Fm 200

CONTENTSHYGOOD

FM-200® Installation Guide/11100/01.07.01/Issue3.0

SECTION 1 - INTRODUCTION

About this Manual ....................................... 5Definitions .................................................... 5Contacts ....................................................... 5Introduction .................................................. 5Approvals and Standards ............................. 5Health and Safety ......................................... 6First Aid ........................................................ 7FM-200® Agent characteristics ..................... 7

Agent Physical Properties ..................... 8Table 1: FM-200®

.............................................................. 8

Table 2: Nitrogen ................................... 8

Table 3: Toxicology/Environmental ....... 8

SECTION 2 - SYSTEM COMPONENTS

System Components ..................................... 9FM-200® Container ................................ 9Table 4: Container Details ...................... 9Container Label........................................... 10Fixing Bracket ........................................ 11Valve Assembly ..................................... 11Principle of Operation ............................ 11Burst Disc.................................................... 12Low Pressure Switch ............................. 12Manual Actuator ................................... 13Pneumatic Actuator ............................... 13Removable Electrical Actuator .............. 13Side Mounted Electrical Actuator............ 14Flexible Discharge Hose ........................ 14Solenoid Adaptor .................................. 15Manifold Check Valve ............................ 15Manifold ................................................ 16Table 5: Manifold Dimensions ............... 16Manifold Bracket Assembly .................. 17Flexible Pilot Hose ................................. 18Male Adaptor ........................................ 18Male Tee ................................................ 19Male Elbow ............................................ 19Pressure Switch ..................................... 19Discharge Nozzle ................................... 20Door Notice ........................................... 21Manual Release Notice.............................. 21Typical Manifold System ....................... 22

SECTION 3 - SYSTEM DESIGN

System Design .............................................. 23Hazard Analysis .................................... 23Hazard Structure......................................... 24Hazard Volume ....................................... 24Ventilation .............................................. 25Hazard Temperature ............................... 25Hazard Fuels .......................................... 25Personnel Safety .................................... 25Agent Quantities ................................... 25Agent Storage ....................................... 25Manifolds .............................................. 26Agent Distribution ................................ 26

Agent Flow Characteristics .......................... 27Nitrogen Superpressurisation ................ 27Flow in Pipe ........................................... 27Initial Vapour Discharge ........................ 27Trailing Vapour Pressure ....................... 27

Nozzle selection and location ....................... 27Example: Max Limits in pipe Work ......... 28Example: Nozzle Selection ...................... 29

System Design Procedure ............................. 29Example: Tee Split Designs .................... 30

Design Example - Calculations ...................... 31

Example .................................................. 31

Piping Practices ............................................ 33

SECTION 4 - FLOW CALCULATIONS

Introduction .................................................. 34Table 6: Weight Calculations Imperial .... 34Table 6a: Weight Calculations Metric .... 35Table 7: Altitude Correction...................... 35

FM-200® Equation Calculations .................... 35Engineered Systems ..................................... 36

Program Parameters ............................... 36Table 8: Max/Min Flow Rates ................ 36Table 9: Equivalent Lengthfor Pipe Fittings ..................................... 37Table 10: Equivalent Length for otherComponents .......................................... 37

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SECTION 7 - SYSTEM OPERATION

General Comments ........................................ 56System Detection & Actuation ..................... 56

General ................................................... 56Manual System ...................................... 56Fully Automatic System ........................ 56Fully Automatic System with Manual Inter-vention .................................................. 57

Conditions During a Fire ............................... 57FM-200®Concentration .......................... 57FM-200® Decomposition ....................... 57FM-200® Discharge Conditions ............. 57

Actions Following a Fire ............................... 58General ................................................... 58Actions Immediately Following a Fire ... 58

SECTION 8 - MAINTENANCE

Introduction .................................................. 59User's Programme of Inspection ................... 59Contract Service & Maintenance .................. 60Mechanical Service Procedure ...................... 61Specialised Maintenance Duties. .................. 62

Finally .................................................... 62

SECTION 9 - RECHARGING

Valve Refurb ................................................. 63Testing .......................................................... 63Container/Valve Assy ................................... 64Filling ............................................................ 64 Table 19: Fill Tolerance Table ................. 66 Table 20: Temperature Correction Chart . 66Container/Valve Assy Leak Test ................... 67Decanting ..................................................... 67Transportation .............................................. 68

SECTION 5 - INSTALLATION

General Information ...................................... 38Container Installation ................................... 38Single Container Installation ......................... 39

Table 11: Bracket Fixing Heights ............ 39Multiple Container Installation ..................... 40

Manifold Bracket Installation ................ 40Table 12: Manifold Bracket Height ........ 41

Pipe Installation ............................................ 42Table 13: UK Steel Pipe Requirements ... 42Table 14: UK Fittings ............................. 42Table 15: US Steel Pipe Requirements .... 43Table 16: US Fittings .............................. 43Pipe Hangers ......................................... 43Table 17: Hanger Spacing ...................... 43

Earthing & Electrical Clearance........................ 44Table 18: Safety Clearances ................... 44

Nozzles .......................................................... 44Actuation Installation ................................... 45

Single Container Actuation ................... 45Multiple Container Actuation ................ 47

Ancillary Equipment ..................................... 49Discharge Pressure Switch .................... 49Low Pressure Switch ............................. 50

Accessories .................................................. 50Door Notices ......................................... 50Manual Release Notices ........................ 50

Completion Procedures ................................. 50Pre-checks and Visual Inspections ........ 50Final Connections .................................. 51

Handover Procedures ................................... 52

SECTION 6 - INTEGRITY TESTING

Introduction .................................................. 53Principle ........................................................ 53Equivalent Leakage Area (ELA) ................... 53Below Ceiling Leakage Area (BCLA) ............ 53Predicting Retention Time ............................ 53

Slab to Slab Walls .................................. 53Coordination and Planning ........................... 53

Integrity Test Procedure ........................ 54Enclosure Evaluation ............................. 54

Calculation .................................................... 55Leakage Location .......................................... 55

CONTENTSHYGOOD


SECTION 10 - WARRANTY, DISCLAIMERS & LIMITATIONS

Warranty ....................................................... 69Disclaimers & Limitations ............................. 69

SECTION 11 - APPENDICES

Appendix A - Site Survey / Request Form .... 71Appendix B - Temperature Correction Chart . 73Appendix C - Hughes Program printout ....... 74Appendix D - FM-200® Material Safety Data Sheet (MSDS).................84

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FM-200® Installation Guide/11100/01.07.01/Issue3.0: 5

About this Manual

This manual is a comprehensive guide that contains allthe information necessary to design, install and main-tain the FM-200® Engineered Extinguishing system sup-plied by Macron Safety Systems Limited. However themanual does not address information relating to fire de-tection. Please refer to the BFPSA Code of Practice forGaseous Fire Fighting Systems.

Users of this manual are assumed to be competentfire engineers with a basic knowledge of such systems.The contents are arranged in a logical order describingthe various procedures in turn, alternatively specific sec-tions can be referred to as required. Users who are notfamiliar with the equipment should first read the com-plete manual.

Definitions

FM-200® FM-200® is a registered trade markof the Great Lakes Chemical Corpo-ration.

System In this manual ‘system’ refers to theextinguishing equipment and doesnot include any electrical systemwhich may initiate an agent release.

Engineered Hydraulic flow program used topredict the two phase flow ofFM-200® through a pipe network.

Contacts

Should any part of this manual not be understood, orthere are any queries concerning a system, please con-tact:

Macron Safety Systems (UK) LimitedWoodlands PlaceWoodlands RoadGuildfordSurreyGU1 1RNEngland

Tel. (+44) (0)1483 572222Fax. (+44) (0)1483 302180

Introduction

FM-200® is a clean, safe fire fighting agent for use intotal flooding automatic extinguishing systems. It is in-tended as a long term replacement for Halon 1301 and,whilst maintaining the excellent fire suppression prop-erties of Halon, has none of the environmental prob-lems. Storage and distribution requirements are similarto Halon and the majority of system components areidentical. However, FM-200® is not a direct replacementfor existing Halon 1301 installations due to the differ-ence in agent quantity and discharge characteristics.The FM-200® design concentration for Class A fire risksis 7.17%, and therefore requires approximately 45% ad-ditional storage capacity over that required for Halon inthe same area.

The manufacturers claim that FM-200® is safer thanHalon 1301 for use in total flooding applications and theUS Environmental Protection Agency (EPA) accepts ex-tended use exposures of up to 9%. This has been fur-ther confirmed by a recently published HAG report. FM-200® is rated as Zero Ozone Depletion (ODP), is electri-cally non-conductive, clean, and leaves no residue. Re-fer to NFPA 2001, 2000 edition "Clean Agent Fire Extin-guishing Systems," Section 1-6 "Safety," for additionalexposure requirements.

The systems described in this manual are 'engi-neered'. Engineered systems for example can consist ofseveral FM-200® containers, manifolded together andconnected via a pipe network to a number of dischargenozzles.

Systems may be activated mechanically or electri-cally. Mechanical manual actuation is via a strike knobattached to the container valve. Electrical actuation isvia a removable side mounted solenoid. The solenoidcan be energised automatically by a signal from a de-tection and alarm control panel.

Users of this manual should find that sufficient in-formation is provided to plan, design, purchase compo-nents, install, operate and maintain the system. How-ever, in the event that part of the document is not under-stood, or if there is any concern as to the suitability ofthe protection, do not hesitate to contact one of ourspecialist engineers for the matter to be quickly resolved.

Approvals and Standards

Macron's manufactured equipment and the FM-200®

agent, manufactured by Great Lakes Chemical Corpora-tion, have acquired comprehensive approvals and list-ings providing further support to the overall product.

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FM-200® Installation Guide/11100/01.07.01/Issue3.0:6

FM-200® Agent

� Factory Mutual (Approved)

� Underwriters Laboratories Inc. (UL) RecognisedComponent

� NFPA 2001 Clean Agent Fire Extinguishing Sys-tems (Listed Alternative)

� US EPA SNAP Rpt. (Unrestricted Listed Alterna-tive)

� Australian Industrial Chemicals Notification (Ap-proved)

� German Institute for Environmental Hygiene andMedicine (Approved)

Macron Safety Systems ManufacturedSystems

��Underwriters Laboratories Inc. (UL Listed)

� Loss Prevention Council Board (Listed)

� Factory Mutual (Listed)

Macron Safety Systems manufacture in strict accord-ance with the internationally recognised Quality assur-ance Standard, BS EN ISO 9000 and approved to ISO9001.

Macron Safety Systems FM-200® Extinguishing SystemUnits are to be designed, installed, inspected, main-tained, tested and recharged by qualified, trained per-sonnel in accordance with The Standard on Clean AgentFire Extinguishing Systems, NFPA2001, 2000 edition andto be used in accordance with Environmental ProtectionAgency (EPA) Significant New Alternatives Program(SNAP). Where determined to be appropriate by theauthority having jurisdiction, applicable BS Standardsmay additionally be utilized to specific system require-ments for these purposes.

Health and Safety

A properly designed and installed extinguishing systemshould not present any significant health or safety prob-lems, however, there are basic precautions to be taken toavoid accidents, and aspects of the system operationthat should be understood. End-users often require re-assurance regarding the safety of personnel, and thiscan only be given if a thorough understanding of theproperties of the agent and its effects in different situa-tions are known. Current best practice should be ob-

served e.g. BS5306: Part 5: Section 5.1 and the BFPSACode of Practice for Gaseous Fire Fighting Systems.

Reference should also be made to NFPA 2001 andBFPSA Volume 3 section 19 A review of the toxic andasphyxiating hazards of clean agents replacements forHalon 1301.

FM-200®, like halon, extinguishes by causing a chemi-cal reaction with the combustion products, and doesnot remove oxygen like CO

2 and other inert agents.

Therefore, exposure to FM-200® at the design con-centration of 7.17%, and up to 9.0%, is not hazardous tohealth. Exposure to higher concentrations is permissiblefor limited periods. Refer to NFPA 2001, 2000 editionSection 1-6 "Safety," for exposure requirements. As withhalons, the US EPA and the National Fire ProtectionAssociation (NFPA) recommend that unnecessary ex-posure to any agent be avoided and that personnelevacuate protected areas as quickly as possible to avoidthe decomposition products of the fire.

FM-200® can decompose at high temperatures to formhalogen acids. If so, their presence is readily detected asa sharp, pungent odour long before hazardous maximumexposure levels are reached. Fire toxicity studies con-clude that generally decomposition products from thefire itself, especially carbon monoxide, smoke, heat, andoxygen depletion, create a greater hazard.

The noise created by the FM-200® agent discharg-ing can be loud enough to startle people in the vicinity,but is unlikely to cause any permanent injury. Turbu-lence caused by the high velocity discharge can dis-lodge substantial objects directly in its path, and causeenough general turbulence within the protected area tomove paper and light objects.

Direct contact with the vaporising liquid dischargedfrom an FM-200® nozzle has a chilling effect on objectsand in extreme cases can cause frostbite to the skin. Theliquid phase vaporises rapidly when mixed with air andtherefore limits the risk to the immediate vicinity of thenozzle. Minor reduction in visibility may occur for a briefperiod due to the condensation of water vapour.

The discharge of clean agent systems to extinguisha fire can result in a potential hazard to personnelfrom the natural form of the clean agent or from theproducts of combustion that results from exposureof the agent to the fire or hot surfaces. Unnecessaryexposure of personnel either to the natural agent orto the products of decomposition shall be avoided.

WARNING

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The present understanding of the functioning of FM-200® is that 80% of its fire fighting effectiveness isachieved through heat absorption and 20% through di-rect chemical means (action of the fluorine radical on thechain reaction of a flame). Complete suppression usingFM-200® has the following advantages:

� The low concentration of FM-200® required meansless visual obscurity and minimal risk to personnel.

� The small quantity of agent discharged minimisesover-pressurisation of the protected area.

� Maximum safety for personnel due to low toxicity.

� Most effective when used with automatic detectionto introduce FM-200® rapidly.

� The ability to prevent re-ignition as long as con-centration levels are maintained.

FM-200® is stored as a liquified compressed gas and isdischarged into the protected area as a vapour. It is storedin approved DOT(HSE)4BW500 or DOT(HSE)4BW450containers and is super-pressurised with dry nitrogento 25 Bar @ 210 C (360 PSI @ 70 0F).

WARNING

FM-200® shall not be used on fires involving the follow-ing materials unless they have been tested to the satis-faction of the authority having jurisdiction:

• Certain chemicals or mixtures of chemicals, such ascellulose nitrate and gunpowder, that are capable of rapidoxidation in the absence of air.

• Reactive metals such as lithium, sodium, potassium,magnesium, titanium, zirconium, uranium and plutonium.

• Metal hydrides.

• Chemicals capable of undergoing autothermal decom-position, such as certain organic peroxidase andhydrazine.

FM-200® Agent Characteristics

FM-200® (HFC-227ea) is a clean, gaseous agent con-taining no particles or oily residues. It is produced un-der ISO 9002 guidelines to strict manufacturing specifi-cations ensuring product purity. FM-200® leaves no resi-due or oily deposits on delicate electronic equipment,and can be removed from the protected space by venti-lation.

FM-200® is thermally and chemically stable, but with-out the extremely long atmospheric lifetimes associatedwith other proposed halon replacements. The atmos-pheric lifetime of FM-200® has been determined to be36.5 years (Reference GLCC). The US EPA SNAP does notconsider FM-200® to be a long lived substance whendischarged, and as such has placed no restrictions onits use. (Environmental Protection Agency's SignificantNew Alternatives Program).

Typical areas that can be protected by an FM-200®

system are detailed below; the list is by no means ex-haustive:

Bank VaultsLibrariesRare Book StoresElectronic Data ProcessingTelephone ExchangesStudiosCommunication CentresTransformer and SwitchroomsControl RoomsTest LaboratoriesFlammable Liquid Stores

HMIS: 2-0-0/heptafloropropane/contents underpressure. 0-0-0/nitrogen expellant gas/very cold, con-tents under pressure. Consult Great Lakes ChemicalsCo., P.O. Box 2200, West LaFayette, IN 47996-2200.Emergency phone number 800-949-5167.

First Aid

Skin Maintain at body temperature, thawaffected area with gentle heat. If frost-bite occurs seek medical attention. Donot rub affected area.

Eyes Apply gentle heat, Do not allow patientto touch affected area.

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FM-200® Installation Guide/11100/01.07.01/Issue3.0:8

Table 3: Toxicology/Environmental

Agent Physical Properties HFC-227ea

Chemical structure CF3CHFCF3

Chemical name Heptafluoropropane

Molecular weight 170.03

Boiling point -16.40C (1.9oF) Freezing point -131.10C (-204 oF) Critical temperature 101.70C (214 oF) Critical pressure 2912 kPa (422 psi)

Critical volume 274 cc/mole (.0258cu Ft./lb.)

Critical density 621 kg/m3 (38.76 lb./Ft3) Saturated vapour density @ 20 oC (68 oF)

31.18 kg/m3 (1.95 lb./ft3)

Agent Physical Properties

Chemical structure N2

Chemical name Nitrogen

Molecular weight 28.0

Boiling point -195.80C (-320.4oF) Freezing point -210.00C (-346 oF) Critical temperature -146.90C (-232.4 oF) Critical pressure 3399 kPa (492.9 psi)

�

�(Reference: NFPA 2001, 2000 edition)

Agent Physical Properties

FM-200® Environmental

Ozone Depletion (ODP) 0 Atmospheric Lifetime (yrs) 36.5

Toxicology

Acute Exposure LC50 (ppm) >800,000 Cardiac Sensitization No Observed Adverse Effect Level (NOAEL) 9.0% Lowest Observed Adverse Effect Level (LOAEL)

>10.5%

(Reference: Great Lakes Chemical Corporation)

(Reference: NFPA 2001, 2000 edition)

Table 1.

Table 2.

(Reference: NFPA 2001, 2000 edition)

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FM-200® Container

The agent storage vessel consists of a container fittedwith a valve and internal syphon tube, factory filled withFM-200®, and super-pressurised with dry nitrogen to 25bar @ 210C(360 psi @ 700F). Containers sharing the samemanifold shall be equal in size and fill density. Contain-ers are finished in Alkyd Gloss Enamel Federal red andare available in various sizes ( Figure 1). A nameplate isadhered to the container displaying the agent weight,tare weight, gross weight, fill density and charge date.

Figure 1 - FM-200® Container

Technical Information

Manufactured in accordance with DOT(HSE)4BW500or 4BW450.

MaterialCarbon % 0.220% maxManganese % 1.250% maxPhosphorus % 0.045% maxSulphur % 0.050% max

4BW500Hydraulic test pressure: 68.95 bar (1000 psi)Working Pressure: 34.47 bar (500 psi)

4BW450Hydraulic test pressure: 62.1 bar (900 psi)Working Pressure: 31.0 bar (450 psi)

Paint Specification: Alkyd Gloss EnamelP-20187 Federal Red

System Components

This section describes the individual components thatcomprise a complete system. Some items are optionaldepending on the application, and are indicated as such.

Dimension APart Nom. Volume Outlet Size (nominal) Diameter Empty Weight No. Kg (Lbs.) mm (In) mm (In) mm (In) kg (Ibs)

9180 (8 litre) 4.5 to 8.0 (10 to 18) 25 (1") 304 (12.") 254 (10") 14.8 (32.6")9190 (16 litre) 9.0 to 17.5 (20 to 39) 25 (1") 502 (19.8") 254 (10") 18.4 (40.6") 9200 (32 litre) 17.0 to 33.5 (38 to 74) 25 (1") 833 (32.8") 254 (10") 26.1 (57.5")9210 (52 litre) 27.0 to 53.0 (59 to 117) 50 (2") 596 (23.5") 406 (16") 49.1 (108.3")9220 (106 litre) 53.5 to 106.5 (118 to 235) 50 (2") 1021 (40.2") 406 (16") 71.8 (158.3")9230 (147 litre) 74.0 to 147.5 (163 to 325) 50 (2") 1354 (53.3") 406 (16") 89.9 (198.2")9240 (180 litre) 91.5 to 182.0 (201 to 401) 50 (2") 1634 (64.3") 406 (16") 105.8 (233.2")

Figure 1 - FM-200® ContainerTable 4: Container details.

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10 FM-200® Installation Guide/11100/01.07.01/Issue3.0:

Container Label

The container label details the weight of FM-200® con-tained, empty weight, fill density and charge date. Oncethe label is applied to the container surface, and to avoidpossible tampering it can not be removed intact.

Figure 2 - Container Label


Material: Aluminum

Adhesive: Pre-applied 3M adhesive 9485

Dimensions: 150mm x 210mm (Pt.No.4294)(5.9") (8.3")350mm x 50mm (Pt.No.4284)

(13.8") (1.9")

Macron Safety Systems (UK) Ltd Guildford, Surrey GU1 1RN

Tel: +44 (0) 1483 57 2222Fax: +44 (0) 1483 302 180

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The bracket assembly consists of a nut and bolt, twobracket straps and one back channel. To securely holdthe container in position during the system discharge,two bracket assemblies are required per container. Theonly exception is the 8 litre container which only re-quires one.

Each strap is notched for insertion into the back channelallowing the container to be properly aligned. The bracketassembly is designed to be mounted to a rigid verticalsurface with the container assembly resting fully on thefloor.

Fixing Brackets

Valve Assembly

The Macron Safety Systems designed and manufac-tured container valve is the result of extensive researchand development and incorporates many unique safetyfeatures. The valve assembly is factory-fitted to thecontainer and is supplied pre-assembled with a low pres-sure switch, pressure gauge and burst disc.

Part No. Cont.size Dim.A mm (in)

9011 8-32 Ltr 400 (15.75") 254mm dia. (10 in)

9012 52-180 600 (23.6") 406mm dia. (16 in)

Principle of Operation

The Macron Safety Systems FM-200® valve is a high-flow-rate device specially designed for fire protectionuse. Operation is by means of a pressure-differential pis-ton. Container pressure is used within the valve to cre-ate a positive force on the piston, sealing the valveclosed. Operation of the valve occurs when the upperchamber is vented faster than the 'make up device' in theshuttle can replace the pressure. Thereby allowing, theshuttle to be forced up, and free flow of FM-200® fromthe valve. Upper chamber pressure is released by theelectrical, mechanical or pneumatic actuator.

25mm (1") valve assembly Part No. 641050mm (2") valve assembly Part No. 6430


Material: Brass CZ 121Body Proof Pressure: 150 bar (2175 psi)Outlet Adaptor: 1" BSP, 2"BSPLow Pressure Port: 1/8" NPTGauge Port: 1/8" NPTPilot Pressure Port: 1/4" BSPPSolenoid Adaptor Port: 1/8" NPT

Figure 3 - Fixing Bracket

Figure 4 - Valve Assembly



The valve incorporates the following features:

• A pressure operated safety release device (burstdisc).• Main outlet, fitted with safety shipping cap.• A connection for a pneumatic or mechanicalactuator, fitted with safety cap.• A connection for an electrical solenoid.• A connection for the pneumatic pilot signaloutput used for multiple container operation.

Figure 6 - Low Pressure Switch (Part No. 94181)

Low Pressure Switch

A low pressure warning switch is fitted to every con-tainer and must be utilised to safeguard the warrantyrequirements. The device continuously monitors thecontainer pressure and in the event of the pressure drop-ping below 20 bar (290 psi) the switch operates to enablethe condition to be signalled to a control unit.

Burst Disc

A burst disc is factory fitted to every valve assembly. Itis designed to rupture when the container becomes overpressurised when subjected to temperatures above thedesigned storage temperature of the container.

Figure 5 - Burst Disc

Technical Information PS20

Body: Hermetically sealed Stainless Steel

Switch point: Open at 20 bar +/-0.7 bar (290 psi (+/- 10psi)Switch Type: Close on rise at 24 bar +/-0.7 bar (350 psi (+/- 10psi)Proof pressure: 345 bar (5003 psi)Connection: Brass 1/8" NPTMax. Current: Max 2.9AVoltage Range: 5-28 vdcWire leads 1.82m (6Ft)


Body: Brass CZ 121Rating: 50 bar (725 psi) @ 50oC

(120oF)Thread 25mm Valve(1") : M14 x 1.25 (Pt.No. 94080)Thread 50mm Valve(2") : M18 x 1.00 (Pt.No. 94085)Hole Orientation: 90o to BodyTorque: 18 Nm (13.3Ibs.ft)

(M14 Thread)Torque: 20 Nm (14.8Ibs.ft)

(M18 Thread)

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Manual Actuator

The manual actuator is a simple ‘strike knob’ assemblywhich is fitted to the top of the valve assembly or sole-noid actuator. Inadvertent operation is prevented by apin which has to be removed before activation.

Figure 7 - Manual Actuator (Part No. 2880)

Pneumatic Actuator

The pneumatic actuator is an assembly similar to themanual actuator but without the strike knob. Pressurefrom a ‘master’ container or other sources is used toactuate the valve, via small bore piping or, preferably, aflexible hose.

Figure 8 - Pneumatic Actuator (Part No. 2900)


Body: Brass CZ 121Knob: NylonSafety Pin: Zinc Plated Mild SteelActuation Pin: Stainless SteelMin Actuation Force: 25.5N (5.73 Ibf)


Body: Brass CZ121Actuation Pin: Stainless SteelPipe connection: 1/4" BSPP FemaleMin. Actuation Pressure: 2 bar (29 psi)

Removable Electrical Actuator

The removable electrical actuator is also similar to themanual actuator and locates to the top of the containervalve. 24v dc is required for solenoid operation. Provi-sion is made for the connection of a manual strike Knobto the top of the actuator assembly.

Figure 9 - Electrical Actuator (Part No. 9490)


Body: Mild Steel & Dull NickelSwivel nut: Brass CZ121Actuation Pin: Stainless SteelActuation Type: LatchingRest Requirement: Manual Force RequiredConnection: 1" BSPPPower requirement: 24vdcCurrent: 0.2AManual Actuation Force: 5 kgf (11. Ib.f)Electrical connection: 3-pin plug connectorDiode Type: SuppressionTemperature Range: -20oC to +55oC

(-4oF to131oF)Life Span: 10 years from manufactureTesting: 100% Check on start /

Finish positionApproval: Underwriters Laboratories

Recognised to UL508Tested in accordance withUL864



Figure 11 - 32mm (1 1/4") Hose & Brass Adapter Assy (Part No. 4125)

Side Mounted Electrical Actuator

This solenoid actuator differs from other actuators inthat it is side mounted. It can be located directly on theside of the valve or via a solenoid adaptor. The adaptorenables the actuator to be removed safely without ac-tuation of the container valve. It is designed to be usedin explosive atmospheres (Class I , groups C and D, ClassII, groups E, F & G). It is operated by a 24v dc inputsignal.

Figure 10 - Electrical Actuator (Part No 95550)

Flexible Discharge Hose

Multiple FM-200® container installations are connectedto the system by means of a flexible discharge hose.This enables containers to be disconnected for mainte-nance or recharge without dismantling other containermountings, manifold connections and pipework, etc.

The flexible discharge hose is connected to each mani-fold valve outlet. A swivel fitting at the inlet of the hoseenables the container to be readily coupled to the distri-bution system. The 32mm (1 1/4") discharge hose (PartNo.4120) requires the addition of a brass adapter (PartNo. 6412) between the valve outlet and the swivel fittingat the inlet of the hose.


Construction: Twin steel wire braidedOil resistantSeamless synthetic rubbercore to DIN 20022.

Connection: Zinc Passivated Mild Steel

Max Bend Angle: 15o @ 0oC (32oF)

- 50mm (2") Hose (Part No 6540)


Solenoid Enclosure: Stainless SteelPower Requirement: 24v dcPower Consumption: 9.5 wattsConduit Thread: 1/2" NPTPressure Connection: 1/8" NPT FemalePressure Range: 0 - 103 bar (1500 psi)Certification: ULMax. Ambient Temp: 105oC (221oF)Solenoid Orientation: 0-30o Off Vertical

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Solenoid Adaptor

The adaptor enables the actuator to be removed safelywithout actuation of the container valve. To remove thesolenoid the adapter body should be unscrewed in theanticlockwise direction. This action will close theschrader valve and then allow the pressure between theschrader and solenoid actuator to be released safelythrough the threads of the adaptor body.

Figure 12 - Solenoid Adaptor (Part No 5550)

Manifold Check Valve

Manifold check valves are of mushroom pattern typeand lift into the manifold as discharge occurs. The func-tion of the check valve is to prevent loss of extinguish-ing agent during discharge from an outlet, should a con-tainer have been removed. All check valves are suppliedready fitted to the manifold assembly.

Figure 13 - Manifold Check Valve

32mm (1.25") Check Valve Assy. Part No. 409050mm (2") Check Valve Assy. Part No. 6550


Body: Brass CZ121Circlip: Stainless SteelMax Working Pressure: 75 bar (1088 psi)Proof Pressure: 150 bar (2175 psi)Solenoid Connection: 1/8" NPT


Body: Brass CZ122Stem: Stainless SteelSpring: Stainless Steel



Manifold

Manifolds are fabricated sections of steel pipe-work. They enable multiple containers to be connected to a commonpipe network. They can be used in conjunction with check valves in situations where main / reserve containersarrangements are required.

Figure 14 - Typical Manifold Assembly


Material: BS 3601 Schedule 80Inlet: Check valve flange connectionOutlet: BSP TaperTest Press. 90 bar (1305 psi)Finish: Primed, Ready to paint on site.

Note: Assembly includes 32 / 50mm check valvesand end cap.

Part Size Dim. A Dim. BNo. mm mm mm

9335 2 port 65 (2.5") 150 (6") 350 (14")9336 3 port 65 (2.5") 150 (6") 350 (14")9337 4 port 65 (2.5") 150 (6") 350 (14")9352 2 port 80 (3") 150 (6") 508 (20")9353 3 port 80 (3") 150 (6") 508 (20")9345 4 port 80 (3") 150 (6") 508 (20")9346 5 port 80 (3") 150 (6") 508 (20")9355 2 port 100 (4") 150 (6") 508 (20")9356 3 port 100 (4") 150 (6") 508 (20")9354 4 port 100 (4") 150 (6") 508 (20")

Part Size Dim. A Dim. B No. (mm) (mm) (mm)

9357 5 port 100 (4") 150 (6") 508 (20")9358 6 port 100 (4") 150 (6") 508 (20")9312 3 port 150 (6") 150 (6") 508 (20")9313 4 port 150 (6") 150 (6") 508 (20")9314 5 port 150 (6") 150 (6") 508 (20")9315 6 port 150 (6") 150 (6") 508 (20")9316 7 port 150 (6") 150 (6") 508 (20")9317 8 port 150 (6") 150 (6") 508 (20")9318 9 port 150 (6") 150 (6") 508 (20")9319 10 port 150 (6") 150 (6") 508 (20")

Table 5: Manifolds.

HYGOOD



Manifold Bracket Assembly

A manifold bracket assembly consists of two lengths of unirax, mounted vertically on a wall or bulk head to enableheight adjustment of the manifold assembly. Cantilever brackets are located over the unirax and each are held inposition using a uninut long spring, washer and hex head screw. Manifold brackets slot into the cantilever and areclamped using a hex head screw and plain nut.

Figure 15 - Manifold Bracket Assembly

65mm (2.5") Manifold Bracket Part No. 3046080mm (3") Manifold Bracket Part No. 30500100mm (4") Manifold Bracket Part No. 30510150mm (6") Manifold Bracket Part No. 30515




Material: BrassConnection: 1/4"BSPT x 1/4" BSPP

Flexible Pilot Hose

The flexible pilot hose is used to connect pressure acti-vated devices to the system, e.g. slave container, pres-sure switch, etc.

Figure 16 - Flexible hose (Part No. 6490)

Male Adaptor

This adaptor is used to connect the pilot hose to thecontainer valve assembly.

Figure 17 - Male Adaptor (Part No. 91105)


Outer sheath: Stainless Steel BraidedInner sheath: PTFE to BS 4976Max. Working Pressure: 190 bar (2755 psi)Min. Burst Pressure: 759 bar (11008 psi)MIn. Bend Radius: 60mm (2.4")@ 0oC (32oF)Connections: 1/4" BSP swivel femaleLength: 710mm (28")

HYGOOD



Figure 18 - Male Tee (Part No. 91109)


Material: BrassConnection: 1/4" BSPP x 1/4" BSPT

Male Elbow

This elbow can be used on the last slave container whenthe pressure switch connection is taken from the mani-fold or piping networks.

Figure 19 - Male Elbow (Part No. 91101)

Male Tee

This is used primarily in manifold systems for connect-ing pilot lines from one slave container to the next.

Figure 20 - Pressure Switch (Part No. 99205)

Pressure Switch

The pressure switch is activated by pressure from theagent during discharge and can be used to signal to acontrol panel that the system has actually discharged.The pressure switch incorporates a reset button whichhas to be depressed following a discharge.


Material: BrassConnection: 1/4" BSPT x 1/4" BSPP


Housing: Die-cast AluminiumPressure Connection: Nickel Plated BrassSwitch Point: 4 bar Rising (58 psi)Tolerance: +/- 0.34 Bar (+/- 5 psi)Connection: 1/4" NPT FemaleProof Pressure: 172.4 bar (2500 psi)

DC Switch Rating: 1 A 24v DCTemperature Range: -40oC to +71oC (-40 oF to 160 oF)Installation Environment: non-corrosive / indoor



Discharge Nozzle

FM-200® is distributed within the protected area by thedischarge nozzle which is sized to ensure the correctflow of agent for the risk. Nozzles are available with sevenor eight ports to allow for 180o or 360o horizontal dis-charge patterns. Ports are drilled in 0.1mm (0.004 in) in-crements to the specified system design. BSP nozzlesare supplied as standard in Brass and Stainless Steelwith NPT as optional.


Material: Brass / Stainless Steel

Figure 21 - 7 & 8 Port Nozzle Configuration

10mm (3/8") BSP Nozzle: Part No. 3381/215mm (1/2") BSP Nozzle: Part No. 3391/220mm (3/4") BSP Nozzle: Part No. 3401/225mm (1") BSP Nozzle: Part No. 3411/232mm (1 1/4") BSP Nozzle: Part No. 3421/240mm (1 1/2") BSP Nozzle: Part No. 3431/250mm (2") BSP Nozzle: Part No. 3441/2

HYGOOD



Manual Release Notice

A notice should be located at each manual release posi-tion.

Door Notice

A door notice is required at each entrance to the risk toadvise personnel that they are entering a protectedarea.


Material 2mm (0.08 in) CraylonFinish Gloss, scratch resistant


Material 2mm (0.08 in) CraylonFinish Gloss, scratch resistant

Figure 23 - Manual Release Sign (Part No. 2659)Figure 22 - Door Notice (Part No. 2675)

for areas protected by concentrations greater thanNOAEL (unoccupied spaces only).

��

D o N O T enter unless extinguishing system is locked off

W hen alarm sounds

��

evacuate hazard area

After system discharge do N O T re-enter until thoroughly ventilated.

HYGOOD LTD WOODLANDS ROAD GULIDFORD SURREY GU1 1RN TEL 01483 572222 FAX 01483 302180

��

RELEASE MANUAL CONTROL

POINT

��

�� ENSURE ALL PERSONEL ARE EVACUATED

BEFORE RELEASING EXTINGUISHANT

��

for areas protected by concentrations less thanNOAEL (Part No. 2676).

��

T his area is protected by a FM 200� fire extinguishing system

W hen alarm sounds

��

or upon gas discharge

evacuate hazard area

After system discharge do N O T re-enter until thoroughly ventilated.

HYGOOD LTD WOODLANDS ROAD GULIDFORD SURREY GU1 1RN TEL 01483 572222 FAX 01483 302180

Macron Safety Systems Limited

Tel: +44 (0)1483 572222Fax: +44 (0)1483 302180

Macron Safety Systems (UK) LimitedSouth Denes Road, Great YarmouthNR30 3PJ

Macron Safety Systems (UK) LimitedSouth Denes Road, Great YarmouthNR30 3PJ Tel: +44 (0)1483 572222

Fax: +44 (0)1483 302180



Typical Manifold System

Figure 24 indicates a typical two container system complete with electrical actuation, manual strike knob, pressureswitch, 2 x low pressure switch, flexible connections, distribution pipework and nozzles.

Figure 24 - Typical Manifold System

HYGOODSECTION 3 - SYSTEM DESIGN


The FM-200® cupburner valve is 6.7% for commercial grade Heptane. Nozzle distribution test concentration = 6.9%

Calculations:

Cupburner or fire test concentration X nozzle efficiency factor X safety factor.

Nozzle efficiency factor = 6.9 = 1.03 6.7

Safety factor: Class A = 1.2Class B = 1.3

Class C = Class A

For Class A (Determined by fire test) - 5.8% x 1.03 x 1.2 =7.17%

For Class B (Commercial grade Heptane)-6.7% x 1.03 x 1.3 =9.0%

For Class B (Other class B fuels)-cupburner x 1.03 x 1.3 = Designconcentration, but not less than9.0%

For Class C - Use at least design concentration for Class A surfaces fires (7.17)

For systems with only manual actuation - cupburner x 1.03 x 1.3 = design

concentration but not less than 9.0%

Rugged environments, and those requiring intrinsi-cally safe or flameproof equipment, require special con-sideration and should be discussed fully with MacronSafety Systems before finalising a system design. FM-200® is suitable for use with the following materials:

Class A Fires involving solid materials usually ofan organic nature, in which combustionnormally takes place with the formationof glowing embers.

Class B Fires involving flammable liquids orliquefiable solids and flammable gases.

Class C Fires involving energized electrical equip-ment where the electrical nonconductivityof the extinguishing media is of importance

System Design

There are two main elements of system design. The firstis the risk assessment; determining the type of protec-tion required, considerations such as ventilation, open-ings and restrictions; equipment location. etc. The sec-ond is calculating the quantity of FM-200® required,including floor and/or ceiling voids, positioning of noz-zles, electrical requirements, etc.

A Site Survey / Request form is a useful tool to aide-memory for addressing the relevant factors, and can beused subsequently to substantiate the design criteria.This can be found in Appendix A. All systems are de-signed in accordance with the BFPSA Code of Practisefor Gaseous Fire Fighting Systems, the appropriate Brit-ish Standards, currently BS5306 section 5.1. and NFPA2001.

Hazard Analysis

The first, and one of the most important, exercises inplanning an FM-200® extinguishing system is the haz-ard survey. The information derived from the surveyshould include risk assessment, environmental condi-tions, personnel considerations, system operation bothin normal conditions and after a discharge, access andconstruction limitations, dimensions, volumes, and anyspecial requirements.

FM-200® systems are suitable for use in normal com-mercial and industrial environments. The design con-centration for Class A & C fires is 7.17% but differs forClass B fires. To determine other recommended designconcentrations for Class B flammable liquids, consultMacron Safety Systems Limited as well as referring toNFPA 2001, 2000 edition, paragraph 3-4.2 and UL -2166,first edition, paragraph 61.2(b). However the minimumdesign concentration for flammable liquids is 9%. Alldesign concentration calculations are based on extin-guishing concentrations plus an additional 20% safetyfactor for Class A & C and 30% safety factor for ClassB, and manually actuated only systems, plus an addi-tional 3% safety factor for nozzle performance (commer-cial grade Heptane excluded).

All system design calculations are calculated at mini-mum design concentration to determine agent quantity.Maximum design concentration should be at the maxi-mum anticipated enclosure temperature, for comparisonsee NOAEL / LOAEL values.

See table 3 or Refer to NFPA 2001, 2000 edition.

SECTION 3 - SYSTEM DESIGNHYGOOD


Note. Certain materials in this group mayrequire increased concentrations to achievesatisfactory extinguishment. Consult Macronfor details of specific risk.

Caution. FM-200® is not effective on the following: -

• Class A Deep seated fires.

• Class D Combustible metals.

• Chemicals capable of auto-thermal recomposition.

• Chemicals capable of rapid oxidation.

• Enclosures with hot surfaces (>400oC) (752oF)

Hazard Structure

The protected enclosure shall be bounded by rigid ele-ments of building constrution. The ceiling should benot less than 0.3m (1.ft) above the hazard. The rigidelements should have a fire resistance of not less than30 min when tested in accordance with BS476: Part 20,Part 21, Part 22 or Part 23 as appropriate.

During agent discharge, the hazard enclosure willexperience a pressure change. The hazard structure mustbe capable of withstanding a pressure of 600 pa (0.201ftH20) developed during discharge.

Hazard Volume

In total flooding applications the risk area must com-prise an enclosed space with no significant openings sothat the design concentration can be achieved and main-tained. Generally, the calculation is based on an emptyarea; the subsequent furniture and fittings having littleeffect on the actual concentration. Similarly, large equip-ment cabinets and control panels should not be consid-ered in the calculation as it is assumed that the internalarea is required to be filled with agent.

Each enclosed space is considered as a risk area andrequires at least one nozzle. A floor void, ceiling void,cable duct, etc., is treated as a separate adjacent areaand requires simultaneous discharge to occur.

Ceiling obstructions such as beams that are less than300mm (12") below the slab need not be considered.Obstructions greater than 300mm (12") can affect thedistribution of agent and may require additional nozzles.Consult Macron Safety Systems if in doubt. Please notethat floor voids cannot be protected separately from theassociated room.

To determine the volume refer to the site drawings,ensuring that the scale is accurate and that heights aredenoted, or make a sketch of the area adding dimen-sions and any relevant details. Calculate the volume ofeach area.



Personnel Safety

Natural Agent: To avoid possible injury, avoid any expo-sure to FM-200® in volume concentrations greater than9% unless using self contained breathing apparatus.Limit exposure times as in NFPA 2001, Section 1-6"Safety."

Symptoms of overexposure to concentrations greaterthan 10.5% may include dizziness, impaired coordina-tion, reduced mental acuity, cardiac effects or uncon-sciousness. In the event of overexposure, remove tofresh air immediately and summon medical assistance.

Frostbite: Direct skin contact with FM-200® in theimmediate area of discharge may cause frostbite.

Agent Quantities

Normally the agent quantity is the weight required toproduce the desired concentration at the lowest tem-perature within the hazard enclosure.

Agent Storage

FM-200® is stored as a liquified compressed gas inappropriate containers to meet DOT4BW500 & 450 re-quirements. Nitrogen in the container maintains asuperpressurisation of 25 bar at 21oC (360 psi at 70oF).The chosen location should provide protection fromsevere weather, mechanical, chemical, or other types ofdamage. The ambient temperature of the storage areamust be between 0 oC to 49 oC (32 oF to 120 oF), theoptimum temperature being 21oC (70oF).

Hydraulic calculations are made at 21oC (70 oF). Whenthe storage temperature varies by + 5.5 oC (+ 10 oF) from21oC (70 oF), there is a risk that the system will not sup-ply the designed quantity of extinguishing agent.

(ii) Central air conditioning unit

A central air conditioning unit relies on air from outsideand is often linked by ducts to other parts of the build-ing, therefore, prior to a discharge, the unit should beshut down and/or dampers operated to close the ducts.Sufficient time must be allowed for the plant to stop, ordampers to close, before discharge occurs.

Dampers should be installed in both supply and re-turn air ducts, as close as possible to the area. The ductvolume between the hazard and the damper must beadded to the overall volume.

Hazard Temperature

Determine as accurately as possible the anticipated mini-mum and maximum temperatures likely to be experiencedwithin the protected area. Minimum agent quantity re-quirements are based on minimum hazard. At maximumtemperature, hazard concentration must not exceed theNOAEL/LOAEL values for normally occupied spaces,reference NFPA 2001, Section 1-6 "Safety."

Once assembled , filled and pressurised the FM-200®

extinguishing system should not be exposed to tem-peratures other than the storage / operating temperaturerange of 0 to 500C. (32oF to 120oF). This also includeswhile being in storage or transported.

Ventilation

If the hazard enclosure has no means of adequate vent-ing after discharge, consideration should be given toinstalling a normally closed means of ventilation withextraction arrangements which will discharge directly toopen air.

Air conditioning and/or forced ventilation can affect thesystem performance and the quantity of agent required.

(i) Self-contained air conditioning unit

A self-contained unit conditions the air within the en-closure and does not rely on a fresh air supply, or drawair from other parts of the building.

If the hazard has a self-contained unit and it is lo-cated within the area without an outside air supply, noadditional agent is required. It is not necessary to shutdown the unit prior to a discharge as the mixing effect isbeneficial.

Hazard Fuels

All fuels in the hazard must be identified and the corre-sponding agent concentration requirements. The designconcentration (percent by volume) required for the haz-ard will be the highest concentration required by anyone of the fuels present in the hazard.



Whenever containers are manifolded, the following rulesmust be observed.

1. All containers connected to the same manifoldor pipe must be the same size and filled with thesame agent weight, pressure and fill density.

2. Agent containers must be located in a singlerow and spaced according to section.

3. A connected reserve may be employed in somecircumstances providing a secondary supply ofagent.

4. Flexible discharge hoses and check valves mustbe used at each inlet.

Agent Distribution

Distribution piping will be installed only with approvedpiping as indicated in Section 5.

Pipe size reductions may be made by using reducingtees or reducing bushings or reducing couplings.

Manifolds

It may be necessary to manifold agent containers toprovide the required amount of agent for a hazard, or tomake available the proper increments of agent weightfor the protection of multiple hazards.



Agent Flow Characteristics

Nitrogen Superpressurisation

Nitrogen is added to the FM-200® containers. This ad-dition of nitrogen, known as superpressurisation, willcause a portion of the nitrogen to mix with the FM-200®,the remaining portion of the nitrogen will remain in thevapour space above the liquid providing the increasedpropulsion necessary to discharge the FM-200® fromthe container.

Flow in Pipe

In a properly designed distribution piping network theflow of FM-200® will consist of a two phase mixture ofliquid and vapour. The properties of this mixture willvary with its composition; therefore, when the mixturecontacts the pipeline walls, the friction decreases thedensity of the mixture resulting in a non-linear pressuredrop and an increase in flow velocity.

Another consequence of two-phase flow is the poten-tial for separation of liquid and vapour. In a properlydesigned pipe network, the velocity of the mixture willbe high enough to maintain highly turbulent flow. How-ever, if the pipeline diameter is too large for the designflow rate, the two phases may separate, leading to alter-nate discharges of liquid and vapour (slugging) or lay-ering of the two phases. Therefore, the pipeline must beproperly sized to keep the FM-200® flow turbulentenough to prevent phase separation.

Hydraulic calculations are made at 210C (70oF). Tempera-tures other than 21oC (70oF) may result in variations insystem discharge characteristics. When the storage tem-perature varies by + 5.5oC (+ 10oF) there is a risk that thesystem will not supply the designed quantity of extin-guishing agent.

Initial Vapour Discharge

At the instant the discharge valve is opened, rapid ex-pansion of the agent will cool the piping network.

Trailing Vapour Pressure

Discharge time is defined as the average liquid dischargetime through all nozzles in the system. After the liquidportion of the discharge has been completed, there willbe a short transition period followed by the delivery of

Nozzle selection and location

The number of nozzles required is based on the hazardsize and configuration and the coverage provided bythe nozzle. Nozzles are available in 7-port or 8-port ver-sions to provide 180 or 360 degree discharge patternsrespectively. When considering the optimum nozzle lo-cation, the following factors should be taken into ac-count.

• Nozzle location is affected by the shape of thehazard area.

• The maximum discharge radius is 8.7m(28.6ft) for a 360o nozzle and 10.05m(33ft) for a 180o nozzle.

• The maximum coverage area for either nozzle is95.3m2 (1026 ft2)

• Nozzle orifices must not be placed where they maydischarge into nearby objects.

• Nozzles must be installed a maximum of 300mm(12")below the ceiling.

• 4.87m(16 ft) maximum protection height for 360o and180o nozzle.

• 180 degree nozzles must be mounted adjacent to awall and must be located to cover the entire area.

• 300mm(12") minimum void height (i.e. Sub-floors &false ceilings).

• Maximum distance 180 degree nozzles should beplaced from a wall 300mm (12"), the minimum 50mm(2"). Measured from centre of the nozzle to the wall.

• Nozzles located both above and below the container outlet, Maximum distance between 9.1m (30ft)

• Nozzles located either above or below the containeroutlet, maximum distance between them 9.1m (30ft)

the remaining FM-200® nitrogen mixture as a vapour.This is due to flashing of the trailing edge of the fluid asit moves from the tank to the nozzles. In some systemsthe transition period is relatively long; this can lead toconfusion as to when the discharge is complete, possi-bly resulting in an inaccurate measurement of the dis-charge time.



Maximum Limits in Pipe Work.

Figure 25a -

Figure 25b -

Figure 25c -

If nozzles are only located above thecontainer outlet, then the maximum elevation differencebetween the container outlet and the furthest horizontalpipe run or discharge nozzle (whichever is furthest) shallnot exceed 9.1m (30 ft). See figure 25a.

If nozzles are only located below thecontainer outlet, then the maximum elevation differencebetween the container outlet and the furthest horizontalpipe run or discharge nozzle (whichever is furthest) shallnot exceed 9.1m (30 ft). See Figure 25b.

If nozzles are located both above andbelow the container outlet, then the maximum distancebetween the furthest horizontal pipe runs, or dischargenozzles (whichever is further) shall not exceed 9.1m (30ft). See figure 25c.

Note: If a system design violatesthese limits, contact Macron SafetySystems to determine what actionhas to be taken.

Examples:



Figure 26 - Nozzle Discharge Radius System Design Procedure

The following procedure must be followed when design-ing FM-200® systems.

• Determine hazard material and required designconcentration.

• Identify individual enclosure volumes and deductany impermeable volumes where appropriate.

• Determine hazard altitude and correction factor.

• Calculate quantity of FM-200® per enclosure, atminimum design temperature.

• Determine container size and fill density.

• Select nozzle type and location.

• Design pipe network.

• Calculate quantity of FM-200® per nozzle.

• Check percentage agent split at tee's.

• Identify all pipe lengths, rises, falls and nozzlereference numbers.

Note: The side tee splits shall be between 10-30%,bull tee splits will be between 30-70%. All Tee out-lets must be in the same horizontal plane.

See examples figure 27 a-f.

Example: Nozzle Selection

Switch Room:

120.7m3 (4262.6ft3) 1 x 7 port nozzle

Computer Room:

543.3m3 (19237.1ft3) 4 x 8 port nozzles

Floor Void:

63.36m3 (2275.4ft3) 2 x 8 port nozzles

Nozzle placement and piping arrangements for the exam-ple are shown in Figure 28.

(28.6ft)

(33ft)

8.7m

10.05m



Example: Tee Split Designs

Figure 27a - Side Tee Split limits.

Figure 27c - Side tee orientation "correct"

Figure 27e - Bull tee orientation "correct"

Figure 27b - Bull Tee Split limits.

Figure 27d - Side tee orientation "incorrect"

Figure 27f - Bull tee orientation "incorrect"

NOTE: Incorrect orientation of side and bull tee could result in separation of the FM200 from the Nitrogen (due to FM-200®

greater density). The design would also be outside the parameters permitted by the calculation software. See figures 27d and 27f.



Example:

Calculation for two rooms and floor void with the fol-lowing dimensions:

Switch Room: 22.9 x 22.7 x 8.2 = 4262.6ft3

Computer Room: 52.5 x 39.4 x 9.3 = 19237.1ft3

Floor Void: 52.5 x 39.4 x 1.1 = 2275.4ft3

t = 21o C (70oF) for calculation example

Switch Room: (7.20% required design concentration example only)

W = 4262.6 X 7.2 = 149.9Ibs

2.207 (100-7.2)

Computer Room: (7.2% required design concentration example only)

W = 19237.1 X 7.2 = 676.3lbs 2.207 (100-7.2)

To calculate the required agent for each hazard volumeas a percentage of the total agent required;

% Hazard Agent = Individual hazard VolumeSum of hazard volumes

Switch Room: 4262.6/25775.1 = 16.6% of Agent

Computer Room: 19237.1/25775.1 = 74.6% of Agent

Floor Void: 2275.4/25775.1 = 8.8% of Agent

It is determined from the above that both the switchRoom and the Computer Room can be fed by one mani-folded system using 3 x 180 Litre containers, each filledwith 276lbs of Agent. The Floor Void would use 1 x 52Litre container filled with 80lbs as it requires less than10% of the total Agent and therefore equates as follows.(Separate tank is required for floor voids. If protectedwith nozzle from computer room system, the piping wouldbe outside the tee split limits.)

Design Example - Calculations

Minimum Agent Quantity is based on the hazard vol-ume at the minimum anticipated temperature and con-centration required. To determine the minimum agentquantity the following equation is used:

W = (V/S)* (C/100-C)

W = Weight of Agent required (lbs)

V = Hazard Volume (ft3)

S = Specific Vapour Volume (ft3/lb)

S = 1.885 + 0.0046t

t = Design Temperature in Hazard Area (oF)

C = Required FM-200® Design Conc. (% by volume) at DesignTemperature (t).

Floor Void: (7.2% required design concentration example only)

W = 2275.4 X 7.2 = 80.0lbs

2.207 (100-7.2)

When the minimum quantity of FM-200® has been cal-culated the weight is compared to the available agentcontainer size. The container size must be equal to orgreater then the weight of agent (see Figure 1).

With the appropriate container selected, the previousequation can be rearranged to determine the concentra-tion based on the actual weight as containers are filledto the nearest kg.

C = 100 WSWS + V



After determining the minimum weight and concentra-tion, the maximum concentration can be determined byrecalculating the equation based on the maximum tem-perature anticipated in each enclosure 270C (800F) maxi-mum design temperature. This calculation is required todetermine if the maximum concentration is below theNOAEL limit for normally occupied areas.

Switch Room: C = 100 x 150.2 x 2.2538 = 7.36% (150.2 x 2.253) + 4262.6

Computer Room: C = 100 x 677.8 x 2.2538 = 7.36% (677.8 x 2.253) + 19237.1

Floor Void: C = 100 x 80 x 2.2538 = 7.34% (80 x 2.253) + 2275.4

The minimum enclosure concentrations can be calcu-lated based on the actual container fill (70oF minimumdesign temperature).

Switch Room: C = 100 x 150.2 x2.207 = 7.22% (150.2x2.207)+4262.6

Computer Room: C = 100 x 677.8 x 2.207 = 7.22% (677.8 x 2.207)+19237.1

Floor Void: C = 100 x 80 x 2.207 = 7.2% (80 x 2.207) + 2275.4

Figure 28 - Example Nozzle Location

Switch Room: 4262.6/23499.7 = 18.14% of Agent

Computer Room: 19237.1/23499.7 = 81.9% of Agent

Floor Void: 2275.4/2275.4 = 100% of Agent

Actual agent to switch Room :

0.1814 x 3 x 276 = 150.2 lbs

Agent to Computer room :

3 x 276 - 150.2 = 677.8



Piping Practices

Due to the two phase flow of FM-200®, certain pipingpractices must be adhered to. Mainly that the flow splitmust be on the horizontal plane. There are two types oftee used in FM-200® systems, a through /side tee and abull tee. Both have limitations on the minimum and maxi-mum allowable flow splits which are detailed in section4, page 36.

It should also be noted that system designers shall al-low a minimum of 10 times the nominal pipe diameteraround tee splits before any change of direction.

System designers should aim to design as far as possi-ble balanced pipe networks, use minimum lengths of pipe,use minimum numbers of elbows, maximize pipe volumebefore the 1st tee and incorporate similar pipe run lengthsto nozzles.

SECTION 4 - FLOW CALCULATIONSHYGOOD


Table 6: FM-200® Weight CalculationsImperial

Note: Specific Vapour Volume data shown inTable 7 are experimentally derived values andthe specific vapour volume equation (S) hasa correlation coefficient of 0.99. However theequation can be used to give a close approxi-mation of required agent quantities.

Example:

Hazard Volume: 9182ft3

Room Temperature: 70oF

Agent Concentration: 7.17%

Flooding Factor: 0.0351

Quantity of FM-200® required: 0.0351 x 9182 =322.3lbs

Introduction

In determining the quantity of FM-200® required fora particular application, it is important to assess the haz-ard area correctly. The following information will needto be determined as discussed in Section 3.

1. Hazard Volume.

2. Minimum Room Temperature.

3. Hazard Type.

4. Height above sea-level.

The Hazard volume can be determined by calculatingthe room volume and deducting any impermeable vol-umes that may be contained within the area. The antici-pated temperature of the Hazard area will normally beadvised by the client. The agent concentration is de-pendant upon the type of hazard being protected, thetype of nozzle used and hazard altitude. The quantity ofFM-200® can be calculated by using the flooding fac-tors (Table 6. imperial / 6a. metric) or by using the for-mula (FM-200® Equation Calculations) and then multi-plying by the altitude correction factor (table 7).

Weight Requirements of Hazard Volume, W/V (lb/ft3)

Design Concentration (% by Volume) Temp.

t

(oF )c

Specific Vapor

Volume s

(ft3/lb)d

6 7 7.17 8 9 10 11 12 13 14 15

10 1.9264 0.0331 0.0391 0.0401 0.0451 0.0513 0.057 0.0642 0.0708 0.0776 0.0845 0.0916 20 1.9736 0.0323 0.0381 0.0391 0.0441 0.0501 0.0563 0.0626 0.0691 0.0757 0.0825 0.0894 30 2.0210 0.0316 0.0372 0.0382 0.0430 0.0489 0.0550 0.0612 0.0675 0.0739 0.0805 0.0873 40 2.0678 0.0309 0.0364 0.0373 0.0421 0.0478 0.0537 0.0598 0.0659 0.0723 0.0787 0.0853 50 2.1146 0.0302 0.0356 0.0365 0.0411 0.0468 0.0525 0.0584 0.0645 0.0707 0.0770 0.0835 60 2.1612 0.0295 0.0348 0.0357 0.0402 0.0458 0.0514 0.0572 0.0631 0.0691 0.0753 0.0817 70 2.2075 0.0289 0.0341 0.0349 0.0394 0.0448 0.0503 0.056 0.0618 0.0677 0.0737 0.0799 80 2.2538 0.0283 0.0334 0.0342 0.0386 0.0439 0.0493 0.0548 0.0605 0.0663 0.0722 0.0783 90 2.2994 0.0278 0.0327 0.0335 0.0378 0.0430 0.0483 0.0538 0.0593 0.0650 0.0708 0.0767 100 2.3452 0.0272 0.0321 0.0329 0.0371 0.0422 0.0474 0.0527 0.0581 0.0637 0.0694 0.0752 110 2.3912 0.0267 0.0315 0.0323 0.0364 0.0414 0.0465 0.0517 0.0570 0.0625 0.0681 0.0738 120 2.4366 0.0262 0.0309 0.0316 0.0357 0.0406 0.0456 0.0507 0.0560 0.0613 0.0668 0.0724 130 2.4820 0.0257 0.0303 0.0311 0.0350 0.0398 0.0448 0.0498 0.0549 0.0602 0.0656 0.0711 140 2.572 0.0253 0.0298 0.0306 0.0344 0.0391 0.0440 0.0489 0.0540 0.0591 0.0644 0.0698

SECTION 4 - FLOW CALCULATIONS HYGOOD


Table 7: Altitude Correction Factor

A ltitude above sea-level

ft

C orrection F actor

-3000 (-0 .92 km ) 1 .11 -2000 (-0 .61 km ) 1 .07 -1000 (-0 .30 km ) 1 .04

0 (0 .00 km ) 1 .00 1000 (0 .30 km ) 0 .96 2000 (0 .61 km ) 0 .93 3000 (0 .91 km ) 0 .89 4000 (1 .22 km ) 0 .86 5000 (1 .52 km ) 0 .82 6000 (1 .83 km ) 0 .78 7000 (2 .13 km ) 0 .75 8000 (2 .45 km ) 0 .72 9000 (2 .74 km ) 0 .69

10000 (3 .05 km ) 0 .66

At elevations above sea-level, FM-200® has a greater spe-cific volume because of the reduced atmospheric pres-sure. A system designed for sea-level conditions will there-fore develop an actual higher concentration at levels abovesea-level and an actual lower concentration at levels be-low sea-level. The adjusted agent quantity is calculatedby multiplying W (from the equation on the left) by thealtitude correction factor. The design quantity of the cleanagent shall be adjusted to compensate for ambient pres-

FM-200® Equation Calculations

The weight of agent required for a hazard area can alsobe calculated from the formula shown below;

W = (V/S) * (C/100-C)

(BS5306: Part 5: Section 5.1 / NPFA2001 Table 3-6)W = Weight of Agent required kg (lbs)

V = Hazard Volume m3 (ft3)

S = Specific Vapour Volume cu.m/kg (ft3/lbs)

where S = 0.1269 + 0.0005131 t ( oC)

Or (S= 1.885 + 0.0046 t o F)

t = Design Temperature in Hazard Area oC (oF)

C = Required FM-200® Design Conc. (% by volume) atDesign Temperature (t).

Table 6a: FM-200® Weight CalculationsMetric.

Weight Requirements of Hazard Volume, W/V (kg/m3) Design Concentration (% per volume)

Temp t

(oC )c

Specific Vapor Volume

s (m3/kg)d

6 7 7.17 8 9 10 11 12 13 14 15

-10 0.1215 0.5254 0.6196 0.6357 0.7158 0.8142 0.9147 1.0174 1.1225 1.2301 1.3401 1.4527 -5 0.1241 0.5142 0.6064 0.6223 0.7005 0.7987 0.8951 0.9957 1.0985 1.2038 1.3114 1.4216 0 0.1268 0.5034 0.5936 0.6091 0.6858 0.78 0.8763 0.9748 1.0755 1.1785 1.2839 1.3918 5 0.1294 0.4932 0.5816 0.5968 0.6719 0.7642 0.8586 0.955 1.0537 1.1546 1.2579 1.3636 10 0.132 0.4834 0.57 0.5851 0.6585 0.749 0.8414 0.936 1.0327 1.1316 1.2328 1.2264 15 0.1347 0.474 0.5589 0.5734 0.6457 0.7344 0.8251 0.9178 1.0126 1.1096 1.2089 1.3105 20 0.1373 0.465 0.5483 0.5625 0.6335 0.7205 0.8094 0.9004 0.9934 1.0886 1.1859 1.2856 25 0.1399 0.4564 0.5382 0.5520 0.6217 0.7071 0.7944 0.8837 0.975 1.0684 1.164 1.2618 30 0.1425 0.4481 0.5284 0.5420 0.6104 0.6943 0.78 0.8676 0.9573 1.049 1.1428 1.2388 35 0.145 0.4401 0.519 0.5326 0.5996 0.6819 0.7661 0.8522 0.9402 1.0303 1.1224 1.2168 40 0.1476 0.4324 0.5099 0.5232 0.5891 0.6701 0.7528 0.8374 0.9230 1.0124 1.1029 1.1956 45 0.1502 0.425 0.5012 0.5142 0.579 0.6586 0.7399 0.823 0.0908 0.995 1.084 1.1751 50 0.157 0.418 0.4929 0.4919 0.5694 0.6476 0.7276 0.8093 0.8929 0.9784 1.066 1.1555 55 0.1553 0.4111 0.4847 0.4973 0.56 0.6369 0.7156 0.796 0.8782 0.9623 1.0484 1.1365

sure that vary more than 11 percent (equivalent to approxi-mately 915m (3000 ft) of elevation change) from standardsea level pressure 760 mm Hg at 0 oC (29.92 in Hg at 70 oF).

SECTION 4 - FLOW CALCULATIONSHYGOOD


Engineered Systems

Macron Safety Systems Engineered systems are basedon a Hydraulic Flow Program developed by Hughes As-sociates Inc. The program predicts the two phase flow ofFM-200® and nitrogen through a pipe network. Informa-tion detailing the enclosure is entered and the programcalculates the required pipe sizes, nozzle drill sizes, aver-age nozzle pressures and discharge time. For further infor-mation on the Flow Program, refer to the Hughes Hy-FlowUser's Manual.

As system design calculations are critical to the suc-cess of the extinguishing system, only Macron SafetySystems or Macron Safety Systems trained personnel arepermitted to perform system calculations. If in the future,companies other than Macron Safety Systems wish to usethe program, representatives will be required to attend aformal training session. All system calculations are con-ducted either 'in house' by Macron Safety Systems or au-thorised suppliers.

Program Parameters

When designing pipe network systems, the followingdesign parameters should be considered to avoid systemreject when running the calculation.

• 4.87 bar (70.6 psi) minimum nozzle pressure.

• 80% maximum agent in pipe.

• Between 6 - 10 seconds discharge time.

• 10 - 30 % side tee split.

• 30 -70 % bull tee split.

• 0.5 kg/L(31.2lbs/ft3) - 1.0 kg/L(62.4lbs/ft3) filldensity.

(For extended discharge consult Ma-cron Safety Systems Ltd.)

Table 8 : Max. & Min. Flow Rates.

Pipe Size mm (in)

Minimum flow rate kg/s (lb/s)

Maximum flow rate

kg/sec.(lb/s) 10 (3/8) 0.272 (0.60) 0.907 (2.00) 15(½ ) 0.454 (1.00) 1.361 (3.00) 20 (¾) 0.907 (2.00) 2.495 (5.50) 25 (1) 1.588 (3.50) 3.855 (8.50)

32 (1 ¼) 2.722 (6.00) 5.67 (12.50) 40 (1 ½) 4.082 (9.00) 9.072 (20.00) 50 (2) 6.35 (14.00) 13.61 (30.00)

65 (2 ½) 9.072 (20.00) 24.95 (55.00) 80 (3) 13.61 (30.00) 44.92 (99.00)

100 (4) 24.95 (55.00) 56.7 (125.00) 125 (5) 40.82 (90.00) 90.72 (200.00) 150 (6) 54.43 (120.00) 136.1 (300.00)

Note: This information is for Schedule 40 pipe, and serves as an estimate only.

Pipe and nozzle sizes need to be confirmed by the computer program.

NOTE: The calculation method has been de-signed for specific types of fittings, pipes, andpipe inside diameter. When these limitationsare not maintained, there is a risk that the sys-tem will not supply the required quantity of ex-tinguishing agent.

• Max. liquid arrival time imbalance of 1.0 seconds.

• Maximum liquid run out time of 2.0 seconds.

• Maximum nozzle height is 4.87m (16.0ft)

• Minimum of 10% agent in pipe before first tee.

• Maximum of 20 nozzles per system.

• Maximum of 10 enclosures per system.

• The ratio between the nozzle area and the pipe crosssectional area immediately preceding the nozzle islimited to a minimum of 0.20 (20%) and a maximumof 0.80 (80%).

SECTION 4 - FLOW CALCULATIONS HYGOOD


Diam eter M m (in)

90º Elbow m (ft)

45º Elbow m (ft)

Thru Tee m (ft)

Side Tee m (ft)

Union m (ft)

10 (3/8) 0.4 (1.2) 0.18 (0.5) 0.24 (0.7) 0.82 (2.5) 0.09 (0.3) 15 (1/2) 0.52 (1.6) 0.24 (0.7) 0.3 (0.9) 1.04 (3.2) 0.12 (0.4) 20 (3/4) 0.67 (2.0) 0.3 (0.9) 0.42 (1.3) 1.37 (4.2) 0.15 (0.5) 25 (1) 0.85 (2.6) 0.4 (1.2) 0.55 (1.7) 1.74 (5.3) 0.18 (0.6)

32 (1 ¼ ) 1.13 (3.4) 0.52 (1.6) 0.7 (2.1) 2.29 (7.0) 0.24 (0.7) 40 (1 ½ ) 1.31 (4.0) 0.61 (1.7) 0.82 (2.5) 2.65 (8.0) 0.27 (0.8)

50 (2) 1.68 (5.1) 0.79 (2.4) 1.06 (3.2) 3.41 (10.4) 0.37 (1.1) 65 (2 ½ ) 2.01 (6.1) 0.94 (1.5) 1.25 (3.8) 4.08 (12.4) 0.43 (1.3)

80 (3) 2.5 (7.6) 1.16 (3.5) 1.55 (4.7) 5.06 (15.4) 0.55 (1.7) 100 (4) 3.26 (10.0) 1.52 (4.6) 2.01 (6.1) 6.64 (20.2) 0.73 (2.2) 125 (5) 4.08 (12.4) 1.92 (5.9) 2.56(7.8) 8.35 (25.5) 0.91 (2.8) 150 (6) 4.94 (15.0) 2.32 (7.1) 3.08 (9.4) 10 (30.5) 1.07 (3.3)

Equivalent length table for pipe fittings. Figures based upon schedule 40 ASTM A 106-77 pipe (nominal pipe size given in table).

Table 9 :Equivalent Length

Component Nominal

pipe size Equivalent

length M (ft) 25 mm valve (1 in. valve) 25 mm (1 in.) 6.096 (20) 50 mm valve (2 in. valve) 50 mm (2 in.) 10.668 (35) 32 mm flex hose (1-1/4 in. flex hose) See note 1 See note 1 50 mm flex hose (2 in. flex hose) 50 mm (2 in.) 5.37 (17.6) 25 mm Check & Flex (1 in. Check & Flex) 25 mm (1 in.) 7.593 (24.91) 32 mm Check & Flex (1-1/4 in. Check & Flex) 32 mm (1.25 in.) 15.285 (50.15) 50 mm Check & Flex (2 in. Check & Flex) 50 mm (2 in.) 12.02 (39.429)

Figures based upon schedule 40 ASTM A 106-77 pipe (nominal pipe size given in table).

Note 1 – Flex hose consists of two segments. The first segment has a diameter of 25 mm (1 in.) with a total equivalent length of 0.14 m (0.5 ft). The second segment has a diameter of 32 mm (1-1/4 in.) with a total equivalent length of 10.74 m (35.2 ft).

Table 10 : Equivalent Length for othersystem components.

HYGOOD SECTION 5 - INSTALLATION

38 FM-200® Installation Guide/11100/01.07.01/Issue2.0

General Information

All installation shall be carried out by an approved Ma-cron Safety Systems contractor with the correct equip-ment and previous experience of gaseous extinguishingsystems. Macron Safety Systems can supply this serv-ice or provide a list of their factory trained installationcontractors. Installation instructions are described un-der the following main headings, and in the order ofinstallation.

• Container Installation

• Piping and Nozzles

• Actuation Controls

• Ancillary Equipment

• Completion Procedures

Specific installation drawings must be prepared forthe hazard area in accordance with system design ascalculated by the FM-200® Hydraulic Flow Program. Thesedrawings should be followed closely in order to ensurethe system meets its design criteria. The pipe network issized in order to obtain correct discharge time, nozzlepressures, agent quantity and various other design con-siderations. If for any reason, the pipe network requiresmodifications the system must be recalculated beforeproceeding with installation. Installation drawings con-tain the following information;

• Enclosure Volumes.

• Agent Quantities.

• Scaled Pipe Network Plan.

• Pipe Network Isometric.

• Pipe Diameters, Pipe Length Drops & Rises.

• Nozzle Data.

• Container Data.

• Solenoid Actuator Technical Data.

• Low Pressure Switch Wiring Chart

• Fittings Data.

Figure 29 - Safety Outlet and Actuation Caps

50mm(2") Safety Outlet Cap Part No. 9446625mm(1") Actuation Cap Part No. 9118525mm(1") Safety Outlet Cap Part No. 94463

Installation drawings shall be submitted for approval tothe appropriate authority prior to system installation.

On receipt, unpack the Macron Safety Systems sup-plied items and ensure that the components comply withthe packing list and installation drawings.

The container weight is checked at the factory priorto dispatch, and recorded on the label attached to thecontainer. If there is any doubt regarding the weight, orleakage is suspected, the container should be weighedto confirm there is no weight loss. Determine the con-tainer storage temperature and refer to the TemperatureCorrection Chart to check the pressure within the con-tainer (see Appendix B).

Container Installation

The container location is identified on the system draw-ings and should be protected from extremes of tempera-ture, and be accessible for service and maintenance. Thecontainers must be firmly secured to a wall or bulkhead.No Safety Outlet and Actuation Caps should be removedat this stage.

Actuation Cap

Safety Outlet Cap

HYGOODSECTION 5 - INSTALLATION

FM-200® Installation Guide/11100/01.07.01/Issue3.0 39

Single Container Installation

1. Fix the back channels of the mounting brackets tothe wall at the appropriate heights (see table 11),using suitable anchor type bolts (not supplied).

2. Position the container against the back channelwith the valve outlet pointing left.

3. Insert the container straps at top and bottom andsecure with the bolts provided (see Figure 30).

4. Remove the Safety Outlet cap from the valveoutlet adaptor (see Figure 29).

5. With the outlet cap removed from the valve outletadaptor, install a union coupling.

Caution. Do not over tighten the containerconnection. Excessive tightening may cause thevalve outlet thread to be damaged and adverselyaffect the system operation.

6. Remove the union and replace the Safety OutletCap after the initial pipe run has been installed.

Container Size L

No. of Unirax

Channels

Height From Floor to Bracket mm (in)

8 liter : 4.5 to 8.0 kg (10 to 18 lbs.)

1 130 (5”)

16 liter : 9.0 to 17.5 kg (20 to 39 lbs.)

2 60, 330 (2.5”, 13”)

32 liter : 17.0 to 33.5 kg (38 to 74 lbs.)

2 160, 595 (6.25”, 23.5”)

52 liter : 27.0 to 53.0 kg (59 to 117 lbs.)

2 110, 343 (4.25”, 13.5”)

106 liter : 53.5 to 106.5 kg (118 to 235 lbs.)

2 300, 750 (11.75”, 29.5”)

147 liter : 74.0 to 147.5 kg (163 to 325 lbs.)

2 300, 1000 (11.75”, 39.25”)

180 liter : 91.5 to 182.0 kg (201 to 401 lbs.)

2 300, 1200 (11.75”, 47.25”)

Figure 30 - Container Strap Location

Table 11: Bracket Fixing Heights



Multiple Container Installation

Containers are manifolded together for three main rea-sons;

• To reduce the amount of piping required byconnection to one feeder pipe.

• For systems that require main and reserve.

• Combining the correct containers to obtain therequired quantity of agent within a specific haz-ard area.

A typical 80mm (3"), three port manifold assembly con-sists of the manifold, three check valves and an endcap. Each check valve is bolted to a flanged inlet on themanifold (50mm (2") only) using four M8 x 20mm caphead screws.

2. Locate and secure the cantilever brackets to eachchannel using M10 x 40mm Hex Head screw anduninut long spring 10mm.

3. Locate manifold brackets in cantilever channel andunirax end caps.

4. Remove outlet safety cap and attach discharge hosebetween valve and manifold. Adjust cantileverheight as required and secure in position.

5. For safety remove discharge hose and replace safetycaps, while pipework is installed.

1 Fix the back channels of the mounting brackets tothe wall at the appropriate heights (see table 11),using suitable anchor type bolts (not supplied).

2 Position the containers against the back channelswith the valve outlets pointing left at the requiredspacing for the manifold ports (see Figure 14,dimension B).

3 Insert the container straps at top and bottom andsecure with the bolts provided (see Figure 30).

Manifold Bracket Installation

1. Fix the two back vertical channels to the wall at theappropriate height using suitable anchor type bolts(see table 12).

Back channels are used to ensure that the appropriateheight adjustment is available when connecting the dis-charge hose from the valve outlet to the manifold checkvalve (see figure 31).



Figure 31 - Manifold Assembly

Table 12: Manifold Bracket Fixing Heights

C o n t a i n e r S i z e ( L )

V a l v e S i z e ( m m )

M a n i f o l d S i z e ( m m )

N o m i n a l H e i g h t f r o m F l o o r t o t o p o f c a n t i l e v e r ( m m )

8 4 . 5 t o 8 . 0 k g ( 1 0 t o 1 8 l b )

2 5 ( 1 ” )

6 5 ( 2 . 5 ” ) 7 5 0 ( 2 9 ½ i n . )

1 6 9 . 0 t o 1 7 . 5 k g ( 2 0 t o 3 9 l b )

2 5

6 5 ( 2 . 5 ” )

9 4 9 ( 3 7 3 / 8 i n . )

3 2 1 7 . 0 t o 3 3 . 5 k g

( 3 8 t o 7 4 l b )

2 5

6 5 ( 2 . 5 ” )

1 2 8 9 ( 5 0 ¾ i n . )

5 2 2 7 . 0 t o 5 3 . 0 k g ( 5 9 t o 1 1 7 l b )

5 0 ( 2 ” )

8 0 ( 3 ” )

1 1 3 3 ( 4 4 5 / 8 i n . )

1 0 6 5 3 . 5 t o 1 0 6 . 5 k g ( 1 1 8 t o 2 3 5 l b )

5 0 8 0 ( 3 ” )

1 6 0 1 ( 6 3 . 0 ” )

1 0 6

5 0 1 0 0 ( 4 ” )

1 6 0 1 ( 6 3 i n )

1 4 7 7 4 . 0 t o 1 4 7 . 5 k g ( 1 6 3 t o 3 2 5 l b )

5 0 8 0 ( 3 ” )

1 9 3 1 ( 7 6 i n . )

1 4 7 5 0 1 0 0 ( 4 ” )

1 9 3 1 ( 7 6 i n . )

1 4 7 5 0 1 5 0 ( 6 ” )

1 9 3 1 ( 6 7 i n . )

1 8 0 9 1 . 5 t o 1 8 2 . 0 k g ( 2 0 1 t o 4 0 1 l b . )

5 0 1 0 0 ( 4 ” )

1 9 3 1 ( 7 6 i n . )

1 8 0 5 0 1 5 0 ( 6 ” )

2 2 1 0 ( 8 7 i n )



Pipe Installation

In general, the installation should commence at the un-ion elbow / manifold assembly and progress along tothe discharge nozzles. Install the Pipework to the instal-lation drawings provided, ensuring that the following isadhered to:

• The piping material must conform to therequirements of BS5306: Part 5 Section 5.1./ NFPA 2001 2-2

• The pipe must be reamed, blown clear andswabbed with an appropriate solvent to removemill varnish and cutting oil before assembly asrequired by BS5306: Part 5 Section 5.1./ NFPA 2001 2-2.

• PTFE tape is the only acceptable pipe sealant andmust be applied to the male threads.

Table 13: UK Steel PipeworkRequirements

Table 14: UK Fittings

Fitting Description

Pipe Size

Screwed, complying with BS1256,BS1740 or Class 150 of ANSI B16.3; or

up to & including

20mm Forged Steel, Screwed complying with grade WPA or WPB of BS3799; or

Forged Steel, Socket Weld, complying with grade WPA or WPB of BS3799; or

Forged Steel, Butt Weld, complying with grade WPA or WPB of BS1640: Part 3 or Class 300 of ANSI B16.9;

Screwed, complying with BS1740 or Class 150 of ANSI B16.3; or

above 20mm up to &

including 80mm

Forged Steel, Screwed complying with grade WPA or WPB of BS3799; or


Forged Steel, Butt Weld, complying with grade WPA or WPB of BS1640: Part 3 or Class 300 of ANSI B16.9;

Screwed, complying with BS1740; or

above 80mm

Forged Steel, Screwed complying with grade WPA or WPB of BS3799; or


Forged Steel, Butt Weld, complying with grade WPA or WPB of BS1640: Part 3;

(Note: Only use Fittings from table 15 that comply with USrequirements specified in table 16. Do not use 90o sharp elbows/tees for system installation)

1) Abbreviations:BW butt welded / CD cold drawn / HFS hot finished seamless / CFS cold finishedseamless / S seamless

2) Where schedule numbers are given, these determine the minimum wall thickness in accordance with BS1600. Where the specified pipe is not obtainable in these dimensions,the next larger thickness should be used.

Nominal Pipe Size

Publication Type of Pipe1) Grade of Steel Minimum Wall Thickness2)

BS1387 BW - Heavy

Up to and BS3601 S 430

including BS3602 : Pt 1 HFS or CFS 360 or 430

50mm ASTM A106-77 HF or CD A or B Schedule 40

Over 50mm up to and

BS3601 S 430 (Schedule 80 for screwed

including BS3602 : Pt 1 HFS or CFS 360 or 430 joints)

100mm ASTM A106-77 HF OR CD A or B

Above 100mm BS3601 S 430 Schedule 80

BS3602 : Pt 1 HFS or CFS 360 or 430 Schedule 40

(Schedule 80 for screwed joints)

ASTM A106-77 HF or CD A or B



Table 15: US Steel Pipe Requirements

Table 17: Hanger Spacing

Pipe Hangers

Pipe hangers must be spaced according to the size ofpipe (see table 17).

• Hangers must be placed within 300mm (12") ofthe discharge nozzle (see Figure 32).

• Hangers must be placed between elbows that aremore than 600mm (24") apart (see Figure 33).

• Hangers must be fixed to a structure capable ofsupporting the Pipework.

Pipe Size mm

Maximum Spacing m

10 (3/8”) 1. (3 ft) 15 (1/2”) 1.5 (5 ft) 20 (3/4”) 1.8 (6 ft) 25 (1”) 2.1 (7 ft)

32 (1 ¼”) 2.4 (8 ft) 40 (1 ½”) 2.7 (9 ft)

50 (2”) 3.4 (11 ft) 65 (2 ½”) 3.5 (11.5 ft)

80 (3”) 3.7 (12 ft) 100 (4”) 4.3 (14 ft) 150 (6”) 5.2 (17 ft)

Note: Cautionary information indicating the calcula-tion method has been investigated for specific types offittings, type of pipe and pipe inside diameter. Also thatwhen the specified limitations are not maintained thereis the risk that the system will not supply the requiredquantity of extinguishing agent. The Flow Program con-tains pipe & fittings options together with EquivalentLength information for UK / US pipe & fittings.

Fitting Description

Pipe Size

Class 300 Malleable or Ductile Iron Up to or < 3” NPS 1000-Ib Rated Ductile Iron or Forged Steel Class 300 Flanged Joints

> 3” NPS All

Table 16: US Fittings

Pipe Reference Connection Pipe Type Nominal Pipe Size

ASTM A-106 seamless Grade C Threaded Schedule 40 3/8” - 6” NPS ASTM A-106/A-53 seamless Grade B Threaded Schedule 40 3/8” - 6” NPS ASTM A-106/A-53 seamless Grade A Threaded Schedule 40 3/8” - 6” NPS ASTM A-53 ERW Grade B Threaded Schedule 40 3/8” - 6” NPS ASTM A-53 ERW Grade A Threaded Schedule 40 3/8” - 6” NPS ASTM A-53 Furnace Weld Class F Threaded Schedule 40 3/8” - 6” NPS ASTM A-106 seamless Grade C Welded Schedule 40 3/8” - 6” NPS ASTM A-106/A-53 seamless Grade B Welded Schedule 40 3/8” - 6” NPS ASTM A-106/A-53 seamless Grade A Welded Schedule 40 3/8” - 6” NPS ASTM A-53 ERW Grade B Welded Schedule 40 3/8” - 6” NPS ASTM A-53 ERW Grade A Welded Schedule 40 3/8” - 6” NPS ASTM A-53 Furnace Weld Class F Welded Schedule 40 3/8” - 6” NPS

(Reference: BS ISO 14520-1:2000)



Figure 32 - Nozzle Fixing

Figure 33 - Elbow Support

Table 18: Safety Clearances.

Max. Rated Voltage

(kV)

Min. Section Clearance

(m)

Min. Ground Clearance

(m) 15 2.59 (8.5ft) - 33 2.74 (9ft) - 44 2.89 (9.5ft) - 66 3.05 (10ft) - 88 3.20 (10.5ft) 2.44 (8ft)

110 3.35 (11ft) 2.44 (8ft) 132 3.50 (11.5ft) 2.44 (8ft) 165 3.81 (12.5ft) 2.44 (8ft) 220 4.27 (14.0ft) 2.44 (8ft) 275 4.57 (15ft) 2.44 (8ft)

Earthing & Electrical Clearance

Systems within electrical substations or switchroomsshall be efficiently earthed to prevent the metalwork be-coming electrically charged. Adequate earthing of sys-tems will minimize the risk of electrostatic discharge.Where exposed electrical conductors are present and,where practicable, clearances no smaller than thosegiven in table 18 shall be provided, between the electri-cal conductors and all parts of the system that may beapproached during maintenance (BS5958: Pt.1 & Pt.2).

Minimum clearance from any point on or about thepermanent equipment where a person may be requiredto stand (measure from position of the feet). Sectionclearance - to the nearest unscreened live conductor inair. Ground clearance - to the nearest part not at earthpotential of an insulator supporting a live conductor.Reference NFPA 2001, section 1-5.2

Nozzles

All nozzles require the installation of a dirt trap compris-ing 1 side tee, 2 nipples, and 1 pipe cap. Fit the nozzle tothe nipple on the dirt trap and check the nozzle orifice toensure proper orientation. Dirt trap lengths should beno more than 10 times nominal pipe diameter.

A false ceiling comprising loose tiles must have the tilesretained within a 2m (6.5ft) radius of the nozzle, to pre-vent movement during system discharge. Nozzles shouldbe installed a maximum of 300mm (12") below the ceiling.

Figure 34 - Dirt Trap



Actuation Installation

The method of actuation depends on the system con-figuration and any specific contract requirements andcan be broken down as follows:

• Single Container Actuation

• Multiple Container Actuation

Single Container Actuation

Side Mounted Electrical Actuator

The electrical actuator is factory fitted to the side port ofthe valve assembly. The actuator cannot be removed ortested on site unless fitted with solenoid adaptor partno. 5540 as this will cause the upper valve chamber to bevented, discharging the container (see figure 35 for lo-cation of side mounted actuator fitted with adaptor andfigure 36 for location of side mounted actuator with noadaptor). Ensure that solenoid is installed between 0-30o

off vertical. If no other actuators are to be installed en-sure that the actuation cap on the valve is retained inposition.

Figure 36 - Side Mounted Electrical ActuatorLocation (No Solenoid Adaptor Fitted)

Figure 37 - Side Mounted Electrical Actuator Wiring DiagramFigure 35 - Side Mounted Electrical Actuator &

Solenoid Adaptor Location



Removable Solenoid Actuator

The removable electrical actuator is fitted to the top ofthe valve assembly as follows:

• Check the actuator mechanism to ensure that it is inthe non-fired position, i.e. pin retracted (see Figure38).

• Remove the actuator cap from the top of the valveassembly (see Figure 29).

• Carefully screw the actuator to the valve assembly(see Figure 39).

Note: The actuator must be hand tight only.

Figure 38 - Actuator Non-Fire Position

If no other actuators are to be installed ensure that theprotective cap on the actuator is retained in position.

The electrical signal from the detection and/or con-trol equipment is connected in accordance with the wir-ing diagram detailed in Figure 40 when all other installa-tions have been completed.

Figure 40 - Electrical Actuator Wiring Diagram

Figure 39 - Electrical Actuator Location

The Solenoid Actuator is fitted with a suppression di-ode in parallel to the coil as indicated. Connect +ve fromcontrol panel to terminal 1 and -ve from control panel toterminal 2, on plug connector. End of line monitoringdevice (if required) to be fitted on site.

Before this system is put into operation, the removablesolenoid can be checked by firing the system. To dothis, REMOVE THE SOLENOID ACTUATOR from thevalve. With power to the actuator, the pin should befirmly in the down position.

SOLENOIDCAN BELOCATEDANY 9Oo

ANGLE

4.5-5.0 mm(.177-.197 in)WITH NUTAGAINSTBODY



Manual Actuator

The manual strike knob actuator can be fitted to the topof the electrical actuator or directly onto the valve, afterfirst removing the protective cap.

Caution. Before attaching the strike knob to the electri-cal actuator or valve, ensure that the firing pin is re-tracted and the safety pin is in place (see Figure 41). Thestrike knob must be hand-tight only.

Figure 42 - Manual Actuator Location

Figure 41 - Manual Actuator Non-Fire Position

Multiple Container Actuation

Where several containers comprise one system and aredischarged simultaneously, one container is designatedas the ‘master’ container, and the others are ‘slave’containers. The master container can be actuated elec-trically or manually. The slave containers are actuatedpneumatically by the action of the master container dis-charging.

Pneumatic Actuator

Check that the actuating plungers are in the raised posi-tion (see Figure 43). Remove the actuation cap from thetop of the valve assembly (see Figure 29) and carefullyscrew the pneumatic actuator to the valve on each slavecontainer.

Note. The actuator must be hand-tight only.

Figure 43 - Pneumatic Actuator Non-Fire Position

Figure 44 - Pneumatic Actuator Location

6.4mm (1/4")

MINIMUM

6.4mm (1/4")

MINIMUM



Slave Actuation Pilot Line

For slave containers the pneumatic connection is madeusing flexible pilot hoses. To fit the pilot hoses, re-move the 1/4" pilot pressure port plug from the mastercontainer valve assembly and install the 1/4" male adap-tor, part number 91105.

Install the pilot line tee, Part No. 91109 on to all pneu-matic actuators (wrench tight). Connect one end of thepilot hose Part No. 6490 to the adaptor on the mastercontainer and one end to the pilot line tee on the pneum-atic actuator. Connect pilot hoses between pilot line teeson all pneumatic actuators (see Figure 45). The maximumnumber of slave actuated containers is 9 (10 containerssystem in total).

Figure 45 - Multiple Container Actuation



Multiple Container Systems

On multi-container installations the pressure switchshould be located close to the last slave container andconnected by pilot hose to the tee connector on thepneumatic actuator (see Figure 47).

Figure 46 - Discharge Pressure Switch Installation

Figure 47 - Discharge Pressure Switch Installation

Ancillary Equipment

Discharge Pressure Switch

Single Container Systems

On single container installations the pressure switchshould be located close to the valve assembly and con-nected with a pilot hose from the pressure port outlet onthe valve to the connector on the pressure switch (seeFigure 46).



Discharge Pressure Switch continued...

To wire the discharge pressure switch to the controlpanel, unscrew and remove the switch cover plate. Con-nect to the appropriate terminals on the microswitch or ifsupplied with wires, to the coloured wires which are la-belled as follows:-

Common (C) (violet)

Normally Open (NO) (blue)

Normally Closed (NC) (black)

CAUTION:

The completion of the installation system,commissioning tests and hand-over mayoccur before the area is ready for use. Inthe event of delay between hand-over andthe risk area being available for protection,then the system must be left in a 'safe' con-dition to avoid accidental discharge. Thesystem must only be made operative oncethe area for protection has been completedand is operational.

Low Pressure Switch

All container valves are 'Factory fitted' with low pres-sure warning switches. Voltage input can be applied toeither terminal.

Accessories

Door Notices

Warning notices are required at all exits and entrancesto protected area, ideally mounted on the door. Platesmay be drilled and screw fixed or attached using suitableadhesive.

Manual Release Notices

Manual release notices are required at all manual ac-tuators, remote manual actuators and call points. Platesmay be drilled and screw fixed or attached using suit-able adhesive.

Completion Procedures

For ease of reference completion procedures may besubdivided into the following sections;

• Pre Checks and Visual Inspections.

• Final Connections.

• Hand over Procedures.

Figure 48 - Low Pressure Switch to Control Paneldiagram.

Connections to Pyrochem PCR-100

NOTE: Program output circuit 4 as a supervisory inputcircuit. See Pyrochem PCR-100 manual for programmingdetails.

Connections to Pyrochem FMM-101 orFMM-1 Module

NOTE: Program the addressable module as supervisory.See Pyrochem PCR-400 manual for programming details.

NOTE: When the device (i.e. pressure switch) is con-nected to a standard supervisory input circuit, there willbe no distinction between a wiring fault and device ac-tuation . This device is to only be utilised when acceptedby the authority having jurisdiction.



Electrical Checks

The electrical systems may include interfaces with manyother systems for alarm, indication, actuation, shutdown,etc. For complex electrical systems the scope and oper-ating requirements will be described in other documents.Electrical checks are given below for a basic system us-ing electrical actuation of the container valve;

Final Connections

Discharge Piping

The final connection of the discharge piping occurs atthe container valve assembly. For single container sys-tems, the valve safety outlet cap can be removed andthe discharge pipe connected to the container outlet.For multi-container systems, the valve safety caps canbe removed and all discharge hoses fitted.

Pre-checks and Visual Inspections

General

When the installation is complete, and before makingthe final connections, the following checks should bemade:

Mechanical Checks

Inspect protected area closely for conformance to origi-nal risk specifications and for enclosable openings orsources of agent loss which may have been overlookedin the original specification.

• Building work should be thoroughly checked toensure that enclosures have been properlyconstructed and that voids in floors and abovesuspended ceilings have been sealed.

• All back channels should be secured firmly to thewall or bulk head.

• Containers should be securely held withinbrackets.

• Piping should be securely fixed within hangers.

• All pipe connections must be tight.

• Nozzles to be the proper type, correctly placed,and properly orientated.

• Check model and weight markings on containernameplates to verify that correct containers andcharges have been installed as required.

• Verify that all warning and instruction plates aremounted where required.

• Remove top mounted or side mounted solenoid (ifconnected via solenoid adaptor) from valve.Check that solenoid is activated when system istriggered. If the solenoid adaptor is not present,remove electrical connections from side mountedsolenoid and check wiring voltage is correct foractuation when system is triggered.

During detection system actuation verify the followingfunctions operate;

• All apertures in hazard enclosure are closed bydampers or other suitable methods.

• Electrical equipment in the protected area istripped and isolated.

Pneumatic Checks

The slave actuators on manifolded systems are fired byagent discharge. Pneumatic checks are detailed below;

• Remove pneumatic actuator from container valve.

• Disconnect pilot hose from the master containervalve adaptor (see Figure 45).

• Provide 4 bar (58 psi) pressure to the mastercontainer valve pilot hose.

• Verify all pneumatic actuator pistons are in the firedposition.

Before replacing the pneumatic actuators, ensure thatall pistons are fully reset (see Figure 43). After reinstall-ing the pneumatic actuators, reconnect the pilot hose tothe master container valve adaptor (see Figure 45).



Hand-over Procedures

The entire system shall be thoroughly inspected to makesure that it is complete and that all tests required duringinstallation have been properly carried out. In addition,the following items are particularly important.

1. A container should be refilled or replaced when itshows a loss in agent quantity of more than 5% ora loss in pressure (adjusted for temperature) ofmore than 10%.(Operating pressure of unit at 25bar at 21oC , 360 psi at 70oF). Refer to Appendix Bfor pressures at other container temperatures.

2. Check container weight information label againstsystem requirement. If there is any doubt or ifthere has been a loss of pressure the containermust be weighed.

3. Make sure the system is armed and the actuatingsystems are operational.

Ensure adequate escape routes with directional signsare provided. Issue of the appropriate documentationshall constitute completion of the Hand-over procedure.

Appropriate records shall be issued by fire and/orinsurance authorities as to the suitability, acceptabilityand availability of the system for the hazard area.

SECTION 6 - INTEGRITY TESTING HYGOOD


Below Ceiling Leakage Area(BCLA)

Experience has shown that leakage above a suspendedceiling has a negligible effect on the FM-200® concen-tration. Like water leaking from the holes in the bottomof a swimming pool, FM-200® tends to escape from leaksin the lower part of the enclosure due to the weight ofthe mixture above it. The rate at which FM-200® is lost istherefore primarily governed by the leakage below thefloor, and walls beneath the ceiling. This is called theBelow Ceiling Leakage Area.

Predicting Retention Time

Once the ELA, BCLA and static pressures have beenmeasured the next step is to calculate the retention timeof the enclosure. The formula is derived from a standardengineering/fluid dynamics principle. The result of thecalculation is the number of minutes it takes for the FM-200®/air interface to reach the minimum protected heightrequired, normally about 75% of the enclosure area.

Slab to Slab Walls

The only major limitation is that it cannot be used toaccurately predict a retention time if the perimeter wallsdo not extend from slab to slab. The enclosure will al-most invariably fail due to extensive leakage throughthe ceiling tiles.

Coordination and Planning

It should only be necessary to conduct one integritytest, therefore it is essential to ensure that the enclosureis ready, and that the relevant people have been in-formed. Having established that any outstanding worksare completed prior to the test date, advise all interestedparties in writing, if necessary outlining the testingmethod and principles involved.

Introduction

The hazard integrity is the ability to retain the dischargedFM-200®. For a total flooding extinguishing system tobe effective, the design concentration must be achievedand then maintained for at least ten minutes. The onlymethod of testing the agent retention within the pro-tected area is to verify the integrity of the enclosure byapplying proven test procedures.

The enclosure integrity test has been developed tolocate the source of leaks and, from the data collected,predict the retention time, proving system performanceand removing the need for actual FM-200® discharge.In order to determine with any degree of confidence thatthe hazard area will hold the gas for the required timeperiod, where necessary an Enclosure Integrity Test inaccordance with BS5306:Part 5: Section 5:1 / NFPA 2001appendix B. must be conducted.

Principle

The test is conducted with a device known as a doorfan, which has been used in the energy conservationfield for over 25 years. It has three basic components asfollows:

• An adjustable panel that fits in the doorway ofthe protected area

• A calibrated fixed speed fan

• A variable speed fan

The pressure created by the door fan causes the airto move through leaks in the enclosure at high speedmaking it easy to pinpoint where leaks exist. A cool chemi-cal smoke or other air current indicator is used to detectthe approximate size and location of leaks.

Equivalent Leakage Area (ELA)

The test to measure the ELA is conducted by blowingair into or out of the enclosure to develop the same pres-sure differential as would be created by the dischargingFM-200®. By measuring the air flow required it becomespossible to calculate the ELA, which is the total of allcracks, gaps and holes in the enclosure. The leakagemeasurement achieved by taking air out of the enclo-sure (depressurisation), and then blowing air into theenclosure (pressurisation), is then averaged.

SECTION 6 - INTEGRITY TESTINGHYGOOD


Integrity Test Procedure

Evaluation. The enclosure and immediate surroundingarea is initially examined visually to assess the readi-ness for testing, the existence of any attached spacesthat could affect the results, and that there is an ad-equate relief area and return air path. The volume of theenclosure is confirmed and the highest equipment meas-ured to ascertain the required level for retention time.

Preparation. All doors outside the area that are requiredto be open for the test are wedged open with suitablenotices posted to advise personnel. Where voids areprotected by FM-200®, tiles are removed to ensure auniform air flow.

The enclosure is put in the state it would be in priorto a discharge, e.g. ventilation system shut down, damp-ers closed, etc.

Note. Equipment within the enclosure that does not af-fect the integrity may be left running even if it will beshut down in the event of a discharge, preventing un-necessary disruption and inconvenience.

Ventilation. Air conditioning and/or forced ventilationcan affect the system performance and the quantity ofagent required.

(i) Self-contained air conditioning unit

A self-contained unit conditions the air within the en-closure and does not rely on a fresh air supply, or drawair from other parts of the building. If the hazard has aself-contained unit and it is located within the area with-out an outside air supply, no additional agent is required.It is not necessary to shut down the unit prior to a dis-charge as the mixing effect is beneficial. However if theair-conditioning unit is left running, a depleting concen-tration rather than a descending FM-200®/air interfacewill be formed. The concentration will be depleted dueto leakage. Therefore the enclosure should be over-gassed to obtain the required ten minute retention timeat minimum concentration.

(ii) Central air conditioning unit

A central air conditioning unit relies on air from outsideand is often linked by ducts to other parts of the build-ing, therefore, prior to a discharge, the unit should beshut down and/or dampers operated to close the ducts.Sufficient time must be allowed for the plant to stop, ordampers to close, before discharge occurs.

Dampers should be installed in both supply and returnair ducts, as close as possible to the area. The duct vol-ume between the hazard and the damper must be addedto the overall volume.

Door Fan Installation. A Retrotec RD860 door fan unitis installed in the designated test door in accordancewith the manufacturer’s instructions.

The gauges are zeroed by taking them to full scale de-flection and holding for approximately ten seconds, af-ter which the gauges are gently tapped and zeroed.

Enclosure Evaluation

Static Pressure Measurements. With the door fan equip-ment fully installed and set up, but with all openingsclosed, a measurement of any pressure difference be-tween the enclosure and the relief area is made. If themeasurement is unduly high its causes are ascertainedand if possible permanently reduced or eliminated.

Total Enclosure Leakage Method. Using an adequaterange on one fan, or a number of fans, a pressure differ-ence of between column pressure and column pressureplus 30% is created. The pressure difference, and the airflow required to generate this, is then recorded. This iscarried out for both pressurisation and depressurisationmodes. The total equivalent leakage area and the pre-dicted retention time is calculated.

Suspended Ceiling Leakage Neutralisation Method.This procedure is used to improve the accuracy of thepredicted retention time where a reasonable air-tight ceil-ing exists, whether or not the ceiling is protected withFM-200®.

Note. Leak paths through the ceiling may be temporarilysealed.

The volumes above and below the false ceiling aredepressurised to the same extent but using separate fans.This is confirmed by using cool chemical smoke to checkthat no air is flowing through the false ceiling.

Readings of the pressure difference between the en-closure, relief area, and the air flow through the fan(s)used to depressurise the room and false ceiling are made,and then the procedure is repeated in the pressurisationmode. The below ceiling leakage area is then calculatedand used in conjunction with the ELA to predict a re-vised retention time.

SECTION 6 - INTEGRITY TESTING HYGOOD


Calculation

A portable computer is used to collate the data and cal-culate the values. The associated printer provides a de-tailed hard copy of the data on site.

Leakage Location

If the enclosure fails the test, or if the client requests, aninspection of the enclosure with the door fan runningcan be made. This makes it possible to locate the sourceof any leakage by using cool chemical smoke. This pro-cedure also tests the efficiency of any dampers, etc.

Figure 49 - Typical Printout

RETROTEC DISCHARGE SIMULATION VER. HA5.1 RETENTION TIME PREDICTION MODEL

Location: Hygood. Test EnclosureRoom Name: Test HouseTesting Company: HYGOOD LIMITEDTechnician: C UzzellDate: 12.12.96Whole Room Test.All Outputs are in METRIC Units.

Gas Being Modelled: FM200Lbs/Kgs of Agent in Cylinder(s): 17.00Net Room Volume (m3): 30.00Room Height (m): 3.20Minimum Protected Height (m). 2.90Minimum Retention Time (min): 10.00Initial Gas Concentration (%): 7.22Static Pressure @ Discharge: 0.00

Equivalent Leakage Area (ELA m2): 0.0050Hole in Ceiling (m2): 0.0025Hole in Floor (BCLA m2): 0.0025

This Room PASSES the Test as the Predicted Retention Time is10.1 minutes for the agent/air interface to drop below theminimum protected height.

Witnessed By:

X

Software Conforms to 1992 NFPA 12A/2001 TCD Room Integrity Procedure.

Maximum Allowable ELA (m2): 0.005Interface Height @ 10 minutes: 2.903

FAN TEST READINGS & DATA

Location: Hygood. Test EnclosureRoom Nam e: Test House

Tem perature IN: 20 Tem perature OUT: 20Static Pressure @ Fan Test: 0

DEPRESSURE PRESSURE

Operator and Gauges Location OUT OUTRoom Pressure Gauge R eading 14.0 14.0Corrected Room Delta P(pa) -14.0 14.0Blower Range Config Used 0.1 0.1Flow Pressure Gauge Reading 45.0 45.0Corrected Flow Pressure 31.0 45.0Calcu lated Air Flow (1s) 13.4 16.2Tem p. Corrected Flow 13.4 16.2Leakage Area (m 2) 0.0046 0.0055Average Leakage Area (m 2) 0.0050

RM= 1.639 PC= 13.7AT= 0.003 ALL- 0.002C3= 3.019 C4= 0.000GD= 7.260 K1- 1.8850AR= 9.374 T= 605.679PA= 13.7 FA= 0.500CF= 1.000 K2= 0.0046EL= 0.000 TD= 20.000

Page 1 Of 2 Licensed to: MARCRON SAFETY SYSTEMS (UK) LIMITED Registration # : 207

Page 2 Of 2 Licensed to: MARCRON SAFETY SYSTEMS (UK) LIMITED Registration # : 207

SECTION 7 - SYSTEM OPERATIONHYGOOD


General Comments

Personnel required to work in the protected area shouldbe conversant with the detection and extinguishingequipment installed, and trained in fire procedures. Alllife-saving equipment must be properly maintained.

The method of system operation is chosen at thedesign stage to suit the protection required for the haz-ard area and the environmental factors appropriate tothat area. This part of the document provides informa-tion relevant to ALL the standard operational systemsto cover the eventuality of changes to, or expansion ofthe original design.

System Detection and Actuation

General

Each system is designed to suit the hazard area, whetherthe area is normally manned or unmanned, and whetherthe detection/actuation devices are to be manual or au-tomatic. The permutation of systems is large but froman operational point of view, the systems are bestgrouped as:-

• Manual.

• Fully Automatic.

• Automatic with Manual Intervention.

Manual System

Manual systems depend on human detection of a fire inthe hazard area and prompt action to actuate the local orremote strike knob for the FM-200® system to dischargeand flood the protected area and extinguish the fire.

All other instructions associated with manual op-eration form part of the user’s procedures on safetyprecautions and fire drill. If required MACRON SAFETYSYSTEMS can assist the user to prepare the proceduresfor safety and fire precautions.

Fully Automatic System

Where a sensitive fire detection system is included forthe automatic release of extinguishing agent, the systemshall only be capable of automatic release once two ormore sensors detect the fire.

The number of detectors and their spacing is de-signed to ensure a satisfactory response time. To en-sure personnel may safely evacuate the risk area an ad-justable time delay should be fitted such that sufficienttime may elapse prior to system discharge. Ideally, thedelay period shall not exceed 30 seconds (BS5306 Pt5).

Prior to system discharge (and at the commencementof any time delay period) a clearly audible alarm differentfrom any other used shall sound and continue until thecomplete system is reset. In areas of high ambient noiselevel, a visual indication may also be required, in addi-tion to the audible warning.

The design of a system for automatic detection, sig-nal distribution, alarms, etc. is not always of MACRONSAFETY SYSTEMS supply. Therefore, details appertain-ing to fire detection and alarm operation and mainte-nance are not included in this document.

UL Listed Detection & Control Equipment

Detectors shall be UL Listed for the intended applica-tion. Control Panels shall be UL Listed for releasing de-vice service and compatible with detection and MA-CRON SAFETY SYSTEMS FM-200® Engineered TotalFlooding Fire Extinguishing System.

SECTION 7 - SYSTEM OPERATION HYGOOD


Fully Automatic System with Manual Inter-vention

Manual intervention of an automatic system may be in-cluded for the following condition;

• Where personnel are required to work within theprotected area.

In protected areas where personnel are present andthe concentration is greater than NOAEL, it isrecommended that the automatic feature of thesystem is isolated during occupation. This may beachieved either by an electrically contacted lockassembly or by a clearly marked key switch at asuitable location outside the risk area.

FM-200® Decomposition

FM-200® decomposes when exposed to temperaturesexceeding 482oC (900oF); such as flames, hot metalsurfaces, etc. The rate of this decomposition is depend-ent upon the size of the area where extreme temperaturesare found, and also upon the length of FM-200® exposuretime.

To avoid decomposition, MACRON SAFETY SYS-TEMS are designed to discharge and extinguish the firequickly. The average duration of discharge for thesesystems at 21oC (70oF) is less than 10 seconds, so theminimum amount of decomposition occurs. HydrogenFluoride is the most toxic decomposition product. Thismaterial generates a sharp acrid odour, which is easilydetected and acts as a warning and a good safeguard topersonnel.

FM-200® Discharge Conditions

FM-200® has low boiling point, consequently the dis-charge is very cold at the point where it leaves the noz-zle. Care should be taken to avoid working within 1 me-tre (3.ft) of FM-200® discharge nozzles.

The velocity of discharge of FM-200® from a dis-charge nozzle is very high, care should be taken to in-sure that objects which may become dangerous projec-tiles are secured or removed from the hazard area.

FM-200® Concentration

FM-200® total flooding systems greater than 9% designconcentration should only be used with manual actua-tion in normally occupied areas. A normally occupiedarea is defined as an area intended for occupancy.

Any area protected by FM-200® should be evacu-ated prior to start of system discharge. Where egress ofnormally occupied areas cannot be accomplished withinone minute, FM-200® total flooding systems shall bedesigned not to exceed 9.0% concentration.

Refer to NFPA 2001, Paragraph 1-6.1.2.1 for additionalinformation.

Conditions During a Fire

The user’s fire and safety instructions to personnelshould include advice on the conditions prevailing dur-ing the discharge of an FM-200® system. This advice isintended to prepare the personnel for the situations likelyto arise and therefore minimise the risks of panic. Threemajor conditions prevail during FM-200® discharge ofwhich personnel should be made aware:

SECTION 7 - SYSTEM OPERATIONHYGOOD


Actions Following a Fire

General

These notes are only applicable to the hazard area(s)protected by a FM-200® fire extinguishing system. Wheresuch a system may form part of, or combine with otherforms of fire protection systems then composite instruc-tions for all systems are necessary to ensure the safetyof personnel and property following a fire. MACRONSAFETY SYSTEMS are available to assist a client pre-pare composite instructions. In accordance with BS5839:Part 1 the organisation will have appointed, or nomi-nated, a responsible person to act as a ‘Fire Officer’.Actions following a fire should be co-ordinated and/ordirected by the Fire Officer.

Actions Immediately Following a Fire

These actions should, at a minimum, include the follow-ing:

• Advise the emergency services, Fire, Accident,Police if appropriate.

• Organize a ‘roll-call’ of employees and any visitors.

• Prevent unauthorised personnel from entering thehazard area.

• In the case of deep seated fires, the hazard spaceshould be kept tightly closed for at least 60 minutesafter discharge of the FM-200® extinguishing agent.It is essential that the fire be completely extinguishedbefore ventilating the space. Before permitting anyone to enter the space, ventilate thoroughly orensure self-contained breathing equipment is used.

• Do not enter the hazard area in which fire has beenextinguished with an open flame or lighted cigaretteas the possible presence of flammable vapours maycause re-ignition or explosion.

Should it be necessary to enter a space containing FM-200® or decomposition products the following precau-tions should be taken;

• Use a fresh air mask or self contained breathingequipment.

• Do Not use a filter mask or canister type mask.

• Do Not enter space unless you are under observa-tion from outside the space, or tethered by a lifeline.

• Ensure that all pressurised equipment is isolated orsafe from release.

HYGOODSECTION 8 - MAINTENANCE


Introduction

This section provides user inspection and maintenanceguidance for FM-200® Engineered Systems. A log bookwill be provided to record all inspections, maintenance,measurements and actions taken. The continued capa-bility for effective performance of an FM-200® TotalFlooding Fire Suppression System depends on fullyadequate maintenance procedures, with periodic test-ing. Reference NFPA 2001 section 4-1 to 4-6.

User's Programme of Inspection

The installer should provide the user with an inspectionprogramme for the system and components. The pro-gramme shall include instructions on the action to betaken in respect of faults. The user's inspection pro-gramme is intended to detect faults at an early stage toallow rectification before the system may have to oper-ate.

A suitable programme is as follows:-

Weekly Check of Hazard Area

Inspect the hazard area against the original layout toensure that there have been no changes that might af-fect the proper performance of the fire protection sys-tem. Changes might include:

• Contents of area.

• Use of area.

• Air Handling equipment in area.

• Openings in area.

• Floor/ceiling voids.

• Partitioning.

Weekly Check of Containers

Check storage container pressure gauges and ambienttemperature, compare these pressures to the Tempera-ture Correction Chart to determine temperature correctedpressure. If the container corrected pressure shows aloss of more than 10%, the containers should be removedfor weighing. All measurements and actions shall be re-corded in the log book.

Weekly Check of System Components

Make a visual inspection of the system components,distribution piping and nozzles. Check the immediate vi-cinity of all equipment to ensure that no accidental dam-age or tampering has occurred.

Weekly General Check

Inspect the hazard area, access routes, container stor-age area, floor voids and areas above suspended ceil-ings to ensure housekeeping is good and that no refusehas accumulated. Ensure that access to the system con-tainer assemblies and local remote controls is unob-structed.

Monthly Check of Notices

Inspect system and protected spaces to ensure that warn-ing signs, safety precautions and operating instructionsare posted and clearly visible.

Monthly Personnel Training Check

Check that all personnel who may have to operate theequipment or system are properly trained and are au-thorized to do so, and in particular that new employeeshave been instructed in its use.

SECTION 8 - MAINTENANCEHYGOOD


Contract Service & Maintenance

Systems shall be thoroughly inspected and tested forproper operation by qualified contract personnel in ac-cordance with the requirements of British Standard 5430Part 2. Before any checks are carried out, ensure theextinguishing system is isolated electrically and mechani-cally and remove all solenoid and pneumatic actuators.No maintenance work should be carried out without ob-taining approval from the Fire Officer and advising anypersonnel within the hazard area. The following Pro-gramme should be carried out in addition to the User'sProgramme of Inspection. The user shall be providedwith a signed and dated report of the inspection advis-ing any rectification carried out or needed.

3 Monthly Actuator Check.

Test and service all actuating mechanisms.

3 Monthly Electrical Systems Check

Test and service all electrical detection and alarmsystems as recommended in BS 5839 Part 1

6 Monthly Container Check

Externally inspect containers for signs of damage orunauthorised modifications. Check container labels aresecurely fixed and legible. Check container brackets andfittings.

6 Monthly Contents Check

Examine the container pressure gauge reading and referto the temperature correction chart. If the container pres-sure corrected to temperature is below 10% of the statedpressure it must be replaced or recharged.

Verification of the content of FM200® in the containersmay be achieved through either liquid level detection orcontainer weighing. If containers show a extinguis-hant loss of more than 5% or a pressure loss for super-pressurised liquefiable gases (adjusted for temperature)of more than 10%, the container should be refilled orreplaced.

Container Weighing

Where a Client does not wish to use a MACRONSAFETY SYSTEMS maintenance contract or the spe-cialised liquid level detection equipment, then contain-ers must be weighed to establish the FM200® content.The weighing procedure is as follows:

• Remove all manual controls, pressure actuatorsand pressure actuation pipe or tubing and flexibleelectrical connectors.

• Disconnect and remove discharge piping /discharge hoses from container valves.

• Fit Safety Outlet Caps onto container valves.

• Remove containers from bracketing and weighcontainers. Any container showing more than themaximum allowable weight loss must be rechargedby a qualified recharge agent.

• Record weight of container on record tag.

• Replace containers in bracketing and removeSafety Outlet Caps.

• Reconnect discharge piping / discharge hosesand all control heads, pressure actuators,pressure actuation pipe or tubing and flexibleelectric connectors.

HYGOODSECTION 8 - MAINTENANCE


Mechanical Servicing Procedure

a. Remove valve actuator(s) (where possible) from the container valve(s) and replace actuation cap(s).

b. For master/slave system complete thefollowing steps to check the slave actuationsystem:-

1. Disconnect pneumatic valve actuators fromthe slave container valves and installactuation caps.

2. Disconnect the pilot loop from the mastercontainer valve and install the appropriateplug.

3. Introduce 4 bar (58 psi) pressure into thepilot actuation line to the pneumaticactuators.

4. Check that the pistons in the pneumaticvalve actuators have fully fired.

5. Before installing the pneumatic actuatoronto the container valve ensure that thepiston is reset.

c. This section only applies if:

(1) Macron Safety Systems Ltd. is carrying out the maintenance on the detection system.

(2) If the servicing of the detection system is being carried out at the same time as the mechanical service by another nominated body.

Personnel Training

All persons who may be expected to inspect , test, main-tain or operate the fire extinguishing system shall bekept adequately trained in the functions they are ex-pected to perform.

Personnel working in an enclosure protected by a gase-ous extinguishant shall receive training in the operation,use of the system and safety issues.

6 Monthly Control Valve & Actuator Check

Check all manual and pneumatic actuators for free move-ment of the piston. Replace whole unit where appropri-ate. Check all control valves for correct manual functionand automatic valves additionally, for correct automaticfunction.

6 Monthly Pipe Network Check

Externally check Pipe-work to determine its conditions.Replace or pressure test and repair as necessary Pipe-work showing corrosion or mechanical damage.

6 Monthly Nozzle Check

Inspect nozzles for dust and debris, clean out wherenecessary.

6 Monthly Enclosure Check

Carry out a full visual check of the enclosure for integ-rity and confirm the dimensions and the configurationof the hazard are as the original drawings or previousvisit. If drawings are not available and this is the firstvisit then dimensions should be taken and passed to theengineering department together with the quantity ofagent to enable a calculation to be carried out to ensurethe correct quantity of gas has been used.

12 Monthly Hose Check

All system hoses should be examined for damage. Ifvisual examination shows any deficiency, the hose shallbe replaced.

12 Monthly Integrity Test

Integrity test the enclosure to determine if the leakagearea has changed sufficiently from that measured dur-ing installation.

SECTION 8 - MAINTENANCEHYGOOD


Specialised Maintenance Duties

Container Hydrostatic Pressure Testing

Providing containers are submitted to a full external in-spection every 12 months from the date of introduction,the allowable interval period before the first periodic in-spection and hydrostatic pressure test is 20 years.

Any container that is discharged between 10 years and20 years of being introduced into service shall be sub-mitted to a full periodic inspection and a hydrostaticpressure test before being refilled. The interval betweenthe first and second periodic inspection and hydrostaticpressure test may not exceed 10 years. Subsequent re-tests are not to exceed 5 years. (BS5430: Part 1) ( NFPA2001 Section 4-2 ref: containers & Section 4-3 ref: hoses)

Finally

Carry out a final visual inspection of the system and theprotected area to ensure that all equipment has beenreinstalled and reconnected properly. Ensure that anyassociated control/indication panel is displaying nor-mal operation. Complete the site log book, recordingwork carried out and parts used. Inform the responsibleperson that the work is complete and that the system isback on-line.

i) Remove solenoid actuators from valveassembles.

ii) Activate the detection system in accordancewith procedures provided with the system.When this test is performed, the release circuitof the detection system must operate theelectric actuators causing the plungers to befirmly extended.

iii) Examine the auxiliary electrical device/alarm,door closers etc., have all operated correctly.

iv) Ensure actuator is reset before refitting.

d. For master/slave system, remove theappropriate port plug and reconnect the pilotactuation line to the slave port on theback of the master valve.

e. If Pressure switch(es) have operated, checkthat connected devices have activated or shutdown as required and reset.

HYGOODSection 9 - RECHARGING PROCEDURE


Recharging

This section describes the procedures to enable therefilling of a container that has been discharged and willrequire recharging. This covers both 25mm(1") and50mm(2") container valve assemblies.

Valve Refurb

On receiving a container that requires to be rechargedthe following operations are carried out.

1. Check that the container is empty.

2. Remove valve, syphon tube grub screw and sy-phon tube from container. (This operation only needsto be undertaken if the burst disc needs replacing).

3. Unscrew top cap by removing locking grub screwlocated behind safety cap chain fixing screw. Once thathas been taken off the schrader should also be removed.

All O ring seals must be lubricated using PTFE /silicone grease.

4. O ring seal for the top cap has to be removed andreplaced : 25mm(1") valve O ring No. 122 (part no.90025)& 50mm(2") valve O ring No. 231(part no.90120)

5. Remove shuttle from valve body.

6. The shuttle has two O rings an upper and lower,both have to be replaced. Upper O ring : 25mm(1") valveO ring No. 122 & 50mm(2") valve O ring No. 227. (partno.90130)

7. Remove bottom cap from shuttle and replace lowerO rings : 25mm(1") valve O ring No. 212(part no.90185) &50mm(2") valve O ring No. 327(part no.90140)

8. Replace bottom cap to shuttle and shuttle to valve,spray a small quantity of PTFE silicone grease into thebore of the valve body.

9. Screw new schrader into top cap using schradertool set to 0.6Nm. Replace top cap to valve and lock intoplace with grub screw.

10. If valve has been removed from neck ring, re-place neck seal : (This is to pre-dome burst disc ifrequired)

25mm(1") valve - 2" 8UN neck O ring No. 327

50mm(2") valve - 3 1/4" 8UN neck O ring No.337

11. The outlet adapter may require to be replaced ifthis is so the outlet will need to be removed and threadscleaned. Apply Loctite 648 to the thread of the new out-let adapter and screw fully home. Re-fit outlet safetycap.

In the event that the pressure gauge or pressureswitch needs to be replaced:

12. Remove to reveal grub screw. Check the grubscrew setting, this should be initially tighten fully andthen loosen by 1/2 a turn.

13. Apply PTFE tape to replacement componentsand refit.

14. Remove 50 bar (725psi) burst disc assy if dam-aged from burst disc port and replace with a new assy.

25mm(1") valve : M14 assy. torque to 18Nm, (94080)

50mm(2") valve : M18 assy. torque to 20Nm, (94085)

Testing

On completion of a valve refurb the valve assy issubjected to two tests - Valve Assy Pre-dome and LeakTest. (test required if burst disc was replaced)

The tests are conducted on a Nitrogen rig using aoutlet filling adapter cap, test bottom cap and closingdown adaptor. (See figure 51)

Figure 5050mm (2") Valve exploded View.

Section 9 - RECHARGING PROCEDUREHYGOOD


Replacing Valve Assembly to container

1. Take container and clean neck thread using apower drill and the appropriate attachment. Use carewhen cleaning neck threads as the O ring seal could bedamaged.

2. Remove debris from inside the container as wellas from the neck thread, this should be done using theworkshop vacuum cleaner and airline.

3. PTFE grease must be applied to the clean con-tainer neck thread.

4. Take the appropriate syphon tube for the correctcontainer and valve assy, making sure that the syphontube and grub screw hole has been properly de-burred.

5. The syphon must be cleaned either by hand withpaper towels or in the workshop washer.

6. Apply Loctite 572 around the circumference ofthe syphon tube above the grub screw hole. Fit the sy-phon tube into the valve assy, ensuring that the grubscrew hole's line up.

7. Remove excess loctite adhesive and screw in grubscrew.

8. Fit valve and syphon tube assembly to container,insuring that the neck O ring is in place.

25mm (1") valve - 2"8UN neck ring No. 327

50mm (2") valve - 3 1/4"8UN neck ring No. 337

9. Secure the container in to the pneumatic belt viceand tighten the valve using the "C" spanner, until thevalve bottoms onto the top of the neck ring.

1. The valve assy is assembled to the nitrogen rigbottom cap using PTFE/silicon greased O ring on thevalve neck thread. The outlet adapter cap is also fitted,ensuring that the vent tap is closed.

2. The nitrogen regulator is opened to 40 bar (580psi)and the pressure to the valve is slowly increased to thispressure, this is to pre-dome the burst disc. This pres-sure is held for 1 minute ensuring that there is no drop inpressure indicated by nitrogen rig gauge.

3. A Water /soap solution is poured into the top capschrader and leak detection spray is applied to all portson the valve to check for leakage. If no leaks are presentthe pressure to the valve must be reduced to 25 bar(362.5psi) and the closing down adapter fitted. To closethe valve shuttle down, 40 bar (580psi) is applied throughthe closing down adapter.

4. Once again check for leaks.

5. Slowly release the gas from the test rig, vent fromclosing down adapter and ensure that the outlet capadapter tap is opened before attempting to remove theadapter.

If a leak is identified it should be rectified, if the leakpersists the valve assembly should be rejected.

Figure 51Nitrogen Test Station Component Layout

FILLING

1. With the Container ready for filling a check ismade to the filling instruction sheet and the containerfill weight, time, date and fill details record.

2. The container is placed on a scales and theappropriate filling adapter attached to the container valvedischarge port.

3. Attach the fill hose / vent line from the filling rigoutlet to filling adapter.

4. Reset the scale to zero to compensate for weightof container and fill hose.



13. Remove the closing down line adapter.

14. If valve does not close after 5 applications, thecylinder must be de-pressurised. Refer to section on"Decanting Containers through rig." Ensure vent valveis closed when not required to prevent contaminationon fill line.

15. Test all ports with leak detection spray, andSchrader with water/soap solution.

If a leaks is observed, minor leaks may be cured bytightening the offending components.

16. Remove fill hose and filling adapter, leak test theoutlet and attach safety cap. Note : When leak testingoutlet with spray, do not look directly into port, examinequickly from an angle.)

17. Reset scales and note down gross weight.

18. Make certain all safety caps are in place, schraderprotection cap Part No' 91185.

19. Attach label to container stating the followinginformation. Job number, Customer, Project, Containersize, Fill weight, Gross weight, Date filled, Type of agent.

20. Place container in bonded area for leak monitor-ing for at least 24 hours prior to dispatch.

21. After 24 hours a Leak Test on the container isconducted - see section on Container / valve assy leak-age test.

22. Insert fill information on to container label.

8 Ltr Container: Label part No.4284

16 to 180 Ltr Container: Label part No.4294

23. Adhere label to container 50mm (2") below thecontainer top fixing bracket height.

5. Switch on the pump marked 'Liquid' on fillingcabinet and fill container to required weight, refer to filltolerances table 19. (less approximately 0.7kg ( 1.5lbs)which is present in pipework and will be forced throughduring pressurisation). When the fill is reached switchoff pump.

6. Remove container from scales, zero scales andweigh to verify fill is within tolerance, adjust if required.

7. Attach low pressure switch wires to test box andregulate nitrogen pressure to 13.8 bar (200psi) on fill rigand switch on supply.

8. Slowly increase the nitrogen pressure on the ap-proved pressure regulator to the stated pressure on thefilling instruction sheet, making the relevant allowancesin pressure to compensate for the current room tempera-ture (see the temperature correction chart Table 20.). Readoff the calibrated external fill pressure gauge to deter-mine when the intended charging pressure has beenreached. (Check that the container pressure gauge readswithin +/- 1bar (+/- 14.5 psi) of the fill gauge, replacecontainer gauge if outside this tolerance).

Caution. When superpressurising, a pressure regulator must be used when the pressure source is a tank of high pressure gas.

Ensure that the test box registers a change in state(normally open to normally closed or normally closed tonormally open) at approximately 21 bar rising (350 psi).

9. Agitate the container to accelerate nitrogen ab-sorption into the agent and top up the pressure accord-ingly. Switch off nitrogen supply once absorption hasstopped.

10. Attach the closing down adaptor to the con-tainer valve top cap and connect the nitrogen closingdown line. Regulate the nitrogen pressure to 40 bar (580psi) with the fill rig.

11. Open the closing down valve for 1 second onlyto force the valve shuttle down. The container valve canbe heard to close. Turn off the nitrogen supply and ventthe closing down line with the needle valve.

12. Vent the fill hose to atmosphere. If the pressuredrops to zero as shown on fill rig gauge marked outletwithin 10 seconds, the valve has closed. (Top up ifnecessary)



Container Size Fill Tolerance Charging Pressure8ltr +0.04, -0 kg (+0.09, -0 lb) +0.75, -0 bar (+11, -0 psi)

16ltr +0.08, -0 kg (+0.18, -0 lb) +0.75, -0 bar (+11, -0 psi)32ltr +0.16, -0 kg (+0.35, -0 lb) +0.75, -0 bar (+11, -0 psi)52ltr +0.26, -0 kg (+0.57, -0 lb) +0.75, -0 bar (+11, -0 psi)106ltr +0.50, -0 kg (+1.10, -0 lb) +0.75, -0 bar (+11, -0 psi)147ltr +0.75, -0 kg (+1.65, -0 lb) +0.75, -0 bar (+11, -0 psi)180ltr +1.00, -0 kg (+2.21, -0 lb) +0.75, -0 bar (+11, -0 psi)

Table 19 :Fill Tolerance Table.

Table 20: Temperature Correction Chart.

o o

Temperature Developed Temperature Developed Temperature Developed Temperature DevelopedPressure Pressure Pressure Pressure

C ( F) Bar (Psi) C ( F) Bar (Psi) C ( F) Bar (Psi) C ( F) Bar (Psi)

0 (32) 19.9 (288.1) 12.8 (55) 22.8 (331.0) 25.6 (78) 26.0 (376.7) 38.3 (101) 29.5 (427.5)0.5 (33) 20.0 (289.9) 13.3 (56) 22.9 (332.9) 26.1 (79) 26.1 (378.7) 38.9 (102) 29.6 (429.9)1.0 (34) 20.1 (291.7) 13.9 (57) 23.1 (334.8) 26.7 (80) 26.3 (380.8) 39.4 (103) 29.8 (432.3)1.6 (35) 20.2 (293.6) 14.4 (58) 23.2 (336.7) 27.2 (81) 26.4 (383.0) 40.0 (104) 30.0 (434.7)2.0 (36) 20.4 (295.4) 15.0 (59) 23.4 (338.6) 27.8 (82) 26.6 (385.1) 40.6 (105) 30.1 (437.1)2.8 (37) 20.5 (297.2) 15.6 (60) 23.5 (340.5) 28.3 (83) 26.7 (387.3) 41.1 (106) 30.3 (439.5)3.3 (38) 20.6 (299.0) 16.1 (61) 23.6 (342.5) 28.9 (84) 26.9 (389.4) 41.7 (107) 30.5 (441.9)3.9 (39) 20.8 (300.9) 16.7 (62) 23.8 (344.4) 29.4 (85) 27.0 (391.6) 42.4 (108) 30.6 (444.3)4.4 (40) 20.9 (302.7) 17.2 (63) 23.9 (346.4) 30.0 (86) 27.2 (393.7) 42.8 (109) 30.8 (446.7)5.0 (41) 21.0 (304.6) 17.8 (64) 24.0 (348.4) 30.6 (87) 27.3 (395.9) 43.3 (110) 31.0 (449.1)5.6 (42) 21.1 (306.4) 18.3 (65) 24.2 (350.4) 31.1 (88) 27.4 (398.0) 43.9 (111) 31.1 (451.6)6.1 (43) 21.3 (308.3) 18.9 (66) 24.3 (352.3) 31.7 (89) 27.6 (400.2) 44.4 (112) 31.3 (454.2)6.7 (44) 21.4 (310.2) 19.4 (67) 24.4 (354.3) 32.2 (90) 27.7 (402.3) 45.0 (113) 31.5 (456.77.2 (45) 21.5 (312.1) 20.0 (68) 24.6 (356.3) 32.8 (91) 27.9 (404.6) 45.6 (114) 31.7 (459.3)7.8 (46) 21.6 (313.9) 20.6 (69) 24.7 (358.2) 33.3 (92) 28.1 (406.9) 46.1 (115) 31.9 (461.9)8.3 (47) 21.8 (315.8) 21.1 (70) 24.8 (360.2) 33.9 (93) 28.2 (409.1) 46.7 (116) 32.0 (464.5)8.9 (48) 21.9 (317.7) 21.7 (71) 25.0 (362.3) 34.4 (94) 28.4 (411.4) 47.2 (117) 32.2 (467.0)9.4 (49) 22.0 (319.5) 22.2 (72) 25.1 (364.3) 35.0 (95) 28.5 (413.7) 47.8 (118) 32.4 (469.610.0 (50) 22.2 (321.4) 22.8 (73) 25.3 (366.4) 35.6 (96) 28.7 (416.0) 48.3 (119) 32.6 (472.2)10.6 (51) 22.3 (323.3 23.3 (74) 25.4 (368.4) 36.1 (97) 28.8 (418.3) 48.9 (120) 32.7 (474.8)11.1 (52) 22.4 (325.2) 23.9 (75) 25.6 (370.5) 36.7 (98) 92.0 (420.5)11.7 (53) 22.6 (327.1 24.4 (76) 25.7 (372.6) 37.2 (99) 29.2 (422.8)12.2 (54) 22.7 (329.0) 25.0 (77) 25.8 (374.6) 37.8 (100) 29.3 (425.1)

oo ooo o



Container / Valve Assy leakage Test

This Test is required for all filled FM-200® valvesand container assemblies after being left to stand in abonded area for at least 24 hours. The test equipmentused is a leak detector and calibration gas.

1. After 24hrs standing, the valve pressure gaugeshould be checked for pressure loss (refer to tempera-ture correction chart to adjust for temperature change).The container and valve assembly should then bechecked for leakage using the Halotek leak detector unit.

2. Switch on the fan to pressurise/purge the roomfor a minimum of 20 minutes before testing.

3. Take the Halotek unit & calibration gas and retireto an FM200® free environment to calibration of the unit.

4. Adjust the Halotek leak detector to gain a steadyaudible pulse, in free air, of about 2 to 4 pulses per sec-ond.

5. Conduct a stability check by leaving the Halotekunit for approximately 3 minutes in a clean air environ-ment. If the pulse rate is observed to stay within therange of 2 to 4 pulses per second, proceed to therepeatability check.

If the stability check is inconclusive, repeat stabilitycheck in an alternative clean environment. If stabilityproblems persist, contact R&D department for instruc-tion.

6. The leak standard of 0.21oz/year should be condi-tioned to a temperature of 200C +/-50C (680F +/- 90F) forat least 24 hours.

Calibration Repeatability Test

1. Remove the cap from the leak standard, screw thecalibration nozzle into the outlet of the bottle and openthe hand valve fully.

2. Place the Halotek probe into the calibration noz-zle. Within 5 seconds the pulse rate should start toincrease and be a continuous tone within 15 seconds.

3. Remove the probe from the nozzle and positionthe Halotek unit away from the gas source. The pulserate should revert back to the original rate of 2 to 4 pulsesper second within 15 seconds.

4. Repeat test a further two times. If repeatabilitytest indicates that the unit is functioning within the setparameters, proceed to the container leak test.

However, if the repeatability check is inconclusive,repeat check in an alternative clean environment. Ifrepeatability problems persist, contact R&D departmentfor instruction. Close the hand valve of the leak stand-ard after use.

Container Leak Test.

Carefully probe the container/valve assembly at allprobes and openings. Ensure that the probe is notbrought into direct contact with any objects as this canlead to spurious results and ensure that the dwell time ofthe probe is sufficiently long (more than 5 seconds) toensure any leak is detected. Any significant and repeat-able increase of the audible pulse rate should be takenas an indication of a leak and the container and valveassembly should be rejected.

Once the leakage source has been rectified, the con-tainer and valve assembly should be subjected to a fur-ther leak test using the Halotek unit.

Decanting a container through filling rig.

Decanting is necessary if a container / valve assyhas been rejected due to a leak after filling, if this isnecessary the appropriate outlet adapter should be at-tached to the valve and a direct line connected to a stor-age vessel.

Caution. Make certain that the container issecured to a rigid surface. Failure to do so couldcause severe container movementupon actuation, resulting in personal injury orproperty damage.

If the valve has been shut down, ensure that the lineis shut off and activate the valve. Open the ball valve onthe line that is direct to the storage vessel and flush theFM200® back into it. Shut off line and vent remainingpressure to atmosphere.

Label up cylinder with appropriate instructions i.e.Refit or rejection.



Transportation

Containers that have passed all required tests andhave been filled or recharged must be stored, trans-ported and installed in the vertical position. A warninglabel will be placed on a container to indicate this re-quirement. See figure 52.

This only applies to 8 - 52 Ltr containers only.

Figure 52.Transportation Warning Label.

HYGOODSection 10 - Warranty, Disclaimers & Limitations


Warranty

Following the commissioning of the system, all equip-ment will be covered by the company's twelve monthparts warranty (excluding parts accidentally or mali-ciously damaged by others). For further information, re-fer to MACRON SAFETY SYSTEMS 'Terms and condi-tions' document.

Disclaimers & Limitations

Whilst every care has been taken in the publicationof this user's guide to describe our products accurately,it is not considered binding. MACRON SAFETY SYS-TEMS reserves the right to make any alterations with-out notice. All issues are uncontrolled copies.

SECTION 11 - APPENDICESHYGOOD


Fm 200

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