INSTALLATION AND MAINTENANCE MANUAL
FOR JOCKEY PUMP CONTROLLERS MODEL JPLT
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TABLE OF CONTENTS
Important Safety Information 3
Introduction 5
Technical Data 5
Installation 6
Storage 6
Seismic 6
Environment 6
Electromagnetic compatibility (EMC) 6
Handling 6
Location 6
Mounting 7
Wall mounting 7
Making System Pressure Connections 7
Making Electrical Connections 8
Important Precautions 8
Procedure 8
Operator Interface 10
How to configure the controller 10
Methods of Starting/Stopping 11
Automatic mode 11
Manual mode 11
Off mode 11
Bump for rotation 11
Commissioning 12
Maintenance 13
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IMPORTANT SAFETY INFORMATION
DANGER
RISK OF ELECTROCUTION
PERSONAL INJURY OR DEATH COULD OCCUR.
ENSURE ALL POWER IS DISCONNECTED BEFORE INSTALLING OR SERVICING
THIS EQUIPMENT.
DANGER
Do not attempt to install or perform maintenance on equipment while it is energized! Death,
personal injury or substantial property damage may result from contact with energized equip-
ment. Always verify that no voltage is present before proceeding and always follow generally
accepted safety procedures. Controller disconnect switch must be in the “off” position in
order to open the enclosure door. Tornatech cannot be liable for any misapplication or incor-
rect installation of its products.
Warning:
This product can expose you to chemicals including DINP, which is known to the State of Cali-
fornia to cause cancer, and DIDP which is known to the State of California to cause birth
defects or other reproductive harm.
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Warning:
This product can expose you to chemicals including lead and lead compounds, which are
know to the State of California to cause cancer and birth defects or other reproductive harm.
For more information go to: www.P65Warnings.ca.gov
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INTRODUCTION
Tornatech Jockey Pump Controllers are intended for use with fire pump systems. They are used for pres-
sure maintenance in fire pump installations to prevent unnecessary cycling of the main fire pump.
They are listed by Underwriters’ Laboratories, Inc., in accordance with UL508A, Standard for Industrial
Controllers. They are built to meet or exceed the requirements of the approving authorities as well as
NEMA and the latest edition NFPA 70 National Electrical Code.
They also comply with the requirements of the Electromagnetic Compatibility (EMC) Directive
2014/30/EU, the Low Voltage Directive (LVD) 2014/35/EU, the Electromagnetic Compatibility Regu-
lations (2016 No. 1091) and The Electrical Equipment (Safety) Regulations (2016 No. 1101).
These instructions are intended to assist in the understanding of the installation and operation of these
controllers. Read the instructions thoroughly prior to connecting or operating the controller. If there are
any unanswered questions, please contact the local Tornatech representative or the factory service
department.
TECHNICAL DATA
Rating Value
Rated Operational Current Ie According to the Motor (HP/kW)
Rated Insulation Voltage Ui 690, 600 (IEC)
Rated Operational Voltage Ue According to the controller rating label
Rated Impulse Withstand Voltage Uimp 6000V
Rated Operational Frequency 50/60Hz
Standard environmental temperature 4°C to 40°C
Altitude ≤ 2000m
Relative humidity 5% to 80%
Pollution degree 3
Short Circuit Current Rating Icc (SCCR) (A) According to the controller rating label
Rated Peak Withstand Current Ipk According to IEC 61439-1:2020 Table 7
Standard degree of protection NEMA Type 2
Standby power consumption 5W
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INSTALLATION
STORAGE
If the controller is not installed and energized immediately, Tornatech recommends following the
instructions in chapter 3 of NEMA ICS 15.
SEISMIC
Jockey Pump controllers are optionally seismic approved and has been tested in accordance with the
ICC-ES AC156, IBC 2015 & CBC 2013 standards. Proper installation, anchoring and mounting is required
to validate this compliance report. Refer to this manual and drawings to determine the seismic mount-
ing requirements and location of the center of gravity (you may need to contact factory). The equipment
manufacturer is not responsible for the specification and performance of anchorage systems. The struc-
tural engineer of record on the project shall be responsible for anchorage details. The equipment install-
ation contractor shall be responsible for ensuring the requirements specified by the structural engineer
of record are satisfied. If detailed seismic installation calculations are required, please contact the man-
ufacturer for the performance of this work.
ENVIRONMENT
Jockey Pump controllers are intended to be installed in locations where ambient temperatures are
within 4°C and 40°C and the relative humidity is controlled between 5% and 80%. Optionally, the con-
troller can have an extended temperature of up to 55 °C and as low as -5°C, provided that the controller
and the pressure water pipes are heated to prevent water freezing and damaging the electronics and
the piping system.
They are intended for pollution degree 3 and shall be installed at an altitude of no more than 2000
meters. For abnormal installation environment, consult factory.
ELECTROMAGNETIC COMPATIBILITY (EMC)
Jockey Pump controllers have been tested for the most stringent conditions for emissions (Environment
B) and immunity (Environment A), hence controllers can be installed in either environment. All con-
trollers variants share the same electronics and comply to those criteria without requiring additional
measures.
HANDLING
The weight of each Jockey Pump controller is indicated on the packing label. Lightweight controllers do
not require special handling instructions, while heavy controllers are equipped with lifting means and
should be handled following the guidelines specified in Tornatech's document "Large Enclosure Safe
Handling Requirements_PN12162021".
LOCATION
Consult the appropriate job plans to determine the controller mounting location.
The controller shall be located as close as practical to the engine or motor it controls and shall be within
sight of the engine or motor. The controller shall be located or protected such that it will not be
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damaged by water escaping from pump or pump connections. Current carrying parts of the controller
shall be not less than 12 in. (305 mm) above the floor level.
Working clearances around controller shall comply with NFPA 70, National Electrical Code, Article 110 or
C22.1, Canadian Electrical Code, Article 26.302 or any applicable local codes.
The standard controller enclosure is rated NEMA Type 2. It is the installer’s responsibility to insure that
either the standard enclosure meets the ambient conditions or that an enclosure with an appropriate
rating has been provided. Controllers must be installed inside a building and they are not designed for
outside environment. The paint color may change if the controller is exposed to ultraviolet rays for a
long period of time.
MOUNTING
WALL MOUNTING
Refer to the controller dimension drawing for necessary mounting dimensions.
The controller is wall mounted by using at least four (4) wall anchors, 2 anchors for the top mounting
brackets and 2 anchors for the bottom mounting brackets. The brackets are dimensionally on the same
centerline for ease in mounting. There should be a clearance of at least 6 inches (152mm) around the
controller to allow proper air circulation around the equipment.
1. Using either the dimension print or by measuring the distance between the center lines of the
lower bracket slots, transcribe this dimension on to the wall. Note: The bottom edge of the enclos-
ure should be a minimum of 12” (305mm.) from the floor in case flooding of the pump room
occurs.
2. Drill and put anchors into the wall for the lower mounting brackets.
3. Mark on the wall, the location of the holes in the upper mounting brackets.
4. Drill and put anchors into wall for the upper mounting brackets.
5. Install bolts and washers in lower anchors.
6. Align holes in upper mounting brackets and install bolts and washers in anchors.
7. Shim anchors as necessary to ensure rear of enclosure is vertical level and enclosure is not
stressed.
8. Tighten all anchor bolts.
9. Check to be sure enclosure door open and closes freely and that enclosure is level.
MAKING SYSTEM PRESSURE CONNECTIONS
The controller requires one (1) “System Pressure” connection from the system piping to the enclosure.
The connection fitting, 1/2” NPT male port, is provided on the bottom, external side of the enclosure for
this purpose. Refer to NFPA 20 for correct field piping procedure of the sensing line between the pump-
ing system and the controller.
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MAKING ELECTRICAL CONNECTIONS
IMPORTANT PRECAUTIONS
A licensed electrician must supervise the electrical connections. The dimension drawings show the area
suitable for incoming power and motor connections. No other location shall be used. Only watertight
hub fittings shall be used when entering the cabinet to preserve the NEMA or IP rating of the cabinet.
The installer is responsible for adequate protection of the Jockey Pump controller com-
ponents against metallic debris or drilling chips. Failure to do so may cause injuries to per-
sonnel, damage the controller and subsequently void warranty.
Prior to making any field connections
1. Open door of enclosure and inspect internal components and wiring for any signs of frayed or
loose wires or other visible damage.
2. Verify that the controller information is what is required on the project:
1. Tornatech catalog number
3. Project's electrical contractor must supply all necessary wiring for field connections in accordance
with the National Electrical Code, local electrical code and any other authority having jurisdiction.
4. Refer to the appropriate field connection drawing for wiring information.
PROCEDURE
All field connections, remote alarm functions and AC wiring are brought into the enclosure through the
top or bottom conduit entrances as indicated on the dimensional drawing.
Do not place conduit entrances on the sides of the enclosure unless a gland plate is provided.
1. Using a hole (conduit) punch, create a hole in the enclosure for the size conduit being used.
2. Install necessary conduit.
3. Pull all wires necessary for field connections, remote alarm functions, AC power and all other
optional features. Bring enough wire inside the enclosure to make up connections to the appro-
priate line, load and control terminal block points. Be sure to consult the appropriate field con-
nection diagram for connection points and acceptable wire size. For proper wire sizing, refer to
the National Electrical Code, NFPA 70.
4. Make all field connections to the remote alarm functions and any other optional features.
5. Connect motor to controller load terminals.
6. Find nameplate on Jockey Pump motor and make note of its full load amp rating. Verify the over-
load within the controller is set for that number of amps.
7. Verify AC line voltage, phase and frequency with the controller data plate on the enclosure door
prior to connecting.
8. Connect AC power.
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9. Check to see that all connections are both correctly wired (in accordance with the field con-
nection diagram) and tight.
10. Close the enclosure door.
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OPERATOR INTERFACE
1. LCD screen
2. Hand-Off-Auto selector
3. Menu navigation buttons.
1. Down / decrease value
2. Enter configuration / enter
3. Up / increase value
4. Integrated alarm buzzer
HOW TO CONFIGURE THE CONTROLLER
To enter the configuration, press the enter configuration button. Use the up and down buttons to select
the value to edit, then press enter. Use the increase or decrease value button to edit the value. Holding
those buttons will change the value with an increased speed. Once satisfied with the value, press the
enter button.
Edited items are not directly applied to the controller and are marked on the screen with an asterisk.
Once satisfied with your new values, exit the menu by selecting the first menu line and pressing enter. A
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confirmation popup will appear asking you to apply the new values to the controller, select "yes" then
press enter. You may alternatively discard all changes made by selecting "no".
METHODS OF STARTING/STOPPING
AUTOMATIC MODE
When the mode selector is in automatic, the controller will start automatically on low pressure detec-
tion by the pressure sensor (below the cut-in threshold).
The motor is automatically stopped after the restoration of the pressure (above the cut-out threshold),
after a programmable run period timer.
MANUAL MODE
When the mode selector is in manual, the controller will run the motor continuously.
OFF MODE
When the mode selector is in off, the motor cannot be started and will be stopped if it was previously
running.
BUMP FOR ROTATION
Successively applying manual mode and off mode to the controller can be used to bump for the motor
and check rotation. If the rotation is incorrect, turn OFF power with the door mounted disconnect. Swap
any two existing motor lead wires that are on the motor contactor in the controller
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COMMISSIONING
1. Verify, and adjust if necessary, the motor overload setting.
2. For three-phase motors, verify the motor rotation by bumping the motor. In case of incorrect
rotation, power off the controller and swap two wires at the contactor load side.
3. Enter the configuration menu and input the appropriate values for
1. Pressure unit if required, in the Advanced sub menu;
2. Cut-out1;
3. Cut-in;
4. Timer on;
5. Timer off.
4. Exit the configuration menu and save changes.
5. Place the hand-off-auto selector in auto.
1Cut-out is required to be at least 10 PSI more than cut-in value and should be edited first.
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MAINTENANCE
Tornatech controllers are covered by a limited warranty and backed by a 10-years service life or until
supply last, provided that proper installation, commissioning, use and maintenance of the controller is
made as per this document and any maintenance standard applicable.
Proper controller performance must be asserted at least once a month by executing the following:
1. With the system being at nominal pressure, ensure that the pressure reading is within tolerances
2. Perform an automatic start sequence on both the VFD and the bypass starting meansby creating
a pressure drop and verify that
1. The motor starts when the pressure falls below cut-in
2. There are no alarms
3. There is no nuisance tripping
4. The motor starts properly and is able to accelerate within the expected time
5. The motor rotates in the appropriate direction
6. The pump is able to rise the pressure above the cut-out
7. The motor stops when the pressure is above cut-out
In addition to the above, the following preventative maintenance must be performed at least once year:
1. Turn off the controller
2. Do a visual inspection of the exterior of the controller
3. Open the enclosure and do a visual inspection of the interior of the controller
4. Make sure that there is no dust accumulation inside the controller
5. Clean the fans and air outlet filters from dust accumulation
6. Inspect the tightness of each dead cable
7. Put the controller back in service
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AMERICAS
Tornatech Inc.
Head Office
Laval, Quebec, Canada
Tel.: +1 514 334 0523
Toll free: +1 800 363 8448
EUROPE
Tornatech Europe SA
Mont-Saint-Gilbert, Belgium
Tel.: +32(0)10 84 40 01
MIDDLE EAST
Tornatech FZE
Dubai, United Arab Emirates
Tel.: +971(0)4 821 7555
ASIA
Tornatech Pte Ltd.
Singapore
Tel.: +65 6795 8114
Tel.: +65 6795 7823
FOLLOW US
www.tornatech.com
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