co2 operation & installation.pdf

Issue B December 2004 Manual No 59812-400

High PressureCarbon DioxideFire Protection Equipment

INSTALLATION,COMMISSIONING &MAINTENANCE MANUAL

K.F.P.S. Ltd December 2004 Manual No 59812-400

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PROPRIETARY RIGHTS NOTICE

This document and the information that it contains are the property of Kidde Fire Protection. Rights toduplicate or otherwise copy this document and rights to disclose the document and the informationthat it contains to others and the right to use the information contained therein may be acquired onlyby written permission signed by a duly authorised officer of Kidde Fire Protection.

Copyright Kidde Fire Protection Services Ltd.


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TABLE OF CONTENTS

Chapter Page

FOREWORD.........................................................................................................11 GENERAL....................................................................................................2

1.1 SAFETY PRECAUTIONS ....................................................................21.2 PRELIMINARY CHECKS.....................................................................3

PART 1 INSTALLATION......................................................................................42 CO2 CYLINDERS AND RACKING...............................................................4

2.1 CO2 CYLINDERS .................................................................................42.1.1 Klem Cylinder Valves K23521 and K24509.............................5

2.2 INSTALLATION....................................................................................62.2.1 Single Cylinder ........................................................................62.2.2 Single Row Cylinders ..............................................................72.2.3 Double Row Cylinders .............................................................8

3. CO2 MANIFOLD PIPE ................................................................................103.1 MANIFOLD BRACKETS, SINGLE ROW ...........................................113.2 MANIFOLD BRACKETS, DOUBLE ROW..........................................11

4. DISTRIBUTION PIPING.............................................................................124.1. PIPING...............................................................................................124.2 ELECTRICAL CLEARANCES............................................................154.3 INSTALLATION..................................................................................16

5. PRESSURE OPERATED DIRECTION VALVES .......................................175.1 TO 2 INCH POD VALVES..............................................................18

5.1.1 Pressure Operation ...............................................................195.1.2 Manual Operation ..................................................................195.1.3 Valve Open Indication ...........................................................19

5.2 3 AND 4 INCH POD VALVES ............................................................205.2.1 Pressure Operation ...............................................................215.2.2 Manual operation...................................................................215.2.3 Valve Open Indication ...........................................................21

5.3 3 AND 4 INCH COMPANION FLANGE, BOLTS AND GASKET........225.4 SAFETY OUTLETS K 921 AND K22968 ..........................................235.5 INSTALLATION..................................................................................26


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6. DISCHARGE LOOPS K21578 AND K97112.............................................276.2. RIGID DISCHARGE LOOP K21578...................................................276.2 FLEXIBLE DISCHARGE LOOP K97112............................................286.3 INSTALLATION..................................................................................29

7. SYSTEM ACTUATOR ASSEMBLY...........................................................307.1 NITROGEN PILOT GAS CYLINDER AND VALVE ............................317.2 OPTIONAL PRESSURE MONITORING SWITCH.............................327.3 CONTROL HEAD K62303 .................................................................337.4 CONTROL HEAD WITH SWITCHES K62304 ...................................347.5 CONTROL HEAD MOUNTING BRACKET K62487 ...........................357.6 SAFETY AND RESET PIN K62401 ...................................................36

Retain reset pin in safe location for future use. ..................................367.7 INSTALLATION..................................................................................37

8. CONTROL HEAD ACTUATING DEVICES................................................398.1 MANUAL PUSH-TO-FIRE BUTTON K62412.....................................408.2 SOLENOID ACTUATORS K62422B AND K93206/AX ......................418.3 FLAMEPROOF 24V D.C SOLENOID K93206/AX .............................428.4 INSTALLATION..................................................................................43

8.4.1 Standard Solenoid .................................................................438.4.2 Flameproof Solenoid .............................................................448.4.3 Control Head and Solenoid Wiring ........................................458.4.4 Special Instructions to comply with 94/9/EC (ATEX) .............46

8.5 PNEUMATIC DIAPHRAGM ACTUATOR K62459 .............................478.6 PNEUMATIC BREATHER VENTS K62895 .......................................488.7 INSTALLATION..................................................................................498.8 CABLE RELEASE ASSEMBLY K62478 ............................................49

8.8.1 Installation .................................................................................508.9 PULL BOX K 1114 .............................................................................52

8.9.1 Corner Pulley K 1122 ................................................................538.9.2 Installation .............................................................................53

9. CYLINDER VALVE PRESSURE/LEVER ACTUATOR K62341 ................559.1 INSTALLATION..................................................................................56

10. PILOT GAS FLEXIBLE LOOPS K93433 and K93434 ..............................5710.1 PILOT GAS VENT K24051 ................................................................5710.2 PILOT GAS RIGID TUBING AND FITTINGS.....................................5910.3 INSTALLATION..................................................................................61

11. TIME DELAY UNIT K23650 .......................................................................62


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11.1 INSTALLATION..................................................................................6311.2 TESTING............................................................................................6311.3 TIME DELAY BY-PASS VALVE K60736 ...........................................67

12. CO2 OPERATED PRESSURE SWITCH K60218 .......................................6912.1 INSTALLATION..................................................................................71

13. CO2 OPERATED PRESSURE TRIP K17554 .............................................7213.1 INSTALLATION..................................................................................73

14. CO2 DISCHARGE NOZZLES.....................................................................7414.1 MULTIJET NOZZLE K61792 AND K61793........................................7414.2 FLANGED MULTIJET NOZZLE K5814..............................................7514.3 FLANGED NOZZLE DUCT ADAPTORS K61420A-D ........................7614.4 DUCT NOZZLE K13045.....................................................................7714.5 FAN TYPE NOZZLE K6490 ...............................................................78

15. PNEUMATIC DETECTION - HEAT ACTUATED DEVICES ......................7915.1 PNEUMATIC RATE OF RISE DETECTOR K18724 ..........................7915.2 PNEUMATIC FIXED TEMPERATURE DETECTOR K18689.............8015.3 PNEUMATIC CHECK UNIT K24412..................................................8115.4 PNEUMATIC LOCK-OFF UNIT K24300 ............................................8215.5 BELLOWS AND MICROSWITCH ASSY K20057 ..............................8315.6 PNEUMATIC CAPILLARY TUBE, CONDUIT AND FITTINGS...........8415.7 CO2 OPERATED SIREN K18307.......................................................85

16. ODORISER ASSEMBLY K62586 ..............................................................8617. CO2 WARNING LABELS ...........................................................................87PART 2 COMMISSIONING ................................................................................8918. COMMISSIONING......................................................................................89

18.1 VISUAL CHECKS ..............................................................................8918.2 MECHANICAL FUNCTION ................................................................90

18.2.1 General..................................................................................9018.2.2 Manual Push-to Fire ..............................................................9018.2.3 Pull Box .................................................................................9018.2.4 Pneumatic System.................................................................9118.2.5 Pressure/Lever Actuator and POD Valves ............................9618.2.6 Pressure Trip .........................................................................9618.2.7 Pressure Switch.....................................................................97

PART 3 MAINTENANCE....................................................................................9819. MAINTENANCE .........................................................................................98

19.1 PRELIMINARY CHECKS...................................................................98


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19.2 COMPONENT FUNCTION TESTS....................................................9919.2.1 General..................................................................................9919.2.2 Control Head .........................................................................9919.2.3 Pressure/Manual Release Heads and POD Valves.............10019.2.4 Pressure Trip .......................................................................10119.2.5 Pressure Switch...................................................................102

19.3 INSTRUCTIONS FOR COMMISSIONING THE SYSTEM AFTER ITSOPERATION....................................................................................102

PART 4 TERMS AND CONDITIONS................................................................10320. TERMS AND CONDITIONS.....................................................................103


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LIST OF ILLUSTRATIONSFigure PageFigure 1 CO2 Cylinder ................................................................................................4Figure 2 Klem Cylinder Valves ...................................................................................5Figure 3 Single Cylinder Racking ...............................................................................6Figure 4 Single Row Cylinders ...................................................................................7Figure 5 Additional Centre Racks for Two Rows of Cylinders ....................................9Figure 6 CO2 Manifold Pipes ....................................................................................10Figure 7 Manifold Brackets, Single Row...................................................................11Figure 8 Manifold Brackets, Double Row .................................................................11Figure 9 POD Valve System.....................................................................................17Figure 10 to 2 inch POD Valves ...........................................................................18Figure 11 Indicator Switch........................................................................................19Figure 12 3 & 4 inch POD Valves.............................................................................20Figure 13. 3 and 4 inch Companion Flange, Bolts and Gasket ................................22Figure 14 Safety Outlets ..........................................................................................23Figure 15 All CO2 Cylinders discharging to either space ..........................................24Figure 16 Two Spaces Requiring differing CO2 cylinders .........................................25Figure 17 Rigid Discharge Loop ...............................................................................27Figure 18 Flexible Discharge Loops .........................................................................28Figure 19 System Actuator Assembly ......................................................................30Figure 20 Nitrogen Pilot Gas Cylinder and Valves ...................................................31Figure 21 Pressure Monitoring Switch......................................................................32Figure 22 Control Head ............................................................................................33Figure 23 Control Head with Switches .....................................................................34Figure 24 Standard Mounting Bracket......................................................................35Figure 25 Safety and Reset Pin................................................................................36Figure 26 Control Head Mounting Bracket ...............................................................38Figure 27 Control Head Actuating Devices...............................................................39Figure 28 Manual Push-to-Fire Button .....................................................................40Figure 29 Standard 24V d.c Solenoid.......................................................................41Figure 30 Flameproof ATEX approved 24V d.c. Solenoid........................................42Figure 31 Control Head and Solenoid Wiring ...........................................................45Figure 32 Pneumatic Diaphragm Actuator ...............................................................47Figure 33 Pneumatic Breather Vents .......................................................................48Figure 34 Cable Release Assy .................................................................................49


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Figure 35 Cable Pull Ring Connection .....................................................................50Figure 36 Curvature of Cable ...................................................................................51Figure 37 Cable Release Assembly, Cover Removed .............................................51Figure 38 Pull Box ....................................................................................................52Figure 39 Corner Pulley ...........................................................................................53Figure 40 Cylinder Valve Pressure/Lever Actuator...................................................55Figure 41 Pilot Gas Flexible Loops...........................................................................57Figure 42 Pilot Gas Vent ..........................................................................................58Figure 43 Pilot Gas Rigid Tubing and Fittings ..........................................................59Figure 44 Single Cylinder Row Pilot Gas Operation.................................................61Figure 45 Double Cylinder Row Pilot Gas Operation ...............................................61Figure 46 Time Delay Unit........................................................................................62Figure 47 Single Protected Space System...............................................................64Figure 48 Two Protected Spaces System ................................................................65Figure 49 Two Protected Spaces Requiring Different CO2 Quantities ......................66Figure 50 Time Delay By-Pass Valve.......................................................................67Figure 51 Installation ................................................................................................68Figure 52 CO2 Operated Pressure Switch ................................................................69Figure 53 Pressure Trip............................................................................................72Figure 54 Installation ................................................................................................73Figure 55 Multijet Nozzle..........................................................................................74Figure 56 Flanged Multijet Nozzle ............................................................................75Figure 57 Flanged Nozzle Duct Adaptor ..................................................................76Figure 58 Duct Nozzle..............................................................................................77Figure 59 Fan Type Nozzle ......................................................................................78Figure 60 Pneumatic Rate of Rise Detector .............................................................79Figure 61 Pneumatic Fixed Temperature Detector...................................................80Figure 62 Pneumatic Check Unit..............................................................................81Figure 63 Pneumatic Lock-Off Unit ..........................................................................82Figure 64 Bellows and Microswitch Assembly..........................................................83Figure 65 Pneumatic Capillary Tube, Conduit and Fittings ......................................84Figure 66 CO2 Operated Siren..................................................................................85Figure 67 Odoriser Assembly ...................................................................................86Figure 68 Odoriser Check Valve ..............................................................................86Figure 69 Entrance Door Warning Label ..................................................................87Figure 70 Manual Control Point Label ......................................................................88Figure 71 Manometer Test System ..........................................................................91


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LIST OF TABLES

Table PageTable 1 CO2 Cylinder Specification............................................................................4Table 2 Closed and open ended pipework section High pressure systems..........12Table 3a Open Ended Pipework................................................................................13Table 3b Closed Section Pipework 13Table 4 Pipe Support Spacing.................................................................................14Table 5 Safety Clearances for Pipework .................................................................15

K.F.P.S. Ltd November 2004 Manual No 59812-400

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FOREWORDKidde Fire Protection recognises its responsibility to ensure that the products it manufactures are, as faras is reasonably practical, without risk to the health and safety of the users. The following informationshould be disseminated to all persons using such products.

The information is furnished in good faith based upon technical data and tests, which are believed to bereliable. Products undergo rigorous quality control checks during manufacture to ensure that theypresent no hazards in the use and application for which they are intended.

Technical data and literature which may assist customers in the discharge of their general duties areavailable on request. Should you require further information on this context please contact our salesoffice.

Nothing contained in this publication shall form part of any contract made between a customer andKidde Fire Protection.

It is of vital importance that the CO2 equipment should be correctly installed. The Installation Engineershould become fully conversant with the contract files and all installation drawings before going to site.


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1 GENERAL

1.1 Safety Precautions

Characteristics of Carbon DioxideCarbon Dioxide (CO2) at atmospheric pressure is a colourless, odourless and electrically non-conductinginert gas which is almost 1.5 times as dense as air.

CO2 extinguishes fire by reducing the oxygen content of the atmosphere to a point where it will not supportcombustion. Reducing the oxygen content from the normal 21% in air to 15% will extinguish most surfacefires, though for some materials a greater reduction is necessary. In some applications the cooling effect ofCO2 may assist extinction.

Hazards to personnelExposure to atmospheres containing about 5% CO2 leads to shortness of breath and slight headache. Atthe 10% level, headache, visual disturbance, ringing in the ears (tinnitus) and tremor are followed by loss ofconsciousness.

Fire extinguishing concentrations of CO2, which are normally in excess of 30%, especially near to the pointof discharge from total flooding or local application systems, carry a risk of almost immediate asphyxiation.The gas is also more dense than air and will drift and accumulate in low spaces, such as cellars, pits andfloor voids, which may be difficult to ventilate effectively.

The rapid expansion of large quantities of CO2 results in a substantial localised cooling of the installationand of the air surrounding the point of discharge. This can present a frostburn hazard.

Handling and storage of CO2 cylindersObserve the following precautions to prevent accidental discharge of CO2:

On despatch, all cylinder and valve assemblies are fitted with transport caps which must not be removeduntil after the cylinders have been securely restrained, store the transport caps for future use.

Never use the cylinder valve to turn or move the cylinder, this could cause damage or leakage: use atransport trolley.

Never store cylinders in direct sunlight or in location where the cylinder temperature is likely to exceed55C.


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Never depress the cylinder valve actuating pin as this action will open the valve and discharge its contentscausing the cylinder, unless securely restrained, to act as a projectile.

Never fit any release device to a cylinder valve until it has been secured in the cylinder rack and connectedto the discharge pipework.

Re-entry into a flooded areaNever enter an area after a CO2 discharge until it has been thoroughly ventilated to external atmosphere.

If it is necessary to enter an area containing CO2 always use self-contained Breathing Apparatus, never usea filter or canister type mask. As an added precaution the person entering should be tethered by a mannedlifeline.

Dismantling and modificationsIt is recommended that Kidde Fire Protection be notified of any intention to alter or extend the system orareas protected in order that advice be given of any effect that this may have on the original design.

1.2 Preliminary checks

Check that all equipment has been delivered, any damaged equipment must be replace.

Check that the area(s) to be protected agree with the installation drawings.

Check the CO2 cylinder location for ease of access during maintenance; also safety. Check that theambient temperature of the cylinder location complies with the following limitations: -

Total flooding systems: -18 to 55C.

Local Application flooding Systems: Minimum 0C Maximum 46C.


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PART 1 INSTALLATION2 CO2 CYLINDERS AND RACKING

2.1 CO2 Cylinders

CO2 is stored in solid drawn steel cylinders containing gas in liquid form equal to two thirds of its watercapacity. The pressure within the cylinder varies with changes in ambient temperature, increasing withrising temperature. At 21C the pressure is 58.6 bar.

The cylinder assembly comprises a cylinder, cylinder valve and rigid syphon tube which must ALWAYS beinstalled in an upright position.

Figure 1 CO2 Cylinder

Table 1 CO2 Cylinder Specification

Part No WaterCapacity(Litres)

Fill Weight(kg)

Total Weight(kg)

Dimension (mm)A B

E7194-001 67.5 45 120 Approx 267 1515K24069/FM 67.5 45 120 Approx 267 1531K24338 34.0 22.6 81 Approx 229 1102

NOTE: All dimensions B are 10mm

Cylinder Specification: 1999/36/EC (TPED)Material: SteelTest Pressure: 250 barFill Ratio: 0.661kg/litreStandard Point Finish: Red


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2.1.1 Klem Cylinder Valves K23521 and K24509

The Klem cylinder valve is a compact, horizontal servo-assisted valve which can be operated by eitherpressure or use of its integral manual lever.

The valve is opened by depressing the actuator rod by applying a force of between 23 and 27kg.

WARNINGThe valve will close immediately the force is removed from the actuator rod.

Each cylinder valve incorporates a safety disc designed to rupture and discharge the CO2 cylinder contentswhen the ambient temperature reaches approximately 60C (140F).

MaterialsBody: BrassSeals: Silicone Rubber Shore 70 - 90Actuator Rod: St. SteelSafety Burst Disc: Ruptures at 179 to 196 bar

Figure 2 Klem Cylinder Valves


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2.2 INSTALLATION

2.2.1 Single Cylinder

Storage containers should be located as near as possible to the hazard they protect, but should not beexposed to the fire in a manner that is likely to impair performance. They should not be exposed toweather conditions or put in a location where they can be subjected to chemical or other damage. Suitableguards or enclosures should be provided when necessary.

1. Offer strap up to a suitable structure or wall and mark the hole centres for drilling at an elevation fromground level, see in Figure 3.

2. Drill appropriate fixing holes.3. Place and clamp the container in position.

Part No Cyl Size Dim A FixingHoles

Materials Weight(kg)

K16896 6.8 175 9.5mm

1.0

K4881 22.6 292 10.5mm

Mild Steel 25mm x 3mm1.2

K62943 45.0 320 12.7mm

Nylon Dipped Black 1.5

Figure 3 Single Cylinder Racking


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2.2.2 Single Row Cylinders


1. Offer the cylinder back rack up to a suitable structure or wall and mark the hole centres for drilling atan elevation from the ground as shown in Figure 3. Check that the back rack is correctly offset inrelation to the manifold inlet. See Figure 4.

2. Drill appropriate fixing holes.

3. Fix the back rack to the suitable structure or wall using the bolts.

4. Place the cylinders in position against the cut-outs in the back rack.

5. Hook the rack bolts through the 17.5mm diameter hole(s) in the back rack.

6. Locate the straight end of the rack bolts through the 17.5mm diameter holes in the front strap andclamp the containers firmly in place using the nuts and washers supplied with the rack bolts.

Part No Material Finish Weight(kg)

2 Cylinder K17238 MS Angle Paint Black 1.8Steel BackRacks 3 Cylinder K17235 MS Angle Paint Black 2.7

2 Cylinder K13744 MS Strap 2.7Steel FrontStraps 3 Cylinder K13745 MS Strap

Nylon DippedBlack 4.5

Single Row Rack BoltAssembly

K62752 MS Rod Paint Black 0.4

Figure 4 Single Row Cylinders


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2.2.3 Double Row Cylinders


1. Offer the cylinder back rack up to the wall and mark the hole centres for drilling at an elevation fromthe ground as shown in Figure 5. Check that the back rack is correctly offset in relation to themanifold inlet. See Figure 5.

2. Drill appropriate fixing holes.

3. Fix the back rack a suitable structure or wall using the bolts.

4. Place the cylinders in position against the cut-outs in the back rack.

5. Slide the rack bolt through the wood centre rack and hook onto the back rack.

6. Place the front row of cylinders into position.

7. Place the front straps in position and clamp the cylinders firmly in position using the nuts andwashers supplied.


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45kg CylindersPart No Weight (kg)

2 Cylinder K24334 1.4Cylinder CentreRacks 3 Cylinder K24335 2.0Two Row Rack Bolt K62753 1.1Two Rack Special Rack Bolt K17327 0.7

22.6kg CylindersPart No Weight (kg)

2 Cylinder K22654 1.1Cylinder CentreRacks 3 Cylinder K22655 1.8Two Row Rack Bolt K17245 1.0Two Rack Special Rack Bolt K17327 0.7

Figure 5 Additional Centre Racks for Two Rows of Cylinders


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3. CO2 MANIFOLD PIPE

On multiple cylinder systems manifold pipes are supplied as a complete assembly including factoryinstalled check valves.

1 (25mm) NB Manifold 1 (32mm) NB Manifold

AssemblyPart No.

Number ofCylinders

Weight(kg)

AssemblyPart No.

Number ofCylinders

Weight(kg)

K21207 2 2.7 K21215 2 3K21209 3 3.9 K21217 3 4.5K21211 4 5.0 K21219 4 5.9K21213 5 6.3 K21221 5 7.3

Figure 6 CO2 Manifold Pipes


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3.1 MANIFOLD BRACKETS, SINGLE ROW

Dimension (mm)Part No Pipe SizeA B

Material - Finish Weight (kg)

K24267D 1 Mild SteelK24267E 1

101.6 174.5Painted Black

2.0

Figure 7 Manifold Brackets, Single Row

3.2 MANIFOLD BRACKETS, DOUBLE ROW

Dimension (mm)Part No Pipe SizeA B

Material - Finish Weight (kg)

K24268D 1 Mild SteelK24268E 1

101.6 479.4Painted Black

2.5

NOTE: Pipe Clips and Pipe Clip Bolts are supplied with the Brackets.

Figure 8 Manifold Brackets, Double Row


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4. DISTRIBUTION PIPING

All the pipework sizes shown in the schematic of the installation have been determined using a computerprogramme. It is IMPORTANT that these sizes are used to ensure the correct flow of CO2 within the stateddischarge time.

4.1. PIPING

1. The pipe and fittings materials must conform with the-requirements of BS 5306 Part 4 as shown inthe following tables.

Table 2 Closed and open ended pipework section High pressure systems

Closed section of pipeworkNominal pipe size Type of fitting Grade or Material Conforms to

WPA or WPB BS 3799:1974Forged steel, screwed,3000 lb ASTM A105N ANSI B16.11:1996

Up to and including 40mm

Wrought steel, buttwelded

WPA or WPB BS 1640-3:1968

WPA or WPB BS 3799:1974Above 40mm up to 50mm Forged steel, socketwelded, 3,000 lb ASTM A105N ANSI B16.11:1996

Open section of pipeworkNominal pipe size Type of fitting Grade or Material Conforms toUp to and including 20mm Screwed fittings Malleable iron BS EN

10242:1995a

Screwed fittings Wrought steel BS EN 10241:2000Up to and including 40mm

Wrought steel, buttwelded

WPA or WPB BS 1640-3:1968

WPA or WPB BS 3799:1974Forged steel, screwed,3000 lb ASTM A105N ANSI B16.11:1996

WPA or WPB BS 3799:1974

All sizes up to 150mm

Forged steel, socketwelded, 3,000 lb ASTM A105N ANSI B16.11:1996

a Fittings conforming to BS EN 10242 may be used on open section pipework greater than 20 mm provided that they aresuitable certified by the manufacturer for the anticipated pressure


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Table 3a Open Ended Pipework

BS1387 BW - HeavyBS 3601 S 430BS 3601 ERW 430BS 3601 BW 320 or 430BS 3602-1 HFS or CFS 360 or 430API 5L S or ERW B

Up to & incl 40mm

ASTM A106-77 HF or CD A or B

Schedule 40

BS 3601 S 430BS 3601 ERW 430BS 3602-1 HFS or CFS 360 or 430ASTM A106-77 HF or CD A or B

Over 40mm up to & incl50mm

API 5L S or ERW B

Schedule 80

* AbbreviationsHF Hot Finished CFS Cold Finished SeamlessCD Cold Drawn HFS Hot Finished SeamlessS SeamlessERW Electric Resistance Welded & Induction Welded

Flange bolts, studs, nuts and washers

Bolts and studs shall conform to BS EN 1515-1. Nuts shall conform to BS EN 1515-1. Washers shallconform to BS 3410 or BS 4320NOTE: Plain washers should be fitted under bolt head and nut. A minimum of two threads should project above the nut when fullytightened

Gasket for flanged joints

Flanges joints shall be fitted with a gasketCOMMENTARY AND RECOMMENDATIONS ON 19.4: The recommendation of the gasket manufacturer should be followed inselecting the grade, specification and thickness to be used.

Table 3b Closed Section Pipework

High pressure carbon dioxide systems

Nominal pipe size Conforms to Type of Pipe a Grade of steel Minimum wall thickness b

BS 3601 S 430

BS 3602-1 HFS or CFS 430

ASTM A106-77 HF or CD B

Up to and including40mm

API 5L S or ERW B

Schedule 40 (schedule80 for joints)

BS 3602-1 HFS or CFS 430

ASTM A106-77 HF or CD B

50mm and above

API 5L S or ERW B

Schedule 80

a For abbreviations see footnote to Table 3 on previous pageb Schedule numbers determine the minimum wall thickness in accordance with BS 1600. Where the specified pipe is notobtainable in these dimensions, the next largest thickness should be used.


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NOTE: Crosses must not be used.

2. All pipe and fittings shall be galvanised inside and out.

3. Screwed threads shall comply with the dimensions specified in BS21.

4. Use PTFE pipe tape on all pipe screw threads (or other approved thread sealant).

5. The pipework MUST BE FIRMLY SUPPORTED because, in the event of a fire, the discharge willimpose a force on the pipework. If the piping became dislodged, considerable damage could becaused and the extinguishing system may not function correctly. Allowance must be made forexpansion and contraction of the pipework. See Table 4 for the minimum recommended pipe supportspacing.

Table 4 Pipe Support Spacing

Pipe Size (mm) 15 20 25 32 40 50 80 100 150Max Spacing (m) 1.5 1.8 2.1 2.4 2.7 3.4 3.7 4.3 5.2


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4.2 ELECTRICAL CLEARANCES

Where exposed electrical conductors are present, clearance no smaller than those given in Table 5 shallbe provided where practicable, between the electrical conductors and all parts of the CO2 system that maybe approached during maintenance, where these clearance distances cannot be achieved, warning noticesshall be provided and a safe system of maintenance work shall be adopted.

Minimum clearance from any point on or about the permanent equipment where a man may be required tostand (measured from position of the feet)

Table 5 Safety Clearances for PipeworkTo the nearestunscreened liveconductor in air(section clearance)

Metres 2.59 2.59 2.74 2.74 2.89 3.05 3.20 3.35 3.50 3.81 4.27 4.57To the nearest partnot at earth potentialof an insulatorsupporting a liveconductor ('groundclearance')

Metres 2.44Max rated Voltage(XY) 11 15 22 33 44 66 88 110 132 165 220 275

The term insulator includes all forms of insulating supports, such as pedestal and suspension insulators,bushings, cable sealing ends and the insulating supports of certain types of circuit breaker etc.

IMPORTANT: See qualifying notes of clause 34 and definitions 30 and 31 of BS 7354: 1990 fromwhich this table is taken.


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4.3 INSTALLATION

Piping is normally supplied to site in random lengths. Installation of this pipework must be carried out inaccordance with the site fabrication drawings.

Table 5 shows recommended clearances to enable operation, maintenance and repair work to be carriedout safely.

NOTE: All dirt, swarf and cutting oil must be removed from each section of pipe beforeinstallation. CO2 pressure will remove any debris and may deposit it on valuableequipment.

Before installation of any pipework check the following:

(a) That all screw threads are clean and free of any damage.

(b) That all flange faces are clean and free of any damage.

(c) That pipe bores are clean and unobstructed.

(d) The route of the piping. Make sure that it is possible to fix the piping securely on the wall and in theceiling and floor voids.

(e) That none of the pipe fittings have been used before because of the risk of distortion.

NOTE: Use PTFE pipe tape on all pipe screw threads. (Or other approved thread sealant).

To install the pipework, carry out the following procedure:

(a) Mark the positions of the supports and hangers.

(b) Drill the wall or ceiling and install the required quantity of rawbolts or anchor bolts to suit the type ofsupport being used.

(C) Install a pipe hangar or clip adjacent to each nozzle in order to prevent movement of the nozzlesduring discharge.

(d) All CO2 pipework should be painted signal red to BS 381C ref 537 (equivalent to BS 4800 Ref04E53)

(e) All exposed metalwork in CO2 systems shall be efficiently earthed to prevent the metal workbecoming electrically charged.


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5. PRESSURE OPERATED DIRECTION VALVES

When two or more areas are to be protected using a central bank of CO2 cylinders, a Pressure OperatedDirection (POD) valve is installed in each of the CO2 main feed pipes leading to the designated areas, seeFigure 9.

Figure 9 POD Valve System


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5.1 to 2 INCH POD VALVES

PartNumber

Size(inch)

WithSwitch

Dimension mmA

Dimension mmB

Weight(kg)

K24004 NO 171 117 3.4K24628 YES 216 117 3.5K24005 1 NO 171 100 3.2K24629 1 YES 216 100 3.3K24175 1 NO 210 156 5.7K24630 1 YES 255 156 5.8K24176 1 NO 210 137 5.4K24631 1 YES 255 137 5.5K24177 2 NO 295 191 17.0K24632 2 YES 340 191 17.1

Figure 10 to 2 inch POD Valves


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5.1.1 Pressure Operation

Application of Nitrogen pilot gas to the pilot gas inlet port depresses the valve piston. When the valve pistonis at the bottom of its stroke a pilot gas outlet port is uncovered thus allowing the pilot gas to be conveyed,by the pilot gas line, to the CO2 cylinder pressure release heads.

NOTE: The valve remains open until the pilot gas pressure is vented from the pilot gas line.

5.1.2 Manual Operation

Remove the safety pin and operate lever fully.

NOTE: The valve can be opened while subjected to CO2 pressure.

5.1.3 Valve Open Indication

The indicator switch provides means for operating audible/visual alarms to give warning of a partial or fullyopen valve.

Figure 11 Indicator Switch


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5.2 3 and 4 INCH POD VALVES

Dimension (mm)PartNumber

Sizeinch

WithSwitch A B C

FlangeFixing Holes

Weight(kg)

K24775 3 YES 330 292 2038-EQUI spaced21mm Dia On165mm PCD

43.3

K24777 4 YES 406 340 2418-EQUI spaced25 mm Dia On197mm PCD

69.5

Figure 12 3 & 4 inch POD Valves


21

5.2.1 Pressure Operation

Application of Nitrogen pilot gas to the pilot gas inlet port lifts the valve piston. When the valve piston is atthe top of its inlet stroke an outlet port is uncovered thus allowing the pilot gas to be conveyed, by the pilotgas line, to the CO2 cylinder pressure release heads.

NOTE: The valve remains open until the pilot line is depressurised.

5.2.2 Manual operation

Turn the hand wheel fully anti-clockwise to open the valve.

NOTE: The valve can be opened while subjected to CO2 pressure.

5.2.3 Valve Open Indication

The indicator switch provides means for operating audible/visual alarms to give warning of a partial of fullyopen valve, see Figure 11.


22

5.3 3 and 4 INCH COMPANION FLANGE, BOLTS AND GASKET

Dimension (mm)PartNumber

Sizeinch A B C

Bolt PartNumber

Weight

K60103 3 203 165 32 K60101 7 kgK60104 4 241 197 35 K60102 8.5 kg

NOTE: Use Gasket K60105 (3) or K60106 (4)

Figure 13. 3 and 4 inch Companion Flange, Bolts and Gasket


23

5.4 SAFETY OUTLETS K 921 and K22968

On systems employing normally closed directional/stop valves there is a possibility of CO2 entrapment inpipework between the CO2 cylinders and the valves therefore a safety outlet must always be fitted. Theindicator sleeve is blown-off when the disc ruptures giving a visual indication of operation.

WARNINGTHESE DEVICES SHOULD BE FITTED SO THAT THE DISCHARGE IN THE EVENT OF OPERATIONWILL NOT INJURE OR ENDANGER PERSONNEL, IF NECESSARY THE DISCHARGE SHOULD BEPIPED TO AN AREA WHERE IT WILL NOT BECOME A HAZARD TO PERSONNEL (AS PER THEREQUIREMENTS OF BS 5306 part 4).

K 921 K22968

Figure 14 Safety Outlets

K 921 Specification: K22968 Specification:

Burst/Opening Pressure: 150 bar 5% 126 barMaterial: Brass BrassFinish: Natural NaturalWeight: 0.35 kg 0.8 kg

Figures 15 and 16 show the Nitrogen pilot gas installation requirements for opening the pressure operateddirection valve prior to operation of the CO2 cylinders.


24

Figure 15 All CO2 Cylinders discharging to either space


25

Figure 16 Two Spaces Requiring differing CO2 cylinders


26

5.5 INSTALLATION

Before installation of POD valves check the following:

1. All screw threads are clean and free of any damage.

2. If using a flanged valve check that all flanges are clean and free of damage.

3. That all flange bolt holes on the valve align with the flange bolt holes on feed pipe.

4. With the Safety Lock pin removed check that the indicator switch clicks into operation.

After the checks have been carried out satisfactorily install the POD valve as follows:-

1. Install the POD valve in the main feed line at a position where access for manual operation ofmaintenance/service is unhindered by other obstacles. Where possible install the POD valve at aheight of approximately (1.5 meters) 5- 0 (maximum). Make sure that the arrow shown on the valvebody to indicate the direction of flow faces away from the CO2 manifold.

2. Connect a nipple and socket union to the outlet side of the POD valve for ease of installation to themain CO2 feed line.

3. Use PTFE pipe tape on all screwed pipe fittings.

4. To prevent accidental discharge of fire fighting systems during installation work check the followingbefore connecting the pilot gas lines:

(i) That the Safety and Reset pin is screwed fully home in the control head.

(ii) That all safety pins are fully inserted in the cylinder release heads, and POD valves.

5. Using 3/16 bundy tubing and fittings, see Figure 44, connect the Nitrogen pilot cylinder valve to thepilot gas inlet port of the POD valves and from the POD valve gas outlet port to the CO2 cylinderpressure release head as shown in Figure 15 and 16.

NOTES

1. Clip the bundy tube to the wall at approx 457mm centres.

2. to 2 inch POD valves require adaptors K90220 and K90219 fitted in the pilot gas inlet port andadaptor K90219 fitted to the pilot gas outlet port. See Datasheet 841-5036

3. 3 and 4 inch POD valves require adaptor K90219 fitted to both inlet and outlet pilot gas ports.

6. A POD valve indicator switch, if fitted, must be wired as shown in Figure 11.


27

6. DISCHARGE LOOPS K21578 AND K97112

6.2. RIGID DISCHARGE LOOP K21578

The discharge loop is used to convey CO2 from the gas outlet of the cylinder valve to the check valvemanifold above the cylinders.

Figure 17 Rigid Discharge Loop

Materials:Tube: 12.7mm x 18 SWG Annealed.Material: CopperCoupling Nuts: BrassThread: W21.8 x 1/14 DIN 477. 30.5mm A/FTest Pressure: 152 Bar ApproxWeight: 0.3kg


28

6.2 FLEXIBLE DISCHARGE LOOP K97112

This loop is used when in-situ weighing of the cylinders are required. It is also recommended for use onsingle cylinder systems for ease of connection to rigid discharge piping. When used for this purpose a loopto pipe adaptor K62755 is required.

Figure 18 Flexible Discharge Loops

Materials - K97112Hose: Reinforced RubberConnectors: Mild Steel Zinc Plate and Chromate PassivatedCoupling Nuts: Mild Steel Zinc Plate and Chromate PassivatedTest Pressure: 210 barWeight: 0.5kg

Adaptor K62755: Brass


29

6.3 INSTALLATION

Manifold Heights

Height To Underside Of ManifoldCyl Size (kg) Cyl Part No Copper Loop K21578 Flexible Loop K97112

22.6 K24338 1267 157745.0 K24069/FM45.0 E7194-001

1700 1800 100

NOTE: All dimensions in mm

WARNINGALWAYS CONNECT THE LOOP TO THE MANIFOLD INLET OR PIPEWORK IF SINGLE CYLINDER,BEFORE CONNECTING TO THE CYLINDER VALVE OUTLET.


30

7. SYSTEM ACTUATOR ASSEMBLY

The system actuator assembly incorporates the source of pilot Nitrogen gas supply and the mechanism torelease it either automatically and/manually.

Figure 19 System Actuator Assembly


31

7.1 NITROGEN PILOT GAS CYLINDER AND VALVE

Figure 20 Nitrogen Pilot Gas Cylinder and Valves

Specification:

Cylinder: CF-CD01 Issue 2Water Capacity: 0.4 LitresMaterial: Steel Test Pressure: 250 barValve: BrassCharge: Dry Nitrogen to 65 bar at 20 (Recharge required at 55 bar)Weight: 1.7kgFinish: Grey PaintK62462 Standard AssyK62462A Complete with switch (Factory fitted)


32

7.2 OPTIONAL PRESSURE MONITORING SWITCH

This switch provides means of signaling low-pressure within the Nitrogen pilot cylinder.

WARNINGPRESSURE HEAD - DO NOT ATTEMPT TO REMOVE FROM CYLINDER.

Figure 21 Pressure Monitoring Switch

Sensor Capacity: Max System Pressure 207 barProof Pressure 621 bar

Electrical Rating: 28 V d.c 5 Amp resistive3 Amp inductive

Connections: Common - EarthOpen under pressure - 1Closed under pressure - 2

Temperature Range: -54 to +107CConstruction: ST.ST Housing, Black Nylon CapOperating Pressure: Factory set at 50 bar - decreasing


33

7.3 CONTROL HEAD K62303

The control head is mounted directly onto the Nitrogen pilot gas cylinder valve and is secured by a couplingnut. When the control head is operated the firing pin shoots out (extends) by approximately 3mm.

Figure 22 Control Head

Materials:Body: BrassWeight: 2.35kg

IP55 Rating


34

7.4 CONTROL HEAD WITH SWITCHES K62304

As K62303 plus switches to provide remote indication that the safety and reset pin has been inserted and asecond switch to indicate the condition of the control head.

Figure 23 Control Head with Switches

Safety/Reset Pin Switch

Orange - CommonRed - N.O.Black - N.C.

Control Head Condition SwitchGrey - CommonWhite - N.O.Yellow - N.C.

Electrical Rating

250 V a.c - 7A Resistive 7A Inductive30 V d.c - 4A Resistive 3A Inductive50 V d.c - 1A Resistive 0.25A Inductive125 V d.c - 0.4A Resistive 0.3A Inductive


35

7.5 CONTROL HEAD MOUNTING BRACKET K62487

Figure 24 Standard Mounting Bracket

Material: Mild SteelFinish: Painted Black


36

7.6 SAFETY AND RESET PIN K62401

This device, supplied with the control head, when screwed fully home will reset the control head causingthe firing pin to retract to its normal position.

WARNINGDO NOT ATTEMPT TO RESET WHILST STILL ELECTRICALLY OR PNEUMATICALLY ENERGISED.

When carrying out servicing or maintenance, screw the safety/reset pin fully home to inhibit (isolate) thesystem.

Retain reset pin in safe location for future use.

Figure 25 Safety and Reset Pin

Body Material: SteelWeight: 0.1kg


37

7.7 INSTALLATION

The installation procedure is as follows:-

1. Install the control head mounting bracket.

NOTE: Check the distance to the 1st cylinder valve release head to ensure that the long pilot gasflexible hose K93434 can be easily coupled to the Nitrogen pilot gas cylinder valve outlet,see Figures 44 and 45.

2. Lower the control head so that its swivel nut projects through the hole in the mounting bracket andbolt onto the bracket.

WARNINGDO NOT FIT THE NITROGEN PILOT GAS CYLINDER AT THIS TIME.

3. Check the operation of the control head safety and reset.

(i) Remove the red plastic dust cap from the control head threads.

(ii) Ensure that the Safety and Reset pin is screwed fully in.

(iii) Verify that the actuating pin, see Figures 22 and 23, does not project by more than 3mm.

(iv) Check that when the Safety and Reset pin is screwed FULLY OUT and the Push-to-Firebutton of the control head is operated the actuating pin extends so that it now projects by aminimum of 6mm. If a Push-to-Fire button is not supplied, remove the port plug, Section 8.1,and push the pin in. Ensure that no dirt or foreign matter falls into the control head while theport is open. reconnect the port plug.

(v) Verify that as the Safety and Reset pin is screwed in, the actuating pin retracts, reverting to itsoriginal position when the Safety and Reset pin is FULLY IN.


38

Figure 26 Control Head Mounting Bracket

TORQUE TO 5/5.5 NO


39

8. CONTROL HEAD ACTUATING DEVICES

There are various options available for automatically or manually operating the control head as illustratedbelow:-

Figure 27 Control Head Actuating Devices

1. Manual Push-to-Fire Button K624122. Pneumatic Diaphragm K624593. 24V d.c Solenoid K62422B4. 24V d.c Flameproof Solenoid K93206/AX5. Remote Cable Release Assy K62489


40

8.1 MANUAL PUSH-TO-FIRE BUTTON K62412

To manually operate the control head, pull safety pin and operate push to fire button

Figure 28 Manual Push-to-Fire Button

Unscrew the port plug on the control head and screw the button fully home, as shown below.

Port Plug


41

8.2 SOLENOID ACTUATORS K62422B and K93206/AX

Figure 29 Standard 24V d.c Solenoid

K62422B

Designed to meet with BS5490 IP55. The unit is prewired and supplied complete with flexible conduit.

Case Material: Aluminium Alloy.Finish: Grey Anodise.Weight: 0.77kg.

Electrical SpecificationCable:. PVCCoil resistance at 20C: 64.5 Ohms 5% 24V d.c (Nominal) 8.5 Watts.


42

8.3 FLAMEPROOF 24V d.c SOLENOID K93206/AX

Figure 30 Flameproof ATEX approved 24V d.c. Solenoid

K93206/AX

Designed in accordance with ATEX directive: ATEX 94/9/EC classification: for potentially explosiveatmospheres flameproof enclosure EX II 2 G Eex d II C T6 to T4

II 2 D IP65 T 85 to T135C

Case material: Aluminium Alloy.Finish: Epoxy Gloss Grey/GreenWeight: 1.4kg.

Suitable for offshore and marine conditions.

Electrical Specification

Coil resistance at 20C: 16 Ohms 10% 24V d.c (Nominal), 16.8 Watts.


43

8.4 INSTALLATION

Before installation of the standard or flameproof solenoid check the following:

1. All screw threads are clean and free of damage.

2. The tip of the plunger does not project by more than 3mm.

8.4.1 Standard Solenoid

1. Make sure that the Safety and Reset pin is screwed fully home into the control head before attachingthe solenoid.

2. Attach the solenoid to the 24mm diameter screwed port on the control head by hand, taking care notto cross thread the unit. When fully home the solenoid can be finally tightened using an open-endedspanner (27mm A/F thin section).

3. Insert the 20mm screwed thread of the cable gland, which is attached to the loose end of the flexiblecable of the solenoid, through the 20mm diameter hole located in the junction box and, using a20mm back nut tighten the gland from inside the junction box.

4. Connect the two crimp terminals to their relevant connections inside the junction box.

WARNINGENSURE THAT THE NITROGEN PILOT GAS CYLINDER HAS NOT BEEN FITTED.

5. Remove the Safety and Reset pin and energise the solenoid causing the firing pin, see Figures 22and 23, to operate.

6. To reset de-energise the solenoid and re-insert the Safety and Reset pin.


44

8.4.2 Flameproof Solenoid

1. Make sure that the Safety and Reset pin is screwed fully home into the control head before attachingthe solenoid.

2. Check the solenoid nameplate for correct voltage, wattage and service. The solenoid must beinstalled only in locations covered by group II category 2 G/D enclosures and where the flammablegases present in the atmosphere have ignition temperatures higher than the temperatureclassification stamped on the nameplate. Ambient temperatures must not exceed the value stampedon the nameplate.

3. Attach the solenoid to the 24mm diameter screwed port on the control head by hand, taking care notto cross thread the unit. Once fully home the solenoid can be finally tightened using an A/F open-ended spanner.

4. Connect the solenoid to the control circuit via a ATEX approved junction box or MICC cable gland.

5. Access to the cable terminal connector is achieved by removing the four cap screws and springwashers and withdrawing the housing cover. It may be necessary to rotate the cover slightly to easewithdrawal.

6. After the cover has been removed connect the MICC cable into the terminal connector and tightenthe screws.

Operation Check

WARNINGENSURE THAT THE NITROGEN PILOT GAS CYLINDER HAS NOT BEEN FITTED.

7. Remove the Safety and Reset pin and energise the solenoid causing the firing pin, see Figures 22and 23, to operate.

8. To Reset de-energise the solenoid and re-insert the Safety and Reset pin.


45

8.4.3 Control Head and Solenoid Wiring

The internal switches of the control head can be used to indicate whether the Safety and Reset pin hasbeen inserted or the control head has been operated or reset. A suitable junction box should be used forthe connections, see Figure 31. Normally the operate switch is not used to signal to the control panel thatthe extinguishing system has operated; the manifold mounted pressure switch is utilised instead.

Figure 31 Control Head and Solenoid Wiring

Colour State TerminalReset and Safetypin switch

RedBlackOrange

NCNOCommon

123

Operate Switch YellowWhiteGrey

NONCCommon

456

FROMCONTROLHEAD

From Solenoid 78

Recommended terminal connections to be made in a junction box.

NOTE: If a solenoid is used, connect the control panel between terminals 5 and 8, and link 6 and7.

After the control head, K62304, has been operated, the actuation signal is removed if the solenoid is wiredas shown in Figure 31.


46

8.4.4 Special Instructions to comply with 94/9/EC (ATEX)

1. Area classification

Control Head Basic and Control Head c/w Switches part numbers, K62303 and K62304 respectively.

Control heads are one part of a pneumatic activation system for extinguishers. These Control heads havebeen designed and certified as a non-electric equipment for compliance to the following hazardous areaclassification:

Group II category 3 GD c T6 X

The user of this equipment should make themselves aware of the following information;

2. Placing the device into service

These Control Heads may be installed in an area classified as Zone 2 or Zone 22 or unclassified.

3. Safe use of Control Heads

Control Heads are for use only as a component of a pneumatic activation system for extinguisherscompatible with the activation pressure (65 bar at 20 C.). The Control Head solenoid activation option islimited to certified version K93206/AX.

The switched version is to be used with an intrinsically safe supply suitable for the hazard area.

Control Heads are supplied with a resetting tool that also acts as a disable device to allow maintenance onthe extinguishing system.

4. Assembling and dismantling

Control Heads are supplied complete and ready to install in accordance with KFP High Pressure CarbonDioxide Fire Protection Equipment Installation, Commissioning and Maintenance Manual 59812-400.

5. Installation

Control Head installation shall be in accordance with KFP High Pressure Carbon Dioxide Fire ProtectionEquipment Installation, Commissioning and Maintenance Manual 59812-400, except that for zone 2 orzone 22 compliance solenoid K62422B SHALL NOT be used.

6. Maintenance (service and emergency repair)

The Safety and Reset Pin must be used to disable the control head before any system maintenance isperformed refer to manual 59812-400. For maintenance of control head refer to this manual.

7. Adjustment

Control Heads have no adjustable components

8. Training

Consult KFP High Pressure Carbon Dioxide Fire Protection Equipment Installation, Commissioning andMaintenance Manual 59812-400 before use.

9. Limitations of use

Control Heads must only be used within areas specified by the hazardous area certification as indicated onthe equipment label

10. Special Parameters

The ambient temperature for this equipment is 18C to 55C.


47

8.5 PNEUMATIC DIAPHRAGM ACTUATOR K62459

The pneumatic diaphragm actuator is used to operate the control head. The two 1/8 screwed connectorson the cover plate of the actuator allow connection to a detector line and a breather assembly.

Air pressure from the detectors deflects the diaphragm which moves the firing pin approximately 3mm intothe control head. After operation the firing pin returns to its normal position, assisted by a spring assemblywhich is located under the diaphragm.

Figure 32 Pneumatic Diaphragm Actuator

Diaphragm Housing Material: Aluminium BronzeFinish: AnodisedConnector Material: BrassFinish: Dull Nickel PlateWeight: 0.93kg


48

8.6 PNEUMATIC BREATHER VENTS K62895

The pneumatic breather is a calibrated leak used in pneumatic fire detecting systems.

The purpose of the breather is to relieve slight increases or decreases of air pressure within the detectorcircuit caused by normal atmospheric temperature changes or heating of the premises. etc.

Part Number Breather Setting

K62895/5 5 SecondsK62895/10 10 SecondsK62895/15 15 SecondsK62895/20 20 SecondsK62895/25 25 SecondsK62895/30 30 SecondsK62895/100 100 Seconds

Figure 33 Pneumatic Breather Vents

Vent settings to be used (seconds)

Temperature Variation: For 1 & 2Detectors

For 3 & 4Detectors

For 5 & 6Detectors

NORMAL 15 20 25CONSTANT(Thermostatically controlled)

25 30 30

RAPID (Ovens, etc) 5 10 10

NOTES:1. A 100 second breather is used only if a pneumatic check unit is employed.2. The breather in a lock-off unit must be rated the same as the breather fitted to the

Pneumatic Diaphragm Actuator see Figure 32.


49

8.7 INSTALLATION

Before installation of the pneumatic diaphragm actuator check the following:

1. That all screw threads are clean and free of damage,

2. The tip of the plunger does not project by more than 3mm,

3. That the Safety and Reset pin is screwed fully home into the control head before attaching theactuator.

After the above checks have been carried out satisfactorily install the pneumatic actuator as follows:

1. Attach the pneumatic diaphragm actuator to the 24mm diameter screwed port on the control head byhand, taking care not to cross thread the unit. Once fully home the actuator can be finally tightenedusing an open-ended spanner.

2. Attach the breather vent assembly, see Figure 32, to one of the connections on the actuator.

3. Attach the compression coupling on the copper detection tubing to the second connection.

8.8 CABLE RELEASE ASSEMBLY K62478

This device is used in conjunction with a remote pull box and cable system to manually operate the controlhead.

Figure 34 Cable Release Assy

Material: Mild steel box painted black


50

8.8.1 Installation

To install the single release assembly, see Figure 35 and proceed as follows:

1. Unscrew and remove the box lid and gasket. Slacken the cable clamp locking screws and slideclamp off the inner bowden cable (use a 2.5mm A/F hex wrench).

2. Pull out the inner cable from the release assembly.

NOTE: Do not remove top cover from control head.

3. Unscrew both blanking plugs from the control head body (use a A/F hex wrench).

NOTE: A manual Push-to-Fire button, if fitted, should be unscrewed.

Figure 35 Cable Pull Ring Connection

Cable Connection Port, see Figure 35.

4. Feed in the inner cable through the blanking plug port on the Safety and Reset pin side of thecontrol head, through the top hole of the cable pull-ring inside the control head and out through theblanking plug port on the other side of the control head.

5. Slide the outer Bowden cable, complete with box, onto the free end of the inner cable and screwcable into the blanking port and tighten.

6. Attach the cable box to the wall at a point convenient to the remote pull cable conduit.


51

Figure 36 Curvature of Cable

Curvature of Cable, see Figure 36

7. Make sure that the control head cable is not forced to bend through a radius of less than 45mm(approximately 1 ) along its length.

Figure 37 Cable Release Assembly, Cover Removed

8. Slide the cable clamp into the inner cable, loop the inner cable end and feed back through the clampas illustrated above.

NOTE: With Safety and Reset pin screwed fully home make sure that there is approximately3mm of slack cable between the cable clamp and the cable attachment nut inside the box.Adjust if necessary.

9. Feed remote pull cable into the cable clamp and secure with the two locking screws.

10. Test for satisfactory operation with the pilot valve and cylinder assembly removed and adjust tensionof remote cable if necessary. Refit the box lid and gasket.

11. Leave the system in an operable condition.


52

8.9 PULL BOX K 1114

The pull box is used where remote emergency manual operation of a system is required. The handle isconnected to the gas release device by flexible phosphor bronze cable run in mild steel conduit forprotection. Abrupt changes in direction to the routing of the manual pull line are affected by means ofenclosed brass pulleys. Part No. K 1122.

Pulley can be mounted in 90 increments.

Figure 38 Pull Box

Specification: BS5490 IP40Materials: Box-Steel painted signal red BS 381C/537

Front Cover - PlasticWeight: 1.65kg


53

8.9.1 Corner Pulley K 1122

Figure 39 Corner Pulley

Materials: Brass - NaturalWeight: 0.5kg

8.9.2 Installation

To install the pull box proceed as follows:

WARNINGTO PREVENT ACCIDENTAL DISCHARGE OF THE FIRE FIGHTING SYSTEM DURING INSTALLATIONWORK, MAKE SURE THAT THE SAFETY AND RESET PIN IS SCREWED FULLY HOME INTO THECONTROL HEAD OR THE COMPLETE PILOT VALVE AND GAS CYLINDER ASSEMBLY ISUNSCREWED FROM THE CONTROL HEAD.

1. Attach the pull box using the single 7/16 (11.1mm) diameter fixing hole.

2. With front plate and glass removed, use a slotted screwdriver to remove the 7/16 Whitworthgrubscrew from the centre of the pull handle.

3. Feed the 1/8 diameter bronze cable through the pull handle, steel conduit and pulley assemblies, upto the cable clamp located inside the cable release box.

4. With the cable protruding inside the cable release box slacken the two cable-clamp locking-screwsand attach the bronze cable as shown for single release mechanism.

5. With approximately 76mm of cable protruding out through the pull handle, tie a single knot in cable.Solder the knot completely.

6. Slide the cable into the handle recess, tighten and then cut-off excess cable.

7. Re-fit the 7/16 Whitworth grubscrew to the pull handle.


54

8. With the pilot gas cylinder detached from the control head, remove the Safety and Reset pin, pull thehandle in the pull box and test the system for each operation.

9. Check that the control head operates.

10. Insert the Safety and Reset pin.

11. Refit the pilot cylinder.

12. When satisfied with the operation re-locate glass and front plate and tighten using the four long 2long x 2BA round head screws.

13. Remove the Safety and Reset pin and hand it to a responsible person.

NOTE: All cable runs must be straight. Changes in direction must only be accomplished by theuse of pulleys; bends and dog legs must not be used.


55

9. CYLINDER VALVE PRESSURE/LEVER ACTUATOR K62341

The release head is a piston device which is fitted to the cylinder valve by means of a U pin and can beoperated by means of independent Nitrogen gas pressure and/or by use of the manual lever. Two gaspressure ports provide the means of interconnecting a series of release heads by using flexible pilot gashoses. (K93433 & K93434)

All pilot lines must include a pilot vent (K24051) as part of the assembly.

WARNINGTHIS DEVICE IS NOT SELF-RESETTING. AFTER OPERATION THE PISTON MUST BE MANUALLYRESET BY PUSHING THE PISTON BACK ONTO ITS SEATING.

NOTE: If manually operated the lever must be returned to its original position and secured beforere-setting.

Figure 40 Cylinder Valve Pressure/Lever Actuator

MaterialsBody: BrassSeals: NitrileLever: Plated SteelSecuring Pin: Stainless SteelSafety Pin: Stainless SteelWeight: 0.4kg


56

9.1 INSTALLATION

Before installation check the following:-

1. Remove Safety pin and rotate manual lever for ease of movement of both the lever and piston.

2. Return lever original position and insert Safety pin.

3. Manually reset the piston.

After these checks have been carried out satisfactorily install as follows:

(a) Remove the securing pin.

(b) Slide the release head onto the cylinder valve and refit the securing pin, lightly tap fully home.

Leave safety pin in place until commissioning system. Refer to section 19 Maintenance.


57

10. PILOT GAS FLEXIBLE LOOPS K93433 and K93434

The short pilot loop K93433 is used to interconnect the pressure / lever actuator K62341 pressure inletports on multiple cylinder systems.

The long pilot loop K93434 is used to interconnect the release head where the cylinders are installed in adouble row. It is also used to convey the pilot nitrogen gas from a system actuator to the inlet port of thefirst release head.

Figure 41 Pilot Gas Flexible Loops

Materials

Hose: Polyamide inner tube, synthetic branding/polyamide coverEnd Fittings: Brass - Natural FinishMinimum Bend Radius: 50mmTest Pressure: 207 barWeight: 50 grammes

10.1 PILOT GAS VENT K24051

This device is fitted in the last unused pressure inlet port of the release head K62341 allowing the pilot gaspressure to slowly vent (bleed) to atmosphere. The rate at which the pilot gas is vented is slow enough tomaintain adequate operation pressure in the pilot gas line far in excess of the duration of the main CO2discharge for normal flooding systems. See Datasheet 811-9040A

The bleed valve is factory calibrated to vent at 0.8 litres/min at 750psi.


58

Figure 42 Pilot Gas Vent

Materials

Body: BrassWeight: 0.02kg


59

10.2 PILOT GAS RIGID TUBING AND FITTINGS

On systems where either the system actuator is remote from the CO2 cylinders or when the systemincorporates directional valves the pilot gas line consists of steel (bundy) tubing and compression fittings.

Figure 43 Pilot Gas Rigid Tubing and Fittings

K

K

K K

K K K

K K

K

K


60

ASSEMBLY

1. Tubing must be cut off square and all burrs and swarf removed as loose particles could damage anyseals used elsewhere in the pipeline.

2. Place tubing nut and sleeve on tube.

3. Offer the tubing to the coupling, pushing it right home so that the tubing bottoms on the tubing stopinside the fitting.* This is important as it ensures that the correct amount of tubing projects beyond the sleeve to

give a sound joint.

4. Hold the tubing square to the coupling and screw the tubing nut up finger tight so that the sleeve istrapped between the tubing nut and the seating radius of the counterbore.

5. While holding the tube firmly in contact with the tubing stop, screw the tubing nut down to areasonable spanner tightness. This varies between 3/4 and one full turn. On fittings for tubing sizesof 12mm outside diameter and over, a smear of lubricant applied to the sleeve and the threads of thetubing nut will effect a sound joint with the minimum of effort.

6. Slacken off the assembly about a turn then pinch down once again.

Where an inaccessible fitting would make the assembly of a sound joint difficult, it is recommendedthat the sleeve is pre-assembled onto the tubing. This can be done by following the above procedurebut using a fitting of the correct size clamped in a vice. The tubing assembly can then be done andreleased and transferred to the final union with the sleeve already correctly positioned.

WARNINGDo not use loctite, adhesive or tape on any part of this assembly.


61

10.3 INSTALLATION

Install the correct length pilot gas flexible loops as shown in Figure 44 for single row cylinders or Figure 45for double row cylinders.

Install a pilot gas vent, see Figure 42, in the last open port of the pressure/lever actuator, Figure 40.

NOTES:

1. Do not use PTFE or other pipe sealant.

2. Do not overtighten fittings.

Figure 44 Single Cylinder Row Pilot Gas Operation

Figure 45 Double Cylinder Row Pilot Gas Operation


62

11. TIME DELAY UNIT K23650

This hydraulic device can be installed in a system to ensure that personnel are given time to evacuate aprotected space following a warning of imminent CO2 discharge. It is fitted in the Nitrogen pilot gas line fromthe System Actuator thus delaying the flow of pilot gas to the CO2 cylinder pressure release heads and/orP.O.D valve for a pre-determined time of 15 or 30 seconds.

This unit is factory pre-set do not adjust. Tampering with this unit could cause failure.

Figure 46 Time Delay Unit


63

Spec Factory set at 15 or 30 sec.

Material: Brass - Painted RedPart No: K23650/15 = 15 secs

K23650/30 = 30 secsWeight: 1.9 kg

11.1 INSTALLATION

1. Install vertically with the pilot gas inlet at the top.

2. Fit adaptor K90219 to both inlet and outlet pilot gas points.

11.2 TESTING

Wait approximately 1 hour before testing.


64

Figure 47 Single Protected Space System


65

Figure 48 Two Protected Spaces System


66

Figure 49 Two Protected Spaces Requiring Different CO2 Quantities


67

11.3 TIME DELAY BY-PASS VALVE K60736

This device may be used to by-pass the time delay units.

Figure 50 Time Delay By-Pass Valve

Materials: Box Mild SteelFinish: Hammer Grey


68

Figure 51 Installation


69

12. CO2 OPERATED PRESSURE SWITCH K60218

The universal pressure switch is a gas pressure operated device which is connected to the distributionpiping or manifold. A gas pressure of 4 bar - 110 bar is required to operate the piston which makes orbreaks electrical contacts.

When the system is activated, gas pressure forces the piston against the operating rod which movesacross the housing, operating the switch. The switch completes an electrical circuit and illuminates thesystem discharged lamp on the indicating lamp panel or operates the alarm etc. The rod extends into thetransparent cover to indicate the switch has operated.

To reset, unscrew re-setting cap (transport cover) from box, - reverse, and screw onto the operating rod.Press until switch clicks home. Remove resetting cap from rod - reverse and screw back into box.

Refer to Datasheet 811-9119

Figure 52 CO2 Operated Pressure Switch

MaterialsHousing: Aluminium CastingFinish: Red EnamelTesting: 2KV tested

BSPT


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Inductive Rating

Power Factor 250 Volts 440 Volts 600 Volts1 30 Amps 25 Amps 20 Amps

0.74 25 Amps 20 Amps 16 Amps0.50 17.5 Amps 14 Amps 11.5 Amps

D.C. Rating

Resistance 220 Volts 500 VoltsLoadings 30 Amps 15 Amps


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12.1 INSTALLATION

Before installation of the pressure switch (see Figures 52), check the following:

1. The BSP inlet thread is clean and free of any damage.

2. When manually operated, using the visual indicator and re-setting cap, the switch roller is in thecoupler channel and the operation is smooth with no binding.

After the above checks have been satisfactorily carried out, install the pressure switch as follows:-

1. A BSP screwed connection is required on the end of the manifold, attach a BSP galvanisedhexagon nipple.

2. Attach the pressure switch or, wall mount the switch, make up all pipework to suit the site location ofyour pressure switch making sure that there is a BSP galvanised union in this line for each ofinstallation and/or removal of equipment.

3. To the BSP outlet connection on the pressure switch attach a BSP galvanised hexagon nippleand one half of the union as mentioned in (2) above.

4. Connect the pressure switch to the pipework via the union and hand tighten.

5. Mark the two pressure switch fixing holes on the wall or framework.

6. Loosen the union nut and remove the pressure switch.

7. Drill the two holes.

8. Reconnect the pressure switch to the pipework and tighten the union nut.

9. Fix the pressure switch to the wall or framework.

Alternatively, the switch may be wall mounted by adapting the threads to 3/16 ENOT and using bundytube to connect.


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13. CO2 OPERATED PRESSURE TRIP K17554

The pressure trip is fitted into the CO2 distribution piping and is used to automatically release ventilationshutters, fire curtains, ducting dampers, fuel valves, etc. CO2 pressure of approximately 2 bar is sufficient tooperate the piston and unlatch -the catch mechanism.

Figure 53 Pressure Trip

Materials: Body - GunmetalFinish: Nickel Plate


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13.1 INSTALLATION

Figure 54 Installation

NOTES:

Always install the pressure trip in a vertical position as shown. Dimension from top of doorframe is typical & should be adhered to where possible. Use PTFE tape on all screw threads. The maximum load that can be suspended from a pressure trip is 100lb (45kg).

Install the pressure trip as follows:-

1. To the BSP male screwed connection on the pressure trip attach a BSP elbow a suitablelength of BSP galvanised pipe and one half of a BSP union.

2. Offer the pressure trip assembly up to the CO2 distribution piping and hand tighten the union nut.

3. Making sure that the pressure trip is located in the centre of the doorway and at a suitable verticaldimension above the door frame so as not to hinder the operation of the equipment mark the one offfixing hole on the wall.

4. Loosen and disconnect the pressure trip assembly.

5. Drill the pressure trip fixing hole on the wall.

6. Reconnect the pressure trip assembly to the CO2 pipework.

7. Using a adequate wall fixing to attach the pressure trip to the wall.

8. Once attached to the wall finally tighten the union nut.

9. Attached the cable & cable ring to the pressure trip.


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14. CO2 DISCHARGE NOZZLES

There are various nozzles suitable for either total flooding and/or local application systems. In all cases itis essential that they are installed in their correct locations as defined by the code number stamped on thenozzle body.

14.1 MULTIJET NOZZLE K61792 AND K61793

These nozzles are the standard carbon dioxide discharge nozzles. The horn has been developed toprevent the scattering of burning material that can take place with a high velocity discharge.

Datasheet 811-9148

Figure 55 Multijet Nozzle

Environment: Industrial/Offshore/MarineMaterial: Horn - mild steel

Nozzle - brassFinish: Horn - black paint.

Nozzle - NaturalWeight: K61792 N13 - N18 :- 0.8 kg approx.

K61793 N3 - N12 :- 0.6 kg approx.


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14.2 FLANGED MULTIJET NOZZLE K5814

The flanged carbon dioxide horn is designed for use in those areas where the nozzle may become blockedby dirt or the process being protected. The force of the discharge automatically blows the disc clear. Threediscs are available:-

Refer to Datasheet 811-9139

Figure 56 Flanged Multijet Nozzle

1. Bakelite - temperatures up to 200C and ambient pressures below 50 psig.2. Tin Foil - temperatures up to 400C and ambient pressures below 25 psig. (used where

fragmented pieces cannot be tolerated)3. Mica - temperatures above 400C and ambient pressures below 50 psi.

The flanged horn may be fitted to ductwork by the addition of the appropriate adaptor.

Material: Body: Aluminium Nozzle: BrassFinish: Body: Natural Nozzle: NaturalWeight: 0.9 kg approx.


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14.3 FLANGED NOZZLE DUCT ADAPTORS K61420A-D

The range of duct adaptors is designed for those situations where it is required to fit the flanged CO2 nozzle(K5814 N3 - N8) to circular or square section ductwork.

Figure 57 Flanged Nozzle Duct Adaptor

Material: Cast aluminium.Finish: Black paint

NOTE: 4 - 5/16" Whit. Hex. Hd. Screws C/W nuts and washers together with joint sealing tapesupplied with each adaptor.

Adaptor Assembly Weight (approx) Ducting SizeK61420A 1.3kg 610mm DiaK61420B 1.3kg 457mm DiaK61420C 1.3kg 305mm DiaK61420D 1.1kg Flat


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14.4 DUCT NOZZLE K13045

The CO2 nozzle and duct adaptor is used to protect ductwork in areas where space is limited.

Datasheet 811-9151

Figure 58 Duct Nozzle

Material: Mounting plate : mild steelNozzle : brass

Finish: Mounting plate : zinc plated and passivated.Nozzle : natural

Weight: 0.4kg approx.


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14.5 FAN TYPE NOZZLE K6490

Fan type nozzles are designed to be mounted at the sides of the protected equipment and to direct carbondioxide across the hazard.

Figure 59 Fan Type Nozzle

Material: Body: Grey cast iron. Nozzle: Brass

Finish: Body: Black paint. Nozzle: Natural

Weight: 2.6kg approx.


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15. PNEUMATIC DETECTION - HEAT ACTUATED DEVICES

The Rate of Rise system is a thermo-pneumatic system consisting of one or more detectors connected toa release actuator in which there is a diaphragm and a compensating vent.

15.1 PNEUMATIC RATE OF RISE DETECTOR K18724

The pneumatic detector is a hollow copper chamber of 12cc capacity containing air at normal atmosphericpressure. It is fixed to the ceiling or in any other positions best suited to site conditions. The function of thedetector is to absorb heat thereby increasing the air pressure within it which is then transmitted throughsmall bore copper capillary tube running in protective steel conduit to a release actuator. Operation of thediaphragm in the release actuator will discharge the extinguishing agent or initiate an alarm.

Figure 60 Pneumatic Rate of Rise Detector


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15.2 PNEUMATIC FIXED TEMPERATURE DETECTOR K18689

This detector works on the same principle as the Rate of Rise detector but is fitted with a slug assemblycontaining a fusible alloy disc which will melt at a predetermined temperature. These are used to protectareas which are subjected to rapid increases in ambient temperatures such as ovens, kitchens, boilerhouses, lantern lights, etc.

Be aware that capillary tubing can act as a rate-of rise detector so routes outside the rapid change areamust be found.

K18689 = Pneumatic Fire Detector less slug assembly, washers and identification disc.

Order appropriate slug assembly kit for fitting on site and for spares. (see table)

Slug assembly kit comprises - slug assembly, 2 washers, identification disc with fitting screwand fitting instructions.

Note: Slug assembly kits are available in a limited range of temperatures. Please contact Kidde FireProtection for further details.

Figure 61 Pneumatic Fixed Temperature Detector


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15.3 PNEUMATIC CHECK UNIT K24412

The pneumatic check is used on pneumatic type fire detection systems incorporating Rate of Risedetectors.

The checks are used to divide the detectors into groups of no more than six. Each group is, in this way,isolated, so that air pressure rise caused by a detector sensing fire can pass through the check to thesystem actuator etc, without being dissipated into other detector groups.

The pneumatic check is formed by making use of silicone fluid. The unit being filled with fluid at the factory.No adjustment should be necessary, but check fluid level.

Installation

This unit must be installed in a vertical position as shown above. Fit pneumatic breathers in the two inletports, see Figure 62 for correct setting.

Figure 62 Pneumatic Check Unit

K 6 2 8 9 5


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15.4 PNEUMATIC LOCK-OFF UNIT K24300

An extinguishing system utilising non-electrical heat detectors can be fitted with a pneumatic lock-off unit inorder to prevent automatic actuation when the area protected by the system is occupied. With the unitswitched to AUTOMATIC & MANUAL the pneumatic signal from the heat detectors is allowed to passthrough the unit to the extinguishing system.

However, when the unit is switched to MANUAL ONLY the signal is directed to a pneumatic switch fittedwithin the Lock-off unit which can thus provide remote indication, and is prevented from actuating theextinguishing system. A second Pneumatic breather of the same vent setting as the one fitted to theextinguishing system actuator must be fitted to the pneumatic switch in the Lock-off unit.

Figure 63 Pneumatic Lock-Off Unit


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15.5 BELLOWS AND MICROSWITCH ASSY K20057

The bellows and microswitch assembly is used to convert an air pressure signal received from a non-electrical heat detection device into an electric signal for indication or the operation of a releasemechanism.

The assembly consists of a pair of aluminium castings enclosing a diaphragm and connected to amicroswitch. On receipt of an air pressure signal a spindle housed in the upper casting actuates themicroswitch.

The unit is self-resetting when the air pressure signal is removed. No maintenance is required. Orderappropriate Pneumatic Breather for fitting on site, see Figure 64.

Figure 64 Bellows and Microswitch Assembly

K.F.P.S. Ltd D

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