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ANSUL

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INSTALLATION OPERATION RECHARGE INSPECTION AND MAINTENANCE MANUAL

SAPPHIRE™ PRE-ENGINEERED CLEAN AGENT FIRE SUPPRESSION SYSTEMS

006777

This manual is intended for use with Ansul SAPPHIRE™ Clean Agent Fire Suppression Systems. Those who install, operate, recharge or maintain these fire suppression systems should read this entire manual. Specific sections will be of particular interest depending upon one’s responsibilities. Design, installation, recharge, and maintenance of the system must conform to the limitations detailed in this manual and performed by an individual who attended an Ansul training program and became trained to install, recharge, design, and maintain the Ansul system. Fire suppression systems are mechanical devices. They need periodic care. Maintenance is a vital step in the performance of your fire suppression system. As such it must be performed in accordance with NFPA 2001 “Clean Agent Fire Extinguishing Systems” and this manual, by an authorized Ansul distributor. To provide maximum assurance that the fire suppression system will operate effectively and safely, maintenance must be conducted at six-months intervals, or earlier if the situation dictates. Refer to NFPA 2001, Paragraph 4-2, for testing and inspection information. ANSUL PART NO. 570527

ANSUL and SAPPHIRE are trademarks of Ansul Incorporated or its affiliates.

TABLE OF CONTENTS UL EX-4510 5-15-03

SECTION ________ I.

GENERAL INFORMATION 3M™ NOVEC™ 1230 FIRE PROTECTION FLUID General Information Storage and Handling Recommendations Disposal Information Health and Safety DESCRIPTION OF SAPPHIRE SYSTEMS APPROVALS MSDS

II. SYSTEM COMPONENTS NOVEC 1230 LIQUID AGENT AGENT TANK ASSEMBLY TANK BRACKET ASSEMBLY 1 IN. FLEXIBLE DISCHARGE HOSE 1 IN. UNION ADAPTOR AUTOPULSE CONTROL SYSTEM ANSUL AUTOMAN II-C RELEASING DEVICE (FOR PNEUMATIC ACTUATION) 1 IN. VALVE SHIPPING ASSEMBLY REMOVABLE ELECTRIC ACTUATOR PNEUMATIC ACTUATOR 1/4 IN. ACTUATION HOSE 1/4 IN. FEMALE ACTUATION HOSE MALE ACTUATION CONNECTOR MALE ACTUATION TEE MALE ACTUATION ELBOW SAFETY RELIEF VALVE DISCHARGE NOZZLE SPANNER WRENCH RECHARGE ADAPTORS WARNING PLATES

PAGES ______ 1 – 10 1 1 1 1 1–2 2 2 3– 9 11 – 14 11 11 11 11 12 12 12 12 13 13 13 13 14 14 14 14 14 14 14 14

III. SYSTEM DESIGN 15 – 18 GENERAL INFORMATION 15 HAZARD ANALYSIS 15 PIPING AND NOZZLE DESIGN REQUIREMENTS 15 SYSTEM DESIGN REQUIREMENTS 15 – 17 DETECTION REQUIREMENTS 17 ACTUATION REQUIREMENTS 17 – 18 IV. INSTALLATION MOUNTING TANK AND BRACKET ASSEMBLY INSTALLING DISTRIBUTION PIPING INSTALLING DETECTION SYSTEM INSTALLING ACTUATION PIPING

19 – 20 19 19 19 19 – 20

V. INSPECTION

21 – 22

SECTION ________

PAGES ______

VI. MAINTENANCE

23 – 24

VII. RESETTING AND RECHARGE CLEARING ELECTRICAL EQUIPMENT CHECKING MECHANICAL AND ELECTRICAL EQUIPMENT RECHARGING

25 — 26 25 25 25 – 26

SECTION I – GENERAL INFORMATION UL EX-4510 5-15-03 Page 1

3M™ NOVEC™ 1230 FIRE PROTECTION FLUID

20 microns) be used when filling container.

General Information

Standards used by the fire protection industry typically specify that clean agents meet certain standards of quality. In order to maintain the low water content of the original Novec 1230 fluid, procedures must be used to prevent the entry of moist, ambient air into the storage containers. When transferring fluid, the receiving containers should be free of water and purged with dry nitrogen prior to filling with Novec 1230 fluid to remove moisture-laden air. The end of the fluid dispensing pipe must extend into the receiving container. The dispensing container should be fitted with a vent drier or nitrogen purge to prevent the influx of moist air as Novec 1230 fluid is withdrawn. Vent driers employing disposable or refillable desiccant cartridges are available from vendors such as W.A. Hammond Drierite Co. Ltd. Alternatively, a nitrogen purge can be set up by installing a “tee” onto the vent bung of the dispensing container and establishing flow of dry nitrogen at a volumetric flow rate that is in excess of the rate of withdrawal of Novec 1230 fluid from the container.

3M™ Novec™ 1230 Fire Protection Fluid has been developed as an alternative to Halon 1301, production of which has ceased at the end of 1993, under the agreed adjustments made to the Montreal Protocol in Nov. 1992. Novec 1230 contains no Bromine or Chlorine and has no ozone depleting potential. Novec 1230 systems utilize one or more storage containers arranged to provide the protected area with a pre-determined quantity of agent. Novec 1230 storage container are designed to hold Novec 1230 in liquid form. Nitrogen is used to super-pressurize the container to 360 psi (24.8 bar) at 70 °F (21 °C). Handling and installation of Novec 1230 equipment should only be conducted by persons trained in dealing with this type of equipment. Under normal conditions Novec 1230 is a colorless and low odor fluid with a density around 11 times greater than air. It has negligible vapor pressure and is super-pressurized with nitrogen to 360 psi (24.8 bar) when used in fire suppression applications. It contains no particulates or oily residues and is produced under ISO 9001 guidelines to strict manufacturing specifications ensuring product purity. Present understanding of Novec 1230 is that fire suppression is through heat absorption and chemical means. Novec 1230 decomposes at temperatures in excess of 932 °F (500°C) and it is therefore important to avoid applications involving hazards where continuously hot surfaces are involved. Upon exposure to the flame, Novec 1230 will decompose to form halogen acids. Their presence will be readily detected by a sharp, pungent odor before maximum hazardous exposure levels are reached. Storage and Handling Recommendations The unique properties of Novec 1230 fluid necessitate the user to follow certain handling and storage guidelines. Failure to follow these recommendations may result in contamination of the agent and potential failure of the system in which it is used. Contact with water or solvents either polar or hydrocarbon could render Novec 1230 fluid ineffective. Novec 1230 fluid should not be mixed with other extinguishing agents (liquid, powder, or foam) without consulting Ansul to determine compatibility. Novec 1230 fluid should be stored indoors, out of direct sunlight at temperatures below 104 °F (40 °C). If container must be stored outdoors, confirm that all openings are fully closed. Protect container from direct sunlight and precipitation to every extent possible, and fully dry the exterior of the container prior to opening. Based on the results of accelerated aging studies, Novec 1230 fluid is expected to have a shelf life and perform as a clean agent for at least 30 years in a properly designed, maintained, and operating fire suppression system, provided the agent has been stored and handled in accordance with the information provided in this manual. Novec 1230 fluid is a liquid at room temperature allowing it to be transferred using conventional pumping or pouring methods. Novec 1230 fluid has a viscosity similar to water. Consequently, it can be transferred using any pump that would be used to transport a low viscosity, nonflammable liquid. A gravity feed method may also be used to fill the system tanks, in lieu of pumping. If using a pump, it is recommended that an inline filter (equal to or less than

Good industrial hygiene practices should be followed when handling Novec 1230 fluid. Novec 1230 fluid must be used in a wellventilated area. Provide local exhaust ventilation at transfer points. If adequate ventilation cannot be accomplished to maintain air concentrations below the recommended exposure guideline, use respiratory protection. The use of vented goggles for eye protection is required when handling Novec 1230 fluid. Always wear gloves when handling Novec 1230 fluid. Gloves made from butyl rubber are recommended. For more specific information regarding the use of Novec 1230 fluid, refer to the Material Safety Data Sheet. Disposal Recommendations Novec 1230 fluid may be disposed using an approved industrial or commercial incinerator. Since Novec 1230 fluid is nonflammable, it must be burned in the presence of a combustible material. Refer to the Material Safety Data Sheet, section 13, for additional details. Health and Safety A proper designed and installed suppression system should not present any significant health or safety problems. However, there are basic precautions to be taken to avoid accidents, and aspects of the system operation that should be understood. Reference should be made to NFPA 2001 for the toxic and asphyxiating hazards of clean agent replacement for Halon 1301. Novec 1230 agent has acceptable toxicity for use in occupied spaces when used as specified in the United States Environmental Protection Agency (EPA) proposed Significant New Alternative Policy (SNAP) program rules and NFPA 2001, “Clean Agent Fire Extinguishing Systems.” Novec 1230 agent extinguishes by causing a chemical reaction with the combustion products, and does not remove oxygen like CO2 and some other inert agents. Therefore, exposure to Novec 1230 at the design concentration of up to 10.0% is not a hazard to health. Exposure to higher concentrations is permissible for limited periods. Refer to NFPA 2002 for exposure requirements. As with halons, the EPA and the National Fire Protection Association (NFPA) recommend that unnecessary exposure to any agent be avoided and that personnel evacuate protected areas as quickly as possible to avoid the decomposition products of the fire. Novec 1230 can decompose at high temperatures to form acids. If so, their presence is readily detected as a sharp, pungent odor long before hazardous maximum exposure levels are reached.

SECTION I – GENERAL INFORMATION 5-15-03 Page 2 UL EX-4510

3M™ NOVEC™ 1230 FIRE PROTECTION FLUID (Continued) Health and Safety (Continued) The noise created by the Novec 1230 agent discharging can be loud enough to startle people in the vicinity, but is unlikely to cause any permanent injury. Turbulence caused by the high velocity discharge can dislodge substantial objects directly in its path, and cause general turbulence within the protected area to move paper and light objects. Direct contact with the vaporizing liquid discharged from a Novec 1230 nozzle has a chilling effect on objects and in extreme cases can cause frostbite to the skin. The liquid phase vaporizes rapidly when mixed with air and therefore limits the risk to the immediate vicinity of the nozzle. Reduction in visibility will occur due to the condensation of water vapor. !

CAUTION

The discharge of clean agent systems to extinguish a fire can result in a potential hazard to personnel from the natural form of the clean agent or from the products of combustion that result from exposure of the agent to the fire or hot surfaces. Unnecessary exposure of personnel either to the products of decomposition shall be avoided. DESCRIPTION OF SAPPHIRE SYSTEMS SAPPHIRE systems are designed to suppress fires in Class A, B (minimum Class B design concentration is 5.85%; contact Ansul for all Class B applications), and C hazards. Novec 1230 suppress fires by a combination of physical and chemical means. It does not significantly deplete the oxygen content in the room and tests have shown it to be less toxic than Halon 1301. A system comprises one or more containers connected to a system of piping and nozzles. Novec 1230 is liquid under pressure and is stored in steel containers, each of which is fitted with a valve specially designed to allow the contents of the container to discharge within 10 seconds. When the valve opens, Novec 1230 flows into the distribution piping to the discharge nozzles where it is rapidly dispersed as a vapor. Discharged Novec 1230 gives the appearance of a fog which may reduce visibility. This normally clears rapidly and should not obstruct the ability of personnel to safely exit the protected area. SAPPHIRE Fire Suppression Systems are particularly valuable in extinguishing fires in enclosures containing hazards or equipment where a clean, electrically non-conductive medium is essential or where the cleaning up of foam, water or dry chemical would be a problem. APPROVALS The SAPPHIRE Fire Suppression System has been tested and listed by Underwriters Laboratories, Inc. (EX-4510) and Underwriters Laboratories of Canada (CEX1151) as a pre-engineered system for Class A, B, and C fire suppression, at temperatures between 0 °F to 130 °F (–18 °C to 55 °C).

SECTION I – GENERAL INFORMATION UL EX-4510 5-15-03 Page 3

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006757c

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NOTES:

SECTION II – SYSTEM COMPONENTS UL EX-4510 5-15-03 Page 11

3M™ NOVEC™ 1230 FIRE PROTECTION FLUID

TANK BRACKET ASSEMBLY

Novec 1230 fluid has been developed as a halon replacement alternative to HFCs, HCFCs, and PFCs in special hazard, high value applications. It has unique qualities that provide the right balance of fire extinguishing performance, end use safety, and environmental sustainability. Novec 1230 fluid is low in toxicity and environment impact. It is a liquid at room temperature, with a low vapor pressure, which allows for ease in handling, storage, and shipping.

The bracket assembly consists of a nut, bolt, and two bracket straps (back channel must be supplied by others. Approved type of Unistrut Channel is series P1000T, 1.6 in. x 1.6 in. (41 mm x 41 mm). To securely hold the tank in position during system discharge, two bracket assemblies are required per tank.

Novec 1230 is available is two sizes of containers:

Each strap is notched for insertion into the channel, allowing the tank to be properly aligned. The bracket assembly is designed to be mounted to a rigid vertical surface with the tank assembly resting fully on the floor or rigid surface.

Part No. 570533 – 30 gallon Drum Shipping Assembly

Part No. 570085 – Bracket Shipping Assembly

Part No. 570534 – 220 gallon Tote Shipping Assembly AGENT TANK ASSEMBLY The agent storage tanks are manufactured in accordance with DOT4BW450 and consist of a tank fitted with a valve and internal siphon tube. Tanks are available in two sizes: 40 lb. and 80 lb. A nameplate is adhered to the tank displaying the agent weight, and gross weight.

15.7 IN. (400 mm)

Note: Quantity of agent will have to specified on customer P.O when ordering factory filled tank shipping assemblies. Part No. 570636 – 40 lb. (18 kg) Tank Shipping Assembly Part No. 570637 – 80 lb. (36 kg) Tank Shipping Assembly FIGURE 2 006759

1 IN. FLEXIBLE DISCHARGE HOSE The flexible discharge hose is connected to the rigid distribution piping. A swivel fitting at the inlet of the hose enables the tank valve to be coupled to the hose. The hose is 16 in. (406 mm) in length. Part No. 570539 – 1 in. Flexible Discharge Hose Shipping Assembly

A B

1 IN. NPT THREAD (FIXED)

16 IN. (406 mm) C

FIGURE 1 006758

Tank ____ 40 lb. (18 kg)

Part No. _______ 570636

A _______ 23 in. (588 mm)

B _______ 19.6 in. (499 mm)

C _______ 10 in. (254 mm)

80 lb. (36 kg)

570637

36 in. (920 mm)

32.7 in. (831 mm)

10 in. (254 mm)

1 IN. BSP 90° FEMALE SWIVEL UNION 3 IN. (79 mm)

FIGURE 3 006760

SECTION II – SYSTEM COMPONENTS 5-15-03 Page 12 UL EX-4510

1 IN. UNION ADAPTOR The 1 in. union adaptor is required to attach the valve outlet to rigid piping. The adaptor has a BSP thread on the valve end and an NPT thread on the pipe end. Part No. 570557 – 1 in. Union Adaptor Shipping Assembly

Part No. 68739 – ANSUL AUTOMAN II-C Releasing Device Shipping Assembly Part No. 13193 – LT-10-R Nitrogen Cartridge Shipping Assembly (order separately) Part No. 26310 – Cocking Lever (order separate) RELEASE MECHANISM

STRIKE BUTTON

1 IN. NPT THREAD (PIPE END)

1 IN. BSP THREAD (VALVE END)

NAMEPLATE 2 1/2 IN. (63.5 mm)

TERMINAL BOARD LT-10-R CARTRIDGE (ORDERED SEPARATELY)

FIGURE 4 006761

AUTOPULSE CONTROL SYSTEM The AUTOPULSE Control system is designed to monitor fixed fire hazards. The control system can automatically actuate the fire suppression system after receiving an input signal from one or more initiating devices, i.e., manual pull station or detector. The control system incorporates an internal power supply, on-line emergency batteries, and solid state electronics. Refer to Detection and Control Manual for additional information.

FIGURE 6 000442

1 IN. VALVE SHIPPING ASSEMBLY The replacement valve assembly is available for field replacement. The valve is fully assembled, with internal components, gauge and burst disc assembly. The replacement valve is 100% leak tested before it leaves the factory. Part No. 570535 – 1 in. Valve Shipping Assembly

0°

Supervisory Pressure Switch Flameproof Solenoid Port

180°

Burst Disc Actuation Port Flameproof Solenoid Port

240°

Pressure Gauge

FIGURE 5 002195

ANSUL AUTOMAN II-C RELEASING DEVICE (FOR PNEUMATIC ACTUATION) The ANSUL AUTOMAN II-C Releasing Device consists of a metal enclosure which contains a spring-loaded puncture pin release mechanism, an actuation cartridge, electrical circuitry, and an input/output terminal strip for making electrical connections. The ANSUL AUTOMAN II-C releasing device provides automatic pneumatic actuation of the SAPPHIRE System. When wired to an AUTOPULSE Control System, it will provide supervised electric detection and release. It also provides manual actuation using the strike button on the release enclosure and with optional remote manual cable pull station. When an AUTOPULSE Control System is used, manual actuation is accomplished using an electric manual pull station. The ANSUL AUTOMAN II-C releasing device requires an LT-10-R nitrogen cartridge for system actuation. Cartridge must be ordered separately.

Actuation Port

120°

0°

270° PORT POSITIONS ARE DIAGRAMMATIC FOR CLARITY. PRESSURE GAUGE NOT SHOWN.

90°

240°

120° 180°

FIGURE 7 006762

SECTION II – SYSTEM COMPONENTS UL EX-4510 5-15-03 Page 13

REMOVABLE ELECTRIC ACTUATOR

PNEUMATIC ACTUATOR

The 24 VDC electric actuator is required to electrically actuate the tank valve. An electric signal is received from the AUTOPULSE Control Panel which operates the solenoid in the actuator. This causes the actuator to open the tank valve and discharge the agent. On multiple tank systems, only one electric actuator is required, on the master tank valve. The remaining tanks will be actuated pneumatically through 1/4 in. stainless steel hose installed between each pilot pressure port.

The pneumatic actuator is required to pneumatically actuate the agent tanks. The actuator operates from pressure received from the nitrogen cartridge located in the ANSUL AUTOMAN II-C release. When the pneumatic actuator is pressurized, the internal actuator piston pushes down on the valve stem, opening the tank valve, allowing the agent to discharge. Part No. 570550 – Pneumatic Actuator Shipping Assembly

Actuator current draw is 0.2A. Part No. 570537 – Removable Electric Actuator Shipping Assembly

O-RING

1 IN. BSP

CLIP PISTON

ACTUATOR BODY 3.3 IN. (85 mm)

FIGURE 9 006764

1/4 IN. ACTUATION HOSE The 1/4 in. stainless steel actuation hose is used to connect the 1/4 in. actuation line to the pneumatic actuator located on the tank valve. This hose is used when the actuation line is rigid 1/4 in. pipe and fittings. The hose has a 1/4 in NPT male thread on one end and a 7/16-20 female thread on the other end. A male straight adaptor, Part No. 32338, is required with this hose.

1.8 IN. (45 mm)

Technical Information Solenoid Enclosure: Actuation Pin: Actuation Type: Power Requirement: Current: Connection: Actuation Type: Reset Requirement: Manual Actuation Force: Electrical Connection: Diode Type: Certification: Temperature Range:

Part No. 73597 - 1/4 in. Actuation Hose Shipping Assembly Mild Steel & Dull Nickel Stainless Steel Latching 24V dc 0.2A 1 in. BSP Latching Manual Force Required 11 lb. Force (5 KgF) 3-pin plug connector Suppression Recognized to UL508 Tested in accordance with UL864 –4 °F to 131 °F (–20 °C to +55 °C)

FIGURE 8 006763

16 IN. (40.6 cm)

FIGURE 10 000432

1/4 IN. FEMALE ACTUATION HOSE The 1/4 in. stainless steel, female actuation hose is used to connect the actuation line compression tees between each agent tank. The hose has the same thread, 7/16-20, as the compression tees. The actuation hose allows flexibility between the rigid actuation piping and the tank valve. Part No. 32336 – 1/4 in. Female Actuation Hose Shipping Assembly 24 IN. (61 cm)

7/16-20

7/16-20

FIGURE 11 000433

SECTION II – SYSTEM COMPONENTS 5-15-03 Page 14 UL EX-4510

MALE ACTUATION CONNECTOR The male connector is used to connect the 1/4 in. female actuation hose to rigid 1/4 in. actuation fittings and also the pneumatic actuator. The connector has a 7/16-20 thread for connecting to the actuation hose and a 1/4 in. NPT thread for connecting to the actuation piping and pneumatic actuator.

SAFETY RELIEF VALVE The safety relief valve is used to relieve the nitrogen pressure in the actuation line after the system has been actuated by an ANSUL AUTOMAN II-C Release. After agent discharge, pulling the ring on the relief valve can relieve the pressure in the line. Part No. 15677 – Safety Relief Valve Shipping Assembly

Part No. 32338 – Male Actuation Connection Shipping Assembly 1/4-18 NPT

7/16-20

FIGURE 15

FIGURE 12

0000437

000434

MALE ACTUATION TEE The male actuation tee is used to connect multiple actuation hoses together. The actuation tee has a 7/16-20 thread for connecting to the female actuation hose and a 1/4 in. NPT thread for connecting to the pneumatic actuator on the tank valve. Part No. 31811 – Male Actuation Tee Shipping Assembly

DISCHARGE NOZZLE Two sizes of discharge nozzles are available: 1 1/4 in. thread size to be used only on the 80 lb. tank distribution piping and a 1 in. thread size to be used only on the 40 lb. tank distribution piping. Nozzles are designed to discharge agent in a 360° pattern. Nozzles are constructed of brass and have a female NPT thread. Part No. 570555 – 1 in. Nozzle Shipping Assembly Part No. 570556 – 1 1/4 in. Nozzle Shipping Assembly

7/16-20

1/4 IN. NPT

FIGURE 13 000435

FIGURE 16 006771

MALE ACTUATION ELBOW The male actuation elbow is used to connect the actuation hose to a single or last tank in a multiple tank system. The elbow connects between the hose and the pneumatic actuator on the valve. The elbow has a 7/16-20 thread for connecting to the hose and a 1/4 in. NPT thread for connecting to the pneumatic actuator on the tank valve.

SPANNER WRENCH This tool is required to remove the valve bonnet assembly for access to the valve piston for O-ring replacement. Part No. 570574 – Spanner Wrench

Part No. 31810 – Male Actuation Elbow Shipping Assembly 7/16-20

FIGURE 17 006766

RECHARGE ADAPTORS Recharge adaptors are required to recharge cylinder assembly. Part No. 570579 – Top Adaptor Assembly Part No. 570576 – Fill Adaptor Assembly

1/4 IN. NPT

FIGURE 14 000436

WARNING PLATES Two warning plates are available for warning personnel that the space is protected by a SAPPHIRE system and no one should enter after a discharge without being properly protected. Each plate is made of aluminum and contains four mounting holes for ease of installation. Part No. 570580 – Warning Plate for Outside Room Part No. 570581 – Warning Plate for Inside Room

SECTION III – SYSTEM DESIGN UL EX-4510 5-15-03 Page 15

This manual has been prepared to give an understanding in the application and design of SAPPHIRE systems. Systems are suitable only for the total flooding of Class A and Class C hazard enclosures.

PIPING AND NOZZLE DESIGN REQUIREMENTS

The SAPPHIRE system is specifically pre-engineered in accordance with the equipment description, hazard type, size, piping limitations, nozzle type, installation, operation, recharge, and maintenance instructions prescribed. All systems must be applied entirely in accordance with the guidelines described in the manual.

• Maximum length of 1 in. pipe (including the flex discharge hose) for 40 lb. (18 kg) tank is 45 ft. 9 in. (13.9 m).

GENERAL INFORMATION • SAPPHIRE systems are approved for hazard and storage temperatures from 0 °F to 130 °F (–18 °C to 55 °C) • Maximum single nozzle area coverage is 32 ft. x 32 ft. (9.8 m x 9.8 m)

• Pipe size for 40 lb. (18 kg) tank is 1 in. • Pipe size for 80 lb. (36 kg) tank is 1 1/4 in.

• Maximum length of 1 1/4 in. pipe (including the flex discharge hose) for 80 lb. (36 kg) tank is 36 ft. 2 in. (11 m). • In addition to above listed pipe lengths, a maximum of 3 – 90° elbows are allowed. Tee at nozzle (dirt trap assembly) counts as one of the 3 allowed elbows. • Maximum net vertical rise from the bottom of the tank to the tip of the nozzle is 14 ft. (4.3 m). • Only one nozzle allowed per tank.

HAZARD ANALYSIS

• 1 in. nozzle for 40 lb. (18 kg) tank and 1 1/4 nozzle from 80 lb. (36 kg) tank.

Prior to starting with the design of SAPPHIRE systems, the designer should have, as a minimum, the following details:

• Maximum nozzle area coverage is 32 ft. by 32 ft. (9.8 m by 9.8 m).

• Enclosure dimensions.

• Nozzle must be located as close to the center of the protected area as possible.

• Specific details of the hazard, such as chemicals, excessive fire load, etc. • The minimum and maximum temperatures of the hazard enclosure. • Height of hazard above (or below) sea level. • Confirmation that the hazard integrity is adequate. • Details of the ventilation system. Note: Ventilation system must be shut down prior to agent discharge. • Intended occupancy of the hazard enclosure. • Tank mounting location. Agent tanks should be located in areas with suitable ventilation, be protected from fire, not subject to weather, mechanical damage, or corrosion and where they can be easily accessed for maintenance. Floor loading should also be taken into account. Novec 1230 is suitable for the protection of hazards involving Class A, Class B and Class C materials. Fires must be detected quickly and the agent discharged promptly and the concentration is maintained for an adequate period of time to allow embers to cool, surface fires and embers associated with the burning of solid materials are quickly extinguished. Novec 1230 is suitable for use on fires involving live electrical equipment but is not effective on, and should not be used to fight fires involving: 1. Chemicals containing their own supply of oxygen, such as cellulose nitrate. 2. Mixtures containing oxidizing agents, such as sodium chlorate or sodium nitrate. 3. Chemicals capable of undergoing autothermal decomposition such as some organic peroxides. 4. Reactive metals. 5. Solid materials in which fires quickly become deep seated. 6. Enclosures already protected by a gaseous system utilizing a different agent.

• Nozzle must be located a maximum of 12 in. (30.5 cm) below the hazard ceiling. • Minimum hazard height is 12 in. (30.5 cm). PRE-ENGINEERED SYSTEM DESIGN REQUIREMENTS Total Flooding is the only application method approved for SAPPHIRE Fire Suppression Systems. After completing the Hazard Analysis, determine the system design requirements by completing the following steps: Step No. 1 – Determine net hazard volume The first step in designing a SAPPHIRE Fire Suppression System is to calculate the net volume of the area being protected. Multiply the length x the width to determine the area, and then multiply the area x the height to determine the volume. If the area is an odd shape, the designer may need to divide it into regular shapes that will allow volume calculations, and then total all the volumes together to determine the actual volume of that area. Example: Hazard size is 12 ft. x 13 ft. x 10 ft. high. Total volume = 1560 cu. Ft. Metric: 3.66 m x 3.96 m x 3.05 m high. Total volume = 44.2 cu. m The second part of this step allows the hazard volume to be reduced by the volume of any impermeable, non-removable objects. Determine the volume of these type objects and subtract this volume from the hazard volume. This will determine the hazard net volume. Example: There is a support column near a wall in the hazard which measures 1 ft. x 1 ft. by 10 ft. high (.3 m x .3 m x 3.1 m). The volume of this impermeable, non-removable object is 10 cu. ft. (.28 cu. m). Subtracting 10 cu. ft. (.28 cu. m) from the total hazard volume of 1560 cu. ft. (44.2 cu. m) equals 1550 cu. ft. (43.9 cu. m). 1550 cu. ft. (43.9 cu. m) is the hazard net volume.

SECTION III – SYSTEM DESIGN 5-15-03 Page 16 UL EX-4510

PRE-ENGINEERED SYSTEM DESIGN REQUIREMENTS (Continued) Step No. 2 – Determine quantity of agent required Two calculations are required to determine the quantity of agent: The first calculation will determine the amount needed for the hazard volume. The second calculation will require multiplying the amount required for the hazard volume, by a factor based on elevation, to determine the final quantity of agent required. Calculation No. 1 Refer to AGENT QUANTITY CHART to determine the amount of agent required for the protected hazard. Referring to the “Maximum Cubic Feet Of Volume” column, find the hazard volume size. If the exact volume is not listed on the chart, pick the next closest larger volume. Example: Follow down the maximum volume column until you find 1550 cu. ft. (43.9 cu. m). As you will note, the exact number 1550 cu. ft. (43.9 cu. m) is not listed. Pick the closest larger number, which is 1551 cu. ft. (43.9 cu. m). Read across to the left of the chart to determine the amount of agent required. Example: From the 1551 cu. ft. (43.9 cu. m) position, reading across the chart to the left, it is determined that 69 lb. (31.3 kg) of Novec 1230 agent is required to protected this hazard net volume. NOVEC 1230 Pre-Engineered AGENT QUANTITY CHART Maximum Volumes at 4.2% Concentration 40 lb. Tank Lbs. Agent _____ 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

Maximum Cubic Ft. Volume ______ 360 382 404 427 449 472 494 517 539 562 584 607 629 652 674 697 719 742 764 787 809 831 854 876 899

Kgs Agent _____ 7.3 7.7 8.2 8.6 9.1 9.5 10.0 10.4 10.9 11.3 11.8 12.2 12.7 13.2 13.6 14.1 14.5 15.0 15.4 15.9 16.3 16.8 17.2 17.7 18.1

Maximum Cubic Meters Volume _______ 10.2 10.8 11.5 12.1 12.7 13.4 14.0 14.6 15.3 15.9 16.5 17.2 17.8 18.5 19.1 19.7 20.4 21.0 21.6 22.3 22.9 23.5 24.2 24.8 25.5

NOVEC 1230 Pre-Engineered AGENT QUANTITY CHART Maximum Volumes at 4.2% Concentration (Continued) 80 lb. Tank Lbs. Agent _____ 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80

Maximum Cubic Ft. Volume ______ 921 944 966 989 1011 1034 1056 1079 1101 1124 1146 1169 1191 1213 1236 1258 1281 1303 1326 1348 1371 1393 1416 1438 1461 1483 1506 1528 1551 1573 1596 1618 1640 1663 1685 1708 1730 1753 1775 1798

Kgs Agent _____ 18.6 19.1 19.5 20.0 20.4 20.9 21.3 21.8 22.2 22.7 23.1 23.6 24.0 24.5 24.9 25.4 25.9 26.3 26.8 27.2 27.7 28.1 28.6 29.0 29.5 29.9 30.4 30.8 31.3 31.8 32.2 32.7 33.1 33.6 34.0 34.5 34.9 35.4 35.8 36.3

Maximum Cubic Meters Volume _______ 26.1 26.7 27.4 28.0 28.6 29.3 29.9 30.5 31.2 31.8 32.5 33.1 33.7 34.4 35.0 35.6 36.3 36.9 37.5 38.2 38.8 39.5 40.1 40.7 41.4 42.0 42.6 43.3 43.9 44.5 45.2 45.8 46.5 47.1 47.7 48.4 49.0 49.6 50.3 50.9

Calculation No. 2 The agent quantity calculated above will either require increasing or decreasing depending on the altitude of the hazard above or below sea level. Refer to the Altitude Correction Factors Chart below. Determine the elevation of the hazard. Find that elevation on the chart, or the closest one to it. Select the correction factor from the chart for that elevation. Multiply the amount of agent, determined in Calculation No. 1, by the correction factor. This will determine the final agent quantity required. Example: From calculation No. 1, it was determined the hazard required 69 lb. (31.3 kg) of agent. The hazard is located at 2000 ft. (610 m) above sea level. Referring to the Altitude Correction Factor Chart, at that elevation, the correction factor is 0.93. Multiply 69 lb (31.3 kg) X 0.93 = 64.7 lb. (29.4 kg). Therefore, 65 lb. (29.5 kg) of agent is required for this hazard.

SECTION III – SYSTEM DESIGN UL EX-4510 5-15-03 Page 17

SYSTEM DESIGN REQUIREMENTS (Continued)

DETECTION REQUIREMENTS

Step No. 2 – Determine quantity of agent required (Continued)

See “AUTOPULSE Detection and Control Systems Design, Installation, Programming, and Maintenance Manual” and Detection CD for complete detection design requirements.

Atmospheric Correction Factors Chart Altitude Above Sea Level Correction Factor ____________________ ______________ –3000 ft. (–0.92 km) 1.11 –2000 ft. (–0.61 km) 1.07 –1000 ft. (–0.30 km) 1.04 0 ft. (0.00 km) 1.00 1000 ft. (0.30 km) 0.96 2000 ft. (0.61 km) 0.93 3000 ft. (0.91 km) 0.89 4000 ft. (1.22 km) 0.86 5000 ft. (1.52 km) 0.82 6000 ft. (1.83 km) 0.78 7000 ft. (2.13 km) 0.75 8000 ft. (2.45 km) 0.72 9000 ft. (2.74 km) 0.69 10000 ft. (3.05 km) 0.66

ACTUATION REQUIREMENTS Pneumatic actuation can actuate up to 10 or 11 SAPPHIRE agent tanks depending on the type of actuation design chosen. Two options of pneumatic actuation are available: Option No. 1 – Master SAPPHIRE tank off an ANSUL AUTOMAN II-C releasing devise and then additional slave SAPPHIRE tanks off the master tank or Option No. 2 – All SAPPHIRE tanks directly off an ANSUL AUTOMAN II-C releasing device. Option No. 1 – Master/Slave option – This option allows 11 SAPPHIRE tanks to be simultaneous actuated from the nitrogen pressure from the ANSUL AUTOMAN II-C releasing device. The first tank is actuated pneumatically via a pneumatic actuator located on top of the tank valve. The remaining 10 tanks are actuated through the pilot pressure ports on the side of the each tank valve.

Step No. 3 – Determine Nozzle and Tank Location(s) The discharge nozzle must be located as close to the center of the hazard area as possible. To determine nozzle and tank locations, refer to “General Information” in the Installation Section for details on maximum pipe lengths, maximum number of elbows, maximum vertical rise of piping, etc. If the hazard design required several tanks, tanks sizes can vary, as long as the volume of protection for each tank does not exceed the maximum volumes listed in the “AGENT QUANTITY CHART.” If multiple tanks are required, each nozzle must be centered within the designed area of coverage. Example: It has been determined that a hazard, with a net volume of 3596 cu. ft. (101.8 cu. m), requires 160 lb. (72.6 kg) of agent, after the elevation factor has been calculated in. The hazard can be divided into modules, each not exceeding the maximum volume allowed per quantity of agent. After each module has been selected, the nozzle protecting individual areas, must be centered within that area. See Figure 1. .2 NO LE U D MO LE DU MO

.1 NO

NOZZLE CENTERED IN MODULE

1/4 IN. ACTUATION PIPING 120 FT. (36.6 m) MAXIMUM LENGTH

100 FT. (36.6 m) MAXIMUM LENGTH

SAFETY RELIEF VALVE

ANSUL AUTOMAN II-C RELEASE

ANSUL AUTOPULSE CONTROL PANEL

MASTER TANK

SLAVE TANK

SOLENOID ACTUATOR

SLAVE TANK

SLAVE TANK

SLAVE TANK

OPTION 1: 1 MASTER + 10 SLAVES = 11 TOTAL TANKS MAXIMUM NOTE: ANY SIZE PARTIAL FILLED TANKS CAN BE ACTUATED SIMULTANEOUSLY

ELECTRIC SOLENOID ACTUATOR OPTION

NOZZLE LOCATION

MODULE VOLUME MUST NOT EXCEED MAXIMUM TANK COVERAGE

The maximum actuation line length from the Master tank valve to the last Slave tank valve is 100 ft. (30.5 m) (including all drops to the valves) of 1/4 in. stainless steel hose or stainless steel tubing. See Figure 2.

WIRING TO ANSUL AUTOPULSE CONTROL PANEL

NOZZLE LOCATION NOZZLE CENTERED IN MODULE

The maximum actuation line length from the ANSUL AUTOMAN II-C release is 120 ft. (36.6 m) of 1/4 in. Schedule 40 piping or stainless hose or tubing to the pneumatic actuator located on the Master tank valve. See Figure 2.

MASTER TANK

FIGURE 2 006773

NOTE: ONE NOZZLE PER TANK MAXIMUM

FIGURE 1 006772

SECTION III – SYSTEM DESIGN 5-15-03 Page 18 UL EX-4510

ACTUATION REQUIREMENTS (Continued) Option No. 2 – All tanks actuated directly from ANSUL AUTOMAN II-C option – This option allows 10 SAPPHIRE tanks to be simultaneous actuated from the nitrogen pressure from the ANSUL AUTOMAN II-C releasing device. All tanks are actuated pneumatically via a pneumatic actuator located on top of each tank valve. The maximum length of 1/4 in. Schedule 40 piping or stainless hose or tubing that can be utilized from the ANSUL AUTOMAN II-C release to actuate one pneumatic valve actuator is 120 ft. (36.6 m) (including all drops to the valves). When additional tanks are required, refer to Actuation Piping Table below for maximum actuation pipe length. Actuation Piping Chart (For Option No. 2) Quantity of Pneumatic Actuated Valves _____________ 1 2 3 4 5 6 7 8 9 10

Maximum Length of 1/4 in. Actuation Line _________________ 120 ft. (36.6 m) 118 ft. (35.9 m) 116 ft. (35.4 m) 114 ft. (34.7 m) 112 ft. (34.1 m) 110 ft. (33.5 m) 108 ft. (32.9 m) 106 ft. (32.3 m) 104 ft. (31.7 m) 102 ft. (31.1 m)

Note: It is important to note that the actuation lengths listed include branch lines to accessory items (pressure switches, pressure trips, etc.). For each actuation line accessory, deduct a foot from the above maximum lengths. NOTE: ANY SIZE PARTIAL FILLED TANKS CAN BE ACTUATED SIMULTANEOUSLY 1/4 IN. ACTUATION PIPING MAXIMUM 120 FT. (36.6 m) INCLUDING DROPS TO PNEUMATIC ACTUATOR(S)

SAFETY RELIEF VALVE

ANSUL AUTOMAN II-C RELEASE

10 TANKS MAXIMUM OPTION 2

FIGURE 3 006774

SECTION IV – INSTALLATION UL EX-4510 5-15-03 Page 19

All installations are to be performed in accordance with the parameters of this manual and all appropriate codes and standards from the local, state, and federal authority having jurisdiction. Before the SAPPHIRE fire suppression system is installed, the qualified installer should have developed a sketch in order to locate the equipment, to determine an actuation and distribution piping routing (refer to Piping/Nozzle Design and Actuation Requirements, located in SECTION V – DESIGN, for both actuation and distribution piping for limitations). For successful system performance, the SAPPHIRE system components must be located within their approved temperature ranges. The system components and the hazard area must be within a temperature range between 0 °F to 120 °F (–17.8 °C to 49 °C). MOUNTING TANK AND BRACKET ASSEMBLY !

CAUTION

Do not remove the outlet safety shipping cap until tank is securely mounted in the bracket. Failure to comply could result in personal injury or death from violent tank movement or overexposure to high concentrations of Novec 1230 agent. 1. Mount the back channels (supplied by others) for the mounting brackets to a rigid, vertical surface at the appropriate heights. See Figure 1. Make sure to use suitable fastening hardware.

INSTALLING DISTRIBUTION PIPING General Piping Requirements • Use Schedule 40 black iron, galvanized, chrome-plated, or stainless steel pipe conforming to ASTM A53, or A106. All fittings must be 300 lb. Class minimum. Distribution pipe sizes are 1 in. (40 lb. tank only) and 1 1/4 in. (80 lb. tank only). • Pipe unions are acceptable. • Cast iron pipe and fittings are not acceptable. • PTFE (Teflon) tape is the only acceptable pipe sealant and must be applied to male threads only. NOTICE Do not allow tape to overlap the pipe opening, as this could cause possible blockage of the gas pressure. Thread sealant or compound must not be used. • Before assembling the pipe and fittings, make certain all ends are carefully reamed and blown clear of chips and scale. Inside of pipe and fittings must be free of oil and dirt. • All pipe lengths are measured center to center of fittings. • Hangers must be placed within 12 in. (30.5 cm) of the discharge nozzle. • Hangers must be mounted to a structure capable of supporting the weight of the pipe. Piping and Nozzle Installation 1. With the tank properly secured in the bracket, remove the discharge outlet safety shipping cap.

Tank Size ____ 40 lb.

No. of Unistrut Channels ________ 1

80 lb.

1

Height from Floor to Bracket Centerline _______________ 13.0 in. (330 mm) 23.5 in. (595 mm)

FIGURE 1 006732

2. Position the tank against the back channel with the valve outlet pointing to the left. 3. Insert the tank straps at top and bottom and secure with the bolts provided.

2. If utilizing a 1 in. discharge hose, connect the hose directly to the valve outlet. If rigid piping directly to the valve, first attach the 1 in. Union Adaptor, Part No. 570557, to the valve outlet. This adaptor is required to convert the outlet BSP threads to NPT. 3. Continue piping remainder of distribution piping, following the piping sketch completed in System Design Section. 4. Verify that the nozzle location is correct and rigidly mount the nozzle and connect to the distribution piping. Make certain not to exceed the piping and elbow limitations as stated in “PIPING AND NOZZLE DESIGN REQUIREMENTS” in the System Design Section. INSTALLATION DETECTION SYSTEM All detection and control design and installation requirements are located on the ANSUL AUTOPULSE DETECTION AND CONTROL SYSTEMS TECHNICAL CD, No. 2001093. INSTALLATION ACTUATION PIPING General Actuation Piping Requirements 1. Use only 1/4 in. Schedule 40 black iron, hot-dipped galvanized, chrome-plated, or stainless steel pipe/braided hose and fittings conforming to ASTM A120, A53, or A106. 2. Before assembling the pipe and fittings, make certain all ends are carefully reamed and blown clear of chips and scale. Inside of pipe and fittings must be free of oil and dirt.

SECTION IV – INSTALLATION 5-15-03 Page 20 UL EX-4510

INSTALLATION ACTUATION PIPING (Continued)

2. Remove actuation port protector cap from the valve assembly and install the pneumatic actuator, hand tighten. See Figure 3.

General Actuation Piping Requirements (Continued) 3. The piping and fitting connections must be sealed with pipe tape. When applying pipe tape, start at the second male thread and wrap the tape (two turns maximum clockwise around the threads, away from the pipe opening.

PNEUMATIC ACTUATOR

NOTICE Do not allow tape to overlap the pipe opening, as this could cause possible blockage of the gas pressure. Thread sealant or compound must not be used. 4. Cast iron pipe and fittings are not acceptable. 5. Actuation piping must be rigidly supported by UL listed hangers. 6. Refer to “ACTUATION REQUIREMENTS – OPTIONS 1 AND 2” in Design Section for detailed piping limitations. FIGURE 3

Actuation Piping Installation

006776

3. Install 1/4 in. actuation piping/hose from gas outlet port on the ANSUL AUTOMAN II-C release to the tank(s) location.

Install actuation gas line by completing the following: !

4. If pneumatic operated accessories are required, branch off the 1/4 in. actuation piping and run to each accessory.

CAUTION

Piston in each pneumatic valve actuator must be in the “UP” position before installing on valve. If piston is not in the “UP” position, tank may actuate, causing personal injury or property damage. 1. Make certain the piston in each pneumatic actuator is in the “UP” position. See Figure 2.

5. Complete actuation piping from the NPT pipe to the pneumatic actuator(s) using the 1/4 in. stainless steel hose and fittings listed in the Component Section. 6. Install safety relief valve, Part No. 15677, in the last fitting of the actuation piping. See Figure 4. 1/4 IN. ACTUATION LINE

LAST FITTING IN ACTUATION LINE SAFETY RELIEF VALVE, PART NO. 15677

1/4 IN. STAINLESS STEEL HOSE TO PNEUMATIC ACTUATOR

FIRED

COCKED APPROX. 3/16 IN. (4.5 mm)

RESET

FIGURE 2 006775

FIGURE 4 006765

SECTION V – INSPECTION UL EX-4510 5-15-03 Page 21

Inspection is a “quick check” that a system is operable. It is intended to give reasonable assurance that the system is fully charged and will operate. This is done by seeing that the system has not been tampered with and there is no obvious physical damage, or condition, to prevent operation. The value of an inspection lies in the frequency, and thoroughness, with which it is conducted. Systems should be inspected at regular monthly intervals, or at more frequent intervals when circumstances require. The following visual checks should be performed during a SAPPHIRE system inspection: • Visually inspect the hazard area to verify that it has not changed. Look for different fuels, new equipment, blocked open doors or dampers. • Check detectors to make certain they are in place, not damaged or coated with dirt, grease, paint, or any contaminating substance. • Check all manual pull stations to assure they have not been tampered with and are not blocked from use. • Check all alarm devices for damage, dirt, corrosion, etc. • Check that the piping is secure and nozzles are in place. Make certain the nozzles are not covered with dirt, grease, or paint and that there is nothing structural blocking the discharge. • Visually inspect all components for signs of damage, such as disconnected or loose parts, corrosion, twisted or dented components, etc. • Check each SAPPHIRE tank gauge to determine that tank pressure is in the operable range. • Visually verify that the control panel and/or releasing device is functioning properly. • Perform any other checks that may be required by the authority having jurisdiction. • Record that the system has been inspected and inform the proper personnel.

SECTION V – INSPECTION 5-15-03 Page 22 UL EX-4510

NOTES:

SECTION VI – MAINTENANCE UL EX-4510 5-15-03 Page 23

Annual Maintenance Examination Systems shall be maintained at regular intervals, not more than one year apart, or when specifically indicated by an inspection. Maintenance is a “thorough check” of the system. It is intended to give maximum assurance that a system will operate effectively and safely. It includes a thorough examination and any necessary repair, recharge, or replacement. It will reveal if there is a need for hydrostatic testing of the tank. The procedures listed in this section are the minimum that are necessary to maintain a system. If circumstances warrant them, a more thorough procedure should be followed to assure system performance. Make certain that all people affected by the maintenance are informed before you start. This may include the owner, security personnel, the local Fire Department, and possibly local workers that may be affected by equipment shutdown or start up. NOTICE If the system includes an ANSUL AUTOMAN II-C releasing device, before proceeding with annual maintenance examination, insert lock pin in ANSUL AUTOMAN II-C release and remove nitrogen cartridge. Install safety shipping cap on cartridge. 1. Survey the hazard to make certain it has not changed from what the system was designed to protect. While surveying the hazard, look for different fuels, loss of hazard integrity, new hazards, etc. 2. Check all nozzles to make certain they are in place. Check the condition of the nozzle for corrosion or damage and make certain it is not obstructed internally or externally. 3. Check the condition of the piping to make certain that it is properly secured in the hangers and that all fittings are connected tightly. 4. Check all warning nameplates (signs) throughout the area. Make certain they are in place, mounted securely, readable, and are not damaged. 5. Check all tank bracketing. Make certain all tanks are secured in the brackets. Check for corrosion, damage, or missing components. 6. Check the condition of all tanks. Look for signs of damage or corrosion, and check the tank’s last hydro date. (NFPA 2001 states “Cylinders continuously in service without discharging shall be given a complete external visual inspection every five years or more frequently if required. The visual inspection shall be in accordance with Compressed Gas Association Pamphlet C-6, Section 3; except that the cylinders need not be emptied or stamped while under pressure.”) Refer to NFPA 2001, Chapter 4 Inspection, Maintenance, Testing, and Training, for hydro requirements. 7. Check condition of all tank discharge hoses. Look for signs of structural problems like abrasions or weather checking. Make certain all hoses are connected properly. All hoses must be tested every 5 years. Refer to NFPA 2001, Chapter 4 Inspection, Maintenance, Testing, and Training, for detailed testing requirements.

8. Check condition of all actuators by completing the following: • Remove all actuators from the tank valves (both electric and pneumatic) and leave them off until the final step in Maintenance Section. • For pneumatic actuators, check the condition of each actuator to make certain they operate freely. When finished, reset the pin in the up position. Do not install on tank valves. • For electric actuators, make certain all wires are properly connected. Do not install on tank valves. NOTICE Before proceeding with Step No. 9, make certain all electric actuators have been removed from all valves and that the nitrogen cartridge has been removed from the ANSUL AUTOMAN II-C release and that the locking pin in the release mechanism has also been removed. 9. Check condition of control panel for tampering, corrosion, or damage. Test panel at this point by referring to the appropriate AUTOPULSE Control System manual. Note: If system includes an ANSUL AUTOMAN II-C release, make certain cartridge is removed, release is cocked, and locking pin is not in place before each test. 10. Check all detectors. Make certain they are in place, clean, and not damaged. If required, check the sensitivity of each per the instructions of the detector manufacturer. See appropriate AUTOPULSE Control System manual for detailed instructions. 11. Check all pull stations. Make certain they are in place, that they are not blocked or damaged. Operate each pull station to make certain that they operate the control panel. Reset each pull station. 12. While checking the detectors and electric pull stations, inspect each alarm device. Check the alarm’s condition and verify that they operate properly when energized. Reset the alarm circuit after each test. 13. If the system includes an ANSUL AUTOMAN, check release by completing the following: • Make certain locking pin is not in place, and manually test release by operating the “STRIKE” button on the release mechanism. • Cock ANSUL AUTOMAN II-C release using cocking lever, Part No. 26310, and install locking pin. • Remove gasket from cartridge receiver in ANSUL AUTOMAN II-C release mechanism. Check gasket for elasticity or cuts and replace if necessary. Clean and coat gasket lightly with a good grade of extreme temperature grease such as Dow Corning No. 4. Reinstall gasket into cartridge receiver. Do not install cartridge at this time. 14. When all tests are complete, reset control panel and all accessory electrical equipment. 15. Make certain all electric and pneumatic actuators are reset. 16. Install all electric and pneumatic actuators on tank valves. Hand tighten.

SECTION VI – MAINTENANCE 5-15-03 Page 24 UL EX-4510

17. Install nitrogen cartridge in ANSUL AUTOMAN II-C release by completing the following: • Make certain release mechanism is cocked and locking bar is in place. • Remove shipping cap and weigh nitrogen cartridge. Replace if weight is 1/2 oz. (14.2 g), or more, below the weight stamped on the cartridge. • Screw cartridge into release mechanism, hand tighten. • Remove locking pin. • Close cover on enclosure, install locking pin through “STRIKE” button, and secure with visual seal, Part No. 197. 18. Record annual maintenance date on tag attached to unit and/or in a permanent file. 19. Inform proper personnel that the system is back in service.

SECTION VII – RESETTING AND RECHARGE UL EX-4510 5-15-03 Page 25

CLEARING ELECTRICAL EQUIPMENT Refer to AUTOPULSE Installation, Operation, and Maintenance manuals for detailed instructions on resetting the electric detection system. NOTICE If AUTOPULSE Control System is utilizing an ANSUL AUTOMAN II-C releasing device for pneumatic actuation, AUTOPULSE panel will remain in trouble condition until ANSUL AUTOMAN II-C release is cocked.

e. Remove the piston assembly, Part No. 570551, by pushing up on it from the bottom of the valve. Discard complete piston assembly. f. Remove collar O-ring, and siphon tube O-ring. Discard both. g. Clean all internal valve surfaces. Use caution not to cause any scratching to surfaces. h. Use O-ring kit, Part No. 570559, to replace with all new O-rings. Apply Dow Corning No. 4 lube to all O-rings before installing on components.

CHECK MECHANICAL AND ELECTRICAL EQUIPMENT

i. Push in new piston assembly, Part No. 570551.

Piping and Nozzles

j. Screw in bonnet assembly, including new O-ring. Tighten with spanner wrench.

A fire condition could cause damage to the piping and nozzles and possibly support members. Check all rigid pipe supports and all fitting connections. Take the nozzles off the piping, inspect for damage, corrosion, or obstructions, clean and re-install.

k. Thread in bonnet locking screw followed by washer, chain and socket head cap screw. The cap screw holds the recoil cap chain to the tank valve body. l. Install collar and siphon tube O-ring. Before installing, coat with Dow Corning No. 4 lube.

Electric Detection System ANSUL AUTOMAN II-C RELEASING DEVICE – For complete resetting instructions, refer to Installation, Operation, and Maintenance manuals, Part No. 17788 and 31496. Note: Before resetting release mechanism, bleed pressure from actuation piping by pulling ring on safety relief valve located on end of actuation piping. AUTOPULSE Control System – For complete resetting instructions, refer to the appropriate installation, operation, and maintenance manual.

m. Push siphon tube into base of valve and rotate until locking screw hole in the siphon tube is aligned with the siphon tube locking screw hole in the valve base. Install siphon tube locking screw. n. Do not install valve into tank until Step “g” in “Recharging Instructions, Step 5.” BONNET ASSEMBLY, PART NO. 570543

RECOIL CAP, PART NO. 570553

RECHARGING !

CAUTION

Make certain tanks contain no pressure before removing valves. If tank contains pressure, removing valve could cause violent tank movement, causing personnel injury or property damage.

PISTON ASSEMBLY, PART NO. 570551

1

M4 X 6 MM SOCKET HEAD CAP SCREW STAINLESS STEEL

1. Remove empty SAPPHIRE tanks by removing the actuators (either electric or pneumatic). 2. Remove empty tanks from brackets.

M4 WASHER STAINLESS

3. Tank valves must be cleaned internally and all O-rings replaced prior to tanks being recharged. Follow instructions listed in Step No. 4.

SIPHON TUBE LOCKING SCREW M5 X 10 MM SOCKET HEAD DOG POINT

4. Valve cleaning/O-ring replacement instructions. Refer to Figure 1 for component descriptions. The following components are required for valve rebuilding: • Bonnet assembly, Part No. 570543 • Piston assembly, Part No. 570551 • O-ring kit, Part No. 570559 a. Remove the valve from the tank. b. Remove the siphon tube locking screw to allow removal of the siphon tube from the valve. c. Remove the socket head cap screw that holds the recoil cap chain to the valve body. d. Remove bonnet locking screw from the same port as socket head cap screw mentioned in Step “c” and unscrew the bonnet assembly, Part No. 570543, using the spanner wrench, Part No. 570574. Remove and discard O-ring from bonnet assembly.

BONNET LOCKING SCREW M4 X 10 MM STAINLESS STEEL, DOG POINT

NOTE: O-RING KIT, PART NO. 570559, INCLUDES ITEMS 1, 2, 3

2 3

1 IN. VALVE COMPONENTS

FIGURE 1 006768

SECTION VII – RESETTING AND RECHARGE 5-15-03 Page 26 UL EX-4510

RECHARGING (Continued)

w. Once tank pressure is correct, remove from fill station.

5. Recharging Instructions: a. See Figure 2 for a typical recharge station configuration. b. Install a drier (such as a Hammond DRIERITE filter) in a threaded port on the Novec 1230 agent container. A drier is required because humid air may cause the agent to convert to an acid.

VENT VALVE

VENT VALVE

d. The agent can either be pumped or gravity fed to the tank.

006767

6. Replace recharged tanks in bracket and follow “Installation” procedures to put system back in service. 7. Inform proper personnel that the system is back in service.

k. After correct pressure is reached, close valve near tank valve outlet. l. Close tank valve by using Top Adaptor Assembly, Part No. 570579, as follows. Set regulator to 450 psi (31.0 bar). Pressure Top Adaptor Assembly. Open and close the valve rapidly to prevent over-pressurizing of tank. m. Vent pressure from tank valve outlet. n. Remove Fill Adaptor Assembly and install recoil cap on valve outlet. o. Agitate tank violently so that the agent can absorb the nitrogen. p. Add more nitrogen through the Top Adaptor Assembly. Using the pressure vs. temperature chart at ambient temperature, set the regulated pressure at the corresponding pressure plus 8 psi (.6 bar). It takes 8 psi (.6 bar) to overcome the spring force in the valve core. Note: Do not use gauge on valve to determine recharge pressure. q. Repeat Steps “o” and “q” until the agent has fully absorbed the nitrogen. r. Let tank assembly sit for 3 hours. s. Check the tank valve for leaks by using soap and water solution. t. Check tank gauge pressure based on pressure vs. temperature chart. u. Repeat Step “o.” v. Recheck gauge pressure. If gauge reading decreased, repeat Step “p.”

NOVEC 1230 PRESSURE VS. TEMPERATURE CHART 430 410 390 PRESSURE (PSIG)

j. Set regulator to 20 psi (1.4 bar) lower than the required tank pressure based on ambient temperature. Refer to pressure vs. temperature chart in this section. Pressurize tank. Forcefully agitate tank while pressurizing.

FILTER (20 OR LESS MICRONS)

FIGURE 2

h. Purge tank by pressurizing through a Fill Adaptor Assembly, Part No. 570576, to 100 psi (6.9 bar) with dry nitrogen, then vent pressure. This process will remove humid air from the tank. i. Fill tank with correct amount of agent by weight. See nameplate for this information.

AGENT STORAGE TANK

FILL ADAPTOR

e. Tank must be visually inspected and clean inside. IMPORTANT – no moisture is allowed in the tank. It must be completely dried. Water mixed with agent will cause acid. g. Reinstall valve and siphon tube assembly into tank. Tighten securely.

DRYER

FILL PRESSURE GAUGE

c. The outlet of the container requires an inline (20 micron or smaller) filter.

f. Rebuild valve. See “Valve Rebuild Instructions,” Step 4.

PUMP OR GRAVITY FED

TOP ADAPTOR

370 350 330 310 290 270 250 0

20

40

60 80 TEMPERATURE (F)

100

120

140 006770

Part No. 570527

© 2003 Ansul Incorporated

Litho in U.S.A. ANSUL INCORPORATED MARINETTE, WI 54143-2542