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HomeMy WebLinkAboutRANGE GUARD.pdfR LISTEDP/N 60-9127100-000 January 2007 LISTED ULC EX3559/CEX887UL300 Listed and Tested U.L. EX-2458 Design, Installation, Operation and Maintenance Manual P/N 9127100 i January 2007 Foreword Note:This Manual, P/N 9127100, is to be used by qualified and factory-trained personnel, knowledgeable of NFPA standards, and any other applicable standards in effect. This manual is intended to describe the design, installation, operation and maintenance of Wet Chemical Fire Suppression Systems. Badger Fire Protection assumes no responsibility for the application of any systems other than those addressed in this manual. The technical data contained herein is limited strictly for informational purposes only. Badger Fire Protection believes this data to be accurate, but it is published and presented without any guarantee or warranty whatsoever. Badger Fire Protection disclaims any liability for any use that may be made of the data and information contained herein by any and all other parties. Any questions concerning the information presented in this manual should be addressed to: Badger Fire Protection 4251 Seminole Trail Charlottesville, VA 22911 Phone: (434) 973-4361 Toll Free: (800) 446-3857 Fax: (800) 248-7809 January 2007 ii P/N 9127100 Terms and Abbreviations Listings and Approvals UL: Underwriters’ Laboratories Listing File Number - UL EX2458 MEA: New York City Department of Buildings Materials & Equipment Acceptance Division - 94-95-E °C: °Centigrade lb.: Pound °F: °Farenheit LPF: Low Proximity Fryer AC: Alternating Current LPR: Low Proximity Range ADA: Americans with Disabilities Act m: Meter ADP: Appliance-Duct-Plenum MAX.: Maximum AHJ: Authority Having Jurisdiction MEA: Materials and Equipment Acceptance AMP: Ampere MIN.: Minimum AWG: American Wire Gauge mm: Millimeter AC: Alternating Current NC: Normally Closed C: Common NEC: National Electrical Code CGA: Compressed Gas Association NFPA: National Fire Protection Association CSA: Canadian Standards Association NO: Normally Open DC: Direct Current NPT: National Pipe Thread DIOM: Design, Installation, Operation, and Main- tenance Manual P/N: Part Number DM: Mesquite PSI: Pounds per Square Inch DOT: Department of Transportation PTFE: Polytetrafluoroethylene (Teflon) EMT: Electrical Metallic Tubing R: Range F: Fryer QTY: Quantity ft.: Feet SVA: System Valve Actuator GRW: Gas Radiant/Wok TC: Transport Canada HMIS: Hazardous Materials Information System UL/ULI: Underwriters Laboratories, Inc. HP: Horse Power Vac: Volts AC HZ: Hertz (Frequency) Vdc: Volts DC in.: Inch WHMIS: Workplace Hazardous Materials Informa- tion System P/N 9127100 iii January 2007 Safety Summary Definitions •Note: Notes are used to call out information that requires extra attention. •Caution: Cautions are placed throughout the manual in areas where the possibility of property/equipment damage. The general cautions in the Safety Summary should be adhered to at all times when working with a BadgerRange Guard Wet Chemical System. •Warning: Warnings are placed throughout the manual in areas where the possibility of severe property/equip- ment damage, system failure, personal injury, and in some cases, death could occur. The general warnings in the Safety Summary should be adhered to at all times when working with a Range Guard Fire Systems Wet Chemical System. General Warnings • Protective eye wear must always be worn when working with pressurized cylinders. Never service the Cylin- der and Valve Assembly unless the Anti-Recoil Plate (P/N 255681) and Shipping Inspection Plate (P/N 255096) are installed. Death, serious injury or property damage could occur. • Under no circumstances while performing cylinder recharge should a charged cylinder be allowed to “free stand” without either the charging apparatus attached or the anti-recoil plate installed. Whenever these devices are not installed, a charged cylinder must be securely clamped to a rigid structure capable of with- standing the full thrust that would result should the valve inadvertently open. • It is possible that applications involving flammable or combustible liquids and greases could be enclosed within or surrounded by areas that are classified as Class-I or Class-II, Division-1 or Division-2 locations (Zone 1 or Zone 2). Wet chemical system electrical components, such as heat detectors, located within these areas shall be rated for use in classified areas as required, and all wiring to these components shall conform to the provisions of NFPA 70, National Electric Code, for Class-I or Class-II, Division-1 or Division-2 locations (Zone 1 or Zone 2), as required. Consult NFPA Standard 70 and NFPA Standard 96 for proper installation of electrical components within and adjacent to grease extraction exhaust systems and grease vapor producing appliances • Do not use oxygen to blow out piping. The use of oxygen is very dangerous as the possible presence of even a minute quantity of oil may cause an explosion, thereby causing death, serious injury and/or property damage. • The system uses high pressure. Safety goggles or glasses must be worn. Loosen the fitting slowly and care- fully. Bleed all pressure out gradually. Failure to observe these cautions could result in bodily injury. • The braided High-Pressure Nitrogen Tubing, is required on all installations in which the UCH Control System is connected to a System Valve Actuator (SVA). Use of a different type of connection in such an installation could result in serious personal injury and/or malfunction of the system. • Never dispose of a pressurized cartridge. Cartridges must be discharged before discarding. Filled gas car- tridges may be dangerous if not handled properly. Do not heat cartridges above 120°F (49°C). Death, serious injury and/or property damage could occur. Pressurized cartridges that become overheated can explode, and thereby cause property damage, severe personal injury, and possibly death. WARNING January 2007 iv P/N 9127100 General Cautions • Where electric detection and/or actuation is provided, supervision shall be provided in accordance with NFPA 17A. Alarms and indicators, along with a supervisory power source, shall be provided in accordance with NFPA 72, National Fire Alarm Code. Electrical wiring and equipment shall be provided in accordance with NFPA 70, National Electric Code. All installations are subject to the approval of the Authority Having Juris- diction (AHJ). • When using the UCH Control System, a System Nitrogen Cartridge, P/N B120043, is required for final system set up. When using the A+ Control Box, a CO2 Cartridge, P/N 9197203, is required for final system setup. Using any other cartridge could cause malfunction or non-function of the system. • No action shall be taken by the system owner other than visual. If further maintenance is determined neces- sary as a result of owner inspection, contact an authorized Badger Distributor. • Do not attempt to recharge any cylinder with out first checking for last hydrostatic test date. The U.S. Depart- ment of Transportation (DOT) and Transport Canada (TC) has ruled that any pressurized container of the type used in dry chemical systems shall not be recharged or transported with out first being inspected inter- nally and externally and hydrostatically tested if more than five (5) years have elapsed since the date of the last hydrostatic test. Regardless of previous inspection dates, it is illegal to refill any pressurized container that leaks, which bulges, has defective safety devices, bears evidence of physical abuse, fire or heat damage, or detrimental rusting or corrosion, until it is properly repaired and requalified as specified in DOT and TC regulations. For more information, refer to Compressed Gas Association (CGA) Pamphlet C-6. GENERAL PRECAUTIONS The following general safety precautions are to be observed at all times: 1. All electrical components associated with equipment shall be installed and grounded in accordance with NEC and local regulatory requirements. 2. Special precautionary measures are essential to prevent applying power to equipment at any time maintenance work is in progress. 3. Before working on electrical equipment, use a voltmeter to ensure that system is not energized. 4. When working near electricity, do not use metal rulers, flashlights, metallic pencils, or any other objects having exposed conductive material. 5. When connecting a meter to terminals for measurement, use a voltage range higher than expected voltage to be measured. CAUTION P/N 9127100 v January 2007 Pressurized Cylinders The Range Guard fire suppression systems use pressurized equipment; therefore, personnel responsible for fire suppression systems must be aware of the dangers associated with the improper handling, installation or main- tenance of this equipment. Fire suppression system service personnel must be thoroughly trained in the proper handling, installation and service of Range Guard equipment and follow the instructions used in this manual and on the cylinder nameplate. Badger has provided warnings and cautions at appropriate locations throughout the text of this manual. These warnings and cautions are to be adhered to at all times. Failure to do so may result in property/equipment damage, serious personal injury, and even death. SAFETY BULLETIN 1, MARCH 2, 1987 SUBJECT: SAFE CYLINDER HANDLING PROCEDURES Pressurized (charged) cylinders are extremely hazardous and if not handled properly are capable of violent discharge. This may result in death, serious personal injury, and/or property damage. Before handling Badger system products, all personnel must be thoroughly trained in the safe handling of the cyl- inders as well as in the proper procedures for installation, removal, filling, and connection of other critical devices, such as System Valve Actuators (SVAs). READ, UNDERSTAND and ALWAYS FOLLOW the operation and maintenance manuals, owners manuals, service manuals, etc., that are provided with the individual systems. The following safety procedures must be observed at all times: Moving Cylinders: Cylinders must be shipped compactly in the upright position, and properly secured in place. Containers must not be rolled, dragged or slid, nor allowed to be slid from tailgates of vehicles. A suitable hand truck, fork truck, roll platform or similar device must be used. Rough Handling: Cylinders must not be dropped or permitted to strike violently against each other or other sur- faces. Storage: Cylinders must be stored standing upright where they are not likely to be knocked over, or the cylinders must be secured. For additional information on safe handling of compressed gas cylinders, see CGA Pamphlet PI titled “Safe Han- dling of Compressed Gases in Containers”. CGA pamphlets may be purchased from The Compressed Gas Asso- ciation, Crystal Square Two, 1725 Jefferson Davis Highway, Arlington, VA 22202. WARNING January 2007 vi P/N 9127100 SAFETY BULLETIN, May 1, 1993 SUBJECT: SAFE CYLINDER HANDLING PROCEDURES SUBJECT: SAFE CYLINDER HANDLING PROCEDURES FOR 175 PSI BADGER WET CHEMICAL CYLINDERS Pressurized (charged) cylinders are extremely hazardous and if not handled properly are capable of violent discharge. This will result in serious bodily injury, death and property damage. BEFORE handling Badger system products, all personnel must be thoroughly trained in the safe handling of the containers as well as in the proper procedures for installation, removal, filling, and connection of other critical devices, such as System Valve Actuators (SVAs). READ, UNDERSTAND and ALWAYS FOLLOW the operation and maintenance manuals, owners manuals, service manuals and other information that is provided with the individual systems. THESE INSTRUCTIONS MUST BE FOLLOWED IN THE EXACT SEQUENCE AS WRITTEN TO PREVENT SERIOUS INJURY, DEATH OR PROPERTY DAMAGE. Anti-Recoil Plate a. Each Badger Range Guard cylinder is factory equipped with a Anti-Recoil Plate installed on the valve outlet to prevent loss. This device is a safety feature, and will provide controlled safe discharge when installed if the cylinder is actuated accidentally. b. The valve diffuser plate must be installed in the valve outlet AT ALL TIMES except when the cylinders are connected into the system piping or being filled, at which time the cylinders shall be securely attached to bracket mounts. Valve Protection Plate/Shipping Cap A Valve Protection Plate/Shipping Cap is factory installed on the actuation port to prevent loss. The Valve Protec- tion Plate/Shipping Cap is attached to the actuation port to prevent tampering or depression of the actuating pin. No attachments (e.g., System Valve Actuators) are to be connected to the actuation port during shipment, storage or handling. WARNING P/N 9127100 vii January 2007 CHAPTER 1 GENERAL INFORMATION 1-1 Introduction............................................................................................................1-1 1-2 Classification of Fire...............................................................................................1-1 1-3 General Characteristics of the Badger System ........................................................1-1 1-4 System Description.................................................................................................1-2 1-5 Operational Sequence.............................................................................................1-3 1-6 Applications and Limitations of Wet Chemicals ......................................................1-4 1-6.1 Extinguishing Properties.........................................................................................1-4 1-7 Hazardous Materials Information System (HMISSM)..............................................1-4 1-8 Workplace Hazardous Materials Information System (WHMIS) ..............................1-5 1-9 Clean-up .................................................................................................................1-5 CHAPTER 2 COMPONENT DESCRIPTION 2-1 Suppression Components.......................................................................................2-2 2-1.1 Cylinder and Valve Assembly, P/N B12000X...........................................................2-2 2-1.1.1 Cylinder Brackets ...................................................................................................2-4 2-1.1.1.1 Floor Mount Bracket Kit, P/N 100010.....................................................................2-5 2-1.1.2 Discharge Adapter Kit, P/N 844908 ........................................................................2-6 2-1.1.3 Discharge Nozzles...................................................................................................2-7 2-1.1.3.1 ADP Nozzle, P/N B120011.......................................................................................2-9 2-1.1.3.2 F Nozzle, P/N B120012 ...........................................................................................2-9 2-1.1.3.3 GRW Nozzle, P/N B120013 .....................................................................................2-10 2-1.1.3.4 R Nozzle, P/N B120014...........................................................................................2-10 2-1.1.3.5 DM Nozzle, P/N B120015........................................................................................2-11 2-1.1.3.6 LPF Nozzle, P/N B120022.......................................................................................2-11 2-1.1.3.7 LPR Nozzle, P/N B120024.......................................................................................2-12 2-1.1.3.8 Swivel Adapter, P/N B120021 .................................................................................2-12 2-2 Controls..................................................................................................................2-13 2-2.1 UNIVERSAL CONTROL HEAD (UCH) Control System, P/N B120099 .....................2-13 2-2.1.1 System Nitrogen Cartridge, P/N B120043 ...............................................................2-14 2-2.1.2 Test Cartridge, P/N B120044..................................................................................2-14 2-2.1.3 System Valve Actuator (SVA), P/N B120042............................................................2-15 2-2.1.4 High-Pressure Nitrogen Tubing, P/N B120045 ........................................................2-16 2-2.1.5 Solenoid, P/N B100034...........................................................................................2-17 2-2.1.6 Microswitch Kit, P/N B120039, B120039-501 (For UCH) .......................................2-18 2-2.1.7 Terminal Type Microswitch Kit, P/N B120047 (For UCH).......................................2-19 2-2.2 A+ Control Box, P/N B120010................................................................................2-20 2-2.2.1 CO2 Cartridge, P/N 9197203 ..................................................................................2-21 2-2.2.2 Cable Tension Block, P/N 9197220.........................................................................2-21 2-2.2.3 Single SPDT Microswitch Kit, P/N 9197227 (For A+) .............................................2-22 2-2.2.4 Dual SPDT Microswitch Kit, P/N 9197228 (For A+) ...............................................2-23 2-2.3 Automatic Detectors and Accessories...................................................................... 2-24 2-2.3.1 Detector Housing Kit, P/N 804548 (UCH Only)........................................................2-24 2-2.3.2 Universal-Link Housing Kit, P/N 120064.................................................................2-25 2-2.3.3 Thermo-Bulb Links, P/N B12009X-XXX .................................................................2-26 2-2.3.4 Fusible-Links, P/Ns B282661, B282662, B282664 and B282666...........................2-27 2-2.3.5 Fusible-Link, P/N 9196903 .....................................................................................2-28 TABLE OF CONTENTS January 2007 viii P/N 9127100 TABLE OF CONTENTS (CONT.) 2-2.3.6 Electrical Detection (Detect-A-Fire)..........................................................................2-28 2-2.3.7 Corner Pulley, P/N B844648....................................................................................2-29 2-2.3.8 Tee Pulley, P/N 843791 (UCH only) .........................................................................2-30 2-2.4 Remote Manual Releases.........................................................................................2-31 2-2.4.1 Remote Manual Release, P/N B875572 (UCH ONLY) ...............................................2-31 2-2.4.2 Remote Manual Release Pull Station, P/N 87-120110-001.......................................2-32 2-2.4.3 Surface Mounted Remote Manual Control...............................................................2-33 2-2.4.4 Recess Mounted Remote Manual Control for A+ Control Box and UCH Control Box..........................................................................................................................2-34 2-3 Auxiliary Components.............................................................................................2-36 2-3.1 Pneumatic Release, P/N 9189412 ............................................................................2-36 2-3.2 Pressure Switch, P/N 9197023................................................................................2-37 2-3.3 Mechanical Gas Valve, P/N B12007X.......................................................................2-38 2-3.4 Electric Gas Valve, P/N 9197XXX............................................................................2-39 2-3.5 Manual Reset Relay for Electric Gas Valve, P/N 9101735 ........................................2-40 2-3.6 EMT and O-Ring Connector Kit, P/N B120058 ........................................................2-41 2-3.7 1/16-inch Control Cable, P/N 219649......................................................................2-41 2-3.8 Crimp Sleeve, P/N 214951.......................................................................................2-41 2-3.9 “S” Hooks, P/N 9189413 .........................................................................................2-42 2-3.10 Crimping Tool, P/N 253538.....................................................................................2-42 2-3.11 1/2-inch Vent Plug, P/N 9196984.............................................................................2-43 2-3.12 Keeper Pin, P/N 9197108 ........................................................................................2-43 2-3.13 System Recharge.....................................................................................................2-43 CHAPTER 3 SYSTEM DESIGN 3-1 Introduction ............................................................................................................3-1 3-2 Design Procedure ....................................................................................................3-1 3-2.1 General Design Procedure.......................................................................................3-1 3-2.1.1 Hazard Analysis ......................................................................................................3-1 3-2.1.2 Nozzle Selection and Location.................................................................................3-2 3-2.1.3 Cylinder Determination (Number, Size, and Location of Cylinder(s)) ......................3-2 3-2.1.4 Detector Selection ...................................................................................................3-2 3-2.1.5 Piping Layout ..........................................................................................................3-2 3-2.1.6 Auxiliary Requirements...........................................................................................3-2 3-3 Designing for Appliance Protection..........................................................................3-3 3-3.1 Nozzle Height ..........................................................................................................3-4 3-3.2 Nozzle Aim ..............................................................................................................3-4 3-3.3 Hazard Area ............................................................................................................3-4 3-4 Appliances...............................................................................................................3-5 3-4.1 Single Vat Deep Fat Fryer With Drip Boards ...........................................................3-6 3-4.2 18-1/2 in. x 24-1/2 in. Deep Fat Fryer With Drip Board...........................................3-7 3-4.3 Split Vat Deep Fat Fryer..........................................................................................3-8 3-4.4 14 in. x 14 in. (356 mm x 356 mm) Deep Fat Fryer ................................................3-9 3-4.5 Single Vat Deep Fat Fryer (with Dripboards less than 1 in. [25 mm])......................3-10 3-4.6 Split Vat Fryer (Low Proximity Application) ............................................................3-11 3-4.7 Low Proximity Nozzle for Deep Fat Fryer ................................................................3-12 3-4.8 Krispy Kreme Model 270 d/h Doughnut Fryer.........................................................3-14 3-4.9 Four Burner Ranges................................................................................................3-15 P/N 9127100 ix January 2007 TABLE OF CONTENTS (CONT.) 3-4.10 Two Burner Ranges ................................................................................................3-16 3-4.11 Single Burner Range...............................................................................................3-17 3-4.12 Four Burner Ranges (LPR), P/N B120024...............................................................3-18 3-4.13 Upright Broilers......................................................................................................3-20 3-4.14 Charbroilers (Lava, Pumice, Ceramic or Synthetic Rock)........................................3-21 3-4.15 Gas Radiant/Electric Charbroiler............................................................................3-22 3-4.16 Natural or Mesquite Charcoal Charbroiler..............................................................3-23 3-4.17 Mesquite Logs Charbroiler......................................................................................3-24 3-4.18 Chain Broiler (Closed-Top).....................................................................................3-25 3-4.19 Chain Broiler (Open-Top) .......................................................................................3-26 3-4.20 Griddle — Flat Cooking Surface (With or without Raised Ribs) ..............................3-27 3-4.21 Wok ........................................................................................................................ 3-28 3-4.22 Tilt SkilletS (Braising Pans)....................................................................................3-29 3-5 Module Protection (Multiple Nozzles)......................................................................3-30 3-5.1 Example — Module Protection of Fryers With Dripboards Less Than 1 in. (25 mm)3-30 3-5.2 Example — Single Vat Deep Fat Fryer — With Dripboards 1 in. (25 mm) to 6 in. (152 mm)........................................................................................................3-32 3-6 Ventilation ..............................................................................................................3-33 3-6.1 Plenums..................................................................................................................3-33 3-6.1.1 Ducts ...................................................................................................................... 3-35 3-6.1.1.1 Protection of Ducts 0 to 50 inches in Perimeter......................................................3-35 3-6.1.1.2 Ducts 50 to 100 inches in Perimeter.......................................................................3-36 3-6.1.1.3 Designing For Large Ducts......................................................................................3-37 3-6.1.1.4 Upper/Lower Plenum Examples..............................................................................3-39 3-6.1.2 Special Configurations............................................................................................3-40 3-6.1.2.1 Protection of Electrostatic Precipitators..................................................................3-40 3-6.1.2.2 Transitional Duct....................................................................................................3-41 3-7 Cylinder Flows........................................................................................................3-42 3-8 Piping Requirements...............................................................................................3-43 3-8.1 Stainless Steel Tubing and Fittings.........................................................................3-43 3-8.2 Pipe Sizing..............................................................................................................3-43 3-8.3 General Rules .........................................................................................................3-43 3-8.4 Discharge Line Volume Limitations ........................................................................3-44 3-8.4.1 Equivalent Length Limitations ................................................................................3-45 3-8.4.2 Minimum Pipe Length.............................................................................................3-47 3-8.4.3 Special 3/8-inch Piping Only System.......................................................................3-49 3-8.4.4 Detector.................................................................................................................. 3-50 3-9 UCH Control System Design and Installation Parameters.......................................3-51 3-10 A+Design and Installation Parameters....................................................................3-52 CHAPTER 4 INSTALLATION 4-1 Introduction............................................................................................................4-1 4-2 General Installation Requirements..........................................................................4-1 4-3 Installation of Suppression.....................................................................................4-1 4-3.1 Wall Mounting Bracket Installation, P/N 9197430, 9197263, 9197414, 9197415, 100013 ...................................................................................................................4-1 4-3.2 Floor Mount Bracket Kit Installation, P/N 100010 ..................................................4-4 January 2007 x P/N 9127100 TABLE OF CONTENTS (CONT.) 4-3.3 Cylinder and Valve Assembly Installation................................................................4-5 4-3.4 Installing the Discharge Adapter Kit, P/N 844908....................................................4-6 4-3.5 Installation of Pipe/Tubing and Fittings...................................................................4-7 4-3.5.1 Agent Distribution Piping ........................................................................................4-7 4-3.5.2 Pressure Switches (if Applicable), P/N 9197023 ......................................................4-9 4-3.5.3 1/2-inch Vent Plug, P/N 9196984.............................................................................4-10 4-3.6 Installing Nozzles ....................................................................................................4-10 4-4 Installation of Controls............................................................................................4-11 4-4.1 UCH Control System Installation.............................................................................4-11 4-4.1.1 Installing the UCH Control System (Wall Mount).....................................................4-12 4-4.1.2 Installing UCH Control System (Cylinder Mount) ....................................................4-14 4-4.1.3 Actuation.................................................................................................................4-18 4-4.1.4 Mechanical Detection Installation............................................................................4-19 4-4.1.4.1 Installing Detection Components.............................................................................4-19 4-4.1.4.2 Cabling Mechanical Detection — Both Lines............................................................4-22 4-4.1.4.3 Cabling Detection Line 1 Only — Includes Lockout of Detection Line 2...................4-24 4-4.1.4.4 Cabling Detection Line 2 Only (Option 1)— Includes Lockout of Detection Line 1...4-25 4-4.1.4.5 Cabling Detection Line 2 Only (Option 2)— Includes Lockout of Detection Line 1...4-26 4-4.1.5 Attaching Microswitches..........................................................................................4-27 4-4.1.5.1 High Mount Location for Microswitches ..................................................................4-27 4-4.1.5.2 Deep Mount Location for Microswitches..................................................................4-28 4-4.1.6 Wiring Microswitches for UCH ................................................................................4-30 4-4.1.7 Mounting the Solenoid, P/N B100043......................................................................4-32 4-4.1.7.1 Locking Out Detection Lines 1 and 2.......................................................................4-35 4-4.2 Installation of the A+ Control Box...........................................................................4-37 4-4.3 Mounting the A+ Control Box .................................................................................4-38 4-4.3.1 Detection Installation ..............................................................................................4-38 4-4.3.1.1 Installing Detection Components.............................................................................4-38 4-4.3.2 A+ To System Valve Actuator Connection...............................................................4-43 4-4.3.3 Installation of SIngle SPDT Switch Kit (P/N 60-9197227-000) into the A+ Control Box..........................................................................................................................4-44 4-4.3.3.1 A+ Microswitch Wiring Schematic For Alarm Initiation ..........................................4-46 4-4.3.4 Installation of the Optional Dual SPDT Switch Kit (P/N 9197228) into the A+ Control Box.............................................................................................................4-47 4-4.4 Optional Equipment Installation .............................................................................4-50 4-4.4.1 Installing Remote Manual Release, P/N B875572 (UCH Only)..................................4-50 4-4.4.1.1 Attaching Remote Manual Release...........................................................................4-52 4-4.4.1.2 Attaching Remote Manual Release Pull Station, P/N 87-120110-001 (Pull-to-Trip — XV ONLY)4-54 4-4.4.1.3 Attaching Remote Manual Release Pull Station, P/N 87-120110-001 (Release-to-Trip)......................................................................................................4-57 4-4.4.2 Installation of Surface Mounted Remote Manual Control for the UCH Control System and the A+ Control Box, P/N 9197463........................................................4-60 4-4.4.2.1 End-Of-Line Surface Mounted Remote Manual Control...........................................4-60 4-4.4.2.2 In-Line Surface Mounted Remote Manual Control...................................................4-62 4-4.4.3 Installation of Recess Mounted In-Line Remote Manual Control, P/N 9197460 .......4-64 4-4.4.4 Installation of Recess Mounted End-Of-Line Remote Manual Control, P/N 91974614-67 P/N 9127100 xi January 2007 TABLE OF CONTENTS (CONT.) 4-4.4.5 Cabling Mechanical Gas Valve in the UCH Control System .....................................4-70 4-4.4.5.1 Cabling Mechanical Gas Valve.................................................................................4-71 4-4.4.6 Cabling Mechanical Gas Valve in the A+ Control Box.............................................4-73 4-4.4.6.1 Cabling Mechanical Gas Valve.................................................................................4-74 4-4.4.7 Electrical Gas Valve, P/N 9197XXX.........................................................................4-75 4-4.4.8 Installing Pneumatic Release, P/N 9189412 ............................................................4-78 4-5 Post-Installation Checkout......................................................................................4-80 4-5.1 Extinguishing System Visual Inspection..................................................................4-80 4-5.2 Agent Distribution Piping Checkout........................................................................4-81 4-5.3 Detection System Inspection...................................................................................4-81 4-5.4 Mechanical Systems Inspection (UCH and A+).......................................................4-82 4-6 Commissioning the System - UCH Control System .................................................4-83 4-6.1 Arming the System..................................................................................................4-83 4-6.1.1 Checking Microswitches..........................................................................................4-87 4-6.1.2 Checking Solenoid ..................................................................................................4-89 4-6.1.3 Checking Gas Valve.................................................................................................4-89 4-6.2 Functional Testing of the UCH Control System.......................................................4-90 4-6.2.1 Test Mechanical Link Lines for the UCH Control System (If Applicable).................4-90 4-6.2.2 Test Remote Manual Release, P/N B875572 (if applicable)......................................4-91 4-6.2.3 Test Solenoid, P/N B100043 (if applicable).............................................................4-91 4-6.2.4 Inspect High-Pressure Nitrogen Tubing...................................................................4-92 4-6.3 Actuation Test For the UCH Control System...........................................................4-93 4-6.3.1 Disposal of Cartridge..............................................................................................4-98 4-7 Commissioning the A+ Control System..................................................................4-99 4-7.1 Arming the System..................................................................................................4-99 4-7.1.1 Checking Microswitches..........................................................................................4-99 4-7.1.2 Checking Gas Valve.................................................................................................4-99 4-7.1.3 Checking System Valve Actuator Connection ..........................................................4-99 4-7.2 Functional Testing of the A+ Control Box...............................................................4-100 4-7.2.1 Test Mechanical Link Lines for the A+ Control Box (If Applicable).........................4-100 4-7.2.2 Test Remote Manual Release, P/N 9197463 (if applicable)......................................4-101 4-7.2.3 Testing Microswitches (If Applicable)......................................................................4-101 4-7.2.4 Inspect 1/4 in. O.D. Copper Tubing.........................................................................4-102 4-7.2.5 Installing the CO2 Gas Cartridge in the A+ Control Box.........................................4-103 4-7.3 Actuation Test for the A+ Control Box (If Applicable).............................................4-104 4-7.3.1 Disposal of Cartridge..............................................................................................4-105 CHAPTER 5 MAINTENANCE 5-1 Introduction............................................................................................................5-1 5-2 Inspection and Maintenance Procedures.................................................................5-1 5-2.1 Monthly Inspection Procedure (by Owner) ..............................................................5-2 5-2.2 Semi-Annual Service Procedure (By Authorized Badger Distributor Only)..............5-3 5-2.2.1 Preparation for Servicing and Testing the UCH Control System..............................5-4 5-2.2.2 Arming the UCH Control System ............................................................................5-7 5-2.2.3 Checking Microswitches..........................................................................................5-11 5-2.2.4 Checking Solenoid ..................................................................................................5-12 5-2.2.5 Checking Gas Valve.................................................................................................5-12 January 2007 xii P/N 9127100 TABLE OF CONTENTS (CONT.) 5-2.2.6 Functional Testing of the UCH Control System........................................................5-13 5-2.2.6.1 Test Mechanical Link Lines for the UCH Control System (If Applicable) .................5-13 5-2.2.6.2 Test Remote Manual Release, P/N B875572 (If Applicable)......................................5-14 5-2.2.6.3 Test Solenoid, P/N B100043 (If Applicable).............................................................5-14 5-2.2.6.4 Inspect High-Pressure Nitrogen Tubing ...................................................................5-15 5-2.2.7 Actuation Test For the UCH Control System ...........................................................5-16 5-2.2.7.1 Disposal of Cartridge...............................................................................................5-20 5-2.2.8 Preparation for Servicing and Testing the A+ Control Box......................................5-21 5-2.2.9 Arming the A+ Control Box.....................................................................................5-23 5-2.2.9.1 Checking Microswitches..........................................................................................5-24 5-2.2.9.2 Checking Gas Valve.................................................................................................5-24 5-2.2.10 Functional Testing of the A+ Control Box ...............................................................5-25 5-2.2.10.1 Test Mechanical Link Lines for the A+ Control Box (If Applicable) .........................5-25 5-2.2.11 Test Remote Manual Release, 9197463 (if applicable).............................................5-26 5-2.2.12 Testing Microswitches (If Applicable) ......................................................................5-26 5-2.2.12.1 Visual Inspection of the Copper Tubing...................................................................5-27 5-2.2.12.2 Installing the CO2 Gas Cartridge in the A+ Valve Body...........................................5-28 5-2.2.13 Actuation Test for the A+ Control Box (If Applicable)..............................................5-29 5-2.2.13.1 Disposal of Cartridge...............................................................................................5-30 5-2.3 Twelve-Year Maintenance ........................................................................................5-31 5-2.3.1 Wet Chemical Cylinders...........................................................................................5-31 5-2.3.2 Hydrostatic Testing .................................................................................................5-31 5-2.3.3 Recharge Instructions..............................................................................................5-32 5-2.3.3.1 General Information................................................................................................5-32 5-2.3.3.2 Depressurize Cylinder and Valve Assembly.............................................................5-32 5-2.3.3.3 Disassemble the Cylinder Valve...............................................................................5-33 5-2.3.3.4 Rebuilding Cylinder Valve .......................................................................................5-33 5-2.3.3.5 Recharging Cylinders...............................................................................................5-35 5-2.3.3.6 Cylinder Leak Test ..................................................................................................5-36 5-2.3.4 UCH Control System Component Maintenance .......................................................5-36 5-2.3.4.1 Rebuild the UCH Control System Valve...................................................................5-36 5-3 Post-Discharge Maintenance....................................................................................5-40 5-3.1 General Information................................................................................................5-40 5-3.2 Appliance Cleanup ..................................................................................................5-40 5-3.3 Cylinder and Valve Assembly...................................................................................5-40 5-3.3.1 Valve Disassembly - See Paragraph 5-2.3.3.3, Disassemble the Cylinder Valve .......5-40 5-3.4 Resetting the Mechanical System.............................................................................5-41 5-3.5 Resetting the Electrical System................................................................................5-41 5-3.6 Clean Distribution System and Nozzles...................................................................5-41 5-3.7 Flushing Procedure .................................................................................................5-42 5-3.8 Recharge Cylinders - See Paragraph 5-2.3.3.5, Recharging Cylinders......................5-43 5-3.9 Cylinder and Valve Reassembly...............................................................................5-43 5-3.10 Cylinder Leak Test ..................................................................................................5-44 5-3.11 Rechecking the System............................................................................................5-44 CHAPTER 6 PARTS LIST P/N 9127100 xiii January 2007 TABLE OF CONTENTS (CONT.) APPENDIX A ELECTRICAL DETECTION INSTALLATION (DETECT-A-FIRE®) A-1 Introduction............................................................................................................A-1 A-2 Location..................................................................................................................A-1 A-3 Mounting ................................................................................................................A-1 A-4 Installation..............................................................................................................A-3 A-4.1 Ceiling Locations ....................................................................................................A-3 A-4.1.1 Ordinary Locations.................................................................................................A-3 A-4.1.2 Hazardous Locations ..............................................................................................A-4 A-4.1.3 Non-Hazardous Outdoor Locations.........................................................................A-5 A-4.2 Duct Applications ...................................................................................................A-5 A-4.3 Field Wiring Requirement.......................................................................................A-6 A-5 Functional Test.......................................................................................................A-7 January 2007 xiv P/N 9127100 THIS PAGE INTENTIONALLY LEFT BLANK. P/N 9127100 xv January 2007 Figure Name Page Number 1-1 Typical Range Guard Wet Chemical System..............................................................................1-2 1-2 Operational Sequence Flow Chart.............................................................................................1-3 1-3 WHMIS Class B — Division 2 (D2B) Symbol.............................................................................1-5 2-1 Dimensions of Cylinder and Valve Assembly, P/N B-12XXXX ...................................................2-3 2-2 Mounting Brackets ...................................................................................................................2-4 2-3 Shelf Bracket, P/N 100013........................................................................................................ 2-5 2-4 Floor Mount Bracket Kit, P/N 100010.......................................................................................2-5 2-5 Discharge Adapter Kit, P/N 844908 ..........................................................................................2-6 2-6 ADP Nozzle, P/N B120011 ........................................................................................................ 2-9 2-7 F Nozzle, P/N B120012.............................................................................................................2-9 2-8 GRW Nozzle, P/N B120013....................................................................................................... 2-10 2-9 R Nozzle, P/N B120014.............................................................................................................2-10 2-10 DM Nozzle, P/N B120015.......................................................................................................... 2-11 2-11 LPF Nozzle, P/N B120022.........................................................................................................2-11 2-12 LPR Nozzle, P/N B120024.........................................................................................................2-12 2-13 Swivel Adapter, P/N B120021................................................................................................... 2-12 2-14 UCH Control System, P/N B120099..........................................................................................2-13 2-15 System Nitrogen Cartridge, P/N B120043.................................................................................2-14 2-16 Test Cartridge, P/N B120044....................................................................................................2-14 2-17 System Valve Actuator (SVA), P/N B120042..............................................................................2-15 2-18 External Tubing for UCH Control System, P/N B120045 ..........................................................2-16 2-19 Solenoid, P/N B100034.............................................................................................................2-17 2-20 Microswitch Kit, P/N B120039.................................................................................................. 2-18 2-21 Terminal Type Microswitch, P/N B120047 ...............................................................................2-19 2-22 A+ Control Box, P/N B120010 (Cover Removed)......................................................................2-20 2-23 CO2 Cartridge, P/N 9197203.................................................................................................... 2-21 2-24 Cable Tension Block, P/N 9197220 ..........................................................................................2-21 2-25 Single SPDT Microswitch Kit, P/N 9197227..............................................................................2-22 2-26 Dual SPDT Microswitch Kit, P/N 9197228................................................................................2-23 2-27 Example of End-of-line and In-line Detector Housing Kit, P/N 804548......................................2-24 2-28 Example of End-of-line and In-line Universal Link Housing Kit, P/N 120064............................2-25 2-29 Thermo-Bulb Link, P/N B12009X-XXX.....................................................................................2-26 2-30 Fusible-Link, P/N B28266X ......................................................................................................2-27 2-31 Fusible-Link, P/N 9196903....................................................................................................... 2-28 2-32 Corner Pulley, P/N B844648.....................................................................................................2-29 2-33 Tee Pulley, P/N 843791.............................................................................................................2-30 2-34 Remote Manual Release, P/N B875572 .....................................................................................2-31 2-35 Remote Manual Release Pull Station, P/N 87-120110-001 ........................................................2-32 2-36 Surface Mounted End-of-Line Remote Manual Release, P/N 9197463.......................................2-33 2-37 Recess Mounted End-of-Line, Remote Manual Release, P/N 9197461.......................................2-34 2-38 Recess Mounted, In-Line Remote Manual Release, P/N 9197460 ..............................................2-35 2-39 Pressure Operated Release, P/N 9189412.................................................................................2-36 2-40 Pressure Switch, P/N 9197023 ................................................................................................. 2-37 2-41 Mechanical Gas Valve, P/N B12007X........................................................................................2-38 2-42 Electric Gas Valve, P/N 9197XXX .............................................................................................2-39 2-43 Manual Reset Relay Box, P/N 9101735 .....................................................................................2-40 2-44 Manual Reset Relay Box, P/N 9101735 (Used Before 2006)......................................................2-40 2-45 EMT and O-Ring Connector Kit, P/N B120058..........................................................................2-41 2-46 Crimp Sleeve, P/N 214951........................................................................................................ 2-41 2-47 “S” Hook, P/N 9189413 ............................................................................................................2-42 2-48 Crimping Tool, P/N 253538......................................................................................................2-42 2-49 1/2-inch Vent Plug, P/N 9196984.............................................................................................. 2-43 LIST OF FIGURES January 2007 xvi P/N 9127100 LIST OF FIGURES (CONT.) Figure Name Page Number 2-50 Keeper Pin, P/N 9197108..........................................................................................................2-43 3-1 Examples of Hazard Areas for Typical Appliances ....................................................................3-4 3-2 Single Vat Deep Fat Fryer..........................................................................................................3-6 3-3 18-1/2 in. x 24-1/2 in. (470 mm x 622 mm) Deep Fat Fryer......................................................3-7 3-4 Split Vat Deep Fat Fryer............................................................................................................3-8 3-5 14 in. x 14 in. (356 mm x 356 mm) Deep Fat Fryer..................................................................3-9 3-6 Single Vat Deep Fat Fryer (with Dripboards less than 1 in. (25mm) .........................................3-10 3-7 Split Vat Fryer (Low Proximity Application)..............................................................................3-11 3-8 Low Proximity Nozzle for Deep Fat Fryer (LPF).........................................................................3-13 3-9 Krispy Kreme Model 270 d/h Doughnut Fryer...........................................................................3-14 3-10 R Nozzle Coverage for a 4-Burner Range...................................................................................3-15 3-11 R Nozzle Coverage for a 2-Burner Range...................................................................................3-16 3-12 R Nozzle Coverage for a 1-Burner Range...................................................................................3-17 3-13 LPR Nozzle Coverage for a 4-Burner Range (LPR).....................................................................3-18 3-14 LPR Nozzle Assembly................................................................................................................3-19 3-15 ADP Nozzle Placement for Upright Broilers...............................................................................3-20 3-16 Lava, Pumice, Ceramic, or Synthetic Rock Charbroiler.............................................................3-21 3-17 Gas Radiant/Electric Charbroiler..............................................................................................3-22 3-18 Natural or Mesquite Charcoal Charbroiler ................................................................................3-23 3-19 Mesquite Logs Charbroiler........................................................................................................3-24 3-20 ADP Nozzle Installation for Closed Top Chain Broiler...............................................................3-25 3-21 ADP Nozzle Installation for Open-Top Chain Broiler.................................................................3-26 3-22 Griddle - Flat Cooking Surface..................................................................................................3-27 3-23 Wok...........................................................................................................................................3-28 3-24 Tilt Skillet (Braising Pan)..........................................................................................................3-29 3-25 Example of Modular Protection, Single Vat Deep Fat Fryer (Less than 1-inch Dripboard).........3-30 3-26 Nozzles for Deep Fat Fryer........................................................................................................3-31 3-27 Example of Nozzle Position (Typical for each module) for Multiple Nozzle Coverage.................3-32 3-28 ADP Protection Nozzle, P/N B120011........................................................................................3-34 3-29 Duct Protection Using Single ADP Nozzle, P/N B120011 ...........................................................3-35 3-30 Duct Protection Using Two ADP Nozzles, P/N B120011 ............................................................3-36 3-31 Modular Protection of Large Ducts............................................................................................3-37 3-32 Optional Duct Nozzle Placement................................................................................................3-38 3-33 Special Plenum Arrangements ..................................................................................................3-39 3-34 Special Plenum Arrangements With 6 in. (152 mm) Risers.......................................................3-39 3-35 Nozzle Placement with Electrostatic Precipitator.......................................................................3-40 3-36 Transitional Duct......................................................................................................................3-41 3-37 1/2 in. (13 mm) Piping with 90° Elbow......................................................................................3-46 3-38 Tees ..........................................................................................................................................3-46 3-39 Pipe Size and Nozzle Distance...................................................................................................3-48 3-40 Positioning Detectors ................................................................................................................3-50 4-1 Wall Mounting Bracket..............................................................................................................4-2 4-2 RG-6.0G Wall Mounting Bracket...............................................................................................4-3 4-3 Floor Mount Bracket Kit Attached to Wall Mounting Bracket ....................................................4-4 4-4 Anti-Recoil and Valve Protection Plates .....................................................................................4-5 4-5 Installing the Discharge Adapter Kit, P/N 844908......................................................................4-6 4-6 Stainless Steel Tubing...............................................................................................................4-8 4-7 Installing Pressure Switch, P/N 9197023 ..................................................................................4-9 4-8 1/2-inch Vent Plug, P/N 9196984...............................................................................................4-10 4-9 Pipe Connection Knockout Designations...................................................................................4-11 4-10 Location of Mounting Holes (Housing).......................................................................................4-12 P/N 9127100 xvii January 2007 LIST OF FIGURES (CONT.) Figure Name Page Number 4-11 SVA in ‘Set’ Position .................................................................................................................4-13 4-12 Example of Copper Tubing Loop Method .................................................................................4-13 4-13 SVA in ‘Set’ Position .................................................................................................................4-14 4-14 SVA Installation (Cylinder Mount) ............................................................................................ 4-14 4-15 Mounting the UCH Control System to the SVA..........................................................................4-15 4-16 Example of Copper Tubing Loop Method .................................................................................4-16 4-17 Installing High Pressure Nitrogen Tubing .................................................................................4-16 4-18 Dimensions of Cylinder, Valve, SVA, and UCH Control System ................................................4-17 4-19 Decision Flow Chart for Actuation............................................................................................ 4-18 4-20 Unacceptable Cable Configuration............................................................................................4-19 4-21 Detector Housing Kit Installation, P/N 804548..........................................................................4-20 4-22 Universal Link Housing Installation.......................................................................................... 4-21 4-23 Cabling Mechanical Detection...................................................................................................4-22 4-24 Close Up View of Detection Lines 1 and 2 Beam Stops.............................................................4-23 4-25 UCH with Detection Line 2 Locked Out ....................................................................................4-24 4-26 UCH with Detection Line 1 Locked Out ....................................................................................4-25 4-27 UCH with Detection Line 1 Locked Out ....................................................................................4-26 4-28 High Mount Microswitch, 'Released' and ‘Set’ Positions ............................................................4-27 4-29 Deep Mount Microswitch, 'Released' and ‘Set’ Positions............................................................4-29 4-30 Microswitch Kit (in Released Position), P/Ns B120039, B230039-501......................................4-30 4-31 Position of Switch in Released Position.....................................................................................4-30 4-32 Microswitch in Released Position, P/N B120047.......................................................................4-31 4-33 Microswitch (Terminal Type) Position in Released Position......................................................4-31 4-34 Solenoid Mounted and Wired in the UCH Control System ........................................................4-33 4-35 Alarm Wiring with Terminal Type Microswitch.........................................................................4-34 4-36 Release Wiring with Terminal Type Microswitch.......................................................................4-34 4-37 Locking Out Detection Lines 1 and 2 with Solenoid Mounted in UCH ......................................4-35 4-38 A+ Control Box ........................................................................................................................4-37 4-39 Location of Mounting Holes ...................................................................................................... 4-38 4-40 Unacceptable Cable Configuration............................................................................................4-39 4-41 Universal Link Housing Installation.......................................................................................... 4-40 4-42 A+ Control Box in “SET” Position ............................................................................................4-41 4-43 Cable Tension Block Assembly, P/N 9197220...........................................................................4-42 4-44 Installing 1/4-inch O.D. (6 mm) Copper Tubing........................................................................4-43 4-45 Single SPDT Microswitch Installation.......................................................................................4-44 4-46 Single SPDT Microswitch and Mounting Bracket......................................................................4-44 4-47 Single SPDT Microswitch Adjustment.......................................................................................4-45 4-48 A+ Microswitch Wiring Schematic for Alarm Initiation.............................................................4-46 4-49 Dual SPDT Microswitch Installation.........................................................................................4-47 4-50 Dual SPDT Microswitches and Mounting Bracket, P/N 9197228 ..............................................4-48 4-51 Dual SPDT Microswitch Installation.........................................................................................4-49 4-52 Remote Manual Release with Detection Lines 1 and 2 Locked Out ...........................................4-50 4-53 Exploded View of the Remote Manual Release..........................................................................4-52 4-54 Installing the Remote Manual Release, P/N B875572................................................................4-53 4-55 Remote Manual Release Pull Station, Pull-to-Trip (EMT/Conduit at Top) .................................4-54 4-56 Remote Manual Release Pull Station, Pull-to-Trip (EMT/Conduit at Bottom)............................4-54 4-57 Remote Manual Release Pull Station Handle Assembly.............................................................4-55 4-58 Securing the Remote Manual Release Pull Station ....................................................................4-56 4-59 Wrap Tamper Seal Around Pull Handle....................................................................................4-56 4-60 Exploded View of the Remote Manual Release Pull Station, Release-to-Trip .............................4-57 4-61 Remote Manual Release Pull Station, Release-to-Trip (Side View).............................................4-59 4-62 End-of-Line Remote Manual Control, P/N 9197463 ..................................................................4-60 4-63 End-of-Line Remote Manual Control (Side View), P/N 9197463................................................4-61 January 2007 xviii P/N 9127100 LIST OF FIGURES (CONT.) Figure Name Page Number 4-64 In-Line Remote Manual Control Kit (Front View), P/N 9197463 ................................................4-62 4-65 Recess Mounted In-Line Remote Manual Control, P/N 9197461................................................4-65 4-66 Recess Mounted In-Line Remote Manual Control (Side View), P/N 9197460 .............................4-66 4-67 Recess Mounted End-of-Line Remote Manual Control, P/N 9197461 ........................................4-68 4-68 Recess Mounted End-of-Line Remote Manual Control (Side View), P/N 9197461......................4-68 4-69 Cabling Gas Valve (Cam/Flag in ‘Released' State).......................................................................4-70 4-70 Cabling Gas Valve (Cam/Flag in 'Set' State) ...............................................................................4-71 4-71 Installing Mechanical Gas Valve ................................................................................................4-72 4-72 Cabling Mechanical Gas Valve Cable in the A+ Control Box......................................................4-73 4-73 Installing Mechanical Gas Valve ................................................................................................4-74 4-74 Electric Gas Valve, P/N 9197XXX..............................................................................................4-75 4-75 Manual Reset Relay Box, P/N 9101735......................................................................................4-76 4-76 Manual Reset Relay Wiring Detail..............................................................................................4-76 4-77 Manual Reset Relay Box, P/N 9101735 (Used Before 2006).......................................................4-77 4-78 Manual Reset Relay Wiring Diagram..........................................................................................4-77 4-79 Example of a Pneumatic Release Installation.............................................................................4-79 4-80 Setting the Detection Beams......................................................................................................4-83 4-81 Detection Beam Stops...............................................................................................................4-84 4-82 View of Ratchet Spool and Pawl ................................................................................................4-84 4-83 Detection Beam Stops...............................................................................................................4-85 4-84 Position of Detection Beams in 'Set' Position.............................................................................4-85 4-85 Latch Shown in “Set’ Position ...................................................................................................4-86 4-86 High Mount Microswitch, 'Released' and ‘Set’ Positions.............................................................4-87 4-87 Deep Mount Microswitch, 'Released' and ‘Set’ Positions ............................................................4-88 4-88 SVA in ‘Set’ Position..................................................................................................................4-92 4-89 UCH Control System, Test Cartridge Placement........................................................................4-93 4-90 UCH Control System, Cover Attached .......................................................................................4-94 4-91 Fitting on Outside of UCH Control System................................................................................4-95 4-92 Valve Body with Flat Gasket......................................................................................................4-96 4-93 Cylinder Mounted UCH Control System....................................................................................4-97 4-94 A+ Control Box in “SET” Position.............................................................................................4-99 4-95 SVA in ‘Set’ Position..................................................................................................................4-102 4-96 Installing CO2 Gas Cartridge.....................................................................................................4-103 4-97 A+ with Cover Installed ............................................................................................................4-105 5-1 High-Pressure Nitrogen Tubing Location, Close Up...................................................................5-4 5-2 UCH Control System, Internal View ..........................................................................................5-5 5-3 Valve Body and Flat Gasket Location........................................................................................5-6 5-4 System Valve Actuators.............................................................................................................5-6 5-5 Removing Discharge Adapter Kit...............................................................................................5-7 5-6 Setting the Detection Beams......................................................................................................5-8 5-7 Detection Beam Stops...............................................................................................................5-8 5-8 View of Ratchet Spool and Pawl ................................................................................................5-9 5-9 Detection Beam Stops...............................................................................................................5-10 5-10 Position of Detection Beams in 'Set' Position.............................................................................5-10 5-11 Latch Shown in “Set’ Position ...................................................................................................5-11 5-12 SVA in ‘Set’ Position..................................................................................................................5-15 5-13 UCH Control System, Test Cartridge Placement........................................................................5-16 5-14 UCH Control System, Cover Attached .......................................................................................5-17 5-15 Fitting on Outside of UCH Control System................................................................................5-18 5-16 Valve Body with Flat Gasket......................................................................................................5-19 5-17 Cylinder Mounted UCH Control System....................................................................................5-20 5-18 Disconnect Copper Tubing........................................................................................................5-21 P/N 9127100 xix January 2007 LIST OF FIGURES (CONT.) Figure Name Page Number 5-19 System Valve Actuators ............................................................................................................5-22 5-20 Removing Discharge Adapter Kit ..............................................................................................5-23 5-21 A+ Control Box in “SET” Position ............................................................................................5-23 5-22 Cable Tension Block Assembly................................................................................................. 5-24 5-23 SVA in ‘Set’ Position .................................................................................................................5-27 5-24 Installing CO2 Gas Cartridge.................................................................................................... 5-28 5-25 A+ with Cover Installed............................................................................................................5-30 5-26 Valve Assembly.........................................................................................................................5-34 5-27 Recharge Hookup .....................................................................................................................5-36 5-28 Valve Body with Piercing Pin Shown.........................................................................................5-37 5-29 Removal of Piercing Pin and Flat Gasket ..................................................................................5-38 5-30 LPR Nozzle Assembly ...............................................................................................................5-41 5-31 Diagram for Flushing the Badger System..................................................................................5-42 5-32 Recharge Hookup .....................................................................................................................5-44 A-1 Mounting a Detect-A-Fire..........................................................................................................A-4 A-2 System Wiring ..........................................................................................................................A-6 January 2007 xx P/N 9127100 THIS PAGE INTENTIONALLY LEFT BLANK. P/N 9127100 xxi January 2007 Table Name Page Number 2-1 Cylinder and Valve Assembly Specifications .............................................................................2-3 2-2 Mounting Bracket Dimensions..................................................................................................2-4 2-3 Mounting Bracket Dimensions..................................................................................................2-5 2-4 Floor Mounting Kit Specifications.............................................................................................2-5 2-5 Range Guard Nozzles................................................................................................................2-8 2-6 External Tubing for UCH Control System.................................................................................2-16 2-7 Microswitch Electrical Ratings..................................................................................................2-18 2-8 Terminal Type Microswitch Electrical Ratings..........................................................................2-19 2-9 SPDT Microswitch Electrical Ratings........................................................................................2-22 2-10 Dual SPDT Microswitch Electrical Ratings ...............................................................................2-23 2-11 Detector Housing Kit, P/N 804548............................................................................................2-24 2-12 Universal Link Housing Kit, P/N 120064 ..................................................................................2-25 2-13 Rapid and Standard Response Thermo-Bulb Link Temperature Ratings .................................2-26 2-14 Fusible-Link Temperature Ratings ...........................................................................................2-27 2-15 Fusible-Link (Model RGA) Temperature Ratings ......................................................................2-28 2-16 Pressure Switch (SPDT) Electrical Specifications .....................................................................2-37 2-17 Mechanical Gas Valve Sizes...................................................................................................... 2-38 2-18 Electric Gas Valve Sizes............................................................................................................2-39 2-19 1/16-inch Control Cable............................................................................................................2-41 2-20 Crimp Sleeve ............................................................................................................................2-41 2-21 “S” Hook...................................................................................................................................2-42 2-22 Wet Chemical Agent..................................................................................................................2-43 3-1 Appliance References................................................................................................................3-5 3-2 F Nozzle Coverage Area.............................................................................................................3-6 3-3 F Nozzle Coverage Area.............................................................................................................3-7 3-4 F Nozzle Coverage Area.............................................................................................................3-8 3-5 F Nozzle Coverage Area.............................................................................................................3-9 3-6 F Nozzle Coverage Area.............................................................................................................3-10 3-7 ADP Nozzle Coverage Area........................................................................................................3-11 3-8 LPF Nozzle Coverage Area ........................................................................................................3-12 3-9 Nozzle Offset At Given Heights..................................................................................................3-12 3-10 Pipe Limitations for LPF Nozzle................................................................................................3-12 3-11 Eight ADP Nozzles Coverage Area.............................................................................................3-14 3-12 Krispy Kreme Model 270 d/h Doughnut Fryer Minimum Pipe Length.......................................3-14 3-13 R Nozzle Coverage Area — Four Burner Range.........................................................................3-15 3-14 R Nozzle Coverage Area — Two Burner Range..........................................................................3-16 3-15 R Nozzle Coverage Area — Single Burner Range.......................................................................3-17 3-16 LPR Nozzle Coverage Area — Four Burner Range.....................................................................3-18 3-17 LPR Nozzle Parameters.............................................................................................................3-18 3-18 Piping Parameters ....................................................................................................................3-19 3-19 ADP Nozzle Coverage Area........................................................................................................ 3-20 3-20 F Nozzle Coverage Area.............................................................................................................3-21 3-21 GRW Nozzle Coverage Area.......................................................................................................3-22 3-22 ADP Nozzle Coverage Area........................................................................................................ 3-23 3-23 DM Nozzle Coverage Area.........................................................................................................3-24 3-24 Single ADP Nozzle Coverage Area .............................................................................................3-25 3-25 Dual ADP Nozzle Coverage Area................................................................................................ 3-26 3-26 ADP Nozzle Coverage Area........................................................................................................ 3-27 3-27 GRW Nozzle Coverage Area.......................................................................................................3-28 3-28 F Nozzle Coverage Area.............................................................................................................3-29 3-29 Plenum Protection ....................................................................................................................3-33 3-30 Cylinder Flow Number Limits................................................................................................... 3-42 LIST OF TABLES January 2007 xxii P/N 9127100 LIST OF TABLES (CONT.) Table Name Page Number 3-31 Flow Number Range and Pipe Type...........................................................................................3-43 3-32 Piping Discharge Line Volume...................................................................................................3-44 3-33 Tubing Discharge Line Volume .................................................................................................3-44 3-34 Maximum Allowable Piping Volume ..........................................................................................3-44 3-35 Pipe Fitting Equivalent Length ..................................................................................................3-45 3-36 Tube Fitting Equivalent Length .................................................................................................3-45 3-37 Remote Nozzles.........................................................................................................................3-46 3-38 Minimum Allowable Pipe...........................................................................................................3-47 3-39 3/8 in. Piping Only System ........................................................................................................3-49 3-40 UCH Control System Cable Limitations ....................................................................................3-51 3-41 UCH Control System Actuation Length Limitations..................................................................3-51 3-42 A+ Detection Line Limitations ..................................................................................................3-52 3-43 A+ Actuation Limitations..........................................................................................................3-52 4-1 Wall Mounting Bracket Specifications .......................................................................................4-2 4-2 Wall Mounting Bracket Wall Support Load ...............................................................................4-2 4-3 RG-6.0G Wall Mounting Bracket Specifications ........................................................................4-3 4-4 Tubing Radius...........................................................................................................................4-8 4-5 Cylinder and Valve Assembly Specifications..............................................................................4-17 4-6 Cabling Detection Line 1 Only...................................................................................................4-24 4-7 Cabling Detection Line 2 Only - Option 1 ..................................................................................4-25 4-8 Cabling Detection Line 2 Only - Option 2 ..................................................................................4-26 4-9 Electrical Ratings for Microswitch Kit, P/Ns B120039, B120039-501 .......................................4-30 4-10 Electrical Ratings for Microswitch P/N B120047.......................................................................4-31 4-11 Locking Out Detection Lines 1 and 2 ........................................................................................4-35 5-1 Preventative Maintenance Schedule...........................................................................................5-1 5-2 Owner’s Monthly Inspection......................................................................................................5-2 5-3 Semi-Annual Service Procedure ................................................................................................5-3 5-4 Wet Chemical Cylinder Inspection.............................................................................................5-31 6-1 Parts List ..................................................................................................................................6-1 A-1 Electrical Rating....................................................................................................................... A-1 A-2 Detect-A-Fire Spacing............................................................................................................... A-2 A-3 Hazardous Location Applications.............................................................................................A-2 A-4 Non-Hazardous Outdoor Locations.......................................................................................... A-5 General Information P/N 9127100 1-1 January 2007 CHAPTER 1 GENERAL INFORMATION 1-1 INTRODUCTION The Range Guard Wet Chemical System provides fire protection for commercial kitchen applications such as appliances and ventilation. The Wet Chemical system holds UL listings as a pre-engineered system. Systems shall be designed and implemented according to the following: • NFPA Standard 17A, “Standard for Wet Chemical Systems”, • NFPA Standard 96, "Standard for Ventilation Control and Fire Protection of Commercial Cooking Operations", • Other applicable NFPA standards as required for a particular application and design, including, but not limited to, NFPA 70 (NEC), and NFPA 72, Fire Alarm Standard. • This Design, Installation, Operation, and Maintenance Manual (DIOM). • Any other standards enforced by a local Authority Having Jurisdiction (AHJ). Configurations in Chapter 3, System Design, are tested and listed to Underwriters Laboratories (UL) Standard 300, 1994 Edition, unless otherwise noted. 1-2 CLASSIFICATION OF FIRE The classification of fire is defined as the following: • Class A: Surface Type Fires; wood or other cellulose-type material (ordinary combustibles) • Class B: Flammable liquids • Class C: Energized electrical equipment • Class D: Combustible metals (such as magnesium, sodium, zirconium, potassium, and titanium) • Class K: Combustible cooking media (vegetable or animal oils and fats) Note:Range Guard Wet Chemical system is suited for Class K type of fire. 1-3 GENERAL CHARACTERISTICS OF THE BADGER SYSTEM The Range Guard System is a wet chemical fire suppression system with one type of agent. The system is capable of encompassing a wide variety of application requirements. The system utilizes stored pressure agent cylinders. Stored pressure cylinders: • Remain free of contamination • Provide a smooth flow throughout the discharge The cylinders are powder-coated, welded mild-steel shell conforming to DOT specification 4BW/4BA construction and NFPA standards. The valve is forged brass with nickel plating. The plating and cylinder coating makes it corrosion resistant. General Information January 2007 1-2 P/N 9127100 The system can be activated mechanically from manual release, thermo-bulb links, and fusible links. The system can be activated electrically with a 24 Vdc control panel that is tested and listed with the Range Guard system. Both automatic detection and manual release devices are used on control panels. Refer to Paragraph 2-2.1.5 for power requirements. Cylinders are activated from stored high-pressure gas. Automatic and manual actuation are available for the Range Guard System. Other actuations are available, such as: • Mechanical gas valve closure • Dry contacts for annunciation and electrical shutdowns 1-4 SYSTEM DESCRIPTION The Range Guard Wet Chemical System consists of a supply of wet chemical stored in one or more Cylinder and Valve Assemblies. Each cylinder is pressure activated by a System Valve Actuator. The system can be actuated either automatically and/or manually, using mechanical, electrical, or pressure actuation devices. Upon actuation, the wet chemical is discharged through agent distribution piping and specially designed nozzles positioned throughout the protected area. Figure 1-1. Typical Range Guard Wet Chemical System General Information P/N 9127100 1-3 January 2007 1-5 OPERATIONAL SEQUENCE Figure 1-2. Operational Sequence Flow Chart FIRE OR EXTREME TEMPERATURE RISE OCCURS AUTOMATIC ELECTRICAL ACTIVATION AUTOMATIC MECHANICAL ACTIVATION MECHANICAL LINK SEPARATES MANUAL ACTIVATION UCH CONTROL SYSTEM MANUAL ACTIVATION REMOTE MANUAL RELEASE ACTIVATION ELECTRIC PULL STATION ACTIVATION HEAT DETECTOR REACHES PREDETERMINED TEMPERATURE UCH CONTROL SYSTEM TRIPS RELEASING NITROGEN FROM THE SYSTEM CARTRIDGE TO SYSTEM VALVE ACTUATORS (SVAs), OPENING CYLINDER VALVES WET CHEMICAL FLOWS THROUGH AGENT DISTRIBUTION PIPING AND NOZZLES, SUPPRESSING FIRE UL LISTED FIRE CONTROL PANEL SENDS ACTUATION SIGNAL TO ELECTRIC SOLENOID IN UCH CONTROL SYSTEM MICROSWITCH(ES) TRIP FUNCTIONS ... General Information January 2007 1-4 P/N 9127100 1-6 APPLICATIONS AND LIMITATIONS OF WET CHEMICALS The Range Guard system uses a liquid chemical called Karbaloy® as its agent. Karbaloy, a solution of potassium carbonate in water, suppresses fires through a process involving the: • Saponification of surface grease (turning it into combustion-resistant soap), • Cooling effects of water vaporization, • Inerting effects of resultant steam formation, and • Interruption of the chemical chain reaction of combustion. Hazards and equipment that can be protected using wet chemical extinguishing systems include the following: • Restaurant, commercial, and institutional hoods • Plenums, ducts, and filters with their associated cooking appliances • Special grease removal devices The wet chemicals used in the Range Guard Wet Chemical System are stable at both low and high temperatures. The upper storage temperature limit for the system is 120°F (49°C). The lower temperature limit is 0°F (-18°C). 1-6.1 Extinguishing Properties When Karbaloy wet chemical agent is applied in a concentrated liquid spray to a burning surface, it reacts quickly with the hot grease or oil to produce a foam blanketing the surface. This reaction, combined with the cooling effect of the Karbaloy wet chemical agent, also reduces the possibility of fire reflash. 1-7 HAZARDOUS MATERIALS INFORMATION SYSTEM (HMIS SM) The HMIS rating for Karbaloy wet chemical is as follows: • Health (H) = 2 • Flammability (F) = 0 • Reactivity (R) = 0 Refer to http://www.badgerfire.com web site for latest MSDS information. WARNING Upon system alarm notification, all personnel must evacuate the protected space. Failure to do so may result in temporary respiratory difficulties, disorientation, or personal injury. CAUTION Wet chemical fire extinguishing agent is considered nontoxic, but is classified as a skin/eye irritant, and may cause temporary irritation to the eyes, skin, or respiratory system. Avoid unnecessary exposure. General Information P/N 9127100 1-5 January 2007 1-8 WORKPLACE HAZARDOUS MATERIALS INFORMATION SYSTEM (WHMIS) The WHMIS rating for Karbaloy wet chemical is — D2B - Skin/Eye Irritation Figure 1-3. WHMIS Class B — Division 2 (D2B) Symbol 1-9 CLEAN-UP No unusual cleanup procedure is required. After the appliances have completely cooled, the residue from the discharge may be cleaned up with a wet cloth or sponge. Wear rubber gloves while cleaning. If skin or eyes come in contact with the agent, flush thoroughly with water. WARNING Do not disturb the foam until the cooking appliances, plenum, and duct have cooled sufficiently. Do not put water on hot grease as this will cause violent steaming and spattering. WARNING Karbaloy wet agent is electrically conductive. To avoid electric shock, de-energize all electric circuits to appliances, outlets, and wiring by disconnecting or turning off the electric power at the main fuse or circuit breaker box. Do not clean up Karbaloy wet agent or touch electric appliances, outlets, power cords, or other wiring with electric power on. General Information January 2007 1-6 P/N 9127100 THIS PAGE INTENTIONALLY LEFT BLANK. Component Description P/N 9127100 2-1 January 2007 CHAPTER 2 COMPONENT DESCRIPTION The Range Guard Wet Chemical Fire Suppression System consists of the following major components: • Suppression — Agent storage cylinders distribution piping, nozzles, and detection devices (mechanical and electrical) • Controls • Auxiliary Components Cylinder and Valve Assembly The Wet Chemical Fire Suppression System utilizes five sizes of cylinders. The cylinders consist of a factory-filled wet chemical agent and valve assembly. The cylinders conform to DOT specification 4BW/4BA and NFPA standards. Distribution Piping The distribution piping (not supplied by Badger Fire Protection) is designed to distribute the wet chemical agent to the hazard areas. In the Range Guard pre-engineered system, pipe sizes, minimum and maximum pipe lengths and number of pipe fittings are predetermined. See Chapter 3 for more details. Nozzles There are seven types of nozzles for the Wet Chemical Fire Suppression System. Each type of nozzle has been designed and tested for specific applications and areas of coverage. The nozzles are: •ADP •R •LPF •LPR •GRW •F •DM Detection Devices There are two methods of detection that can be employed in the system: mechanical or electrical. Mechanical detection uses fusible-link or thermo-bulb link detectors to provide reliable performance. The detectors are designed to separate at a specific temperature and release tension on the detection cable which causes the release mechanism to activate. Fusible-link detectors are available in four temperature ratings, and the thermo-bulb detectors are available in six temperature ratings. Electrical detection uses heat detectors that are equipped with self-restoring, normally-open contacts which close when a predetermined temperature is reached. Heat detectors are available in six set points. Component Description January 2007 2-2 P/N 9127100 UCH Control System The UCH Control System is used for actuating the Range Guard Cylinder and Valve Assembly. The UCH Control System can be mounted directly on the cylinder or to a wall. The UCH Control System can be operated with: • Automatic mechanical detection (fusible-links and thermo-bulb links) • Remote and local manual operation • Automatic electrical activation A+ Control Box The A+ Control Box is used for actuating the Range Guard Cylinder and Valve Assembly and mounted directly to a wall. The A+ can be operated with: • Automatic mechanical detection (fusible-links and thermo-bulb links), • Remote manual operation. 2-1 SUPPRESSION COMPONENTS 2-1.1 Cylinder and Valve Assembly, P/N B12000X Table 2-1 outlines the dimensions for each Cylinder and Valve Assembly model. The DOT Cylinder and Valve Assembly: • Conforms to DOT Specification 4BW/4BA • Cylinder and Valve Assembly is pressurized with nitrogen to 175 PSIG (12.1 bar) at 70°F (21°C) WARNING Protective eye wear must always be worn when working with pressurized cylinders. Never service the Cylinder and Valve Assembly unless the Anti-Recoil Plate (P/N 255681) and Valve Protection Plate (P/N 255096) are installed. Death or serious injury and/or property damage could occur as the cylinder may be violently propelled. Refer to the Safety Summary for more information regarding pressurized cylinders. Component Description P/N 9127100 2-3 January 2007 Figure 2-1. Dimensions of Cylinder and Valve Assembly, P/N B-12XXXX Refer to Figure 5-26 for Cylinder Valve details. Table 2-1. Cylinder and Valve Assembly Specifications Cylinder and Valve Assembly Part Number Model Maximum Flow Number Dimensions A B C B120001 RG-1.25G 4 15-1/4 in. (387 mm) 13-3/4 in. (349 mm) 8 in. (203 mm) B120002 RG-2.5G 8 21 in. (534 mm) 19-5/8 in. (498 mm) 9 in. (230 mm) B120003 RG-4GS 12 19 in. (483 mm) 17-1/2 in. (444 mm) 12-1/4 in. (311 mm) B120006 RG-4GM 12 24-3/8 in. (619 mm) 23 in. (584 mm) 10 in. (254 mm) B120005 RG-6G 18 35-1/8 in. (892 mm) 33-3/4 in. (857 mm) 10 in. (254 mm) A TOP OF CYLINDER VALVE C NOMINAL CYLINDER DIAMETER B CENTER OF DISCHARGE PORT Component Description January 2007 2-4 P/N 9127100 2-1.1.1 CYLINDER BRACKETS Figure 2-2. Mounting Brackets Table 2-2. Mounting Bracket Dimensions Part No. Model Dimensions AB C 9197430 RG-1.25G 3 in. (76 mm) 9-3/8 in. (238 mm) 1-3/8 in. (35 mm) 9197263 RG-2.5G 4-1/2 in. (114 mm) 12 in. (305 mm) 2-1/2 in. (64 mm) 9197414 RG-4GM 4-1/2 in. (114 mm) 20-1/2 in. (521 mm) 2-1/2 in. (64 mm) 9197415 RG-4GS 4-1/2 in. (114 mm) 11-1/2 in. (290 mm) 2 in. (51 mm) A B B C FRONT VIEW SIDE VIEW CYLINDER STRAPCYLINDER STRAP Component Description P/N 9127100 2-5 January 2007 Figure 2-3. Shelf Bracket, P/N 100013 2-1.1.1.1 Floor Mount Bracket Kit, P/N 100010 A Floor Mount Bracket Kit is used for mounting the RG-6G/RG-4M cylinder to the floor. The Floor Mount Bracket Kit requires Wall Mounting Bracket P/N 100013. Figure 2-4. Floor Mount Bracket Kit, P/N 100010 Table 2-3. Mounting Bracket Dimensions Part No. Model Dimensions AB C 100013 RG-6G RG-4GM 11 in. (279 mm) 10-1/8 in. (258 mm) 21-1/8 in. (537 mm) Table 2-4. Floor Mounting Kit Specifications Dimension A Dimension B Dimension C 3 in. (76 mm) 9-5/8 in. (245 mm) 6-9/16 in. (168 mm) CYLINDER STRAP A B C C 3/8 in. DIAMETER BOLTS TO ATTACH TO WALL MOUNTING BRACKET 3/8 in. DIAMETER BOLTS TO ATTACH TO WALL MOUNTING BRACKET BA Component Description January 2007 2-6 P/N 9127100 2-1.1.2 DISCHARGE ADAPTER KIT, P/N 844908 The Discharge Adapter provides a means to connect agent distribution pipe to all Range Guard Wet Chemical Cylinder and Valve Assemblies. The Discharge Adapter Kit consists of a 3/4-inch NPT adapter and a steel flange plate (Figure 2-5). Note:The nuts and bolts used to secure the Anti-Recoil Plate to the discharge valve should be retained and used for mounting the Discharge Adapter to the valve outlet. The Discharge Adapter can also be used as a recharge adapter to pressurize the cylinder with nitrogen after filling with wet chemical. Note:This part must be ordered separately. It is not included with the Cylinder and Valve Assembly. Figure 2-5. Discharge Adapter Kit, P/N 844908 FLANGE PLATE O-RING ADAPTER 3/4 in. NPT Component Description P/N 9127100 2-7 January 2007 2-1.1.3 DISCHARGE NOZZLES There are essentially seven types of nozzles in the Range Guard wet chemical system. They are: •ADP •F •DM •R •GRW •LPF •LPR Each nozzle has: • Stainless steel internal strainer and nickel-chrome plated brass body • Special foil seal over the discharge orifice to prevent grease from depositing in the orifice and plugging the nozzle • Grooved rings on the body define the nozzle type (Refer to Table 2-5) Component Description January 2007 2-8 P/N 9127100 Table 2-5. Range Guard Nozzles Nozzle Type Part Number Flow Number Grooves ADP Nozzle B120011 1 1 F Nozzle B120012 2 2 GRW Nozzle B120013 1 3 R Nozzle B120014 1 4 DM Nozzle B120015 3 0 LPF Nozzle B120022 2 1 & 4 LPR Nozzle B120024 1 Disc & Core Component Description P/N 9127100 2-9 January 2007 2-1.1.3.1 ADP Nozzle, P/N B120011 ADP nozzles are used for the following hazards: •Ducts •Plenums • Flat cooking surfaces (griddle) • Split Vat Deep Fat Fryers (low proximity) • Upright Broilers (Salamander) • Closed-top Chain Broilers • Open-top Chain Broilers • Natural/Mesquite Charcoal Charbroiler • Krispy Kreme Model 270 d/h Donut Fryer Figure 2-6. ADP Nozzle, P/N B120011 2-1.1.3.2 F Nozzle, P/N B120012 F nozzles are used for the following hazards: •Fryers • Tilt Skillets/Braising Pans • Pumice Rock (Lava, Ceramic) • Charbroilers Figure 2-7. F Nozzle, P/N B120012 1-7/ 8 i n . ( 4 8 m m ) 13/16 in. (21 mm) 9/16 in. (14 mm) INTERNAL THREAD 3/8 in. NPT 1 GROOVE 1-7/ 8 i n . ( 4 8 m m ) 13/16 in. (21 mm) 9/16 in. (14 mm) INTERNAL THREAD 3/8 in. NPT 2 GROOVES Component Description January 2007 2-10 P/N 9127100 2-1.1.3.3 GRW Nozzle, P/N B120013 GRW nozzles are used for the following hazards: •Woks • Electric Charbroiler (Open Grid) • Radiant Charbroiler Figure 2-8. GRW Nozzle, P/N B120013 2-1.1.3.4 R Nozzle, P/N B120014 R nozzles are used for the following hazard: •Ranges Figure 2-9. R Nozzle, P/N B120014 1-7/8 i n . ( 4 8 m m ) 13/16 in. (21 mm) 9/16 in. (14 mm) INTERNAL THREAD 3/8 in. NPT 3 GROOVES 1-7/ 8 i n . ( 4 8 m m ) 13/16 in. (21 mm) 9/16 in.(14 mm) INTERNAL THREAD 3/8 in. NPT 4 GROOVES Component Description P/N 9127100 2-11 January 2007 2-1.1.3.5 DM Nozzle, P/N B120015 DM nozzles are used for the following hazards: • Mesquite Charbroiler (Chips, Wood, Logs) Figure 2-10. DM Nozzle, P/N B120015 2-1.1.3.6 LPF Nozzle, P/N B120022 LPF nozzles are used for the following hazard: •Fryers Figure 2-11. LPF Nozzle, P/N B120022 1-7/ 8 i n . ( 4 8 m m ) 13/16 in. (21 mm) 9/16 in.(14 mm) INTERNAL THREAD 3/8 in. NPT NO GROOVES 1-7/ 8 i n . ( 4 8 m m ) 13/16 in. (21 mm) 9/16 in.(14 mm) INTERNAL THREAD 3/8 in. NPT 2 GROOVES Component Description January 2007 2-12 P/N 9127100 2-1.1.3.7 LPR Nozzle, P/N B120024 LPR nozzles are used for the following hazard: •Ranges Figure 2-12. LPR Nozzle, P/N B120024 2-1.1.3.8 Swivel Adapter, P/N B120021 The swivel adapter may be used conjunction with any nozzle. Figure 2-13. Swivel Adapter, P/N B120021 1-3/ 4 i n . ( 4 4 m m ) 13/16 in. (21 mm) 13/16 in. (21 mm) INTERNAL THREAD 3/8 in. NPT NO GROOVES 2-1/16 i n . ( 5 2 m m ) 3/8 in. (10 mm) NPT (INTERNAL THREAD) 3/8 in. (10 mm) NPT 1 in. (25 mm) HEX 7/8 in. (22 mm) HEX Component Description P/N 9127100 2-13 January 2007 2-2 CONTROLS 2-2.1 UNIVERSAL CONTROL HEAD (UCH) Control System, P/N B120099 The UCH Control System, P/N B120099, is used for actuating the Range Guard Cylinder and Valve Assembly. The UCH Control System can be attached to the System Valve Actuator, P/N B120042 for direct cylinder mounting, or to a wall for remote mounting. Knockouts are provided to accommodate either type of mounting. The controller can be operated with: • Automatic mechanical detection (fusible-links and thermo-bulb links), • Automatic electrical operation, and • Remote and local manual operation. Figure 2-14. UCH Control System, P/N B120099 3-3/4 in. (95 mm) 8-3/16 in. (208 mm) 9-7/16 in. (240 mm) Component Description January 2007 2-14 P/N 9127100 2-2.1.1 SYSTEM NITROGEN CARTRIDGE, P/N B120043 The UCH Control System uses a nitrogen cartridge for actuating the wet chemical cylinders and is charged with dry nitrogen (see Figure 2-15). The cartridge is mounted inside the UCH Control System to protect it from tampering and provides the date of manufacturing and space (gray band) for recording the installation date. Figure 2-15. System Nitrogen Cartridge, P/N B120043 2-2.1.2 TEST CARTRIDGE, P/N B120044 The Test Cartridge is used for testing of the Badger Wet Chemical System. The cartridge has a red band and labeled “TEST CARTRIDGE” as shown in Figure 2-16. Note:The System Nitrogen Cartridge P/N B120043 is required for actuation and full discharge or "puff" tests. Figure 2-16. Test Cartridge, P/N B120044 CAUTION The Test Cartridge (P/N B120044) must be removed and the System Nitrogen Cartridge (P/N B120043) must be installed at the completion of any work done on the system. Failure to do so will result in malfunction of the system. 5-1/8 in. (130 mm) 1-9/16 in. (40 mm) GRAY BAND 4 in. (102 mm) 1 in. (25 mm) Component Description P/N 9127100 2-15 January 2007 2-2.1.3 SYSTEM VALVE ACTUATOR (SVA), P/N B120042 A System Valve Actuator (SVA) is mounted to every wet chemical cylinder valve assembly (see Figure 2-17). The SVA has ports for low profile tubing runs, and is also equipped with a spring loaded plunger that locks the piston in the discharged position, ensuring complete discharge of the cylinder(s) contents. Figure 2-17. System Valve Actuator (SVA), P/N B120042 1/8 in. NPT PLUG (IF APPLICABLE) 5/16-18 UNC THROUGH HOLE (TYP) (NOT SHOWN) PISTON IN ACTUATED POSITION (TOWARDS CYLINDER VALVE) 1-3/4 in. (44 mm) SPRING LOADED PLUNGER 1/8 in. NPT PORT SVA PISTON IN SET POSITION Component Description January 2007 2-16 P/N 9127100 2-2.1.4 HIGH-PRESSURE NITROGEN TUBING, P/N B120045 The High-Pressure Nitrogen Tubing is used to connect the UCH Control System to the SVA (see Figure 2-18). A 1/8-inch NPT (male) x 3/8-24 JIC Adapter is included with the High Pressure Nitrogen Tubing. Figure 2-18. External Tubing for UCH Control System, P/N B120045 WARNING The braided High-Pressure Nitrogen Tubing, is required on all installations in which the UCH Control System is mounted to a wet chemical cylinder. Use of another hose in such an installation could result in death or serious personal injury and/or malfunction of the system. Table 2-6. External Tubing for UCH Control System Part Number Length "A" B120045-001 7-1/2 in. (191 mm) B120045-002 24 in. (610 mm) B120045-003 60 in. (1524 mm) 1/8 in. NPT THREAD 1/2 in. HEX, 1/4 in. 37 DEGREE FLARE, SWIVEL A (END TO SEAT) SEAT 1/8 in. NPT (MALE) x 3/8-24 JIC ADAPTER Component Description P/N 9127100 2-17 January 2007 2-2.1.5 SOLENOID, P/N B100034 Note:Where electric detection and/or actuation is provided, supervision shall be provided in accordance with NFPA 72. Alarms and indicators, along with a supervised power source, shall be provided in accordance with NFPA 72, National Fire Alarm Code. Electrical wiring and equipment shall be provided in accordance with NFPA 70, National Electric Code. All installations are subject to the approval of the Authority Having Jurisdiction (AHJ). An optional solenoid can be installed into the UCH Control System, just under the actuation latch. The solenoid operates directly on the actuation latch to activate the system. This installation allows simultaneous usage of mechanical detection lines, or the lines can be locked out. The solenoid includes two mounting bolts, the bracket and a push plate which mounts onto the solenoid body (see Figure 2-19). The solenoid coil is 24 Vdc at 1.5 Amp and at 70°F (21°C). Note:When actuating the UCH Control System with an optional solenoid, a UL Compatible and Listed fire control panel with a supervised power supply is required. For example: Scorpio. Figure 2-19. Solenoid, P/N B100034 ELECTRICAL LEADS 24 in. (610 mm) MOUNTING BRACKET (DO NOT REMOVE) PUSH PLATE (DO NOT REMOVE) SOLENOID BODY 9/64 in. ALLEN SCREWS (2) Component Description January 2007 2-18 P/N 9127100 2-2.1.6 MICROSWITCH KIT, P/N B120039, B120039-501 (FOR UCH) The Microswitch Kit is a single pole, double-throw switch (see Figure 2-20 and Table 2-7). Included in the kit is the microswitch, pigtail assembly and four mounting screws (two short and two long). Note:Microswitch Kit P/N B120039-501 includes pigtail assembly with white stripes. The wire leads are 24-inches (610 mm) in length. Four Microswitch Kits can be mounted in the UCH Control System. There are two mounting locations to accommodate the four Microswitch kits (two stacked at each mounting location), with EMT ports for each mounting location. This allows for the use of two electrical junction boxes for separation of signal lines and AC lines. These are used when it is necessary to open or close electrical circuits. The following are examples, but not limited to: • Electric appliance shutdown • Make up air shutdown • Electric gas valve shutdown • Shuntbreaker/relay Electrical appliances usually have a higher amp rating than the switches. In this case, such appliances shall not be wired directly to the microswitch. A magnetic contactor or relay must be used. To wire the microswitch for UCH, refer to Figure 4-30. Figure 2-20. Microswitch Kit, P/N B120039 Table 2-7. Microswitch Electrical Ratings 125/250 Vac 20.5 Amps 250 Vac 1-1/2 HP 125 Vac 1/2 HP ELECTRICALCONNECTOR MICROSWITCH Component Description P/N 9127100 2-19 January 2007 2-2.1.7 TERMINAL TYPE MICROSWITCH KIT, P/N B120047 (FOR UCH) The Microswitch Kit is a single pole, double-throw switch (see Figure 2-21). Note:Use the Terminal Type Microswitch when using the UCH Control System for alarm and release functions. Four Microswitch Kits can be mounted in the UCH Control System. There are two mounting locations to accommodate the four Microswitch kits (two stacked at each mounting location), with EMT ports for each mounting location. This allows for the use of two electrical junction boxes for separation of signal lines and AC lines. Microswitch to be used for • Alarm initiationTrip a magnetic contactor to turn off the electrically operated cooking appliance •Solenoid release Electrical appliances usually have a higher amp rating than the switches. In this case, such appliances shall not be wired directly to the microswitch. A magnetic contactor or relay must be used. To wire the microswitch for UCH, refer to Figure 4-35 and Figure 4-36. Figure 2-21. Terminal Type Microswitch, P/N B120047 Table 2-8. Terminal Type Microswitch Electrical Ratings 250 Vac 15 Amps 250 Vac 1/2 HP 125 Vac 1/2 HP MICROSWITCH SHIELD T1T4 T2 FLAG ENGAGED BY UCH Component Description January 2007 2-20 P/N 9127100 2-2.2 A+ Control Box, P/N B120010 The A+ Control Box (shown in Figure 2-22) is comprised of a CO2 cartridge, spring mechanism and a discharge lever which discharges the CO2 cartridge when: • a thermo-bulb and/or fusible-link separates in any detector or, • the Remote Manual Release is operated. The valve, with the CO2 cartridge, is connected to a System Valve Actuator mounted on system cylinders by 1/4 in. (6 mm) O.D. copper tubing using compression or flare fittings. Note:The tubing is standard, commercially available tubing and is not supplied with the system. Figure 2-22. A+ Control Box, P/N B120010 (Cover Removed) The A+ Control Box can operate a maximum of five cylinders, regardless of size. A System Valve Actuator (B100042) is required on each system cylinder. One is supplied with the A+ Control Box. SPRING VALVE BODY SUBASSEMBLY LEVER (Part of Valve Body Subassembly) MECHANICAL GAS VALVE CABLE CABLE TENSION BLOCK ASSEMBLY DETECTION CABLE (NOT SUPPLIED) TUBING ELBOW FITTING (Part of Valve Body Subassembly) GROMMET 1/4 in. O.D. (6 mm) COPPER TUBING TO SVA (NOT SUPPLIED) C CARTRIDGEO2 Component Description P/N 9127100 2-21 January 2007 2-2.2.1 CO2 CARTRIDGE, P/N 9197203 When the CO2 cartridge discharges, the CO2 gas pressurizes the 1/4 in. (6 mm) O.D. tubing to the System Valve Actuator(s), located on the system Cylinder Valve, and actuates the cylinder(s) (see Figure 2-23). Figure 2-23. CO2 Cartridge, P/N 9197203 2-2.2.2 CABLE TENSION BLOCK, P/N 9197220 The Cable Tension Block in Figure 2-24 is used to set and maintain tension on the detector cable within the A+ Control Box. Figure 2-24. Cable Tension Block, P/N 9197220 11/16 in. (19 mm) 3-1/4 in. (83 mm) GRAY BAND CABLE TENSION BLOCK ADJUSTING SCREW Component Description January 2007 2-22 P/N 9127100 2-2.2.3 SINGLE SPDT MICROSWITCH KIT, P/N 9197227 (FOR A+) The Single SPDT Microswitch Kit is a single pole, double-throw microswitch (see Figure 2-25 and Table 2-9). Included in the kit: • Microswitch • Pigtail assembly • Mounting bracket and hardware (screws, lockwashers and hex nuts) • Microswitch mounting hardware (screws, lockwashers and hex nuts) The wire leads are 24-inches (610 mm) in length. One Single SPDT Microswitch Kit can be mounted in the A+ Control Box. These are used when it is necessary to open or close electrical circuits. The following are examples, but not limited to: • Electric appliance shutdown • Make up air shutdown • Electric gas valve shutdown • Shuntbreaker/relay Electrical appliances usually have a higher amp rating than the switches. In this case, such appliances shall not be wired directly to the microswitch. A magnetic contactor or relay must be used. To wire the microswitch for A+, refer to Figure 4-48. Figure 2-25. Single SPDT Microswitch Kit, P/N 9197227 Table 2-9. SPDT Microswitch Electrical Ratings 125/250/277 Vac 15 Amps 125/250/277 Vac 1/2 HP 125 Vdc 1/2 Amp 250 Vdc 1/4 Amp 120 Vac “L” 5.0 Amp ELECTRICAL CONNECTOR MICROSWITCH Component Description P/N 9127100 2-23 January 2007 2-2.2.4 DUAL SPDT MICROSWITCH KIT, P/N 9197228 (FOR A+) The Dual SPDT Microswitch Kit consists of two single pole, double-throw (SPDT) microswitches (see Figure 2-26 and Table 2-10). Included in the kit: • Microswitches (2 - cut lever paddle and bent lever paddle microswitches) • Pigtail assembly • Mounting bracket and hardware (screws, lockwashers and hex nuts) • Microswitch mounting hardware (screws, lockwashers, and hex nuts) The wire leads are 24-inches (610 mm) in length. One Dual SPDT Microswitch Kit can be mounted in the A+ Control Box. These are used when it is necessary to open or close electrical circuits. The following are examples, but not limited to: • Electric appliance shutdown • Make up air shutdown • Electric gas valve shutdown • Shuntbreaker/relay Electrical appliances usually have a higher amp rating than the switches. In this case, such appliances shall not be wired directly to the microswitch. A magnetic contactor or relay must be used. To wire the microswitch for A+, refer to Figure 4-48. Figure 2-26. Dual SPDT Microswitch Kit, P/N 9197228 Table 2-10. Dual SPDT Microswitch Electrical Ratings 125/250/277 Vac 15 Amps 125/250/277 Vac 1/2 HP 125 Vdc 1/2 Amp 250 Vdc 1/4 Amp 120 Vac “L” 5.0 Amp 4-40 x 1 in. (25 mm) SCREWS ELECTRICAL CONNECTOR BENT LEVER MICROSWITCH 4-40 NUTS AND LOCKWASHERS MICROSWITCH BRACKET CUT LEVER MICROSWITCH TOP VIEW ENSURE THE CUT LEVER MICROSWITCH PADDLE GOES UNDER THE PADDLE OF THE BENT LEVER MICROSWITCH Component Description January 2007 2-24 P/N 9127100 2-2.3 Automatic Detectors and Accessories 2-2.3.1 DETECTOR HOUSING KIT, P/N 804548 (UCH ONLY) The Detector Housing Kit, shown in Figure 2-27, consists of the following: These items are used to attach the detectors to the 1/16-inch cable leading to the UCH Control System. The Detector Housing can be configured as an End-of-Line or In-Line bracket. Figure 2-27. Example of End-of-line and In-line Detector Housing Kit, P/N 804548 Table 2-11. Detector Housing Kit, P/N 804548 Item Quantity 7-9/16 in. (192 mm) Detector Housing 1 1/2-inch EMT Connectors 2 Crimp Sleeves 4 “S” Hook 1 LOCKNUT (NOT SUPPLIED) “S” HOOKS CRIMP SLEEVE 1/16 in. CABLE TO UCH CONTROL SYSTEM (NOT SUPPLIED) 1/2 in. EMT PIPE (NOT SUPPLIED) THERMO-BULB OR FUSIBLE-LINK (NOT SUPPLIED) “S” HOOKS 1/2 in. EMT CONNECTOR AND LOCKNUT (NOT SUPPLIED) 1/16 in. CABLE TO UCH CONTROL SYSTEM (NOT SUPPLIED) 1-1/2 in. (38 mm) MIN. EXAMPLE OF END-OF-LINE DETECTOR HOUSING KIT EXAMPLE OF IN-LINE HOUSING KITDETECTOR THERMO-BULB OR FUSIBLE-LINK (NOT SUPPLIED) Component Description P/N 9127100 2-25 January 2007 2-2.3.2 UNIVERSAL-LINK HOUSING KIT, P/N 120064 The Universal-Link Housing Kit, shown in Figure 2-28, consists of the following: The items above are used to attach the Fusible-Link or Thermo-Bulb Links to the 1/16-inch cable leading to the UCH Control System or A+ Control Box. The Universal-Link Housing can be configured as an End-of-Line or In-Line bracket. Figure 2-28. Example of End-of-line and In-line Universal Link Housing Kit, P/N 120064 Table 2-12. Universal Link Housing Kit, P/N 120064 Item Quantity 11-1/2 in. (292 mm) Detector Housing 1 Crimp Sleeves 2 “S” Hooks 2 EXAMPLE OF IN-LINE UNIVERSAL HOUSING KIT EXAMPLE OF END-OF-LINE UNIVERSAL HOUSING KIT 1/2 in. EMT CONNECTOR (NOT SUPPLIED) LOCKNUT (NOT SUPPLIED) “S” HOOKS CRIMP SLEEVE 11-1/2 i n . ( 2 9 2 m m ) 1/16 in.CABLE TO CONTROL SYSTEM (NOT SUPPLIED) “S” HOOK CRIMP SLEEVE THERMO-BULB LINK OR FUSIBLE-LINK (NOT SUPPLIED)THERMO-BULB LINK OR FUSIBLE-LINK (NOT SUPPLIED) Component Description January 2007 2-26 P/N 9127100 2-2.3.3 THERMO-BULB LINKS, P/N B12009X-XXX Thermo-Bulb Links, shown in Figure 2-29, are used in conjunction with Universal-Link Housing Kits (P/N 120064) and/or Detector Housing Kits (P/N 804548). The links are held together with a liquid- filled glass tube (Thermo-Bulb), which bursts at a predetermined temperature, allowing the two halves of the link to separate. The types of Thermo-Bulb links are: •Rapid Response • Standard Response These Thermo-Bulb links are available in various temperature ratings with a minimum/maximum load rating of 0 lb./50 lb. (0 kg/23kg) (see Table 2-13). Figure 2-29. Thermo-Bulb Link, P/N B12009X-XXX Table 2-13. Rapid and Standard Response Thermo-Bulb Link Temperature Ratings Rapid Response Part Numbers Standard Response Part Numbers Temperature Color Maximum Exposure Temperature B120095-165 B120090-165 165°F (74°C) Red 100°F (38°C) B120095-212 B120090-212 212°F (100°C) Green 150°F (66°C) B120095-286 B120090-286 286°F (141°C) Blue 225°F (107°C) B120095-360 B120090-360 360°F (182°C) Mauve 300°F (149°C) B120095-450 B120090-450 450°F (232°C) Black 375°F (191°C) B120095-500 B120090-500 500°F (260°C) Black 475°F (246°C) RAPID RESPONSE THERMO-BULB LINK STANDARD RESPONSE THERMO-BULB LINK Component Description P/N 9127100 2-27 January 2007 2-2.3.4 FUSIBLE-LINKS, P/Ns B282661, B282662, B282664 and B282666 Fusible-Links are available in various temperature ratings with a minimum/maximum load rating of 10 lb./40 lb. (5 kg/18 kg) (see Table 2-14). Figure 2-30. Fusible-Link, P/N B28266X The rating temperature, which is stamped on the Fusible-Link, is the temperature at which the link will separate when new. However, continual exposure to cycling ambient temperatures may cause a degradation of the link over time. Table 2-14. Fusible-Link Temperature Ratings Fusible-Link Rating Maximum Exposure Temperature Color Part Number 165°F (74°C) 100°F (38°C) Yellow B282661 212°F (100°C) 150°F (65°C) White B282662 360°F (182°C) 300°F (149°C) Unpainted B282664 500°F (260°C) 440°F (226°C) Orange B282666 Component Description January 2007 2-28 P/N 9127100 2-2.3.5 FUSIBLE-LINK, P/N 9196903 Fusible-Links are available with a minimum/maximum load rating of 3 lb. — 45 lb. (1.4 Kg — 20.4 Kg). See Table 2-15. Figure 2-31. Fusible-Link, P/N 9196903 2-2.3.6 ELECTRICAL DETECTION (DETECT-A-FIRE) Refer to Appendix A for electrical detection (Detect-A-Fire). Table 2-15. Fusible-Link (Model RGA) Temperature Ratings Fusible-Link Rating Maximum Exposure Temperature Part Number 360°F (182°C) 300°F (149°C) 9196903 Component Description P/N 9127100 2-29 January 2007 2-2.3.7 CORNER PULLEY, P/N B844648 The Corner Pulley is used to change the direction of the control cable runs. The cable’s protective conduit (1/2-inch EMT) is attached to the Corner Pulleys with the coupling nuts provided. The Corner Pulley is equipped with a ball-bearing pulley for minimum resistance to the cable travel. Figure 2-32. Corner Pulley, P/N B844648 3 in. (76.2 mm) 3 in. (76.2 mm) Component Description January 2007 2-30 P/N 9127100 2-2.3.8 TEE PULLEY, P/N 843791 (UCH ONLY) The Tee Pulley is required when more than one Remote Manual Release (P/N B875572) or two (2) gas valves are used in the same system. Figure 2-33. Tee Pulley, P/N 843791 SINGLE OUTLET END TO REMOTE MANUAL RELEASE TO REMOTE MANUAL RELEASE4-5/16 in. (110.2 mm) 4-1/2 in. (114 mm) Component Description P/N 9127100 2-31 January 2007 2-2.4 Remote Manual Releases 2-2.4.1 REMOTE MANUAL RELEASE, P/N B875572 (UCH ONLY) The Remote Manual Release, shown in Figure 2-34, is provided as a means of manually actuating the system from a remote location. The Remote Manual Release is attached to the UCH Control System with 1/16-inch control cable. To actuate the system at the Remote Manual Release, pull out the safety pin and pull hard on the handle. Each Remote Manual Release is supplied with a separate nameplate. This nameplate must be attached to the mounting surface 1-inch above or below the Remote Manual Release. Figure 2-34. Remote Manual Release, P/N B875572 3-5/8 in. (92.2 mm) 1-1/2 in. (38 mm) Component Description January 2007 2-32 P/N 9127100 2-2.4.2 REMOTE MANUAL RELEASE PULL STATION, P/N 87-120110-001 The Remote Manual Release Pull Station, shown in Figure 2-34, is provided as a means of manually actuating the system from a remote location. The Remote Manual Release is attached to the XV Control System or the KRS-50 Control Box, with 1/16-inch control cable. The Remote Manual Release Pull Station is available for use in both the “un-tensioned” Pull-to-Trip and “tensioned” Release-to- Trip lines. To actuate the system at the Remote Manual Release Pull Station, pull out the safety pin and pull hard on the handle. In the Pull-to-Trip mode (XV ONLY), tension will be applied to the cable, allowing the XV Control System to activate the Cylinder and Valve Assembly. In the Release-to-Trip mode, removing the safety pin will release tension from the cable, allowing the XV Control System or KRS-50 Control Box to activate the Cylinder and Valve Assembly. The Remote Manual Release Pull Station may be mounted in a recess or surface mount configuration. The assembly is packaged with all necessary components needed to install in either configuration. Mounting hardware is not included. Each Remote Manual Release Pull Station is supplied with a choice of labels. The proper label must be attached to the faceplate so as to be easily read after installation. Applying the label after installation allows for vertical or horizontal mounting of the Remote Manual Release Pull Station. Figure 2-35. Remote Manual Release Pull Station, P/N 87-120110-001 4-7/8 in. (125 mm) 3-9/16 in. (91 mm) 2-1/16 in. (52 mm) Component Description P/N 9127100 2-33 January 2007 2-2.4.3 SURFACE MOUNTED REMOTE MANUAL CONTROL There are two types of Surfaced Mounted Remote Manual Releases available for the UCH Control System and A+ Control Box: • End-of-Line Surface Mounted Remote Manual Control, P/N 9197463 (Figure 2-36) • In-Line Surface Mounted Remote Manual Control (with In-Line Kit), P/N B100030 (Figure 2-37) Each is used as a means to actuate the system manually from a remote location. This is accomplished by removing the pull pin, releasing the tension in the detection cable, allowing the Control Box to activate the cylinder. If an End-of-Line Remote Manual Release is not applicable, it can be converted to an In-Line Remote Manual Release by using an In-Line Kit. Refer to the installation section of this manual. An In-Line Kit uses a Tee Pulley and Corner Pulley Bearing to modify the End-of-Line Remote Manual Release. Refer to the installation section of this manual for installation parameters. Note:Only use End-of-Line Remote Manual Release if no detectors are installed. Figure 2-36. Surface Mounted End-of-Line Remote Manual Release, P/N 9197463 4-3/4 in. (121 mm) 3 in. (76 mm) Component Description January 2007 2-34 P/N 9127100 2-2.4.4 RECESS MOUNTED REMOTE MANUAL CONTROL FOR A+ CONTROL BOX AND UCH CONTROL BOX The Recess Mounted Remote Manual Control provides a means to operate the system manually from a remote location. It is designed to be mounted to a wall stud and is provided with a cover plate. Two types of Recess Mounted Remote Manual Controls are available: • End-of-Line Remote Manual Control (P/N 9197461) — designed for use at the end of the detection line (Figure 2-37 ). • In-Line Remote Manual Control (P/N 9197460) — designed for installation within the detection line. A Tee Pulley is included with the In-Line Remote Manual Control (Figure 2-38). Note:Only use End-of-Line Remote Manual Release if no detectors are installed. Figure 2-37. Recess Mounted End-of-Line, Remote Manual Release, P/N 9197461 2-13/16 in. (72 mm) 4-9/16 in. (116 mm) 5-7/8 in. (149 mm) Component Description P/N 9127100 2-35 January 2007 Figure 2-38. Recess Mounted, In-Line Remote Manual Release, P/N 9197460 CONDUIT (NOT SUPPLIED) CONDUIT (NOT SUPPLIED) 3-1/4 in. (83 mm) 2-5/16 in. (59 mm) 4 in. (102 mm) 2-1/8 in. (54 mm) 2-13/16 in. (72 mm) TEE PULLEY 1/16 in. CABLE (NOT SUPPLIED) Component Description January 2007 2-36 P/N 9127100 2-3 AUXILIARY COMPONENTS 2-3.1 Pneumatic Release, P/N 9189412 The Pneumatic Release can be used to release the stem of a spring loaded gas shut off valve with a minimum operating pressure of 35 PSI (241 kPa). When a system discharges, pressure on the piston within the Pneumatic Release causes the piston to move, thereby retracting a normally protruding pin. The pin is used as a support for a cable linkage to: • Gas valve stem • Ventilation dampers The 1/8-inch by 1-1/2-inch pipe nipple connects the Pneumatic Release to a 12-inch riser off the agent distribution piping. Retraction of the pin removes support for the linkage allowing it to pull away, thus releasing the valve stem which now moves to the closed position under the force of the valve closing spring. Figure 2-39. Pressure Operated Release, P/N 9189412 PNEUMATIC RELEASE S-HOOK CABLE CRIMP 4 in. (102 mm) 3/4 in. (19 mm) 1/8 in. (3 mm) x 1-1/2 in. PIPE NIPPLE 1/16 in. CABLE (NOT SUPPLIED) Component Description P/N 9127100 2-37 January 2007 2-3.2 Pressure Switch, P/N 9197023 The Pressure Switch, P/N 9197023 (Figure 2-40), can be used in place of microswitches to open or close electrical circuits to: • sound an alarm • trip a magnetic contactor to turn off the electrically operated cooking appliance • operate an electric gas valve • shut off exhaust fans The adjustable range of the Pressure Switch is 10—100 PSI. The setpoint is factory set at 20 PSI in rise. Note:There is no limit to the quantity of Pressure Switches in a Range Guard System. Figure 2-40. Pressure Switch, P/N 9197023 Table 2-16. Pressure Switch (SPDT) Electrical Specifications 115/230 Vac 15 Amps 28 Vdc 5 Amps 75 Vdc 1 Amp 125 Vdc 1/2 Amp 250 Vdc 1/4 Amp Yellow Wire Common Blue Wire Normally Open Black Wire Normally Closed WARNING Electrical appliances usually have a higher amperage rating than 15 amps and must not be wired directly to the Pressure Switch. A magnetic contactor or relay must be used. 3-1/2 in. (89 mm) 1-15/16 in. (49 mm) 1/2 in. (13 mm) NPT 5/8 in. (16 mm) 9/16 in. (14 mm) Component Description January 2007 2-38 P/N 9127100 2-3.3 Mechanical Gas Valve, P/N B12007X A Mechanical Gas Valve is required on systems used to protect gas-fueled appliance(s). Upon system actuation, the control stem closes, stopping the gas flow to the appliance(s). Note:Only Mechanical Gas Valves that are specifically UL listed and identified by part number in this manual may be used with the Range Guard system. Figure 2-41. Mechanical Gas Valve, P/N B12007X Table 2-17. Mechanical Gas Valve Sizes Pipe Size Part Number 3/4 in. (19 mm) B120071 1 in. (25.4 mm) B120072 1-1/4 in. (32 mm) B120073 1-1/2 in. (38 mm) B120074 2 in. (51 mm) B120075 2-1/2 in. (64 mm) B120076 3 in. (76 mm) B120077 CONTROL STEM OUTLETINLET Component Description P/N 9127100 2-39 January 2007 2-3.4 Electric Gas Valve, P/N 9197XXX Electric Gas Valve (Figure 2-42) operates on (120V, 60 Hz) which powers a solenoid holding the valve open. This valve is controlled by a pressure switch or microswitch and the Manual Reset Relay Box. See Paragraph 2-3.5. Upon system actuation, the valve closes, stopping the gas flow to the appliance(s). A loss of electrical power will also cause the Electric Gas Valve to close. See Table 2-18 for a list of the electric gas valve sizes. All Electric Gas Valves must be installed horizontally with the solenoid up. Note:The electric gas valve and the Manual Reset Relay must be specifically UL listed for use with the Range Guard system. Figure 2-42. Electric Gas Valve, P/N 9197XXX Table 2-18. Electric Gas Valve Sizes Size Part Number 1/2 in. (13 mm) 9197017 3/4 in. (19 mm) 9197018 1 in. (25 mm) 9197019 1-1/4 in. (32 mm) 9197020 1-1/2 in. (38 mm) 9197021 2 in. (51 mm) 9197022 2-1/2 in. (64 mm) 9197444 3 in. (76 mm) 9197445 SOLENOID Component Description January 2007 2-40 P/N 9127100 2-3.5 Manual Reset Relay for Electric Gas Valve, P/N 9101735 The Manual Reset Relay Box (Figure 2-43 and Figure 2-44) provides DPDT contacts rated for 6 amps at 115 Vac and prevents immediate reopening of the Electric Gas Valve (P/N 9197XXX). Figure 2-44 shows the Manual Reset Relay Box used before 2006. Note:The Electric Gas Valve and the Manual Reset Relay must be specifically UL listed for use with the Range Guard system. Figure 2-43. Manual Reset Relay Box, P/N 9101735 Figure 2-44. Manual Reset Relay Box, P/N 9101735 (Used Before 2006) Component Description P/N 9127100 2-41 January 2007 2-3.6 EMT and O-Ring Connector Kit, P/N B120058 If using more than the three EMT connectors supplied with the UCH Control System, you must use EMT Connector and O-Ring Connector Kit. Figure 2-45. EMT and O-Ring Connector Kit, P/N B120058 2-3.7 1/16-inch Control Cable, P/N 219649 The Control Cable used in the system is stainless-steel, 1/16-inch O.D., 7x7 stranded cable. The control cable runs from the various system devices, through 1/2-inch EMT conduit, to the UCH or A+ Control System. 2-3.8 Crimp Sleeve, P/N 214951 In order to ensure that a crimp sleeve is secure, the cable must always be looped so that there are two lengths of cable inside the Crimp Sleeve before crimping. Cable must not be spliced anywhere along its length. Figure 2-46. Crimp Sleeve, P/N 214951 Table 2-19. 1/16-inch Control Cable Part Number Description 219649 1/16, 7x7 Cable, Stainless Steel, Reel of 500 ft. (152 m) Table 2-20. Crimp Sleeve Part Number Description 214951 Cable Crimp Sleeve (order in package of 50 only) 9197288 Cable Crimp Sleeve (package of 50 of 214951) Component Description January 2007 2-42 P/N 9127100 2-3.9 “S” Hooks, P/N 9189413 "S" Hooks are used to attach the Fusible-Link to the 1/16-inch. cable leading to the UCH Control System. Figure 2-47. “S” Hook, P/N 9189413 2-3.10 Crimping Tool, P/N 253538 The Crimping Tool (P/N 253538), shown in Figure 2-48, is used in conjunction with Crimp Sleeves. Wherever the system 1/16-inch Control Cable must be looped or terminated, the Crimp Sleeves and Crimping Tool must be used. Note:Splicing of the 1/16-inch Control Cable is not permitted. Other Crimping Tools are not authorized. Figure 2-48. Crimping Tool, P/N 253538 Table 2-21. “S” Hook Part Number Description 9189413 “S” Hook (order in package of 50 only) 9187287 “S” Hook (package of 50 of 9189413)WK253538 Component Description P/N 9127100 2-43 January 2007 2-3.11 1/2-inch Vent Plug, P/N 9196984 A 1/2-inch Vent Plug is used in the discharge piping near a Range Guard cylinder to prevent pressure build-up in the discharge pipe system, caused by heat, from rupturing the foil seals on each nozzle. The 1/2-inch Vent Plug is to be installed in the discharge piping so that it faces the ceiling or the wall. Figure 2-49. 1/2-inch Vent Plug, P/N 9196984 2-3.12 Keeper Pin, P/N 9197108 The Keeper Pin (P/N 9197108) is used to prevent actuation while installing the system. Figure 2-50. Keeper Pin, P/N 9197108 2-3.13 System Recharge For recharge purposes, select the size of the Karbaloy agent recharge container (see Table 2-22) that fits the cylinder. CAUTION NEVER INSTALL IT FACING DOWN OR AT THE FLOOR. Table 2-22. Wet Chemical Agent Part Number Wet Chemical 9197428 RG-1.25G Karbaloy Recharge Container 9197257 RG-2.5G Karbaloyl Recharge Container 9196991 RG-4GS/RG-4GM Karbaloy Recharge Container 9196783 RG-6G Karbaloy Recharge Container 1-1/8 in. (29 mm) 1/2 in. (13 mm) NPT Component Description January 2007 2-44 P/N 9127100 THIS PAGE INTENTIONALLY LEFT BLANK. System Design P/N 9127100 3-1 January 2007 CHAPTER 3 SYSTEM DESIGN 3-1 INTRODUCTION This chapter introduces the designer and installer to the process whereby Range Guard® Wet Chemical Systems are designed. It outlines the process, introduces the limitations imposed on design by system hardware, as well as those mandated by performance considerations. As the designer becomes familiar with this material, they should remember that analysis and design is a careful, step-by-step process. All steps must be followed, none can be omitted, and all unique aspects of a given application must be taken into account if the resulting fire-suppression system is to deliver the desired results. All systems must be designed in accordance with the latest edition of NFPA Standard 17A, “Standard for Wet Chemical Systems”, and other applicable NFPA standards. All configurations are UL and ULC/ORD 1254.6 Listed to Underwriters Laboratories 300, 1994 Edition, unless otherwise noted. 3-2 DESIGN PROCEDURE This section covers the design aspects of the Karbaloy systems. It contains all the necessary information to design a complete system including nozzle placement, detector placement, cylinder sizing, piping limitations and auxiliary hardware. 3-2.1 General Design Procedure Analysis and design should be approached as a methodical process, and performed step-by-step. Only when all the steps are followed is the resulting system likely to perform as desired. If any step is omitted, it is probable that the system will not function as well as it should. The steps in the analysis and design process are: • Hazard analysis • Nozzle selection, number and location • Cylinders (Number, size, and location of cylinders) • Detector selection • Piping layout • Auxiliary requirements 3-2.1.1 HAZARD ANALYSIS Sketch out the kitchen exhaust hood and appliances, taking note of the path of egress for remote pull station location, discuss with owner the placement of cylinders and control heads, automatic fuel shut down device locations, and any power shutdowns required. Consult NFPA 17A and 96 for design guidelines. Record the following and include in your sketch: • Size of exhaust hood(s) and exhaust duct opening(s) • Size and fuel type of appliances (take note if open flames are sufficiently separated from combustible cooking media) • Size of gas line(s) feeding appliances • Building or local alarms System Design January 2007 3-2 P/N 9127100 • Make up air or auxiliary equipment • Are the correct hand portable fire extinguishers present or are additional extinguishers required 3-2.1.2 NOZZLE SELECTION AND LOCATION Select the number and type(s) of nozzle(s) needed and locate them so that the entire hazard is covered. Use the coverage/distribution specifications for each nozzle type to determine the number of discharge nozzles required to deliver the necessary quantity of wet chemical given nozzle placement appropriate to the hazard. 3-2.1.3 CYLINDER DETERMINATION (NUMBER, SIZE, AND LOCATION OF CYLINDER(S)) Determine the number of nozzles required, whether additional agent or nozzles may be needed, and select the cylinder which will supply the needed amounts wet chemical. After determining the quantity and types of wet chemical needed to control the hazard itself, determine whether any special conditions necessitate additional wet chemical quantities and/or nozzles. For example, it may be necessary to adjust the agent discharge rate in order to offset the effects of ventilation, or it may be necessary to screen openings in an enclosure to prevent wet chemical leakage through those openings. 3-2.1.4 DETECTOR SELECTION Detector selection will depend on the response speed required, the probable heat level and rate of spread of the fire. The detectors sense the heat energy released by the combustion of fuel and oxygen. Upon detection of a fire, the detection system sends a signal to the system control head(s) which initiates the wet chemical discharge. The most commonly used detectors are the: 1. Fixed-temperature thermo-bulb or fusible link 2. Fixed-temperature rate-compensated thermostat 3-2.1.5 PIPING LAYOUT Careful piping layout assures that the agent reaches the distribution nozzles appropriately, and that piping parameters are not exceeded. These parameters involve pipe lengths, the number of elbows, and other factors such as the allowable distances (equivalent/feet) from Cylinder and Valve Assembly. These parameters are discussed in detail in the design examples in Paragraph 3-8. 3-2.1.6 AUXILIARY REQUIREMENTS Controls are required to turn off force-draft ventilation systems, fuel (or combustible-liquid) pumps, conveyors, and so on. System Design P/N 9127100 3-3 January 2007 3-3 DESIGNING FOR APPLIANCE PROTECTION To determine the number and size of cylinders required for each system, the term "flow number" is used. A flow number is assigned to each type of nozzle used in the Range Guard system and is a relative indicator of the discharge rate of each nozzle. Refer to Table 3-1 for coverage on a specific appliance. ADP nozzles have a flow number of one. The ADP nozzle is used to protect a variety of cooking appliances. These appliances are solid fuel charbroilers, upright broilers, low proximity Split Vat Deep Fat Fryers, griddles and chain broilers. Additionally, the ADP nozzle is used to protect the duct and plenum areas of the hood. The ‘F’ nozzle has a flow number of two and is used to protect fryers and lava rock broilers. The 'R' nozzle has a flow number of one and is used to protect a burner range. The GRW nozzle has a flow number of one and is used to protect a radiant charbroiler or a wok. The LPF nozzle has a flow number of two and is used to protect a deep fat fryer requiring a low nozzle height. The LPR nozzle has a flow number of one and is used to protect a four burner range requiring a low nozzle height (eg. range with a backshelf or an integral broiler). The DM nozzle has a flow number of three and is used to protect the mesquite log charbroiler. After completing your design for locating nozzles over the cooking appliances to be protected, determine the total of the flow numbers required, including those for the plenum and exhaust duct(s). This will render the required cylinder size for the total number of flow points. Note:Protection of combination appliances requires a seperate nozzle for each appliance. CAUTION While nozzles can be placed anywhere in the areas denoted in the following sections, caution should be exercised regarding placement and aiming of nozzles from the back of the appliance toward appliance operators. System Design January 2007 3-4 P/N 9127100 3-3.1 Nozzle Height Measurement of the nozzle heights are to be from the tip of the nozzle to the top of the appliance. When using the grid style nozzle location the nozzle height is measured from the nozzle tip to the aiming point. When using perimeter style nozzle location the nozzle height is measured from the nozzle tip straight down to the appliance surface. EXCEPTION: Woks are measured to the inside bottom of the wok. 3-3.2 Nozzle Aim Correct aiming of the appliance nozzles is extremely important to the performance of the system. Care should be taken to insure accurate aiming and that the conical spray from the nozzle is not obstructed. Aiming must comply with the parameters outlined in the design section of this manual. 3-3.3 Hazard Area The hazard area is the actual size of the portion of the appliance which can be used for cooking. The physical width of an appliance does not represent the width of the hazard area. The thickness to the appliance wall must be deducted to arrive at the hazard area width. The appliance area is the size of the appliance that includes the cooking area (fry pot or vat) and the integral drip board area. Figure 3-1. Examples of Hazard Areas for Typical Appliances CAUTION All appliances being protected must be shut off automatically upon system actuation. Appliance Area Length Appliance Area Width System Design P/N 9127100 3-5 January 2007 3-4 APPLIANCES Table 3-1 lists the various appliances and nozzle type used to protect that appliance. Table 3-1. Appliance References Appliance Reference Nozzle Flow Number Deep Vat Fryer Single Vat Deep Fryer with Drip Boards Paragraph 3-4.1 F 2 18-1/2 in. x 24-1/2 in. Deep Fat Fryer Paragraph 3-4.2 (2) F 4 Split Vat Deep Fat Fryer Paragraph 3-4.3 F 2 14 in. x 14 in. (356 mm x 356 mm) Deep Fat Fryer Paragraph 3-4.4 F 2 Single Vat Deep Fryer with Drip Boards less than 1 in. (25 mm) Paragraph 3-4.5 F 2 Split Vat Deep Fat Fryer (Low Proximity) Paragraph 3-4.6 ADP 1 Deep Fat Fryer (Low Proximity) Paragraph 3-4.7 LPF 2 Krispy Kreme Model 270 d/h Doughnut Fryer Paragraph 3-4.8 ADP 1 Ranges Four-Burner Range Paragraph 3-4.9 R 1 Two-Burner Range Paragraph 3-4.10 R 1 Single Burner Range Paragraph 3-4.11 R 1 Four-Burner Range Paragraph 3-4.12 LPR 1 Broilers Upright Broilers Paragraph 3-4.13 ADP 1 Charbroilers (Lava, Pumice, Ceramic, or Synthetic Rock) Paragraph 3-4.14 F 2 Gas Radiant/Electric Charbroiler Paragraph 3-4.15 GRW 1 Natural or Mesquite Charcoal Charbroiler Paragraph 3-4.16 ADP 1 Mesquite Logs Charbroiler Paragraph 3-4.17 DM 3 Chain Broiler (Closed-Top) Paragraph 3-4.18 ADP 1 Chain Broiler (Open-Top) Paragraph 3-4.19 ADP 1 Griddle - Flat Cooking Surface Paragraph 3-4.20 ADP 1 Wok Paragraph 3-4.21 GRW 1 Tilt Skillets (Braising Pans)Paragraph 3-4.22 F 2 System Design January 2007 3-6 P/N 9127100 3-4.1 Single Vat Deep Fat Fryer With Drip Boards Figure 3-2. Single Vat Deep Fat Fryer Table 3-2. F Nozzle Coverage Area Items Parameters Maximum Hazard Area 18 in. x 18 in. (457 mm x 457 mm) Maximum Appliance Area (with drip board) 18 in. x 23 in. (457 mm x 584 mm) Nozzle Aim Midpoint of hazard area Nozzle Location (from top of appliance at an angle of 45° or more from the horizontal) 27 in. (686 mm) Min. 45 in. (1143 mm) Max. AN F NOZZLE MAY BE LOCATED ANYWHERE WITHIN THE GRID DIAGONAL FROM AIM POINT 45 in. (1143 mm) MAX. AIMPOINT: MIDPOINT OF HAZARD AREA 45 in. (1143 mm) MAX. 45 in. (1143 mm) MAX. 18 in. (457 mm) MAX.23 in. (584 mm) MAX. DRIP BOARD 18 in. (457 mm) MAX. AIM POINT: MIDPOINT OF HAZARD AREA 18 in. (457 mm) MAX. 23 in. (584 mm) MAX. APPLIANCE AREA DRIP BOARD FRONT VIEW SIDE VIEW HAZARD AREA 27 in. (686 mm) MIN + AN F NOZZLE MAY BE LOCATED ANYWHERE WITHIN THE GRID NOZZLE LOCATION 45 OR MORE FROM HORIZONTAL o 27 in.(686 mm) MIN.45 in. (1143 m m) MAX. System Design P/N 9127100 3-7 January 2007 3-4.2 18-1/2 in. x 24-1/2 in. Deep Fat Fryer With Drip Board Figure 3-3. 18-1/2 in. x 24-1/2 in. (470 mm x 622 mm) Deep Fat Fryer Table 3-3. F Nozzle Coverage Area Items Parameters Maximum Hazard Area 18-1/2 in. x 18 in. (470 mm x 457 mm) Maximum Appliance Area (with drip board)18-1/2 in. x 24-1/2 in. (470 mm x 622 mm) Nozzle Aim Midpoint of module area per nozzle Nozzle Location (at an angle of 45° or more from the horizontal above each module) 27-1/2 in. (699 mm) Min. 45 in. (1143 mm) Max. Module Area (half of hazard area) 18-1/2 in. x 9 in. (470 mm x 229 mm) 18-1/2 in. (470 mm) MAX. 27-1/2 in. (699 mm) MIN. 24-1/2 in. (622 mm) MAX. 9 in. (229 mm) 9 in. (229 mm)DRIP BOARD IMAGINARY LINE DIVIDING MODULES 45 in. (1143 mm) MAX. 45 in. (1143 mm) MAX. MIDPOINT OF MODULE AREA DIAGONAL FROM AIM POINT 45 in. (1143 mm) MAX. 45 in. (1143 mm) MAX. AN F NOZZLE MAY BE LOCATED ANYWHERE WITHIN THE GRID SIDE VIEW ANFNOZZLE MAY BE LOCATED ANYWHERE WITHIN THE GRID 2 F NOZZLES ARE REQUIRED FOR THIS APPLIANCE + AN F NOZZLE MAY BE LOCATED ANYWHERE WITHIN THE GRID AIM POINT: MIDPOINT OF HAZARD AREA 18-1/2 in. (470 mm) MAX. 24-1/2 in. (622 mm) MAX. APPLIANCE AREA DRIP BOARD NOZZLE LOCATION 45 OR MORE FROM HORIZONTAL (TYP) o SIDE VIEW HAZARD AREA 27-1/2 in.(699 m m) MIN. (TYP)45 in. (1143 m m)MAX. (TYP) + FRONT OF APPLIANCE AN F NOZZLE MAY BE LOCATED ANYWHERE WITHIN THE GRID System Design January 2007 3-8 P/N 9127100 3-4.3 Split Vat Deep Fat Fryer Figure 3-4. Split Vat Deep Fat Fryer Table 3-4. F Nozzle Coverage Area Items Parameters Maximum Hazard Area 14 in. x 15 in. (356 mm x 381 mm) Maximum Appliance Area (with drip board) 14 in. x 21 in. (356 mm x 533 mm) Nozzle Aim Midpoint of module area per nozzle Nozzle Location (at an angle of 45° or more from the horizontal above each module) 27 in. (686 mm) Min. 45 in. (1143 mm) Max. AIMPOINT: MIDPOINT OF HAZARD AREA AN F NOZZLE MAY BE LOCATED ANYWHERE WITHIN THE GRID DIAGONAL FROM AIM POINT 45 in. (1143 mm) MAX.45 in. (1143 mm) MAX. 45 in. (1143 mm) MAX. DRIP BOARD 14 in. (356 mm) MAX. 15 in. (381 mm) MAX. 21 in. (533 mm) MAX. AIM POINT: MIDPOINT OF HAZARD AREA 15 in. (381 mm) MAX. 21 in. (533 mm) MAX. APPLIANCE AREA DRIP BOARD NOZZLE LOCATION 45 OR MORE FROM HORIZONTAL o SIDE VIEW HAZARD AREA FRONT VIEW 27 in. (686 mm) MIN + AN F NOZZLE MAY BE LOCATED ANYWHERE WITHIN THE GRID 45 in. (1143 mm) MAX.27 in.(686 mm) MIN. System Design P/N 9127100 3-9 January 2007 3-4.4 14 in. x 14 in. (356 mm x 356 mm) Deep Fat Fryer Figure 3-5. 14 in. x 14 in. (356 mm x 356 mm) Deep Fat Fryer Table 3-5. F Nozzle Coverage Area Items Parameters Maximum Hazard Area 14 in. x 14 in. (356 mm x 356 mm) Maximum Appliance Area (with drip board)14 in. x 24-1/2 in. (356 mm x 622 mm) Nozzle Aim Midpoint of hazard area Nozzle Location (from top of appliance at an angle of 45° or more from the horizontal) 27-1/2 in. (686 mm) Min. 45 in. (1143 mm) Max. 45 in. (1143 mm) MAX 45 in. (1143 mm) MAX 45 in. (1143 mm) MAX AN F NOZZLE MAY BE LOCATED ANYWHERE WITHIN THE GRID DIAGONAL FROM AIM POINT MIDPOINT OF HAZARD AREA 14 in. (356 mm) MAX 14 in. (356 mm) MAX 24-1/2 in. (622 mm) MAX DRIP BOARD 27-1/2 in. (699 mm) MIN AN F NOZZLE MAY BE LOCATED ANYWHERE WITHIN THE GRID AIM POINT: MIDPOINT OF HAZARD AREA 45 in. (1143 m m) MAX. 14 in. (356 mm) MAX. 24-1/2 in. (622 mm) MAX. APPLIANCE AREA DRIP BOARD SIDE VIEW HAZARD AREA FRONT VIEW NOZZLE LOCATION 45 OR MORE FROM HORIZONTAL o +27 in.(686 mm) MIN. System Design January 2007 3-10 P/N 9127100 3-4.5 Single Vat Deep Fat Fryer (with Dripboards less than 1 in. [25 mm]) Figure 3-6. Single Vat Deep Fat Fryer (with Dripboards less than 1 in. (25mm) Table 3-6. F Nozzle Coverage Area Items Parameters Maximum Hazard Area 24 in. x 24 in. (610 mm x 610 mm) Maximum Appliance Area (with drip board) 24 in. x 25 in. (610 mm x 635 mm) Nozzle Aim Midpoint of hazard area Nozzle Location (at any point on or within the perimeter of the hazard area) 27-1/2 in. (699 mm) Min. 46 in. (1168 mm) Max. DRIP BOARD TOP OF APPLIANCE AIM POINT: MIDPOINT OF HAZARD AREA 27-1/2 in. (699 mm) MIN. 46 in. (1164 mm) MAX. LOCATE THE NOZZLE ANYWHERE WITHIN THE PERIMETER OF THE HAZARD AREA. AIMED AT THE MIDPOINT OF THE HAZARD AREA. 24 in. (610 mm) MAX.25 in. (635 mm) MAX. 24 in. (610 mm) MAX. FRONT VIEW SAMPLE NOZZLE PLACEMENT, ANYWHERE WITHIN THE SHADED AREA 27-1/2 in. (699 mm) MIN. 46 in. (1164 mm) MAX. System Design P/N 9127100 3-11 January 2007 3-4.6 Split Vat Fryer (Low Proximity Application) Figure 3-7. Split Vat Fryer (Low Proximity Application) Table 3-7. ADP Nozzle Coverage Area Items Parameters Maximum Hazard Area 14 in. x 15 in. (356 mm x 381 mm) Appliance Area (with drip board) 14 in. x 21 in. (356 mm x 533 mm) Nozzle Aim Midpoint of hazard area Nozzle Location (at any point on or within the perimeter of the hazard area) 16 in. (406 mm) Min. 27 in. (686 mm) Max. DRIP BOARD TOP OF APPLIANCE AIM POINT: MIDPOINT OF HAZARD AREA 16 in. (406 mm) MIN. 27 in. (686 mm) MAX. LOCATE THE NOZZLE ANYWHERE WITHIN THE PERIMETER OF THE HAZARD AREA. AIMED AT THE MIDPOINT OF THE HAZARD AREA. 15 in. (381 mm) MAX. 21 in. (533 mm) MAX. 14 in. (356 mm) MAX. FRONT VIEW SAMPLE NOZZLE PLACEMENT, ANYWHERE WITHIN THE SHADED AREA 16 in. (406 mm) MIN. 27 in. (686 mm) MAX. System Design January 2007 3-12 P/N 9127100 3-4.7 Low Proximity Nozzle for Deep Fat Fryer 1 For pipe sizes larger than 1/2-inch, use the formulae below for the equivalent length as measured in 1/2-inch pipe. Table 3-8. LPF Nozzle Coverage Area Items Parameters Maximum Hazard Area 14 in. x 15-1/2 in. (356 mm x 394 mm) longest vat side Maximum Appliance Area (with drip board) 14 in. x 23-1/4 in. (356 mm x 591 mm) Nozzle Aim Midpoint of appliance area (includes drip board) Nozzle Location (top of appliance) See Table 3-9 for Nozzle Offset Information and Table 3-10 for minimum pipe length to prevent splash from the cylinder to a LPF Nozzle protecting a fryer. 12 in. (305 mm) Min. — offset from center shall not exceed 3-1/2 in. (89 mm) 24 in. (610 mm) Max. — offset from center shall not exceed 13-1/2 in. (343 mm) Table 3-9. Nozzle Offset At Given Heights Nozzle Tip Height Distance From Center 12 in. (305 mm) 3-1/2 in. (89 mm) 14 in. (356 mm) 5-13/64 in. (132 mm) 16 in. (406 mm) 6-13/16 in. (173 mm) 18 in. (457 mm) 8-1/2 in. (216 mm) 20 in. (508 mm) 10-13/64 in. (259 mm) 22 in. (559 mm) 11-13/16 in. (300 mm) 24 in. (610 mm) 13-1/2 in. (343 mm) Table 3-10. Pipe Limitations for LPF Nozzle Pipe Size Minimum Pipe From Cylinder Discharge Port to First LPF Nozzle Linear Pipe & Fittings Minimum Number of Flows in Complete System Minimum Total Pipe Required For All Remaining Nozzles Beyond the First LPF Nozzle Linear Pipe & Fittings 1/2 in. 7-1/2 ft. (2 m) and (1) Bull Tee 8 7 in. (178 mm) and One Full Tee (Run and Bull Connections) 3/4 in. and 1 in.1 11 Equivalent Feet (3 m) of 1/2 in. Pipe 8 5-13/64 Equivalent Feet (1.6 m) of 1/2 in. Pipe 1 foot (1 meter) of 3/4-inch (19 mm) pipe equals 0.254 equivalent feet of 1/2-inch (13 mm) pipe. 1 foot (1 meter) of 1-inch (25 mm) pipe equals 0.079 equivalent feet of 1/2-inch (13 mm) pipe. System Design P/N 9127100 3-13 January 2007 Figure 3-8. Low Proximity Nozzle for Deep Fat Fryer (LPF) 24 in. (610 mm) MAX 14 in. (356 mm) MAX 15-1/2 in. (394 mm) MAX DRIP BOARD 15-1/2 in. (394 mm) MAX. 23-1/4 in. (591 mm) MAX. APPLIANCE AREA DRIP BOARD SIDE VIEW HAZARD AREA FRONT VIEW AIM POINT: MIDPOINT OF APPLIANCE AREA (INCLUDES DRIP BOARD) 12 in. (305 mm) MIN. AN LPF NOZZLE MAY BE LOCATED ANYWHERE WITHIN THE GRID 23-1/4 in. (591 mm) MAX. AIM POINT: MIDPOINT OF APPLIANCE AREA (INCLUDES DRIP BOARD) 12 in. (305 mm) MIN. 24 in. (610 mm) MAX.3-1/2 in. (89 mm) MAX. OFFSET FROM CENTERLINE 13-1/2 in. (343 mm) MAX. OFFSET FROM CENTERLINE AN LPF NOZZLE MAY BE LOCATED ANYWHERE WITHIN THE GRID System Design January 2007 3-14 P/N 9127100 3-4.8 Krispy Kreme Model 270 d/h Doughnut Fryer Eight ADP nozzles (P/N B120011), are dedicated to protect this appliance. Figure 3-9. Krispy Kreme Model 270 d/h Doughnut Fryer System must use a complete six-gallon RG-600 cylinder for proper protection. Maximum piping limitations can be taken from the listed RG-600 cylinder size piping parameters (see Table 3-12). The minimum pipe length, to prevent splash, that is required between cylinder and closest cooking appliance nozzle is listed below. Table 3-11. Eight ADP Nozzles Coverage Area Items Parameters Maximum Depth (front-to-back) 33 in. (840 mm) Maximum Length (left-to-right) 93 in. (2362 mm) Nozzle Location (lined up on both sides of the appliance, front and back outside perimeter of the cooking area 3-1/2 inches (89 mm) Min. 6-1/2 in. (165 mm) Max. Nozzle Height (measured from the top of the appliance to the tip of the nozzle) 22-1/2 in. (572 mm) Min. 29-1/2 in. (749 mm) Max. Maximum Module (aiming points is the centerline of the hazard area — center of each module of the unit) 33 in. (838 mm) x 23-1/4 in. (591 mm) Table 3-12. Krispy Kreme Model 270 d/h Doughnut Fryer Minimum Pipe Length Piping Size Minimum Allowable Pipe 1/2 in. (13 mm) 39 Equivalent feet 1/2 in. (13 mm) 27 Linear feet 33 in. (838 mm) MAXIMUM NOZZLE HEIGHT 29-1/2 in. (749 mm) MINIMUM NOZZLE HEIGHT 22-1/2 in. (572 mm) TOP OF APPLIANCE EACH NOZZLE IS AIMED AT MIDPOINT OF MODULE LOCATE NOZZLES 3-1/2 in. (89 mm) TO 6-1/2 in. (165 mm) OUTSIDE THE PERIMETER OF THE APPLIANCE, ALONG THE FRONT AND BACK EDGE, WITHIN HEIGHT PARAMETERS. 93 in. (2362 mm) CENTERLINE FRONT-TO-BACK AIMING POINT TYPICAL CENTERLINE NOZZLE MODULE DIMENSIONS ARE MAXIMUMS 93 in. (2362 mm) 23.25 in. (591 mm) 23.25 in. (591 mm) 23.25 in. (591 mm) 23.25 in. (591 mm) 16.5 in. (419 mm) 33 in. (838 mm) 6-1/2 in. (165 mm) MAX. 3-1/2 in. (89 mm) MIN. System Design P/N 9127100 3-15 January 2007 3-4.9 Four Burner Ranges Figure 3-10. R Nozzle Coverage for a 4-Burner Range Table 3-13. R Nozzle Coverage Area — Four Burner Range Items Parameters Maximum Hazard Area 28 in. x 28 in. (711 mm x 711 mm) Nozzle Aim Midpoint of Hazard Area Nozzle Location — Anywhere within the area of a circle generated by a 9 in. (229 mm) radius about the midpoint Note: Shape of burner not important. 20 in. (508 mm) Min. 42 in. (1067 mm) Max. 14 in. (356 mm) MAX. BURNER CENTERLINE TO CENTERLINE 28 in. (711 mm) MAX. HAZARD AREA LENGTH 14 in. (356 mm) MAX. BURNER CENTERLINE TO CENTERLINE AIM POINT: MIDPOINT OF HAZARD AREA A ‘R’ NOZZLE MAY BE LOCATED ANYWHERE WITHIN THE SHADED AREA 42 in. (1067 mm) MAX. (FROM TOP OF RANGE) 18 in. (457 mm) DIA. 20 in. (508 mm) MIN. (FROM TOP OF RANGE) 28 in. (711 mm) MAX. HAZARD AREA WIDTH System Design January 2007 3-16 P/N 9127100 3-4.10 Two Burner Ranges Figure 3-11. R Nozzle Coverage for a 2-Burner Range Table 3-14. R Nozzle Coverage Area — Two Burner Range Items Parameters Maximum Hazard Length 28 in. (711 mm) Nozzle Aim Midpoint of hazard area Nozzle Location - Anywhere within the area of a circle generated by a 9 in. (229 mm) radius about the midpoint Note: Shape of burner not important. 20 in. (508 mm) Min. 42 in. (1067 mm) Max. AIM POINT: MIDPOINT OF HAZARD AREA 42 in. (1067 mm) MAX. (FROM TOP OF RANGE) 18 in. (457 mm) DIA. A ‘R’ NOZZLE MAY BE LOCATED ANYWHERE WITHIN THE SHADED AREA 20 in. (508 mm) MIN. (FROM TOP OF RANGE) 28 in. (711 mm) MAX. HAZARD AREA LENGTH 14 in. (356 mm) MAX. BURNER CENTERLINE TO CENTERLINE System Design P/N 9127100 3-17 January 2007 3-4.11 Single Burner Range Figure 3-12. R Nozzle Coverage for a 1-Burner Range Table 3-15. R Nozzle Coverage Area — Single Burner Range Items Parameters Nozzle Aim 7 in. (178 mm ) from center of burner Nozzle Location — Anywhere within the area of a circle generated by a 9 in. (229 mm) radius about the aim point. Note: Shape of burner not important. 20 in. (508 mm) Min. 42 in. (1067 mm) Max. 42 in. (1067 mm) MAX. (FROM TOP OF RANGE) 18 in. (457 mm) DIA. A ‘R’ NOZZLE MAY BE LOCATED ANYWHERE WITHIN THE SHADED AREA AIM POINT 20 in. (508 mm) MIN. (FROM TOP OF RANGE) 7 in. (178 mm) FROM BURNER CENTERLINE TO AIM POINT CENTERLINE System Design January 2007 3-18 P/N 9127100 3-4.12 Four Burner Ranges (LPR), P/N B120024 The low proximity range top coverage provides protection for a range top that has a back shelf or a broiler integral to the regular range. Figure 3-13. LPR Nozzle Coverage for a 4-Burner Range (LPR) Table 3-16. LPR Nozzle Coverage Area — Four Burner Range Items Parameters Maximum Hazard Area 24 in. x 24 in. (610 mm x 610 mm) Nozzle Aim Midpoint of hazard area Nozzle Location — Dimension A in Figure 3-13 Refer to Table 3-17 Table 3-17. LPR Nozzle Parameters Burner Spacing Centerline to Centerline (Dimension B in Figure 3-13) Note: Shape of burner not important. Nozzle Height (Dimension A) (centrally over the range and under shelf/broiler) 14 in. (356 mm) 16 in. (406 mm) Min. 20 in. (508 mm) Max. Between 12 in. and 14 in.(305 mm and 432 mm) 16 in. — 17 in. (406 mm — 432 mm) Between 10 in. and 12 in. (254 mm and 305 mm) 16 in. (406 mm) DIMENSION “B” 24 in. (610 mm) MAX. HAZARD AREA LENGTH AIM POINT: MIDPOINT OF HAZARD AREA AN LPR NOZZLE MAY BE LOCATED OVER THE CENTER OF THE HAZARD AREA. SEE TABLE FOR NOZZLE HEIGHTS. 24 in. (610 mm) MAX. HAZARD AREA WIDTH DIMENSION “B” DIMENSION “A” (NOZZLE HEIGHT MEASURED TO TOP OF BURNERS System Design P/N 9127100 3-19 January 2007 The minimum pipe length to prevent splash from the cylinder to a LPR nozzle protecting an appliance is defined in Table 3-18. Note:If the LPR nozzle is disassembled for inspection or cleaning, reassemble the disc/core unit with the center core ‘nub’ facing upstream. The flat side should face towards the threaded nozzle cap. Refer to Figure 3-14. Figure 3-14. LPR Nozzle Assembly Table 3-18. Piping Parameters 1 Minimum length to LPR nozzle — linear: 9 ft. (2.7 m) 2 Minimum length to LPR nozzle — equivalent: 12 ft. (3.6 m) 3 Minimum total length in system — linear: 11.08 ft. (3.4 m) DISC/CORE ASSEMBLY NOZZLE CAP NOZZLE BODY NUB FLAT SURFACE System Design January 2007 3-20 P/N 9127100 3-4.13 Upright Broilers Figure 3-15. ADP Nozzle Placement for Upright Broilers Table 3-19. ADP Nozzle Coverage Area Items Parameters Broiler Compartment With Maximum Internal Horizontal Dimensions 30-1/4 in. x 34 in. (768 mm x 864 mm) Nozzle Aim Through grill toward the center of the grease drain-off opening Nozzle Location Within the top 4 in. (102 mm) of space in the broiler compartment. Commonly mounted near the front opening and directed inside the broiler BROILER COMPARTMENT 4 in. (102 mm) MAX.30-1/4 in. (768 mm) MAX. GRILL WARMING OVEN GREASE DRAIN PAN 34 in. (864 mm) MAX. GREASE DRAIN-OFF EXHAUST DUCT RIGHT SIDE FRONT (BROILER DOOR REMOVED) NOTE: DIMENSIONS SHOWN ARE INSIDE BROILER COMPARTMENT ADP NOZZLES SHOULD BE MOUNTED ON THE PERIMETER OF THE BROILER TOP (SHADED AREA). IT SHOULD BE DIRECTED THROUGH THE GRILL TOWARD THE CENTER OF THE GREASE DRAIN-OFF OPENING. NOZZLE DISCHARGE SHALL NOT BE OBSTRUCTED BY ANY STRUCTURAL PART OF THE BROILER. System Design P/N 9127100 3-21 January 2007 3-4.14 Charbroilers (Lava, Pumice, Ceramic or Synthetic Rock) Figure 3-16. Lava, Pumice, Ceramic, or Synthetic Rock Charbroiler Table 3-20. F Nozzle Coverage Area Items Parameters Maximum Appliance Area (maximum of two layers of lava, pumice, or stone) 22 in. x 23 in. (559 mm to 584 mm) Nozzle Aim Midpoint of the hazard area Nozzle Location (at an angle of 45° or more from the horizontal above grate area) 24 in. (610 mm) Min. 48 in. (1219 mm) Max. AIM POINT: MIDPOINT OF HAZARD AREA 48 in. (1219 mm) MAX. 48 in. (1219 mm) MAX. 48 in. (1219 mm) MAX. AN F NOZZLE MAY BE LOCATED ANYWHERE WITHIN THE GRID DIAGONAL FROM AIM POINT 22 in. (559 mm) MAX. 23 in. (584 mm) MAX. 24 in. (610 mm) MIN. AN F NOZZLE MAY BE LOCATED ANYWHERE WITHIN THE GRID AIM POINT: MIDPOINT OF HAZARD AREA 24 in.(610 mm) MIN.48 in. (1219 mm) MAX. 23 in. (584 mm) MAX. APPLIANCE AREA NOZZLE LOCATION 45 OR MORE FROM HORIZONTAL o SIDE VIEWFRONT VIEW System Design January 2007 3-22 P/N 9127100 3-4.15 Gas Radiant/Electric Charbroiler Figure 3-17. Gas Radiant/Electric Charbroiler Table 3-21. GRW Nozzle Coverage Area Items Parameters Maximum Cooking Surface 21 in. x 24 in. (533 mm to 610 mm) Nozzle Aim Midpoint of the hazard area above cooking surface Nozzle Location (located at an angle of 45° or more from the horizontal) 24 in. (610 mm) Min. 48 in. (1219 mm) Max. A GRW NOZZLE MAY BE LOCATED ANYWHERE WITHIN THE GRID DIAGONAL FROM AIM POINT AIM POINT: MIDPOINT OF HAZARD AREA RADIANT LAYER GAS FLAME 48 in. (1219 mm) MAX. 48 in. (1219 mm) MAX. 48 in. (1219 mm) MAX. 24 in. (610 mm) MAX. 21 in. (533 mm) MAX. 24 in. (610 mm) MAX. FRONT VIEW A GRW NOZZLE MAY BE LOCATED ANYWHERE WITHIN THE GRID AIM POINT: MIDPOINT OF HAZARD AREA 21 in. (533 mm) MAX. APPLIANCE AREA NOZZLE LOCATION 45 OR MORE FROM HORIZONTAL o SIDE VIEW24 in.(610 mm) MIN.48 in. (1219 m m) MAX. System Design P/N 9127100 3-23 January 2007 3-4.16 Natural or Mesquite Charcoal Charbroiler The depth of mesquite charcoal pieces or charcoal is limited to 6 in. (152 mm) maximum. Mesquite logs or wood are not acceptable. Figure 3-18. Natural or Mesquite Charcoal Charbroiler Table 3-22. ADP Nozzle Coverage Area Items Parameters Maximum Cooking Surface 24 in. x 24 in. (610 mm x 610 mm) Nozzle Aim Midpoint of the hazard area above cooking surface Nozzle Location (at an angle of 45° or more from the horizontal) 24 in. (610 mm) Min. 48 in. (1219 mm) Max. AN ADP NOZZLE MAY BE LOCATED ANYWHERE WITHIN THE GRID DIAGONAL FROM AIM POINT 48 in. (1219 mm) MAX. 48 in. (1219 mm) MAX. 48 in. (1219 mm) MAX. 24 in. (610 mm) MAX. 24 in. (610 mm) MAX. 24 in. (610 mm) MAX. 6 in. (152 mm) MAX. FUEL AIM POINT: MIDPOINT OF HAZARD AREA AN ADP NOZZLE MAY BE LOCATED ANYWHERE WITHIN THE GRID AIM POINT: MIDPOINT OF HAZARD AREA 24 in. (610 mm) MAX. APPLIANCE AREA NOZZLE LOCATION 45 OR MORE FROM HORIZONTAL o SIDE VIEW 6 in. (152 mm) MAX. FUEL FRONT VIEW 24 in.(610 mm) MIN.48 in. (1219 mm) MAX. System Design January 2007 3-24 P/N 9127100 3-4.17 Mesquite Logs Charbroiler Figure 3-19. Mesquite Logs Charbroiler Table 3-23. DM Nozzle Coverage Area Items Parameters Maximum Cooking Surface Note: If the charbroiler has a blower, it shall be shut off when the Range Guard system operates. 30 in. x 24 in. (762 mm x 610 mm) Nozzle Aim Midpoint of the hazard area above cooking surface Nozzle Location (located at an angle of 45° or more from the horizontal) 24 in. (610 mm) Min. 48 in. (1219 mm) Max. Mesquite wood charbroiler may use wood chips, chunks, logs (or any combination thereof). The natural-charcoal/mesquite- charcoal charbroiler may use charcoal. Depth of 10 in. (254 mm) Max. A DM NOZZLE MAY BE LOCATED ANYWHERE WITHIN THE GRID DIAGONAL FROM AIM POINT 48 in. (1219 mm) MAX. 48 in. (1219 mm) MAX. 48 in. (1219 mm) MAX. 24 in. (610 mm) MAX. 24 in. (610 mm) MAX. 30 in. (762 mm) MAX. 10 in. (254 mm) MAX. FUEL AIM POINT: MIDPOINT OF HAZARD AREA A DM NOZZLE MAY BE LOCATED ANYWHERE WITHIN THE GRID AIM POINT: MIDPOINT OF HAZARD AREA 24 in. (610 mm) MAX. APPLIANCE AREA NOZZLE LOCATION 45 OR MORE FROM HORIZONTAL o SIDE VIEW 10 in. (254 mm) MAX. FUEL FRONT VIEW 24 in.(610 mm) MIN.48 in. (1219 mm) MAX. System Design P/N 9127100 3-25 January 2007 3-4.18 Chain Broiler (Closed-Top) Figure 3-20. ADP Nozzle Installation for Closed Top Chain Broiler Table 3-24. Single ADP Nozzle Coverage Area Items Parameters Maximum Internal Horizontal Dimensions 28 in. x 29 in. (711 mm x 737 mm) Nozzle Location (centered vertically in the chain broiler tunnel space above the chain) Positioned at one corner of the chain broiler tunnel aimed at opposite diagonal of the tunnel. Pipe drop and fittings 1/4 in. (6 mm) 1/4 in. (6 mm) PIPE DROP NOZZLE CENTERED VERTICALLY IN OPENING ABOVE CHAIN System Design January 2007 3-26 P/N 9127100 3-4.19 Chain Broiler (Open-Top) Figure 3-21. ADP Nozzle Installation for Open-Top Chain Broiler Table 3-25. Dual ADP Nozzle Coverage Area Items Parameters Maximum Internal Broiler Tunnel Dimensions 28 in. x 29 in. (711 mm x 737 mm) Maximum External Top Dimensions 28 in. x 29 in. (711 mm x 737 mm) First Nozzle Location Located at one corner of the chain broiler tunnel and aimed toward the opposite diagonal corner of the tunnel — spaced 1-inch (25 mm) back from the tunnel opening. Second Nozzle Location (centered over the top opening of chain broiler) from the top surface 12 in. (305 mm) Min. 48 in. (1219 mm) Max. Drop pipe and fittings to the chain broiler 1/4 in. (6 mm) CAUTION The second nozzle must be used when there is any exhaust opening on the top of the appliance. TOP OPENING SECOND NOZZLE LOCATION - CENTERED OVER TOP OPENING OF BROILER 12 in. (305 mm) MIN. 48 in. (1219 mm) MAX. NOZZLE CENTERED VERTICALLY IN OPENING ABOVE CHAIN 29 in. (737 mm) 28 in. (711 mm) SECOND NOZZLE: CENTERED OVER TOP OPENING OF BROILER 12 in. (305 mm) MIN. 48 in. (1219 mm) MAX.FIRST NOZZLE: CENTERED VERTICALLY IN OPENING ABOVE CHAIN FRONT VIEW SIDE VIEW 1/4 in. PIPE DROP 1/4 in. PIPE DROP 1/4 in. PIPE DROP SECOND NOZZLE: CENTERED OVER TOP OPENING OF BROILER 12 in. (305 mm) MIN. 48 in. (1219 mm) MAX. 1 in. (25 mm) System Design P/N 9127100 3-27 January 2007 3-4.20 Griddle — Flat Cooking Surface (With or without Raised Ribs) Figure 3-22. Griddle - Flat Cooking Surface Table 3-26. ADP Nozzle Coverage Area Items Parameters Maximum Hazard Area 30 in. x 42 in. (762 mm x 1067 mm) Nozzle Aim At a point 3 in. (76 mm) from the midpoint of hazard area Nozzle Location — any point on the perimeter of appliance 13 in. (330 mm) Min. 48 in. (1219 mm) Max. Note: Positioning the nozzle directly over the appliance is not permitted. 42 in. (1067 mm) MAX. 30 in. (762 mm) MAX. 13 in. (330 mm) MIN. 48 in. (1219 mm) MAX. TOP OF APPLIANCE AIM POINT: 3 in. (76 mm) RADIUS FROM THE MIDPOINT OF HAZARD AREA System Design January 2007 3-28 P/N 9127100 3-4.21 Wok Figure 3-23. Wok Table 3-27. GRW Nozzle Coverage Area Items Parameters Wok Diameter 14 in. to 28 in. (356 mm to 1829 mm) Wok Depth 3 in. to 8 in. (76 mm to 508 mm) Nozzle Aim Center of Wok Nozzle Location — Must be over center and within 2 in. (51 mm) from center and nozzle height must be measured over center and within 2 in. (51 mm) from center from inside bottom of Wok. Only one nozzle per Wok. 35 in. (889 mm) Min. 56 in. (1422 mm) Max. 2 in. (51 mm) MAX. OFFSET 14 in. (356 mm) TO 28 in. (711mm) DIAMETER CENTER OF HAZARD AREA AT BASE WOK INSIDE BOTTOM OF WOK 3 in. (76 mm) TO 8 in. (203 mm) DEPTH 35 in. (889 mm) MIN. 56 in. (1422 mm) MAX. ONE GRW NOZZLE MUST BE LOCATED ANYWHERE WITHIN THE SHADED AREA AIMED AT CENTER OF WOK System Design P/N 9127100 3-29 January 2007 3-4.22 Tilt SkilletS (Braising Pans) Figure 3-24. Tilt Skillet (Braising Pan) Table 3-28. F Nozzle Coverage Area Items Parameters Maximum Hazard Area 24 in. x 24 in. (610 mm x 610 mm) Nozzle Aim Midpoint of hazard area and placed so it does not interfere with appliance operation Nozzle Location — At the front perimeter line of the appliance 27-1/2 in. (699 mm) Min. 46 in. (1168 mm) Max. Note: Appliance cover cannot interfere with distribution of agent from the nozzle. CL THE NOZZLE IS TO BE PLACED TOWARD THE FRONT OF THE APPLIANCE TO MINIMIZE THE POTENTIAL FOR THE SKILLET OR BRAISING PAN COVER TO INTERFERE WITH THE NOZZLE DISCHARGE. CENTERLINE OF HAZARD ZONE COVER MUST NOT INTERFERE WITH EDGE OF DISCHARGE PATTERN F NOZZLE System Design January 2007 3-30 P/N 9127100 3-5 MODULE PROTECTION (MULTIPLE NOZZLES) For appliances that exceed single nozzle coverage, multiple nozzles can be used to protect that appliance by modularizing (dividing up into smaller sections) the larger appliance's hazard area. Exception: for deep fat fryers the maximum protected area for a single vat is 6 ft.2 (1.9 m2). For a deep fat fryer that exceeds single nozzle coverage, multiple F nozzles can be used by dividing the hazard area into smaller modules that meet the limitation of a single nozzle. 3-5.1 Example — Module Protection of Fryers With Dripboards Less Than 1 in. (25 mm) Each module that the larger hazard area is divided into, must not exceed 24 in. x 24 in. (610 mm x 610 mm) and appliance area of 24 in. x 25 in. (610 mm x 635 mm) if a drip board is included. A single F nozzle is then used to protect each of these smaller modules. See Figure 3-25. The nozzle shall be located anywhere within the perimeter of the hazard area, and aimed at the midpoint of the hazard. Figure 3-25. Example of Modular Protection, Single Vat Deep Fat Fryer (Less than 1-inch Dripboard) DRIP BOARD 18 in. (457 mm) 36 in. (914 mm) 25 in. (635 mm) 24 in. (610 mm) MAX. IMAGINARY LINE DIVIDING MODULES TOP OF APPLIANCE AIM POINT: MIDPOINT OF MODULE HAZARD AREA 27-1/2 in. (699 mm) MIN. LOCATE THE NOZZLES ANYWHERE WITHIN THE PERIMETER OF THE HAZARD AREA. AIMED AT THE MIDPOINT OF EACH MODULE HAZARD AREA. 46 in. (1168 mm) MAX. System Design P/N 9127100 3-31 January 2007 Figure 3-26. Nozzles for Deep Fat Fryer NOZZLE A NOZZLE B MODULE A MODULE B NOZZLE CAN BE PLACED ANYWHERE WITHIN THE SHADED AREA DIRECTLY OVER THE MODULE THAT IS BEING PROTECTED BY THE NOZZLE. System Design January 2007 3-32 P/N 9127100 3-5.2 Example — Single Vat Deep Fat Fryer — With Dripboards 1 in. (25 mm) to 6 in. (152 mm) Each module that the larger hazard is divided into, must not exceed 18 in. x 18 in. (457 mm x 457 mm) and an appliance area of 18 in. x 23 in. (457 mm x 584 mm) if a dripboard is included. A single F nozzle is then used to protect each of these smaller modules (see Figure 3-27). Figure 3-27. Example of Nozzle Position (Typical for each module) for Multiple Nozzle Coverage 16 in. (406 mm) (TYP.)48 in. (1219 mm) DRIP BOARD IMAGINARY LINE DIVIDING MODULES DIAGONAL FROM AIM POINT NOZZLE PLACEMENT SAME AS SINGLE VAT WITH DRIP BOARD COVERAGE NOZZLE POSITION (TYPICAL FOR EACH MODULE) FOR MULTIPLE NOZZLE 45 in. (1143 mm) MAX. 45 in. (1143 mm) MAX. 27 in. (686 mm) MIN. 23 in. (584 mm) MAX.MAX. LIQUID COOKING SURFACE 864 in. (5574 cm ) 22 System Design P/N 9127100 3-33 January 2007 3-6 VENTILATION 3-6.1 Plenums 1 When no filters are present, the nozzle protecting the plenum is used to discharge the wet chemical on the under- side of the hood. In this case, the hood may not exceed a length of 10 ft. (3 m) or a width of 4 ft (1.2 m). Longer plenums may be similarly protected with a single ADP nozzle being used for each 10 ft. (3.0 m) of plenum length and each 4 ft. (1.2 m) of plenum width. ADP nozzles may be used in combinations (see Figure 3-28). Multiples may be installed facing in the same direction, and/or at the ends of the plenum pointing in. Each nozzle shall provide a maximum of 10 ft. (3 m) of coverage. ADP nozzles must be centrally located in the plenum with their discharge directed along the length of the plenum and located in relation to the filters as shown in Figure 3-28. Refer to Figure 3-28 for filter height. Table 3-29. Plenum Protection Items Parameters ADP Nozzle No Filter 1 10 ft. x 4 ft. (3 m x 1.2 m) Max. 1 - located at one end of the plenum “V” Filter 10 ft. x 4 ft. (3 m x 1.2 m) 20 ft. x 4 ft. (6 m x 1.2 m) 1 - located at one end of the plenum 2 - located at end of plenum pointing inwards Single Bank Filter 10 ft. x 4 ft. (3 m x 1.2 m) 20 ft. x 4 ft. (6 m x 1.2 m) 1 - located at one end of the plenum 2 - located at end of plenum pointing inwards System Design January 2007 3-34 P/N 9127100 Figure 3-28. ADP Protection Nozzle, P/N B120011 4ft. (1.2 m) 4ft. (1.2 m) 10 ft. (3 m) “V” FILTER BANK COVERAGE 10 ft. (3 m) PLENUM 4ft. (1.2 m) 4ft. (1.2 m) SINGLE FILTER BANK COVERAGE 10 ft. (3 m) PLENUM DUCT XXXXXX X XXXXXX X XXXXX X XXXXX X XXXXXX X XXXXX X X XXXXX X XXXXX X XXXXX X X XXXXX X X XXXXXX XXXXXX XXXXXX X XXXXX X X XXXXX X XXXXX X XXXXXX X XXXXXX X XXXXX X XXXXX X XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX X XXXXX X X XXXXX X XXXXX X XXXXX X X XXXXX X X XXXXXX XXXXX X XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX XXXXXXX XXXXXX X XXXXX X X XXXXX X XXXXX X XXXXX X X XXXXXX X XXXXXX XXXXX X XXXXXX X XXXXX X X XXXXX X XXXXX X XXXXX X X XXXXXX X XXXXXX XXXXX X XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX X XXXXXX X XXXXX X XXXXX X XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX X X XXXXX X X XXXXX X XXXXX DUCT XXXXX X X XXXXXX X XXXXXX XXXXX X XXXXXX X XXXXXX X XXXXX X XXXXX X XXXXX X X XXXXX X X XXXXX X XXXXXX XXXXXX X XXXXXX X XXXXX X XXXXX X XXXXXX X XXXXX X X XXXXX X XXXXX X XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX X X XXXXX X X XXXXX X XXXXXX XXXXX X X XXXXX X X XXXXXX XXXXXX XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX X X XXXXXX X XXXXX X XXXXX XXXXXX X XXXXX X X XXXXX X XXXXX X 10 ft. (3 m) 4ft. (1.2 m) 20 ft. (6 m) DUCT XXXXX X X XXXXXX X XXXXXX XXXXX X XXXXXX X XXXXXX X XXXXX X XXXXX X XXXXX X X XXXXX X X XXXXX X XXXXXX XXXXXX X XXXXXX X XXXXX X XXXXX X XXXXXX X XXXXX X X XXXXX X XXXXX X XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX X X XXXXX X X XXXXX X XXXXXX XXXXX X X XXXXX X X XXXXXX XXXXXX XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX X X XXXXXX X XXXXX X XXXXX XXXXXX X XXXXX X X XXXXX X XXXXX X 4ft. (1.2 m) 4ft. (1.2 m) DUCT XXXXX X X XXXXX X X XXXXX X XXXXXX XXXXX X X XXXXX X X XXXXX X XXXXXX XXXXX X X XXXXXX X XXXXXX XXXXX X XXXXX X X XXXXX X X XXXXX X XXXXXX XXXXX X X XXXXX X X XXXXX X XXXXXX XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX X X XXXXX X X XXXXX X XXXXXX XXXXX X X XXXXX X X XXXXX X XXXXXX XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX XXXXXXX XXXXX X X XXXXX X X XXXXX X XXXXXX XXXXXX X XXXXX X X XXXXX X XXXXX X XXXXX X X XXXXX X X XXXXX X XXXXXX XXXXXX X XXXXX X X XXXXX X XXXXX X XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX X X XXXXXX X XXXXXX XXXXX X XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX X X XXXXX X X XXXXXX XXXXX 20 ft. (6 m) “V” FILTER BANK COVERAGE 20 ft. (6 m) PLENUM SINGLE FILTER BANK COVERAGE 20 ft. (6 m) PLENUM 4ft. (1.2 m) NOZZLE NOZZLE NOZZLE NOZZLE NOZZLENOZZLE NOZZLE “V” FILTER BANK COVERAGE (END VIEW) NOZZLE 3/4 H H SINGLE BANK FILTER COVERAGE (END VIEW) 1/3 W 3/4 H H W 24 i n. MAX. 24 i n. MAX. System Design P/N 9127100 3-35 January 2007 3-6.1.1 DUCTS The ADP nozzle, P/N B120011, is used for protection of the exhaust ductwork. The duct cross section can be any shape, not including obstructions (i.e., round, square, or rectangular) and the duct itself can be of unlimited length. In accordance with NFPA 96, the exhaust fan should be left running at the time of system discharge. This will help to remove smoke and other airborne materials and gases from the hazard area in the event of a fire. Check with the Authority Having Jurisdiction for local requirements. A damper, if present, should be left open at system discharge. However, if the damper is closed, the system designer must insure that additional nozzles are required. 3-6.1.1.1 Protection of Ducts 0 to 50 inches in Perimeter One ADP nozzle, P/N B120011, is required for protection of a duct with a perimeter up to 50-inches (refer to Figure 3-29). Length of duct is unlimited. The nozzle is located at the geometric center of the cross-sectional area that it is protecting, and is located in the duct within six inches of the entrance. Note:All Range Guard systems are listed by UL and ULC for use with the exhaust fan either on or off when the system is discharged. Figure 3-29. Duct Protection Using Single ADP Nozzle, P/N B120011 11.78 in. (300 mm) MAX. DIAGONAL RECTANGULAR DUCT 2 “A” + 2 “B” = 65 in. (1651 mm) DUCT PERIMETER UP TO AND INCLUDING 50 in. (1270 mm) DUCT HOOD 11.78 in. (300 mm) MAX. DIAGONAL SQUARE DUCT ROUND DUCT “A” “B” 15.91 in. (404 mm) MAX. 12.5 in. (318 mm) MAX. DUCT ENTRANCE ADP NOZZLE VERTICAL/HORIZONTAL DUCT ADP NOZZLE 2 to 4 in. (51 to 102 mm) NOZZLE TIP to DUCT HIP OF VERTICAL DUCT AIM POINT OF HORIZONTAL DUCT 0 - 6 in. (0 - 152 mm) System Design January 2007 3-36 P/N 9127100 3-6.1.1.2 Ducts 50 to 100 inches in Perimeter Two ADP nozzles, P/N B120011, pointing in the same direction are required for protection of ducts with perimeters greater than 50 inches and less than or equal to 100 inches. Ducts can be of unlimited length (refer to Figure 3-30). For other option of ducts up to 75 perimeter inches (See Figure 3-32). Note:All Range Guard systems are listed by UL and ULC for use with the exhaust fan either on or off when the system is discharged. Figure 3-30. Duct Protection Using Two ADP Nozzles, P/N B120011 MAX. DIAMETER 31.83 in. (809 mm) NOZZLES TO BE ALONG ONE CENTERLINE AT THE 1/4 POINTS. NOZZLES TO BE0-6in.(0-152 mm) UP FROM ENTRANCE OF VERTICAL DUCT DUCT 25 in. (635 mm) MAX. SIDE MAX. DIAGONAL 11.78 in. (300 mm) MAX. DIAGONAL 11.78 in. (300 mm) SQUARE RECTANGULAR TYP. (2) ADP NOZZLES ROUND ADP NOZZLE DUCT ENTRANCE OF VERTICAL DUCT OF HORIZONTAL DUCT AIM POINT VERTICAL/HORIZONTAL DUCT ADP NOZZLE 2 - 4 in. (51 mm - 102 mm) NOZZLE TIP TO DUCT HIP 0to6in. (0 to 152 mm) HOOD System Design P/N 9127100 3-37 January 2007 3-6.1.1.3 Designing For Large Ducts Large Ducts (Perimeters Greater than 100 Inches) For ducts larger than 100 in. (2540 mm) perimeter, the total perimeter of the duct must be divided by 50. If the answer contains a decimal (or fraction), it must be rounded-up to the nearest whole number. That will provide the number of nozzles necessary for proper protection of the duct. The diagonal dimension (nozzle to corner of duct) of each module must not exceed 11.78 inches (297 mm). If this diagonal dimension is exceeded, additional module divisions must be added until the diagonal dimension is not exceeded. A nozzle must then be centered in each "module" (refer to Figure 3-31). EXAMPLE You have a duct with a perimeter of 156 in. (3962 mm). Take the perimeter: 156 and divide it by the maximum allowable perimeter of a single nozzle: 50. 156/50 = 3.12 Round the 3.12 up to the next highest integer: 4. Four nozzles are required to protect this duct. A2 + B2 = C2 Where A is length, B is width and C is diagonal. Each “section” of the duct is 18L x 15W. 182 + 152 = C2 324 + 225 = 549 The square root of 549 is 23.43 inches (23.43= 549); therefore, the diagonal of each module is 23.43 inches. One-half of 23.43 is 11.71, which is the measurement from the nozzle to the corner of the duct. Our maximum allowable diagonal is 11.78 inches, as stated above. Figure 3-31. Modular Protection of Large Ducts NOZZLE TO CORNER: 11.73 in. (298 mm) MAXIMUM ALLOWABLE is 11.78 in. (299 mm) 15 15 15 15 18 LARGE DUCT: 18 X 60 in. (457 mm x 1524 mm) TOTAL: 156 PERIMETER INCHES System Design January 2007 3-38 P/N 9127100 Alternative Method: Ducts 0 to 75 Inches in Perimeter Two ADP nozzles can be used in ducts with a perimeter of 0 up to 75 inches (1651 to 1905 mm). The ratio of the longest to shortest perimeter sides shall not exceed 3 to 1. One of these nozzles is pointed into the duct and the other is pointed into the plenum. The tip of the upper nozzle, of the pair of nozzles required for each duct, shall be positioned in the center of the duct opening and above the plane of the hood-duct opening between 1 in. (25 mm) and 24 in. (610 mm). The duct length is unlimited. See Figure 3-32. Note:When a damper is present at the hood duct opening, the duct nozzles are to be located above the damper and should not interfere with the operation of the damper. Note:All Range Guard systems are listed by UL and ULC for use with the exhaust fan either on or off when the system is discharged. Figure 3-32. Optional Duct Nozzle Placement DUCT HOOD 24 in. (610 mm) MAX. 1 in. (25.4 mm) MIN. System Design P/N 9127100 3-39 January 2007 3-6.1.1.4 Upper/Lower Plenum Examples Protection of special or unique plenum arrangements should be reviewed by the AHJ (Authority Having Jurisdiction). Badger recommends that upper/lower plenum arrangements be protected as shown below. Note:All Range Guard systems are listed by UL and ULC for use with the exhaust fan either on or off when the system is discharged. 1. If risers are less than 6 in. (152 mm), nozzles are required to protect the upper and lower plenums and in the main exhaust duct. (See Figure 3-33 and Figure 3-34). Example 1 — Riser less than 6 in. (152 mm) in Length Figure 3-33. Special Plenum Arrangements 2. If risers are 6 in. (152 mm) or longer, the risers become the exhaust ducts and there is no upper plenum. Nozzle(s) are required in the lower plenum and also in each such riser. The riser portion is to be treated now as the hood duct opening and protected accordingly. (See Figure 3-34). Example 2 — Riser more than 6 in. (152 mm) in Length Figure 3-34. Special Plenum Arrangements With 6 in. (152 mm) Risers ADP NOZZLES RISER 10ft.(3m) RISER System Design January 2007 3-40 P/N 9127100 3-6.1.2 SPECIAL CONFIGURATIONS 3-6.1.2.1 Protection of Electrostatic Precipitators Electrostatic precipitators (ESP) are designed to remove smoke and other airborne contaminants from the airstream flowing through exhaust ductwork. ESPs are used in restaurant kitchen exhaust systems as a means of pollution control. They are not intended to replace grease filters as the primary means of grease extraction. ESPs obstruct exhaust airflow and therefore require nozzle coverage in addition to a nozzle(s) protecting the ductwork. Exhaust ductwork using ESPs require ADP nozzle(s). The ADP nozzle(s) must be located centrally in the ductwork and should be aimed at the middle of the ESP. Distribution piping to the ADP nozzle located above the ESP and the ADP nozzle aimed at the precipitator must not interfere with the function of the ESP unit. See Figure 3-35. Figure 3-35. Nozzle Placement with Electrostatic Precipitator CENTERLINE OF HAZARD ZONE CL KITCHEN HOOD ADP NOZZLE ELECTROSTATIC PRECIPITATOR ADP NOZZLE System Design P/N 9127100 3-41 January 2007 3-6.1.2.2 Transitional Duct The proposed protection for transitional duct applications should be approved by the AHJ (Authority Having Jurisdiction) prior to starting this system installation. Badger recommends that transitional ducts be protected as follows. Measure the dimensions at six inches into the transition piece. Determine the number of nozzles required by the perimeter measured at the six-inch location. Place the tip of the nozzle(s) at six inches into the transition piece. See Figure 3-36. Figure 3-36. Transitional Duct ADP NOZZLE 6 in. (152 mm) TRANSITION SECTION System Design January 2007 3-42 P/N 9127100 3-7 CYLINDER FLOWS After finding how many nozzles of each type are required for a system, the sum of all the nozzle flow numbers is used to determine the number and size of the cylinders required, in accordance with the cylinder flow number limits given below. 1 Only like cylinders can be manifolded (i.e., four RG-4GS or 4GM; two RG6G) Table 3-30. Cylinder Flow Number Limits Maximum Flow Numbers of Cylinders Cylinder Flow Number RG-1.25G 4 — Single Cylinder Only (cannot manifold) RG-2.5G 8 — Single Cylinder Systems Only (cannot manifold) RG-4GS/RG4GM 1 Cylinder 2 Cylinders 3 Cylinders 4 Cylinders Can manifold up to 4 cylinders1 12 24 36 48 RG-6GS 1 Cylinder 2 Cylinders Can manifold up to 2 cylinders1 18 36 System Design P/N 9127100 3-43 January 2007 3-8 PIPING REQUIREMENTS Range Guard systems do not require balanced piping to achieve proper distribution of wet chemical to all nozzles. Balanced piping is not necessary because a liquid has no difficulty in turning corners or changing directions. Range Guard nozzles come equipped with permanent predetermined orifices. This means that the liquid will be delivered in the exact quantities necessary to the duct, plenum and appliance hazards as required. All pipe shall be schedule 40 (standard weight) black steel. Pipe may be chrome plated. Galvanized pipe shall not be used. All pipe and fittings must be made tight without pipe dope or thread sealant. Pipe fittings shall be standard weight steel, cast iron, malleable iron or ductile iron. Galvanized fittings shall not be used. Branch line connection and individual nozzle connections may be made by using either the outlet or the run of a tee. 3-8.1 Stainless Steel Tubing and Fittings Stainless steel tubing may be used on all Range Guard systems. Fittings may be stainless steel compression or stainless steel flare types. Bending of tubing using mandrels is permissible. 3-8.2 Pipe Sizing Pipe sizes are determined by the total number of flow numbers running through a particular piece of pipe. This is the flow demand for that portion of the system. Note:It is not permissible to drop pipe diameters below the required value. For example, using 1/2- inch pipe to flow 18 flow numbers is not permissible. However, increasing pipe diameter is acceptable (i.e., using 1-inch pipe to flow 18 flow numbers) providing the system complies with internal pipe volume limitations. 3-8.3 General Rules • A maximum of 100 equivalent ft. (30.5 m) but not more than 40 linear ft. (12.2 m) of 1/4-in. pipe may be used from each branch line. • The highest point of the system shall not exceed 12 ft. (3.7 m) above the cylinder outlet. • The vertical rise of a branch line above the supply line shall not exceed a maximum of 4 ft. (1.2 m). • Maximum discharge pipe volume limitations shall not be exceeded. • Maximum equivalent length limitations shall not be exceeded. • Maximum flow points for a given pipe shall not be exceeded. • There are to be no low points or “traps” present in discharge piping. Table 3-31. Flow Number Range and Pipe Type Flow Number Range Minimum Pipe Size .035 Wall Stainless Steel Tubing Size 1 — 2 1/4-inch 3/8-inch 1 — 8 3/8-inch N/A 1 — 12 1/2-inch 5/8-inch 13 — 24 3/4-inch 7/8-inch 25 — 48 1-inch 1-inch System Design January 2007 3-44 P/N 9127100 3-8.4 Discharge Line Volume Limitations There is a discharge line volume limitation in Range Guard systems. Discharge line volume is the total volume of all pipe, tubing, and fittings used in single or multiple cylinder systems. To measure discharge line volume, it is necessary to measure all pipe length from the center of one fitting to the center of the next fitting and multiply by the volume-per-foot factor given in Table 3-32 and Table 3-33. 1 Cannot Manifold Note:The maximum allowable 3/8-inch pipe volume is not in addition to the total discharge line volume, but represents a portion of the total volume which may be dedicated to 3/8-inch pipe alone. Table 3-32. Piping Discharge Line Volume Size Piping Discharge Line Volume 1/4 in.1.25 in.3 per linear foot — (67.2 cm3 per linear meter) 3/8 in. 2.29 in.3 per linear foot — (123.1 cm3 per linear meter) 1/2 in. 3.65 in.3 per linear foot— (196.2 cm3 per linear meter) 3/4 in. 6.40 in.3 per linear foot — (344.1 cm3 per linear meter) 1 in. 10.37 in.3 per linear foot — (557.5 cm3 per linear meter) Table 3-33. Tubing Discharge Line Volume Size Piping Discharge Line Volume 3/8 in. 0.88 in.3 per linear foot — (47.3 cm3 per linear meter) 5/8 in.2.90 in.3 per linear foot — (155.9 cm3 per linear meter) 7/8 in. 6.11 in.3 per linear foot — (328.5 cm3 per linear meter) 1 in. 8.15 in.3 per linear foot — (438.2 cm3 per linear meter) Table 3-34. Maximum Allowable Piping Volume Cylinder Size Total Discharge Pipe Volume Max. per Cylinder Total Discharge Tubing Max. per Cylinder Max. Allowable 3/8-inch Pipe Volume per System RG-125 (4.7 L)72 in.3 (1180 cm3) 1 51 in.3 (836 cm3) 1 72 in.3 (1180 cm3) RG-250 (9.5 L)139 in.3 (2278 cm3) 1 99 in.3 (1622 cm3) 1 95 in.3 (1557 cm3) RG-400 (15 L)400 in.3 (6555 cm3) 282 in. 3 (4621 cm3) 1 95 in.3 (1557 cm3) RG-600 (22.7 L)400 in.3 (6555 cm3) 282 in. 3 (4621 cm3) 1 95 in.3 (1557 cm3) System Design P/N 9127100 3-45 January 2007 3-8.4.1 EQUIVALENT LENGTH LIMITATIONS Equivalent feet is defined as the actual measured length of discharge line plus the equivalent length for each fitting in the line as obtained from the data given in Table 3-35 and Table 3-36. Equivalent feet is measured from the cylinder (the farthest cylinder in a manifold) to the most remote nozzle. Equivalent feet is also measured between the two most remote nozzles. Equivalent feet is measured only along that branch with the most equivalent feet. Table 3-36 lists the maximum equivalent lengths for each cylinder size. Table 3-36. Tube Fitting Equivalent Length Table 3-35. Pipe Fitting Equivalent Length Pipe Fittings Equivalent Length 1/4 in. (6.3 mm) 3/8 in. (9.5 mm) 1/2 in. (13 mm) 3/4 in. (19 mm) 1 in. (25.4 mm) 90° Elbow 0.9 ft. (.27 m) 1.3 ft. (.40 m) 1.5 ft. (.46 m) 2.1 ft. (.64 m) 2.7 ft. (.82 m) 45° Elbow 0.4 ft. (.12 m) 0.6 ft. (.18 m) 0.8 ft. (.24 m) 1.0 ft. (.30 m) 1.3 ft. (.40 m) Tee (Outlet) 2.0 ft. (.61 m) 2.7 ft. (.82 m) 3.5 ft. (1.07 m) 4.5 ft. (1.37 m) 5.8 ft. (1.77 m) Tee (Run) 0.5 ft. (.15 m) 0.8 ft. (.24 m) 1.1 ft. (.34 m) 1.4 ft. (.43 m) 1.7 ft. (.52 m) Red. (1/2 in. to 1/4 in.) (13 mm to 6.3 mm) 0.3 ft. (.09 m) ———— Red. (1/2 in. to 3/8 in.) (13 mm to 9.5 mm) — 0.3 ft. (.09 m) ——— Red. (3/4 in. to 1/2 in.) (19 mm to 13 mm) — — 0.4 ft. (.12 m) —— Red. (1 in. to 3/4 in.) (25.4 mm to 19 mm) — — — 0.5 ft. (.15 m) — Tube Fittings Equivalent Length 3/8 in. (9.5 mm) 5/8 in. (16 mm) 7/8 in. (22 mm) 1 in. (25.4 mm) 90° Elbow 1.5 ft. (.46 m) 2.5 ft. (.76 m) 4.0 ft. (1.22 m) 4.5 ft. (1.37 m) 90° Bend 0.5 ft. (.15 m) 1.0 ft. (.30 m) 1.0 ft. (.30 m) 1.0 ft. (.30 m) 45° Elbow 0.8 ft. (.24 m) 1.3 ft. (.40 m) 2.0 ft. (.61 m) 2.3 ft. (.70 m) 45° Bend 0.5 ft. (.15 m) 0.5 ft. (.15 m) 0.5 ft. (.15 m) 0.5 ft. (.15 m) Tee (Outlet) 1.5 ft. (.46 m) 2.5 ft. (.76 m) 4.0 ft. (1.2 m) 4.5 ft. (1.37 m) Tee (Run) 0.5 ft. (.15 m) 0.5 ft. (.15 m) 1.0 ft. (.30 m) 1.0 ft. (.30 m) System Design January 2007 3-46 P/N 9127100 Figure 3-37. 1/2 in. (13 mm) Piping with 90° Elbow A tee can be considered one of two ways, depending on orientation. Figure 3-47 shows the different orientations that can occur. The equivalent feet for a reducing tee is determined by the larger size of the tee. Refer to Table 3-9 or 3-10 for equivalent feet. EXAMPLE Figure 3-38. Tees 2 The maximums listed in Table 3-37 apply to manifold systems as well as single cylinder systems. Equivalent Feet (from Table 3-35) 90° 1/2 in. (13 mm) Elbow: 1.5 eq. ft. 90° 1/2 in. (13 mm) Elbow: 1.5 eq. ft. 1.0 ft. of 1/2 in. (13 mm) Pipe 4.0 eq. ft. TOTAL Table 3-37. Remote Nozzles Cylinder Size Equivalent Feet from Cylinder to Most Remote Nozzle Equivalent Feet Between Most Remote Nozzles RG-125 39 ft. (11.9 m) 33 ft. (10.1 m) RG-260 63.4 ft. (14.3 m) 43.7 ft. (13.3 m) RG-400 132 ft. (40.2 m)2 95 ft. (29 m)2 RG-600 75 ft. (22.9 m)2 80 ft. (24.4 m)2 12 in. (.3 m) 1/2 in. (13 mm) PIPE90 ELBOW o 90 ELBOW o System Design P/N 9127100 3-47 January 2007 3-8.4.2 MINIMUM PIPE LENGTH The minimum pipe length, to prevent splash, required between cylinder and closest cooking appliance nozzle used to protect a liquid hazard, such as a deep fat fryer, is given in Table 3-38. For pipe sizes larger than 1/2-inch (1.3 cm) use formulas 1 and 2, to find the equivalent length in 1/2-inch (1.3 cm) pipe. Formula 1: # equivalent feet (meters) of 1-inch (25 mm) pipe x (0.079) = # of equivalent feet (meters) of 1/2-inch (13 mm) pipe Formula 2: # equivalent feet (meters) of 3/4-inch (19 mm) pipe x (0.254) = # of equivalent feet (meters) of 1/2-inch (13 mm) pipe Table 3-38. Minimum Allowable Pipe Pipe Size Minimum Allowable Pipe 1/4-inch and 3/8-inch 8-1/2 (2.6 m) linear feet plus (1) 90° elbow (2.6 m) 1/2-inch Two (2) 90° Elbows and 7 linear feet (2.1m) 3/4-inch and 1-inch 10 equivalent feet of 1/2-inch (13 mm) pipe (see formulas 1 & 2 and Figure 3-39) System Design January 2007 3-48 P/N 9127100 Figure 3-39. Pipe Size and Nozzle Distance 3/4-inch Pipe (1) 1/2-inch to 3/4-inch reducer; (2) 90o 3/4-inch elbow; (1) 3/4-inch to 1/2-inch reducing Tee (run); Linear Feet of 3/4-inch Pipe: Equivalent Feet of 3/4-inch Pipe; (1)(0.4) = 0.4 ft. of 3/4-inch Pipe (2)(2.1) = 4.2 ft. of 3/4-inch Pipe (1)(1.4) = 1.4 ft. of 3/4-inch Pipe 16.0 22 ft. of 3/4-inch Pipe (a) (22.0) x (0.254) = 5.5 eq ft. of 1/2-inch Pipe. (from Formula 2) 3/4-inch Pipe From (a) (1) 1/2-inch Tee (Outlet); (1) 1/2-inch to 3/8-inch reducer; Linear Feet of 1/2-inch Pipe: Equivalent Feet of 3/4-inch Pipe; 5.5FT. of 1/2-inch Pipe (1)(3.5) = 3.5 ft.. of 1/2-inch Pipe (1)(0.3) = 0.3 ft. of 1/2-inch Pipe 5.5 14.8 ft. of 1/2-inch Pipe Therefore, this example does meet the minimum pipe requirement. 3/4 in. (19 mm) 1/2 in. (13 mm) 6 in. (152 mm) 1ft.6in. (.5 m) 10 ft. (3 m) 10 ft. (3 m) 3ft. (.9 m) 3ft. (.9 m) 4ft. (1.2 m) 4ft. (1.2 m) 3/4 in. (19 mm) 2ft. (.6 m) EQUIVALENT FEET CYLINDER TO CLOSEST NOZZLE RG-6G System Design P/N 9127100 3-49 January 2007 3-8.4.3 SPECIAL 3/8-INCH PIPING ONLY SYSTEM On RG-125, RG-260, and RG-400 single cylinder systems only, 3/8-inch discharge piping may be used for the entire piping network following the guidelines in Table 3-39. If a pneumatic release or pressure switch is used, it must be on the upper end of a 12 in. (305 mm) vertical length of black pipe. 2 The limitations on this section (Paragraph 3-8.4.3) supersedes all other limitations when designing a system using 3/8-inch pipe originating from the 4-gallon cylinder outlet. Table 3-39. 3/8 in. Piping Only System Limitations RG-1.25G RG-2.50G RG-4GS/RG-4GM2 Maximum Discharge Line Volume 72 in.3 (1180 cm3) 99 in.3 (1622 cm3) 161 in.3 (2638 cm3) Maximum Equivalent Length of Discharge Line Between Cylinder and Most Remote Nozzle 39 ft. (11.9 m) 40 ft. (12.2 m) 59 ft. (18.0m) Maximum Equivalent Length of Discharge Line Between Most Remote Nozzles 33 ft. (10 m) 42 ft. (12.8 m) 50 ft. (15.2 m) Maximum Equivalent Length of 1/2-inch (13 mm) Discharge Pipe Between Cylinder and Hood 12 ft. (3.7 m) 12 ft. (3.7 m) 24 ft. (7.3 m) Minimum Equivalent Length of Discharge Line Between Cylinder and an Appliance Nozzle Protecting a Liquid Hazard, such as Deep Fat Fryer 8-1/2 ft. (2.6 m) linear feet plus 90° elbow 8-1/2 ft. (2.6 m) linear feet plus 90° elbow 8-1/2 ft. (2.6 m) linear feet plus 90° elbow System Design January 2007 3-50 P/N 9127100 3-8.4.4 DETECTOR Detectors using Range Guard approved fusible link detectors are required over cooking appliances and in the ducts of kitchen cooking equipment per NFPA 17A and NFPA 96. For protection of the duct, a detector must be centered either flush with the hood-duct opening or in the duct but not more than 12 feet (3.7 m) downstream from where the duct is connected to the hood. When mounted in the duct, the detector should be oriented so that the bracket does not shield the link from the hot air stream, and the fusible link is centered in the duct. Maximum dimension per detector is 54 in. x 54 in. (1372 mm x 1372 mm). Appliances having a surface area larger than 54 in. x 54 in. (1372 mm x 1372 mm) require additional detectors. When a cooking appliance is under the hood-duct opening, the appliance is protected by the detector mounted at the hood-duct opening or 12 in. (305 mm) maximum into the duct. An additional detector is not needed to protect that appliance. A temperature survey must be performed at all locations where detectors will be installed. The survey must be conducted under maximum cooking or appliance cleaning conditions in order to determine the optimum exhaust air flow locations and to record the peak temperatures that are expected to occur. Once the survey is completed: • Select the lowest temperature rated detector that can be used. • Make sure the maximum exposure temperature of the link exceeds the maximum temperature obtained from the survey. • Make sure links are located in the exhaust air flow, not in dead air spaces. This will provide the fastest detector response. Note:Care must be taken not to install links directly in the exhaust flow of appliance flue gas. Figure 3-40. Positioning Detectors 12 in. (305 mm) MAX. IF APPLIANCE IS UNDER HOOD DUCT OPENING 3/4 in. (19 mm) DISCHARGE PIPING 24 in. (610 mm) 24 in. (610 mm) 24 in. (610 mm) 18 in. (457 mm) 30 in. (762 mm) 34 in. (864 mm) 48 in. (1219 mm) 56 in. (1422 mm) STOVEGRIDDLEFRYER STOVEFRYERSTOVE CHARBROILER UPRIGHT BROILER GRIDDLE 24 in. (610 mm) LIQUID SEAL ADAPTERS 3/4 in.3/4 in. System Design P/N 9127100 3-51 January 2007 3-9 UCH CONTROL SYSTEM DESIGN AND INSTALLATION PARAMETERS A System Valve Actuator (SVA) is used on every cylinder of the system. 1/4-inch tubing or hose is used to connect from the Control System to each SVA. It has inlet and outlet ports for low profile tubing runs. The following tables define the UCH Control System design and installation parameter limitations. • Table 3-40 - Cable Limitations • Table 3-41 - Actuation Length Limitations * Tee pulleys count as two Corner Pulleys. Maximum is from Control System, through the pulley, to each device The following are additional information and requirements regarding the actuation line tubing and flex hose. 1. Flex hose (P/N B120045), is required to connect the UCH Control System to the System Valve Actuator when the UCH Control System is cylinder mounted. 2. Copper tubing shall be 1/4-inch O.D. x 0.031-inch wall high pressure tubing. 3. When Control System is cylinder mounted and two or more cylinders are being actuated, a minimum of 5 ft. (1.5 m) of 1/4-inch O.D. x 0.031-inch wall tubing shall be used for actuation lines. 4. When Control System is wall mounted, a minimum of 5 ft. (2 m) of 1/4-inch O.D. x 0.031-inch wall tubing shall be used in the overall actuation line. 5. In every system, either single cylinder or multiple cylinder, a 1/8-inch NPT plug or vent check (P/N 877810) shall be used in the outlet port of the last System Valve Actuator(s) in the actuation line. 6. High pressure nitrogen tubing (P/N B120045-001 through B120045-003) may be used in place of copper tubing and not to exceed a maximum length of 30 feet (9 m). Table 3-40. UCH Control System Cable Limitations Cable Line Max. Cable Length Max. Corner Pulleys Max. Detectors Max. Tee Pulleys Detection and Manual Release-to-Trip Line 1 200 ft. (61 m) 50 40 - Detection and Manual Release-to-Trip Line 2 200 ft. (61 m) 50 40 - Pull-to-Trip Remote Manual Release 100 ft. (31 m) 30 - * Mechanical Gas Valve Release 100 ft. (31 m) 30 - * Table 3-41. UCH Control System Actuation Length Limitations Min. Operating Temp. Number of Extinguishing System Cylinders Max. Total Length of 1/4 in. O.D. x 0.031 in. Wall High Pressure Tubing Max. Number of Pressure Switches (P/N 486536) in Actuation Line Min. Tubing 0° F (-18° C)1 — 12 106 ft. (32 m) — See Note 6 2 5 ft. (2 m) 0° F (-18° C)13 — 20 91 ft. (28 m) — See Note 6 2 5 ft. (2 m) System Design January 2007 3-52 P/N 9127100 3-10 A+ DESIGN AND INSTALLATION PARAMETERS The following tables define the A+ design and installation parameter limitations. • Table 3-42 - Detection Line Limitations • Table 3-43 - Actuation Limitations 1 Includes use of Remote Manual Control. 2 If using Gas Valve, maximum 50 ft. (15 m) cable and 16 Corner Pulleys. 3A combined maximum of 23 ft. total (7 m) of 1/4-inch O.D. x .031 wall thickness copper tubing may be used to con- nect the A+ Control Box to the SVA(s) on the cylinder(s). The 23 ft. (7 m) total is comprised of 3 ft. (1 m) of tubing from the A+ to the 1st cylinder and 20 ft. (6 m) from 1st to the last cylinder. Table 3-42. A+ Detection Line Limitations Item Limitations Detection Line 200 ft. (61 m)1, 2 Detectors 40 Corner Pulleys 402 Table 3-43. A+ Actuation Limitations Item Limitations Copper Tubing3 1/4-inch O.D. x .031 wall thickness x 23 ft. (7 m) Total3 3 feet (1 m) from A+ to 1st Cylinder (Min.) SVAs 5 Installation P/N 9127100 4-1 January 2007 CHAPTER 4 INSTALLATION 4-1 INTRODUCTION This chapter is intended for system installers. It outlines the steps needed to install the Range Guard Wet Chemical Fire Suppression System. Before system installation begins, the entire hood, plenum, filters and exhaust duct should be thoroughly cleaned. A suppression system is not an alternative to good housekeeping. It does not eliminate the need for periodic cleaning of hoods, filters, and ducts. 4-2 GENERAL INSTALLATION REQUIREMENTS All components shall be installed in accordance with the appropriate NFPA standard(s): • Extinguishing system per NFPA 17A and NFPA 96 • Detection and alarm-control units (other than detectors) per NFPA 72, • Electrical connections per NFPA 70, • This Design, Installation, Operation, and Maintenance Manual (DIOM) (P/N 9127100), and • Local Authority Having Jurisdiction (AHJ). Only factory trained and authorized personnel are permitted to install or maintain Range Guard Wet Chemical fire suppression systems. 4-3 INSTALLATION OF SUPPRESSION 1. Install the mounting brackets to hold the Cylinder and Valve Assembly. For wall mounting, see Paragraph 4-3.1. For floor mounting, see Paragraph 4-3.2. 2. Mount the Cylinder and Valve Assembly on mounting brackets. 3. Install agent distribution piping. 4. Install nozzles. 4-3.1 Wall Mounting Bracket Installation, P/N 9197430, 9197263, 9197414, 9197415, 100013 The Wall Mounting Bracket is to be mounted vertically (plumb) with the Cylinder and Valve Assembly in the upright position. The mounting location shall be in a clean, dry and protected area where the ambient temperature is between 0°F (-18°C) and 120°F (49°C) and sufficiently away from the hazard(s) so as not to be exposed to process or fire temperatures in excess of 120°F (49ºC). The bracket must be mounted in such a way that no part of the assembly stands in water or other liquid. The Cylinder and Valve Assembly should be mounted at least 4 inches (102 mm) above the floor. 1. Determine the Wall Mounting Bracket mounting locations and mark the mounting holes for bracket. When mounting to a wall stud, use the two in-line vertical holes in the bracket back. If mounting to a hood, use the two horizontal holes in the bracket back. Before drilling the mounting holes, be sure that the mounting surface will support the loads identified in Table 4-2. Installation January 2007 4-2 P/N 9127100 2. Drill three holes for each Mounting Bracket and attach the bracket to the mounting surface with three (3) 3/8-inch diameter bolts or screws of suitable length and type. Use of other approved hardware is permitted. Figure 4-1. Wall Mounting Bracket Table 4-1. Wall Mounting Bracket Specifications Wall Mounting Bracket P/N Model Dimensions ABCDEFG 9197430 RG-1.25 3 in. (76 mm) 9-3/8 in. (238 mm) 1-3/8 in. (35 mm) 2 in. (51 mm) 3-1/4 in. (83 mm) 3-3/8 in. (86 mm) — 9197263 RG-2.50 4-1/2 in. (114 mm) 12 in. (305 mm) 2-1/2 in. (64 mm) 3-1/2 in. (89 mm) 3-3/4 in. (95 mm) 3 in. (76 mm) 5-1/4 in. (133 mm) 9197414 RG-4.0M 4-1/2 in. (114 mm) 20-1/2 in. (521 mm) 2-1/2 in. (64 mm) 3-1/2 in. (89 mm) 13-1/4 in. (337 mm) 2 in. (51 mm) 11-1/4 in. (286 mm) 9197415 RG-4.0S 4-1/2 in. (114 mm) 11-1/2 in. (290 mm) 2 in. (51 mm) 3-1/2 in. (89 mm) 3-3/4 in. (95 mm) 4-1/4 in. (108 mm) 4-1/4 in. (108 mm) 100013 RG-6.0 /RG-4.0 See Figure 4-2 Table 4-2. Wall Mounting Bracket Wall Support Load Wall Mounting Bracket P/N Model Wall Support Load 9197430 RG-1.25 43 lb. (19.4 kg) 9197263 RG-2.50 80 lb. (36 kg) 9197414 RG-4.0GM 132 lb. (60 kg) 9197415 RG-4.0GS 132 lb. (60 kg) 100013 RG-6.0G and RG-4.0G 225 lb. (102 kg) RG-125 BRACKET 1-5/8 in. (41 mm) 3/4 in. (19 mm) D E F 3/4 in. (19 mm) D E F 2-1/2 in. (64 mm) RG-260, 400M, and 400S BRACKET 1 in. (25 mm) G GENERAL RG BRACKET DIMENSIONS B A C Installation P/N 9127100 4-3 January 2007 Figure 4-2. RG-6.0G Wall Mounting Bracket Table 4-3. RG-6.0G Wall Mounting Bracket Specifications Wall Mounting Bracket P/N Model Dimensions Wall Support LoadABCDEF 100013 RG-6.0G and RG-4.0G 21-1/8 in. (537 mm) 11 in. (279 mm) 10-1/8 in. (258 mm) 5-5/8 in. (143 mm) 12-1/2 in. (318 mm) 4 in. (102 mm) 225 lb. (102 kg) A B C CYLINDER STRAP F D E 5/8 in. (16 mm) Installation January 2007 4-4 P/N 9127100 4-3.2 Floor Mount Bracket Kit Installation, P/N 100010 A Floor Mount Bracket Kit is used for mounting the RG-6.0G and RG-4.0GM cylinder to the floor. The Floor Mount Bracket Kit requires Wall Mounting Bracket P/N 100013 See Figure 4-3. 1. Attach the Floor Mount Bracket Kit to the Wall Mounting Bracket using four (4) 3/8-inch diameter bolts of suitable length. 2. Determine the Floor Mount Bracket mounting locations and mark the mounting holes for each bracket. 3. Drill two holes for each Floor Mount Bracket and attach the bracket to the floor surface with four (4) 3/8-inch diameter bolts or screws of suitable length and type. See Table 4-3 for dimensions and load bearing information. Note:Use of other approved hardware is permitted. Figure 4-3. Floor Mount Bracket Kit Attached to Wall Mounting Bracket WALL MOUNTING BRACKET P/N 100013 6-9/16 in. (167.6 mm) 9-5/8 in. (244.5 mm) 4 in. (101.6 mm) 19-1/ 4 i n . (489 m m ) 6 in. (152.4 mm) 1-1/4 in. (31.8 mm) 1-13/16 in. (46 mm) 16-3 / 4 i n . (425 . 5 m m ) Installation P/N 9127100 4-5 January 2007 4-3.3 Cylinder and Valve Assembly Installation Upon removal of each Cylinder and Valve Assembly from its shipping carton, carefully check the following: 1. Ensure that the Anti-Recoil Plate and the Valve Protection Plate are secured to the valve. Figure 4-4. Anti-Recoil and Valve Protection Plates 2. Check that the cylinder pressure is within the acceptable range shown on the pressure gauge. If not, replace with a properly charged cylinder. 3. Inspect the Cylinder and Valve Assembly for any signs of damage such as dents, nicks or scratches. Refer to Compressed Gas Association (CGA) pamphlet C-6 for cylinder inspection procedures. Refer to http://www.cganet.com for more details. 4. Place each Cylinder and Valve Assembly on its bracket shelf, tighten the cylinder strap and check the mounting for proper fit. Make any necessary final adjustments. WARNING The Anti-Recoil Plate must remain installed on the valve outlet at all times except when the cylinder is mounted to a properly secured mounting bracket. The Protection Cap must remain on the valve until the System Valve Actuator (SVA) is installed. Refer to the Safety Summary for more information on pressurized cylinders. ANTI-RECOIL PLATE VALVE PROTECTION PLATE VALVE AND CYLINDER ASSEMBLY Installation January 2007 4-6 P/N 9127100 4-3.4 Installing the Discharge Adapter Kit, P/N 844908 1. Remove the cylinder Anti-Recoil Plate. Do not discard. 2. Lubricate the O-ring with a light coating of Parker Super-O-Lube. Do not grease the bonded seal on valve check. Place the O-ring in the groove near the inlet end of the Discharge Adapter. 3. Insert the Discharge Adapter through the hole in the flange plate (see Figure 4-5). 4. Install the Discharge Adapter into the valve outlet. 5. Install the two 5/16-18 x 1-inch bolts through the cylinder valve and flange adapter and tighten. Each Cylinder and Valve Assembly must be installed in an upright position using the Mounting Bracket specified in Table 4-1 and Table 4-3. Each Cylinder and Valve Assembly will also utilize a Discharge Adapter Kit (P/N 844908). Figure 4-5. Installing the Discharge Adapter Kit, P/N 844908 FLANGE PLATE DISCHARGE ADAPTER O-RING NUT 5/16-18 BOLTS 5/16-18 X 1 in. LONG SHIPPING CAP CYLINDER AND VALVE ASSEMBLY NUT 5/16-18 Installation P/N 9127100 4-7 January 2007 4-3.5 Installation of Pipe/Tubing and Fittings 4-3.5.1 AGENT DISTRIBUTION PIPING Note:If a Pneumatic Release (P/N 9189412) is to be used, refer to Paragraph 4-4.4.8. If a Pressure Switch (P/N 9197023) is to be used, refer to Paragraph 4-3.5.2. Install the agent distribution piping as defined in Chapter 3, or enclosures being protected. Note:Use of bushings is permitted. Piping may be Schedule 40, black steel, or stainless steel. All fittings shall be a minimum of 150 lb. class. Examples of acceptable fitting materials include malleable iron, ductile iron or stainless steel compression or stainless steel flare types. Couplings and unions may be used where necessary, and reducing bushings or reducing tees can be used for changes in pipe diameter. Refer to NFPA 17A, latest edition. Pipe hangers or pipe clamps shall be used for support as required. Refer to local plumbing codes for piping requirements. Before installing the agent distribution piping, ensure that the inside of the pipe is clean and free of obstructions. Piping shall be reamed and cleaned before assembly. After the piping is installed, it must be blown clean with dry air or nitrogen. Pipe thread compound or tape shall not be used. Refer to NFPA 17A, latest edition. Avoid low points or "traps" in the pipe work that would allow liquid to accumulate. CAUTION Do not exceed the maximum pipe lengths, equivalent pipe lengths or pipe fitting parameters as defined in Chapter 3 or the system may not operate as intended. CAUTION Galvanized pipe and fittings are not permitted. WARNING Do not use water or oxygen to blow out piping. Moisture will cause blockage. The use of oxygen is very dangerous as the possible presence of even a minute quantity of oil may cause an explosion, thereby causing death, serious personal injury and/or property damage. Installation January 2007 4-8 P/N 9127100 When using stainless steel tubing, the following minimum bend radii must be maintained: Figure 4-6. Stainless Steel Tubing Table 4-4. Tubing Radius .035 Wall Stainless Steel Tubing Minimum Bend Radius, R 3/8 in. (9.5 mm) 15/16 in. (24 mm) 1/2 in. (13 mm) 1-1/4 in. (32 mm) 5/8 in. (16 mm) 1-1/2 in. (38 mm) 7/8 in. (22 mm) 2 in. (51 mm) 1 in. (25 mm) 3 in. (76 mm) STAINLESS STEEL TUBING R Installation P/N 9127100 4-9 January 2007 4-3.5.2 PRESSURE SWITCHES (IF APPLICABLE), P/N 9197023 The Pressure Switch is screwed on the upper end of a 12-inch (305 mm) length of vertical black pipe (riser). The vertical riser is fastened to a tee which may be located wherever convenient in the discharge pipe. The piping used to plumb the pressure switch must be included in the total volumetric calculation for the overall discharge piping and individual branch line. Note:Risers used are part of total piping volume and must be considered when doing piping calculations. The required mounting position is upright. The Pressure Switch has 1/2-inch NPT pressure inlets to connect to the piping. The electrical connections are either 1/2-inch conduit knockouts or 1-inch NPT fittings. Note:Two Pressure Operated Switches can be installed on pressure actuation lines. Figure 4-7. Installing Pressure Switch, P/N 9197023 PRESSURE SWITCH RESET BUTTON COVER SCREW 1/2 in.(13 mm)NPT Installation January 2007 4-10 P/N 9127100 4-3.5.3 1/2-inch VENT PLUG, P/N 9196984 The vent plug has a 1/2-inch (13 mm) NPT and can be installed in the outlet or the run of the tee in the discharge pipe. In all systems requiring multiple cylinder systems, only one vent plug is required. The vent plug must always point up or horizontally, never down, to assure that it will remain open during discharge. Note:It is necessary to use a bushing with the vent plug when installing the vent plug in a tee larger than 1/2-inch (13 mm). Figure 4-8. 1/2-inch Vent Plug, P/N 9196984 4-3.6 Installing Nozzles Note:Ensure nozzle caps are installed on the nozzles. Do not overtighten or foil seals will be damaged. CAUTION Do not use teflon tape or pipe compound when installing nozzles. Refer to NFPA 17A. CAUTION The nozzles are made of brass. Use a 13/16 open-end or adjustable wrench and tighten until snug. Do not overtighten. Installation P/N 9127100 4-11 January 2007 4-4 INSTALLATION OF CONTROLS 4-4.1 UCH Control System Installation Remove the UCH Control System from its shipping carton. Identify the knockouts that will be used for cable connections to the UCH Control System enclosure. It is easiest if these knockouts are removed before mounting the UCH Control System enclosure. Refer to Figure 4-9 for knockout designations. Note:If using more than the three EMT connectors supplied with the UCH Control System, you must use EMT Connector and O-Ring Kit, P/N 120058. Figure 4-9. Pipe Connection Knockout Designations Note:If using Detection Line 2, select Detection Line 2 (Option 1) OR Detection Line 2 (Option 2). You cannot use both Detection Line 2 knockouts. Note:The knockouts are an integral part of the housing. Ensure that only required knockouts are broken out. Planning ahead and opening only the knockouts necessary for the system will help in keeping the box sealed from dirt, grease, water and other contaminants. • If wall mounting, refer to Paragraph 4-4.1.1. • If cylinder mounting, Paragraph 4-4.1.2. CAUTION Use care when removing the knockouts as you can damage the UCH Control System enclosure. CAUTION Ensure that the knockout pieces of the mounting holes do not remain inside the UCH Control System (P/N B120099) enclosure. Failure to remove these could cause malfunction of the mechanism. KNOCKOUT 3 (DETECTION LINE 1) KNOCKOUT 4 (DETECTION LINE 2) (OPTION 1) - SEE NOTE KNOCKOUT 5 (REMOTE MANUAL RELEASE) KNOCKOUT 6 (DETECTION LINE 2) (OPTION 2) - SEE NOTE KNOCKOUT 8 (MECHANICAL GAS VALVE) KNOCKOUT 1 (SWITCH LEAD FOR HIGH MOUNT MICROSWITCHES OR SOLENOID) KNOCKOUT 2 (SWITCH LEAD FOR DEEP MOUNT MICROSWITCHES OR SOLENOID) KNOCKOUT 7 (NOT USED) KNOCKOUTS FOR MOUNTING UCH TO SVA ACTUATION (OUTPUT) PORT LOCAL MANUAL RELEASE Installation January 2007 4-12 P/N 9127100 4-4.1.1 INSTALLING THE UCH CONTROL SYSTEM (WALL MOUNT) 1. With the UCH Control System cover removed, lay the box on its back. Locate the four mounting holes in the housing. Position the box so that the mounting holes are not flat on the work surface and break out the knockouts. See Figure 4-10 for location of mounting holes. Figure 4-10. Location of Mounting Holes (Housing) 2. Using 1/4-20 x 3-inch long toggle bolts or equivalent hangers, mount the box to the wall making sure it is level. Attach the conduit fittings and other fittings to the box. Run cables and wiring as normal, within the parameters of the UCH Control System. See Paragraph 4-7.1.4.1 for cable parameters. 3. Locate the System Valve Actuators (SVA). 4. Ensure the piston of the SVA is in the 'Set' position. See Figure 4-11. MOUNTING HOLE MOUNTING HOLE MOUNTING HOLE5-1/2 in. (140 mm) 7-5/8 in. (194 mm) 4-3/8 in. (112 mm) 1-5/16 in. (34 mm) 3/4 in. (19 mm) MOUNTING HOLE Installation P/N 9127100 4-13 January 2007 Figure 4-11. SVA in ‘Set’ Position 5. Remove the Valve Protection Plate from the top of the cylinder valve. 6. Install the SVAs onto each cylinder valve (the piston facing cylinder valve). Do not tighten them as they will be removed at a later time. 7. Install 1/8-inch NPT pipe plug (P/N 877810) or optional vent check on last SVA (end of line). 8. Install 1/8 NPT (M) x 1/4 copper tubing adapters. Compression type adapters are permissible. 9. Measure and install the 1/4 O.D. x 0.031 wall thickness copper tubing. A 2-1/2 inch (64 mm) loop between each cylinder and on the inlet tubing is recommended, but not required. See Figure 4-12. Ensure that each connection is secure. Figure 4-12. Example of Copper Tubing Loop Method 10. Remove the SVAs from the cylinder valves and re-install the Valve Protection Plates. SVA PISTON IN SET POSITION 1/8 in. PIPE PLUG OR OPTIONAL VENT PLUG 2-1/2 in. LOOP EXAMPLES (Recommended) Installation January 2007 4-14 P/N 9127100 4-4.1.2 INSTALLING UCH CONTROL SYSTEM (CYLINDER MOUNT) 1. Locate the System Valve Actuators (SVA). 2. Ensure the piston of the SVA is in the 'Set' position. Figure 4-13. SVA in ‘Set’ Position 3. Remove the Valve Protection Plate from the top of the cylinder valve. 4. Install the SVAs onto each cylinder valve (the piston facing cylinder valve). The ports on the SVA should be positioned towards the discharge adapter. Do not tighten the SVA(s) as it will be removed at a later time. Figure 4-14. SVA Installation (Cylinder Mount) 5. Install UCH Control System onto the SVA. SVA PISTON IN SET POSITION VALVE PROTECTION PLATE BOLTS SVA CYLINDER VALVE Installation P/N 9127100 4-15 January 2007 6. Install SVA bolts through the bottom of the UCH Control System into the SVA. Figure 4-15. Mounting the UCH Control System to the SVA 7. For multiple cylinder installations, install 1/8 NPT (M) x 1/4 copper tubing adapters. Compression type adapters are permissible. 8. For multiple cylinder installations, measure and install the 1/4 O.D. x 0.031 wall thickness copper tubing. A 2-1/2-inch (64 mm) loop between each cylinder and on the inlet tubing is recommended, but not required. See Figure 4-16. Ensure that each connection is secure. Note:Minimum 5 ft. (1.2 m) copper tubing (total). 9. Install the 1/8 NPT (M) x 3/8-24 JIC flare adapter (included with the High Pressure Nitrogen Tubing, P/N B120045) onto the outlet port of the UCH Control System. Note:Do not use teflon tape. SVA BOLTSVA BOLT SVA Installation January 2007 4-16 P/N 9127100 Figure 4-16. Example of Copper Tubing Loop Method 10. Secure the 3/16-inch braided High Pressure Nitrogen Tubing (P/N B120045) onto the SVA. Ensure the connection is tight. Note:Do not attach the swivel end of the hose onto the outlet of the UCH Control System. Figure 4-17. Installing High Pressure Nitrogen Tubing 11. Remove the SVAs from the cylinder valves and re-install the valve protection plates. CAUTION The High Pressure Nitrogen Tubing is required between the UCH Control System and the primary SVA on all cylinder mounted installations. 1/8 in. PIPE PLUG 2-1/2 in. LOOP EXAMPLES (Recommended) UCH CONTROL SYSTEM 1/8 NPT FITTING HIGH PRESSURE NITROGEN TUBING SVA Installation P/N 9127100 4-17 January 2007 Figure 4-18. Dimensions of Cylinder, Valve, SVA, and UCH Control System Table 4-5. Cylinder and Valve Assembly Specifications Model Dimensions A Center of Discharge Port B Top of Cylinder Valve C Center of SVA Port D Top of SVA E Overall Height RG-1.25G 13-3/4 in. (349 mm) 15-1/4 in. (387 mm) 16-1/2 in. (419 mm) 17 in. (432 mm) 25-1/8 in. (638 mm) RG-2.50G 19-9/16 in. (497 mm) 21 in. (534 mm) 22-5/16 in. (567 mm) 22-3/4 in. (578 mm) 30-15/16 in. (786 mm) RG-4.0GS 17-1/2 in. (445 mm) 19 in. (483 mm) 20-1/4 in. (514 mm) 20-3/4 in. (527 mm) 28-7/8 in. (733 mm) RG-4.0GM 22-15/16 in. (583 mm) 24-7/16 in. (621 mm) 25-11/16 in. (652 mm) 26-3/16 in. (665 mm) 34-5/16 in. (872 mm) RG-6.0G 33-11/16 in. (856 mm) 35-3/16 in. (894 mm) 36-7/16 in. (929 mm) 36-15/16 in. (938 mm) 45-1/16 in. (1145 mm) AB CD E Installation January 2007 4-18 P/N 9127100 4-4.1.3 ACTUATION Figure 4-19 illustrates the steps to follow when deciding what type of actuation to use. Figure 4-19. Decision Flow Chart for Actuation Mechanical, electrical or both? ElectricalMechanical “Mechanical Detection Installation” on page 4-19. “Mounting the Solenoid, P/N B100043” on page 4-32. Includes Lockout of both Detection Lines Both Installing both Detec- tion Lines?No Yes See “Cabling Mechanical Detection — Both Lines” on page 4-22. Detection Line 1 or 2? See “Cabling Detection Line 2 Only (Option 1)— Includes Lockout of Detection Line 1” on page 4-25. See “Cabling Detection Line 1 Only — Includes Lockout of Detection Line 2” on page 4-24. Line 1 Line 2 Note: Refer to the DIOM manual for the specified fire control panel. Installation P/N 9127100 4-19 January 2007 4-4.1.4 MECHANICAL DETECTION INSTALLATION 4-4.1.4.1 Installing Detection Components 1. Drill holes as necessary for installation of the Quick Seal Adapters (P/N 2649930X) or Compression Seal Adapters (P/N 2650460X). 2. Mount the detector brackets as required. 3. Install conduit from the UCH Control System detector conduit knockout(s) (top or right side of the UCH Control System) to the detector brackets using Corner Pulleys (P/N B844648) at all changes in direction. 4. Remove screws and covers from the Corner Pulleys and set aside for reuse later. Note:No bends or offsets are permitted in conduit lines. Be sure the system is adequately supported. Figure 4-20. Unacceptable Cable Configuration 5. Run the 1/16-inch Control Cable from the various system devices, through 1/2-inch EMT conduit, to the UCH Control System. 6. Install detectors of proper rating as described in Paragraph 2-2.3. To install detectors, use the following steps. Always start detector installation at the last detector (see Figures 4-21 and 4-22). Note:Detector Housing Kit, P/N 804548 cannot be used on the A+ Control Box. WARNING Be sure mounting penetrations are liquid and grease tight. Not Acceptable Installation January 2007 4-20 P/N 9127100 7. To install detectors, create a cable loop using a Crimp Sleeve (P/N 214951), and Crimp Tool (P/N 253538). Figure 4-21. Detector Housing Kit Installation, P/N 804548 Note:In order to ensure the crimp sleeve is secure, the cable must always be looped so that there are two lengths of cable inside the Crimp Sleeve before crimping. Cable must not be spliced anywhere along its length. 8. Place the Crimp Tool on the end of the sleeve. Ensure the flat of the sleeve rests in the saddle of the Crimp Tool jaw. Secure the sleeve in the tool carefully to ensure the sleeve does not shift in the saddle before pressing. 9. Squeeze the handles of the Crimp Tool until the tool releases itself. The tooth of the jaw is pressing on the wall of the sleeve without cracking the malleable copper. The first crimp is complete. 10. Remove the crimp from the tool. 11. Put the Crimp Tool onto the other end of the sleeve. The sleeve shall be 180° turned in the tool from the first crimp. Note:This is pressing the loop end of the sleeve (opposite that of the first press). 12. Squeeze the handles of the Crimp Tool until the tool releases itself. The tooth of the jaw is pressing on the wall of the sleeve without cracking the malleable copper. The second crimp is complete. 13. Remove the crimp from the tool. WARNING Use of a crimp tool besides P/N 253538 can cause malfunction and/or unwanted discharge of the system. CAUTION To ensure proper system operation, each detector must be installed so that at least 1-1/2 inches of cable movement toward the UCH Control System is maintained. “S” HOOKS CRIMP SLEEVE “S” HOOKS 1/16 in. CABLE TO UCH CONTROL SYSTEM (NOT SUPPLIED) EXAMPLE OF END-OF-LINE DETECTOR HOUSING KIT EXAMPLE OF IN-LINE HOUSING KITDETECTOR 1-1/2 in. (38 mm) MIN. Installation P/N 9127100 4-21 January 2007 14. Attach an “S” hook (P/N 9189413) to the end of the last detector mounting bracket. 15. Attach proper detector onto the “S” hook. 16. Attach 1/16-inch cable to the hook at the other end of the detector, forming a cable loop held in place by a Crimp Sleeve. Figure 4-22. Universal Link Housing Installation WARNING Be sure mounting penetrations are liquid and grease tight. EXAMPLE OF IN-LINE UNIVERSAL HOUSING KIT EXAMPLE OF END-OF-LINE UNIVERSAL HOUSING KIT “S” HOOKS CRIMP SLEEVE 1/16 in. CABLE TO CONTROL SYSTEM (NOT SUPPLIED) “S” HOOK CRIMP SLEEVE SPACING REQUIREMENTS UCH: 1-1/2 in. (38 mm) MIN. A+: 3 in. (76 mm) MIN. Installation January 2007 4-22 P/N 9127100 4-4.1.4.2 Cabling Mechanical Detection — Both Lines Line 1 (knockout 3), turn ratchet wheel (counterclockwise) of detection beam until the cable through- hole is vertical (see Figure 4-23). Line 2 (knockout 4/6), turn ratchet wheel of detection beam until the cable through-hole is horizontal. Note:When cabling detection line 2, use either Knockout 4 or Knockout 6. 1. Feed the end of the cable through the hole into the center of the ratchet wheel and pull the cable toward you. Leave approximately 6 inches (152 mm) of cable. 2. Slip a Crimp Sleeve (P/N 214951) over the end of the cable. Making a loop, slip the end back through the Crimp Sleeve. 3. Using Crimping Tool (P/N 253538) crimp the sleeve to the cable. Figure 4-23. Cabling Mechanical Detection 4. Cut the loop off of the crimped cable assembly. Cut any loose ends off as close to the Crimp Sleeve as possible. THROUGH HOLE IN RATCHET SPOOL, DETECTION LINE 2 THROUGH HOLE IN RATCHET SPOOL, DETECTION LINE 1 DETECTION BEAMS IN RELEASED POSITION DETECTION BEAMS IN SET POSITION ACTUATION LATCH IN HORIZONTAL (SET) POSITION Installation P/N 9127100 4-23 January 2007 5. Pull the ends of the crimped cable back through until the end of the cable seats inside the central chamber of the ratchet wheel. 6. By hand, turn the wheel until the cable wraps around the spool of the ratchet. The cable line is now ready to be set. If the line is fully cabled, the detection line may be set. Note:If using Detection Line 2, Knockout 4, the cable must go around the pulley wheel before going into the cable port of the ratchet wheel. When tightening the cable around the spool, it is important that the cable be seated in the bottom of the groove on the pulley wheel. The cable may tend to wrap itself around other components in the UCH Control System. Use caution in tightening the cable to ensure the proper path or a cable jam could occur resulting in the malfunction of the system. Figure 4-24. Close Up View of Detection Lines 1 and 2 Beam Stops CAUTION Use care when tightening the cable. Tighten cable until the detection arm makes contact with the beam stop. Do not overtighten. BEAM STOP FOR DETECTION LINE 1 BEAM STOP FOR DETECTION LINE 2 DETECTION ARMDETECTION ARM Installation January 2007 4-24 P/N 9127100 4-4.1.4.3 Cabling Detection Line 1 Only — Includes Lockout of Detection Line 2 Figure 4-25. UCH with Detection Line 2 Locked Out 1. Ensure that nothing is armed or set in the UCH. 2. With the UCH completely disarmed, remove the spring from its respective post (item 3A, Detection Line 2). It is permissible to remove the spring from the detection beam. 3. Push the detection beam (item 3) against its respective beam stop (item 6). 4. Using a 9/64-inch allen key (hex) remove one of the red lockout screws from storage pad (item 1) and carefully thread into lockout pad (item 8). Table 4-6. Cabling Detection Line 1 Only Item Description 1 Lockout screw pad (shown with one red lockout screw removed) 2 Actuation Latch 3 Spring and beam for Detection Line 2 (locked out) 3A Spring Post for Detection Line 2 (spring removed) 4 Spring and beam for Detection Line 1 (set with cable) 4A Spring Post for Detection Line 1 5 Beam Stop for Detection Line 1 6 Beam Stop for Detection Line 2 7 Lockout pad for Detection Line 1 (not used, line set) 8 Lockout pad for Detection Line 2 (red lockout screw inserted) 4A 6 1 3 3A 8 5 4 7 2 Installation P/N 9127100 4-25 January 2007 4-4.1.4.4 Cabling Detection Line 2 Only (Option 1)— Includes Lockout of Detection Line 1 Figure 4-26. UCH with Detection Line 1 Locked Out 1. Ensure that nothing is armed or set in the UCH. 2. With the UCH completely disarmed, remove the spring from its respective post (item 4A, Detection Line 1). It is permissible to remove the spring from the detection beam. 3. Push the detection beam (item 4) against its respective beam stop (item 5). 4. Using a 9/64-inch allen key (hex) remove one of the red lockout screws from storage pad (item 1) and carefully thread into lockout pad (item 7). Table 4-7. Cabling Detection Line 2 Only - Option 1 Item Description 1 Lockout screw pad (shown with one red lockout screw removed) 2 Actuation Latch 3 Spring and beam for Detection Line 2 (set with cable) 3A Spring Post for Detection Line 2 4 Spring and beam for Detection Line 1 (locked out) 4A Spring Post for Detection Line 1 (spring removed) 5 Beam Stop for Detection Line 1 6 Beam Stop for Detection Line 2 7 Lockout pad for Detection Line 1 (red lockout screw inserted) 8 Lockout pad for Detection Line 2 (not used, line set) 4A 6 1 3 3A 8 5 4 7 2 Installation January 2007 4-26 P/N 9127100 4-4.1.4.5 Cabling Detection Line 2 Only (Option 2)— Includes Lockout of Detection Line 1 Figure 4-27. UCH with Detection Line 1 Locked Out 1. Ensure that nothing is armed or set in the UCH. 2. With the UCH completely disarmed, remove the spring from its respective post (item 4A, Detection Line 1). It is permissible to remove the spring from the detection beam. 3. Push the detection beam (item 4) against its respective beam stop (item 5). 4. Using a 9/64-inch allen key (hex) remove one of the red lockout screws from storage pad (item 1) and carefully thread into lockout pad (item 7). Table 4-8. Cabling Detection Line 2 Only - Option 2 Item Description 1 Lockout screw pad (shown with one red lockout screw removed) 2 Actuation Latch 3 Spring and beam for Detection Line 2 (set with cable) 3A Spring Post for Detection Line 2 4 Spring and beam for Detection Line 1 (locked out) 4A Spring Post for Detection Line 1 (spring removed) 5 Beam Stop for Detection Line 1 6 Beam Stop for Detection Line 2 7 Lockout pad for Detection Line 1 (red lockout screw inserted) 8 Lockout pad for Detection Line 2 (not used, line set) 4A 6 1 3 3A 8 5 4 7 2 Installation P/N 9127100 4-27 January 2007 4-4.1.5 ATTACHING MICROSWITCHES 4-4.1.5.1 High Mount Location for Microswitches The High Mounted Microswitch mounts with the paddle(s) facing up into the Cam/Flag. When in the 'Set' position, the Cam/Flag pushes down on the paddle(s) of the microswitch. When the Cam/Flag is released, the microswitch(es) release and change position (see Figure 4-28 for mounting, and Figure 4-31 for wiring diagram). The microswitches are best mounted when the system is in the 'Released' position. Two pairs of #4 screws are included with each microswitch kit: 5/8-inch long and 1-inch long x 3/32-inch Allen Key. If mounting a single switch, use the 5/8-inch screws. If mounting two switches, use the 1-inch long screws. After mounting the microswitch, turn the Cam/Flag to the 'Set' position to ensure the paddles move far enough down to change the phase of the microswitch. Use the included pigtail assembly to connect the microswitch to the circuit being monitored. See Figure 4-33 to see the terminal type microswitch positions when the UCH Control System is in the Set and Released states. See Figures Figure 4-30, Figure 4-31, Figure 4-32, and Figure 4-33 for wiring diagrams. Note:It is recommended that the pigtails be threaded into the port before attempting to plug it onto the microswitch contacts. All splices and connections should be made in a separate approved electrical box connected by EMT or other approved conduit. See NFPA 70, and NFPA 72 for proper wiring guidelines. Figure 4-28. High Mount Microswitch, 'Released' and ‘Set’ Positions HIGH MOUNT MICROSWITCH HIGH MOUNT MICROSWITCH SET POSITIONRELEASED POSITION Installation January 2007 4-28 P/N 9127100 4-4.1.5.2 Deep Mount Location for Microswitches The Deep Mounted Microswitch mounts with the paddle(s) facing down, away from the Cam/Flag and trigger. When in the 'Set' position, the trigger pin pushes up on the paddle(s) of the microswitch. When the Cam/Flag is released, the microswitch(es) release and changes position. See Figure 4-29 for mounting information. See Figure 4-31 for wiring diagram. The microswitches should be mounted when the system is in the 'Released' position. Two pairs of #4 screws are included with each microswitch kit: 5/8-inch long and 1-inch long x 3/32-inch Allen Key. If mounting a single microswitch, use the 5/8-inch screws. If mounting two microswitches, use the 1- inch long screws. After mounting the microswitch, turn the Cam/Flag to the 'Set' position to ensure the paddles move far enough up to change the position of the microswitch. Use the included pigtail assembly to connect the Microswitch to the circuit being monitored. See Figure 4-33 to see the terminal type microswitch positions when the UCH Control System is in the Set and Released states. See Figures 4-30, 4-31, 4-32, and Figure 4-33 for wiring diagrams. See Figure Figure 4-37 and Figure 4-38 for initiating and releasing wiring diagrams. Note:It is recommended that the pigtails be threaded into the port before attempting to plug it onto the microswitch contacts. All splices and connections should be made in a separate electrical junction box connected by EMT or other approved conduit. See NFPA 70, and NFPA 72 for proper wiring guidelines. Mounting the microswitch with the pigtails attached and inserted into the outlet is recommended. CAUTION When setting the Cam/Flag, make sure the trigger pin turns under the microswitch paddle(s) and pushes up to set the microswitch. If the trigger pin is “above” or between the paddle and the microswitch, the microswitch will not change position upon actuation of the UCH Control System which could result in system malfunction. Installation P/N 9127100 4-29 January 2007 Figure 4-29. Deep Mount Microswitch, 'Released' and ‘Set’ Positions DEEP MOUNT MICROSWITCH DEEP MOUNT MICROSWITCH SET POSITIONRELEASED POSITION PIN ENGAGING MICROSWITCH PADDLE Installation January 2007 4-30 P/N 9127100 4-4.1.6 WIRING MICROSWITCHES FOR UCH These are used when it is necessary to open or close electrical circuits. The following are examples, but not limited to: • Electric appliance shutdown • Make up air shutdown • Electric gas valve shutdown • Shuntbreaker/relay Not for alarm initiation. Figure 4-30. Microswitch Kit (in Released Position), P/Ns B120039, B230039-501 Figure 4-31. Position of Switch in Released Position Table 4-9. Electrical Ratings for Microswitch Kit, P/Ns B120039, B120039-501 125/250 Vac 20.5 Amps 250 Vac 1-1/2 HP 125 Vac 1/2 HP MICROSWITCH ELECTRICAL CONNECTOR NC NOCOM RED LT. BROWN LT. BROWN/WHITE BLACK YELLOW YELLOW/WHITE WHITE BLUE BLUE/WHITE SWITCH POSITION WHEN UCH CAM/FLAG IS IN ‘RELEASED’ POSITION RED LT. BROWN LT. BROWN/WHITE OPEN CLOSED BLACK YELLOW YELLOW/WHITE COMMON WHITE BLUE BLUE/WHITE Installation P/N 9127100 4-31 January 2007 Microswitch to be used for: • Alarm initiation • Solenoid release Not to be used for: • Electric appliance shutdown • Make up air shutdown • Electric gas valve shutdown • Shuntbreaker/relay Figure 4-32. Microswitch in Released Position, P/N B120047 Figure 4-33. Microswitch (Terminal Type) Position in Released Position Table 4-10. Electrical Ratings for Microswitch P/N B120047 250 Vac 15 Amps 250 Vac 1/2 HP 125 Vac 1/2 HP T1 T4 T2 OPEN CLOSED COMMON T2 T4 T1 SWITCH POSITION WHEN UCH CAM/FLAG IS IN ‘RELEASED’ POSITION Installation January 2007 4-32 P/N 9127100 4-4.1.7 MOUNTING THE SOLENOID, P/N B100043 The Solenoid can be used in conjunction with mechanical detection, or if mechanical detection or a Remote Manual Release is not needed. Red lockout screws are mounted in the control system. The Solenoid includes an attached mounting bracket. Included in the hardware kit are two Allen screws. 1. Using a 3/32-inch Allen key, position the Solenoid behind the High-Pressure Nitrogen Tubing, aligning the mounting bracket with the mounting screw holes on the actuator mounting pad (see Figure 4-34). 2. Secure the Solenoid and bracket assembly to the UCH Control System enclosure with the enclosed 3/32-inch Allen screws. 3. Dress the wires from the Solenoid up above the internal nitrogen hose, along the bottom of the UCH and in front of the high mount microswitch mounting pad. 4. Using a cable tie, secure the Solenoid wires to the internal nitrogen hose. Note:Wiring of the Solenoid must be done according to NFPA 72, National Fire Alarm Code, and NFPA 70, CSA and National Electrical Code. Wiring the Solenoid through a microswitch is required. The solenoid coil is 24 Vdc at 1.5 Amp and at 70°F (21°C). 5. Wire the Solenoid to the microswitch: – Wire one lead from the Solenoid to terminal T1 of the microswitch. – Wire the second lead from the Solenoid through Knockout 1 or Knockout 2 through the conduit and into an approved control panel. – Finish the releasing loop by attaching a wire to T4 of the microswitch, through the conduit and into an approved control panel. See Figure 4-34. Releasing the UCH Control System opens the contact and stops the releasing current. WARNING The Solenoid operates on 24 Vdc only. Connection to any other voltage can result in non- operation, burning out of the coil or electrical injury to personnel. Work on the Solenoid should never take place while the system is in the 'Set' and ready position. The Solenoid operates directly on the latch. Ensure that the System Nitrogen Cartridge is removed and the Cam/Flag assembly is released or locked out with the Keeper Pin (P/N 9197108). Installation P/N 9127100 4-33 January 2007 Figure 4-34. Solenoid Mounted and Wired in the UCH Control System Note:Dress the wires from the Solenoid down along in front of the high mount microswitch mounting pad and out through Knockout 1 or Knockout 2. Refer to Figure 4-37 and Figure 4-38 for initiation and releasing wiring diagrams. KNOCKOUT 1 SOLENOID TO APPROVED JUNCTION BOX OR CONTROL PANEL 3/32 in. HEX MOUNTING SCREWS CABLE TIE Installation January 2007 4-34 P/N 9127100 Figure 4-35. Alarm Wiring with Terminal Type Microswitch Figure 4-36. Release Wiring with Terminal Type Microswitch ALARM WIRES TO EOL AND/OR OTHER DEVICES WIRE TYPE KEY MICROSWITCH (INTERNAL) ATTACH EOL TO TERMINAL 2 OF MICROSWITCH EOL FLAG DISENGAGED BY UCH ATTACH ONE SIDE OF ALARM CIRCUIT TO TERMINAL 1 OF MICROSWITCH COMMON TERMINAL 1 OPEN TERMINAL 4 ATTACH ONE SIDE OF ALARM CIRCUIT AND EOL TO TERMINAL 4 OF MICROSWITCH DETECTION LOOP TERMINALS SWITCH POSITION WHEN UCH FLAG/CAM IS IN RELEASED POSITION ALARM WIRES FROM CONTROL PANEL CLOSED TERMINAL 2 FLAG ENGAGED BY UCHTERMINAL 2 NOT USED OPEN TERMINAL 2 ATTACH SOLENOID LEAD TO TERMINAL 1 OF MICROSWITCH COMMON TERMINAL 1ATTACH RELEASING CIRCUIT TO TERMINAL 4 OF MICROSWITCH CLOSED TERMINAL 4SPLICE SOLENOID LEAD TO RELEASING CIRCUIT RELEASING CIRCUIT IN COMPATIBLE CONTROL PANEL ( )24 VDC ONLY UCH SOLENOID P/N 83-100034-001 24 VDC ONLY SWITCH POSITION WHEN UCH FLAG/CAM IS IN SET POSITION ALARM WIRES TO UCH SOLENOID AND/OR OTHER DEVICES WIRE TYPE KEY MICROSWITCH (INTERNAL) ALARM WIRES FROM CONTROL PANEL Installation P/N 9127100 4-35 January 2007 4-4.1.7.1 Locking Out Detection Lines 1 and 2 Figure 4-37. Locking Out Detection Lines 1 and 2 with Solenoid Mounted in UCH Table 4-11. Locking Out Detection Lines 1 and 2 Item Description 1 Lockout screw pad (shown with red lockout screws removed) 2 Actuation Latch 3 Spring and beam for Detection Line 2 (locked out) 3A Spring Post for Detection Line 2 (spring removed) 4 Spring and beam for Detection Line 1 (locked out) 4A Spring Post for Detection Line 1 (spring removed) 5 Beam Stop for Detection Line 1 6 Beam Stop for Detection Line 2 7 Lockout pad for Detection Line 1 (red lockout screw inserted) 8 Lockout pad for Detection Line 2 (red lockout screw inserted) T1T4 T2 2 6 1 3 3A 5 8 4 7 4A SOLENOID Installation January 2007 4-36 P/N 9127100 1. Ensure that nothing is armed or set in the UCH. 2. With the UCH completely disarmed, remove the springs from their respective posts (item 3A, Detection Line 2, and item 4A, Detection Line 1). It is permissible to remove the spring from the detection beam. 3. Push the detection beam (item 4) against its respective beam stop (item 5). 4. Push the detection beam (item 3) against its respective beam stop (item 6). 5. Using a 9/64-inch allen key (hex) remove red lockout screws from storage pad (item 1) and carefully thread into lockout pads (items 7 and 8). CAUTION Never lock out a detection line that is being used in a fire protection system. CAUTION Refer to the tested and listed Control Panel DIOM manual for proper wiring instructions. Installation P/N 9127100 4-37 January 2007 4-4.2 Installation of the A+ Control Box Figure 4-38. A+ Control Box First, determine if an optional microswitch (Single SPDT or Dual SPDT) kit is to be used as part of the A+ Control Box. If a microswitch is to be used, it must be installed in the A+ Control Box prior to mounting the control box to a wall. See the microswitch installation information in Paragraph 4-4.3.3 and Paragraph 4-4.3.4. SPRING VALVE BODY SUBASSEMBLY LEVER (Part of Valve Body Subassembly) MECHANICAL GAS VALVE CABLE (NOT SUPPLIED) CABLE TENSION BLOCK ASSEMBLY DETECTION CABLE (NOT SUPPLIED) TUBING ELBOW FITTING (Part of Valve Body Subassembly) GROMMET 1/4 in. O.D. (6 mm) COPPER TUBING TO SVA (NOT SUPPLIED) C CARTRIDGEO2 Installation January 2007 4-38 P/N 9127100 4-4.3 Mounting the A+ Control Box The A+ Control Box (Figure 4-39) is mounted with four 3/8-inch diameter bolts or screws to a wall. The A+ Control Box may be installed in any position, allowing the cable to enter from the top, bottom or either side. The cover labels are applied to the outside of the cover after the A+ Control Box is mounted. Figure 4-39. Location of Mounting Holes 4-4.3.1 DETECTION INSTALLATION Note:The maximum length of the detection line including a remote manual control, if used, is 200 feet (62 m). Corner Pulleys (P/N B844648) are used for each change in direction. No bends or offsets are permitted. A maximum of 40 Corner Pulleys are allowed in the detection line. A maximum of 16 Corner Pulleys is allowed in the mechanical gas shut off valve cable line. 4-4.3.1.1 Installing Detection Components 1. Drill holes as necessary for installation of the Quick Seal Adapters (P/N 2649930X) or Compression Seal Adapters (P/N 2650460X). 2. Mount the detector brackets as required. 3. Install conduit from the A+ Control Box detector conduit knockout(s) to the detector brackets using Corner Pulleys (P/N B844648) at all changes in direction. WARNING Be sure mounting penetrations are liquid and grease tight. 5 in. (127 mm) 7 in. (178 mm) 5 in. (127 mm) 6-1/8 in. (155 mm) 1 in. (25 mm) 1/2 in. (12 mm) Installation P/N 9127100 4-39 January 2007 4. Remove screws and covers from the Corner Pulleys and set aside for reuse later. Note:No bends or offsets are permitted in conduit lines. Be sure the system is adequately supported. Figure 4-40. Unacceptable Cable Configuration 5. Run the 1/16-inch Control Cable from the various system devices, through 1/2-inch EMT conduit, to the A+ Control Box. 6. Install detectors of proper rating as described in Paragraph 3-2.4. To install detectors, follow the steps below. Always start detector installation at the last detector (see Figure 4-41). Note:Detector Housing Kit, P/N 804548 cannot be used on the A+ Control Box. 7. To install detectors, create a cable loop using a Crimp Sleeve (P/N 214951), and Crimp Tool (P/N 253538). Note:In order to ensure the crimp sleeve is secure, the cable must always be looped so that there are two lengths of cable inside the Crimp Sleeve before crimping. Cable must not be spliced anywhere along its length. 8. Place the Crimp Tool on the end of the sleeve. Ensure the flat of the sleeve rests in the saddle of the Crimp Tool jaw. Secure the sleeve in the tool carefully to ensure the sleeve does not shift in the saddle before pressing. 9. Squeeze the handles of the Crimp Tool until the tool releases itself. The tooth of the jaw is pressing on the wall of the sleeve without cracking the malleable copper. The first crimp is complete. WARNING Use of a crimp tool besides P/N 253538 can cause malfunction and/or unwanted discharge of the system. Not Acceptable Installation January 2007 4-40 P/N 9127100 10. Remove the crimp from the tool. 11. Put the Crimp Tool onto the other end of the sleeve. The sleeve shall be 180° turned in the tool from the first crimp. Note:This is pressing the loop end of the sleeve (opposite that of the first press). 12. Squeeze the handles of the Crimp Tool until the tool releases itself. The tooth of the jaw is pressing on the wall of the sleeve without cracking the malleable copper. The second crimp is complete. 13. Remove the crimp from the tool. 14. Attach an “S” hook (P/N 9189413) to the end of the last detector mounting bracket. 15. Attach proper detector onto the “S” hook. 16. Attach 1/16-inch cable to the hook at the other end of the detector, forming a cable loop held in place by a Crimp Sleeve. Figure 4-41. Universal Link Housing Installation CAUTION To ensure proper system operation, each detector must be installed so that at least 3-inches of cable movement toward the A+ Control Box is maintained. WARNING Be sure mounting penetrations are liquid and fire tight. EXAMPLE OF IN-LINE UNIVERSAL HOUSING KIT EXAMPLE OF END-OF-LINE UNIVERSAL HOUSING KIT “S” HOOKS CRIMP SLEEVE 1/16 in. CABLE TO CONTROL SYSTEM (NOT SUPPLIED) “S” HOOK CRIMP SLEEVE SPACING REQUIREMENTS UCH: 1-1/2 in. (38 mm) MIN. A+: 3 in. (76 mm) MIN. Installation P/N 9127100 4-41 January 2007 17. Remove the white plastic plug from hole “A” on the side of the A+ Control Box. 18. Connect 1/2-inch (13 mm) EMT to hole “A”. 19. Thread about 18 inches (452 mm) of cable through the hole “A” of the A+ Control Box. 20. Locate the slot in the back panel located behind the lever. Place the tip of a screwdriver in the slot. 21. Pull down on the screwdriver causing the spring to stretch until the Keeper Pin holes in the valve body and lever are lined up. 22. Install the Keeper Pin (P/N 9197108). The A+ Control Box is now held in the "SET" position (see Figure 4-42). Figure 4-42. A+ Control Box in “SET” Position 23. Locate the Cable Tension Block Assembly. The adjusting screw and central roller must be in the uppermost position. Thread the detection cable through the cable tension block, passing over the two pins and under the central roller (see Figure 4-43). Note:It is necessary for you to have already cut and crimped the detection line cable and installed the "S" hooks and fusible links prior to the step of removing the cable slack and making the final adjustments. KEEPER PIN CABLE TENSION BLOCK ASSEMBLY DETECTION CABLE (NOT SUPPLIED) LEVER (Part of Valve Body Subassembly) SCREWDRIVER SLOT VALVE BODY SUBASSEMBLY HOLE A Installation January 2007 4-42 P/N 9127100 Figure 4-43. Cable Tension Block Assembly, P/N 9197220 12. Thread the end of the detection cable through the hole in the lever and through the hole on the left side of the A+. 13. Fasten vise grips to the end of the detection cable. Pull on the detection cable and make sure to remove most of the cable slack. 14. Tighten the lever set screw onto the cable. 15. Tighten the adjustment screw on the Cable Tension Block Assembly until the tension on the cable is balanced and allows the Keeper Pin to easily slide out of the valve body. Leave the Keeper Pin in place until after the CO2 cartridge is installed. This will prevent accidental discharge. If the Keeper Pin does not slide out easily, not enough cable slack was removed when the cable was pulled through the valve body lever. Loosen the adjusting screw in the Cable Tension Block Assembly and then repeat steps above. Note:It is recommended that you cut the detection cable close to the lever. 16. After completing the tensioning of the detection system, make sure that each detector has the required 3 inches (76 mm) minimum spacing, in the direction of cable travel, between the cable clamp or block and the end of the conduit fitting in the detector bracket. ALLEN HEAD ADJUSTINGSCREW INITIAL INSTALLATION DETECTION CABLE CENTRAL ROLLER PINS Installation P/N 9127100 4-43 January 2007 4-4.3.2 A+ TO SYSTEM VALVE ACTUATOR CONNECTION Connect 1/4-inch (6 mm) O.D. copper tubing between the tubing elbow fitting on the A+ Control Box valve and to each cylinder valve's System Valve Actuator. Make sure each tubing connection is tight (tubing fittings may be flared or compression type). Maximum length of all copper tubing is 23 feet (6.1 m). Note:Fittings supplied are compression type. Figure 4-44. Installing 1/4-inch O.D. (6 mm) Copper Tubing 1/4 in. O.D. (6 mm) COPPER TUBING (NOT SUPPLIED) TUBING ELBOW (Part of Valve Body Subassembly) Installation January 2007 4-44 P/N 9127100 4-4.3.3 INSTALLATION OF SINGLE SPDT SWITCH KIT (P/N 60-9197227-000) INTO THE A+ CONTROL BOX These are used when it is necessary to open or close electrical circuits. The following are examples, but not limited to: • Electric appliance shutdown • Make up air shutdown • Electric gas valve shutdown • Shuntbreaker/relay 1. Remove plug from hole “B” on the side of the A+ Control Box. 2. Connect 1/2-inch (13 mm) EMT to hole “B” on the side of the A+ Control Box (Figure 4-45). Figure 4-45. Single SPDT Microswitch Installation 3. Mount the microswitch to the mounting bracket using (Figure 4-46): – two #4-40 X 5/8-inch (16 mm) long screws – two #4 lockwashers – two #4-40 nuts Figure 4-46. Single SPDT Microswitch and Mounting Bracket HOLE B 4-40 x 5/8 in. (16 mm) SCREWS ELECTRICAL CONNECTOR BENT LEVER MICROSWITCH 4-40 NUTS AND LOCKWASHERS MICROSWITCH BRACKET Installation P/N 9127100 4-45 January 2007 4. Attach the mounting bracket to the A+ Control Box prior to wall mounting using: – two #8-32 X 3/8-inch (10 mm) long screws, – two #8 lockwashers – two #8-32 hex nuts 5. Tighten the hex nuts 6. After tensioning the detection cable, rotate the microswitch towards the lever until the microswitch is heard to click (Figure 4-47). 7. Continue moving the microswitch toward the lever until the paddle on the microswitch just touches the top corner of the microswitch body (Figure 4-47). The microswitch is now in the "set" position. 8. Tighten the microswitch screws and nuts. Figure 4-47. Single SPDT Microswitch Adjustment 8-32 x 3/8 in. (10 mm) SCREWS #8 LOCKWASHERS 8-32 HEX NUT 2 PLACES (TYP) SPDT MICROSWITCH SCREWS LEVER SPDT MICROSWITCH SCREWS ELECTRICAL CONNECTOR HOLE B LEVER BEFORE AFTER Installation January 2007 4-46 P/N 9127100 9. Run the wires from the microswitch electrical connector out through hole "B" EMT connection and into an external junction box. Refer to NFPA 70, and NFPA 72 latest editions, and CSA. Refer to Figure 4-49 for alarm initiation wiring diagram. Note:No wiring junctions are to be made in the A+ Control Box. 4-4.3.3.1 A+ Microswitch Wiring Schematic For Alarm Initiation Figure 4-48. A+ Microswitch Wiring Schematic for Alarm Initiation CAUTION Failure to remove the Keeper Pin will result in an inoperative system. UL COMPATIBLE AND LISTED CONTROL PANEL WHITE BLUE BLUE/WHITE BLACK YELLOW YELLOW/WHITE RED LT. BROWN LT. BROWN/WHITE EOL NOTE: ALL WIRING MUST GO THROUGH A CONDUIT ELECTRICAL BOX TERMINAL BLOCK CLASS “B” INITIATING CIRCUIT RECOMMENDED WIRING SCHEMATIC Installation P/N 9127100 4-47 January 2007 4-4.3.4 INSTALLATION OF THE OPTIONAL DUAL SPDT SWITCH KIT (P/N 9197228) INTO THE A+ CONTROL BOX These are used when it is necessary to open or close electrical circuits. The following are examples, but not limited to: • Electric appliance shutdown • Make up air shutdown • Electric gas valve shutdown • Shuntbreaker/relay 1. Remove plug from hole “B” on the side of the A+ Control Box. 2. Connect 1/2-inch (13 mm) EMT to hole “B” on the side of the A+ Control Box (Figure 4-49). Figure 4-49. Dual SPDT Microswitch Installation HOLE B Installation January 2007 4-48 P/N 9127100 3. Mount the microswitches to the mounting bracket. Ensure the cut lever microswitch paddle goes under the paddle of the bent lever microswitch. Refer to Figure 4-50 : • two #4-40 X 1-inch (25 mm) long screws • two #4 lockwashers • two #4-40 nuts Figure 4-50. Dual SPDT Microswitches and Mounting Bracket, P/N 9197228 4. Attach the mounting bracket to the A+ control box prior to wall mounting using: – two #8-32 X 3/8-inch (10 mm) long screws – two #8 lockwashers – two #8-32 hex nuts 5. Tighten the hex nuts. 6. After tensioning the detection cable, rotate the microswitches toward the lever until you hear the microswitches click (Figure 4-51). 4-40 x 1 in. (25 mm) SCREWS ELECTRICAL CONNECTOR BENT LEVER MICROSWITCH 4-40 NUTS AND LOCKWASHERS MICROSWITCH BRACKET CUT LEVER MICROSWITCH TOP VIEW ENSURE THE CUT LEVER MICROSWITCH PADDLE GOES UNDER THE PADDLE OF THE BENT LEVER MICROSWITCH Installation P/N 9127100 4-49 January 2007 7. Continue moving the microswitches toward the lever until the paddle on the microswitches just touches the top corner of the microswitch bodies (Figure 4-51). The microswitches are now in the "set" position. 8. Tighten the microswitch screws and nuts. Figure 4-51. Dual SPDT Microswitch Installation 9. Run the wires from the microswitch electrical connector out through hole "B" EMT connection and into an external junction box. Refer to NFPA 70 and NFPA 72, latest editions. Note:No wiring junctions are to be made in the A+ Control Box. Refer to Figure 4-49 for alarm initiation wiring diagram. CAUTION Failure to remove the Keeper Pin will result in an inoperative system. 8-32 x 3/8 in. (10 mm) SCREWS #8 LOCKWASHERS 8-32 HEX NUT 2 PLACES (TYP) MICROSWITCH SCREWS LEVER MICROSWITCH SCREWS ELECTRICAL CONNECTOR HOLE B LEVER BEFORE AFTER Installation January 2007 4-50 P/N 9127100 4-4.4 Optional Equipment Installation 4-4.4.1 INSTALLING REMOTE MANUAL RELEASE, P/N B875572 (UCH ONLY) The Remote Manual Release is equipped with a safety pin and seal wire which must be removed to permit installation of the control cable from the UCH Control System. Note:The Remote Manual Release is optional if the UCH Control System (local manual release) is in a clearly visible, easily accessible, unobstructed location. If it is not, a Remote Manual Release must be used for mechanical systems. Install the Remote Manual Release as outlined in Steps 1 through 6 (see Figure 4-52). 1. Mount the Remote Manual Release at a means of egress, on a clear, unobstructed exit location between 42 — 48 inches (1067 — 1219 mm) above the floor. Refer to NFPA 17A and NFPA 96, latest editions. The cable can enter the handle from the side hole in the snap-out cover or from the rear of the handle. If the cable is to enter from the rear, perform alternate Steps 1-a and 1-b, otherwise, proceed to Step 2. a. Drill a hole in the wall opposite the position of the Remote Manual Release handle plug (when mounted). b. Attach a 1/2-inch EMT adapter to the hole in the wall. 2. Mount the back plate to the wall using mounting hardware of required length. 3. Remove the Corner Pulley covers to aid in installing the 1/16-inch steel cable through the system. 4. Feed the 1/16-inch steel cable through the Remote Manual Release through 1/2-inch conduit or EMT to the UCH Control System. Use Corner Pulleys (P/N B844648) for all changes in direction. Leave at least 12-inches of 1/16-inch steel cable coming out of the Remote Manual Release. Note:The Remote Manual Release cable attaches to the latch of the UCH Control System. The Remote Manual Release uses Port 5 of the UCH Control System. Figure 4-52. Remote Manual Release with Detection Lines 1 and 2 Locked Out REMOTE MANUAL RELEASE (KNOCKOUT 5) REMOTE MANUAL RELEASE CABLE ACTUATION LATCH CRIMP 1-1/4 in. (32 mm) Installation P/N 9127100 4-51 January 2007 5. There is a through hole in the end of the actuation latch. Carefully feed the control cable through the hole in the actuation latch. Note:It is important that the control cable slips easily through the hole in the end of the actuation latch. The actuation latch must be able to operate without interference from the control cable. Later, the movement of the actuation latch assembly will be tested before completing the setting of the UCH Control System. Approximately 1-1/4 inches (32 mm) of control cable (with crimp end not included) should be left under the actuation latch, when in the 'Released' position. 6. Slip a Crimp Sleeve (P/N 214951) over the end of the control cable. 7. Making a loop, slip the end back through the Crimp Sleeve. 8. Use the Crimping Tool (P/N 253538) to fasten the Crimp Sleeve to the control cable. 9. Cut the loop off of the crimped cable assembly. Cut any loose ends off as close to the Crimp Sleeve as possible. 10. If a second Remote Manual Release is required, use the Tee Pulley assembly (P/N 843791). Installation January 2007 4-52 P/N 9127100 4-4.4.1.1 Attaching Remote Manual Release Note:You can use two Remote Manual Releases with a Tee Pulley (P/N 843791) going to the UCH Control System. Figure 4-53. Exploded View of the Remote Manual Release 1. Attach a length of 1/16-inch steel cable to the Remote Manual Release handle, as follows (refer to Figure 4-54): a. Unscrew the cable nut from the Remote Manual Release pull handle. b. Thread the cable through the cable nut hex-head end at least 3 — 4 inches from the entry of the Remote Manual Release housing. Return the cable through the other hole of the cable nut hex-head. c. Screw the cable nut into the pull handle until tight. Insert the pull handle through the hole in the nameplate and housing. d. Cut excess slack where it emerges from the second hole in the hex-head end of the cable nut. e. Line up the holes in the pull handle and the housing and insert the safety pin to hold the plug in place. Loosely wrap the seal wire around the release handle to lock. MOUNTING PLATE HOUSING CABLE NUT NAMEPLATE SAFETY PIN PULL HANDLE #10 FILLISTER HEAD SCREW 5 in. (127 mm) CHAIN Installation P/N 9127100 4-53 January 2007 2. Attach the cover with nameplate to the mounting plate using the two screws provided. 3. Reattach Corner Pulley covers. Figure 4-54. Installing the Remote Manual Release, P/N B875572 1/2 in. EMT MOUNTING HARDWARE 3-3/4 in. (95 mm) DIA. 1/2 in. EMT 1 in. (25 mm) DIA. HOLE 1 in. (25 mm) MIN. 2-1/4 in. (57 mm)1 in. (25 mm) MIN. 2-1/4 in. (57 mm) Installation January 2007 4-54 P/N 9127100 4-4.4.1.2 Attaching Remote Manual Release Pull Station, P/N 87-120110-001 (Pull-to-Trip — XV ONLY) Note:You can use two Remote Manual Releases with a Tee Pulley (P/N 843791) going to the XV Control System. Figure 4-55. Remote Manual Release Pull Station, Pull-to-Trip (EMT/Conduit at Top) Figure 4-56. Remote Manual Release Pull Station, Pull-to-Trip (EMT/Conduit at Bottom) When installing the Remote Manual Release Pull Station, it may be surface mounted or recess mounted. The Remote Manual Release Pull Station is designed to mount in the same manner for the Pull-to-Trip mode and the Release-to-Trip mode. Note:The supplied plastic sleeve is to be used on surface mount installations only. HOUSING ROLLER SLEEVE (FOR SURFACE MOUNT INSTALLATIONS ONLY) LABEL HANDLE ASSEMBLY TAMPER SEAL SAFETY PIN CHAIN 10-32 x 1/2-in. SCREWS PHL PAN HEAD FACEPLATE 10-32 x 1/2-in. SCREW PHL FLAT HEAD 10-32 x 1/2-in. SCREW PHL FLAT HEAD CONDUIT AND EMT CONNECTOR (NOT SUPPLIED) 10-32 x 1/2-in. SCREW PHL PAN HEAD 1/16 in. DETECTION LINE 1/16 in. DETECTION LINE HOUSING ROLLER SLEEVE (FOR SURFACE MOUNT APPLICATIONS ONLY) LABEL HANDLE ASSEMBLY TAMPER SEAL SAFETY PIN CHAIN 10-32 x 1/2-in. SCREW PHL PAN HEAD FACEPLATE 10-32 x 1/2-in. SCREW PHL FLAT HEAD 10-32 x 1/2-in. SCREW PHL FLAT HEAD CONDUIT AND EMT CONNECTOR (NOT SUPPLIED)10-32 x 1/2-in. SCREW PHL PAN HEAD 1/16 in. DETECTION LINE 1/16 in. DETECTION LINE Installation P/N 9127100 4-55 January 2007 1. Mount the Remote Manual Release Pull Station at a means of egress, on a clear, unobstructed exit location between 42 — 48 inches (1067 — 1219 mm) above the floor. Refer to NFPA 17A and NFPA 96, latest editions. The 1/16-inch (2 mm) diameter stainless steel detection line cable can enter the Pull Handle from the top, bottom, or rear knockout in the housing. If the cable is to enter from the rear of the housing, perform Step 1a., otherwise, proceed to Step 2. a. Drill a hole in the wall opposite the position of the Remote Manual Release Pull Station (when mounted). The hole must be large enough for a 1/2-inch EMT adapter to fit through. 2. Mount the housing to the wall or stud using mounting hardware of required length (Mounting hardware not supplied). If recess mount, attach the housing to a wall stud so that the front surface extends out from the wall stud 1/8-inch to 3/16-inch. 3. Feed the 1/16-inch steel cable through the Remote Manual Release Pull Station into the 1/2-inch conduit or EMT to the XV Control System. Leave at least 12-inches of cable coming out of the Remote Manual Release Pull Station. Note:The Remote Manual Release cable attaches to the actuation latch of the XV Control System. The Remote Manual Release in Pull-to-Trip mode uses Port 5 of the XV Control System. 4. Install the roller to the housing using the #10-32 x 1/2-inch flat head screws provided. If the EMT/Conduit is at the top, refer to Figure 4-55. Route 1/16-inch (2 mm) diameter stainless steel detection line cable as shown. If the EMT/Conduit is at the bottom, refer to Figure 4-56. Route 1/16-inch (2 mm) diameter stainless steel detection line cable as shown. 5. Install the sleeve over the housing (surface mount installations only). 6. Slide the detection line cable through the opening in the faceplate, and attach the faceplate to the housing, using the #10-32 pan head screws provided. 7. Thread the detection line cable through the hole closest to the Handle Assembly. Loop the cable around and through the other open hole. See Figure 4-57. 8. Tighten the setscrew on the end of the Handle Assembly. Pull the cable tight against the handle, and cut off any remaining loose cable close to the Handle Assembly as possible. Figure 4-57. Remote Manual Release Pull Station Handle Assembly WARNING Verify that the 1/16-inch steel cable is behind the roller. Improper cable location will not allow for proper use! SAFETY PIN LOCATION SET SCREW THREAD 1/16 in. CONTROL CABLE IN THIS HOLE 1/16 in. CONTROL CABLE EXITS THIS HOLE BUTTON HEAD SCREW PULL HANDLE Installation January 2007 4-56 P/N 9127100 9. Insert the Handle Assembly into the faceplate, line up the holes on the faceplate collar and the hole on the Handle Assembly, and install the safety pin. Note:Use the #8-32 screw on the handle assembly to rotate the handle to get the hole in the pin and the faceplate collar to line up. Figure 4-58. Securing the Remote Manual Release Pull Station 10. Tightly wrap the tamper seal around the faceplate collar, through the safety pin and behind the handle to lock. Figure 4-59. Wrap Tamper Seal Around Pull Handle Note:If a second Remote Manual Release is required, use the Tee Pulley assembly (P/N 843791). SAFETY PIN HANDLE ASSEMBLY FACEPLATE FACEPLATE COLLAR TAMPER SEAL PULL HANDLE SAFETY PIN SIDE VIEW PULL HANDLE SAFETY PIN TAMPER SEAL FRONT VIEW Installation P/N 9127100 4-57 January 2007 4-4.4.1.3 Attaching Remote Manual Release Pull Station, P/N 87-120110-001 (Release-to-Trip) Figure 4-60. Exploded View of the Remote Manual Release Pull Station, Release-to-Trip When installing the Remote Manual Release Pull Station, it may be surface mounted or recess mounted. The Remote Manual Release Pull Station is designed to mount in the same manner for the Pull-to-Trip mode and the Release-to-Trip mode. Note:The supplied plastic sleeve is to be used on surface mount installations only. 1. Mount the Remote Manual Release Pull Station at a means of egress, on a clear, unobstructed exit location between 42 — 48 inches (1067 — 1219 mm) above the floor. Refer to NFPA 17A and NFPA 96, latest editions. The 1/16-inch (2 mm) diameter stainless steel detection line cable can enter the Pull Handle from the top of the housing. 2. Mount the housing to the wall or stud using mounting hardware of required length (mounting hardware not supplied). If recess mount, attach the housing to a wall stud so that the front surface extends out from the wall stud 1/8-inch to 3/16-inch. 3. Install a 3-Way Pulley (P/N 60-9197602-000) inline with the EMT connector. Note:A 3-Way Pulley (P/N 60-9197602-000) cannot be used to operate dual gas valves. Only one (1) 3-Way Pulley can be used in a given detection system and must be counted as two (2) Corner Pulleys. WARNING The rear knockout may NOT be used in this setup. HOUSING SLEEVE (FOR SURFACE MOUNT INSTALLATIONS ONLY) LABEL HANDLE ASSEMBLY TAMPER SEAL SAFETY PIN CHAIN 10-32 x 1/2-in. SCREW PHL PAN HEAD FACEPLATE PIN BLOCK PULLEY 6-32 x 3/8-in. SCREWS PHL PAN HEAD10-32 x 1/2-in. SCREW PHL PAN HEAD CONDUIT AND EMT CONNECTOR (NOT SUPPLIED) Installation January 2007 4-58 P/N 9127100 4. Feed the 1/16-inch steel detection line cable through the 1/2-inch conduit or EMT into the Remote Manual Release Pull Station. There should be a loop of detection line cable protruding into the Housing and back through the 3-Way Pulley. Note:The Remote Manual Release detection line cable attaches to the actuation latch of the XV Control System or the lever of the KRS-50 Control Box. The Remote Manual Release in Release-to-Trip mode uses Port 3 or 4 of the XV Control System, or Hole A of the KRS-50 Control Box. 5. Loosely install the Pin Block inside the housing using the #6-32 x 3/8-inch pan head screws provided. 6. Install the faceplate using the #10-32 x 1/2-inch screws provided. 7. Insert the Handle Pin so that it protrudes through the Pin Block. 8. Tighten the #6-32 x 3/8-inch pan head screws to secure the Pin Block. 9. Remove the faceplate and Handle Assembly. This step properly aligns the Pin Block with the faceplate. 10. Bring the detection line cable loop down inside the housing while placing it around the provided Pulley. Line up the Pulley with the hole in the Pin Block. 11. Place the Handle Pin through the Pin Block and then through the Pulley. Note:Do not tighten detection line(s) at the XV Control System or KRS-50 Control Box until Remote Manual Release Pull Station is completely assembled. 12. Install the sleeve over the housing (surface mount installations only). 13. Attach the faceplate using the #10-32 x 1/2-inch screws provided. 14. Place the Safety Pin through the Handle Pin and the faceplate collar. Note:Use the #8-32 screw on the handle assembly to rotate the handle to get the hole in the pin and the collar to line up. 15. Attach the handle using the #8-32 flange button head screw. Note:You can now tighten the detection line(s) at the XV Control System or KRS-50 Control Box at this time. If using as an End-of-Line device, use a clamp block instead of the Pulley. CAUTION No Corner Pulleys can be used between the 3-Way Pulley and the Remote Manual Release Pull Station. Installation P/N 9127100 4-59 January 2007 16. Tightly wrap the tamper seal around the faceplate collar, through the safety pin and behind the handle to lock. Figure 4-61. Remote Manual Release Pull Station, Release-to-Trip (Side View) PULLEY PIN BLOCK TAMPER SEAL SAFETY PIN CHAIN #8-32 SCREW BUTTON FLANGE PULL HANDLE HANDLE PIN SIDE VIEW PULL HANDLE SAFETY PIN TAMPER SEAL FRONT VIEW Installation January 2007 4-60 P/N 9127100 4-4.4.2 INSTALLATION OF SURFACE MOUNTED REMOTE MANUAL CONTROL FOR THE UCH CONTROL SYSTEM AND THE A+ CONTROL BOX, P/N 9197463 4-4.4.2.1 End-Of-Line Surface Mounted Remote Manual Control Note:Refer to NFPA 17A and NFPA 96 about End-of-Line and In-Line Remote Manual Controls sharing detection. Note:Only use End-of-Line Remote Manual Release if no detectors are installed. This control may be located at the end of the detection line, or anywhere in the detection line, by using a Tee Pulley. To install the end-of-line surface mounted manual control, proceed as follows: 1. Mount the Remote Manual Control at a means of egress, on a clear, unobstructed exit location between 42 — 48 inches (1067 — 1219 mm) above the floor. Refer to NFPA 17A and NFPA 96, latest editions. 2. Remove the cover plate. The control box is then mounted on the wall or other convenient support utilizing the mounting holes provided. 3. The cable is fastened to the cable block, and the pull pin is inserted through the front hole of the "U" bracket, anchoring the cable securely. 4. Before inserting the pin, it is necessary to slip it through the slot in the cover plate to permit replacement of the cover without interference with the retaining chain. 5. Before replacing the cover plate, a lead seal and wire (or equivalent) must be fastened through the ring of the pull pin and through the front hole of the "U" bracket (Figure 4-62). Figure 4-62. End-of-Line Remote Manual Control, P/N 9197463 Note:The maximum total length of all 1/16-inch (2 mm) diameter stainless steel detection line cable for the A+ Control Box is 200 feet (61 m) and 40 Corner Pulleys maximum. Note:A 3-Way Pulley (P/N 9197286) CANNOT be used to operate dual gas valves. Only one (1) 3- Way Pulley can be used in a given detection system and must be counted as two (2) Corner Pulleys. 1/2 in. (13mm) EMT CONNECTORS OUTLET BOX COVER SCREWS COVER 1/16 in. DETECTION CABLE CLAMP BLOCK“U” BRACKETPULL PIN LEAD SEAL AND BLOCK Installation P/N 9127100 4-61 January 2007 Figure 4-63. End-of-Line Remote Manual Control (Side View), P/N 9197463 CLAMP BLOCK “U” BRACKET OUTLET BOX PULL PIN LEAD SEAL AND WIRE COVER COVER SCREW DETECTION CABLE Installation January 2007 4-62 P/N 9127100 4-4.4.2.2 In-Line Surface Mounted Remote Manual Control Note:Refer to NFPA 17A and NFPA 96 about End-of-Line and In-Line Remote Manual Controls sharing detection. Note:Only use End-of-Line Remote Manual Release if no detectors are installed. To install the in-line surface mount remote control, use In-line Kit (P/N 9197463). 1. Mount the Remote Manual Control at a means of egress, on a clear, unobstructed exit location between 42 — 48 inches (1067 — 1219 mm) above the floor. Refer to NFPA 17A and NFPA 96, latest editions. 2. Install a 3-Way pulley (P/N 9197602) in the horizontal conduit run. 3. Run the cable down through the vertical conduit to an end-of-line Surface Mounted Manual Control Box. Insert cable through conduit connector on one side of the roll pin (Figure 4-62). 4. Remove the cable clamp from the "U" bracket and replace it with the pulley from the In-line Kit (P/N 9197463). 5. Thread the cable around the bearing and back out the opposite side of the roll pin. Note:A 3-Way Pulley (P/N 9197602) CANNOT be used to operate dual gas valves. Only one (1) 3- Way Pulley can be used in a given detection system and must be counted as two (2) Corner Pulleys. 6. Push the pull pin through the bearing and “U” bracket. Figure 4-64. In-Line Remote Manual Control Kit (Front View), P/N 9197463 CAUTION No Corner Pulleys can be used between the 3-Way Pulley and the Remote Manual Release. 1/2 in. (13 mm) EMT CONNECTORS CONTROL BOX 1/16 in. DETECTION CABLE TO DETECTORS BEARING“U” BRACKET 1/16 in. DETECTION CABLE TO CONTROL SYSTEM 1/2 in. (13 mm) EMT CONNECTORS 3-WAY PULLEY Installation P/N 9127100 4-63 January 2007 11. Before replacing the cover plate, a lead seal and wire (or equivalent) must be fastened through the ring on the pull pin and through the small hole on the bracket. Note:A 3-Way Pulley (P/N 9197602) CANNOT be used to operate dual gas valves. Only one (1) 3- Way Pulley can be used in a given detection system and must be counted as two (2) Corner Pulleys. Installation January 2007 4-64 P/N 9127100 4-4.4.3 INSTALLATION OF RECESS MOUNTED IN-LINE REMOTE MANUAL CONTROL, P/N 9197460 Note:Refer to NFPA 17A and NFPA 96 about In-Line Remote Manual Controls sharing detection. Note:Only use End-of-Line Remote Manual Release if no detectors are installed. This control may be located at the end of the detection line, or anywhere in the detection line, by using a 3-way pulley. 1. Mount the Remote Manual Control at a means of egress, on a clear, unobstructed exit location between 42 — 48 inches (1067 — 1219 mm) above the floor. Refer to NFPA 17A and NFPA 96, latest editions. Ensure that the Remote Manual Control is atteched to a wall stud so that the front surface extends out from the wall stud a distance equal to the thickness of the wall board. 2. Remove the cover plate and pull pin from the control. 3. Install a 3-Way pulley (P/N 9197602) in the horizontal conduit run. 4. Run the cable down through the vertical conduit to the Remote Manual Control Box. Insert cable through conduit connector on one side of the roll pin. 5. Thread the cable around the bearing and back out the opposite side of the roll pin. Note:A 3-Way Pulley (P/N 9197602) CANNOT be used to operate dual gas valves. Only one (1) 3- Way Pulley can be used in a given detection system and must be counted as two (2) Corner Pulleys. 6. Push the pull pin through the bearing and “U” bracket. Note:To prevent the cable from going up into the conduit, it is permissable to use an optional S- hook as shown in Figure 4-65 and Figure 4-66. CAUTION No Corner Pulleys can be used between the 3-way pulley and the Remote Manual Release. Installation P/N 9127100 4-65 January 2007 Figure 4-65. Recess Mounted In-Line Remote Manual Control, P/N 9197461 7. Before replacing the cover plate, a lead seal and wire (or equivalent) must be fastened through the ring on the pull pin and through the small hole on the “U” bracket. Note:The maximum total length of all 1/16-inch (2 mm) diameter stainless steel detection line cable for the A+ Control Box is 200 feet (61 m) and 40 Corner Pulleys maximum. Note:A 3-Way Pulley (P/N 9197602) CANNOT be used to operate dual gas valves. Only one (1) 3- Way Pulley can be used in a given detection system and must be counted as two (2) Corner Pulleys. COVER COVER SCREW S-HOOK (OPTIONAL) 1/16 in. DETECTION CABLE PULL PIN WITH CHAIN LEAD SEAL AND WIRE COVER SCREW “U” BRACKET BEARING 3-WAY PULLEY Installation January 2007 4-66 P/N 9127100 Figure 4-66. Recess Mounted In-Line Remote Manual Control (Side View), P/N 9197460 S-HOOK DETECTION CABLE BEARING LEAD SEAL AND WIRE PULL PIN COVER “U” BRACKET 3-WAY PULLEY Installation P/N 9127100 4-67 January 2007 4-4.4.4 INSTALLATION OF RECESS MOUNTED END-OF-LINE REMOTE MANUAL CONTROL, P/N 9197461 Note:Refer to NFPA 17A and NFPA 96 about End-of-Line Remote Manual Controls sharing detection. Note:Only use End-of-Line Remote Manual Release if no detectors are installed. This control is located at the end of the detection line by using a 3-way pulley. To install the surface mount remote manual control proceed as follows: 1. Remove the cover plate and pull pin from the control. 2. Mount the Remote Manual Control at a means of egress, on a clear, unobstructed exit location between 42 — 48 inches (1067 — 1219 mm) above the floor. Refer to NFPA 17A and NFPA 96, latest editions. Ensure that the Remote Manual Control is attahed to a wall stud so that the front surface extends out from the wall stud a distance equal to the thickness of the wall board. 3. Run the cable down through the vertical conduit to the Remote Manual Control Box. Insert cable through conduit connector on one side of the roll pin. 4. Thread the cable around the bearing. 5. Create a cable loop using a Crimp Sleeve (P/N 214951), and Crimp Tool (P/N 253538). Note:In order to ensure the crimp sleeve is secure, the cable must always be looped so that there are two lengths of cable inside the Crimp Sleeve before crimping. Cable must not be spliced anywhere along its length. 6. Place the Crimp Tool on the end of the sleeve. Ensure the flat of the sleeve rests in the saddle of the Crimp Tool jaw. Secure the sleeve in the tool carefully to ensure the sleeve does not shift in the saddle before pressing. 7. Squeeze the handles of the Crimp Tool until the tool releases itself. The tooth of the jaw is pressing on the wall of the sleeve without cracking the malleable copper. The first crimp is complete. 8. Remove the crimp from the tool. 9. Put the Crimp Tool onto the other end of the sleeve. The sleeve shall be 180° turned in the tool from the first crimp. Note:This is pressing the loop end of the sleeve (opposite that of the first press). 10. Squeeze the handles of the Crimp Tool until the tool releases itself. The tooth of the jaw is pressing on the wall of the sleeve without cracking the malleable copper. The second crimp is complete. 11. Remove the crimp from the tool. 12. Cut the excess cable extending past the cable crimp. 13. Place an S-hook through the loop end of the cable. 14. Attach the S-hook up and through the 3/32-inch (2.5 mm) diameter hole on the upper right side of the control box as shown in Figure 4-67 and Figure 4-68. 15. Slip the pull pin through the slot on the cover plate. CAUTION No Corner Pulleys can be used between the 3-way pulley and the Remote Manual Release. WARNING Use of a crimp tool besides P/N 253538 can cause malfunction and/or unwanted discharge of the system. Installation January 2007 4-68 P/N 9127100 16. Push the pull pin through the bearing and “U” bracket. Figure 4-67. Recess Mounted End-of-Line Remote Manual Control, P/N 9197461 Figure 4-68. Recess Mounted End-of-Line Remote Manual Control (Side View), P/N 9197461 CAUTION No Corner Pulleys can be used between the 3-Way Pulley and the Remote Manual Release. COVER COVER SCREW PULL PIN WITH CHAIN LEAD SEAL AND WIRE COVER SCREW S-HOOK 1/16 in. DETECTION CABLE “U” BRACKET BEARING CRIMP S-HOOK 1/16 in. DETECTION CABLE “U” BRACKET BEARING CRIMP COVER PULL PIN WITH CHAIN LEAD SEAL AND WIRE Installation P/N 9127100 4-69 January 2007 17. Before replacing the cover plate, a lead seal and wire (or equivalent) must be fastened through the ring on the pull pin and through the small hole on the bracket. Note:A 3-Way Pulley (P/N 9197602) CANNOT be used to operate dual gas valves. Only one (1) 3- Way Pulley can be used in a given detection system and must be counted as two (2) Corner Pulleys. Installation January 2007 4-70 P/N 9127100 4-4.4.5 CABLING MECHANICAL GAS VALVE IN THE UCH CONTROL SYSTEM Note:The following instructions assume that the cabling will begin from the end of the line (gas valve). The gas valve cable is easier to attach while the Cam/Flag is in the 'Released' position. Final gas valve cable adjustment must take place when the Cam/Flag is in the 'Set' position. The gas valve should be set only after setting the Cam/Flag. 1. Bringing the control cable in from the valve, carefully insert the end of the cable into the hole in the end of the trigger. 2. Pull enough cable through so that there is slack on the outlet side of the trigger. Slip a Cable Crimp (P/N 214951) over the end of the cable. 3. Making a loop, slip the end back through the Cable Crimp. Use the Crimping Tool (P/N 253538) to fasten the Cable Crimp to the cable. Cut the loop off of the crimped cable assembly. Cut any loose ends off as close to the Crimp Sleeve as possible. 4. Pull the cable back through so the crimp rests at the trigger (see Figure 4-69). Figure 4-69. Cabling Gas Valve (Cam/Flag in ‘Released' State) To set the gas valve, use the Keeper Pin (P/N 9197108) to set Cam/Flag and lock it into the 'Set' position. The gas valve can now be set and adjusted. To set the gas valve later, the system must be completely set up, with all detection lines in the 'Set' position. The Cam/Flag can then be set and the gas valve can be properly adjusted. CAUTION Only Tee Pulleys (P/N 843791) can be used to operate Dual Gas Valves. CONNECTION ON TRIGGER FOR GAS VALVE (IN RELEASED STATE) MECHANICAL GAS VALVE (KNOCKOUT 8) Installation P/N 9127100 4-71 January 2007 4-4.4.5.1 CABLING MECHANICAL GAS VALVE 1. To set the gas valve, use the Keeper Pin (P/N 9197108) to set Cam/Flag and lock it into the 'Set' position. Figure 4-70. Cabling Gas Valve (Cam/Flag in 'Set' State) MECHANICAL GAS VALVE (KNOCKOUT 8) CONNECTION ON TRIGGER FOR GAS VALVE (BEHIND MICROSWITCH MOUNTING PAD) IN SET POSITION CRIMP Installation January 2007 4-72 P/N 9127100 2. Remove top and bottom knockouts from the 2x2 electrical box. Install 1/2-inch (13 mm) EMT to top hole of the electrical box (see Figure 4-73). 3. Mount the electrical box to the wall using appropriate hardware. 4. Run conduit and install Corner Pulleys (where appropriate) from the UCH to the electrical box. 5. Install the gas valve to the electrical box using the washer and nut provided with the gas valve. 6. Slip a Cable Crimp (P/N 214951) over the end of the cable. 7. Insert the cable through the gas valve stem. 8. Making a loop, slip the end back through the Cable Crimp. 9. Pull on the cable to lift the gas valve to the open position. 10. Use the Crimping Tool (P/N 253538) to fasten the Cable Crimp to the cable. Cut the loop off of the crimped cable. Figure 4-71. Installing Mechanical Gas Valve CAUTION When pulling on the cable to lift the gas valve, do not over adjust the gas valve. MECHANICAL GAS VALVE 8-32 UNC-2 NUT WASHER CRIMP 1/16 in. CABLE (NOT SUPPLIED) 2 X 2 ELECTRICAL BOX (NOT SUPPLIED) EMT CONNECTOR (NOT SUPPLIED) CONDUIT (NOT SUPPLIED) GAS VALVE STEM Installation P/N 9127100 4-73 January 2007 4-4.4.6 CABLING MECHANICAL GAS VALVE IN THE A+ CONTROL BOX The A+ Control Box can close one mechanical gas valve upon actuation by relaxing the 1/16-inch (2 mm) stainless steel cable installed from the gas valve through conduit and Corner Pulleys to the hole on the valve body lever, next to the spring connection (Figure 4-72). 1. Ensure the Keeper Pin is installed. 2. Remove plug from hole “C” on the side of the A+ Control Box. 3. Connect 1/2-inch (13 mm) EMT to hole “C” on the side of the A+ Control Box (Figure 4-72). 4. Thread the control cable into the bottom hole ("C"). 5. Thread the control cable through the hole in the end of the lever next to the spring connection (opposite of the lever end that is connected to the detection cable). 6. Tighten the lever set screw onto the control cable. Note:It is recommended that you cut the control cable close to the lever. Figure 4-72. Cabling Mechanical Gas Valve Cable in the A+ Control Box MECHANICAL GAS VALVE CABLE (NOT SUPPLIED) LEVER HOLE CSET SCREW KEEPER PIN Installation January 2007 4-74 P/N 9127100 4-4.4.6.1 CABLING MECHANICAL GAS VALVE 1. To set the gas valve, use the Keeper Pin (P/N 9197108) to set the lever and lock it into the 'Set' position. 2. Remove top and bottom knockouts from the 2x2 electrical box. Install 1/2-inch (13 mm) EMT to top hole of the electrical box (see Figure 4-73). 3. Mount the electrical box to the wall using appropriate hardware. 4. Run conduit and install Corner Pulleys (where appropriate) from the electrical box to the A+. 5. Install the gas valve in the electrical box using the washer and nut provided with the gas valve. 6. Slip a Cable Crimp (P/N 214951) over the end of the cable. 7. Insert the cable through the gas valve stem. 8. Making a loop, slip the end back through the Cable Crimp. 9. Pull on the cable to lift the gas valve to the open position. 10. Use the Crimping Tool (P/N 253538) to fasten the Cable Crimp to the cable. Cut the loop off of the crimped cable. Figure 4-73. Installing Mechanical Gas Valve CAUTION When pulling on the cable to lift the gas valve, do not over adjust the gas valve. MECHANICAL GAS VALVE 8-32 UNC-2 NUT WASHER CRIMP 1/16 in. CABLE (NOT SUPPLIED) 2 X 2 ELECTRICAL BOX (NOT SUPPLIED) EMT CONNECTOR (NOT SUPPLIED) CONDUIT (NOT SUPPLIED) GAS VALVE STEM Installation P/N 9127100 4-75 January 2007 4-4.4.7 ELECTRICAL GAS VALVE, P/N 9197XXX Electric Gas Valve is controlled by a pressure switch or microswitch and the Manual Reset Relay Box (P/N 9101735), see Figure 4-75 and Figure 4-76). For Maual Reset Relay Box used before 2006, see Figure 4-77 and Figure 4-78. A loss of electrical power will cause the Electric Gas Valve to close. All Electric Gas Valves must be installed horizontally with the solenoid up. Note:All wiring connections shall be made outside of the solenoid box on the electric gas valve. Figure 4-74. Electric Gas Valve, P/N 9197XXX CAUTION A manual reset relay box is necessary when using an electrical gas valve. SOLENOID Installation January 2007 4-76 P/N 9127100 Figure 4-75. Manual Reset Relay Box, P/N 9101735 Figure 4-76. Manual Reset Relay Wiring Detail 120 VAC, 60 HZ POWER MICROSWITCH CONTACTS SHOWN WITH CONTROLLER IN SET POSITION HOT NEUTRALMANUALRESET RELAYTERMINALBLOCKSUPPLIED POWER WHITE BLUE BLUE/WHITE TERMINAL 1 RED LT BROWN LT BROWN/WHITE TERMINAL 2 BLACK YELLOW YELLOW/WHITE TERMINAL 3 2 3 1 MICROSWITCH ELECTRIC GAS VALVE 1 2 3 4 5 ~~~~JUNCTION BOX ~~~~GROUND SCREW Installation P/N 9127100 4-77 January 2007 Figure 4-77. Manual Reset Relay Box, P/N 9101735 (Used Before 2006) Figure 4-78. Manual Reset Relay Wiring Diagram RESET SWITCH RELAY TERMINAL BOARD MANUAL RESET RELAY BOX MANUAL RESET RELAY BOX (OPEN) RELEASE BUTTON LIGHT RESET BUTTON (RESET AFTER POWER FAILURE) MODEL RB-2 RELAY BOX TERMINAL BLOCK 6A-120V-60Hz PILOT DUTY-125 VA (CIRCUIT SHOWN IN NORMALLY ENERGIZED POSITION) RELAY FACTORY WIRINGFIELD WIRING ELECTRIC GAS VALVE JUNCTION BOX BLACK WHITE BLUE MICROSWITCH (SPDT) POWER 120 VAC - 60 Hz BLACKWHITE Installation January 2007 4-78 P/N 9127100 4-4.4.8 INSTALLING PNEUMATIC RELEASE, P/N 9189412 1. Fasten 12-inch vertical riser to a tee. The purpose of the 12-inch riser is to provide an air cushion during discharge to prevent the entrance of Wet Chemical into the Pneumatic Release. 2. Mount to the wall using suitable hardware. 3. Remove three (3) knockouts from a 4x4 electrical box as illustrated in Figure 4-79. 4. Mount the 4x4 electrical box to the wall using suitable hardware. 5. Install 1-1/2-inch x 1/4-inch NPT nipple into the pneumatic release. 6. Install a spacer or 1-1/4-inch fender washers (usually four or five) on the nipple and pneumatic release. This ensures the pneumatic release is aligned in the 4x4 box. 7. Place the pneumatic release through the center knockout of the 4x4 electrical box as shown in Figure 4-79. The 1-1/2-inch x 1/4-inch NPT nipple should extend outside the electrical box. 8. Install a spacer or 1-1/4-inch fender washer(s) on the 1/4-inch nipple and electrical box. This ensures the space between the reducer and the 1/4-inch NPT nipple will be aligned and secured in the 4x4 box. 9. Install reducer and tighten until pneumatic release is secure inside the electrical box. 10. Attach the vertical riser, tee, and piping to the reducer and tighten. Refer to Figure 4-79. 11. After the Pneumatic Release is installed, push in the piston rod to make sure it moves freely. 12. Install conduit and Corner Pulleys from the window, door, or other ventilating device being closed to the safety pin on the Pneumatic Release in such a manner that the cable pull on the safety pin will be in a straight line and perpendicular to the stem. 13. Route the 1/16-inch control cable through conduit and Corner Pulleys. Connect cable ends to plunger and mechanical release at device. 14. Slip a Cable Crimp (P/N 214951) over the end of the cable. 15. Insert the cable through the gas valve stem. 16. Making a loop, slip the end back through the Cable Crimp. 17. Pull on the cable to lift the gas valve to the open position. 18. Adjust the length of the cable so that the gas valve is in the fully opened position when the "S" hook is placed on the piston rod of the Pneumatic Release. Secure the cable with a crimp or cable block. Refer to Figure 4-79. Ensure that sufficient cable (1-inch (25 mm) minimum) is exposed at the pneumatic release between the crimp and the 1/2-inch (13 mm) EMT to allow full travel of the stem when the pneumatic release operates. A maximum of two Pneumatic Releases may be installed off of one 12-inch (305 mm) vertical riser by the use of a tee on top of the riser and the pneumatic released installed one on each side of the tee. The piping used to plumb the Pneumatic Release must be included in the total volumetric calculation for the overall discharge piping. The piping may be: • 1/2-inch (13 mm), • 3/8-inch (10 mm), • or 1/4-inch (6 mm) black pipe. The tee used with the Pneumatic Release is to be accounted for when calculating equivalent feet. The maximum number of Pneumatic Releases permitted in a single system is 20. Note:When using the A+, the Pneumatic Release must be used when operating two (2) or more spring-loaded fail-close gas valves. Installation P/N 9127100 4-79 January 2007 The Pneumatic Release requires 35 PSI (241 kPa) for operation. Note: The Pneumatic Release may be installed anywhere in the agent distribution pipe. Figure 4-79. Example of a Pneumatic Release Installation MECHANICAL GAS VALVE 2X2 ELECTRICAL JUNCTION BOX (NOT SUPPLIED) 1/16 in. CABLE CRIMP S-HOOK 1/16 in. CABLE CRIMP REDUCER (NOT SUPPLIED) 2X2 ELECTRICAL JUNCTION BOX (NOT SUPPLIED) 1/16 in. CABLE CABLE BLOCK MECHANICAL GAS VALVE CRIMP INSTALLATION CABLE BLOCK INSTALLATION VERTICAL RISER (NOT SUPPLIED) 12-inch (305 mm) CONDUIT (NOT SUPPLIED) CORNER PULLEY (NOT SUPPLIED) PNEUMATIC RELEASE DISTRIBUTION PIPE TO OPTIONAL 2ND PNEUMATIC RELEASE SPACERS OR FENDER WASHERS NEEDED HERE ~~OR ~~REDUCER (NOT SUPPLIED) 1/16 in. CABLECRIMPS-HOOK PNEUMATIC RELEASE SPACERS OR FENDER WASHERS NEEDED HERE 4X4 ELECTRICAL JUNCTION BOX (NOT SUPPLIED) Installation January 2007 4-80 P/N 9127100 4-5 POST-INSTALLATION CHECKOUT Note:Badger Fire Protection recommends that all system installations be recorded by the use of photos for future reference. The Range Guard Wet Chemical System must be checked for proper installation and operation before it can be put into service. The goal of the initial inspection is to verify that the system design is adequate for the application and that the installation conforms to the instructions described in NFPA 17A and NFPA 96 and this manual. The inspection must cover the following parts of the system: • Extinguishing System •Piping System • Detection System • Control System • Mechanical System At this point, the Range Guard Wet Chemical System should be configured as follows: • Cylinder mountings are secure. • Discharge Adapter Kits are secure. • Valve Protection Plates are attached to the top of the cylinder valves. • Nozzles are secure. • For Mechanical Actuation: – Detectors are secure and properly placed. – Remote Manual Releases are secure and in the ready mode. – All conduit and Corner Pulleys are secure, and all Corner Pulleys capped. • For Electrical Actuation: – Ensure that the Solenoid is secure. – Check the fire control panel. Ensure that it is operational and in standby mode. • SVAs are secured to the copper tubing and are not connected to the cylinder valves. • The High-Pressure Nitrogen Tubing from the UCH Control System is not connected to the UCH Control System outlet. • The UCH Control System contains no cartridges, neither the System Test Cartridge, nor the System Nitrogen Cartridge. • The detection lines are in the 'Released' position. • The Cam/Flag is in the 'Released' position. 4-5.1 Extinguishing System Visual Inspection The purpose of this inspection is to ensure that the system is designed according to all applicable standards. The inspection must address the following issues. 1. Is the type and quantity of wet chemical used adequate to extinguish the type of fire presented during risk assessment and review of application? 2. Are the Mounting Brackets securely fastened to a wall or other structural member? 3. Are all Cylinder and Valve Assemblies ready for installation? a. Are all pressure gauges in the operating (“green”) range? b. Are all cylinders in good condition, without evidence of corrosion or damage? c. Are all nameplates in place? 4. Has the agent distribution piping been cleaned and inspected (internally) to remove oil or particulate matter that could affect agent discharge? Refer to agent distribution piping checkout procedures. Installation P/N 9127100 4-81 January 2007 5. Does the agent distribution piping comply with the design parameters in this manual? a. Are all pipe lengths and equivalent pipe lengths within specified limits? b. Are the specified piping material and fittings installed? c. Is the 1/2-inch vent plug installed correctly? 6. Are piping joints, discharge nozzles and pipe supports securely fastened to prevent wet chemical leakage or hazardous movement during discharge? 7. Are all discharge nozzles applicable to the type of coverage required? a. Are all nozzles properly aimed and secured? b. Are all nozzles spaced within parameters listed in this manual? c. Are all nozzles clean? 4-5.2 Agent Distribution Piping Checkout The agent distribution piping must be blown clear with dry air or nitrogen to clean out the system and to check for any leaks or obstructions. One possible method is as follows: 1. Pressurize empty test cylinders with nitrogen or dry air to approximately 100 PSIG (6.89 bar). 2. Be sure that nozzle foil seals are attached to all nozzles. 3. Remove Wet Chemical Cylinder and Valve Assemblies from the Discharge Adapters and brackets. 4. Attach the test cylinders to the Discharge Adapters. 5. Discharge its contents into the piping system. 6. Verify that all nozzle foil seals are broken. 7. Remove all nozzles from the system and clean out any debris. 8. Re-install all nozzles and replace all nozzle foil seals. 9. Re-install the Cylinder and Valve Assemblies and the Discharge Adapters. 4-5.3 Detection System Inspection The purpose of the detection system inspection is to ensure that the system is properly installed and designed. 1. Have temperature changes created by process start-up conditions been measured and accounted for? 2. Has a temperature survey been conducted to determine the maximum ambient temperature in the protected area? 3. Have the detectors been installed in a neat, professional manner, and in accordance with the technical data in this manual? a. Are all detection system signal lines (cable, wiring, or tubing) properly installed in conduit or EMT? b. Has a point-to-point check for signal line continuity been conducted? 4. Is the Remote Manual Release(s) located in a path of exit or egress and is it clearly identified? WARNING Do not use oxygen to blow out piping. The use of oxygen is very dangerous as the possible presence of even a minute quantity of oil may cause an explosion, thereby causing death, serious personal injury and/or property damage. Installation January 2007 4-82 P/N 9127100 4-5.4 Mechanical Systems Inspection (UCH and A+) The Control System must be checked for proper connection to external components. It must also be properly set prior to the final system checkout. Before setting the Control System, check that: 1. All stainless steel cable to detectors and Remote Manual Release(s) is protected with conduit or EMT. Conduit runs must be clean and secure. 2. All cable runs to external components enter the proper Control System input/output ports and are installed in accordance with the instructions in Chapter 4. 3. There is no branching in the cabling to the detectors. 4. Stainless steel control cable lengths, and Corner Pulleys, Tee Pulleys, and 3-Way Pulleys counts are within listed parameters. 5. Inspect copper tubing and fittings. 6. Ensure nitrogen actuation lines are within listed parameters. Next step is commisioning the system. •If UCH, go to Paragraph4-6 • If A+, go to Paragraph 4-7 Installation P/N 9127100 4-83 January 2007 4-6 COMMISSIONING THE SYSTEM - UCH CONTROL SYSTEM Perform the “Post-Installation Checkout” on page 4-80. 4-6.1 Arming the System Set the detection beams by turning the ratchet spools counterclockwise (see Figure 4-80). Tighten the line until the beam reaches the Stop. Do not overtighten. Note:In long cable lines (over 125 ft. [38 m]) there will be stretch in the control cable and in the loops for the detectors. It is important to ensure the control cable is tight without over tightening. Figure 4-80. Setting the Detection Beams CAUTION The actuation latch must be in the horizontal position. If it is in any position other than horizontal, the system could malfunction. THROUGH HOLE IN RATCHET SPOOL, DETECTION LINE 2 THROUGH HOLE IN RATCHET SPOOL, DETECTION LINE 1 DETECTION BEAMS IN RELEASED POSITION DETECTION BEAMS IN SET POSITION ACTUATION LATCH IN HORIZONTAL (SET) POSITION Installation January 2007 4-84 P/N 9127100 Figure 4-81. Detection Beam Stops Be careful not to allow the control cable to become entangled with any other parts in the system. If it does, perform the following steps. 1. Using a 7/8-inch socket (or equivalent), slightly turn the ratchet spool counterclockwise. Do not turn so far that it will click into the next step. Using the thumb release on the pawl, release the ratchet and allow it to turn slowly clockwise. The beam will move back to the 'Released' position. Figure 4-82. View of Ratchet Spool and Pawl 2. Untangle the control cable and guide it onto the spool while ratcheting. Once there is tension, there should be no more entanglement. 3. Using a 7/8-inch socket (or equivalent), carefully ratchet up the slack in the control cable lines (see Figure 4-83). Tighten the line until the beam reaches the stop. Do not overtighten. CAUTION If the Remote Manual Release control cable is interfering with the free movement of the actuation latch, it might require re-cabling. If there is something else interfering with the free movement of the actuation latch, take appropriate corrective action. If it is determined that the interference is due to a mechanical fault of the UCH Control System, it must be replaced and returned to the factory. BEAM STOP FOR DETECTION LINE 1 BEAM STOP FOR DETECTION LINE 2 DETECTION ARMDETECTION ARM RATCHET SPOOL RATCHET SPOOL PAWL HORIZONTAL BEAM BEAM STOP VERTICAL BEAM PAWL BEAM STOP Installation P/N 9127100 4-85 January 2007 Figure 4-83. Detection Beam Stops Note:The actuation latch should now be in the horizontal (‘Set’) position. If it is not, check to ensure the Remote Manual Release control cable is not interfering with the actuation latch and that the actuation latch swings freely. Figure 4-84. Position of Detection Beams in 'Set' Position BEAM STOP FOR DETECTION LINE 1 BEAM STOP FOR DETECTION LINE 2 DETECTION ARMDETECTION ARM ACTUATION LATCH IN HORIZONTAL POSITION REMOTE MANUAL RELEASE CABLE DETECTION LINE 2 DETECTION LINE 1 Installation January 2007 4-86 P/N 9127100 When the two tensioned lines are set, the actuation latch will automatically fall into a horizontal position. Twist the Cam/Flag 90° clockwise until it clicks into place. The actuation latch will move up, then reset into the horizontal position (see Figure 4-85). Install Keeper Pin in the Cam/Flag. Figure 4-85. Latch Shown in “Set’ Position ACTUATION LATCH PORT FOR 1/4 in. SOCKET DRIVE (TO SET CAM/FLAG) KEEPER PIN Installation P/N 9127100 4-87 January 2007 4-6.1.1 CHECKING MICROSWITCHES Check to ensure that the microswitches are set. The Cam/Flag should hold down the High Mount Microswitch paddles. The trigger pin should hold up the Deep Mounted Microswitches. Gently push the microswitch paddles toward the body of the microswitches. If there is a “click,” the microswitch is not adjusted properly in the UCH Control System. Make appropriate adjustments. Figure 4-86. High Mount Microswitch, 'Released' and ‘Set’ Positions CAUTION The trigger pin on the Deep Mounted Microswitches must be underneath the paddle(s) of the microswitch. If the paddle is under the trigger pin, the microswitch will not change position upon actuation of the UCH Control System and the paddle(s) might be bent or broken upon such actuation. HIGH MOUNT MICROSWITCH HIGH MOUNT MICROSWITCH SET POSITIONRELEASED POSITION Installation January 2007 4-88 P/N 9127100 Figure 4-87. Deep Mount Microswitch, 'Released' and ‘Set’ Positions DEEP MOUNT MICROSWITCH DEEP MOUNT MICROSWITCH SET POSITIONRELEASED POSITION PIN ENGAGING MICROSWITCH PADDLE Installation P/N 9127100 4-89 January 2007 4-6.1.2 CHECKING SOLENOID If applicable, ensure that the Solenoid (if installed) is in the de-energized state and the actuation latch is horizontal. Manually test the Solenoid by pushing the Solenoid piston to engage the actuation latch. This allows the Cam/Flag to rotate to the ‘Release’ position. 4-6.1.3 CHECKING GAS VALVE When the Cam/Flag is in the ‘Set’ position, verify the gas valve is in the open position. When the Cam/Flag is in the ‘Release’ position, verify the gas valve is in the closed position. WARNING While performing the manual test of the Solenoid, the rotation of the cam/flag could cause personal injury. Installation January 2007 4-90 P/N 9127100 4-6.2 Functional Testing of the UCH Control System Perform the “Post-Installation Checkout” on page 4-80. 4-6.2.1 TEST MECHANICAL LINK LINES FOR THE UCH CONTROL SYSTEM (IF APPLICABLE) To test the mechanical detector lines, perform the following steps. 1. Remove the Keeper Pin from the Cam/Flag. 2. Go to the far end of the detection line. Cut the detector. 3. Check to ensure the rotation of detection spool and beam assembly as intended. 4. Check to ensure the Cam/Flag has rotated to the ‘Release’ position. 5. Check the microswitches to ensure that they have changed phase as intended. 6. Check the gas valve line to ensure that it has moved freely and that the gas valve has closed. Verify that all gas fired appliances have shut down, including the pilot lights. 7. Check each detector and bracket to ensure the travel distance of the cable. Make sure the line has operated without interference at any place in the system. 8. Replace detector that was cut. 9. Reset detector line. 10. Check and ensure the actuation latch is reset back to the horizontal position. Reset the Cam/Flag. 11. Insert Keeper Pin into Cam/Flag. 12. Reset all electrical shut-offs. Repeat steps 1 through 12 for second detection line, if applicable. CAUTION The mechanical detector lines are under tension. Wearing safety glasses and gloves is required during this process. Before cutting a detector, ensure the System Nitrogen Cartridge is not installed in the UCH Control System and the Keeper Pin is in place in the Cam/Flag. Installation P/N 9127100 4-91 January 2007 4-6.2.2 TEST REMOTE MANUAL RELEASE, P/N B875572 (IF APPLICABLE) 1. Operate the Remote Manual Release by pulling the safety pin located on the release handle and then pulling on the handle. 2. Observe the length of control cable that comes out of the Remote Manual Release. It should be between 3 and 4 inches (76 and 102 mm). 3. Insert the release handle back into the Remote Manual Release. 4. Go to the UCH Control System and check to ensure the Crimp Sleeve is against the bottom of the actuation latch and the actuation latch is pulled up at approximately two o’clock position and Cam/Flag is in the ‘Release’ position. 5. Pull 1-1/2-inches of control cable back into the UCH Control System. 4-6.2.3 TEST SOLENOID, P/N B100043 (IF APPLICABLE) Note:If there is no Solenoid installed in the system, proceed to Paragraph 4-6.2.4. The instructions for testing electrical releasing of the system will be found in the Design, Installation and Maintenance (DIOM) Manual for the fire control panel being used. A complete functional test shall be accomplished according to that manual and NFPA 72. 1. Remove Keeper Pin. 2. Following the instructions in the DIOM manual of the fire control panel, test the electrical operation of the UCH Control System. It will be important to observe all time delays, alarm and releasing features. 3. Verify actuation of the UCH Control System. 4. Check the microswitches to ensure that they have changed phase as intended. 5. Check the gas valve line to ensure that it has moved freely and that the gas valve has closed. Verify that all gas fired appliances have shut down, including the pilot lights. 6. Ensure that the fire control panel has been reset according to the DIOM Manual for the fire control panel being used. The Solenoid should be de-energized. 7. Check and ensure the actuation latch is reset back to the horizontal position. Reset the Cam/Flag. 8. Insert Keeper Pin into port on Cam/Flag. 9. Reset all electrical shut-offs. CAUTION Before testing the Remote Manual Release, ensure the System Nitrogen Cartridge is not installed in the UCH Control System and remove the Keeper Pin from the Cam/Flag. CAUTION It is important that the control cable slips easily through the hole in the end of the actuation latch. The actuation latch must be able to operate without interference from the control cable. Be sure to test the movement of the actuation latch assembly before completing the setting of the UCH Control System. 1-1/4 inch (32 mm) to 1-1/2 inch (38 mm) of control cable (with crimp end not included) should be left under the actuation latch, when in the 'Released' position. CAUTION Before testing the Solenoid, ensure the System Nitrogen Cartridge is not installed in the UCH Control System and that the Keeper Pin is in place in the Cam/Flag. Installation January 2007 4-92 P/N 9127100 4-6.2.4 INSPECT HIGH-PRESSURE NITROGEN TUBING To perform an inspection of the High-Pressure Nitrogen Tubing, use the following steps. 1. Ensure Keeper Pin is in the Cam/Flag. 2. Ensure that all fittings are tightly attached. 3. Check all of the SVA pistons to ensure that they are in the set position. The bottom surface of the piston must be in the body of the SVA. If it is in the released position, push the piston in while pushing the piston into the body of the SVA (see Figure 4-88). Recommendation: Badger recommends that the actuation testing take place before the full test. Figure 4-88. SVA in ‘Set’ Position CAUTION It is important to verify that the UCH Control System is in the 'Set' position. The detection beams must be against their respective stops. The actuation latch must be in the horizontal position and the Cam/Flag in the 'Set' position. The Keeper Pin must be in place in the Cam/Flag. SVA PISTON IN SET POSITION Installation P/N 9127100 4-93 January 2007 4-6.3 Actuation Test For the UCH Control System 1. After ensuring that the system is in the 'Set' position and the Keeper Pin is in place, locate the Test Cartridge (P/N B120044). Carefully install the cartridge into the valve assembly of the UCH Control System. Tighten until cartridge is snug (see Figure 4-89). It is permissible to perform this test with the System Cartridge. Note:Do not use a wrench or other tool to tighten the cartridge. Hand tightening is sufficient. If leakage is observed, check the condition of the flat gasket in the valve bore. Figure 4-89. UCH Control System, Test Cartridge Placement 2. Locate the cover of the UCH Control System. Ensure that the local manual handle is set and that the Safety Pin is inserted (see Figure 4-90). The handle should be locked in the set position. If the handle can turn, adjust until the pin can be inserted all the way through the handle into the body of the cover. Note:Installation of a tamper wire seal can prevent the pin from slipping out. 3. Remove the Keeper Pin from the UCH Control System Cam/Flag. Carefully install the cover onto the enclosure. The cover has a tongue that fits into the groove of the enclosure. Center the cover over the enclosure and fit the tongue and groove together. CAUTION Do not attempt to push the piercing pin down. Pushing the piercing pin too far can cause the O-ring to move out of the valve bore. This could cause the O-ring to chip or break upon actuation of the system. Inserting the System Nitrogen Cartridge will push the piercing pin down to the proper location in the valve bore. TEST CARTRIDGE KEEPER PIN Installation January 2007 4-94 P/N 9127100 4. Fasten the cover to the enclosure with the captive screws. Turn the captive screws until snug. Note:The Valve Protection Plates should remain on the top of the Cylinder and Valve Assemblies until directed to remove it. 5. Attach the High Pressure Nitrogen Tubing. Figure 4-90. UCH Control System, Cover Attached 6. Pull the safety pin and turn the handle in the direction of the arrow about 1/8-turn. The system will fire, pressurizing the actuating lines. Note:Do not loosen any of the fittings on the actuating lines at this time. 7. Inspect the actuating lines and SVAs for leakage. Each SVA piston must be in the released position (down) and locked. Check each piston to ensure that it is fully extended. Note:If any leakage is observed, appropriate steps must be taken to implement corrective action. However, pressure should be bled off before any action is implemented on the actuating lines. CAUTION While the cover is resting on the enclosure, moving it upward could engage the local manual release with the latch, causing the UCH Control System to release. Keep the cover as centered as possible while performing this step. UCH HOUSING COVER SAFETY PIN LOCAL MANUAL RELEASE HANDLE HIGH PRESSURE NITROGEN TUBING SVA Installation P/N 9127100 4-95 January 2007 8. After ensuring there is no leakage, loosen the swivel fitting located at the bottom right side of the UCH Control System (see Figure 4-91). Allow the pressure to vent slowly. When the pressure is completely vented, disconnect the fitting and remove the cover. Figure 4-91. Fitting on Outside of UCH Control System 9. Remove the spent cartridge used for the functional test. WARNING The system uses high pressure. Safety goggles or glasses must be worn. All pressure must be released from the actuation lines before resetting the Cam/Flag. Failure to do so will cause the head of the piercing pin to protrude out of the valve bore, exposing the O-ring. This could result in the O-ring being damaged, thereby causing malfunction or non-function of the system as designed. Always ensure that the pressure has been released before resetting the Cam/Flag. CAUTION To avoid accidental discharge later in the service sequence, it is important to completely disconnect the fitting outside the UCH Control System. Installation January 2007 4-96 P/N 9127100 10. Discard the spent cartridge in an appropriate manner. Check to ensure the detection lines are set. Refer to Paragraph 4-6.3.1. 11. Reset the Cam/Flag and reinstall the Keeper Pin into the Cam/Flag. Note:Ensure the microswitches are setting properly. Check the Deep Mount Microswitches to ensure the trigger pin is under the paddles of the microswitches and is pushing them up. Check the High Mount Microswitches to ensure the Cam/Flag is pushing down on the paddles. 12. Install the Safety Pin into the local manual release handle of the cover assembly. Install a tamper indicator through the Safety Pin and around the handle. 13. Reset all of the SVAs. Push the piston in while pushing the piston into the body of each SVA. 14. Carefully remove the Valve Protection Plate from the cylinder valves and install the SVA to each cylinder. Secure with the bolts included. Ensure that each SVA is securely tightened. Note:Check the condition of the flat gasket in the valve bore. Do not use a wrench or other tool to tighten the cartridge. Hand tightening is sufficient. Figure 4-92. Valve Body with Flat Gasket 15. When all SVAs are secured, locate the System Nitrogen Cartridge (P/N B120043). In the area provided, write the date of installation of the cartridge. Carefully install the System Nitrogen Cartridge into the valve assembly of the UCH Control System. Hand-tighten until it is snug. 16. Locate the cover of the assembly. Ensure the tamper seal remains intact in the safety pin. 17. Remove the Keeper Pin from the Cam/Flag. 18. Carefully install the cover onto the enclosure. The cover has a tongue that fits into the groove of the enclosure. Center the cover over the enclosure and fit the tongue and groove together. CAUTION A System Nitrogen Cartridge is required for final system set up. Using any other cartridge could cause malfunction or non-function of the system. CAUTION While the cover is resting on the enclosure, moving it upward could engage the local manual release with the actuation latch, causing the UCH Control System to release. Keep the cover as centered as possible while performing this step. FLAT GASKET PIERCING PIN Installation P/N 9127100 4-97 January 2007 19. Fasten the cover to the enclosure with the captive screws. Turn the captive screws until snug. 20. Secure the High Pressure Nitrogen Tubing back onto the bottom of the UCH Control System. Ensure that the fit is properly snug to prevent leakage. Refer to Figure 4-93. 21. Apply labels to the cover of the UCH Control System. Figure 4-93. Cylinder Mounted UCH Control System CAUTION Securing the High Pressure Nitrogen Tubing onto the UCH Control System will complete the setup of the Range Guard System. System discharge could occur if the system has not been properly set. TAMPER SEAL SAFETY PIN CAPTIVE SCREW HIGH PRESSURE NITROGEN TUBING CAPTIVE SCREW CAPTIVE SCREW CAPTIVE SCREW Installation January 2007 4-98 P/N 9127100 4-6.3.1 DISPOSAL OF CARTRIDGE Following are the recommended instructions for disposal of spent cartridges. Determine if gas is present in the cartridge. All puncturable type disposable cartridges are presumed to be fully charged unless the small puncturable end (opposite of the rounded bottom) is clearly punctured. If the puncture is not clear, the cartridge may be weighed using a scale capable of reading in grams accurate to 0.1 g. The weight of the cartridge shall be less than the indicated weight imprinted on the side of the cartridge by the amount of the indicated charge. After using one of the methods described to determine that no gas is present in the cartridge, the cartridge may be placed with normal refuse, or may be placed with steel recycling materials. All of the steel cartridges are produced from a low carbon (14) steel product. Once empty, no residue remains. Cross cutting or sectioning is not required. WARNING Never dispose of a pressurized cartridge. Cartridges must be discharged before discarding. Filled gas cartridges may be dangerous if not handled properly. Do not heat cartridges above 120°F (49°C). Pressurized cartridges that become overheated can explode, and thereby cause property damage, severe personal injury, and possibly death. Installation P/N 9127100 4-99 January 2007 4-7 COMMISSIONING THE A+ CONTROL SYSTEM Perform the “Post-Installation Checkout” on page 4-80. 4-7.1 Arming the System If the Keeper Pin does not slide out easily, not enough cable slack was removed when the cable was pulled through the valve body lever. Loosen the adjusting screw in the Cable Tension Block Assembly. Note:It is recommended that you cut the detection cable close to the lever. Figure 4-94. A+ Control Box in “SET” Position After completing the tensioning of the detection system, make sure that each detector has the required 3 inches (76 mm) minimum spacing, in the direction of cable travel, between the cable clamp or block and the end of the conduit fitting in the detector bracket. 4-7.1.1 CHECKING MICROSWITCHES Check to ensure that the microswitches are set. Adjust the microswitch toward the lever until the paddle on the microswitch just toUCHes the top corner of the microswitch body. The microswitch is now in the ‘Set’ position. 4-7.1.2 CHECKING GAS VALVE When the lever is in the ‘Set’ position, verify the gas valve is in the open position. When the lever is in the ‘Discharge’ position, verify the gas valve is in the closed position. 4-7.1.3 CHECKING SYSTEM VALVE ACTUATOR CONNECTION Check to ensure that the copper tubing is tighten at the valve body and at the SVA. MECHANICAL GAS VALVE CABLE (NOT SUPPLIED) LEVER HOLE C SET SCREW KEEPER PIN Installation January 2007 4-100 P/N 9127100 4-7.2 Functional Testing of the A+ Control Box Perform the “Post-Installation Checkout” on page 4-80. 4-7.2.1 TEST MECHANICAL LINK LINES FOR THE A+ CONTROL BOX (IF APPLICABLE) To test the mechanical detector lines, perform the following steps. 1. Remove the Keeper Pin from the valve body. 2. Go to the far end of the detection line. Cut the detector. 3. Check to ensure the lever has rotated to the ‘Discharge’ position. 4. Check the microswitches to ensure that they have changed phase as intended. 5. Check the gas valve line to ensure that it has moved freely and that the gas valve has closed. Verify that all gas fired appliances have shut down, including the pilot lights. 6. Check each detector and bracket to ensure the travel distance of the cable. Make sure the line has operated without interference at any place in the system. 7. Replace detector that was cut. 8. Reset detector line. 9. Check and ensure the lever is reset back to the ‘Set’ position. 10. Insert Keeper Pin into valve body. 11. Reset all electrical shut-offs. CAUTION The mechanical detector lines are under tension. Wearing safety glasses and gloves is required during this process. Before cutting a detector, ensure the CO2 Cartridge is not installed in the A+ Control Box and the Keeper Pin is in place in the valve body. Installation P/N 9127100 4-101 January 2007 4-7.2.2 TEST REMOTE MANUAL RELEASE, P/N 9197463 (IF APPLICABLE) 1. Operate the Remote Manual Release by removing the pull pin. 2. Go to the A+ Control Box and check to ensure the lever is in the ‘Discharge’ position. 4-7.2.3 TESTING MICROSWITCHES (IF APPLICABLE) Note:If there are no microswitches installed in the system, proceed to Paragraph 4-7.2.4. 1. Remove Keeper Pin. 2. Verify actuation of the A+ Control System and the lever is in the ‘Discharge’ position. 3. Using a voltmeter, check the microswitches to ensure that they have changed phase as intended. 4. Check the gas valve line to ensure that it has moved freely and that the gas valve has closed. Verify that all gas fired appliances have shut down, including the pilot lights. 5. Ensure that the fire control panel has been reset according to the DIOM Manual for the fire control panel being used. 6. Check and ensure the lever is reset back to the ‘Set’ position. 7. Insert Keeper Pin into port on valve body. 8. Reset all electrical shut-offs. CAUTION Before testing the Remote Manual Release, ensure the CO2 Cartridge is not installed in the A+ Control Box and remove the Keeper Pin from the valve body. CAUTION Before testing the microswitches, ensure the CO2 Cartridge is not installed in the A+ Control System and that the Keeper Pin is in place in the valve body. Installation January 2007 4-102 P/N 9127100 4-7.2.4 INSPECT 1/4 in. O.D. COPPER TUBING To perform an inspection of the copper tubing, use the following steps. 1. Ensure Keeper Pin (P/N 9197108) is in the valve body. 2. Ensure that all fittings are tightly attached. 3. Check all of the SVA pistons to ensure that they are in the set position. The bottom surface of the piston must be in the body of the SVA. If it is in the released position, push the piston into the body of the SVA (see Figure 4-95). Recommendation:Badger recommends that the actuation testing take place before the full test. Figure 4-95. SVA in ‘Set’ Position CAUTION It is important to verify that the lever is in the 'Set' position and the Keeper Pin must be in place in the valve body. SVA PISTON IN SET POSITION Installation P/N 9127100 4-103 January 2007 4-7.2.5 INSTALLING THE CO2 GAS CARTRIDGE IN THE A+ CONTROL BOX After the gas valve connection has been made and the optional microswitch(es) installed, the CO2cartridge must be installed. 1. In the area provided, write the date of installation of the CO2 cartridge. Carefully install the CO2cartridge into the valve body of the A+. Hand-tighten until it is snug. 2. Remove Keeper Pin. After initial installation, perform the actuation test described in Paragraph 4-7.3. Figure 4-96. Installing CO2 Gas Cartridge CAUTION If the CO2 cartridge is not sealed against the valve gasket, or the valve gasket is missing, the system will not function properly. Verify correct installation. CAUTION Be sure to remove the Keeper Pin. Failure to remove the Keeper Pin will result in an inoperative system. C CARTRIDGEO2 VALVE BODY KEEPER PIN Installation January 2007 4-104 P/N 9127100 4-7.3 Actuation Test for the A+ Control Box (If Applicable) 1. Remove the System Valve Actuator (SVA) from each Range Guard valve and cylinder assembly. Leave the copper tubing connected to the SVAs. 2. Go to the far end of the detection line. Cut the detector. 3. Check the CO2 cartridge to ensure it has discharged. 4. Check the microswitches to ensure that they have changed phase as intended. 5. Check the gas valve line to ensure that it has moved freely and that the gas valve has closed. Verify that all gas fired appliances have shut down, including the pilot lights. 6. Check each detector and bracket to ensure the travel distance of the cable. Make sure the line has operated without interference at any place in the system. 7. Reset all electrical shut-offs. 8. Carefully release residual pressure in the copper tubing line by slightly loosening a tubing nut. 9. Retighten the tubing nut after all the residual pressure is released. 10. Reset all of the SVAs. Push the piston into the body of the SVA. 11. Reset the A+ Control Box by installing the Keeper Pin as previously stated. 12. Remove and discard the used CO2 cartridge. Refer to Paragraph 4-7.3.1. 13. In the area provided, write the date of installation of the cartridge. 14. Carefully install the CO2 cartridge into the valve body of the A+ Control Box. Hand-tighten in until it is snug. 15. Remove Keeper Pin. CAUTION The mechanical detector lines are under tension. Wearing safety glasses and gloves is required during this process. CAUTION This step must be done before the A+ Control Box is reset, otherwise the valve body O-ring could be damaged. CAUTION If the CO2 cartridge is not sealed against the gasket or the gasket is missing, the system may not function properly. Installation P/N 9127100 4-105 January 2007 16. Secure the cover to A+ Control Box, making sure that the lever is visible in the window of the cover and in the ‘Set’ position. Figure 4-97. A+ with Cover Installed 17. Apply labels to the cover of the A+ Control Box. 4-7.3.1 DISPOSAL OF CARTRIDGE Following are the recommended instructions for disposal of spent cartridges. Determine if gas is present in the cartridge. All puncturable type disposable cartridges are presumed to be fully charged unless the small puncturable end (opposite of the rounded bottom) is clearly punctured. If the puncture is not clear, the cartridge may be weighed using a scale capable of reading in grams accurate to 0.1 g. The weight of the cartridge shall be less than the indicated weight imprinted on the side of the cartridge by the amount of the indicated charge. After using one of the methods described to determine that no gas is present in the cartridge, the cartridge may be placed with normal refuse, or may be placed with steel recycling materials. All of the steel cartridges are produced from a low carbon (14) steel product. Once empty, no residue remains. Cross cutting or sectioning is not required. CAUTION Be sure to remove the Keeper Pin. Failure to remove the Keeper Pin will result in an inoperative system. WARNING Never dispose of a pressurized cartridge. Cartridges must be discharged before discarding. Filled gas cartridges may be dangerous if not handled properly. Do not heat cartridges above 120°F (49°C). Pressurized cartridges that become overheated can explode, and thereby cause property damage, severe personal injury, and possibly death. WINDOW LEVER COVER Installation January 2007 4-106 P/N 9127100 THIS PAGE INTENTIONALLY LEFT BLANK. Maintenance P/N 9127100 5-1 January 2007 CHAPTER 5 MAINTENANCE 5-1 INTRODUCTION Note:It is the responsibility of the system installer to review system operation and owner obligations, and to provide the owner’s manual to the owner at the time of system installation. This chapter contains the service and maintenance instructions for the Range Guard® Wet Chemical System. These procedures must be preformed regularly, and in accordance with all applicable regulations. If problems arise, corrective action must be taken. 5-2 INSPECTION AND MAINTENANCE PROCEDURES Use Table 5-1 to identify preventative maintenance schedule of the Range Guard Wet Chemical System. Table 5-1. Preventative Maintenance Schedule Schedule Requirement Paragraph Monthly Owner’s Inspection Paragraph 5-2.1 Semi-Annual System Inspection by an Authorized Badger Distributor Paragraph 5-2.2 Every 12 Years Detailed System Inspection by an Authorized Badger Distributor Paragraph 5-2.3 Maintenance January 2007 5-2 P/N 9127100 5-2.1 Monthly Inspection Procedure (by Owner) Refer to the cylinder nameplate for the proper maintenance instructions. In accordance with NFPA 17A and NFPA 96, make frequent inspections to ascertain that the system is operable. Also, be sure that nothing has occurred which would compromise the effectiveness of the system. The following procedure is to be performed by the Owner of the system. Table 5-2. Owner’s Monthly Inspection Checkbox Procedure ‡Inspect all system components, agent distribution pipe, and conduit runs for physical damage and/or displacement. ‡Inspect all nozzles to see if foil seal caps (if applicable) are in place. Check for possible obstructions to the discharge of the wet chemical. ‡Inspect all detectors (Fusible-links and Thermo-bulbs) for contamination. If contamination is found, contact an authorized Badger Distributor for service. ‡Inspect each Cylinder and Valve Assembly. The pointer on the pressure gauge should be in the “green” range. The cylinder should not show evidence of corrosion or damage. ‡Inspect manual pull stations are unobstructed and in clear view and labeled for intended use. ‡Inspect all tamper seals are intact and the system is in a ready condition. ‡Verify the inspection tag or certificate is in place and current. ‡A record of the monthly inspection is to be kept reflecting the date inspected, initials of the person performing the inspection, and any corrections required. ‡If wall mounted, the UCH Control System must be tightly secured to the wall. If cylinder mounted, the UCH Control System must be tightly bolted to the SVA. The Cam/Flag on the UCH Control System indicator should point to the ‘Set’ position. The safety pin and seal wire on the local manual release handle should be in place. If no Remote Manual Release is installed, the path to the local manual release on the cylinder should be clear and unobstructed and within reach. ‡If any discrepancies are noted while making this inspection, DO NOT CONTINUE OPERATING HAZARDOUS PROCESSES OR TURN ON PROTECTED EQUIPMENT. Immediately contact an authorized Badger Distributor for service and/or repair. ‡The hood, duct, and protected cooking appliances have not been replaced, modified, or relocated. CAUTION No other action shall be taken by the system owner other than visual. If further maintenance is determined necessary as a result of owner inspection, contact an authorized Badger Distributor. WARNING Do not operate hazardous processes or turn on protected equipment until the required system alterations are complete. WARNING Any unauthorized alterations to the protected area or equipment, or to the wet chemical system, can render the fire suppression system ineffective or non-operational. Contact an authorized Badger distributor if any modifications are contemplated. Maintenance P/N 9127100 5-3 January 2007 5-2.2 Semi-Annual Service Procedure (By Authorized Badger Distributor Only) All systems shall be inspected and serviced semi-annually by an authorized Badger distributor. If using an UCH Control System, start with Paragraph 5-2.2.1. If using the A+ Control Box, start with Paragraph 5-2.2.8. Refer to NFPA 17A and NFPA 96 for all Semi-Annual maintenance. Table 5-3. Semi-Annual Service Procedure Checkbox Procedure Section ‡Preparation for Servicing and Testing Paragraph 5-2.2.1 Functional Testing of the UCH Control System ‡Test Mechanical Link Lines Paragraph 5-2.2.6.1 ‡Test Remote Manual Release Paragraph 5-2.2.6.2 ‡Test Solenoid (if applicable) Paragraph 5-2.2.6.3 ‡Inspection of High-Pressure Nitrogen Tubing Paragraph 5-2.2.6.4 ‡Perform Actuation Tests Paragraph 5-2.2.7 ‡Verify the Corner Pulleys and detector bracket conduit openings are free of grease N/A ‡Check that the fan warning sign is legible and conspicuous (if not, replace) N/A ‡Disposal of Cartridge Paragraph 5-2.2.7.1 Functional Testing of the A+ Control Box ‡Test Mechanical Link Lines Paragraph 5-2.2.10.1 ‡Test Remote Manual Release Paragraph 5-2.2.11 ‡Test Microswitches (if applicable) Paragraph 5-2.2.12 ‡Inspect 1/4-inch O.D. (6 mm) Copper Tubing Paragraph 5-2.2.12.1 ‡Perform Actuation Tests Paragraph 5-2.2.13 ‡Verify the Corner Pulleys and detector bracket conduit openings are free of grease N/A ‡Check that the fan warning sign is legible and conspicuous (if not, replace) N/A ‡Disposal of Cartridge Paragraph 5-2.2.13.1 Maintenance January 2007 5-4 P/N 9127100 5-2.2.1 PREPARATION FOR SERVICING AND TESTING THE UCH CONTROL SYSTEM 1. Disconnect the high-pressure nitrogen tubing from the UCH Control System (see Figure 5-1). Figure 5-1. High-Pressure Nitrogen Tubing Location, Close Up 2. Verify that the system design and installation are adequate to protect the hazard area and that the installation conforms to the instructions in this manual. Some of the items to verify are: a. All equipment requiring fire protection within the hazard area is protected. b. There have been no unauthorized alterations to the protected area or equipment, or to the wet chemical system, that render the fire suppression system ineffective or non- operational. c. All Cylinder Mounting Brackets are securely fastened to a wall or other structural member. d. All nozzles are properly aimed, secured and located within the proper distance from the protected equipment. Each nozzle should be clean and equipped with a foil seal cap (if applicable). e. The agent distribution piping is properly sized for the number and type of nozzles required. f. All piping joints and pipe supports are securely fastened to prevent wet chemical leakage and hazardous movement during discharge. g. The pipe lengths, sizes, fittings and material are as specified in this Manual. h. The number, type, and placement of detectors are suitable for all hazards within the hazard area. i. The Remote Manual Release, if used, is located in a path of exit or egress and is clearly identified. j. Stainless steel control cable lengths and Corner Pulley counts are within listed limits. Conduit runs should be clean and secure. k. All wiring is in compliance with local codes. l. All field wiring is free of ground fault or short-circuit conditions. Maintenance P/N 9127100 5-5 January 2007 m. No branch circuits exist in the wiring to the detectors or to the Solenoid. n. All auxiliary components such as Pressure Operated Releases are secure and show no evidence of physical damage. o. All system components and installation material are as specified in this manual. 3. Remove the cover from the UCH Control System. Install Keeper Pin. See Figure 5-2 for Keeper Pin location. Figure 5-2. UCH Control System, Internal View 4. Remove the System Nitrogen Cartridge (P/N B120043). Refer to Figure 5-2 for location in UCH Control System. SYSTEM NITROGEN CARTRIDGE ACTUATION (OUTPUT) PORT KEEPER PIN Maintenance January 2007 5-6 P/N 9127100 5. Check flat gasket inside valve body. If damaged, replace (see Figure 5-3). Figure 5-3. Valve Body and Flat Gasket Location 6. Verify installation of the lockout screws for appropriate usage (refer to Figure 5-2). 7. Remove the System Valve Actuators (SVAs) from all cylinders. See Figure 5-4 for location. Figure 5-4. System Valve Actuators 8. Install cylinder valve protection plates. VALVE BODY FLAT GASKET CAM/FLAG SVA CYLINDER AND VALVE ASSEMBLY Maintenance P/N 9127100 5-7 January 2007 9. Disconnect Discharge Adapter Kit (agent piping) from all cylinders (see Figure 5-5). Note:Disconnecting the Discharge Adapter Kit typically involves removing cylinders. 10. Install the Anti-Recoil Plate. Figure 5-5. Removing Discharge Adapter Kit 5-2.2.2 ARMING THE UCH CONTROL SYSTEM Set the detection beams by turning the applicable ratchet spools counterclockwise (see Figure 5-6). Tighten the line until the beam reaches the Stop. Do not overtighten. Note:In long cable lines (over 125 ft. [38 m]) there will be stretch in the control cable and in the loops for the detectors. It is important to ensure the control cable is tight without over tightening. CAUTION The actuation latch must be in the horizontal position. If it is in any position other than horizontal, the system could malfunction. FLANGE PLATE DISCHARGE ADAPTER O-RING NUT 5/16-18 BOLTS 5/16-18 X 1 in. LONG SHIPPING CAP CYLINDER AND VALVE ASSEMBLY NUT 5/16-18 Maintenance January 2007 5-8 P/N 9127100 Figure 5-6. Setting the Detection Beams Figure 5-7. Detection Beam Stops THROUGH HOLE IN RATCHET SPOOL, DETECTION LINE 2 THROUGH HOLE IN RATCHET SPOOL, DETECTION LINE 1 DETECTION BEAMS IN RELEASED POSITION DETECTION BEAMS IN SET POSITION ACTUATION LATCH IN HORIZONTAL (SET) POSITION BEAM STOP FOR DETECTION LINE 1 BEAM STOP FOR DETECTION LINE 2 DETECTION ARMDETECTION ARM Maintenance P/N 9127100 5-9 January 2007 Be careful not to allow the control cable to become entangled with any other parts in the system. If it does, perform the following steps. 1. Using a 7/8-inch socket (or equivalent), slightly turn the ratchet spool counterclockwise. Do not turn so far that it will click into the next step. Using the thumb release on the pawl, release the ratchet and allow it to turn backwards. The beam will move back to the 'Released' position. Figure 5-8. View of Ratchet Spool and Pawl 2. Untangle the control cable and guide it onto the spool while ratcheting. Once there is tension, there should be no more entanglement. 3. Using a 7/8-inch socket (or equivalent), carefully ratchet up the slack in the control cable lines (see Figure 5-9). Tighten the line until the beam reaches the stop. Do not overtighten. CAUTION If the Remote Manual Release control cable is interfering with the free movement of the actuation latch, it might require re-cabling. If there is something else interfering with the free movement of the actuation latch, take appropriate corrective action. If it is determined that the interference is due to a mechanical fault of the UCH Control System, it must be replaced and returned to the factory. RATCHET SPOOL RATCHET SPOOL PAWL HORIZONTAL BEAM BEAM STOP VERTICAL BEAM PAWL BEAM STOP Maintenance January 2007 5-10 P/N 9127100 Figure 5-9. Detection Beam Stops Note:The actuation latch should now be in the horizontal (‘Set’) position. If it is not, check to ensure the Remote Manual Release control cable is not interfering with the actuation latch and that the actuation latch swings freely. Figure 5-10. Position of Detection Beams in 'Set' Position BEAM STOP FOR DETECTION LINE 1 BEAM STOP FOR DETECTION LINE 2 DETECTION ARMDETECTION ARM ACTUATION LATCH IN HORIZONTAL POSITION REMOTE MANUAL RELEASE CABLE DETECTION LINE 2 DETECTION LINE 1 Maintenance P/N 9127100 5-11 January 2007 When the two tensioned lines are set, the actuation latch will automatically fall into a horizontal position. Twist the Cam/Flag 90° clockwise until it clicks into place. The actuation latch will move up, then reset into the horizontal position (see Figure 5-11). Install Keeper Pin in the Cam/Flag. Figure 5-11. Latch Shown in “Set’ Position 5-2.2.3 CHECKING MICROSWITCHES Check to ensure that the microswitches are set. The Cam/Flag should hold down the High Mount Microswitch paddles. The trigger pin should hold up the Deep Mounted Microswitches. Gently push the microswitch paddles toward the body of the microswitches. If there is a “click,” the microswitch is not adjusted properly in the UCH Control System. Make appropriate adjustments. CAUTION The trigger pin on the Deep Mounted Microswitches must be underneath the paddle(s) of the microswitch. If the paddle is under the trigger pin, the microswitch will not change position upon actuation of the UCH Control System and the paddle(s) might be bent or broken upon such actuation. ACTUATION LATCH PORT FOR 1/4 in. SOCKET DRIVE (TO SET CAM/FLAG) KEEPER PIN Maintenance January 2007 5-12 P/N 9127100 5-2.2.4 CHECKING SOLENOID If applicable, ensure that the Solenoid (if installed) is in the de-energized state and the actuation latch is horizontal. Manually test the Solenoid by pushing the Solenoid piston to engage the actuation latch. This allows the Cam/Flag to rotate to the ‘Released’ position. 5-2.2.5 CHECKING GAS VALVE When the Cam/Flag is in the ‘Set’ position, verify the gas valve is in the open position. When the Cam/Flag is in the ‘Discharge’ position, verify the gas valve is in the closed position. WARNING While performing the manual test of the Solenoid, the rotation of the cam/flag could cause personal injury. Maintenance P/N 9127100 5-13 January 2007 5-2.2.6 FUNCTIONAL TESTING OF THE UCH CONTROL SYSTEM Perform the Post-Installation Checkout procedures in Paragraph 4-5. 5-2.2.6.1 Test Mechanical Link Lines for the UCH Control System (If Applicable) To test the mechanical detector lines, perform the following steps. 1. Remove the Keeper Pin from the Cam/Flag. 2. Go to the far end of the detection line. Cut the detector. 3. Check to ensure the rotation of detection spool and beam assembly as intended. 4. Check to ensure the Cam/Flag has rotated to the ‘Released’ position. 5. Check the microswitches to ensure that they have changed phase as intended. 6. Check the gas valve line to ensure that it has moved freely and that the gas valve has closed. Verify that all gas fired appliances have shut down, including the pilot lights. 7. Check each detector and bracket to ensure the travel distance of the cable. Make sure the line has operated without interference at any place in the system. 8. Replace detector that was cut. 9. Reset detector line. 10. Check and ensure the actuation latch is reset back to the horizontal position. Reset the Cam/Flag. 11. Insert Keeper Pin into Cam/Flag. 12. Reset all electrical shut-offs. Repeat steps 1 through 12 for second detection line, if applicable. CAUTION The mechanical detector lines are under tension. Wearing safety glasses and gloves is required during this process. Before cutting a detector, ensure the System Nitrogen Cartridge is not installed in the UCH Control System and the Keeper Pin is in place in the Cam/Flag. Maintenance January 2007 5-14 P/N 9127100 5-2.2.6.2 Test Remote Manual Release, P/N B875572 (If Applicable) 1. Operate the Remote Manual Release by pulling the safety pin located on the release handle and then pulling on the handle. 2. Observe the length of control cable that comes out of the Remote Manual Release. It should be between 3 and 4 inches (76 and 102 mm). 3. Insert the release handle back into the Remote Manual Release. 4. Go to the UCH Control System and check to ensure the Crimp Sleeve is against the bottom of the actuation latch and the actuation latch is pulled up at approximately two o’clock position and Cam/Flag is in the ‘Released’ position. 5. Pull 1-1/2-inches of control cable back into the UCH Control System. 5-2.2.6.3 Test Solenoid, P/N B100043 (If Applicable) Note:If there is no Solenoid installed in the system, proceed to Paragraph 5-2.2.6.4. The instructions for testing electrical releasing of the system will be found in the Design, Installation and Maintenance (DIOM) Manual for the fire control panel being used. A complete functional test shall be accomplished according to that manual and NFPA 72. 1. Remove Keeper Pin. 2. Following the instructions in the DIOM manual of the fire control panel, test the electrical operation of the UCH Control System. It will be important to observe all time delays, alarm and releasing features. 3. Verify actuation of the UCH Control System. 4. Check the microswitches to ensure that they have changed phase as intended. 5. Check the gas valve line to ensure that it has moved freely and that the gas valve has closed. Verify that all gas fired appliances have shut down, including the pilot lights. 6. Ensure that the fire control panel has been reset according to the DIOM Manual for the fire control panel being used. The Solenoid should be de-energized. 7. Check and ensure the actuation latch is reset back to the horizontal position. Reset the Cam/Flag. 8. Insert Keeper Pin into port on Cam/Flag. 9. Reset all electrical shut-offs. CAUTION Before testing the Remote Manual Release, ensure the System Nitrogen Cartridge is not installed in the UCH Control System and remove the Keeper Pin from the Cam/Flag. CAUTION It is important that the control cable slips easily through the hole in the end of the actuation latch. The actuation latch must be able to operate without interference from the control cable. Be sure to test the movement of the actuation latch assembly before completing the setting of the UCH Control System. 1-1/4 inch (32 mm) to 1-1/2 inch (38 mm) of control cable (with crimp end not included) should be left under the actuation latch, when in the 'Released' position. CAUTION Before testing the Solenoid, ensure the System Nitrogen Cartridge is not installed in the UCH Control System and that the Keeper Pin is in place in the Cam/Flag. Maintenance P/N 9127100 5-15 January 2007 5-2.2.6.4 Inspect High-Pressure Nitrogen Tubing To perform an inspection of the High-Pressure Nitrogen Tubing, use the following steps. 1. Ensure Keeper Pin is in the Cam/Flag. 2. Ensure that all fittings are tightly attached. 3. Check all of the SVA pistons to ensure that they are in the set position. 4. The bottom surface of the piston must be in the body of the SVA. If it is in the released position, push the piston into the body of the SVA (see Figure 5-12). Recommendation: Badger recommends that the actuation testing take place before the full test. Figure 5-12. SVA in ‘Set’ Position CAUTION It is important to verify that the UCH Control System is in the 'Set' position. The detection beams must be against their respective stops. The actuation latch must be in the horizontal position and the Cam/Flag in the 'Set' position. The Keeper Pin must be in place in the Cam/Flag. SVA PISTON IN SET POSITION Maintenance January 2007 5-16 P/N 9127100 5-2.2.7 ACTUATION TEST FOR THE UCH CONTROL SYSTEM 1. After ensuring that the system is in the 'Set' position and the Keeper Pin is in place, locate the Test Cartridge (P/N 120044). Carefully install the cartridge into the valve assembly of the UCH Control System. Tighten until cartridge is snug (see Figure 5-13). It is permissible to perform this test with the System Cartridge. Note:Do not use a wrench or other tool to tighten the cartridge. Hand tightening is sufficient. If leakage is observed, check the condition of the flat gasket in the valve bore. Figure 5-13. UCH Control System, Test Cartridge Placement 2. Locate the cover of the UCH Control System. Ensure that the local manual handle is set and that the Safety Pin is inserted (see Figure 5-14). The handle should be locked in the set position. If the handle can turn, adjust until the pin can be inserted all the way through the handle into the body of the cover. Note:Installation of a tamper wire seal can prevent the pin from slipping out. CAUTION Do not attempt to push the piercing pin down. Pushing the piercing pin too far can cause the O-ring to move out of the valve bore. This could cause the O-ring to chip or break upon actuation of the system. Inserting the System Nitrogen Cartridge will push the piercing pin down to the proper location in the valve bore. TEST CARTRIDGE KEEPER PIN Maintenance P/N 9127100 5-17 January 2007 Figure 5-14. UCH Control System, Cover Attached 3. Remove the Keeper Pin from the UCH Control System Cam/Flag. Carefully install the cover onto the enclosure. The cover has a tongue that fits into the groove of the enclosure. Center the cover over the enclosure and fit the tongue and groove together. 4. Fasten the cover to the enclosure with the captive screws. Turn the captive screws until snug. Note:The Valve Protection Plates should remain on the top of the Cylinder and Valve Assemblies until directed to remove it. 5. Pull the safety pin and turn the handle in the direction of the arrow about 1/8-turn. The system will fire, pressurizing the actuating lines. Note:Do not loosen any of the fittings on the actuating lines at this time. 6. Inspect the actuating lines and SVAs for leakage. Each SVA piston must be in the released position (down) and locked. Check each piston to ensure that it is fully extended. Note:If any leakage is observed, appropriate steps must be taken to implement corrective action. However, pressure should be bled off before any action is implemented on the actuating lines. CAUTION While the cover is resting on the enclosure, moving it upward could engage the local manual release with the latch, causing the UCH Control System to release. Keep the cover as centered as possible while performing this step. UCH HOUSING COVER SAFETY PIN LOCAL MANUAL RELEASE HANDLE HIGH PRESSURE NITROGEN TUBING SVA Maintenance January 2007 5-18 P/N 9127100 7. After ensuring there is no leakage, loosen the swivel fitting located at the bottom right side of the UCH Control System (see Figure 5-15). Allow the pressure to vent slowly. When the pressure is completely vented, disconnect the fitting and remove the cover. Figure 5-15. Fitting on Outside of UCH Control System 8. Remove the spent cartridge used for the functional test. 9. Discard the spent cartridge in an appropriate manner. Check to ensure the detection lines are set. Refer to Paragraph 5-2.2.7.1. 10. Reset the Cam/Flag and reinstall the Keeper Pin into the Cam/Flag. Note:Ensure the microswitches are setting properly. Check the Deep Mount Microswitches to ensure the trigger pin is under the paddles of the microswitches and is pushing them up. Check the High Mount Microswitches to ensure the Cam/Flag is pushing down on the paddles. 11. Install the Safety Pin into the local manual release handle of the cover assembly. Install a tamper indicator through the Safety Pin and around the handle. WARNING The system uses high pressure. Safety goggles or glasses must be worn. All pressure must be released from the actuation lines before resetting the Cam/Flag. Failure to do so will cause the head of the piercing pin to protrude out of the valve bore, exposing the O-ring. This could result in the O-ring being damaged, thereby causing malfunction or non-function of the system as designed. Always ensure that the pressure has been released before resetting the Cam/Flag. CAUTION To avoid accidental discharge later in the service sequence, it is important to completely disconnect the fitting outside the UCH Control System. Maintenance P/N 9127100 5-19 January 2007 12. Reset all of the SVAs. Push the spring-loaded plunger in while pushing the piston into the body of each SVA. 13. Carefully remove the Valve Protection Plate from the cylinder valves and install the SVA to each cylinder. Secure with the bolts included. Ensure that each SVA is securely tightened. Note:Check the condition of the flat gasket in the valve bore. Do not use a wrench or other tool to tighten the cartridge. Hand tightening is sufficient. Figure 5-16. Valve Body with Flat Gasket 14. When all SVAs are secured, locate the System Nitrogen Cartridge (P/N 120043). In the area provided, write the date of installation of the cartridge. Carefully install the System Nitrogen Cartridge into the valve assembly of the UCH Control System. Hand-tighten until it is snug. 15. Locate the cover of the assembly. Ensure the tamper seal remains intact in the safety pin. 16. Remove the Keeper Pin from the Cam/Flag. 17. Carefully install the cover onto the enclosure. The cover has a tongue that fits into the groove of the enclosure. Center the cover over the enclosure and fit the tongue and groove together. 18. Fasten the cover to the enclosure with the captive screws. Turn the captive screws until snug. 19. Secure the High Pressure Nitrogen Tubing back onto the bottom of the UCH Control System. Ensure that the fit is properly snug to prevent leakage. Refer to Figure 5-17. CAUTION A System Nitrogen Cartridge is required for final system set up. Using any other cartridge could cause malfunction or non-function of the system. CAUTION While the cover is resting on the enclosure, moving it upward could engage the local manual release with the actuation latch, causing the UCH Control System to release. Keep the cover as centered as possible while performing this step. CAUTION Securing the High Pressure Nitrogen Tubing onto the UCH Control System will complete the setup of the Range Guard System. System discharge could occur if the system has not been properly set. FLAT GASKET PIERCING PIN Maintenance January 2007 5-20 P/N 9127100 Figure 5-17. Cylinder Mounted UCH Control System 5-2.2.7.1 Disposal of Cartridge Following are the recommended instructions for disposal of spent cartridges. Determine if gas is present in the cartridge. All puncturable type disposable cartridges are presumed to be fully charged unless the small puncturable end (opposite of the rounded bottom) is clearly punctured. If the puncture is not clear, the cartridge may be weighed using a scale capable of reading in grams accurate to 0.1 g. The weight of the cartridge shall be less than the indicated weight imprinted on the side of the cartridge by the amount of the indicated charge. After using one of the methods described to determine that no gas is present in the cartridge, the cartridge may be placed with normal refuse, or may be placed with steel recycling materials. All of the steel cartridges are produced from a low carbon (14) steel product. Once empty, no residue remains. Cross cutting or sectioning is not required. WARNING Never dispose of a pressurized cartridge. Cartridges must be discharged before discarding. Filled gas cartridges may be dangerous if not handled properly. Do not heat cartridges above 120°F (49°C). Pressurized cartridges that become overheated can explode, and thereby cause property damage, severe personal injury, and possibly death. TAMPER SEAL SAFETY PIN CAPTIVE SCREW HIGH PRESSURE NITROGEN TUBING CAPTIVE SCREW CAPTIVE SCREW CAPTIVE SCREW Maintenance P/N 9127100 5-21 January 2007 5-2.2.8 PREPARATION FOR SERVICING AND TESTING THE A+ CONTROL BOX 1. Disconnect the copper tubing from the SVA. Figure 5-18. Disconnect Copper Tubing 2. Verify that the system design and installation are adequate to protect the hazard area and that the installation conforms to the instructions in this manual. Some of the items to verify are: a. All equipment requiring fire protection within the hazard area is protected. b. There have been no unauthorized alterations to the protected area or equipment, or to the wet chemical system, that render the fire suppression system ineffective or non- operational. c. All Cylinder Mounting Brackets are securely fastened to a wall or other structural member. d. All nozzles are properly aimed, secured and located within the proper distance from the protected equipment. Each nozzle should be clean and equipped with a foil seal cap. e. The agent distribution piping is properly sized for the number and type of nozzles required. f. All piping joints and pipe supports are securely fastened to prevent wet chemical leakage and hazardous movement during discharge. g. The pipe lengths, sizes, fittings and material are as specified in this Manual. h. The number, type, and placement of detectors are suitable for all hazards within the hazard area. i. The Remote Manual Release, if used, is located in a path of exit or egress and is clearly identified. j. Stainless steel control cable lengths and Corner Pulley counts are within listed limits. Conduit runs should be clean and secure. k. All wiring is in compliance with local codes. l. All field wiring is free of ground fault or short-circuit conditions. m. No branch circuits exist in the wiring to the detectors. n. All auxiliary components sUCH as Pressure Operated Release are secure and show no evidence of physical damage. o. All system components and installation material are as specified in this manual. 3. Remove the A+ Control Box cover. 4. Remove the CO2 cartridge from the A+ Control Box and dispose of it properly. SVA COPPER TUBING Maintenance January 2007 5-22 P/N 9127100 Note:CO2 cartridge can be used to test the system before discarding. Do not reuse the CO2cartridge. 5. Remove the System Valve Actuators from all cylinders. See Figure 5-19 for location. Figure 5-19. System Valve Actuators 6. Install cylinder valve protection plates. 7. Disconnect Discharge Adapter Kit (agent piping) from all cylinders (see Figure 5-20). Note:Disconnecting the Discharge Adapter Kit typically involves removing cylinders. WARNING Never dispose of a pressurized cartridge. Cartridges must be discharged before discarding. Filled gas cartridges may be dangerous if not handled properly. Do not heat cartridges above 120°F (49°C). Pressurized cartridges that become overheated can explode, and thereby cause property damage, severe personal injury, and possibly death. SVA CYLINDER AND VALVE ASSEMBLY Maintenance P/N 9127100 5-23 January 2007 8. Install the Anti-Recoil Plate. Figure 5-20. Removing Discharge Adapter Kit 5-2.2.9 ARMING THE A+ CONTROL BOX 1. Allow about 18 inches (452 mm) of cable to extend into the box for connection to the valve body lever. 2. Locate the slot in the back panel located behind the valve body lever. Place the tip of a screwdriver in the slot. 3. Pull down on the screwdriver causing the spring to stretch until the tensioning tool holes in the valve body and lever are lined up. 4. Install the Keeper Pin. The A+ Control Box is now held in the "SET" position (see Figure 5-21). Figure 5-21. A+ Control Box in “SET” Position FLANGE PLATE DISCHARGE ADAPTER O-RING NUT 5/16-18 BOLTS 5/16-18 X 1 in. LONG SHIPPING CAP CYLINDER AND VALVE ASSEMBLY NUT 5/16-18 MECHANICAL GAS VALVE CABLE (NOT SUPPLIED) LEVER HOLE CSET SCREW KEEPER PIN Maintenance January 2007 5-24 P/N 9127100 5. Locate the Cable Tension Block Assembly. With the screw threaded out on the Cable Tension Block Assembly, thread the detection cable through the cable tension block (see Figure 5-22). Note:It is necessary for you to have already cut and crimped the detection line cable and installed the "S" hooks and fusible links prior to the step of removing the cable slack and making the final adjustments. Figure 5-22. Cable Tension Block Assembly 6. Thread the end of the detection cable through the hole in the valve body lever. 7. Thread detection cable through hole in the top of the A+ Control Box. 8. Fasten vise grips to the end of the detection cable. Pull on the detection cable and make sure to remove most of the cable slack. 9. Tighten the lever set screw onto the cable. 10. Tighten the adjustment screw on the Cable Tension Block Assembly until the tension on the cable is balanced and allows the Keeper Pin to easily slide out of the valve body. Leave the Keeper Pin in place until after the CO2 cartridge is installed. This will prevent accidental discharge. If the Keeper Pin does not slide out easily, not enough cable slack was removed when the cable was pulled through the valve body lever. Loosen the adjusting screw in the Cable Tension Block Assembly and then repeat steps above. Note:It is recommended that you cut the detection cable close to the lever. After completing the tensioning of the detection system, make sure that each detector has the required 3 inches (76 mm) minimum spacing, in the direction of cable travel, between the cable clamp or block and the end of the conduit fitting in the detector bracket. 5-2.2.9.1 Checking Microswitches Check to ensure that the microswitches are set. Adjust the microswitch toward the lever until the paddle on the microswitch just touches the top corner of the microswitch body. The microswitch is now in the ‘Set’ position. 5-2.2.9.2 Checking Gas Valve When the lever is in the ‘Set’ position, verify the gas valve is in the open position. When the lever is in the ‘Released’ position, verify the gas valve is in the closed position. ALLEN HEAD ADJUSTING SCREW INITIAL INSTALLATION DETECTION CABLE CENTRAL ROLLER PINS Maintenance P/N 9127100 5-25 January 2007 5-2.2.10 FUNCTIONAL TESTING OF THE A+ CONTROL BOX Perform the Post Installation Checkout in Paragraph 4-5. 5-2.2.10.1 Test Mechanical Link Lines for the A+ Control Box (If Applicable) To test the mechanical detector lines, perform the following steps. 1. Remove the Keeper Pin from the valve body. 2. Go to the far end of the detection line. Cut the detector. 3. Check to ensure the lever has moved to the ‘Discharge’ position. 4. Check the microswitches to ensure that they have changed phase as intended. 5. Check the gas valve line to ensure that it has moved freely and that the gas valve has closed. Verify that all gas fired appliances have shut down, including the pilot lights. 6. Check each detector and bracket to ensure the travel distance of the cable. Make sure the line has operated without interference at any place in the system. 7. Replace detector that was cut. 8. Refer to Paragraph 5-2.2.9, "Arming the A+ Control Box". 9. Reset all electrical shut-offs. CAUTION The mechanical detector lines are under tension. Wearing safety glasses and gloves is required during this process. Before cutting a detector, ensure the CO2 Cartridge is not installed in the A+ Control Box and the Keeper Pin is in place in the valve body. Maintenance January 2007 5-26 P/N 9127100 5-2.2.11 TEST REMOTE MANUAL RELEASE, 9197463 (IF APPLICABLE) 1. Operate the Remote Manual Release by removing the pull pin. 2. Go to the A+ Control Box and check to ensure the lever is in the ‘Discharge’ position. 5-2.2.12 TESTING MICROSWITCHES (IF APPLICABLE) Note:If there are no microswitches installed in the system, proceed to Paragraph 5-2.2.12.1. 1. Remove Keeper Pin. 2. Verify actuation of the A+ Control System and the lever is in the ‘Discharge’ position. 3. Using a voltmeter, check the microswitches to ensure that they have changed phase as intended. 4. Check the gas valve line to ensure that it has moved freely and that the gas valve has closed. Verify that all gas fired appliances have shut down, including the pilot lights. 5. Ensure that the fire control panel has been reset according to the DIOM Manual for the fire control panel being used. 6. Check and ensure the lever is reset back to the ‘Set’ position. 7. Insert Keeper Pin into port on valve body. 8. Reset all electrical shut-offs. CAUTION Before testing the Remote Manual Release, ensure the CO2 Cartridge is not installed in the A+ Control Box and remove the Keeper Pin from the valve body. CAUTION Before testing the microswitches, ensure the CO2 Cartridge is not installed in the A+ Control System and that the Keeper Pin is in place in the valve body. Maintenance P/N 9127100 5-27 January 2007 5-2.2.12.1 Visual Inspection of the Copper Tubing To perform an inspection of the copper tubing, use the following steps. 1. Ensure Keeper Pin is in the valve body. 2. Ensure that all fittings are tightly attached. 3. Check all of the SVA pistons to ensure that they are in the set position. The bottom surface of the piston must be in the body of the SVA. If it is in the released position, push the piston into the body of the SVA (see Figure 5-23). Recommendation: Badger recommends that the actuation testing take place before the full discharge test. Figure 5-23. SVA in ‘Set’ Position CAUTION It is important to verify that the lever is in the 'Set' position and the Keeper Pin must be in place in the valve body. SVA PISTON IN SET POSITION Maintenance January 2007 5-28 P/N 9127100 5-2.2.12.2 Installing the CO2 Gas Cartridge in the A+ Valve Body After the gas valve connection has been made and the optional microswitch(es) installed, the CO2cartridge must be installed. 1. Carefully install the CO2 cartridge into the valve body of the A+ Control Box. Hand-tighten until it is snug. 2. Remove Keeper Pin. After initial installation, perform the actuation test described in Paragraph 5-2.2.13. Figure 5-24. Installing CO2 Gas Cartridge CAUTION If the CO2 cartridge is not sealed against the valve gasket, or the valve gasket is missing, the system will not function properly. Verify correct installation. CAUTION Be sure to remove the Keeper Pin. Failure to remove the Keeper Pin will result in an inoperative system. C CARTRIDGEO2 VALVE BODY KEEPER PIN Maintenance P/N 9127100 5-29 January 2007 5-2.2.13 ACTUATION TEST FOR THE A+ CONTROL BOX (IF APPLICABLE) 1. Remove the System Valve Actuator (SVA) from each cylinder and valve assembly. Leave the copper tubing connected to the SVAs. 2. Go to the far end of the detection line. Cut the detector. 3. Check the CO2 cartridge to ensure it has discharged. 4. Using a voltmeter, check the microswitches to ensure that they have changed phase as intended. 5. Check the gas valve line to ensure that it has moved freely and that the gas valve has closed. Verify that all gas fired appliances have shut down, including the pilot lights. 6. Check each detector and bracket to ensure the travel distance of the cable. Make sure the line has operated without interference at any place in the system. 7. Reset all electrical shut-offs. 8. Carefully release residual pressure in the copper tubing line by slightly loosening a tubing nut. If there is no pressure in the line, check for leaks. 9. Retighten the tubing nut after all the residual pressure is released. 10. Reset all of the SVAs. Push the spring-loaded plunger in while pushing the piston into the body of the SVA. 11. Reset the A+ Control Box by installing the Keeper Pin as previously stated. 12. Remove and discard the used CO2 cartridge. Refer to Paragraph 5-2.2.13.1. 13. In the area provided, write the date of installation of the cartridge. 14. Carefully install the CO2 cartridge into the valve body of the A+ Control Box. Hand-tighten in until it is snug. 15. Remove Keeper Pin. CAUTION The mechanical detector lines are under tension. Wearing safety glasses and gloves is required during this process. CAUTION This step must be done before the A+ Control Box is reset, otherwise the valve body O- ring could be damaged. CAUTION If the CO2 cartridge is not sealed against the gasket or the gasket is missing, the system may not function properly. Maintenance January 2007 5-30 P/N 9127100 16. Secure the cover to A+ Control Box, making sure that the lever is visible in the window of the cover. Figure 5-25. A+ with Cover Installed 5-2.2.13.1 Disposal of Cartridge Following are the recommended instructions for disposal of spent cartridges. Determine if gas is present in the cartridge. All puncturable type disposable cartridges are presumed to be fully charged unless the small puncturable end (opposite of the rounded bottom) is clearly punctured. If the puncture is not clear, the cartridge may be weighed using a scale capable of reading in grams accurate to 0.1 g. The weight of the cartridge shall be less than the indicated weight imprinted on the side of the cartridge by the amount of the indicated charge. After using one of the methods described to determine that no gas is present in the cartridge, the cartridge may be placed with normal refuse, or may be placed with steel recycling materials. All of the steel cartridges are produced from a low carbon (14) steel product. Once empty, no residue remains. Cross cutting or sectioning is not required. This completes the Semi-Annual Service of the Range Guard Wet Chemical System. CAUTION Be sure to remove the Keeper Pin. Failure to remove the Keeper Pin will result in an inoperative system. WARNING Never dispose of a pressurized cartridge. Cartridges must be discharged before discarding. Filled gas cartridges may be dangerous if not handled properly. Do not heat cartridges above 120°F (49°C). Pressurized cartridges that become overheated can explode, and thereby cause property damage, severe personal injury, and possibly death. WINDOW LEVER COVER Maintenance P/N 9127100 5-31 January 2007 5-2.3 Twelve-Year Maintenance The 12-year maintenance is typically done in conjunction with the semi-annual maintenance. These procedures shall be performed in addition to the tests conducted at Semi-Annual intervals (Paragraph 5-2.2), and the monthly inspections (Paragraph 5-2.1). Refer to NFPA 17A, NFPA 96, DOT and TC requirements for all 12-year maintenance and hydrostatic testing. 5-2.3.1 WET CHEMICAL CYLINDERS Badger recommends that a complete internal inspection be done in accordance with this schedule. 5-2.3.2 HYDROSTATIC TESTING Refer to Title 49 of the Code of Federal Regulations Paragraph 180, and CGA pamphlets C-1 and C-6. Refer to http://www.cganet.com for more details. Hydrostatic testing is to be performed on the Range Guard cylinder in compliance with the appropriate DOT and TC requirements. The wet chemical is to be discarded when performing the hydrostatic test. Note:Do not reuse the wet chemical per NFPA-17A. To protect the hazard during this testing period, a substitute cylinder is to be used, one equal to the unit under test. An alternate protection method may be used so long as it is acceptable to the Authority Having Jurisdiction (AHJ). Cylinders are to be either hydrostatically tested or volumetric-expansion tested to TWO TIMES the standard rating. A cylinder’s standard rating is stamped on the crown or footing of the cylinder. For example: Table 5-4. Wet Chemical Cylinder Inspection Checkbox Procedure Section ‡Determine date of cylinder manufacture. See CGA pamphlet C-1 for hydrostatic test requirements. Paragraph 5-2.3.2 ‡Depressurize the Cylinder and Valve Assembly. Paragraph 5-2.3.3.2 ‡Remove the valve and siphon tube. Paragraph 5-2.3.3.3 ‡Remove and discard the wet chemical from the cylinder. Paragraph 5-2.3.3.3 ‡Visually inspect the entire inside surface of the cylinder, per CGA pamphlet C-6. ‡Hydrostatically test the cylinder. Paragraph 5-2.3.2 ‡Rebuild valve with new stem/O-ring and new valve/cylinder O-ring (Cylinder Rebuild Kit P/N B120067). Paragraph 5-2.3.3.4 ‡Recharge the cylinder. Paragraph 5-2.3.3.5 CAUTION This is only an example; failure to properly identify and test the cylinder to appropriate DOT and TC requirements may result in damage to cylinder. No leakage, rupture, or expansion greater than 10% shall be allowed. Internal or external corrosion, denting, bulging, or evidence of rough usage that would be likely to weaken the cylinder should cause the cylinder to be condemned and replaced. Maintenance January 2007 5-32 P/N 9127100 When cylinders have been hydrostatically tested, recharge according to Paragraph 5-2.3.3.5. 5-2.3.3 RECHARGE INSTRUCTIONS 5-2.3.3.1 General Information The Karbaloy wet chemical used in extinguishing a fire is not harmful, but if the chemical comes in contact with food, it will cause the food to become unpalatable. It is best to clean the area immediately after fire extinguishment. After the appliances have completely cooled, the residue from the discharge may be cleaned up using a wet cloth or sponge. Wear rubber gloves while cleaning. If skin or eyes come in contact with the agent, flush thoroughly with water. The Pneumatic Release must be disassembled and cleaned of wet chemical. The Pneumatic Release’s stem and piston preformed packing must be lubricated with silicone grease. In addition, the two-way check tee (if used) is to be blown clean with nitrogen to remove all wet chemical. 5-2.3.3.2 Depressurize Cylinder and Valve Assembly Note:Before beginning, refer to Paragraph 5-2.3.3.5 for preparation before recharging. 1. Ensure all pressure is vented by slowly loosening the High-Pressure Nitrogen Tubing at the bottom of the UCH Control System, or by loosening the copper tubing from the valve body of the A+ Control Box. 2. Check each pressure gauge to ensure that all cylinders are empty. 3. Unbolt the Discharge Adapters and the SVAs from all discharged cylinders. 4. Loosen the Mounting Bracket retaining strap(s) and install the Anti-Recoil plate(s) and the Protection Cap(s). 5. Remove all discharged cylinder(s). Note:All cylinders shall be recharged as described Paragraph 5-2.3.3.5. MARKINGS: DOT 4BW-250 TC-4BWM17.2 RATING: 250 PSI 17.2 BAR TEST PRESSURE: 500 PSI 34.5 BAR WARNING Protective eyewear must always be worn when working with pressurized cylinders. Never service a Cylinder and Valve Assembly unless the Anti-Recoil Plate (P/N 255681) and Protection Cap (P/N 255096) are installed. Do not use oxygen to blow out agent distribution piping. The use of oxygen is very dangerous as the possible presence of even a minute quantity of oil may cause an explosion, thereby causing death, serious injury and/or property damage. Maintenance P/N 9127100 5-33 January 2007 5-2.3.3.3 Disassemble the Cylinder Valve 1. Remove the valve and siphon tube assembly from the discharged cylinder. 2. Invert the cylinder and tap the threaded neck end on a wooden block to remove any residual wet chemical. 3. Blow any wet chemical residual from the valve, siphon tube and cylinder threads. 4. Visually inspect the entire inside and outside surface of the cylinder per CGA Pamphlet C-6. 5-2.3.3.4 Rebuilding Cylinder Valve When rebuilding the cylinder valve, use the Cylinder Rebuild Kit, P/N B120067. This kit includes: •Valve stem, •Valve spring, • Spring retainer, • Cylinder O-ring, • Retaining ring, and •Valve stem O-ring. Use the following procedures to rebuild the cylinder valve. 1. Remove siphon tube from the cylinder valve. 2. Secure valve body. Place valve body over a short piece of 3/4-inch pipe (or equivalent) to prevent the valve stem from falling out. 3. Remove the following from the valve body: – Retaining ring – Spring retainer –Valve spring –Valve stem – Cylinder valve O-ring Maintenance January 2007 5-34 P/N 9127100 Figure 5-26. Valve Assembly 4. Put a light coating of lubricant (supplied in the Valve Rebuild Kit) on the valve stem O-ring. Do not grease the bonded seal on valve check (see Figure 5-26). 5. Install the valve stem. 6. Install valve spring. 7. Install spring retainer. 8. Push down on the valve spring and spring retainer. Install the retaining ring. 9. When installing the retaining ring, it is recommended that you use a box wrench to push the valve spring down and to maintain pressure while encompassing the retaining ring in place. 10. Put a light coating of lubricant (supplied in the Valve Rebuild Kit) on the cylinder valve O-ring. 11. Install valve to cylinder O-ring. 12. Reinstall siphon tube to cylinder valve. VALVE STEM CYLINDER O-RING VALVE PRESSURE GAUGE VALVE BODY VALVE SPRINGSPRING RETAINER RETAINING RING CHECK O-RING Maintenance P/N 9127100 5-35 January 2007 5-2.3.3.5 Recharging Cylinders 1. Fill the cylinder with the appropriate weight of the Karbaloy agent as indicated on the cylinder nameplate. Use the following Badger P/Ns: 2. Reinstall the siphon tube and valve and ensure it is tight. 3. Unbolt the Anti-Recoil Plate and bolt the charging adapter to the outlet port of the valve. Securely clamp the cylinder to a rigid structure. 4. Use dry nitrogen to pressurize the cylinder to 175 PSI (12.1 bar) at 70°F (21°C). Use a calibrated gauge. Note:Do not rely on the pressure regulator or the cylinder pressure gauge to determine the container pressure (see Figure 5-32 for a suggested recharging arrangement). 5. Remove the charging adapter and check for leakage using a soap solution. 6. Bolt the Anti-Recoil Plate to the valve outlet. Leave the protection plates in place until the cylinder is ready to be reinstalled. WARNING Under no circumstances while performing cylinder recharge should a charged cylinder be allowed to “free stand” without either the charging apparatus attached or the anti-recoil plate installed. Whenever these devices are not installed, a charged cylinder must be securely clamped to a rigid structure capable of withstanding the full thrust that would result should the valve inadvertently open. Refer to the Safety Summary for more information regarding pressurized cylinders. CAUTION Do not attempt to recharge any cylinder without first checking for last hydrostatic test date. The U.S. Department of Transportation (DOT) and Transport Canada (TC) has ruled that any pressurized container of the type used in wet chemical systems shall not be recharged or transported with out first being inspected internally and externally and hydrostatically tested if more than twelve years have elapsed since the date of the last hydrostatic test. Regardless of previous inspection dates, it is illegal to refill any pressurized container that leaks, which bulges, has defective safety devices, bears evidence of physical abuse, fire or heat damage, or detrimental rusting or corrosion, until it is properly repaired and requalified as specified in DOT and TC regulations. RG-125 B120030 RG-260 B120031 RG-400S B120032 RG-400M B120032 RG-600 B120033 Maintenance January 2007 5-36 P/N 9127100 Figure 5-27. Recharge Hookup After the inspections and procedures described previously in this section, and after having recharged all wet chemical cylinders, the fire suppression system is ready to be fully checked out before installation of the recharged wet chemical cylinders. Perform the steps outlined in Paragraph 5-2.2.6, Functional Testing of the System. 5-2.3.3.6 Cylinder Leak Test 1. Remove the spare discharge adapter and check for leakage using a soap solution. 2. Bolt the anti-recoil plate, P/N 255681, to the valve outlet. Leave the protection plates in place until the cylinder is ready to be reinstalled. 5-2.3.4 UCH CONTROL SYSTEM COMPONENT MAINTENANCE The System Nitrogen Cartridge (P/N B120043) requires replacement at intervals of twelve years. Check the date that was written on the cartridge at the time of installation. At the time of replacement, the old System Nitrogen Cartridge may be used for the functional tests. 5-2.3.4.1 Rebuild the UCH Control System Valve The UCH Pin/Gasket Rebuild Kit (P/N B120046) includes the following: •Valve Gasket •Piercing Pin •O-ring • Retaining Ring • Pin/Gasket Service Label Refer to Figure 5-28 when performing the service operation. CYLINDER AND VALVE ASSEMBLY CALIBRATED PRESSURE GAUGE SHUT-OFF VALVE NITROGEN CYLINDER REGULATOR WITH ADAPTER VENT VALVE Maintenance P/N 9127100 5-37 January 2007 Figure 5-28. Valve Body with Piercing Pin Shown 1. Ensure that the Cam/Flag is in the Released position. 2. Remove the System Nitrogen Cartridge. 3. Carefully remove the retaining ring. Refer to Figure 5-28 for location. 4. Slide the Cam/Flag off the shaft. 5. Using a small screwdriver or other tool, push the Piercing Pin (P/N 9197212) out of the port, in the direction of the shaft. Discard the Piercing Pin. 6. Remove and discard the Flat Gasket (P/N 236204) located inside the gas cartridge inlet. CAUTION The point on the piercing pin is extremely sharp. Handle with care. It is important to discard the piercing pin that is removed from the UCH Control System at the 12-year cycle. It must never be used again. CAUTION Use care not to damage the threads in the gas cartridge inlet. VALVE BODY FLAT GASKET CAM/FLAG RETAINING RING PIERCING PIN SHAFT Maintenance January 2007 5-38 P/N 9127100 Figure 5-29. Removal of Piercing Pin and Flat Gasket 7. Insert a new Flat Gasket (Use only P/N 236204). Ensure that the gasket is seated firmly inside the gas cartridge inlet. 8. With the sharp end of the Piercing Pin pointed into the port, push the Piercing Pin into the port until the O-ring is inside the valve body. 9. Reinstall Cam/Flag. Note:Ensure there is no interference with the Piercing Pin. If there is interference, push the pin further into the body. While sliding the Cam/Flag over the shaft, ensure that the paddles for the microswitches also do not interfere. 10. Install the new retaining ring into the groove on the top of the shaft. Note:The Cam/Flag may seem slightly loose on the shaft. It will turn slightly This is acceptable. There will be further tests to ensure the fit is proper. 11. Turn the Cam/Flag to check engagement with the microswitch paddles. 12. Write the date on the Pin/Gasket Service Date label in the space provided. Attach the Pin/Gasket Service Date label. Note:Do not install the label onto the local manual release handle. Attach it to another part of the system where is will not interfere with system operation. CAUTION Only System Nitrogen Cartridge shall be used for final system set up. Using any other cartridge could cause malfunction or non-function of the system in an emergency situation. RETAINING RING CAM/FLAG VALVE BODY FLAT GASKET PIERCING PIN O-RING Maintenance P/N 9127100 5-39 January 2007 13. Once these steps have been performed, proceed with all Functional and Actuation Tests according to Paragraph 5-2.2.7. At the completion of the Actuation Test, install a new System Nitrogen Cartridge. In the space provided, write in the date the cartridge is being installed. Carefully install the System Nitrogen Cartridge into the valve assembly of the UCH Control System. Hand tighten until it is snug. Note:Do not use a wrench or other tool to tighten the cartridge. Hand tightening is sufficient. If leakage is observed, check the condition of the cam and flat gasket/piercing pin in the valve bore. 14. Review system operation with the owner or other responsible persons. 15. Dispose of cartridge according to the instructions in Paragraph 5-2.2.7.1. Maintenance January 2007 5-40 P/N 9127100 5-3 POST-DISCHARGE MAINTENANCE 5-3.1 General Information The Karbaloy wet chemical used in extinguishing a fire is not harmful. However, it is best to clean the area immediately after fire extinguishment. Prolonged exposure of equipment to wet chemical can result in localized corrosion due to moisture in the air. The pneumatic release must be disassembled and cleaned of wet chemical. The pneumatic release’s stem and piston preformed packing must be lubricated with silicone grease. In addition, the two-way check tee (if used) is to be blown clean with dry nitrogen to remove all wet chemical. 5-3.2 Appliance Cleanup No unusual cleanup procedure is required. The reaction of the wet agent and the grease is one of saponification and it produces a foam which can be wiped off. After the appliances have completely cooled, the residue from the discharge may be cleaned up using a wet cloth or sponge. Wear rubber gloves and eye protection while cleaning. If skin or eyes come in contact with the agent, flush thoroughly with water. 5-3.3 Cylinder and Valve Assembly Check each pressure gauge to ensure that all cylinders are empty. Unbolt the discharge adapters and SVA(s) from all discharged cylinders. Loosen the mounting bracket retaining straps and install the anti-recoil plates and the shipping caps. Remove all discharged cylinders. Bolt a test fixture to each SVA. All cylinders shall be recharged as described in Paragraph 5-2.3.3.5, Recharging Cylinders 5-3.3.1 VALVE DISASSEMBLY - See Paragraph 5-2.3.3.3, Disassemble the Cylinder Valve WARNING Do not disturb the foam until the cooking appliances, plenum, and duct have cooled sufficiently. Do not put water on hot grease as this will cause violent steaming and spattering. WARNING Karbaloy wet agent is electrically conductive. To avoid electrical shock, de-energize all electric circuits to appliances, outlets, and wiring by disconnecting or turning off the electric power at the main fuse or circuit breaker box. Do not cleanup Karbaloy wet agent or touch electric appliances, outlets, power cords, or other wiring with electric power on. WARNING Protective eyewear must always be worn when working with pressurized cylinders. Never service a cylinder-and-valve assembly unless the Anti-Recoil Plate (P/N 255681) and Shipping Cap (P/N 255096) are installed. Maintenance P/N 9127100 5-41 January 2007 5-3.4 Resetting the Mechanical System 1. Replace all detectors with new detectors having the same temperature and load rating as the original detectors. Note:Any detectors exposed to heat will no longer provide reliable protection and must be replaced. 2. After replacing the detectors, remove the front cover from the UCH Control System or A+ Control Box. Reset the UCH Control System or A+ Control Box as described in Chapter 4. 5-3.5 Resetting the Electrical System 1. Inspect and test all thermostats. Replace any thermostats that have obviously been damaged by exposure to excessive heat. Check the actuation set point of the remaining thermostats by heating the thermostats and recording the actuation temperature. If the actuation temperature of any thermostat is more than 10° F higher than its original setting, the thermostat should be replaced. Hot oil and a high-temperature thermometer can be used to check the temperature. Heating should be done slowly. 2. After replacing any damaged thermostats, remove the front cover from the UCH Control System or A+ Control Box. Reset the UCH Control System or A+ Control Box as described in Chapter 4. 5-3.6 Clean Distribution System and Nozzles 1. Remove all nozzles from the system and inspect each nozzle filter for debris. Remove any debris. Clean nozzle filter under running water to remove foreign matter that might impede flow through the nozzle. Also, run water through the nozzle tip to insure the orifice is not clogged. Thoroughly dry nozzles with dry air or nitrogen and reassemble. Note:When LPR nozzle is disassembled for inspection or cleaning, reassemble with the disc/core unit with center core "nub" facing upstream. Flat side should be facing towards threaded nozzle cap. Figure 5-30. LPR Nozzle Assembly 2. Before attaching nozzles, flush out the system with warm water as suggested in Paragraph 5-3.7. Re-install the nozzles on the distribution pipe and replace all nozzle foil seal caps. 3. Inspect the system piping and fittings and replace any pipe or fittings subjected to direct flame or excessive heating. 4. Blow out the distribution pipe with dry air or nitrogen. One possible procedure for accomplishing this is to use a test cylinder-and-valve assembly, without any wet chemical, pressurized with nitrogen to 100 psig. DISC/CORE ASSEMBLY NOZZLE CAP NOZZLE BODY NUB FLAT SURFACE Maintenance January 2007 5-42 P/N 9127100 5. Verify with suitable discharge indicators that proper flow through all nozzles. 6. Remove all nozzles from the system and inspect for debris. Remove any debris. 7. Re-install the nozzles on the distribution pipe and replace all nozzle disc caps. 5-3.7 Flushing Procedure Each Badger system must have all discharge piping (or discharge tubing) flushed out with water after each discharge (see Figure 5-31). A procedure for flushing is given below: 1. Remove nozzles, disassemble and remove strainer screen only. Flush nozzle parts and strainer thoroughly with fresh water and reassemble nozzle(s). 2. Disconnect cylinder(s) and install inlet flushing adapter (9197086). Connect one end of a garden hose to water tap and the other end to inlet flushing adapter. An alternate source of water is to use a cylinder of the same size as installed in the system filled with water and pressurized to 175 psig (1205 kPa). 3. Attach outlet flushing adapter to each nozzle position. 4. Attach garden hose to each adapter. 5. Place discharge end of each hose in sink, bucket, or other point of disposal, or collect water in a properly attached bag or bucket. 6. Turn on fresh water and flush thoroughly, or discharge manually with water-filled cylinder. 7. Blow air through discharge piping to remove all excess water. 8. Install cleaned nozzles in their proper positions with a new foil seal on each. 9. Install charged cylinder(s). Figure 5-31. Diagram for Flushing the Badger System WARNING Do not use oxygen to blow out piping. The use of oxygen is very dangerous as the possible presence of even a minute quantity of oil may cause an explosion. INLET FLUSHING ADAPTER P/N 9197086 NPT 3/8 in. (10 mm) 1/2 in. (13 mm) P/N 9197090 9197091 Maintenance P/N 9127100 5-43 January 2007 5-3.8 Recharge Cylinders - See Paragraph 5-2.3.3.5, Recharging Cylinders 5-3.9 Cylinder and Valve Reassembly 1. Replace the Valve-to-Cylinder O-Ring, P/N 5661-0327. 2. Fill the cylinder with the appropriate weight of the Karbaloy agent as indicated on the cylinder nameplate. Use the following Badger P/Ns: 3. Reinstall the siphon tube and valve and ensure it is tight. 4. Install O-Ring (P/N 1080-1900) on a spare discharge adapter (P/N 844908). 5. Unbolt the anti-recoil plate and bolt the spare discharge adapter to the outlet port of the valve. Securely clamp the cylinder to a rigid structure. 6. Use nitrogen to pressurize the cylinder to 175 PSI (12.1 bar) at 70°F (21°C). Use a calibrated gauge. Note:Do not rely on the pressure regulator or the cylinder pressure gauge to determine the container pressure. Refer to Figure 5-32 for a suggested recharging arrangement. CAUTION Do not attempt to recharge any cylinder without first checking for last hydrostatic test date. The U.S. Department of Transportation (DOT) and Transport Canada (TC) has ruled that any pressurized container of the type used in Wet Chemical systems shall not be recharged or transported with out first being inspected internally and externally and hydrostatically tested if more than twelve years have elapsed since the date of the last hydrostatic test. Regardless of previous inspection dates, it is illegal to refill any pressurized container that leaks, which bulges, has defective safety devices, bears evidence of physical abuse, fire or heat damage, or detrimental rusting or corrosion, until it is properly repaired and requalified as specified in DOT and TC regulations. RG-125 B120030 RG-260 B120031 RG-400S B120032 RG-400M B120032 RG-600 B120033 WARNING Under no circumstances while performing cylinder recharge should a charged cylinder be allowed to "free stand" without either the charging apparatus attached or the anti-recoil plate installed. Whenever these devices are not installed, a charged cylinder must be securely clamped to a rigid structure capable of withstanding the full thrust that would result should the valve inadvertently open. Maintenance January 2007 5-44 P/N 9127100 5-3.10 Cylinder Leak Test 1. Remove the spare discharge adapter and check for leakage using a soap solution. 2. Bolt the anti-recoil plate, P/N 255681, to the valve outlet. Leave the protection plates in place until the cylinder is ready to be reinstalled. Figure 5-32. Recharge Hookup 5-3.11 Rechecking the System After the inspections and procedures described previously in this section, and after having recharged all wet chemical cylinders, the fire-suppression system is ready to be fully checked out before installation of the recharged wet chemical cylinders. 1. Follow the system checkout and test procedures outlined in Chapter 4. Follow the procedures for UCH Control System or A+ Control Box mechanical and/or electrical devices as appropriate. 2. Be sure to check the system for all three modes of operation (automatic, local-manual, and remote-manual actuation). 3. After the system has been satisfactorily checked out, follow the-steps under Paragraph 4-6 “Commissioning the System.” 4. After completing the “Commissioning the System” procedure, the system will be online and ready to protect the process, equipment, or combustibles. As with any equipment, periodic maintenance must be performed as indicated in Table 5-1. CYLINDER AND VALVE ASSEMBLY CALIBRATED PRESSURE GAUGE SHUT-OFF VALVE NITROGEN CYLINDER REGULATOR WITH ADAPTER VENT VALVE Parts List P/N 9127100 6-1 January 2007 CHAPTER 6 PARTS LIST Table 6-1. Parts List WET CHEMICAL CYLINDER AND VALVE ASSEMBLIES RG-125 Cylinder and Valve Assembly with 1.25 Gal. of Wet Agent B120001 RG-260 Cylinder and Valve Assembly with 2.6 Gal. of Wet Agent B120002 RG-400S Cylinder and Valve Assembly with 4 Gal. of Wet Agent B120003 RG-400M Cylinder and Valve Assembly with 4 Gal. of Wet Agent B120006 RG-600 Cylinder and Valve Assembly with 6 Gal. of Wet Agent B120005 Discharge Adapter Kit (one required for each Range Guard cylinder) 844908 Vent Plug (units of 1) — One must be used in each set of piping 9196984 Gauge Shield 131024 CYLINDER MOUNTING EQUIPMENT RG-125 Mounting Bracket 9197430 RG-260 Mounting Bracket 9197263 RG-400S Mounting Bracket 9197415 RG-400M Mounting Bracket 9197414 RG-600 and RG-400M Shelf Bracket 100013 Badger CONTROL SYSTEM UCH Control System Includes: (1) B120042 SVA (1) B120043 System Cartridge (1) B120044 Test Cartridge (1) B120058 EMT Connector Kit (2) B120039 Microswitch Kit B120099 High Pressure Hose (required for cylinder mounted Control System) B120045 System Valve Actuator (SVA)B120042 Solenoid, 24 VDC for P/N B120099 B100034 Microswitch Kit, SPDT, for P/N B120099 B120039 Microswitch Kit, SPDT, Alarm/Release for P/N B120099 B140047 EMT Connector and O-Ring Kit, 3 sets B120058 A+ Control Box Assembly Includes: (1) B120042 System Valve Actuator (2) set screws (1) Grommet (1) 231865 Label (1) 231865 Caution Label B120010 Single SPDT Microswitch Kit for A+ 9197227 Dual SPDT Microswitch Kit for A+ 9197228 SPDT Pressure Operated Switch 9197023 Parts List January 2007 6-2 P/N 9127100 DISCHARGE NOZZLES and ACCESSORIES ADP Nozzle (package of 10 of B120011) B120016 F Nozzle (package of 10 of B120012) B120017 GRW Nozzle (package of 10 of B120013) B120018 LPF Nozzle (package of 10 of B120022) B120023 R Nozzle (package of 10 of B120014) B120019 LPR Nozzle (package of 10 of B120024) B120025 DM Nozzle (package of 10 of B120015) B120020 All nozzles are 3/8 in. NPT Female 3/8 in. Swivel Adapter for Nozzles (each) B120021 Replacement Nozzle Seals (10 pack) 9197054 Disc Cap (10 pack) — not for LPR 9197290 Disc Cap (each) — for LPR ONLY 120026 MECHANICAL ACTUATION COMPONENTS Note: Fusible Links and Thermo-bulb Links are non-returnable Universal Link Housing Includes: (1) Bracket (11-3/4 in.) (2) Cable Crimp Sleeve (2) “S” Hook 120064 Link Housing Kit (not to be used with A+) Includes: (1) 279403 Bracket (1) 216209 “S” Hook (2) 54240800 1/2 in. EMT Connector (4) 214951 Cable Crimp Sleeve 804548 BTBS-165 Standard Response Link, 165°F (57°C), Red B120091-165 BTBS-212 Standard Response Link, 212°F (100°C), Green B120091-212 BTBS-286 Standard Response Link, 286°F (141°C), Blue B120091-286 BTBS-360 Standard Response Link, 360°F (182°C), Mauve B120091-360 BTBS-450 Standard Response Link, 450°F (232°C), Black B120091-450 BTBS-500 Standard Response Link, 500°F (260°C), Black B120091-500 BTBR-165 Rapid Response Link, 165°F (57°C), Red B120096-165 BTBR-212 Rapid Response Link, 212°F (100°C), Green B120096-212 BTBR-286 Rapid Response Link, 286°F (141°C), Blue B120096-286 BTBR-360 Rapid Response Link, 360°F (182°C), Mauve B120096-360 BTBR-450 Rapid Response Link, 450°F (232°C), Black B120096-450 BTBR-500 Rapid Response Link, 500°F (260°C), Black B120096-500 DETECTION AND ACTUATION ACCESSORIES Mechanical Remote Manual Release (Cable) B875572 Corner Pulley B844648 DETECTION AND ACTUATION ACCESSORIES (continued) Tee Pulley 843791 Table 6-1. Parts List (Continued) Parts List P/N 9127100 6-3 January 2007 Cable, 1/16 in. x 500 ft. long 219649 EMT Adapter, 1/2 in. EMT x 3/8 in. NPT 843837 Crimp Sleeve (package of 50 Pieces of 214951) 9197288 “S” Hook (package of 50 pieces 9189413) 9197287 Pressure Operated Switch, 3 Pole (use on UCH only)486536 Type A Fusible Links (not to be used with Badger Mechanical Control Head) RG-360 “A” Link, 360°F (182°C) 120060 A+ / UCH Inline Remote Manual Release, Surface Mount 100030 A+ / UCH Inline Remote Manual Release, Recessed Mount 9197460 A+ / UCH EOL Remote Manual Release, Surface Mount 9197463 A+ / UCH EOL Remote Manual Release, Recessed Mount 9197461 3-Way Pulley for In-line Release ONLY (10 pack) 9197286 Type ML Fusible Link ML-165 Link 165°F (57°C) "ML" Yellow B282661 ML-212 Link 212°F (100°C) "ML" White B282662 ML-360 Link 360°F (182°C) "ML" Unpainted B282664 ML-500 Link 500°F (260°C) "ML" Orange B282666 MECHANICAL CABLE OPERATED GAS SHUTOFF VALVES 3/4 in. NPT B120071 1 in. NPT B120072 1-1/4 in. NPT B120073 1-1/2 in. NPT B120074 2 in. NPT B120075 2-1/2 in. NPT B120076 3 in. NPT B120077 Pneumatic Release 9189412 Table 6-1. Parts List (Continued) Parts List January 2007 6-4 P/N 9127100 ELECTRIC SOLENOID GAS SHUTOFF VALVES 1/2 in. NPT Electric Solenoid Gas Shutoff Valve 9197017 3/4 in. NPT Electric Solenoid Gas Shutoff Valve 9197018 1 in. NPT Electric Solenoid Gas Shutoff Valve 9197019 1-1/4 in. NPT Electric Solenoid Gas Shutoff Valve 9197020 1-1/2 in. NPT Electric Solenoid Gas Shutoff Valve 9197021 2 in. NPT Electric Solenoid Gas Shutoff Valve 9197022 2-1/2 in. NPT Electric Solenoid Gas Shutoff Valve 9197444 3 in. NPT Electric Solenoid Gas Shutoff Valve 9197445 Manual Reset Relay (Required)9101735 BMCS1 AND BMCS7 PRESSURE OPERATED RELEASING SYSTEM BMCS-100 Nitrogen Cylinder 100004 BMCS-100 Actuator Assembly 100010 BMCS-100 Mounting Bracket 100011 System Valve Actuator B120042 Pressure Operated Actuator 100012 BMCS-100 Nitrogen Cylinder 486676 Mounting Bracket 486487 BMCS-700S Discharge Adapter Kit 844921 Check Valve 259404 Vent Check 877810 Replacement Receiver Gasket (for BMCS-100 Actuator Assembly) 263413 QUIK-SEAL™ AND COMPRESSION SEAL ADAPTERS Compression Seal Adapter — 3/8 in. Tubing 26504601 Compression Seal Adapter — 1/2 in. Tubing / 1/4 in. Pipe 26504602 Compression Seal Adapter — 5/8 in. Tubing / 3/8 in. Pipe 26504603 Compression Seal Adapter — 3/4 in. Tubing / 1/2 in. Pipe 26504605 Compression Seal Adapter — 1/2 in. EMT 26504604 QUIK-SEAL™ ADAPTERS Quik-Seal Adapter — 3/8 in. NPT Female 26499301 Quik-Seal Adapter — 1/2 in. NPT Female 26499302 Quik-Seal Adapter — 3/4 in. NPT Female 26499303 Quik-Seal Adapter — 1 in. NPT Female 26499304 Quik-Patch™ (for Hole Patching up to 1-1/8 in. Diameter) 26499305 ELECTRIC COMPONENTS Circuit Monitor 12 Vdc 844533 Circuit Monitor 24 Vdc 844534 Circuit Monitor 120 Vdc 844535 VALVE SPARE PARTS Valve Assembly B120009 Table 6-1. Parts List (Continued) Parts List P/N 9127100 6-5 January 2007 VALVE SPARE PARTS (continued) Replacement Gauge 118031 Valve Rebuild Kit, includes (1) 877343 Valve Stem with 64350006 O-Ring attached (1) 217768 Valve Spring (1) 253299 Valve Spring Retainer (1) 18490004 Retaining Ring Check (1) 56610327 O-Ring, Valve to Cylinder B120067 Fusible Plug 257754 Valve Outlet Anti-Recoil Plate 255681 Protection Plate (for Valve Top)255096 SYSTEM SPARE PARTS In-line Kit for Remote Manual Release P/N 9197463 B100030 Valve Body Assembly, A+9197210 Cable Tensioning Block, A+9197220 O-Ring, Puncture Stem, A+1419239 Flat Gasket, Valve Body, A+9197213 Check Valve for Pneumatic Actuator P/N 87-100012-001 118146 Strap for 125, 260, 400M Bracket 255700 Strap for 400S Bracket, 600 Shelf Bracket 117989 Seal Wire 15262 Fan Caution Decal 282726 Decal (for P/N B875572 Manual Release) 261154 Backplate (for P/N B875572 Manual Release) 277088 O-Ring (for Discharge Adapter Kit) - Minimum 10 pieces 108019000 Fuse (for P/N B899175 Electric Control Heads) 64490024 Replacement Cable Block and Set Screw Assembly for Gas Valves 100014 INSTALLATION TOOLS AND RECHARGE EQUIPMENT Nitrogen Cartridge for Badger UCH Control System B120043 Test Cartridge for Badger UCH Control System B120044 Keeper Pin (UCH Control System and A+)9197108 UCH Valve Rebuild Kit B120046 CO2 Cartridge for A+235557 Positive Action Crimp Tool 253538 Badger Mechanical Control Head Test Fixture 281578 Tensioning Tool, Badger Mechanical Control Head 255003 Recharge Adapter 279262 Hydrostatic Test Adapter 878453 Replacement Label for RG-125 231866 Table 6-1. Parts List (Continued) Parts List January 2007 6-6 P/N 9127100 INSTALLATION TOOLS AND RECHARGE EQUIPMENT (continued) Replacement Label for RG-260 06-231866-179 Replacement Label for RG-400S 06-231866-180 Replacement Label for RG-400L 06-231866-181 Replacement Label for RG-600 06-231866-182 Inlet Flushing Adapter, RG 60-9197086-000 Outlet Flushing Adapter, 3/8 in. RG 60-9197090-000 Outlet Flushing Adapter, 1/2 in. RG 60-9197091-000 1.25 Gallon Karbaloy® Wet Chemical Recharge Container 9197428 2.60 Gallon Karbaloy® Wet Chemical Recharge Container 9197257 4.0 Gallon Karbaloy® Wet Chemical Recharge Container 9196991 6.0 Gallon Karbaloy® Wet Chemical Recharge Container 9196783 MANUALS Wet Chemical System Instruction Manual (Karbolay) 60-9127100-000 Wet Chemical System Owner’s Manual (Karbolay) B120040 Table 6-1. Parts List (Continued) Electrical Detection Installation (Detect-A-Fire®) P/N 9127100 A-1 January 2007 APPENDIX A ELECTRICAL DETECTION INSTALLATION (DETECT-A-FIRE®) A-1 INTRODUCTION DETECT-A-FIRE® thermal detectors are UL Listed (available upon request), and FM Approved detection and release devices used with fire detection systems to activate alarms and actuate extinguishing systems. This Rate Compensated device combines the best features of both fixed temperature and rate-of-rise detectors. 1 Although incandescent lamps are considered resistive, their inrush current is 10 - 15 times their steady current. Do not exceed ratings. A-2 LOCATION DETECT-A-FIRE® Units are precision temperature sensors. They must be mounted in an area (normally a ceiling) so that: 1. The detector spacing complies with both system requirements and requirements of the local Agency Having Jurisdiction. 2. The thermal air path to the shell is not obstructed. Spacing per UL, and FM is shown in Table A-2. Distances given are for between units on smooth ceilings. Distances from partitions or walls are half that shown. To assure that all spacing requirements are met, consult the local Authority Having Jurisdiction. A-3 MOUNTING Detect-A-Fire units are not position sensitive. Horizontal and vertical detectors refer to the most common mounting configuration for that unit. However, each type can be mounted either horizontally or vertically depending on the application and installation requirements. Table A-1. Electrical Rating Model Number Contact Operation on Temperature Rise Electrical Rating1 (Resistive Only) 27120 Opens (450° F Max.)5.0 Amps 125 Vac 0.5 Amps 125 Vdc28020 27121 Closes 5.0 Amps 125 Vac 0.5 Amps 125 Vdc 2.0 Amps 24 Vdc 1.0 Amps 48 Vdc 28021 Electrical Detection Installation (Detect-A-Fire®) January 2007 A-2 P/N 9127100 Note:For clean agents and CO2 suppression systems, ceiling spacing 20 ft. (6.1 m) apart unless otherwise specified. Not all units are suitable for all hazard location applications. Refer to Table A-3 and markings on the detector for hazardous location suitability. 2 Division 1 and 2. Table A-2. Detect-A-Fire Spacing Setting Tolerance SPACINGS (in feet) Color Coding 140°F ±7/-8°F 50 50 25 Black 160°F ±7/-8°F 25 25 25 Black 190°F ±7/-8°F 50 50 25 White 210°F ±7/-8°F 25 50 25 White 225°F ±7/-8°F 25 50 25 White 275°F ±10°F 25 50 25 Blue 325°F ±10°F 50 50 25 Red 360°F ±10°F 25 50 25 Red 450°F ±15°F 25 50 25 Green 500°F ±15°F 50 50 25 Orange 600°F ±20°F N/A 50 25 Orange 725°F ±25°F N/A 50 25 Orange Table A-3. Hazardous Location Applications Hazardous Location Model Number Fittings Required for UL Listings and FM Approval Class I2, Groups A, B, C, and D; Class II2, Groups, E, F, and G 27120-22 27121-20 28020-3 28020-5 Mount detector to a suitably-listed fitting in accordance with National Electric Code and/or Local Authority having Jurisdiction. Class I2, Groups B, C, and D; Class II2, Groups, E, F, and G 27120-0 27121-0 28021-0 UL® Electrical Detection Installation (Detect-A-Fire®) P/N 9127100 A-3 January 2007 A-4 INSTALLATION Heat detectors are to be installed in an anticipated path of convective heat flow from the fire, and spaced at a maximum on-center distance of 20 ft. (6.1 m) for ceiling heights up to 10 ft. (3.7 m) (refer to Chapter 3). The electrical wire from the UCH Control System or the A+ Control Box to the Control Panel must be protected by 1/2-inch EMT (minimum). When the Heat Detector locations have been selected, mount the units as specified in the following sections. A-4.1 Ceiling Locations 1. It is recommended that standard 4-inch octagonal outlet boxes be used to mount detectors. Use explosion-proof conduit boxes, if necessary. 2. Attach detector to the 4-inch. round outlet box cover through the 7/8-inch diameter hole using 1/2-14 NPT retainer nut. The heat detector maximum torque values are: –20 foot-pounds – 27.1 Newton-meters 3. Connect system wiring to detector, observing spacing requirements and applicable electrical codes. 4. Apply RTV sealing compound around the end of the heat detector to which the wires are attached. 5. If moisture is present, you must use a moisture proof box. Mount detector and box cover to box using #8-32 screws. Series 28000 units are similar to Series 27100 units except they have two 1/2-14 NPT threads for mounting. The unit may be mounted as described above or may be threaded into a 1/2-14 NPT tapped hole in the vessel wall or threaded into a coupling brazed or welded to the vessel wall. Note:Wire the Heat Detectors to the listed fire control panel as indicated in an approved wiring diagram. A-4.1.1 ORDINARY LOCATIONS The DETECT-A-FIRE Units are to be installed in grounded metallic junction boxes only. They are to be secured to the boxes using two lock nuts, one on either side of the mounting plate. DETECT-A- FIRE Units are not to be installed in non-metallic junction boxes. WARNING It is likely that industrial applications involving flammable or combustible liquids will be enclosed within or surrounded by areas that will be classified as Class-I or Class-II, Division-1 or Division-2 locations (Zone 1 or Zone 2). Wet Chemical system electrical components, such as heat detectors, located within these areas shall be rated for use in classified areas, and all wiring to these components shall conform to the provisions of NFPA 70, National Electrical Code, for Class-I or Class-II, Division-1 or Division-2 locations (Zone 1 or Zone 2). Failure to follow these instructions could result in death or serious personal injury and/or property damage. Electrical Detection Installation (Detect-A-Fire®) January 2007 A-4 P/N 9127100 A-4.1.2 HAZARDOUS LOCATIONS For Class I, Division 1 and 2 locations, install the DETECT-A-FIRE Unit in a listed explosion-proof enclosure with a minimum thread engagement of five full turns. No non-conductive material is to be placed on the threaded joint of the DETECT-A-FIRE Unit or in the listed explosion-proof enclosure. For Division 2 locations, assure that a protective ground terminal is provided in the listed explosion- proof enclosure when flexible metal conduit is used. Figure A-1. Mounting a Detect-A-Fire 1-1/2 in. (38 mm) 4-3/16 in. APPROX. (106 mm) 2-15/16 in. (75 mm) 5/8 in. (16 mm) 3/8 in. (10 mm) THERMOSTAT SENSING ELEMENT STAINLESS STEEL SHELL CONDUIT BOX (NOT SUPPLIED) THREE 1/2 in. (13 mm) PIPE WASHERS CONDUIT LOCKOUT 5 in. (127 mm) LONG LEADS CONTACT RATING 5 AMP - 125 VAC 1/2 AMP - 125 VDC 1/2 in. (13 mm) I.P.S. THREAD DETECTOR 1/2 in. 14 N.P.T. RETAINER NUT 4 in. (102 mm) OCTAGONAL OUTLET BOX 4 in. (102 mm) ROUND BOX COVER 7/8 in. (22 mm) DIA. HOLE 1/2-14 N.P.T. SERIES 27120 AND 27121 DETECT-A-FIRE 1-1/2 in. (38 mm) 4-3/16 in. APPROX. (106 mm) 2-15/16 in. (75 mm) 5/8 in. (16 mm) 3/8 in. (10 mm) THERMOSTAT SENSING ELEMENT STAINLESS STEEL SHELL CONDUIT BOX (NOT SUPPLIED) THREE 1/2 in. (13 mm) PIPE WASHERS CONDUIT LOCKOUT 5 in. (127 mm) LONG LEADS CONTACT RATING 5 AMP - 125 VAC 1/2 AMP - 125 VDC 1/2 in. (13 mm) I.P.S. THREAD DETECTOR 1/2 in. 14 N.P.T. RETAINER NUT 4 in. (102 mm) OCTAGONAL OUTLET BOX 4 in. (102 mm) ROUND BOX COVER 7/8 in. (22 mm) DIA. HOLE 1/2-14 N.P.T. SERIES28020AND 28021 DETECT-A-FIRE Electrical Detection Installation (Detect-A-Fire®) P/N 9127100 A-5 January 2007 A-4.1.3 NON-HAZARDOUS OUTDOOR LOCATIONS Mount the DETECT-A-FIRE in a listed NEMA Type 3 outlet box, cover and conduit, with 1/2-14 NPT threads and a minimum thread engagement of five full turns. Use of pipe plugs with RTV silicon rubber sealant, a rubber gasket, and self-sealing screws to attach the cover, and PTFE thread seal tape on the DETECT-A-FIRE threads should be appropriate for outdoor applications and in accordance with the National Electric Code and/or Authority Having Jurisdiction. A-4.2 Duct Applications 1. Drill a 1-1/4-inch (32 mm) hole at each selected location. 2. It is recommended that standard 4-inch octagonal outlet boxes be used to mount detectors. Use explosion-proof conduit boxes, if necessary. Mount the conduit box securely to the outside of the duct so that the heat detector tube extends into the duct. 3. Attach the detector to the 4-inch round outlet box cover through the 7/8-inch diameter hole using 1/2-14 NPT retainer nut. 4. Connect the system wiring to the detector, observing spacing requirements and applicable electrical codes. 5. If moisture is present, you must use a moisture proof box. Apply RTV sealing compound around the end of the heat detector to which the wires are attached. 6. Mount the detector and box cover to the box using #8-32 screws. 7. Wire the Heat Detectors to the Listed fire control panel as indicated in an approved wiring diagram. Note:All electric fittings inside of the protected area (work area, plenum/pit/tunnel and exhaust duct) shall be Class I or II, Division I or II (Zone 1 or 2) rated electrical boxes, pipe and fittings. Table A-4. Non-Hazardous Outdoor Locations Model Number °F Temperature Settings Fittings Required for UL Listings and FM Approval 27120-0 27120-22 27121-0 27121-20 140, 160, 190, 225 Mount detector to a fitting suitable for outside use (NEMA Type 3), in accordance with National Electric Code and/or Authority Having Jurisdiction. Electrical Detection Installation (Detect-A-Fire®) January 2007 A-6 P/N 9127100 A-4.3 Field Wiring Requirement Field wiring must be capable of withstanding the maximum anticipated ambient temperature in the application. Figure A-2. System Wiring 2 WIRE 4 WIRE TO ALARM AND MONITORING PANEL TO ALARM AND MONITORING PANEL END OF LINE DEVICE (CURRENT LIMITING)*SUPPLIED BY CUSTOMER 27121, 28021 SERIES (NORMALLY OPEN) TYPICAL FIRE ALARM SYSTEM METHOD 2 WIRE 27120, 28020 SERIES (NORMALLY CLOSED) TYPICALSECURITY SYSTEM METHOD Electrical Detection Installation (Detect-A-Fire®) P/N 9127100 A-7 January 2007 A-5 FUNCTIONAL TEST When used with automatic fire extinguishing systems first disconnect the initiator/solenoid leads from the panel and connect a 24 Vdc bulb to initiator terminals in the control unit. Heat the DETECT- A-FIRE units with a heat lamp or other convenient source. When the bulb in the control unit changes state, remove heat source and allow DETECT-A-FIRE unit to cool. Reset control unit. Test lamp must change state and stay changed after system is reset. Do not reconnect initiator/solenoid leads until all DETECT-A-FIRE units have cooled below set point as indicated by test lamp. When DETECT-A-FIRE units are used in other types of systems, disconnect them from the system, connect a 24 Vdc lamp and power source in series with the DETECT-A-FIRE units and test with heat source as above. Make sure that contacts have reset to normal condition before reconnecting to system circuit. It is possible for a unit to have been abused or damaged and not display any outward indication of the damage. All units should be tested periodically in accordance with National Fire Protection Association requirements (72) or the local Agency Having Jurisdiction. CAUTION 1. In order to function properly, the sensing shell of the unit must remain free from paint, grease, oil, etc. Should such a build up occur, do not, under any circumstances, attempt to remove it. Replace the unit. 2. Detectors mounted in an area subject to physical abuse or damage, other than above, must be suitably protected without obstructing the thermal air path to the unit. 3. Do not install the unit where the shell would be physically damaged by sand, grain, rocks, etc. 4. Do not overtorque the unit when installing. 5. Any detector that has been abused or damaged must be replaced. 6. Consult the factory for special precautions necessary for outdoor use or moist environments. Electrical Detection Installation (Detect-A-Fire®) January 2007 A-8 P/N 9127100 THIS PAGE INTENTIONALLY LEFT BLANK. These instructions do not purport to cover all the details or variations in the equipment described, nor do they provide for every possible contingency to be met in connection with installation, operation and maintenance. All specifications subject to change without notice. Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser’s purposes, the mat- ter should be referred to Badger Fire Protection, Charlottesville, VA Badger Fire Protection 4251Seminole Trail Charlottesville, VA 22911 Phone: (800) 446-3857 Fax: (800) 248-7809 Kidde Canada 130 Esna Park Drive Markham, Ontario L3R IE3 Phone: (905) 940-8080 A UTC Fire & Security Company 60-9127100-000 Rev. BB ©2007 Badger Fire Protection Printed in U.S.A.