Hubbell Heat Pump LX 1500 User Manual

Hubbell Industrial Controls, Inc.  
A subsidiary of Hubbell Incorporated  
50 Edwards St.  
HUBBELL  
Madison, OH 44057  
Telephone (440) 428-1161  
FAX (440) 428-7635  
Instruction Manual  
Fire Pump Controller  
Model LX-1500  
Limited Service  
Electric  
Publication No. 197  
April, 2000  
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Limited Service Fire Pump Controller  
I Introduction  
The Hubbell Limited Service Fire Pump Controller provides automatic and manual control of  
small electric motor driven fire pumps and booster pumps of 30 horsepower or less.  
All Controller components are inside the cabinet with indicating lights and switch handles  
located next to the door. A pressure switch initiates automatic starting of the pump motor. The  
Controller monitors the power phases and voltage.  
The CIRCUIT BREAKER  
DISCONNECTING MEANS handle has a door interlock feature to prevent opening the door  
when the switch is closed. The Controller also has an EMERGENCY MANUAL CONTROL  
handle to start the fire pump manually.  
CIRCUIT  
BREAKER  
DISCONNECTING  
EMERGENCY  
MANUAL  
CONTROL  
MEANS  
Incoming  
Phase  
Line  
To  
Fire Pump Motor  
L1 M1 T1  
Surge  
Suppressor  
Control  
Panel  
PLM  
Pressure  
Switch  
Control  
Transformer  
Figure I-1 Block diagram of LX-1500 showing one phase  
II Specifications and Certifications  
Specifications  
208, 240, 380, 480C  
Voltage  
A-B-C phase rotation  
Phase Loss/Reversal Module  
200 Series  
300 Series  
400 Series  
208–240 VAC, 60 Hz, 3 phase  
380–415 VAC, 50 Hz, 3 phase  
440–480 VAC, 60 Hz, 3 phase  
Maximum Voltage  
Maximum Frequency Shift  
Phase Loss  
10% of highest nominal voltage  
0.1 Hz  
18% of low voltage in one phase  
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Limited Service Fire Pump Controller  
Undervoltage Trip  
Time Delays  
15% below set point  
Pick-up, 1.5 s, fixed  
Drop-out, 1.5 s, fixed  
Output Relays  
10 A, 120 VAC  
5 A, 240 VAC  
Indication  
green LED, on for A-B-C phase rotation  
650 V rating  
Surge Suppressor  
Temperature  
Operating: -4° F to 104° F (-20° C to 40° C)  
Storage: -4° F to 182° F (-20° C to 85° C)  
Certifications  
The Hubbell Limited Service Electric Fire Pump Controller is built to NFPA 20 requirements.  
The Controller is listed by:  
Underwriters Laboratory  
Factory Mutual  
New York City  
Underwriters Laboratory Canada  
Canadian Standards Association  
III Receiving, Handling, and Storage  
1. Immediately upon receipt, carefully unpack and inspect the Controller for damage that may  
have occurred in shipment. If damage or rough handling is evident, file a damage claim with  
the transportation carrier.  
2. If the Controller must be stored, cover it and place in a clean, dry location. Avoid unheated  
locations where condensation can result in damage to the insulation or corrosion of metal  
parts.  
IV Installation  
1. Consult the motor nameplate to determine voltage, current, and horsepower rating and  
compare with the Controller nameplate for matching data.  
2. Release the door interlock by moving the CIRCUIT BREAKER DISCONNECTING  
MEANS to the OFF position.  
3. Inspect the control transformer’s primary connections for agreement with the line voltage of  
the incoming power.  
4. Exercise all switches and contactors, without power, to see that they operate freely.  
5. Choose a location or base for the Controller that is non-combustible and within site of the  
motor. The base should not be subject to excessive vibration that may cause erratic operation  
of the PS (pressure switch). The Controller should be leveled so that the PS is level. Sight  
across the PS cover screws.  
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Limited Service Fire Pump Controller  
Caution: Before drilling and punching holes in the cabinet for wiring  
connections, cover the components inside the cabinet with a  
protective covering. Debris may cause shorts or prevent operation  
of components.  
6. Punch holes in the top or the bottom of the cabinet for conduit.  
7. Connect the water pressure sensing line to the PS (1/4 NPT internal, 3/4-16 external, brass)  
fitting on the bottom of the cabinet. For further details, consult the latest edition of NFPA  
20.  
8. Connect the power supply conductors to the line side of the CIRCUIT BREAKER in the  
correct A-B-C phase sequence.  
9. Connect the motor conductors to the load side of the motor contactor.  
Note  
Refer to the Controller field connection diagrams. Per the requirements of NFPA 20, conductors  
are sized for no less than 125% of the motor FLC (full load current) and not more than the lug  
sizes provided, as shown on the Controller field connection diagrams. Refer to the NFPA 70  
(NEC) for cable ratings. Secure conductors inside the cabinet so they do not interfere with or  
come in contact with the components.  
10. Connect the remote alarm contacts. Refer to the supplied Controller field connection  
diagram for terminal points.  
V Sequence of Operation  
The PLM (phase loss/reversal monitor) provides contact output for phase loss and undervoltage  
(PLM-2) in addition to a separate contact output for phase rotation (PLM-1). Both output relays  
energize if all three phases are present and the phases are in the proper rotation. If a phase loss  
or undervoltage condition occurs, only the phase loss relay de-energizes. If the phases are  
reversed relative to the sequence on the PLM, only the phase reversal relay de-energizes. If there  
is a total loss of the three-phase voltage, both output relays de-energize.  
Closing the CIRCUIT BREAKER DISCONNECTING MEANS energizes the PLM and the  
control transformer. After a 3–5 second delay, contacts PLM-1 open and the PHASE  
REVERSAL light should go off. If there is a phase reversal, PLM-1 remains closed to turn on  
the PHASE REVERSAL light and energize the PRR (phase reversal relay) to provide remote  
indication of phase reversal. The PLM-2 contacts also close, after the 3–5 second delay, to turn  
on the POWER AVAILABLE light and energize the PFR (phase failure relay) to provide remote  
indication that power is available.  
Automatic Start - When the PS (pressure switch) contacts close due to a decrease in pressure,  
the CR relay coil energizes. The CR contacts close to energize the TR1 timing relay, factory set  
at 10 minutes, to begin timing. The TR1 contacts close to latch the CR relay and bypass the PS.  
The CR contacts also energize contactor coil M1 to start the motor. If the pressure increases, the  
PS contacts open to de-energize the CR relay and stop the motor, if TR1 has timed out. If TR1 is  
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Limited Service Fire Pump Controller  
still timing, the CR relay remains energized and the motor continues to run for the duration of the  
timer setting.  
Pressing the STOP push button stops the motor even if TR1 is timing. If the Controller does not  
have a TR1 timing relay, the pump motor runs until the STOP push button is pressed.  
Manual Local Start - Pressing the START push button energizes relay LRSR. The LRSR  
contacts close to latch the LRSR relay and energize the M1 contactor coil to start the motor. The  
motor runs until the STOP button is pressed to de-energize the LRSR coil.  
Manual Stop – Connecting the jumper wire between TB2-4 and TB2-5 bypasses the TR1  
timing relay contacts. When this jumper is installed, the motor runs until the STOP button is  
pressed.  
Remote Start - The remote start circuit requires the closure of remote contacts to start the  
motor. Closing the remote contacts energizes the LRSR relay. The LRSR contacts close and  
latch the LRSR relay until the STOP button is pressed.  
Deluge Valve Start – A normally closed remote switch energizes the optional deluge valve  
relay (DVR). Opening the remote switch de-energizes the DVR, closing the DVR contacts in  
parallel with the PS contacts, to energize the CR relay and the TR1 timing relay. When the  
remote switch closes, the DVR contacts open to de-energize the CR relay and stop the motor, if  
TR1 has timed out.  
Lockout – (This feature is not allowed per NFPA 20 and is permitted only when acceptable to  
the authority having jurisdiction.) The lockout circuit requires the closure of remote contacts to  
stop the motor. Closure of the contacts energizes the LK relay. Contacts LK open to de-  
energize the CR relay and stop the motor. If the remote contacts open while the pressure is low,  
the motor restarts.  
EMERGENCY MANUAL CONTROL - The emergency start handle should only be used if the  
Controller fails to start automatically or with the START push button. The motor runs until the  
handle is returned to the OFF position or the CIRCUIT BREAKER is opened. To start the  
motor when control power is not available, push the T-handle in and rotate counterclockwise  
(45°) to lock in the full ON position in a fast and continuous motion.  
Caution: Failure to engage the handle in a fast and continuous motion can  
result in damage to the contactor and failure to start the motor.  
Pump Run Contacts - The pump run contacts transfer any time the M1 contactor is closed by  
either electrical or mechanical means.  
Phase Loss Contacts - The phase loss contacts transfer when line or control power is lost or  
the line voltage drops more than 15 percent.  
Phase Reversal Contacts - The phase reversal contacts transfer when there is a phase  
reversal, rotation other than A-B-C.  
Page 6 of 12  
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Limited Service Fire Pump Controller  
VI Start Up Procedure  
Danger: Shocks, burns, or death may result from high voltage.  
Caution: Only personnel who are familiar with the power distribution system  
and this manual should be allowed to perform this procedure.  
1. Verify that the motor nameplate horsepower and voltage match the Controller nameplate.  
2. Verify that the CIRCUIT BREAKER DISCONNECTING MEANS is open. Check with  
the electrician to see if the Controller is connected directly to the main transformer. If so,  
apply the Service Disconnect label above the CIRCUIT BREAKER handle operator.  
3. Verify that the PLM is set to the line voltage.  
4. Verify that the customer connections to the CIRCUIT BREAKER and contactor are properly  
tightened.  
5. Carefully remove the foam packing from the PS (pressure switch) between the mercury  
switch and the bourdon tube. Remove the installation instructions above the tube. Replace  
plastic cover.  
6. Adjust the PS set points on the right side of the switch to meet water system requirements.  
Set the upper pointer to the required STOP (HIGH) pressure setting. Set the lower pointer to  
the required START (LOW) pressure setting.  
The scale on the PS is only for initial positioning of the pointers. During testing of the  
Controller, verify the PS settings by referring to the system pressure gage. Readjust settings  
as necessary to obtain desired STOP and START settings. Refer to the instructions packed in  
the PS and NFPA 20 for more information on adjusting the settings.  
7. Verify that the minimum run timer TR1 is set for 10 minutes, per NFPA 20. The timer can  
be field set as required by local jurisdiction.  
8. Close the cabinet door and close the CIRCUIT BREAKER DISCONNECTING MEANS.  
After a five second delay, verify that the POWER AVAILABLE light is on. If equipped with  
a Transfer Switch, verify that the green LED on the PRM (phase reversal monitor) is on after  
a five-second delay. If the LED’s are not on, open the CIRCUIT BREAKER and change  
any two leads (L1, L2, and L3) on the PLM. If equipped with a Transfer Switch, change the  
same two leads on the PRM.  
Caution: Note that the pump should be primed and the water source available  
before running to avoid damage to the pump. To avoid flooding,  
ensure the sprinkler system is completely installed and ready to be  
pressurized.  
9. Bump the motor by pressing the START button and then press the STOP button, to check  
for proper rotation. If not correct, open the CIRCUIT BREAKER and change any two leads  
on the load side of the M1 contactor.  
10. Press the START push button. Verify that the motor starts properly and runs at full speed.  
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Limited Service Fire Pump Controller  
11. Press the STOP push button to stop the motor.  
12. Start and stop the motor with the EMERGENCY MANUAL CONTROL handle. Push and  
rotate the T-handle in a quick motion to lock the contactor in the ON position to start.  
Rotate the T-handle clockwise and release to stop the motor.  
Caution: Failure to engage the handle in a fast and continuous motion can  
result in damage to the contactor and failure to start the motor.  
If equipped with an LX-250 or LX-350 Automatic Transfer Switch, complete the following  
additional tests:  
1. Verify connection of the engine generator set start wires to TB-1 and TB-2 at the top of the  
LX-250 Transfer Switch power panel or to TB8-1 and TB8–2 on the left side of the LX-350  
Transfer Switch power panel.  
2. Close the FIRE PUMP (emergency) ISOLATING SWITCH and open the CIRCUIT  
BREAKER. The Automatic Transfer Switch should transfer to the alternate source per  
system requirements. Bump the motor to check for proper rotation. If incorrect, move the  
FIRE PUMP ISOLATING SWITCH to the OFF position and switch the generator set off using  
the switch located on the generator. Switch any two leads on the line side of the FIRE PUMP  
ISOLATING SWITCH. Return the generator set control switch to the Auto position and close  
the FIRE PUMP ISOLATING SWITCH. The generator set may start.  
3. Operate the pump on the alternate (emergency) source using the START and STOP push  
buttons.  
4. Close the CIRCUIT BREAKER. The Control Module should now be sensing normal power  
and timing for retransfer. Press the BYPASS RETRANSFER TO NORMAL push button to  
return the Transfer Switch to the normal position.  
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Limited Service Fire Pump Controller  
VII Maintenance  
Danger: Do not open the Controller cabinet until ALL power is disconnected.  
Shocks, burns, or death may result from high voltage.  
Caution: Only personnel who are familiar with the power distribution system  
and this manual should be allowed to inspect or perform maintenance  
on the Controller.  
Preventive Maintenance  
A. Protect the equipment against accumulation of dust and metal chips.  
B. Protect the equipment against conditions that result in excessive moisture.  
C. Exercise the equipment every week as part of routine maintenance to verify the integrity of  
the Controller, Transfer Switch, generator set, power conductors, pump, and motor.  
D. Field lubrication is not necessary or required for the Controller.  
Troubleshooting  
Hazardous voltage  
will shock, burn,  
or cause death.  
!
DANGER  
Do not touch  
until ALL power  
is disconnected.  
Warning: Disconnect ALL power supply sources to the Controller before  
servicing to prevent shock or accident hazard.  
Before attempting any troubleshooting on the Controller, verify that the cause of a problem is not  
due to the motor, pump, or power source. Then visually inspect the Controller for component  
damage and lose wiring. If the problem cannot readily be resolved, review the Sequence of  
Operation section for proper operation. Then refer to the supplied wiring diagram and schematic  
and use a volt/ohm meter to check the wiring to determine which component is faulty.  
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Limited Service Fire Pump Controller  
Coil and Contact Replacement  
Spring  
Clip  
Coil  
Retainers  
Coil  
Magnet  
Assembly  
Figure VI-1 Magnet Assembly and Retainers  
Coil Replacement*  
1. Isolate all power sources.  
Contact Replacement*  
Complete steps 1 through 5 in left column.  
2. While pressing against the coil, pull up slightly Remove the magnet assembly from the molded  
on the coil retainers and swing away from coils. cover and movable arm.  
3. Pull the magnet assembly, coil, molded cover,  
and movable arm from the contactor.  
Remove the return spring from the center of  
movable arm.  
4. Remove the spring clip and remove the  
armature from movable arm.  
Remove the molded cover from movable arm.  
5. Remove the coil from the magnet.  
Press and slide the movable contact and spring  
from movable arm.  
6. Replace the coil and reassemble.  
7.  
Remove the screws holding stationary contacts  
in place and remove stationary contacts.  
Replace contacts and reassemble.  
Notes for re-assembly*:  
a. The molded cover only fits one way.  
b. The magnet and movable arm fit either way but operates more quietly if reassembled the  
same way before removal.  
c. Do not attempt to remove or replace arc traps in cover.  
*Source: General Electric, GEH-5168  
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Limited Service Fire Pump Controller  
VIII Limited Service Fire Pump Controller Parts  
Spares  
Symbol  
Description  
Function  
Part No.  
1
1
High Voltage Relay  
2-Pole Relay  
Starting Relay  
Control Relay  
31658141  
31658123  
CR, LRSR  
LK, PFR,  
PRR  
2
1
Fuse, 1 A, MDL-1  
Timing Relay, octal  
Control Power  
Min. Run Time  
57361726  
31658111  
FU1, FU2  
TR1  
Octal socket  
2-Pole Relay socket  
High Voltage Relay socket  
TR1  
LK, PRR, PFR  
CR, LRSR  
48518012  
48518018  
48518022  
1
1
1
Phase Monitor, 208–240 V  
Phase Monitor, 440–480 V  
57418398  
57418399  
Phase Loss/Reversal  
Control Power, 120 V  
PLM  
Transformer,  
208/230/380/460 V  
57511355  
XFMR  
Pressure Switch, 10-300 PSI  
Pressure Recorder, 300 PSI  
Operating handle  
1 NC contact  
Battery driven  
Circuit Breaker  
57501023  
57501013  
57504087  
PS  
EPR  
Emergency Manual T-handle  
Emergency Operator Push Rod Emergency Operator  
Emergency Push Rod Pin  
91158006  
91158005  
57401033  
Push button NO, green  
Push button NC, red  
Start push button  
Stop push button  
80320105  
80320104  
PB1  
PB2  
2
Bulb  
Indicating lights  
Indicating lights  
80324905  
PL4, 5, 6, 7  
PL4, 5, 6, 7  
Lamp Socket  
402066520  
Red lens  
Clear lens  
Phase Reversal  
Power Available  
402067520  
402157520  
PL5, 6, 7  
PL4  
Surge Suppressor  
Surge suppression  
402165820  
SS  
Page 11 of 12  
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Limited Service Fire Pump Controller  
Spares  
Symbol  
Description  
Function  
Part No.  
Breaker, 15 A  
Breaker, 20 A  
Breaker, 25 A  
Breaker, 30 A  
Breaker, 40 A  
Breaker, 50 A  
Breaker, 60 A  
Breaker, 70 A  
Breaker, 90 A  
Breaker, 110 A  
Breaker, 125 A  
Breaker, 150 A  
57504463  
57504373  
57504371  
57504103  
57504378  
57504389  
57504346  
57504347  
57504348  
57504541  
57504101  
57504344  
Circuit Breaker  
Discounting Means  
CB  
(Note 3)  
Contactor, 200/208  
Contactor, 220/240  
Contactor, 440/480  
57300333  
57300330  
57300331  
Main Contactor  
M1  
Contactor Coil, 200/208  
Contactor Coil, 220/240  
Contactor Coil, 440/480  
57300570  
57300571  
57300573  
Pump Run Contact  
1 NO and 1 NC  
Contact  
Auxiliary Contact, M1  
57300391  
M1a1, M1b1  
Notes  
1. Specify Controller serial number, model number, horsepower, and voltage when ordering  
parts.  
2. Refer to Bulletin 1000 for information on one-year parts and labor warranty.  
3. Consult factory for Spectra Circuit Breakers with high interrupt ratings.  
Page 12 of 12  
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