outside effects (moisture,
frost, etc.…).
2.2 Staff Training.

If Transit damage is observed to the system inform to

The Personnel installing the panel must have the
the delivery company (forwarding agent) or our
appropriate qualifications for this work. customer service department, even if you did not find
any damage initially. After removing the packing, the
2.3 Risks incurred by failure to comply with the installation must be stored or installed according to the
safety precautions. installation conditions described above.

Failure to comply with the safety precautions could

result in personal injury or damage to the pump or
installation. Failure to comply with the safety
precautions could also invalidate any claims for

OPERATION & MAINTENANCE MANUAL

4. Installation.
4.1. Room e.g.: ENGINE CONTROL PANEL (STD)-12V MFG

The controller must be installed in a shelter or in a ENGINE PANEL FIRE FIGHTING System Panel
room that is easy to reach, normally ventilated and (STD) Standard. Options: PLC, CB
protected from frost. 12V OPERATING DC VOLTAGE.
Option : 24V
4.2. Electrical connections. MFG / CB MANUFACTURING / CONTACTOR
BLOCK (in case of standby
battery)
SD Special Design

6.2 Technical Data

The electrical connections and checking must be done
by a qualified electrician in accordance with the local Mains supply voltage [V] 1~230V,50Hz
standards.
ENGINE VOLTAGE (Vdc): See name plate
Protection class: IP 42
Refer Motor data plate for the electrical characteristic
(Frequency, Voltage, nominal current) Max. Ambient temp. 400C
In accordance with
Main side protection
Check if the motor complies with the mains supply wiring diagram
used. Provide isolator switch to protect the power supply.

7. Description of the product and the

accessories.

7.1 Description of product and its accessories.

DO NOT FORGET CONNECTING TO EARTH Function description.
(Green-yellow conductor).
The engine control system is provided with engine

5. Operating Principle. Aligned with pump on a skid, batteries, battery

Cables and control panel.
The Control panel is used to automatically control of
The engine control system is designed to offer a
firefighting engine. It is used in residential high-rise
buildings, hotels, and hospitals, administrative and combination of manual and fully automatic control
industrial buildings. in starting of diesel engine – driven firewater-
pumping sets. Batteries will be always kept fully

6. Product Information charged by the control panel. The control panel

keeps constant watch on engine conditions & gives
6.1 Type Key Fire Fighting
visual indications.
This is fix speed system panel. Description details
Note: You will find information on the pump type used
given in below table
in the attached Installation and operating instructions
for the pump.
Regulations of the competent fire protection
authorities must be included where appropriate. Local
conditions (e.g., a hydrant pressure is too high or
fluctuates considerably and which might require the
installation of a pressure relief valve).

7.2 Quick Start Guide.

The complete installation can be completed with

following steps;

OPERATION & MAINTENANCE MANUAL

S.N. Action

1 Ensure that Our Engine Panel is mounted properly

2 Engine starter motor to Battery cable connection should be proper

3 Engine and Panel Earthing should be connected properly

4 Our Engine Panel to Engine Panel Cable should be routed and connected
properly as per drawing,

5 Check Water Present in Source Tank

6 Check Pump Alignment with Engine

7 Check Suction Line and Delivery Line connected properly

8 Check Engine and Pump are coupled properly

9 Check Lubrication Oil, Coolant, Charged Battery, Diesel Line/Filter etc.

10 Charge Panel with 230Vac supply

11 Check indications and hooter working ok by using Test button.

Follow Jumper Link Sheet as per voltages coming from engine.
Preferably crosscheck LLOP sensor is with NO contact or NC contact. And it gives
us negative signal or positive signal.
12
Start / Stop engine properly through engine panel

13 If engine function properly as per S.N.-12 above, then connect engine wires to
our panel. Start/Stop engine from our control panel in Manual Mode and check
for ‘Engine Running Feedback’

14 If hydrant line is pressurized, crosscheck it’s feedback at our panel

15 If ‘hydrant line pressure feedback ‘ & ‘ engine running feedbacks’ are Ok; put
our panel in ‘Auto Mode’

OPERATION & MAINTENANCE MANUAL

Function of the fire fighting
system 7.3 Scope of supply
• Switch Box microcontroller Based.
The Automatic Starting of the Diesel Engine is
• Electrical circuit diagram.
done by means of a Pressure Switch mounted on • Operation and installation Manual.
the delivery end of the Fire Water Pump provided
its Hand Switch (SW2) is kept in A/M Mode. The
7.4 Accessories
‘NO’ contact (under low pressure) of the Accessories must be ordered separately if needed.
pressure switch is wired to the Control Panel to
ensure a fail-safe operation.

On drop of pressure, the ‘NC’ contact of the

pressure switch opens thereby command goes to
PCB 314A Control card. This causes contact of
Relay to close and 12/24 VDC supply is applied
through relay to the starter motor of the Diesel
Engine.

In case of Pressure drop and Auto-Manual

Selector Switch (SW2) is being in Auto Position
the PCB 314A gives starting command to the
Starter Motor mounted on the Diesel Engine.
Further direct Battery Terminals are connected to
the solenoid of Starter motor through batteries
ensuring 12/24 VDC Supply with required current
to Diesel Engine. Simultaneously fuel oil solenoid
gets ‘12/24 VDC’ supply, which will energize the
fuel oil solenoid meant for supplying fuel to
the Diesel Engine on starting of motor and
energization of fuel solenoid, lubricating oil
pressure will increase which acts as feedback for
cranking operation as described. This feedback
is taken from “Lube Oil Pressure Switch” mounted
on the Diesel Engine. Under diesel engine running
condition, the ‘NO’ contact of Lube Oil Pressure
Switch get closed and in turn energies fuel
solenoid which will supply the fuel to the engine
for running.

OPERATION & MAINTENANCE MANUAL

8. Installation/mounting. NPSH of the pump, avoid pressure losses and
cavitation).
8.1 Installation at Site.
The system is installed in the room or in a dry, well 8.2.2 Flushing the pipes and the system reduces
ventilated and frost-proof, separate room that can be the risk of adversely affecting the water quality. The
locked. Adequately dimensioned floor drainage (sewer water must be completely replaced after a longer
connection or similar) must be provided in the period of system standstill.
installation room. No harmful gases must penetrate
the room or be present there. Adequate space must be For simple flushing of the installation, we recommend
provided for maintenance work. The main dimensions
the installation of a T-piece on the end pressure side
are given on the attached installation plan. The
installation should be freely accessible from at least of the system, upstream of the next shut- off device.
two sides. The installation surface must be horizontal Its branch, provided with a shut-off device, drains into
and flat. The system is designed for a maximum the wastewater system during the flushing process and
ambient temperature of +0 °C to 40 °C with a relative must be suitably dimensioned according to the
atmospheric humidity of 50%. Installation and maximum volume flow of an individual pump.
operation in the vicinity of living rooms and bedrooms
is not recommended. To avoid the transmission of 8.2.3 Dry-running protection system and protection
structure-borne noise and to ensure a stress-free
Against low water level (accessory)
connection to upstream and downstream pipes,
Suitable dry run protection device must be used to
compensators with extension limiters or flexible
protect pumps running dry.
connecting pipes should be used!

8.2 Foundation/substrate:
8.2.4 Safety valve (accessory)
The construction of the firefighting allows it to be set
A component-tested safety valve must be installed on
up on a level concrete floor. The base frame is the discharge to limit or protect the installation against
mounted on this floor, suitable measures must be excess pressure.
taken to avoid structure-borne noise.

8.2.1 Hydraulic connection and pipes. 9. Description and Function of Fire Fighting
The installation must not be connected until all the system:
welding and soldering work and the necessary flushing
and, if necessary, disinfecting of the pipe system and The fix speed-based system is specially designed for
the booster installation has been done. automatic control of diesel engine to maintain provide
volume flow at the time of any major incidence.
The customer’s pipes must be installed free from
stresses. Compensators with length limiters or flexible
connecting pipes are recommended for this purpose to
avoid stresses on the pipe connections and minimize
the transmission of installation vibrations to the
building installation.

Pipe connection can be made either on the right or left

of the installation, depending on the site conditions. It
may be necessary to change blind flanges or thread
caps already fitted. In the case of booster installations
with horizontal pumps, the pipes on the suction side
must be supported so that the tilting moments that
can be generated through a shift in the installation’s
center of gravity are safely absorbed. The flow
resistance of the intake pipe must be kept as small as
possible (i.e., short pipe, few elbows, adequately large
shut-off valves), otherwise the low-water protection
device may respond with high volume flows through
high pressure losses. (Note

OPERATION & MAINTENANCE MANUAL

 PB1 is pressed, the contact closes & PCB 314A
9.1 Construction of the Control Panel: will gives command to start the engine.

It consists of following main components.

Another facility is provided if the switch is in
Manual Position, no one can start Diesel Engine
The Panel consists of one set of SMPS based
Automatically – as it is assumed that some
Battery Charger. Battery Charger is capable of
maintenance work is going on and, hence
charging two numbers of 12/24 VDC batteries
pressure is reduced. But after completion of the
to their fullest capacity. The charger is short
work, it is necessary to bring back the switch in
circuit protected.
“Auto-Manual” Position.

When command for engine ‘start’ is given, the

Stop Push Button (PB2) is provided to stop the
starter motor gets power directly from the
Diesel Engine, when this Push button is pressed
12/24 VDC battery which draw heavy current.
it cuts off 12/24 VDC Supply provided to Fuel
Ammeter and voltmeter are provided to Solenoid mounted on the Diesel Engine, PCB
indicate charging current and charging 314A gives stop command.
voltage respectively.

Through Battery Charger Selector Switch

(SW4), one can select which Battery should
gets charged. (in case of double battery only)

Through (SW3) float/boost selector switch we

can charge the battery in boost mode, earlier
than standard time. The voltage observed at
the time of boost is 13.3/25.8 Volt.
The charger goes in boost mode automatically
in case of battery voltage is very low.

At the bottom, two terminals are provided

which gives 12/24 VDC Supply to system for
control and operation. Diodes “AND” ing is
done so that two sets of Batteries do not get
discharge into each other as well they do not
start back charging the Charger. Separate
MCBs are provided for protection.

Relay RLM (Coil 12/24V DC – mounted in Control

Card) is used to have “Mains ON” Indication.

Auto-Manual Selector Switch (SW2) - When

this switch is in Auto-Manual Position the
Engine can be started in Auto as well as Manual
Mode of operation through Start Push Button
PB1.

Start Push Button (PB1 ) is provided to start

the Diesel Engine Manually. Manual start of the
engine / pump is possible in both positions of
the `Operation Mode Selector Switch’. When
OPERATION & MAINTENANCE MANUAL
Common functions in All Operation Modes.
CONTACTOR BLOCK – (In case of Double battery):
12/24 Vdc voltage goes to fuel oil solenoid to stop
the engine through stop push button whenever This is a separate unit consists of two numbers of
required. contactors, `X' and `Y’ for the Automatic & Manual
Starting of the Diesel Engine. Depending upon the logic
When engine takes pick up 30 to 40 %, feedback
selected either contactor “X” or “Y” is get energize for
goes through contact of Lub Oil Pressure switch to
PCB 314A, it means engine is running. giving starting crank to Diesel engine.
Since the battery cables will be connecting the contactor
As soon as Diesel Engine crosses the pre-set speed, PCB
block to starter motor it is essential that the starter motor
314A receives feedback through Over Speed Switch.
(engine), batteries and contactor block are located near
“Engine Over Speed”, annunciation is then provided on
the fascia of the panel. each other. Since the Control Panel controls only the two
contactor coils `X' and `Y', it is possible to locate the
PCB 314A is our logic control card. It gives signal to
Control Panel at a slight distance away for easy operating
electronic hooter which gives out Audio Alarm. It
can be silenced by pressing “ACCEPT” Push Button. for personnel. (Detail wiring diagram shown in sheet 5 of
TEST (PB3 ), ACCEPT ( PB5 ) AND RESET ( PB4 ) Push 5)
Buttons are provided .

PCB 314A is used for generating Visual Annunciation

and give pulse for generating Visual Alarm. The
Alarm is reset only after field conditions are set
normal and RESET Push Button is pressed.

OPERATION & MAINTENANCE MANUAL

10.0 Installation /Fitting.
11.2 Testing of engine:
After taking care of pump starting, start engine from
Installation. Local starter supplied by engine manufacturer.
Note feedback signal polarities, type of fuel solenoid.
Wall mounting: The panels for firefighting systems
are mounted directly on wall. 11.3 Setting in our panel as per site and observations
As per point 11.2:
Check for Factory settings.
If it is as per field requirement, it’s well and good.
Floor mounting: Floor mounted version is to be Otherwise change settings as required. Setting guide
erected on a plane area. It is supplied with 100 mm
Is provided with Panel.
height plinth. Others than this size is optional.
Now start the panel in simulation mode. If operation
Is correct then connect to engine junction box.
First take trial in manual mode and then if satisfied
Then put in Auto mode.
10.1 Electrical connections.
Electrical connection must be carried out by an
Electrical installer authorized by the local power 12 Faults:
Supply Company in accordance with the applicable
local regulations. 12.1 Fault displaying and acknowledgement
PCB 314A is our logic control card. It gives signal
to electronic hooter which gives out Audio Alarm.
ATTENTION!
It can be silenced by pressing “ACCEPT” Push
The engine terminal box is connected to the terminal Button.
blocks in accordance with the wiring diagram. PE must TEST (PB3 ), ACCEPT ( PB5 ) AND RESET ( PB4 )
be connected to the earth bus. Push Buttons are provided .

Pressure switches / level sensor need to connect to the

terminals in accordance with the installation and 12.2 Following Faults are displayed:
operating instructions.
In the event of fault appears the fault will be displayed
on LED Fascia.
11. Commissioning.
We recommend starting the unit into operation by the
1. Mains On.
Wilo customer service personnel. The customer's
2. Pump On Demand
wiring is to be checked to make sure it is correct, 3. System on Auto
especially the earthling, before switching the unit on 4. System on Manual
for the first time. 5. Engine Running
6. Engine Fails to Start
Priming to the pumps and pipework must be done 7. Low Lube Oil Pressure
8. High Engine Water Temp.
before system put into operation for the first time.
9. Engine Over Speed
10. Fuel tank Level Low
All steps for Installation, commissioning and operation 11. Mains Fail
are described in the booster-system's manual. 12. Spare
13. Spare
11.1 Factory setting. 14. Spare
The controller is pre-set at factory preset value. 15. Spare

If the fault cannot rectify, please contact

your nearest Wilo customer service point or
Representative.

OPERATION & MAINTENANCE MANUAL

13 DO’s and DON’Ts

Sr.No. Do’s Don’ts

1 Initially battery should be charged Don’t put our control panel in Auto mode before
confirming ‘Engine Run feedback ‘ in Manual mode
2 Ensure Engine working from engine Panel before Engine Battery to Starter Motor Cable length should
connecting our control panel, not be more than five meters
3 Ensure tightness of power cable connections Our Control Panel to Engine Cable length should not
before Cranking Engine be more than ten meters

OPERATION & MAINTENANCE MANUAL

Further Information:

For Further information please email to us on following ID: -

[email protected]

Technical Specifications are subjected to change.

OPERATION & MAINTENANCE MANUAL