AquaGuard BS9251:2021 Fire Pump Controller

User & Installation Manual

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 Table of Contents

1. Product Description Page 3

2. User Interface Page 4

3. Installation Guide Page 5

4. Controller Set Up and User Guide Page 6 - 8

5. Commissioning Page 9

6. Annual Maintenance Page 10

7. Fault Alarm Table Page 11 - 12

8. Troubleshooting Page 13 - 14

If additional assistance or information is required, please contact

AquaGuard Pumps Technical on 0800 040 7738.

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 1. Product Description

The AquaGuard fire pump controller has been designed as an easy to install, all in one
solution to control the operation, monitoring and automatic testing of the fire pump in
accordance with BS9251:2021.
Incorporating an informative LCD display, easy to use interface and a 128 event log
making the AquaGuard fire pump controller the most advanced on the market.

Features

Jockey Mode - Upon pressure loss the pump will operate, if no flow is detected then
pump will shut off after 1 minute. Jockey limit fault will indicate if Jockey starts have
exceeded weekly limit.

Fire Mode - If pressure loss and flow are detected by either of the two pressure switches
and the flow switch then pump will operate in fire mode until manually shut down.

Test Mode – Each Monday at 10am the controller will open the solenoid valve until both
the pressure switches are activated and run the pump checking voltage/current and
power are within set parameters.

Maintenance - Maintenance interval is pre-set to every 12 Months but can be adjusted

to suit specific interval requirements. Maintenance due indicator will require a physical
flow test to reset.

Event Log - Event log up to 128 entries can be accessed on the control panel.

Setup Mode - All settings can be changed if required with the use of an advanced user
password to prevent unauthorised access to settings.

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 2. User Interface

2.1 – AquaGuard fire pump controller button and LED description.

2.2 – AquaGuard fire pump controller LCD Display ‘Home Screen’ description.

Controller
Home Screen

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 3. Installation Guide

General
3.1 - This product must be installed by a suitably qualified electrician.
3.2 - This controller must be earthed.
3.3 – This controller should be wired to a suitable isolator, fed directly from the electrical
distribution board protected by a dedicated RCD/RCBO suitably sized for the fire pump
installed.

Installation
3.4 – If purchasing in kit form the AquaGuard Fire Pump Controller must be connected as
per diagram below. Take care with solenoid connection as 230v will be present to
solenoid when requested.
Fig.1

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 4. Controller Set Up and User Guide

4.1 – Once controller has been wired as per diagram (Fig.1) the controller power supply
can be switched on, please note that on initial power up the pump will run to reach
system pressure, please ensure that all suction valves are open and pump has been fully
primed and free of any air before switching on for the first time.

It is recommended to proceed to fill the entire sprinkler system shortly after powering
on for the first time and leave the pump delivery valve open to create volume in the
pump manifold, this is to ensure the pump will not repeatedly enter ‘Jockey mode’
caused by the stopping of the pump triggering the pressure switch due to the small
volume in the pump manifold.

Warning: Tank must be full, pump must be fully primed from all bleed nipples and all
suction valves must be open prior to powering the controller up for the first time.

4.2 – Shortly after switching the controller on for the first time, once system pressure
(Pmax) has been made the controller will start a 1 minute countdown indicating ‘Jockey
Mode’ press the ‘Stop’ button and the home screen and green power led should be
visible as image below. If the ‘Spr Activation’ is displayed press the ‘Reset’ button to
reset.

4.3 – Setting Time and Date

From the home screen display, press the up key until the time and date are visible on
display, then press the left and right keys at the same time to edit. Use the up, down,
left, right keys to set time and date then press ok (tick) button to set. Press the down key
until the home screen is displayed. Note: date is in the format of MM/DD/YYYY. Page | 6
4.4 – Accessing the menu

1. To access the menu containing pump set information, reset the annual
maintenance and view event log the Aquaguard controller has a user-friendly
menu interface, to access press the Button, icon descriptions are indicated
below.

2. Most functions can be accessed without the use of a password but to gain access
to the command’s menu or setup menu then a password will need to be entered.
To access the Commands menu, navigate to ‘Enter Password’ (key icon), enter the
user password ‘2000’, press right to the key symbol then press ok (tick).

Note: Access to the setup menu is possible by entering an advanced password but
the installer will be required to speak to Aquaguard technical to obtain and discuss
required changes, as any changes in this menu without technical guidance could
affect operation and invalidate warranty.

3. Within a short period of entering the password, re-enter main menu, navigate to
‘Commands Menu’. To enter commands you must first hold the ‘Manual Mode’
button located on the underside of the controller (below) and press ok on the
keypad, once into the commands menu the manual mode button (shown below)
can be released.

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4.5 – Jockey Limit Reset

If the pump has entered jockey mode five times or more within a week then the ‘Jockey
Limit’ fault will be displayed, this may also be displayed shortly after start-up/initial filling
of the system. To reset the ‘Jockey Limit’ initiate a weekly test procedure by following
the steps in 5.3.

4.6 – Pump Running Indicator

A ‘Pump Running’ fault will be displayed If the fire sprinkler pump was to run for more
than one minute, this is to meet the requirements of BS9251:2021 to ensure in the event
of a fault whereby the pump was running when not called upon then a fault signal is
transmitted. Note: This fault will be present when operating the pump set in ‘Fire Mode’
for more than one minute, this will reset automatically when stopped.

4.7 – Internal Audible Alarm (Optional)

The optional internal audible alarm powered by a 9v battery will make an audible bleep
when any fault condition arises including power failure to the pump controller. This
audible alarm should be requested where the standard fault output contacts cannot be
monitored. Note: Selecting internal audible alarm option will as standard remove the
fault output contacts.

Supplied 9v battery to be inserted into the battery carrier on the underside of the
controller.

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 5. Commissioning

5.1 – Filling the system

If the sprinkler system was not filled upon initial power up in step 4.1, please proceed to
filling the system, this may activate the alarm output therefore it may be required to
temporarily isolate the alarm. Once system pressure (Pmax) has been made the
controller will start a 1 minute countdown indicating ‘Jockey Mode’ press the ‘Stop’
button and the home screen and green power led should be visible. If the ‘Fire Mode’ is
displayed press the ‘Reset’ button to reset.

5.2 – Setting of Pressure Switches (if required)

The pressure switches are pre-set from the factory to suit the associated pump but it
may be required by the installer to adjust the pressure switches from factory set
pressure, it is recommended that the system pressure switches be set at least 1 bar
below system ‘Pmax’ and no less than the pressure required from the ‘most
unfavourable hydraulic calculations’, it is recommended that the pressure switches are
set within 0.3 bar of each other. Refer to pressure switch instruction manual for setting
instructions, this should be undertaken with the Aquaguard pump controller switched
off.

5.2 – Flow Test

From the pump test valve, a flow test should be undertaken to check pump satisfies the
flow and pressure requirements set out in the system Hydraulic Calculations, after 20
seconds of the system flowing the ‘Fire Mode’ will appear triggering the alarm output.
Once flow test has been completed and system repressurised press the ‘Stop’ button
then ‘Reset’ button to return to home screen.

5.3 – Weekly Test

To manually initiate the weekly test to ensure correct operation, press and hold the
black button on the bottom of the controller for at least 10 seconds, this will initiate the
weekly test to start, opening the solenoid valve until both pressure switches are
activated and run the pump for 60 seconds checking voltage/current and power are
within set parameters.
If either of the pressure switches are not detected, then a fault will be displayed
indicating either ‘PS1 not detected’ or ‘PS2 not detected’. If the flow switch is not
detected then ‘FS not detected’ fault will be displayed. Page | 9
 6. Annual Maintenance

6.1 – Annual Maintenance Reset

12 Months from system commissioning the ‘Maintenance 1 Requested’ fault will be
displayed; this will not trigger the fault output unless requested. This maintenance fault
can only be reset by undertaking an annual flow test and no faults other than
‘Maintenance 1 Requested’ should be present, the reset procedure cannot be completed
until faults are rectified.

To reset annual maintenance, undertake the following procedure.

1. Undertake a flow test as per section 5.2, please note if flow detected for more
than 15 seconds the alarm output will be triggered. Once finished press the ‘Stop’
button followed by the ‘Reset’ button.

2. Following the same password and button entry procedure in section 4.4, enter
main menu, navigate to the ‘Enter password’ section, enter code ‘2000’ then press
ok on the key symbol.

3. Enter main menu, navigate to the ‘Commands’ menu, while holding the ‘Manual
mode’ button press ok.

4. Once in ‘Commands’ menu, navigate down to ‘C01 Reset Maintenance Interval 1’

press ok to execute it, the device will prompt for a confirmation, press ok again,
this will reset the maintenance to a further 12 months. Press the ‘Stop’ button
several times to exit to home screen. If the flow test has not been carried out
properly then the reset will prompt for the test to be undertaken again, if this is
the case repeat flow test.

6.2 – Event Log

The Aquaguard controller has a 128 entry event log incorporated, this indicates in detail
with a date and time every event that has occurred. To view, from the controller home
screen press the up key until the ‘Event Log’ screen is displayed, then use the left and
right keys to navigate through the log.
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 8. Fault Alarm Table
If any faults are present on the controller then these will be displayed on the LCD display
with a code A01 – A38 or UA1 - 8, see alarm table below for description.
COD DESCRIPTION ALARM EXPLANATION
A01 Low mains voltage Mains voltage lower than the threshold set in P05.01.
A02 High mains voltage Mains voltage higher than the threshold set in P05.02.
A03 Low mains frequency Mains frequency lower than the threshold set in P05.03.
A04 High mains frequency Mains frequency higher than the threshold set in P05.04.
A05 Voltage asymmetry mains Mains voltage asymmetry higher than the threshold set in
P05.05.
A06 Phase failure Missing of one of the phases.
A07 Incorrect phase sequence The phase sequence is not correct.
A08 Pump starting failure Either the electrical parameters did not enter the limits
and/or delays defined in menu M05 or the programmable
input with function Pump pressure switch did not activate.

A09 Locked rotor Motor current higher than 500% of rated In for a time longer
than 5s.
A10 Dry running Pump dry running. The measured power factor is lower than
the threshold set in P05.13.
A11 Current too low Motor current lower than the threshold set in P05.06

A12 Current too high Motor current higher than the threshold set in P05.07

A13 Unbalanced current The current asymmetry has exceeded the threshold set in
P05.14.
A14 Unexpected current The system detects a current higher than 5% of rated
current In even if there is no command to run the motor.
A15 Wrong CT connection One or more current transformers (CT) are not connected in
the correct way (system measures negative active power).
Check the connections at terminals 57, 58, 59, 60.
A16 System error Internal error. Please contact Lovato Electric Technical
Support (tel. 035 4282422; e-mail:
[email protected]).
A17 Low temperature in pump room The room temperature is lower than the threshold set in
P04.02 for a time longer than P04.03.
A18 High temperature in pump room The room temperature is higher than the threshold set in
P04.04 for a time longer than P04.05.
A19 Water reserve Alarm generated by the input programmed with the
Water supply function
A20 Low water tank level Water level in the tank lower than the threshold set in
P02.18.
A21 Water tank empty Water level in the tank lower than the threshold set in
P02.19.
A22 Low level priming tank The programmable input with function Priming tank level is
active
A23 System is not in automatic mode System not in automatic mode for more than 24 hours

A24 Fire pump running Alarm generated by the input programmed with the
‘Pressure switch start’ function.
A25 Fire pump not in pressure Alarm generated by the programmed input with the function
Pump pressure switch not active after 1min with motor
running.
A26 Pump in pressure Alarm generated by the programmed input with the function
Pump pressure switch active for 1 minute without motor
running. Page | 11
A27 Maintenance 1 requested Alarm generated when the maintenance intervals of its
8. Fault Alarm Table Continued
A28 Maintenance 2 requested range reach zero. See menu M08. Use the command menu
A29 Maintenance 3 requested to reset the hours and reset the alarm.

A30 Suction valve partially opened Alarm generated by the programmed input with the function
‘Suction valve partially open’, in this situation the suction
valve is not capable of delivering the maximum flow rate of
water needed to the pump.

A31 Discharge valve partially opened Alarm generated by the programmed input with the function
‘Delivery valve partially open’, in this situation the delivery
valve is not capable of delivering the maximum flow rate of
water needed to the sprinkler system.
A32 Sprinkler in pump room activated Alarm generated by the programmed input with the function
‘Sprinkler activated’
A33 Max number of start-up jockey Alarm generated when the threshold set to parameter
pump P02.20 is exceeded and if there is a programmed input with
the function ‘Jockey pump activated’.
A34 Jockey pump alarm failure Alarm generated by the programmed input with the function
‘Jockey pump failure’.
A35 Timeout jockey pump Alarm generated when the threshold set to parameter
P02.21 is exceeded and if there is a programmed input with
the function ‘Jockey pump activated’.
A36 Drainage pump alarm failure Alarm generated by the programmed input with the function
‘Drainage pump failure’.
A37 Communication error RS-485 communication among different FFL… is not
working properly. Check wiring and communication settings
in M11 menu.

A38 Pressure input test failed During automatic test (in ON-OUT mode) the pressure
switch remains closed for more than 1 minute.
UA1 User alarms The user alarm is generated by enabling the variable or
… associated input in menu M18.
UA8

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 9. Troubleshooting
Issue Possible Cause Action
Controller not powering on Power supply to controller not on Check all connections, fuses and
or wired incorrectly. MCB/RCBO.
Controller powers on, then goes Pump wired incorrectly Check pump motor wiring
off when pump start requested.
Fuse or MCB/RCBO not sized Replace fuse, MCB/RCBO for an
correctly for pump. adequately sized C rated type.
Pump running not pressurising Suction/delivery valves closed Check all suction and delivery
system valves are open.

Pump not adequately primed of all Open all pump bleed screws until
air. water flows freely. Flow large
amounts of water from test valve.
Pump not generating design Pump not adequately primed of all Open all pump bleed screws until
flow/pressure air. water flows freely. Flow large
amounts of water from test valve.
Obstruction in suction or delivery Check pipe work and clear if
pipe work. necessary.

Suction pipe diameter too small or Pump suction must never be

pipe run too long smaller than pump inlet diameter.
If long suction pipe run then
increased pipe size should be used.
Pump not running when pressure Pressure switches not wired Wire pressure switches between
low or at zero correctly or pressure switch setting COM and 1 (normally closed).
too low.
Set correct pressure on pressure
Pressure switch cable wired to flow switch adjustment screws.
switch
Pump running and not shutting off Pressure switches not wired Wire pressure switches between
correctly or pressure switch setting COM and 1 (normally closed).
too high. Set correct pressure on pressure
switch adjustment screws.

External Fire Panel in fault when Incorrect wiring of fault output Fault output must be wired
pump controller displays no fault normally closed (NC)
on the LCD Display.
Pump controller switched off Turn pump controller on
Faults - A11 Current too low, A12 Correct pump current and power Change saved current and power
Current too high, Power too high, settings not input correctly settings in Setup Menu.
Power too low.
Possible pump fault Check current/power reading if
vastly different to pump data plate
call pump manufacturer.
230v Solenoid valve fails to Incorrect wiring to solenoid Check wiring – may have blown
operate on weekly test followed by 1.6A fast blow fuse in controller,
voltage fault on controller replace if necessary.

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 9. Troubleshooting Continued.
Issue Possible Cause Action
Pump running fault indicated. Pump running for more than 62 Normal under fire pump condition
seconds. if pump running for more than 1
minute.

Faulty component – Investigate.

‘A01 Low mains voltage’ Fault Fuse blown inside controller Check 1.6A fast blow fuse inside
controller, replace if necessary.
‘UA6 Jockey Limit’ Fault Too many pump starts within 7 Force weekly test by pressing and
days holding the black button for 10+
seconds. Procedure in section 5.3
‘UA8 PS2 not detected’ Fault PS2 not seen within 3 seconds of Raise pressure of PS2 closer to PS1
PS1 on weekly test (Switch labelled high – Screw
adjustment clockwise)
‘UA7 PS1 not detected’ Fault PS2 is seen before PS1 on weekly Either raise pressure of PS1 (Low)
test or Lower pressure of PS2 (High)

‘A38 Pressure test input failed’ Weekly test timed out, pressure Test return pipe work too small,
switches not seen within the test recommend a minimum of 3/4”.
period – System pressure dropping Too much air in system – Bleed air
too slowly on test. if no luck call Aquaguard technical.
‘FS not detected’ Flow switch not detected on Check flow switch operates
weekly test correctly

‘UA2 Fire Pump on’ Flow switch triggered for more Check flow switch is operating
‘UA3 Sprinkler Activated’ when than 20 seconds – Possibly stuck correctly and not stuck open or
pump not running or after weekly open. contacts faulty.
test, triggering the alarm.

‘UA1 Tank Level Low’ Fault Tank Level low or wired incorrectly Check tank water level or tank
switch wiring contact requires
normally closed switch – open on
low level
‘A07 Incorrect Phase Sequence’ Phases wired incorrectly to isolator Check wiring in pump isolator from
Fault – Three phase pumps only. controller, swap phases if required.

Any Fault present on controller not Refer to fault alarm table in section Undertake action if possible.
listed above 8 to identify fault and possible
action required. Call Aquaguard if problem persists.

If you have followed the above steps and controller is suspected to be faulty call Aquaguard on 0800 040 7738 for
advice.

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