SAPPHIRE™ Pre-Engineered Clean-Agent Manual (PN570527)

8/12/2019 SAPPHIRE Pre-Engineered Clean-Agent Manual (PN570527)

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ANSUL INSTALLATION SAPPHIREOPERATION PRE-ENGINEEREDRECHARGE CLEAN AGENTINSPECTION AND FIREMAINTENANCE SUPPRESSION

MANUAL SYSTEMS

006777


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This manual is intended for use with Ansul SAPPHIRE Clean

Agent Fire Suppression Systems.Those who install, operate, recharge or maintain these fire sup-pression systems should read this entire manual. Specific sec-tions will be of particular interest depending upon ones responsi-bilities.

Design, installation, recharge, and maintenance of the systemmust conform to the limitations detailed in this manual and per-formed by an individual who attended an Ansul training programand became trained to install, recharge, design, and maintain theAnsul system.

Fire suppression systems are mechanical devices. They needperiodic care. Maintenance is a vital step in the performance ofyour fire suppression system. As such it must be performed inaccordance with NFPA 2001 Clean Agent Fire Extinguishing

Systems and this manual, by an authorized Ansul distributor. Toprovide maximum assurance that the fire suppression system willoperate effectively and safely, maintenance must be conducted atsix-months intervals, or earlier if the situation dictates. Refer toNFPA 2001, Paragraph 4-2, for testing and inspection information.

ANSUL PART NO. 570527

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


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SECTION PAGES________ ______

I. GENERAL INFORMATION 1 10

3M NOVEC 1230 FIRE PROTECTION FLUID 1

General Information 1

Storage and Handling Recommendations 1Disposal Information 1

Health and Safety 1 2

DESCRIPTION OF SAPPHIRE SYSTEMS 2

APPROVALS 2

MSDS 3 9

II. SYSTEM COMPONENTS 11 14

NOVEC 1230 LIQUID AGENT 11

AGENT TANK ASSEMBLY 11

TANK BRACKET ASSEMBLY 11

1 IN. FLEXIBLE DISCHARGE HOSE 11

1 IN. UNION ADAPTOR 12

AUTOPULSE CONTROL SYSTEM 12

ANSUL AUTOMAN II-C RELEASING DEVICE 12

(FOR PNEUMATIC ACTUATION)

1 IN. VALVE SHIPPING ASSEMBLY 12

REMOVABLE ELECTRIC ACTUATOR 13

PNEUMATIC ACTUATOR 13

1/4 IN. ACTUATION HOSE 13

1/4 IN. FEMALE ACTUATION HOSE 13

MALE ACTUATION CONNECTOR 14

MALE ACTUATION TEE 14

MALE ACTUATION ELBOW 14

SAFETY RELIEF VALVE 14

DISCHARGE NOZZLE 14

SPANNER WRENCH 14

RECHARGE ADAPTORS 14

WARNING PLATES 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 19 20

MOUNTING TANK AND BRACKET ASSEMBLY 19

INSTALLING DISTRIBUTION PIPING 19

INSTALLING DETECTION SYSTEM 19

INSTALLING ACTUATION PIPING 19 20

V. INSPECTION 21 22

SECTION PAGES________ ______

VI. MAINTENANCE 23 24

VII. RESETTING AND RECHARGE 25 26

CLEARING ELECTRICAL EQUIPMENT 25CHECKING MECHANICAL AND 25

ELECTRICAL EQUIPMENT

RECHARGING 25 26

TABLE OF CONTENTS

UL EX-4510 5-15-03


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3M NOVEC 1230 FIRE PROTECTION FLUID

General Information

3M Novec 1230 Fire Protection Fluid has been developed asan alternative to Halon 1301, production of which has ceased atthe end of 1993, under the agreed adjustments made to theMontreal Protocol in Nov. 1992.

Novec 1230 contains no Bromine or Chlorine and has no ozonedepleting potential.

Novec 1230 systems utilize one or more storage containersarranged to provide the protected area with a pre-determinedquantity of agent.

Novec 1230 storage container are designed to hold Novec 1230 inliquid form. Nitrogen is used to super-pressurize the container to360 psi (24.8 bar) at 70 F (21 C).

Handling and installation of Novec 1230 equipment should only beconducted by persons trained in dealing with this type of equip-ment.

Under normal conditions Novec 1230 is a colorless and low odor

fluid with a density around 11 times greater than air. It has negligi-ble vapor pressure and is super-pressurized with nitrogen to 360psi (24.8 bar) when used in fire suppression applications.

It contains no particulates or oily residues and is produced underISO 9001 guidelines to strict manufacturing specifications ensur-ing product purity.

Present understanding of Novec 1230 is that fire suppression isthrough heat absorption and chemical means.

Novec 1230 decomposes at temperatures in excess of 932 F(500C) and it is therefore important to avoid applications involv-ing hazards where continuously hot surfaces are involved. Uponexposure to the flame, Novec 1230 will decompose to form halo-gen acids.Their presence will be readily detected by a sharp, pun-gent odor before maximum hazardous exposure levels are

reached.Storage and Handling Recommendations

The unique properties of Novec 1230 fluid necessitate the user tofollow certain handling and storage guidelines. Failure to followthese recommendations may result in contamination of the agentand potential failure of the system in which it is used. Contact withwater or solvents either polar or hydrocarbon could render Novec1230 fluid ineffective. Novec 1230 fluid should not be mixed withother extinguishing agents (liquid, powder, or foam) without con-sulting Ansul to determine compatibility.

Novec 1230 fluid should be stored indoors, out of direct sunlight attemperatures below 104 F (40 C). If container must be storedoutdoors, confirm that all openings are fully closed. Protect con-tainer from direct sunlight and precipitation to every extent possi-

ble, and fully dry the exterior of the container prior to opening.Based on the results of accelerated aging studies, Novec 1230fluid is expected to have a shelf life and perform as a clean agentfor at least 30 years in a properly designed, maintained, and oper-ating fire suppression system, provided the agent has been storedand handled in accordance with the information provided in thismanual.

Novec 1230 fluid is a liquid at room temperature allowing it to betransferred using conventional pumping or pouring methods.Novec 1230 fluid has a viscosity similar to water. Consequently, itcan be transferred using any pump that would be used to transporta low viscosity, nonflammable liquid. A gravity feed method mayalso be used to fill the system tanks, in lieu of pumping. If using apump, it is recommended that an inline filter (equal to or less than

20 microns) be used when filling container.

Standards used by the fire protection industry typically specify thatclean agents meet certain standards of quality. In order to main-tain the low water content of the original Novec 1230 fluid, proce-dures must be used to prevent the entry of moist, ambient air into

the storage containers.When transferring fluid, the receiving con-tainers should be free of water and purged with dry nitrogen priorto filling with Novec 1230 fluid to remove moisture-laden air. Theend of the fluid dispensing pipe must extend into the receivingcontainer. The dispensing container should be fitted with a ventdrier or nitrogen purge to prevent the influx of moist air as Novec1230 fluid is withdrawn. Vent driers employing disposable or refill-able desiccant cartridges are available from vendors such as W.AHammond Drierite Co. Ltd. Alternatively, a nitrogen purge can beset up by installing a tee onto the vent bung of the dispensingcontainer and establishing flow of dry nitrogen at a volumetric flowrate that is in excess of the rate of withdrawal of Novec 1230 fluidfrom the container.

Good industrial hygiene practices should be followed when han-dling Novec 1230 fluid. Novec 1230 fluid must be used in a well-

ventilated area.Provide local exhaust ventilation at transfer pointsIf adequate ventilation cannot be accomplished to maintain airconcentrations below the recommended exposure guideline, userespiratory protection. The use of vented goggles for eye protection is required when handling Novec 1230 fluid. Always weargloves when handling Novec 1230 fluid. Gloves made from butyrubber are recommended.For more specific information regardingthe use of Novec 1230 fluid, refer to the Material Safety DataSheet.

Disposal Recommendations

Novec 1230 fluid may be disposed using an approved industrial orcommercial incinerator. Since Novec 1230 fluid is nonflammableit must be burned in the presence of a combustible material. Refeto the Material Safety Data Sheet, section 13, for additiona

details.Health and Safety

A proper designed and installed suppression system should notpresent any significant health or safety problems. However, thereare basic precautions to be taken to avoid accidents, and aspectsof the system operation that should be understood.

Reference should be made to NFPA 2001 for the toxic andasphyxiating hazards of clean agent replacement for Halon 1301.

Novec 1230 agent has acceptable toxicity for use in occupiedspaces when used as specified in the United StatesEnvironmental Protection Agency (EPA) proposed Significant NewAlternative Policy (SNAP) program rules and NFPA 2001, CleanAgent Fire Extinguishing Systems.

Novec 1230 agent extinguishes by causing a chemical reactionwith the combustion products, and does not remove oxygen likeCO2 and some other inert agents.

Therefore, exposure to Novec 1230 at the design concentration ofup to 10.0% is not a hazard to health.Exposure to higher concentrations is permissible for limited periods. Refer to NFPA 2002 forexposure requirements. As with halons, the EPA and the NationaFire Protection Association (NFPA) recommend that unnecessaryexposure to any agent be avoided and that personnel evacuateprotected areas as quickly as possible to avoid the decompositionproducts of the fire.

Novec 1230 can decompose at high temperatures to form acids. Ifso, their presence is readily detected as a sharp, pungent odorlong before hazardous maximum exposure levels are reached.

SECTION I GENERAL INFORMATION

UL EX-4510 5-15-03 Page 1


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3M NOVEC 1230 FIRE PROTECTION FLUID (Continued)

Health and Safety (Continued)

The noise created by the Novec 1230 agent discharging can beloud enough to startle people in the vicinity, but is unlikely to causeany permanent injury.Turbulence caused by the high velocity dis-

charge can dislodge substantial objects directly in its path, andcause general turbulence within the protected area to move paperand light objects.

Direct contact with the vaporizing liquid discharged from a Novec1230 nozzle has a chilling effect on objects and in extreme casescan cause frostbite to the skin. The liquid phase vaporizes rapidlywhen mixed with air and therefore limits the risk to the immediatevicinity of the nozzle. Reduction in visibility will occur due to thecondensation of water vapor.

DESCRIPTION OF SAPPHIRE SYSTEMS

SAPPHIRE systems are designed to suppress fires in Class A, B(minimum Class B design concentration is 5.85%; contact Ansulfor all Class B applications), and C hazards.

Novec 1230 suppress fires by a combination of physical andchemical means. It does not significantly deplete the oxygen con-tent in the room and tests have shown it to be less toxic than Halon1301.

A system comprises one or more containers connected to a sys-

tem of piping and nozzles. Novec 1230 is liquid under pressureand is stored in steel containers, each of which is fitted with a valvespecially designed to allow the contents of the container to dis-charge within 10 seconds. When the valve opens, Novec 1230flows into the distribution piping to the discharge nozzles where itis rapidly dispersed as a vapor.

Discharged Novec 1230 gives the appearance of a fog which mayreduce visibility. This normally clears rapidly and should notobstruct the ability of personnel to safely exit the protected area.

SAPPHIRE Fire Suppression Systems are particularly valuable inextinguishing fires in enclosures containing hazards or equipmentwhere a clean, electrically non-conductive medium is essential orwhere the cleaning up of foam, water or dry chemical would be aproblem.

APPROVALS

The SAPPHIRE Fire Suppression System has been tested andlisted by Underwriters Laboratories, Inc. (EX-4510) andUnderwriters Laboratories of Canada (CEX1151) as a pre-engi-neered system for Class A, B, and C fire suppression, at temper-atures between 0 F to 130 F (18 C to 55 C).


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CAUTION!

The discharge of clean agent systems to extinguish a fire canresult in a potential hazard to personnel from the natural formof the clean agent or from the products of combustion thatresult from exposure of the agent to the fire or hot surfaces.Unnecessary exposure of personnel either to the products ofdecomposition shall be avoided.


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NOTES:


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3M NOVEC 1230 FIRE PROTECTION FLUID

Novec 1230 fluid has been developed as a halon replacementalternative to HFCs, HCFCs, and PFCs in special hazard, highvalue applications. It has unique qualities that provide the right bal-ance of fire extinguishing performance, end use safety, and envi-

ronmental sustainability. Novec 1230 fluid is low in toxicity andenvironment impact. It is a liquid at room temperature, with a lowvapor pressure, which allows for ease in handling, storage, andshipping.

Novec 1230 is available is two sizes of containers:

Part No. 570533 30 gallon Drum Shipping Assembly

Part No. 570534 220 gallon Tote Shipping Assembly

AGENT TANK ASSEMBLY

The agent storage tanks are manufactured in accordance withDOT4BW450 and consist of a tank fitted with a valve and internalsiphon tube. Tanks are available in two sizes: 40 lb. and 80 lb. Anameplate is adhered to the tank displaying the agent weight, andgross weight.

Note: Quantity of agent will have to specified on customer P.Owhen 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 1006758

Tank Part No. A B C____ _______ _______ _______ _______

40 lb. 570636 23 in. 19.6 in. 10 in.(18 kg) (588 mm) (499 mm) (254 mm)

80 lb. 570637 36 in. 32.7 in. 10 in.(36 kg) (920 mm) (831 mm) (254 mm)

TANK BRACKET ASSEMBLY

The bracket assembly consists of a nut, bolt, and two bracketstraps (back channel must be supplied by others. Approved typeof Unistrut Channel is series P1000T, 1.6 in. x 1.6 in. (41 mm x41 mm). To securely hold the tank in position during system dis-

charge, two bracket assemblies are required per tank.Each strap is notched for insertion into the channel, allowing thetank to be properly aligned. The bracket assembly is designed tobe mounted to a r igid vertical surface with the tank assembly rest-ing fully on the floor or rigid surface.

Part No. 570085 Bracket Shipping Assembly

FIGURE 2006759

1 IN. FLEXIBLE DISCHARGE HOSE

The flexible discharge hose is connected to the rigid distributionpiping. A swivel fitting at the inlet of the hose enables the tankvalve to be coupled to the hose. The hose is 16 in. (406 mm) inlength.

Part No. 570539 1 in. Flexible Discharge Hose ShippingAssembly

FIGURE 3006760

SECTION II SYSTEM COMPONENTS

UL EX-4510 5-15-03 Page 11

B

A

C

15.7 IN.(400 mm)

1 IN. BSP 90FEMALE SWIVELUNION

1 IN.NPTTHREAD (FIXED)

16 IN.(406 mm)

3 IN.(79 mm)


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1 IN. UNION ADAPTOR

The 1 in. union adaptor is required to attach the valve outlet to rigidpiping. The adaptor has a BSP thread on the valve end and anNPT thread on the pipe end.

Part No. 570557 1 in. Union Adaptor Shipping Assembly

FIGURE 4006761

AUTOPULSE CONTROL SYSTEMThe AUTOPULSE Control system is designed to monitor fixed firehazards. The control system can automatically actuate the firesuppression system after receiving an input signal from one ormore initiating devices, i.e., manual pull station or detector. Thecontrol system incorporates an internal power supply, on-lineemergency batteries, and solid state electronics. Refer toDetection and Control Manual for additional information.

FIGURE 5002195

ANSUL AUTOMAN II-C RELEASING DEVICE(FOR PNEUMATIC ACTUATION)

The ANSUL AUTOMAN II-C Releasing Device consists of a metalenclosure which contains a spring-loaded puncture pin releasemechanism, an actuation cartridge, electrical circuitry, and aninput/output terminal strip for making electrical connections. The

ANSUL AUTOMAN II-C releasing device provides automaticpneumatic actuation of the SAPPHIRE System.When wired to anAUTOPULSE Control System, it will provide supervised electricdetection and release. It also provides manual actuation using thestrike button on the release enclosure and with optional remotemanual cable pull station. When an AUTOPULSE Control Systemis used, manual actuation is accomplished using an electric man-ual pull station.

The ANSUL AUTOMAN II-C releasing device requires an LT-10-Rnitrogen cartridge for system actuation. Cartridge must be orderedseparately.

Part No. 68739 ANSUL AUTOMAN II-C Releasing DeviceShipping Assembly

Part No. 13193 LT-10-R Nitrogen Cartridge Shipping Assembly(order separately)

Part No. 26310 Cocking Lever (order separate)

FIGURE 6000442

1 IN. VALVE SHIPPING ASSEMBLY

The replacement valve assembly is available for field replacement.The valve is fully assembled, with internal components, gauge andburst disc assembly. The replacement valve is 100% leak testedbefore it leaves the factory.

Part No. 570535 1 in.Valve Shipping Assembly

FIGURE 7006762


5-15-03 Page 12 UL EX-4510

2 1/2 IN.(63.5 mm)

1 IN.NPTTHREAD(PIPE END)

1 IN.BSPTHREAD(VALVE END)

RELEASEMECHANISM

LT-10-RCARTRIDGE(ORDEREDSEPARATELY)

STRIKEBUTTON

NAMEPLATETERMINALBOARD

0 Actuation Port

120 SupervisoryPressure Switch

FlameproofSolenoid Port

180 Burst DiscActuation PortFlameproofSolenoid Port

240 Pressure Gauge

PORT POSITIONS AREDIAGRAMMATIC FOR CLARITY.

PRESSURE GAUGE NOT SHOWN.

0

180

240

270 90

120


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REMOVABLE ELECTRIC ACTUATOR

The 24 VDC electric actuator is required to electrically actuate thetank valve. An electric signal is received from the AUTOPULSEControl Panel which operates the solenoid in the actuator. Thiscauses the actuator to open the tank valve and discharge the

agent. On multiple tank systems, only one electric actuator isrequired, on the master tank valve. The remaining tanks will beactuated pneumatically through 1/4 in. stainless steel hoseinstalled between each pilot pressure port.

Actuator current draw is 0.2A.

Part No. 570537 Removable Electric Actuator ShippingAssembly

FIGURE 8006763

PNEUMATIC ACTUATOR

The pneumatic actuator is required to pneumatically actuate theagent tanks. The actuator operates from pressure received fromthe nitrogen cartridge located in the ANSUL AUTOMAN II-Crelease. When the pneumatic actuator is pressurized, the interna

actuator piston pushes down on the valve stem, opening the tankvalve, allowing the agent to discharge.

Part No. 570550 Pneumatic Actuator Shipping Assembly

FIGURE 9006764

1/4 IN. ACTUATION HOSE

The 1/4 in. stainless steel actuation hose is used to connect the1/4 in. actuation line to the pneumatic actuator located on the tankvalve.This hose is used when the actuation line is rigid 1/4 in. pipeand fittings. The hose has a 1/4 in NPT male thread on one endand a 7/16-20 female thread on the other end. A male straighadaptor, Part No. 32338, is required with this hose.

Part No. 73597 - 1/4 in. Actuation Hose Shipping Assembly

FIGURE 1000043

1/4 IN. FEMALE ACTUATION HOSE

The 1/4 in. stainless steel, female actuation hose is used to con-nect the actuation line compression tees between each agenttank.The hose has the same thread, 7/16-20, as the compressiontees. The actuation hose allows flexibility between the rigid actua-tion piping and the tank valve.

Part No. 32336 1/4 in. Female Actuation Hose ShippingAssembly

FIGURE 11000433


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1.8 IN.(45 mm)

1 IN.BSP

3.3 IN.(85 mm)

Technical InformationSolenoid Enclosure: Mild Steel & Dull NickelActuation Pin: Stainless SteelActuation Type: LatchingPower Requirement: 24V dcCurrent: 0.2AConnection: 1 in. BSPActuation Type: LatchingReset Requirement: Manual Force RequiredManual Actuation Force: 11 lb. Force (5 KgF)Electrical Connection: 3-pin plug connectorDiode Type: SuppressionCertification: Recognized to UL508

Tested in accordance with UL864Temperature Range: 4 F to 131 F (20 C to +55 C)

O-RING

PISTON

ACTUATORBODY

CLIP

16 IN.(40.6 cm)

24 IN.(61 cm)

7/16-20 7/16-20


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MALE ACTUATION CONNECTOR

The male connector is used to connect the 1/4 in. female actuationhose to rigid 1/4 in. actuation fittings and also the pneumatic actu-ator. The connector has a 7/16-20 thread for connecting to theactuation hose and a 1/4 in. NPT thread for connecting to the actu-

ation piping and pneumatic actuator.Part No. 32338 Male Actuation Connection Shipping Assembly

FIGURE 12000434

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 con-necting to the female actuation hose and a 1/4 in. NPT thread forconnecting to the pneumatic actuator on the tank valve.

Part No. 31811 Male Actuation Tee Shipping Assembly

FIGURE 13000435

MALE ACTUATION ELBOW

The male actuation elbow is used to connect the actuation hose toa single or last tank in a multiple tank system.The elbow connectsbetween the hose and the pneumatic actuator on the valve. Theelbow has a 7/16-20 thread for connecting to the hose and a1/4 in. NPT thread for connecting to the pneumatic actuator on thetank valve.

Part No. 31810 Male Actuation Elbow Shipping Assembly

FIGURE 14000436

SAFETY RELIEF VALVE

The safety relief valve is used to relieve the nitrogen pressure inthe actuation line after the system has been actuated by anANSUL AUTOMAN II-C Release. After agent discharge, pullingthe ring on the relief valve can relieve the pressure in the line.

Part No. 15677 Safety Relief Valve Shipping Assembly

FIGURE 150000437

DISCHARGE NOZZLE

Two sizes of discharge nozzles are available: 1 1/4 in. thread sizeto 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

FIGURE 16006771

SPANNER WRENCH

This tool is required to remove the valve bonnet assembly foraccess to the valve piston for O-ring replacement.

Part No. 570574 Spanner Wrench

FIGURE 17006766

RECHARGE ADAPTORS

Recharge adaptors are required to recharge cylinder assembly.

Part No. 570579 Top Adaptor Assembly

Part No. 570576 Fill Adaptor Assembly

WARNING PLATES

Two warning plates are available for warning personnel that thespace is protected by a SAPPHIRE system and no one shouldenter after a discharge without being properly protected. Eachplate is made of aluminum and contains four mounting holes forease of installation.

Part No. 570580 Warning Plate for Outside Room

Part No. 570581 Warning Plate for Inside Room


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7/16-20

1/4-18 NPT

1/4 IN. NPT

7/16-20

7/16-20

1/4 IN. NPT


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This manual has been prepared to give an understanding in theapplication and design of SAPPHIRE systems. Systems are suit-able only for the total flooding of Class A and Class C hazardenclosures.

The SAPPHIRE system is specifically pre-engineered in accor-

dance with the equipment description, hazard type, size, pipinglimitations, nozzle type, installation, operation, recharge, andmaintenance instructions prescribed. All systems must be appliedentirely in accordance with the guidelines described in the manual.

GENERAL INFORMATION

SAPPHIRE systems are approved for hazard and storage tem-peratures 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 x9.8 m)

HAZARD ANALYSIS

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

Enclosure dimensions. Specific details of the hazard, such as chemicals, excessive fire

load, etc.

The minimum and maximum temperatures of the hazard enclo-sure.

Height of hazard above (or below) sea level.

Confirmation that the hazard integrity is adequate.

Details of the ventilation system. Note: Ventilation systemmust be shut down prior to agent discharge.

Intended occupancy of the hazard enclosure.

Tank mounting location. Agent tanks should be located in areaswith suitable ventilation, be protected from fire, not subject toweather, mechanical damage, or corrosion and where they canbe easily accessed for maintenance. Floor loading should alsobe taken into account.

Novec 1230 is suitable for the protection of hazards involvingClass A, Class B and Class C materials. Fires must be detectedquickly and the agent discharged promptly and the concentrationis maintained for an adequate period of time to allow embers tocool, surface fires and embers associated with the burning of solidmaterials are quickly extinguished. Novec 1230 is suitable for useon 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 cel-lulose nitrate.

2. Mixtures containing oxidizing agents, such as sodium chlorateor sodium nitrate.

3. Chemicals capable of undergoing autothermal decompositionsuch 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 adifferent agent.

PIPING AND NOZZLE DESIGN REQUIREMENTS

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

Maximum length of 1 1/4 in. pipe (including the flex dischargehose) for 80 lb. (36 kg) tank is 36 ft. 2 in. (11 m).

In addition to above listed pipe lengths, a maximum of 3 90elbows are allowed.Tee at nozzle (dirt trap assembly) counts asone of the 3 allowed elbows.

Maximum net vertical rise from the bottom of the tank to the tipof the nozzle is 14 ft. (4.3 m).

Only one nozzle allowed per tank.

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

Maximum nozzle area coverage is 32 ft. by 32 ft. (9.8 m by9.8 m).

Nozzle must be located as close to the center of the protectedarea as possible.

Nozzle must be located a maximum of 12 in. (30.5 cm) below thehazard ceiling.

Minimum hazard height is 12 in. (30.5 cm).

PRE-ENGINEERED SYSTEM DESIGN REQUIREMENTS

Total Flooding is the only application method approved forSAPPHIRE Fire Suppression Systems.

After completing the Hazard Analysis, determine the systemdesign requirements by completing the following steps:

Step No. 1 Determine net hazard volume

The first step in designing a SAPPHIRE Fire Suppression Systemis to calculate the net volume of the area being protected. Multiplythe length x the width to determine the area, and then multiply thearea x the height to determine the volume. If the area is an oddshape, the designer may need to divide it into regular shapes thatwill allow volume calculations, and then total all the volumestogether 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 bereduced by the volume of any impermeable, non-removableobjects. Determine the volume of these type objects and subtracthis volume from the hazard volume. This will determine the haz-ard net volume.

Example: There is a support column near a wall in the hazardwhich measures 1 ft. x 1 ft.by 10 ft.high (.3 m x .3 m x 3.1 m).Thevolume of this impermeable, non-removable object is 10 cu. ft(.28 cu. m). Subtracting 10 cu. ft. (.28 cu. m) from the total hazardvolume 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

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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 haz-

ard volume. The second calculation will require multiplying theamount required for the hazard volume, by a factor based on ele-vation, to determine the final quantity of agent required.

Calculation No. 1Refer to AGENT QUANTITY CHART to determine the amount ofagent required for the protected hazard. Referring to theMaximum Cubic Feet Of Volume column, find the hazard volumesize. If the exact volume is not listed on the chart, pick the nextclosest larger volume.

Example: Follow down the maximum volume column until you find1550 cu. ft. (43.9 cu. m). As you will note, the exact number 1550cu. 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 ofagent required.

Example: From the 1551 cu. ft. (43.9 cu. m) position, readingacross the chart to the left, it is determined that 69 lb. (31.3 kg) ofNovec 1230 agent is required to protected this hazard net volume.

NOVEC 1230 Pre-EngineeredAGENT QUANTITY CHARTMaximum Volumes at 4.2% Concentration

40 lb.Tank

Maximum MaximumLbs. Cubic Ft. Kgs Cubic MetersAgent Volume Agent Volume_____ ______ _____ _______16 360 7.3 10.217 382 7.7 10.818 404 8.2 11.519 427 8.6 12.120 449 9.1 12.721 472 9.5 13.422 494 10.0 14.023 517 10.4 14.624 539 10.9 15.325 562 11.3 15.926 584 11.8 16.527 607 12.2 17.228 629 12.7 17.829 652 13.2 18.530 674 13.6 19.131 697 14.1 19.732 719 14.5 20.4

33 742 15.0 21.034 764 15.4 21.635 787 15.9 22.336 809 16.3 22.937 831 16.8 23.538 854 17.2 24.239 876 17.7 24.840 899 18.1 25.5

NOVEC 1230 Pre-EngineeredAGENT QUANTITY CHARTMaximum Volumes at 4.2% Concentration (Continued)

80 lb.Tank

Maximum Maximum

Lbs. Cubic Ft. Kgs Cubic MetersAgent Volume Agent Volume_____ ______ _____ _______41 921 18.6 26.142 944 19.1 26.743 966 19.5 27.444 989 20.0 28.045 1011 20.4 28.646 1034 20.9 29.347 1056 21.3 29.948 1079 21.8 30.549 1101 22.2 31.250 1124 22.7 31.851 1146 23.1 32.552 1169 23.6 33.153 1191 24.0 33.7

54 1213 24.5 34.455 1236 24.9 35.056 1258 25.4 35.657 1281 25.9 36.358 1303 26.3 36.959 1326 26.8 37.560 1348 27.2 38.261 1371 27.7 38.862 1393 28.1 39.563 1416 28.6 40.164 1438 29.0 40.765 1461 29.5 41.466 1483 29.9 42.067 1506 30.4 42.668 1528 30.8 43.3

69 1551 31.3 43.970 1573 31.8 44.571 1596 32.2 45.272 1618 32.7 45.873 1640 33.1 46.574 1663 33.6 47.175 1685 34.0 47.776 1708 34.5 48.477 1730 34.9 49.078 1753 35.4 49.679 1775 35.8 50.380 1798 36.3 50.9

Calculation No. 2The agent quantity calculated above will either require increasingor decreasing depending on the altitude of the hazard above orbelow sea level.

Refer to the Altitude Correction Factors Chart below. Determinethe elevation of the hazard. Find that elevation on the chart, or theclosest one to it. Select the correction factor from the chart for thatelevation. Multiply the amount of agent, determined in CalculationNo. 1, by the correction factor. This will determine the final agentquantity required.

Example: From calculation No. 1, it was determined the hazardrequired 69 lb. (31.3 kg) of agent.The hazard is located at 2000 ft.(610 m) above sea level. Referring to the Altitude CorrectionFactor 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, 65lb. (29.5 kg) of agent is required for this hazard.


5-15-03 Page 16 UL EX-4510


20/30

SYSTEM DESIGN REQUIREMENTS (Continued)

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

Atmospheric Correction Factors Chart

Altitude Above Sea Level Correction Factor____________________ ______________3000 ft. (0.92 km) 1.112000 ft. (0.61 km) 1.071000 ft. (0.30 km) 1.040 ft. (0.00 km) 1.001000 ft. (0.30 km) 0.962000 ft. (0.61 km) 0.933000 ft. (0.91 km) 0.894000 ft. (1.22 km) 0.865000 ft. (1.52 km) 0.826000 ft. (1.83 km) 0.787000 ft. (2.13 km) 0.758000 ft. (2.45 km) 0.729000 ft. (2.74 km) 0.6910000 ft. (3.05 km) 0.66

Step No. 3 Determine Nozzle and Tank Location(s)

The discharge nozzle must be located as close to the center of thehazard area as possible. To determine nozzle and tank locations,refer to General Information in the Installation Section for detailson maximum pipe lengths, maximum number of elbows, maximumvertical 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 exceedthe maximum volumes listed in the AGENT QUANTITY CHART.If multiple tanks are required, each nozzle must be centered with-in the designed area of coverage.

Example: It has been determined that a hazard, with a net volumeof 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 canbe divided into modules, each not exceeding the maximum vol-ume allowed per quantity of agent. After each module has beenselected, the nozzle protecting individual areas, must be centeredwithin that area. See Figure 1.

FIGURE 1006772

DETECTION REQUIREMENTS

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

ACTUATION REQUIREMENTSPneumatic actuation can actuate up to 10 or 11 SAPPHIRE agenttanks depending on the type of actuation design chosen. Twooptions of pneumatic actuation are available: Option No. 1 Master SAPPHIRE tank off an ANSUL AUTOMAN II-C releasingdevise and then additional slave SAPPHIRE tanks off the mastertank or Option No. 2 All SAPPHIRE tanks directly off an ANSULAUTOMAN II-C releasing device.

Option No. 1 Master/Slave option This option allows 11SAPPHIRE tanks to be simultaneous actuated from the nitrogenpressure from the ANSUL AUTOMAN II-C releasing device. Thefirst tank is actuated pneumatically via a pneumatic actuator locat-ed on top of the tank valve. The remaining 10 tanks are actuatedthrough the pilot pressure ports on the side of the each tank valve

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

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

FIGURE 2006773


UL EX-4510 5-15-03 Page 17

NOZZLELOCATION

NOZZLECENTEREDIN MODULE

NOZZLECENTERED

IN MODULE

NOZZLELOCATION

MODULEVOLUME MUSTNOT EXCEEDMAXIMUMTANKCOVERAGE NOTE: ONE NOZZLE

PER TANKMAXIMUM

MODU

LENO

.1MO

DULE

NO.2

MASTERTANK

MASTER TANK

SLAVETANK

SLAVETANK

SLAVETANK

SLAVETANK

OPTION 1: 1 MASTER + 10 SLAVES =11 TOTAL TANKSMAXIMUM

NOTE: ANY SIZE PARTIAL FILLEDTANKS CAN BE ACTUATEDSIMULTANEOUSLY

SAFETYRELIEFVALVE

1/4 IN. ACTUATION PIPING120 FT. (36.6 m) MAXIMUM LENGTH 100 FT. (36.6 m)

MAXIMUM LENGTH

ANSULAUTOMAN II-CRELEASE

ANSULAUTOPULSECONTROLPANEL

ELECTRICSOLENOIDACTUATOROPTION

SOLENOIDACTUATOR

WIRING TOANSUL AUTOPULSECONTROL PANEL


21/30

ACTUATION REQUIREMENTS (Continued)

Option No. 2 All tanks actuated directly from ANSUL AUTOMANII-C option This option allows 10 SAPPHIRE tanks to be simul-taneous actuated from the nitrogen pressure from the ANSULAUTOMAN II-C releasing device. All tanks are actuated pneumat-

ically via a pneumatic actuator located on top of each tank valve.The maximum length of 1/4 in. Schedule 40 piping or stainlesshose or tubing that can be utilized from the ANSUL AUTOMANII-C release to actuate one pneumatic valve actuator is 120 ft.(36.6 m) (including all drops to the valves).When additional tanksare required, refer to Actuation Piping Table below for maximumactuation pipe length.

Actuation Piping Chart (For Option No. 2)

Quantity of Pneumatic Maximum Length ofActuated Valves 1/4 in. Actuation Line_____________ _________________

1 120 ft. (36.6 m)2 118 ft. (35.9 m)3 116 ft. (35.4 m)4 114 ft. (34.7 m)

5 112 ft. (34.1 m)6 110 ft. (33.5 m)7 108 ft. (32.9 m)8 106 ft. (32.3 m)9 104 ft. (31.7 m)

10 102 ft. (31.1 m)

Note: It is important to note that the actuation lengths listed includebranch lines to accessory items (pressure switches, pressuretrips, etc.). For each actuation line accessory, deduct a foot fromthe above maximum lengths.

FIGURE 3006774


5-15-03 Page 18 UL EX-4510

10 TANKS MAXIMUM

OPTION 2

SAFETYRELIEF

VALVE

1/4 IN. ACTUATION PIPING MAXIMUM120 FT. (36.6 m) INCLUDING DROPS

TO PNEUMATIC ACTUATOR(S)

ANSULAUTOMAN II-CRELEASE

NOTE: ANY SIZE PARTIAL FILLED TANKS CAN BEACTUATED SIMULTANEOUSLY


22/30

All installations are to be performed in accordance with the para-meters of this manual and all appropriate codes and standardsfrom the local, state, and federal authority having jurisdiction.

Before the SAPPHIRE fire suppression system is installed, thequalified installer should have developed a sketch in order to

locate the equipment, to determine an actuation and distributionpiping routing (refer to Piping/Nozzle Design and ActuationRequirements, located in SECTION V DESIGN, for both actua-tion and distribution piping for limitations).

For successful system performance, the SAPPHIRE system com-ponents must be located within their approved temperatureranges. The system components and the hazard area must bewithin a temperature range between 0 F to 120 F (17.8 C to49 C).

MOUNTING TANK AND BRACKET ASSEMBLY

1. Mount the back channels (supplied by others) for the mount-ing brackets to a rigid, vertical surface at the appropriateheights. See Figure 1. Make sure to use suitable fasteninghardware.

FIGURE 1006732

2. Position the tank against the back channel with the valve out-let pointing to the left.

3. Insert the tank straps at top and bottom and secure with the

bolts provided.

INSTALLING DISTRIBUTION PIPING

General Piping Requirements

Use Schedule 40 black iron, galvanized, chrome-plated, orstainless steel pipe conforming to ASTM A53, or A106. All fit-tings 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 mustbe applied to male threads only.

NOTICEDo not allow tape to overlap the pipe opening, asthis could cause possible blockage of the gaspressure. Thread sealant or compound mustnot be used.

Before assembling the pipe and fittings, make certain all endsare carefully reamed and blown clear of chips and scale. Insideof 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 dischargenozzle.

Hangers must be mounted to a structure capable of supportingthe weight of the pipe.

Piping and Nozzle Installation

1. With the tank properly secured in the bracket, remove the discharge outlet safety shipping cap.

2. If utilizing a 1 in. discharge hose, connect the hose directly tothe valve outlet. If rigid piping directly to the valve, first attachthe 1 in. Union Adaptor, Part No. 570557, to the valve outletThis adaptor is required to convert the outlet BSP threads toNPT.

3. Continue piping remainder of distribution piping, following thepiping sketch completed in System Design Section.

4. Verify that the nozzle location is correct and rigidly mount thenozzle and connect to the distribution piping. Make certain notto exceed the piping and elbow limitations as stated in PIP-ING AND NOZZLE DESIGN REQUIREMENTS in theSystem Design Section.

INSTALLATION DETECTION SYSTEM

All detection and control design and installation requirements arelocated on the ANSUL AUTOPULSE DETECTION AND CON-TROL SYSTEMS TECHNICAL CD, No. 2001093.

INSTALLATION ACTUATION PIPING

General Actuation Piping Requirements

1. Use only 1/4 in. Schedule 40 black iron, hot-dipped galva-nized, chrome-plated, or stainless steel pipe/braided hose andfittings conforming to ASTM A120, A53, or A106.

2. Before assembling the pipe and fittings, make certain all endsare carefully reamed and blown clear of chips and scale.Inside of pipe and fittings must be free of oil and dirt.

SECTION IV INSTALLATION

UL EX-4510 5-15-03 Page 19

CAUTION!

Do not remove the outlet safety shipping cap until tank is

securely mounted in the bracket. Failure to comply could resultin personal injury or death from violent tank movement or over-exposure to high concentrations of Novec 1230 agent.

No. of Height fromTank Unistrut Floor toSize Channels Bracket Centerline____ ________ _______________40 lb. 1 13.0 in.

(330 mm)

80 lb. 1 23.5 in.

(595 mm)


23/30

INSTALLATION ACTUATION PIPING (Continued)

General Actuation Piping Requirements (Continued)

3. The piping and fitting connections must be sealed with pipetape. When applying pipe tape, start at the second malethread and wrap the tape (two turns maximum clockwise

around the threads, away from the pipe opening.NOTICE

Do not allow tape to overlap the pipe opening, asthis could cause possible blockage of the gaspressure. Thread sealant or compound mustnot be used.

4. Cast iron pipe and fittings are not acceptable.

5. Actuation piping must be rigidly supported by UL listed hang-ers.

6. Refer to ACTUATION REQUIREMENTS OPTIONS 1 AND2 in Design Section for detailed piping limitations.

Actuation Piping Installation

Install actuation gas line by completing the following:

1. Make certain the piston in each pneumatic actuator is in theUP position. See Figure 2.

FIGURE 2006775

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

FIGURE 3006776

3. Install 1/4 in. actuation piping/hose from gas outlet port on the

ANSUL AUTOMAN II-C release to the tank(s) location.

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

5. Complete actuation piping from the NPT pipe to the pneumat-ic actuator(s) using the 1/4 in. stainless steel hose and fittingslisted in the Component Section.

6. Install safety relief valve, Part No. 15677, in the last fitting ofthe actuation piping. See Figure 4.

FIGURE 4006765

SECTION IV INSTALLATION

5-15-03 Page 20 UL EX-4510

CAUTION!

Piston in each pneumatic valve actuator must be in the UPposition before installing on valve. If piston is not in the UPposition, tank may actuate, causing personal injury or propertydamage.

PNEUMATICACTUATOR

1/4 IN. STAINLESSSTEEL HOSE TOPNEUMATICACTUATOR

SAFETY RELIEFVALVE, PARTNO. 15677

1/4 IN. ACTUATION LINELAST FITTING INACTUATION LINE

FIRED

RESET

COCKEDAPPROX. 3/16 IN.(4.5 mm)


24/30

Inspection is a quick check that a system is operable. It is intend-ed to give reasonable assurance that the system is fully chargedand will operate. This is done by seeing that the system has notbeen tampered with and there is no obvious physical damage, orcondition, to prevent operation. The value of an inspection lies inthe frequency, and thoroughness, with which it is conducted.

Systems should be inspected at regular monthly intervals, or atmore frequent intervals when circumstances require.

The following visual checks should be performed during aSAPPHIRE system inspection:

Visually inspect the hazard area to verify that it has not changed.Look for different fuels, new equipment, blocked open doors ordampers.

Check detectors to make certain they are in place, not damagedor coated with dirt, grease, paint, or any contaminating sub-stance.

Check all manual pull stations to assure they have not been tam-pered 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. Makecertain the nozzles are not covered with dirt, grease, or paintand that there is nothing structural blocking the discharge.

Visually inspect all components for signs of damage, such asdisconnected or loose parts, corrosion, twisted or dented com-ponents, etc.

Check each SAPPHIRE tank gauge to determine that tank pres-sure is in the operable range.

Visually verify that the control panel and/or releasing device isfunctioning properly.

Perform any other checks that may be required by the authorityhaving jurisdiction.

Record that the system has been inspected and inform the prop-

er personnel.

SECTION V INSPECTION

UL EX-4510 5-15-03 Page 21


25/30

NOTES:

SECTION V INSPECTION

5-15-03 Page 22 UL EX-4510


26/30

Annual Maintenance Examination

Systems shall be maintained at regular intervals, not more thanone year apart, or when specifically indicated by an inspection.

Maintenance is a thorough check of the system. It is intended togive maximum assurance that a system will operate effectively

and safely. It includes a thorough examination and any necessaryrepair, recharge, or replacement. It will reveal if there is a need forhydrostatic testing of the tank. The procedures listed in this sectionare the minimum that are necessary to maintain a system. If cir-cumstances warrant them, a more thorough procedure should befollowed to assure system performance.Make certain that all peo-ple affected by the maintenance are informed before you start.This may include the owner, security personnel, the local FireDepartment, and possibly local workers that may be affected byequipment shutdown or start up.

NOTICEIf the system includes an ANSUL AUTOMANII-C releasing device, before proceeding withannual maintenance examination, insert lockpin in ANSUL AUTOMAN II-C release and

remove nitrogen cartridge. Install safety ship-ping cap on cartridge.

1. Survey the hazard to make certain it has not changed fromwhat the system was designed to protect. While surveying thehazard, look for different fuels, loss of hazard integrity, newhazards, etc.

2. Check all nozzles to make certain they are in place.Check thecondition of the nozzle for corrosion or damage and make cer-tain it is not obstructed internally or externally.

3. Check the condition of the piping to make certain that it isproperly secured in the hangers and that all fittings are con-nected 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 securedin the brackets.Check for corrosion, damage, or missing com-ponents.

6. Check the condition of all tanks. Look for signs of damage orcorrosion, and check the tanks last hydro date. (NFPA 2001states Cylinders continuously in service without dischargingshall be given a complete external visual inspection every fiveyears or more frequently if required. The visual inspectionshall be in accordance with Compressed Gas AssociationPamphlet C-6, Section 3; except that the cylinders need not beemptied or stamped while under pressure.) Refer to NFPA2001, Chapter 4 Inspection, Maintenance, Testing, andTraining, for hydro requirements.

7. Check condition of all tank discharge hoses. Look for signs ofstructural problems like abrasions or weather checking. Makecertain all hoses are connected properly. All hoses must betested every 5 years. Refer to NFPA 2001, Chapter 4Inspection, Maintenance, Testing, and Training, for detailedtesting requirements.

8. Check condition of all actuators by completing the following:

Remove all actuators from the tank valves (both electric andpneumatic) and leave them off until the final step inMaintenance Section.

For pneumatic actuators, check the condition of each actu-

ator to make certain they operate freely. When finishedreset the pin in the up position. Do not install on tankvalves.

For electric actuators, make certain all wires are properlyconnected. Do not install on tank valves.

NOTICEBefore proceeding with Step No. 9, make cer-tain all electric actuators have been removedfrom all valves and that the nitrogen cartridgehas been removed from the ANSULAUTOMAN II-C release and that the lockingpin in the release mechanism has also beenremoved.

9. Check condition of control panel for tampering, corrosion, o

damage.Test panel at this point by referring to the appropriateAUTOPULSE Control System manual. Note: If systemincludes an ANSUL AUTOMAN II-C release, make certaincartridge is removed, release is cocked, and locking pin is notin place before each test.

10. Check all detectors. Make certain they are in place, clean, andnot damaged. If required, check the sensitivity of each per theinstructions of the detector manufacturer. See appropriateAUTOPULSE Control System manual for detailed instruc-tions.

11. Check all pull stations. Make certain they are in place, thathey are not blocked or damaged.Operate each pull station tomake certain that they operate the control panel. Reset eachpull station.

12. While checking the detectors and electric pull stations, inspeceach alarm device.Check the alarms condition and verify thathey operate properly when energized. Reset the alarm circuitafter each test.

13. If the system includes an ANSUL AUTOMAN, check releaseby completing the following:

Make certain locking pin is not in place, and manually tesrelease by operating the STRIKE button on the releasemechanism.

Cock ANSUL AUTOMAN II-C release using cocking leverPart No. 26310, and install locking pin.

Remove gasket from cartridge receiver in ANSULAUTOMAN II-C release mechanism. Check gasket for elas-ticity or cuts and replace if necessary. Clean and coat gas

ket lightly with a good grade of extreme temperature greasesuch as Dow Corning No. 4. Reinstall gasket into cartridgereceiver. Do not install cartridge at this time.

14. When all tests are complete, reset control panel and all acces-sory electrical equipment.

15. Make certain all electric and pneumatic actuators are reset.

16. Install all electric and pneumatic actuators on tank valvesHand tighten.

SECTION VI MAINTENANCE

UL EX-4510 5-15-03 Page 23


27/30

17. Install nitrogen cartridge in ANSUL AUTOMAN II-C release bycompleting the following:

Make certain release mechanism is cocked and locking baris in place.

Remove shipping cap and weigh nitrogen cartridge.

Replace if weight is 1/2 oz. (14.2 g), or more, below theweight stamped on the cartridge.

Screw cartridge into release mechanism, hand tighten.

Remove locking pin.

Close cover on enclosure, install locking pin throughSTRIKE button, and secure with visual seal, Part No. 197.

18. Record annual maintenance date on tag attached to unitand/or in a permanent file.

19. Inform proper personnel that the system is back in service.

SECTION VI MAINTENANCE

5-15-03 Page 24 UL EX-4510


28/30

CLEARING ELECTRICAL EQUIPMENT

Refer to AUTOPULSE Installation, Operation, and Maintenancemanuals for detailed instructions on resetting the electric detectionsystem.

NOTICE

If AUTOPULSE Control System is utilizing anANSUL AUTOMAN II-C releasing device forpneumatic actuation, AUTOPULSE panel willremain in trouble condition until ANSULAUTOMAN II-C release is cocked.

CHECK MECHANICAL AND ELECTRICAL EQUIPMENT

Piping and Nozzles

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

Electric Detection System

ANSUL AUTOMAN II-C RELEASING DEVICE For completeresetting instructions, refer to Installation, Operation, andMaintenance manuals, Part No. 17788 and 31496. Note: Beforeresetting release mechanism, bleed pressure from actuationpiping by pulling ring on safety relief valve located on end ofactuation piping.

AUTOPULSE Control System For complete resetting instruc-tions, refer to the appropriate installation, operation, and mainte-nance manual.

RECHARGING

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

2. Remove empty tanks from brackets.

3. Tank valves must be cleaned internally and all O-ringsreplaced prior to tanks being recharged. Follow instructionslisted in Step No. 4.

4. Valve cleaning/O-ring replacement instructions. Refer toFigure 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 ofthe siphon tube from the valve.

c. Remove the socket head cap screw that holds the recoilcap chain to the valve body.

d. Remove bonnet locking screw from the same port as sock-et head cap screw mentioned in Step c and unscrew thebonnet assembly, Part No. 570543, using the spannerwrench, Part No. 570574. Remove and discard O-ring frombonnet assembly.

e. Remove the piston assembly, Part No. 570551, by pushingup on it from the bottom of the valve.Discard complete pis-ton assembly.

f. Remove collar O-ring, and siphon tube O-ring. Discardboth.

g. Clean all internal valve surfaces. Use caution not to causeany scratching to surfaces.

h. Use O-ring kit, Part No. 570559, to replace with all newO-rings. Apply Dow Corning No.4 lube to all O-rings beforeinstalling on components.

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

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

k. Thread in bonnet locking screw followed by washer, chainand socket head cap screw. The cap screw holds the recoicap chain to the tank valve body.

l. Install collar and siphon tube O-ring. Before installing, coatwith Dow Corning No. 4 lube.

m. Push siphon tube into base of valve and rotate until lockingscrew hole in the siphon tube is aligned with the siphontube locking screw hole in the valve base. Install siphontube locking screw.

n. Do not install valve into tank until Step g in RechargingInstructions, Step 5.

FIGURE 1006768

SECTION VII RESETTING AND RECHARGE

UL EX-4510 5-15-03 Page 25

CAUTION!

Make certain tanks contain no pressure before removing

valves. If tank contains pressure, removing valve could causeviolent tank movement, causing personnel injury or propertydamage.

2

1

3

BONNET ASSEMBLY,PART NO. 570543

RECOIL CAP,PART NO.570553

BONNET LOCKINGSCREW M4 X 10 MMSTAINLESS STEEL,

DOG POINT

M4 X 6 MMSOCKET HEADCAP SCREWSTAINLESSSTEEL

SIPHON TUBELOCKING SCREWM5 X 10 MMSOCKET HEADDOG POINT

1 IN. VALVE COMPONENTS

M4 WASHERSTAINLESS

NOTE: O-RING KIT,PART NO. 570559,

INCLUDES ITEMS 1, 2, 3

PISTONASSEMBLY,PART NO.

570551


29/30

RECHARGING (Continued)

5. Recharging Instructions:

a. See Figure 2 for a typical recharge station configuration.

b. Install a drier (such as a Hammond DRIERITE filter) in athreaded port on the Novec 1230 agent container. A drieris required because humid air may cause the agent to con-vert to an acid.

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

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

e. Tank must be visually inspected and clean inside. IMPOR-TANT no moisture is allowed in the tank. It must becompletely dried. Water mixed with agent will causeacid.

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

g. Reinstall valve and siphon tube assembly into tank.Tightensecurely.

h. Purge tank by pressurizing through a Fill AdaptorAssembly, Part No. 570576, to 100 psi (6.9 bar) with drynitrogen, then vent pressure. This process will removehumid air from the tank.

i. Fill tank with correct amount of agent by weight.See name-plate for this information.

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

k. After correct pressure is reached, close valve near tankvalve 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 valverapidly to prevent over-pressurizing of tank.

m. Vent pressure from tank valve outlet.

n. Remove Fill Adaptor Assembly and install recoil cap onvalve outlet.

o. Agitate tank violently so that the agent can absorb thenitrogen.

p. Add more nitrogen through the Top Adaptor Assembly.Using the pressure vs. temperature chart at ambient tem-perature, set the regulated pressure at the correspondingpressure plus 8 psi (.6 bar). It takes 8 psi (.6 bar) to over-come the spring force in the valve core. Note: Do not usegauge on valve to determine recharge pressure.

q. Repeat Steps o and q until the agent has fully absorbedthe nitrogen.

r. Let tank assembly sit for 3 hours.

s. Check the tank valve for leaks by using soap and watersolution.

t. Check tank gauge pressure based on pressure vs. tem-perature chart.

u. Repeat Step o.

v. Recheck gauge pressure. If gauge reading decreased,repeat Step p.

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

FIGURE 2006767

6. Replace recharged tanks in bracket and follow Installationprocedures to put system back in service.

7. Inform proper personnel that the system is back in service.

SECTION VII RESETTING AND RECHARGE

5-15-03 Page 26 UL EX-4510

NOVEC 1230 PRESSURE VS.TEMPERATURE CHART430

410

390

370

350

330

310

290

270

2500 20 40 60 80 100 120 140

TEMPERATURE (F)

PRESSURE

(PSIG)

AGENT

STORAGE TANK

FILTER (20 ORLESS MICRONS)

FILLPRESSUREGAUGE

VENTVALVE

VENT

VALVE

PUMP ORGRAVITYFED DRYER

FILLADAPTOR

TOPADAPTOR

006770


30/30

7

2003AnsulIncorporated

LithoinU.S.A.

ANSUL INCORPORATED

MARINETTE, WI 54143-2542

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SAPPHIRE™ Pre-Engineered Clean-Agent Manual (PN570527)

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