Clarke C18H Instruction Manual
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Clarke C18H Instruction Manual

Clarke C18H Instruction Manual

Electronic variable speed engines for fire pump applications
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Operation and Maintenance
Instructions Manual
C18H MODELS
ELECTRONIC VARIABLE SPEED ENGINES
FOR
FIRE PUMP APPLICATIONS
This manual covers Caterpillar Engines
Prepared by Clarke
for fire pump service
Clarke Fire Protection Products, Inc.
Clarke Fire Protection Products, Ltd.
100 Progress Place
Unit 1, Grange Works
Cincinnati, OH 45246
Lomond Road
U.S.A.
Coatbridge
ML5 2NN
United Kingdom
TELE: +1.513.475.3473
TELE: +44(0)1236 429946
FAX: +1.513.771.0726
FAX: +44(0)1236 427274
www.clarkefire.com
C137882
11/20
RevD

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  • Page 1 ELECTRONIC VARIABLE SPEED ENGINES FIRE PUMP APPLICATIONS This manual covers Caterpillar Engines Prepared by Clarke for fire pump service Clarke Fire Protection Products, Inc. Clarke Fire Protection Products, Ltd. 100 Progress Place Unit 1, Grange Works Cincinnati, OH 45246 Lomond Road U.S.A.

  • Page 2: Table Of Contents

    CONTENTS SUBJECT PAGE 1.0 INTRODUCTION 1.1 IDENTIFICATION/NAMEPLATE 1.2 SAFETY/CAUTION/WARNINGS 1.3 PRECAUTIONS FOR WELDING 2.0 INSTALLATION/OPERATION 2.1 TYPICAL INSTALLATION 2.2 ENGINE STORAGE 2.2.1 Storage Less than 1 year 2.2.2 Extended Storage Maintenance Procedure 2.2.3 Coolant System 2.2.4 Removal from Storage 2.3 INSTALLATION INSTRUCTIONS 2.4 SPECIFIC FLYWHEEL COUPLING ALIGNMENT INSTRUCTIONS 2.4.1 Driveshaft 2.5 WEEKLY TEST...
  • Page 3 3.2.5 Exhaust System 3.3 LUBRICATION SYSTEM 3.3.1 Checking Sump Oil 3.3.2 Changing Engine Oil 3.3.3 Changing Oil Filter Cartridge 3.3.4 Oil Specification 3.3.5 Oil Capacities 3.4 COOLING SYSTEM 3.4.1 Intended Engine Operating Temperature 3.4.2 Engine Coolant 3.4.3 Water 3.4.4 Coolant Capacities 3.4.5 Coolant Inhibitors 3.4.6 Procedure for Filling Engine 3.4.7 Providing Adequate Raw Water Supply to the Engine Heat Exchanger...

  • Page 4: Identification/Nameplate

    It does not relieve the user of their responsibility of using accepted practices in the installation, operation, and maintenance of the equipment. NOTE: CLARKE FPPG Reserves the right to update the contents of this publication without notice.
  • Page 5 Figure #1 Minor RPM adjustments to meet pump requirements are permissible. Clarke model number reflects the base engine type, engine displacement, cooling system, environmental  The engine shall be installed and maintained suitability, approval listing, engine speed, and a in accordance with the guidelines stated in power rating code.

  • Page 6: Safety/Caution/Warnings

    Approach with caution. It is the responsibility of the builder of the machine, using a Clarke engine, to optimize the application in terms of maximum end user safety.
  • Page 7 4100 (1860) [1][2] C18H0-FMAD12-DS 4100 (1860) [1][2] C18H0-FMAD22-S 4100 (1860) C18H0-FMAD22-DS [1][2] 4100 (1860) [1][2] C18H0-FMAD32-S 4100 (1860) [1][2] C18H0-FMAD32-DS 4100 (1860) C18H0-FMAD42-S [1][2] 4100 (1860) [1][2] C18H0-FMAD42-DS 4100 (1860) Figure #4 (1) Clarke PLD Models (2) FM Approved Models...
  • Page 8 Figure #5...
  • Page 9 WHAT TO DO IN AN EMERGENCY CAUSTIC BURNS Any user of the Engine who follows the instructions set 1) Caustic burns to the skin are caused by acid out in this manual, and complies with the instructions escaping from the batteries: on the labels affixed to the engine are working in safe ...

  • Page 10: Precautions For Welding

    Important Note: Labels that show an exclamation Jacket Water Heater Voltage mark indicate that there is a possibility of danger. Heat Exchanger Maximum Working Pressure Coolant Mixture Air Filter Installation Lifting Point 1.3 PRECAUTIONS FOR WELDING IMPORTANT: ALWAYS disconnect electronic Control Module (ECM) connectors before welding.

  • Page 11: Installation/Operation

    2.2.2 Long-Term Storage the inlet by removing the plug for checking turbocharger boost pressure. The minimum Note: It is recommended that a Clarke Service Dealer application rate for the VCI oil mixture is 5.5 perform the steps outlined in this section.

  • Page 12: Coolant System

    VCI oil and 50 percent engine oil onto the Completely fill the cooling system before storage. (It following components: flywheel, ring gear is common for Clarke to ship the engine pre-filled with teeth and starter pinion. Install the covers in coolant.) order to prevent evaporation of the vapors from the VCI oil.

  • Page 13: Installation Instructions

    Operation Data Sheets. If there is any doubt about an cover or covers. Put a large amount of engine installation, contact should be made with Clarke oil on the camshaft, cam followers, and valve Customer Support giving exact details of the problem.

  • Page 14: Specific Flywheel Coupling Alignment Instructions

    Angular tolerance, the drive shaft must be installed 8) Connect jacket water heater (if supplied) to between the flywheel and the flanged hub on the pump AC power source. For C18H Series, the shaft. electrical supply requirements are indicated on Before beginning the alignment checks and making the connection box.
  • Page 15 Note 2 – 4 of the hi-tensile bolts and/or nuts, that are DRIVE BOLT MODELS SHAFT SIZE TORQUE used to connect the driveshaft to the drive disc and that /GRADE ft-lbs connect the driveshaft to the pump companion flange, (N-m) will require a “crow’s foot”...
  • Page 16 Measurement Driveshaft Measurement Driveshaft 123.5 + 1.5mm SC2160A 126.5 + 1mm. SC2160A 145.5 + 1.5mm. SC2390A 142.5 + 1.5mm SC2390A Figure #7a B) With the driveshaft in the same orientation as the Figure #7c previous step (Step A), check the Horizontal Angular alignment of the shafts.

  • Page 17: Weekly Test

    NOTE: This engine is designed to operate at rated load Note: On C18H Engines you can also start engines conditions. For testing purposes the engine can be run using manual starting contactors. at lower load (lower flow) conditions. Running times...

  • Page 18: To Stop Engine

    4) Toggle down the list of menu options and 2.6.2 To Stop Engine highlight “Soft Start”, then press the “Enter” key. If engine is started from main pump controller use 5) The next screen will display one choice, main pump controller to stop the engine. “Request Soft Start”.

  • Page 19: Describing Engine Gauge Panel

    2.6.3 Describing Engine Gauge Panel 2.6.3.1 ECM Selector Switch and Primary/Alternate Clarke UL/FM Engines come equipped with dual BASE & ECMs and an ECM Selector Switch on engine gauge green status panel. (Item #6). Default position of ECM selector switch is to the Primary ECM.

  • Page 20: Programming Ecm With Automatic Switching Device

    SPN 2145 FMI 9 will be displayed on the diagnostic gauge. 2.6.3.3 Programming ECM with Automatic Switching Device This procedure will be performed by Clarke Certified Service Dealer or a Cat Dealer. In the event of a failed or damaged ECM, programming will be required on the replacement unit.
  • Page 21 The PowerView gauge includes a liquid crystal display (LCD) screen. The display is programmed to show six NFPA required engine parameters simultaneously. The diagnostic gauge uses two arrow keys (A) and (B) for scrolling through the engine parameter list and viewing the menu list. An enter key (E) is used for selecting highlighted items.
  • Page 22 3. Pressing the “Arrow” (A&B) keys will scroll through the menu selections. 3. Each of these parameters can be adjusted by highlighting the item with use of the “Arrow” User Settings Adjustment (A&B) keys and then pressing the “Enter” (E) key to bring up the adjustment screen.
  • Page 23 Parameters” screen, press the “Arrow Right” will appear. This screen will not be populated (E) key once or the “Menu” (C) key twice. with data unless the engine is a Clarke PLD 2. To program the parameters displayed on the (Pressure Limiting Driver).
  • Page 24 4. The “Main Menu” will be displayed. Press the 6. Continuing to press the “Arrow Down” (B) “Down Arrow” (B) key to highlight “User key will bring up another screen with four Gauges”. Then press the “Enter” (E) key to more parameters that can be added to the bring up the “User Gauges”...
  • Page 25 “Arrow Right” (E) key once or the “Menu” (C) key twice. Engine Settings Data NOTE: The engine settings data is a read only function. All engine settings parameters are pre-set by Clarke. This menu is primarily used for trouble shooting activities.
  • Page 26 4. Pressing the “Enter” key will access the 6. Press the “Menu” (C) key to return to the main following screen. It displays two numbers. menu. The upper number is the engine speed (RPM) required to trip the overspeed alarm during a Accessing Stored Trouble Codes verification of that alarm circuit.
  • Page 27 5. The top line of the “Stored Faults” screen informs the user of the number of stored fault 3. Press the “Enter” (E) key once “Faults” is codes. If there are two stored faults, beside the highlighted and the “Faults” menu will appear. text “Diagnostic Message”, the text will read 1 of 2.
  • Page 28 Accessing Active Trouble Codes 3. If the arrows appear above keys A&B, there are more trouble codes that can be viewed by For description of trouble codes, see chart in using the arrow keys to scroll to the next Troubleshooting Section. trouble code.
  • Page 29 Reset”. Once reset, the engine will be ready to Engine Shutdown Codes restart. Note: For Clarke Engine models, the only shutdown 4. The engine will NOT restart and run until the will be due to an overspeed condition. overspeed reset procedure is performed. See Section 3.5.3 for more details about the...

  • Page 30: Engine Systems

    3.1.1 Diesel Fuel Specification be stored for a minimum of one year without degradation beyond that allowed in 8.3.4.1.1 All diesel fire pump drivers manufactured by Clarke are designed, tested and warranted for use only with 8.3.4.3 When provided,...

  • Page 31: Bleeding The Fuel System

    Fuel maintenance and testing should 3.1.2.1 Priming C18H Engine Series when secondary begin the day of installation and first fill. filter has been changed: 1) Open the air purge screw (2) three full turns.

  • Page 32: Changing Fuel Filters

    Install the new element on the filter base. Tighten the element by hand. 3.1.2.2 Priming C18H Engine Series when the engine 9) Ensure the drain (3) is in the closed position. has been run out of fuel:...

  • Page 33: Fuel Tanks

    3.2 AIR/EXHAUST SYSTEM 3.2.1 Ambient Conditions Clarke engines are tested in accordance with SAE J1349 (Clarke USA) or ISO 3046 (Clarke UK). In this capacity, they may be de-rated to meet certain site conditions, failure to do so can seriously impede the performance of the engine and could lead to premature failure.

  • Page 34: Crankcase Ventilation

    A slight pressure is maintained within the engine crankcase compartment. Vapors are expelled through a vent pipe attached to the rocker cover. Ref. Figure #15. Contact Clarke for an optional breather kit if vapors accumulate in your pump room.

  • Page 35: Exhaust System

    The installation of the exhaust system should consist of the following:  Personnel protection from hot surfaces.  Adequate supports to prevent strain on the engine exhaust outlet and minimize vibration.  Protection against entry of water and other foreign matter. While the engine is running inspect exhaust pipe outlet outside of the pump room itself for environmental hazards such as excessive smoke conditions.

  • Page 36: Changing Engine Oil

    3.3.4 Oil Specification Diesel Engine Oil This engine is filled at Clarke with SAE 15W-40 oil meeting CAT ECF-3 specification. Important: Do not add makeup oil until the oil level is BELOW the add mark on dipstick. Add Cat DEO 15W-40 or equivalent when makeup oil is required.

  • Page 37: Engine Coolant

    MODEL CAPACITY combination of these. Chlorides and/or sulfates tend to QUARTS (LITERS) accelerate corrosion, while hardness (percentage of C18H-All Models 40 (37.9) magnesium and calcium salts broadly classified as carbonates) causes deposits of scale. Water within the 3.4.5 Coolant Inhibitors limits specified in figure #17 is satisfactory as an engine coolant when properly inhibited.

  • Page 38: Procedure For Filling Engine

    3.4.7.1 Raw Water Supply pressurized system needs space for heat expansion without overflowing. Most Clarke diesel engine fire pump drivers are heat exchanger cooled and some engines also have a charge Install the pressure cap, start and run engine for...
  • Page 39 NOTE: VT type pump applications do not require a In each flow line, there is also a pressure regulator. solenoid valve in the Automatic flow line. Each pressure regulator protects the downstream piping from over-pressurization which includes the The second flow line is called the Manual by-pass line tube side of the engine shell &...

  • Page 40: Setting Raw Water Flow Rate

    3) Verify that when the correct flow rate is the cooling loop. Each Clarke engine model has an achieved that the inlet pressure to the heat Installation and Operation (I&O) Datasheet that...

  • Page 41: Backflow Preventers

    pressure between the two sensors and will send an loop as required by local code. For specific alarm to the controller if a low water flow condition application information contact factory. exists. 3.4.7.7 Raw Water Outlet Temperature Additionally, a raw water temperature switch will send an alarm (terminal 310) when temperature of the Certain local codes may not allow you to discharge water exceeds 105°F (41°...
  • Page 42 Figure 21A – Heat Exchanger cooled Figure 21B- radiator cooled engines...

  • Page 43: Important Service Notice

    Instrument Panel Hold the OVERSPEED VERIFICATION switch in C072736 ECM Harness the “up” position. This will provide the main pump C18H-all models C073017 controller with an overspeed signal and engine Engine Harness shutdown at 30 RPM’s below the rated RPM.

  • Page 44: Field Simulation Of Pump Controller Alarms

    It may take up to 180 3.5.5 Battery Requirements seconds to activate the alarm. (Note: There is no engine mounted High All Clarke engine models require 8D batteries, as Coolant Temperature switch to jumper sized per SAE J537 and NFPA20. The battery across).

  • Page 45: Maintenance Schedule

    To adjust the speed of the engine: Cooling Water Solenoid Valve  A. Start the engine by following the “To Start Exhaust System  Engine” Procedure in this manual. Fuel Tank  B. Let the engine warm-up. General Inspection  C.

  • Page 46: Trouble Shooting

    Advise the appropriate personnel the with FMI 03 yields engine coolant temperature engine has been returned to “Automatic”. input voltage too high. Always contact your Clarke service dealer for 5.0 TROUBLE SHOOTING help in correcting diagnostic trouble codes which are displayed for your engine.

  • Page 47: Parts Information

    Sensor Supply Voltage Low Injector Supply Voltage Problem To ensure best operation and efficiency of all engine 12/13 ECM Error components, always use genuine Clarke spare parts. Cam Position Input Noise Orders should specify: Cam Position Input Missing  Engine Model Number - See Engine General Cam Position Input Pattern Error ...

  • Page 48: Keyword Index

    9, 10, 13, 32, 33, 44, 49 are of primary concern to the Engine Manufacturer, Alternator 11, 42, 44, 49 the Engine Service Dealer and Clarke. All provide support of these products after final installation of the complete fire pump and sprinkler system. Battery Cables...
  • Page 49 Subject Page Parts Illustrations Parts Information 44, 46, 49 Installation Data Powerview Gauge 17-20, 42, 45, 46 Installation Instructions 10-15 Pump: Fuel Pump 11, 13, 32 Water Pump Lubricating Oil Volume Lubricating System 12, 35 Serial Number 4, 46 Shutdown Systems 18-20, 28, 29, 42, 43 Soft Start 16, 17...
  • Page 50 13.0 APPENDIX “A” C18H MODELS PARTS MATRIX C18H0-UFAD12 C18H0-UFAD12-D* C18H0-FMAD12-S* C18H0-FMAD12-DS* C18H0-UFAD22 C18H0-UFAD42 C18H0-UFAD22-D* Clarke Engine Models C18H0-UFAD42-D* C18H0-FMAD22-S* C18H0-FMAD42-S * C18H0-FMAD22-DS* C18H0-FMAD42-DS* C18H0-UFAD32 C18H0-UFAD32-D* C18H0-FMAD32-S* C18H0-FMAD32-DS* Part Description Part Number (standard items only, optional items not shown) 1R1808 (Qty.2)
  • Page 51 14.0 APPENDIX “B”...

  • Page 53: Appendix "C" Pld Maintenance And Operation

    System requires additional engine installation sprinkler system design working pressure. steps, start-up inspection checks, and has its own maintenance requirements. Figure #24 – VSPLC System Performance This appendix to the operator’s manual only pertains to the PLD features of the Clarke Engine.

  • Page 54: Identification/Nameplate

    15.1.1 Identification/Nameplate – DS-VSPLC / VSSLC In addition to the information on a standard engine Smart P/N – Clarke internal P/N to establish nameplate, the PLD equipped Clarke Engine engine bill of material models are also identified by a specific engine model number on the Clarke nameplate.

  • Page 55: Pld Engine Models

    15.1.2 PLD Engine Models Refer to appendix “A” on page 49 of this manual for PLD equipped Clarke Engine Models. 15.2 INSTALLATION INSTRUCTIONS 15.2.1 Connections 15.2.1.1 Discharge / Suction Pressure Engine is provided with a single connection...
  • Page 56 Figure #25 – System Schematic, Clarke PLD...

  • Page 57: Start-Up Inspection Instructions

    15.2.2 Start-Up Inspection Instructions  NOTE: The purpose of disabling the VSPLC / VSSLC is to allow for testing 15.2.2.1 Disabling VSPLC / VSSLC of the pump with the PLD Speed  To disable the VSPLC / VSSLC, Control System de-activated. This only occurs during initial start-up and disconnect the wiring harness by during the annual pump test.

  • Page 58: Operation

    15.2.3 Operation and message will be displayed on the Powerview gauge on the engine instrument 15.2.3.1 Freeze Protection panel (See Figure #26). An alarm signal will also be sent to terminal #302 of the fire Protect the unit from freezing. pump controller.

  • Page 59: Adjustments

    Figure #28 – Clarke Instrument Panel 1 – Powerview Gauge 2 – Emergency operating instructions 5 – Warning Light 3 – Automatic / Manual Mode Selector Switch 6 – VSPLC / VSSLC wiring harness 4 – Manual Crank Controls 7 – Manual Stop 15.2.3.3 Adjustments...
  • Page 60 Figure #29 – Wiring Diagram...

  • Page 61: Maintenance

    15.4 MAINTENANCE 15.4.1 Weekly Exercise – Record pump shutoff pressure and engine RPM. Maintain weekly readings in a log for future reference. 15.5 TROUBLESHOOTING 15.5.1 Powerview Gauge Diagnostics  In the event of the VSPLC or VSSLC pressure transmitter (See Figure #4, Detail “A”) failure, a warning light and message will be displayed on the Powerview on the engine...
  • Page 62 Each engine has a minimum RPM it can operate at. Minimum RPM is based upon several factors, therefore in order to determine if the Clarke PLD equipped engine can “trim” enough pressure for a particular installation, it will be necessary to run Clarke’s “PLD Calculator”...

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