Foam Mix Fire Sup TM HP0296 v2

5/28/2018 Foam Mix Fire Sup TM HP0296 v2

1/126

Toll Free 1-877-HELIPAD707 Carr St. Cincinnati, OH 45203

Foam Mixing Fire Suppression Package

Installation, Operation, & Service Instructions

INSTALLER:PLEASE LEAVE THIS MANUAL FOR THE OWNERS USE.

WARNING: This manual has been prepared as an aid and guide for personnel involved in the installation,operation and maintenance of a Bladder Tank Proportioning System. All Instructions must be read andunderstood thoroughly before attempting any installation, operation, maintenance, or refilling of this system.Failure to follow any instructions could result in personal Injury and/or damage to this equipment.

DESCRIPTIONFrame mounted Fire Suppression Skid consisting of but not limited to: Deluge Valve, Associated Trim Kit, Bladder

Tank, Concentrate Ratio Flow Controller (Proportioner), Releasing Panel, Manual Emergency Release, MountingSkid, 1% Synthetic AFFF Foam. The following options are also available: Hose Reel, Remote Fire Alarm Station,and Station Cover.

OPERATIONAL LIMITSThe standard design pressure is 150 PSI unless otherwise indicated. The ASME nameplates will indicate theratings of the pressure vessels and relief valves. A control panel is also supplied; refer to the nameplate foroperating voltage and full load AMP current draw.


2/126

FEC HELIPORTS FOAM MIXING FIRE SUPPRESSION PACKAGE HP0296 REV B

2 Copyright 2005

SAFETY INSTRUCTIONSVarious Danger, Warning, Caution and Note signal words appear in the Operating and Maintenance Manual textwhich must be observed for safe personal and equipment operation. Signal word selection is based upon hazardclassification. The following explains each signal word. Personnel operating and maintaining equipment mustfamiliarize themselves with each particular signal words intent.

DANGER signal words indicate an extremely hazardous situation, which if not avoided, will result in death or

serious injury to the operator.

WARNINGsignal words indicate a potentially hazardous situation, which, if not avoided, could result in seriousinjury, or death to the operator

CAUTION signal words indicate a potentially hazardous situation, which if not avoided, may result in minor ormoderate injury, or it may damage or destroy equipment or cause a loss of operating effectiveness. It also alertsoperating personnel to unsafe practices.

NOTE signal words indicate statements, which must be observed for essential and effective operatingprocedures, conditions, and as a statement to be highlighted.

It is the responsibility and duty of all personnel involved in the operating and maintenance of this equipment to

fully understand the DANGER, WARNING, CAUTION, and NOTE procedures by which hazards are to bereduced or eliminated. Personnel must become thoroughly familiar with all aspects of safety and equipment priorto operation or maintenance of the equipment.

Operating and Maintenance Instructions and layouts shall be posted at control equipment with a second copy onfile. All persons who may be expected to inspect, test, maintain or operate foam-generating apparatus shall bethoroughly trained and kept thoroughly trained in the functions they are expected to perform. (NFPA 11, Para 5-4,Operating Instructions and Training)

GENERAL NOTES1. All correspondence relating to this system should refer to the Sales Order Number, file number and user nameand location.2. Before installation is begun, the final plans and design data should be presented to the authorities having

jurisdiction.3. Chemguard recommends that those individuals charged with designing, installing, operating, testing andmaintaining a foam fire protection system, or the replacement of equipment and/or components of an existingsystem, refer to the appropriate authority having jurisdiction for compliance with applicable standard(s), code(s)and regulation(s) for that particular type of system and its components.4. AFFF Foam concentrates must be maintained and stored within certain specified temperatures, containers andconditions. Failure to follow these guidelines regarding these concentrates can compromise their effectiveness.5. The foam system provided is based on specific design requirements, that is, product being protected and areaof coverage. The design requirements may or may not have been provided to Federal Equipment Company. Anychanges to the areas of coverage or additions of other products could exceed the design parameters of thesystem. Contact Federal Equipment Company for questions regarding changes to design.6. NFPA 11, Section 5-3, states at least annually, all foam systems shall be inspected and checked for properoperation.7. In accordance with the requirements of NFPA 11, Federal Equipment Company recommends that the systembe inspected and tested by qualified personnel. Testing shall meet the approval of the authority havingjurisdiction, and as a minimum, shall be as outlined in NFPA 11 to insure that the system has been properlyinstalled and will function as intended. The services of a qualified field engineer are available to perform thistesting and inspection. If persons not employed by Federal Equipment Company carry out initial start-up tests,please forward copies of the inspection test report to Federal Equipment Company.8. Before filling the bladder tank, carefully read the concentrate filling instructions to prevent damaging thebladder.9. All electrical installations and equipment must conform to the provisions of the National Electric Code and alllocal codes.


3/126


3 Copyright 2005

Foam Mixing Fire Suppression Package

INSTRUCTIONS

UNIT IDENTIFICATIONThe unit nameplate will give identification and rating information as identified in Figure 1.Units with electrical panels also are identified with a nameplate as shown in Figure 2.

Permanent records for this unit are kept by the factory for each Unit Number and it must thereforebe used with all correspondence and spare parts orders.

----SAMPLE LABEL----

PACKAGED PRODUCTS

Model Number HP0296

Unit Number 6837-FS1

Shipping order - 6837 Date 2/20/2003

Deluge Valve Viking 3 Model E-1

Bladder Tank Chemguard 36 Gallon

Main Control Panel Viking Par III

FEC HELIPORTS

FIGURE 1 SAMPLE LABEL

Model Number HP0296

Unit Number 6837-FS1

Wired for 120 Volts 60 Hz 3 Ph

System FL Amps 5

System Flow GPM 84

Inlet Pressure PSIG 120

Outlet Pressure PSIG 105

Date Code 2/2003

FEC HELIPORTS

FIGURE 2 SAMPLE LABEL


4/126


4 Copyright 2005

TABLE OF CONTENTSFOAM MIXING FIRE SUPPRESSION PACKAGE

Page

SECTION 1System Overview.. 5

SECTION 2What Owners Should Know About Fire Suppression Systems 6

SECTION 3Installation. 10

SECTION 4Start Up Check List Piping... 15Start Up Check List Electrical.. 15

SECTION 5Bladder Tank Filling Instructions.... 18

SECTION 6

Operating Procedures. 26

SECTION 7Maintenance.. 28

SECTION 8Troubleshooting. 35

INDEX ASystem Components... 38

Deluge Valve And Associated Trim Kit 39Priming Shut-Off Valve (PSOV) 49High Pressure Solenoid Valve.. 52Bladder Tank 55Concentrate Ratio Flow Controller (Proportioner). 60Releasing Panel . 62Manual Emergency Release . 107SlowClose, Indicating Butterfly Valves 1101% Synthetic AFFF Foam.. 114Fire Foam Nozzles.. 117

INDEX BOptional Components.. 121

Hose Reel. 121Hose Reel Cover. 122Remote Fire Alarm Station. 123Station Cover .. 125

NOTE:The information contained in this manual is intended to assist operating personnel by providinginformation on the characteristics of the purchased equipment.

It does not relieve the user of the responsibility to adhere to local codes and ordinances and theuse of accepted practices in the installation, operation and maintenance of this equipment.

Further information pertaining to the installation, operation, and maintenance of your Steam HeatTransfer Package can be found in the individual equipment technical manuals for the associatedequipment provided with this manual.


5/126


5 Copyright 2005

SECTION 1SYSTEM OVERVIEW

Product Name: FEC AFFF MIXING PACKAGEModel No.: HP0296

General Description:

The FEC AFFF SKID, model HP0296, is a pre-engineered foam mixing system designed to, upon activation of thesystem, inject up to 36 gallons of 1% AFFF foam concentrate into the water supply at the correct percentage toprovide up to 3600 gallons of AFFF foam for use in a Heliport fire suppression system. Activation of the systemcan be through mechanical or electrical activation at the unit or through a remote electrical activation from anapproved source, i.e. fire alarm pull station. Remote monitoring of the system is available through the releasingpanel.

The FEC AFFF SKID is designed to meet the requirements of NFPA 11, Standard for Low-Expansion Foam, andadditionally when used with a properly designed and installed foam fire extinguishing system the FEC AFFF SKIDmeets the size and supply requirements for both Category H1 and Category H2 heliports under NFPA 418,Standard for Heliports.

The system consists of components that meet all UL and NFPA requirements for use as a foam mixing system.

Operational Description:

The Foam Mixing System employs water pressure and a bladder equipped tank in conjunction with a ratiocontroller to make the foam solution. The proportioning is accomplished by using a water orifice and a foamconcentrate orifice both discharging into a common reduced pressure area (Ratio Controller).

The water supply simultaneously feeds the ratio controller (venturi-type proportioner) and pressurizes the foamconcentrate. A portion of the water supply is diverted upstream of the proportioner and is used to pressurize thefoam concentrate through an elastomeric bladder in the tank separating the foam concentrate from the water.

The water flowing through the controller jet creates a differential pressure common to both the downstream waterand foam concentrate. This pressure difference between the tank and controller concentrate inlet forces foam

concentrate from the tank through the foam concentrate orifice and into the controller. Here it mixes with water toproduce a constant predetermined percent solution at various flow rates. The units have a low pressure drop andconnect directly to the solution discharge valve.

During foam operation, the water outside the bladder gradually displaces the foam concentrate inside the bladdercausing the bladder to collapse until the supply is exhausted, at which time, the system must be shut down, thetank drained and the bladder refilled with foam concentrate. Replenishment of the foam concentrate duringsystem operation is not possible.

Technical:

Size Approximately 3 Ft. Wide x 6 Ft. Long x 5 Ft. TallInlet 3 Grooved EndOutlet 3 Grooved EndWater Supply 90 GPM @ 150 PSIPower Supply Primary - 120 Volts AC, 3 PH, 50/60 Hertz, 1.2 Amps

Back Up 7.0Amp Hours Standard (12 or 18 Amp Hours are Optional)Flow Friction Loss for the FEC AFFF Skid is equivalent to 31 feet of 3 schedule 40 pipe (id = 3.068)

(C = 120). To calculate friction loss for the FEC AFFF SKID at specific flows, use the followingformula. Where P = Friction Loss (PSI), Q = Flow in GPM, and C = Constant (120)

PPSI= (4.52 x Q1.85

/ C1.85

x 3.0684.87

) x 31


6/126


6 Copyright 2005

SECTION 2WHAT OWNERS SHOULD KNOW ABOUTFIRE PROTECTION SYSTEMS

INTRODUCTIONFire protection systems are unique and have many different issues surrounding their design, installation andservice. The following is a discussion of those issues.

Warning:While installing a fire alarm system may make lower insurance rates possible, its not a substitute forfire insurance!

Question One:How does NFPA 409 - 1995 specify the fire protection requirement in aircraft hangars?

Basically, the fire protection requirement is based on the fire hazard size, deck size and construction type. Thereare also other variables involved, but for easy guidelines the following matrix in Figure 1 is provided.

FIRE PROTECTION MATRIX FOR AIRCRAFT HANGARS(Fueled Aircraft)

NFPAGroup*

SizeSq. Ft. (m

2)

Door Ht.Ft. (m)

Type of PrimaryProtection**

I 40,000 or more (3716) 28 or more (8.5) Foam-Water Deluge Activated by Thermal Detection

II Less than 40,000 (3716) Less than 28 (8.5) Foam-Water Deluge Activated by Thermal DetectionOrSprinkler System at the Roof with Low Level LowExpansion Foam System Activated by ThermalDetectionOrClosed-Head Foam-Water SprinklerOrSprinkler System at the Roof with High ExpansionFoam System Activated by Thermal Detection

III Less than 30,000 (2787) Less than 28 (8.5) None Required Except Where HazardousOperations are Preformed

*NOTE: Correct Group Classification must also take into account: Type of Construction, Number of Stories and Layout of Fire Areas.

**Supplemental underwing protection is required for aircraft with wing areas in excess of 3000 ft2 (279 m2) in Group I hangars.

Supplemental protection is optional for other groups and is frequently used to protect military aircraft.

FIGURE 1Question Two:How do you ensure that your helicopter decks foam/water sprinkler system is reliable?

The reliability of the fire protection system is highly dependant on the quality of design, installation, and service(testing/inspection/maintenance).

A foam/water deluge sprinkler system is generally the heart of most fire protection systems. It includes foampumps, or bladder tanks, detection systems, deluge valves and other accessory equipment. These componentswork together as a total package to protect the deck against the threat of fire.

Since the system is integrated, the design should be performed by a fire protection engineer who has experience

in both suppression and detection systems. The installation includes many contractors: general, electrical,mechanical, sprinkler, etc. These contractors must work as a partnership to install an integrated fire protectionsystem that does not lead to the expense of false discharges or lack of operation in a fire emergency.

Lastly, the most overlooked part of ensuring a reliable system is periodic testing, inspection and maintenance. It isimportant to test the system at regular intervals but also to inspect on a weekly basis. These inspections and testsassure that the components are in full operational condition and will perform in a fire condition as designed. NFPA409 1995, Standard on Aircraft Hangars, requires inspection and testing at regular intervals. (See Figure 2 foractions and intervals for periodic inspection, testing and maintenance.)


7/126


7 Copyright 2005

INSPECTION, TEST, AND MAINTENANCE REQUIREMENTSFOR FOAM-WATER DELUGE SYSTEM IN AN AIRCRAFT HANGAR

(Adapted from NFPA 409-1995 Edition)

Item

Frequency

Weekly Monthly Quarterly Semi-Annual Annual Year 5

Foam Pump F O D

Optical Detectors V F O

Sprinkler Alarm Valve V O

Deluge Valve V O D

Water Reservoirs V

Concentrate Pumps F O D

Control Valves V F

Foam Proportioning Device V D

Control Panels V F O

Alarm Transmission F

Hose Station V D

Drains (Floor) V D

Tamper Switch F

Electric and Pneumatic Detector F OSupervisory Alarms F

Manual Actuation Stations F

Piping Deck V

Strainers V

Flow Indication Switch O

KEY: V= Visual InspectionF= Functional TestO= Operational TestD= Operational with Actual Discharge FIGURE 2

Question Three:Why is foam used and what does it add to the fire protection of a helicopter deck?

Fire fighting foam was originally developed in the 1930s to fight flammable liquid fires. Water deluge systemsalone will not suppress a large pool fire on the helicopter deck. This Is due to the very high heat release rate of alarge pool fire of flammable liquid on a helicopter deck. The water alone cannot cool the fuel to create firesuppression. Using foam, which is the aspiration of a water and foam concentrate, will suppress the fire byblanketing the fuel and smothering the flames as well as providing vapor suppression. Today there are many dif-ferent types of foam concentrates including Protein, Fluoroprotein, Film-Forming Fluoroprotein, Aqueous Film-Forming Foam, Alcohol-Resistant Concentrate AFFF and Synthetic Detergent (High/Medium Expansion). Thefoam concentrate is combined with water by mechanical proportioning devices to a 1% to 6% solution to form thefoam/water solution. Although there are several different types of foam concentrates, the most commonly used is3% AFFF or Aqueous Film-Forming Foam.

Many aircraft hangar owners have converted their water deluge systems to foam/water deluge sprinkler systems.NFPA 409 - 1995 makes this conversion a little easier with a few concessions for the higher densities of thesewater deluge systems. The standard allows a reduction of the foam discharge duration for the higher density up to7 minutes and waves the uniform discharge requirement of 15% maximum variation between outputs of thesprinkler head flow rates.


8/126


8 Copyright 2005

Question Four:What are the environmental concerns with foam?

Recently, firefighting foams have been analyzed to determine their environmental impact when released. TheNational Fire Protection Associations Technical Committee on Foam formed a task group to study this issue. Thistask group has determined that firefighting foam should not be restricted, but the task group encourages the useof foam in an environmentally responsible manner. Foam/water deluge sprinkler systems discharge foam duringtesting, during an accidental discharge or during a fire. The local jurisdiction may require that the discharge offoam be contained in a fixed containment system for new installations. Determining if a containment system is

required is based on the location of the facility, the risk to the environment, the possible impairment of facilityoperations, the design of the fixed foam system, the ability of the responding fire department to executetemporary containment measures and any local applicable rules or regulations. These conditions could requirecontainment for volumes of 100,000 gallons (378,540 L) or more.

Ethylene gycol is a freeze point suppressor and is used in freeze protected foam concentrates. Releases ofethylene gycol in excess of 5,000 pounds are reportable under U.S. EPA Comprehensive EnvironmentalResponse Compensation & Liability Act (CERCLA) Sections 102 (h) and 103 (a). Most foam concentrates are notfreeze protected, but check with your foam manufacturer for more information.

Glycol ethers are also used in foam concentrates. As of June 12, 1995; the EPA has issued a final rule on severalbroad categories of chemicals including glycol ethers. At this time, the EPA has no reportable quantities for any ofthe glycol ethers. Additional information is available through Ansul Technical Bulletin No. 60.

Question Five:Are foams compatible and interchangeable?

When foams are tested and listed by Underwriters Laboratories (UL), they are tested with a specificmanufacturers equipment. These listings require that the only foam that can be used in a system is the foamconcentrate tested with the equipment. The foam is tested to determine if it will suppress a minimum fire size withspecific test protocols and if it will meet a film forming test. These tests are performed on most commercial foamagents. There is additional testing required to perform to the military foam standard of MIL-F-24385 and all foamsperforming to this standard are tested for compatibility. Typically the military specification foam agent is moreexpensive than the commercial foam agent.

Question Six:

Are there any limitations to the Fire Alarm System?

An automatic fire alarm system - typically made up of smoke detectors, heat detectors, manual pull stations,audible warning devices, and a fire alarm control with remote notification capability can provide early warning of adeveloping fire. Such a system, however, does not assure protection against property damage or loss of liferesulting from a fire.

Any fire alarm system may fail for a variety of reasons:

Smoke detectors may not sense fire where smoke cannot reach the detectors such as in chimneys, in walls, orroofs, or on the other side of closed doors. Smoke detectors also may not sense a fire on another level or floor ofa building. A second floor detector, for example, may not sense a first floor or basement fire. Furthermore, alltypes of smoke detectors - both ionization and photoelectric types, have sensing limitations. No type of smokedetector can sense every kind of fire caused by carelessness and safety hazards like smoking hi bed, violentexplosions, escaping gas, Improper storage of flammable materials, overloaded electrical circuits, children playingwith matches, or arson.

IMPORTANT!Smoke detectors must be installed in the same room as the control panel and in rooms used by thesystem (or the connection of alarm transmission wiring, communications, signaling, and/or power. If detectors arenot so located, a developing fire may damage the alarm system, crippling its ability to report a fire.


9/126


9 Copyright 2005

Audible warning devices such as bells may not alert people if these devices are located on the other side ofclosed or partly open doors or are located on another floor of a building.

A fire alarm system will not operate without any electrical power. It AC power fails, the system will operate fromstandby batteries only for a specified time.

Rate-of-Rise heat detectors may be subject to reduced sensitivity over time. For this reason, a qualified fireprotection specialist should test the rate-of-rise feature of each detector at least once per year.

Equipment used in the system may not be technically compatible with the control. It is essential to use onlyequipment listed for service with your control panel.

Telephone lines needed to transmit alarm signals from a premise to a central monitoring station may be out ofservice or temporarily disabled.

The most common cause of fire alarm malfunctions, however, is inadequate maintenance. All devices and systemwiring should be tested and maintained by professional fire alarm installers following written procedures suppliedwith each device. System inspection and testing should be scheduled monthly or as required by National and/or

local fire codes. Adequate written records of all Inspections should be kept

SUMMARY

Fire protection systems are unique and present a challenge to owners. It is important to understand how thesesystems work and how to keep them in service.

Your fire protection system will provide protection if the system is designed for the hazard present and the systemis inspected and tested periodically. These parameters are the same for most industrial fire hazards. What makesa helicopter deck unique is the large fuel source present, the high value of the aircraft, the aircrafts mobility andsize, and the aircrafts vulnerability to fire damage. Therefore it is essential that the fire protection systemoperates in a fire or the consequences may he great.


10/126


10 Copyright 2005

SECTION 3INSTALLATION

Note:For additional information on any of the components in the system, refer to appendix A and B.

The Fire Suppression System is design to be stored inside a building or away from freezing temperatures. Itmeets NFPA requirements for operation at 0-49

oC / 32-120F and at a relative humidity of 85% RH (non-

condensing) at 30oC / 86F. However, extreme temperature ranges and humidity may adversely affect the useful

life of the systems standby batteries and the electronic components. Also since the system relies on the flow ofwater and a foam mixture, any temperatures near the freezing mark may have an effect on the efficiency of thesystem. Therefore, it is recommended that this system and its peripherals be installed in an environment with anominal room temperature of 15-27C / 60-80F.

NOTE:Bladder tanks have flanges on both ends of the tank. Vertical tanks always use the top end flange forinternal piping and bladder removal. The flange bolts need to be checked for proper tightness (50 ft. lbs.) beforeplacing the tank into service. Follow the appropriate torque rating to insure that the bolts are fixed securely inplace. If tightening is required, a criss-cross pattern technique is recommended to insure that the flange issecured completely and correctly. If the internal piping and bladder need to be removed at any time, the BladderTank System needs to be tested before being put back into service.

When placing the system, make sure that the control panel is accessible and that the drainpipe is positioned inthe direction of a drain or other waste removal system (in accordance with National and/or Local codes, also all

Authorities Having Jurisdiction). There must also be sufficient space above the tank to permit the filling of the tankwith foam concentrate and for the removal of the internal pipes and bladder, which are the full height of the tank,should they need to be replaced. The system is then bolted to the floor using four anchor bolts.

After the system is secure, then the 3 NPT outlet pipe needs to be attached to the sprinkler system inlet pipes. Ifthe drain is being attached to another system, then that needs to be done at this time. Otherwise the water supplyline is attached to the system at the 3 NPT inlet pipe with the 3 butterfly valve closed. To ensure accurateproportioning over the flow range of the controller, it is recommended that a minimum water inlet pressure of 30psi must always be available during operation of the system.

The ratio controller is designed to have a bladder tank flow rate between 70-750 for AFFF foam. To ensurecorrect operation of the ratio controller, the pressure of the foam concentrate at the controller must be within 2 psiof the incoming water pressure.

All piping that will contain any foam concentrates should be Stainless Steel, Type 304 or 316, brass or bronze.Also, any valves should be Stainless Steel, Type 304 or 316, brass or bronze. Cast brass valves fitted withstainless steel (304 or 316 grades) or brass trim are acceptable. Teflon seats and packing are preferable for foamconcentrate service. EPT (EPDM), Buna-N or Viton are also acceptable seal materials.

CAUTION:Galvanized steel or other internal coatings must never be used in piping which will contain any foamconcentrates.

WARNING: Electrical shock hazard. Inspect all electrical connections prior to powering the unit. Wiringconnections must be made by a qualified electrician in accordance with all applicable codes, ordinances, andgood practices. Failure to follow these instructions could result in serious personal injury, death, and/or propertydamage.


11/126


11 Copyright 2005

Note: All wiring should be done in accordance with National and/or Local codes for fire alarm systems. TheAuthority Having Jurisdiction may have additional requirements.

WARNING:Prevent electrical shocks. Disconnect the power supply before beginning installation. Failure to followthese instructions could result in serious personal injury, death, and/or property damage.

Note:Field wiring must be for the specific mode of operation required. See TABLE 3-1.

Note:Like all solid state electronic devices, this system may operate erratically or can be damaged whensubjected to lightning induced transients. Although no system is completely immune from lightning transients andinterferences, proper grounding will reduce susceptibility. Overhead or outside aerial wiring is not recommended,due to an increased susceptibility to nearby lightning strikes.

Note:Prior to connecting to the panel, verify the continuity of all circuitry, also check for, and correct any shortcircuits.

Note:Do not energize the panel until all associated, modules, and interconnecting cables have been connected.

A. Visually check the connections of all electrical components in the system. Verify that nothing has become looseor disconnected during shipment or placement of the system.

B. All other job site components, not part of the shipped system, should be wired at this time to the systemthrough the knockouts provided. Refer to Figure 3-2.C. Prior to energizing the panel:

1. Verify that dip switches controlling panel operation are in the proper position for the system used.2. Verify that all modules are securely and properly positioned on their pins. If a module is loose, carefullyalign all pins and press firmly into position.

D. Connect non-energized AC power to the panel. Refer to Figure 3-1 & 3-2.1. Connect the wire providing in-coming voltage to the terminal marked H2. Connect the neutral wire to the terminal marked N3. Connect the ground wire to the terminal marked G

E. Procedure for connecting Batteries:

Note:Two battery plug/wire assemblies (long leads with plug) and jumper (short) wires are provided with each

panel. Connectors on one plug/wire assembly fit 7.0 AH Batteries. Connectors on the other plug/wire assembly fit12.0 AH Batteries.

1. Position batteries end-to-end with terminals adjacent. Select the proper plug/wire assembly for the batteriesused.2. Connect the long RED lead to the positive terminal of one battery, and the long black lead to the negativeterminal of the other.3. Place batteries inside the battery compartment of the Par-3 Release Control Panel with the unusedterminals toward the open door. Install batteries in the upright position only.4. Plug the plug-in connector to J9 on the main board of the panel. (Refer to Figure 3-1). DO NOT installjumper at this time.


12/126


12 Copyright 2005

WARNING:This equipment generates, uses, and can radiate radio frequency energy and if not installed andused in accordance with the instruction manual, may cause interference to radio communications. It has beentested and found to comply with the limits for class A computing device pursuant to Subpart B of Part 15of FCCRules, which is designed to provide reasonable protection against such interference when operated in acommercial environment Operation of this equipment in a residential area is likely to cause interference, in whichcase the user will be required to correct the interference at his own expense.

TABLE 3-1Dip Switch Settings for System Configuration

DIP SWITCH SETTINGSMODE DESCRIPTION CONFIGURATION OPERATION 1 2 3 4 5 6

1Single Hazard

Two ZoneOne release circuit.

Two detection circuits.Activation of EITHER detection circuit

energizes the release circuitOFF OFF OFF OFF OFF

NOTUSED

2Single HazardCross Zone

One release circuit.Two detection circuits.

BOTH detection circuits must activateto energize the release circuit.

ON OFF OFF OFF OFF

3Dual HazardCombinedRelease

Two release circuits.Two detection circuits.

Activation of EITHER detection circuitenergizes BOTH release circuits.

OFF ON OFF OFF OFF

4Dual HazardSplit Release

Two release circuits.Two detection circuits.

Activation of detection circuit No. 1energizes release circuit No. 1

Activation at detection circuit No. 2

energizes release circuit No. 2

ON ON OFF OFF OFF

Note: Dip Switches 3, 4, and 5 MUST be OFF to disable timer capabilities of the panel. For informationconcerning timer capabilities, refer to PAR-3 Owner Manual. Also Refer to installation standards, TechnicalData, and all Authorities Having Jurisdiction when using timer configuration.


13/126


13 Copyright 2005

ITEM NO. DESCRIPTION

1 Zone Relay Module 4XZM (Included with Panel)

2 Transmitter Module 4XTM

3 LED Interface Module 4XLM

4 Remote Annunciator Module RZA-4X

5 Voltage, Current Meters 4XMM

6

Battery, 12V, 7 Amp Hr. Capacity OR

Battery, 12V, 12 Amp Hr. CapacityOR

Battery, 12V, 18 Amp Hr. Capacity(Battery Box, Required when using 18 AH Batteries)

7 Fuses, 4 Amp

8a Resistor, Dummy Load (Notifier 71245)

8b Resistor, Dummy Load (Notifier 27027)

9 Power Relay

10a Battery Plug Wire Assembly (7 Amp Battery)10b Battery Plug Wire Assembly (12 Amp Battery)

11 Resistor, End-Of Line (Notifier 71252)

12a Mother Board 110 Volt

12b Mother Board 220 Volt

12c Mother Board 110 Volt (Canadian Panel)

Figure 3-1


14/126


14 Copyright 2005

Figure 3-2


15/126


15 Copyright 2005

SECTION 4START-UP

Start Up Check List Electrical

To energize the panel and place the system in service:1. Energize the AC power supply to the panel. The Piezo will sound, and the System Trouble and Power Trouble

LEDs will flash.

2. Use the jumper (short) wire to connect the unused negative terminal of one battery with the unused positiveterminal of the other battery. The Piezo should silence, and the System Trouble and Power Trouble LEDsshould stop flashing.

3. Perform appropriate tests to verify proper operation of the system.4. After placing the system in service, close and lock the panel to prevent tampering with the unit.

Start Up Check List Piping

Prior to operation

Prior to operation, you should check the integrity of the tanks bladder.

Note:Although each tanks bladder is tested before it leaves our factory, it is recommended that the customerperform the bladder integrity procedure on their tank to check for possible damage, holes or tears in the bladder,that may have occurred to the bladder during shipping, handling or installation.

CAUTION: Failure to perform this procedure could result in loss of foam concentrate and delay in placing thebladder tank proportioning system into service.

1. The following equipment will be required to properly perform the integrity test of the bladder:a. A 55 gallon drum with an open top completely filled with clean fresh water.b. A length of 3/4 rubber garden hose, which allows the air used to compress the bladder and dischargedthrough the Tank Water Vent Valve 4, to be directed to the 55 gallon drum. A weighted end piece to hold andmaintain the hose at the bottom of the drum is required.c. An appropriate length of 1 clear air/foam concentrate vent hose, with a male NPT swivel, for connection toFoam Concentrate Vent Valve 5, a pail or water tight container, large enough to hold at least 6 of water and aweighted end piece to hold and maintain the hose at the bottom of the pail. This arrangement allows any air

inside the bladder to be discharged to the water pail/container.d. A clean air or nitrogen supply (25 psi to 35 psi capacity) along with approximately 25 ft. of heavy dutycompressor hose and fittings required for connection to the 1/4" NPT valve on the Bladder Tank Fill Manifold.The air supply/hose arrangement attaches to the Water Drain/Fill Valve 6 and provides air, used to compressthe bladder, to the inside of the tank shell.

2. Testing Proceduresa. Set up the tank and testing equipment as described above and as shown in the figure 2.b. Open valves 4, 5 & 6. Make sure that all other valves on the bladder tank are closed.

CAUTION:Valves 4, 5 & 6 must be opened to avoid damage to the bladder and assure a proper bladderintegrity test.

c. Add air to the tank through Valve 6. A steady stream of air will start to escape through Valve 5 as the

bladder is collapsed. This air will show itself as bubbles in the pail of water.

NOTE:The amount of time it takes before air escape through Valves 4 & 5 is in relation to the air supplypressure and the size of the tank.

d. As the tank shell fills with air and the bladder is fully collapsed, the air bubbles through Valve 5 will slowdown and bubbles will start to escape through Valve 4. This decrease of air bubbles from Valve 5 and anincrease from Valve 4 will continue for a period of time and should develop into a steady stream of air bubblesescaping from Valve 4. Air bubbles from Valve 5 should stop completely at this point.e. If no air bubbles are noted from Valve 5 into the pail of water, then positive bladder integrity is indicatedand you may proceed with the bladder tank filling procedures.


16/126


16 Copyright 2005

CAUTION:If a steady stream of bubbles continues to escape through Valve 5, then a hole or tear in the bladderis indicated. Contact the Chemguard Service Department for Information on tank bladder replacement or forquestions or problems regarding the bladder Integrity testing procedures.

Figure 2


17/126


17 Copyright 2005

Placing the System in Service

To put the System into Service, you should follow the steps below.1. Verify:

a. The system Main Water Supply Control Valve is closed.b. The system has been cleared out of any debris or has been properly drained.c. Auxiliary drain is open.d. The emergency release is closed.e. The system water supply piping is pressurized up to the closed Main Water Supply Control Valve and the

priming line is pressurized up to the closed Priming Valve.2. For the Electric Release Systems:

a. Open Priming Valve.b. Reset the system control panel. For Viking Par-3 Panel, open the panel and press RESET. Solenoid

valve should close. Flow from the solenoid valve to the drain cup should stop.3. Open flow test valve.4. Partially open Main Water Supply Control Valve.5. When full flow develops from the flow test valve, close the flow test valve.

a. Verify that there is no flow from the open auxiliary drain.6. Close auxiliary drain.7. Fully open and secure the Main Water Supply Control Valve.8. Verify that the alarm shut-off valve is open and that all other valves are in their normal operating position.9. Depress the plunger of drip check. No water should flow from the drip check when the plunger is pushed.

10. Check for and repair all leaks.11. Trip test the system to verify that all equipment functions properly.

Caution: Performing a trip test results in operation of the deluge valve. Water will flow into the sprinkler piping.Take necessary precautions to prevent damage.

12. Remove the system from service.a. Close the Main Water Supply Control Valve and Priming Valve.b. Open the auxiliary drain Valve.c. Relieve pressure in the priming chamber by opening the emergency release.

13. Check all trim for leaks and repair if necessary.14. Once the system is drained, put it back into service by:

a. Opening the Priming Valve.

b. Closing the auxiliary drain.c. Fully opening and securing the Main Water Supply Control Valve.

15. The bladder tank needs to be filled with the 1% AFFF foam concentrate.

Acceptance of the Fire Suppression System

1. Before acceptance, all operating devices and equipment shall be tested for proper function. (NFPA 11, para. 5-2.3, Operating Tests, latest edition).

2. A full scale test should be run after the system is installed and prior to acceptance of the system. The test runshould include running water to each discharge device to insure that proper pressures and flow rates can beachieved and to insure there is no blockage. Then foam solution should be run (1) - to the devices protecting thegreatest single hazard and (2) - to the device with the lowest flow rate. The foam test(s) should last a minimum of

1 minute (actual injection time) to insure the proportioning system has stabilized before taking samples. At thistime, the quality of the foam should be observed and the foam solution concentration should be checked byrefractive index method*. See NFPA 11 for detailed procedures.

3. After completion of acceptance tests, the system shall be flushed and restored to operational condition. (NFPA11, para. 5-2.5, System Restoration, latest edition)


18/126


18 Copyright 2005

SECTION 5BLADDER TANK FILLING INSTRUCTIONS

WARNING: Incorrect filling procedures can damage the internal bladder. Chemguard products have a limitedwarranty for one year from date of purchase.

NOTE: Chemguard recommends the bladder tank be kept completely full at all times to insure maximum firefighting capability of the system. The bladder tank should be refilled or topped off any time the system has been

activated and foam concentrate has been discharged from the tank.

INTRODUCTION

The following describes the recommended method for filling bladder tanks. To assure that the bladder ispositioned so as to be fully supported by the tank shell, it is imperative that this procedure be followed.

The following equipment is required for proper bladder tank fill in cases of initial fill/empty tank or large volumerefill:1. An open top 55 gallon drum (208 L), or appropriate sized container (approx. 3 ft. high x 2 ft. dia.), to becompletely filled with clean fresh water.2. An appropriate length (20 ft.) of 1 clear air/foam concentrate vent hose with a male NPT swivel for connectionto Foam Concentrate Vent Valve 5, and a weighted end piece to hold and maintain the clear hose at the bottom ofthe 55 gal. drum. This length of clear hose connects Valve 5 to the 55 gallon drum allowing bladder air dischargethru the water in the drum, and also allows foam concentrate discharge indicating that the bladder is completelyfilled.3.* A Bladder Tank Fill Manifold which includes the required valves, fittings and pressure gauge. See Fill ManifoldIllustration for parts and description.

NOTE:Federal Equipment Company recommends a pressure gauge in the manifold type setup as an additionalsafeguard when filling. If unreasonably high pressure is shown on the gauge (10 psi or higher), shutdown the filloperation and Check the setup to see that it conforms to Federal Equipment Company instructions, and to insurethat all valves are in the correct position at that point in the procedure.

4.* A clean air or nitrogen supply (25 psi to 35 psi capacity) along with approximately 25 ft. of heavy dutycompressor hose and fittings required for connection to the 1/4" NPT valve on the Bladder Tank Fill Manifold.5.* A foam concentrate pump, positive displacement, rated 20 gpm @ 20 psi. Also, the hose and adapters needed

to connect the pump with the fill manifold and hose, adapters and dip tube needed to transfer the foamConcentrate from its container to the pump.6.* 2 lengths of rubber garden hose (3/4 x 25 ft) which:

a. Are used to add water, when required, to the shell side of the bladder thru the Water Drain/Fill Valve No. 6.b. Allows water discharged from the Tank Water Vent Valve 4 to be directed to a drain.

NOTE: * indicates a complete Bladder Tank Electric Fill Pump Kit available from Chemguard. Kit includes allnecessary hose, tubing, fittings, fill manifold, electric fill pump and air compressor (optional item).

Complete kit w/compressor (Items 3, 4, 5 & 6) Complete kit w/o compressor (Items 3, 5 & 6) Electric Fill Pump Kit only (Item 5)

CAUTION: Before starting the Bladder Tank Fill Procedure, carefully review the valve description chart and

diagrams. Read all fill Instructions before attempting Bladder Tank fill.

WARNING:Failure to follow these filling Instructions may result in a ruptured Internal bladder.


19/126


19 Copyright 2005

Item No. Description Quantity1 Pipe Cross, Std Ml, 1 12 Pipe Union, Std Ml, 1 13 Pipe Nipple, Std Stl, 1 x 2 34 Ball Valve, 1 Brass Full Port 15 Ball Valve, 1/4 Brass Full Port 16 Pipe Bushing, Hex Std Ml, 1/4 x 1 27 Pressure Gauge, 2 0-60 psi 1/4 MNPT Bot. Conn. 18 Pipe Nipple, X-Hvy Stl, 1/4 x 1 Close 19 Pipe Plug, Std. Ml, 1/4" 1

Figure 5-1 Bladder Tank Fill Manifold


20/126


20 Copyright 2005

A. Initial FillEmpty Bladder Tank Using Motor Driven Foam Concentrate Pump

NOTE:Be sure all valves are in their normal stand-by position. Refer to System Operating Drawing Fig. 3 insection 4 for Normal Stand-By Valve Position Chart and valve location. See Figures 5-1, 5-2, and 5-3 for set-up

illustrations.

1. See Figure 5-1. Close Valve 2. Be sure Valve 1, or 1A if appropriate, and Valve 6 are closed. Open Valves 4and 5.2. Attach the fill manifold to Valve 6. Attach one end of overflow hose to Valve 4 and place the other end of thehose into a drain or container. Connect a water source to the concentrate/water shutoff valve. Be sure theconcentrate/water shutoff valve is closed before pressurizing the water line. Open Valve 6 and then slowly openthe fill manifold concentrate/water shutoff valve, and fill the tank shell until all air is vented from the bladder and asteady flow of water comes thru Valve 4.3. Connect the air/foam Concentrate vent hose to the Bladder Foam Concentrate Vent Valve 5. Fill the 55 gallondrum completely with water and place the vent hose discharge end at the bottom of the drum. The vent hose mustbe positioned and maintained at the bottom of the drum using weighted device.4. See Figure 5-2. Close Valve 6 (Valve 4 remains open). Attach the fill manifold to Foam Concentrate Drain/Fill

Valve 7. Make sure the Concentrate/water Shutoff Valve is closed. Connect the air supply to the fill manifold.Open the Air Supply Shutoff Valve. Start the air source, at a pressure between 5-10 psi, and slowly open Valve 7.The bladder will begin to fill with air. Completely fill bladder with air.5. The bladder is filled with air when air bubbles are expelled from the vent hose at the bottom of the drum, andwater no longer flows from Valve 4. Let the vent hose expel air for approximately 30 seconds to insure completeinflation. Open Valve 6 to drain any remaining water from the shell.6. Close Valves 6 and 7 and the manifold Air Supply Shutoff Valve. Shutdown and disconnect air supply from themanifold.7. See Figure 5-3. Connect the foam Concentrate pump to the fill manifold Concentrate/Water Shutoff Valve.Connect the pump to the foam Concentrate source.8. Open the Concentrate/Water Shutoff Valve. Start the foam concentrate pump and slowly open Valve 7. Be sureto start the pump than open Valve 7.

CAUTION:Make certain that vent hose remains securely positioned at bottom of 55 gallon drum.

NOTE:Air bubbles will be expelled thru the vent hose and drum as foam concentrate displaces the air and fillsthe bladder.

9. Continue filling until foam Concentrate is seen in the clear vent hose or is detected coming from the hosedischarge end.

CAUTION: Foam concentrate bubbles may be detected in the vent hose or at the discharge end of the hosewhen nearing bladder capacity. These bubbles do not indicate a full bladder. Continue filling until liquid foamconcentrate is detected.

CAUTION:Normally the actual capacity of a bladder tank will exceed the nominal capacity listed on the tank.Therefore, it is recommended to continue filling until foam concentrate is detected coming from Valve 5 and not

until nominal capacity is reached.

10. Close Valve 7. Remove the fill manifold.

NOTE: Flush the fill manifold and foam concentrate pump (following manufacturers instructions) after fillingbladder tank.

11. Check foam concentrate level using sight tube. Refer to 5E.


21/126


21 Copyright 2005

FIGURE 5-1 TANK SHELL FILLED WITH WATER


22/126


22 Copyright 2005

FIGURE 5-2 BLADDER BEINGFILLED WITH AIR


23/126


23 Copyright 2005

FIGURE 5-3 BLADDER FILLINGWITH FOAM CONCENTRATE


24/126


24 Copyright 2005

B. Refilling or Topping-OffUsing Motor Driven Foam Concentrate Pump When More Than 30% of Tank Volume Needs to be Replenished.

NOTE: The following procedures assume the system has been operated; and therefore, the tank shell is filledwith water. If not, water must be added to the tank thru Valve 6 or Valve 2 until it flows from Valve 4.

CAUTION:When topping-off, make sure foam concentrate pump does not exceed the water venting (discharge)capability of Valve 4. Throttle thru Valve 7, or if using a fill manifold, use the Concentrate/Water Shutoff Valve.

NOTE: Be sure all valves are in their normal stand-by position. Refer to System Operating Drawing Fig. 3 insection 4 for Normal Stand-By Valve Position Chart and valve location.

1. Close Valve 2. Be sure Valve 1, or 1A if appropriate, is closed.2. Attach one end of overflow hose to Valve 4 and place the other end of the hose into a drain or container. OpenValves 4 and 5.3. Proceed using Steps 3 thru 9, Sect. 5-A for Initial Fill or Empty Vertical Bladder Tank.

C. Topping-Off Using Hand Pouring Method

CAUTION:To be used only when less than 30% of tank volume needs to be replenished.

NOTE:Be sure all valves are in their normal stand-by position. Refer to System Operating Drawing Fig. 3 insection 4 for Normal Stand-By Valve Position Chart and valve location.

1. See Figure 5-4, Attach fill funnel to Valves.2. If desired, attach a drain hose to Valves and run it to a drain or drain area. Open Valve 5 and slowly removewater from the shell until pressure inside the bladder drops enough to allow foam concentrate to be added thruthe fill funnel.3. Attach one end of overflow tubing to Valve 4 and place other end of hose into a drain or container.4.Close Valve 2. Make sure Valve 1 is closed. Slowly open Valves 4 and 5.

WARNING:The Bladder Tank may be under pressure when opening Valves 4 and 5. Do not put face or body infront of valves until pressure has been vented.

5. Hand pour foam concentrate into fill funnel. Fill tank to capacity.

NOTE: Foam concentrate must be poured into the fill funnel slowly. The fill funnel must be kept full at all times toprevent air from entering fill connection and causing frothing of the foam concentrate.

6. Check foam concentrate level using sight tube. Refer to 5E.

D. Topping-Off Using Hand Pumping Method

CAUTION:To be used only when less than 30% of tank volume needs to be replenished.

NOTE:Be sure all valves are in their normal stand-by position. Refer to System Operating Drawing Fig. 3 insection 4 for Normal Stand-By Position Chart and valve location.


25/126


25 Copyright 2005

1. See Figure 5-4. Close Valve 2. Make sure Valve 1 is closed.2. If desired, attach a drain hose to Valve 6 and run it to a drain or drain area. Attach one end of overflow hose toValve 4 and place the other end of the hose into a drain or container. Open Valves 4 and 6. Slowly remove waterfrom the shell.3. Attach the fill manifold to Valve 7. Connect the hand pump/foam concentrate supply to the fill manifold

concentrate/water shutoff valve.4. Open Valve 7. Slowly open the fill manifold concentrate/water shutoff valve and start hand pumping foamconcentrate into the bladder.5. Open Valve 5. If required, use the Concentrate/water shutoff valve for throttling the pressure to the bladder.Water may still flow from the shell thru Valve 6 as concentrate is added.6. Continue pumping concentrate until foam concentrate is detected coming from Valve 5. Close theconcentrate/water shutoff valve and then close Valves 4, 5, 6, and 7.7. Check foam concentrate level using sight tube. Refer to 5E.

E. Checking Foam Concentrate Level

NOTE:Be sure all valves are in their normal stand-by position. Refer to System Operating Drawing Fig. 3 insection 4 for Normal Stand-By Valve Position Chart and valve location.

CAUTION:The foam concentrate level cannot be checked while the tank is pressurized. To determine theconcentrate level, follow the procedures below:

1. Depressurize tank by closing Valve 2. Make sure Valves 1 & 7 are closed. Then slowly open the followingvalves: Valve 4 (allow pressure to vent before opening remaining valves), 5, 6 and 8.

CAUTION:The tank will still contain some residual pressure, which will be released.

2. When water stops flowing from Water Drain/fill Valve 6,observe the concentrate level in the sight glass.

NOTE: It may be necessary to drain the sight glass by turning Valve 8 to the third position. Then turn Valve 8back to the second position and allow concentrate level to refill the sight glass before determining the level. Close

Valve 8 before draining.

3. Close Valve 8. Drain the sight glass by turning Valve 8 to the third position. Return all valves to their normalstand-by position as shown on the System Operating Drawing Fig. 3 in section 4.4. If the bladder tank has been completely filled with foam concentrate, no water has to be replaced in the tankshell to return the tank to full stand-by condition. However, if the system has been operated and there is foamconcentrate in the bladder and water occupied the remaining area in the tank shell before checking the foamlevel, water must be replaced in the tank shell to return the tank to full stand-by condition:

a. Attach a water supply to Valve 6.b. Open Valves 5 & 6. Slowly add water thru Valve 6.c. When foam concentrate is discharged from Valve 5, shut off the water supply and close Valve 5.d. Open Valve 4 and slowly add water thru Valve 6 until water flows from Valve 4. Close Valves 4 & 6.

e. Return all valves to normal stand-by position as shown on the System Operating Drawing Fig.4-2. Tank isnow in its stand-by condition.

5. If appropriate, record date of fill and notify appropriate personnel that system is back in service.


26/126


26 Copyright 2005

SECTION 6OPERATING PROCEDURES

OPERATION OF SYSTEM

NOTE: Before operation, verify that all valves on the proportioning system are in their normal stand-by position.Refer to System Operating Drawing Fig. 6-1 for Normal Stand-By Valve Position Chart and valve location.

1. Manual Operationa. Open the door to the manual emergency release enclosure located on the skid.b. Pull the lever.

2. Automatic Operation

The system will initiate the automatic start sequence when a sensor detects a fire, it is remotely tripped from themain fire hazard station, or when someone pulls down on any remote fire alarm stations. Upon initiation of theautomatic start sequence, the following should occur:a. The foam solution discharge valve will open.b. The deluge valve will open to release water into the system.c. Water will then flow through the ratio controller.d. The automatic Foam Concentrate Supply Valve will open.e. The foam concentrate will mix with the water to create foam.f. The foam will then flow out to the sprinkler and suppress the fire in the area.

SHUTDOWN OF SYSTEM

WARNING:Only after the fire is out and the danger of re-ignition has passed, shall consideration be given toflushing and draining the system.

1. Manual Operationa. To reset the system, return the lever to the upright position and close the door.b. Flush the system by allowing the water to flow until clear water issues from devices being operated.c. Stop the water flow to the ratio Controller(s).d. Close the appropriate Foam Solution Discharge Valve.e. Return all valves to their normal stand-by position. Refer to Fig. 6-1 in this section for valve position.

f. Replenish supply of foam Concentrate. Refer to Bladder Tank Filling instructions, Section 5.

CAUTION:Only foam concentrate of the type listed on the tank nameplate should be used to replenish the tank.Mixing of different types or brands of foam concentrate could cause deterioration of foam concentrates or failureof the system.

g. Replace all breakable Components such as glass diaphragms, rupture discs, etc. in foam lines or foam makingdevices.

2. Automatic Operationa. Reset automatic system.

Upon system shutdown and system reset, the following sequence should occur:

1. The foam solution discharge valve will close.2. Water flow to the ratio controller will stop.3. The automatic Foam Concentrate Supply Valve will close.4. Return all valves to their normal stand-by position. Refer to Fig. 6-1 in this section for valve position.5. Replenish supply of foam concentrate. Refer to Bladder Tank Filling Instructions, Chapter 3.

CAUTION:Only foam concentrate of the type listed on the tank nameplate should be used to replenish the tank.Mixing of different types or brands of foam concentrate could cause deterioration of foam concentrates or failureof the system.

6. Replace all breakable components such as glass diaphragms, rupture discs, etc., in foam lines or foam makingdevices.


27/126


27 Copyright 2005

AUTOMATIC SYSTEM FLUSHING

The proportioning system must be flushed and drained after operation. Flushing may be done by control systemor manual override on automated valve or a combination of the two. Allow clear water to flow until clear waterissues from devices operated. Reset automatic system and return all valves to their normal stand-by position.Refer to System Operating Drawing Fig. 6-1 for Normal Stand-By Valve Position Chart and valve location.

VALVE DESCRIPTION

Valve No. Description

Normal Valve Position

Manual System Automatic System1 Foam Concentrate Supply (Manual) N.C. N.O.

1A Foam Concentrate Supply (Automatic) -- N.C.2 Water Pressure Shutoff N.O. N.O.4 Tank Water Vent N.C. N.C.5 Bladder Foam Concentrate Vent N.C. N.C.6 Water Drain/Fill N.C. N.C.7 Foam Concentrate Drain/Fill N.C. N.C.8 Sight Gauge N.C. N.C.

COMPONENT DESCRIPTION:

A - Storage TankB - BladderC - Ratio ControllerD - Check ValveE - Sight Glass

F - Fill Cup (For Top Off Only)G - Water Supply PipingH - Foam Solution Delivery PipingJ - Over Pressure Relief Device

(By others if required)

FIGURE 6-1 SYSTEM OPERATING DRAWINGVALVE DESCRIPTION & POSITION CHART


28/126


28 Copyright 2005

SECTION 7 MAINTENANCE

See Table 7-1 for Recommended Inspection and Maintenance Procedures. If there is any questions about aspecific component in the system, please consult appendix A or B.

WARNING:The owner is responsible for maintaining the fire protection system in proper operating condition. Anysystem maintenance or testing that involves placing a control valve or detection system out of service mayeliminate the fire protection of that system. Prior to proceeding, notify all Authorities Having Jurisdiction and allthose in the area affected by the test. Consideration should be given to employment of a fire patrol in the affectedarea.

WARNING:The following recommendations are based on normal operating conditions. Due to environmental orother conditions unique to your system, the frequency of some inspection and maintenance procedures may needto be adjusted. Additional inspection and maintenance procedures may also be required.

CAUTION: If during the course of normal system maintenance it becomes necessary to replace, repair or modifysystem components, component parts, operating devices or equipment, the system must be tested to insureproper operation before being placed back into service.

CAUTION: Customer modification or alteration of this equipment, or the use of replacement parts other thanthose as specified by Federal Equipment Company may affect the performance of this equipment and may voidthe warranty.

NOTE: It is imperative that fire protection sprinkler systems be inspected and tested on a regular basis. Thefrequency of the inspections is dependent upon the condition of the water and release system. For minimummaintenance and inspection requirements, refer to the National Fire Protection Associations pamphlet thatdescribes care and maintenance of sprinkler systems. In addition, the Authority Having Jurisdiction may have ad-ditional maintenance, testing, and inspection requirements that must be followed. In addition, the alarm devices,detection systems, or other connected trim may require a more frequent schedule.

NOTE:All service must be performed by qualified personnel.

TABLE 7-1 RECOMMENDED INSPECTION & MAINTENANCE SCHEDULE

DESCRIPTION SU AO W M SA A

Total System

1. Check all valves to insure that they are in the normal standby condition. Refer toSystem Operating Drawing Fig. 1 in section 6. (Also check after all maintenanceprocedures)

X X

2. Inspect system for physical damage and repair. X X

3. Check the complete system, all valves, fittings & connections for leakage. X X X

4. Perform normal maintenance and inspection of the water supply system toinsure that it will be operational when required.

X

5. Perform Start up test as prescribed in Section 4. X

6. Perform annual system test as prescribed in this section. X

7. Flush proportioning system. See flushing instructions in Section 6. (Also checkafter all maintenance to piping)

X

8. Cycle automated valve(s). Cycling of valves can be done manually or by controlsystem. X

CAUTION:When cycling automated valves, insure that the Water Pressure Shutoff Valve and Manual FoamConcentrate Supply Valve are closed. After cycling return all valves to their normal standby position.

9. Cycle manual valves to insure freedom of movement.X

CAUTION:Make sure that cycling of valves does not take the bladder system out of the in service status.

10. Check flange bolts for tightness. X X

11. Check system for any external damage to the paint surfaces. X X


29/126


29 Copyright 2005

TABLE 7-1 RECOMMENDED INSPECTION & MAINTENANCE SCHEDULE - Continue

DESCRIPTION SU AO W M SA A

Strainer

1. Remove screens, check, clean and reinstall. X X

Electrically Actuated Valves

1. Cycle valve(s) - Valve(s) may be cycled from control panel or by manualoverride at valve. X X

CAUTION:When cycling automated valves, make sure that the Water Pressure Shutoff Valve 2 and ManualConcentrate Supply Valve 1 are closed. After cycling return all valves to their normal stand-by position.

2. Cycle valve(s) from the control panel to insure, proper operation from control. X X

3.Check supervision of circuit. X X

4. Check for leakage past valve seat. X X X

Water Powered Ball Valves

1. Cycle the valve(s) either manually or thru the control panel.X X

CAUTION:When cycling automated valves, make sure that the Water Pressure Shutoff, Valve and ManualConcentrate Supply Valve are closed. After cycling return all valves to their normal stand-by position.

2. Cycle the valve(s) using the solenoid release (if applicable).X X

CAUTION:When cycling automated valves, make sure that the Water Pressure Shutoff, Valve and ManualConcentrate Supply Valve are closed. After cycling return all valves to their normal stand-by position.

3. Check supervision of circuit if solenoid release if provided. X X

4. Make sure that the quick release pin is securely positioned thru the clevis. X X

5. Make sure the bleeder/vent valve is property tightened. X X

Foam Concentrate Storage Tank

1. Check the level of concentrate in the tank. Refer to Section 5 X X

2. Check water side of tank for traces of foam concentrate.X

NOTE: Open valve 6 and observe the water drained. If traces of foam concentrate are found in the water that isdrained, contact Chemguard service department.

3. Check for rust, corrosion, leakage, and weak spots or other physical damage. X

4. Check flange bolts on both ends of the tank for proper tightness. Refer to section3 for further details.

Check at installation orwhen replacing internal

bladder

Foam Concentrate

1. Check that storage temperature is within acceptable limits. Refer to appendix A,1% Synthetic AFFF Foam, for recommended temperatures.

X

2. Foam concentrate should be sampled and submit ed to foam manufacturer fortesting (sedimentation, corrosion, dilution, or contamination) per foammanufacturer instruction as necessary.

X

Control System

1. Check that proper indicators are present. See control panel data. X X

2. Check supervision of all circuits. X X3. Check alarm operation. X X

4. Check system operation. See control panel data. X X

5. Check that all indicators illuminate. X X

Note:SU - Start UpAO - After OperationW - Weekly

M - MonthlySA - Semi-AnnualA - Annual


30/126


30 Copyright 2005

After Each Operation:

1. Sprinkler systems that have been subjected to a fire must be returned to service as soon as possible. Theentire system must be inspected for damage, and repaired or replaced as necessary.

2. Deluge valves and trim that have been subjected to brackish water, salt water, foam, foam/water solution, orany other corrosive water supply should be flushed with good quality fresh water before being returned to

service.3. The bladder tank needs to be refilled with 1% AFFF foam concentrate. Refer to Section 5.4. Perform SEMI-ANNUAL maintenance after every operation.

Monthly Maintenance:

NOTE:Prior to operating the High Pressure Solenoid Valve, be sure to close the system control valve to avoidunintentional operation of the deluge valve.

1. The High Pressure Solenoid Valve:a. The valve must open and close freely. When open, the water flow must be clear and clean at the properflow rate.b. When closed, a total water shut-off must be observed.

c. After the test, the strainer must be cleaned. Prior to cleaning the strainer, the priming line valve must beclosed and the priming line depressurized.d. After the strainer is cleaned, the priming line valve must be reopened.e. Inspect for cracks, corrosion, leakage, etc., and cleaned, repaired, or replaced as necessary.

2. Emergency Release:a. Verify that the door of the Emergency Release is not obstructed and opens freely.b. Inspect for signs of mechanical damage and/or corrosive activity. If detected, perform maintenance asrequired or, if necessary, replace the device.

Semi-Annual Maintenance:

1. Overall Testing1. Remove the system from service.

a. Close the Main Water Supply Control Valve and Priming Valve.b. Open the door of the Emergency Release and pull the handle for operational test. Air or water from therelease system should discharge to open drain.

c. Open the auxiliary drain Valve.d. When operational testing is complete, return the handle to its normal operating position and close the

door.2. Inspect all trim for signs of corrosion and/or blockage. Clean and/or replace as required.3. Clean and/or replace all strainer screens.4. Establish normal operating pressure in the release system.5. Open the main water supply control valve and place the system back in service.6. Notify the Authority Having Jurisdiction and those in the area affected that the system is back in service.

2. Control Panel

The following test should be perform on the system:

Alarm Activate

Note:Alarm Activate is a latching function. Alarm Silence will silence indicating circuits and System AlarmRelay and light the Alarm Silenced LED.

1. Push Alarm Activate.2. When test is complete, push System Reset. Conditions should return to normal.


31/126


31 Copyright 2005

Water Flow

1. Turn the Alarm Test Valve to Test position. The Water Flow circuits are latching.2. When test is complete return the Alarm Test Valve to the normal position and push System Reset.Conditions should return to normal.Detection

1. Close main water supply control valve, placing the system out of service.

Caution:For deluge preaction systems, performing this test results in operation of the deluge valve. Failureto close the main water supply control valve will cause water to flow into the sprinkler piping.

Caution:Simultaneous operation of both detection circuits on any system utilizing cross-zone detection willresult in operation of the deluge valve. Failure to close the main water supply control valve will cause water toflow into the sprinkler piping.

2. Operate individual detectors, following instructions listed in technical data for the detector used. Seeappendix a control panel for output circuits and relays that should activate for the system used. Detection cir-cuits are latching.3. When Test is complete, push System Reset. Conditions should return to normal.

4. Refer to technical data for the system used to open main water supply control valve and place the systemback in service.

Test Failure

If any of the test fail, take the system out of service. Find and replace, if necessary, any component that failed.

CAUTION: Disconnect all power sources before servicing. The panel and associated equipment may bedamaged by removing and/or inserting cards, modules, or interconnecting cables while the panel is energized.

WARNING- Several different sources of power can be connected to the control panel. Disconnect all sources ofpower before servicing Control unit and associated equipment may be damaged by removing and/or insertingcards, modules, or interconnecting cables while the unit is energized. Do not attempt to install, service, or operate

this unit until the instruction in appendix A, Control Panel, is read and understood.

Caution- System Reacceptance Test after Software Changes: To ensure proper system operation, this productmust be tested in accordance with NFPA 72-1993 Chapter 7 after any programming operation or change in site-specific software. Reacceptance testing is required after any change, addition or deletion of system components,or after any modification, repair or adjustment to system hardware or wiring.

All components, circuits, system operations, or software functions known to be affected by a change must be100% tested. In addition, to ensure that other operations are not inadvertently affected, at least 10% of initiatingdevices that are not directly affected by the change, up to a maximum of 50 devices, must also be tested andproper system operation verified.

Disconnect AC power and batteries prior to removing or inserting circuit boards. Failure to do so can damagecircuits.

This system contains static-sensitive components. Always ground yourself with a proper wrist strap beforehandling any circuits so that static charges are removed from the body. Use static suppressive packaging toprotect electronic assemblies removed from the unit


32/126


32 Copyright 2005

Annual Maintenance:

1. Overall Testing

At least annually, all foam systems shall be thoroughly inspected and checked for proper operation. This shallinclude performance evaluation of the foam concentrate or premix solution quality or both. Deviation of resultsexceeding 10 percent from those recorded in acceptance testing shall be discussed immediately with the

manufacturer. Regular service contracts are recommended.

The goal of this inspection and testing shall be to ensure that the system is in full operating condition, and that itwill remain in that condition until the next inspection. The inspection report, with recommendations, shall be filledwith the owner. Between the regular service contract inspections or tests, the system shall be inspected bycompetent personnel following an approved schedule. (NFPA 11, para 5-3, Periodic Inspection, latest edition)

2. Prime Shut-off ValveThe prime shut-off valve is manufactured with a weep hole to indicate a failure of upper or lower diaphragm. Thebody of the prime shut-off valve is constructed of three cast brass pieces. The center section of the valveassembly houses the piston of the assembly; the housing is created by the upper and lower diaphragm. The valvealso includes an integral spring that guides the diaphragm wrapped housing to the valve seat. If water appearsfrom the weep hole located in the center section of the valve assembly, replace the diaphragm assembly. If the

prime shut-off valve does not positively close upon deluge valve operation (evident by continual prime waterdischarge at the drain cup), flush prime shut off valve. To do this, remove deluge valve from service and eitherflush the prime shut-off valve or disassemble the prime shut-off valve and inspect valve for debris.

A. Prime Shut-off Valve Inspection:1. Place the fire protection system out of service.2. Trip the release system.3. Drain any accumulated condensation for the release line.4. Purge the release system of any foreign matter.5. Place the release system back in service.6. Prime the deluge valve by opening the priming water control valve.7. Trip test the prime shut-off valve by tripping the deluge valve. The prime shut valve will shut the priming

supply to the deluge valve priming chamber.

8. Set up the deluge valve per deluge valve resetting instructions.9. Should the prime shut-off valve fail to close or reset, remove it from service and disassemble. Cleanand/or replace any dirty or worn parts and reinstall. Repeat the inspection procedures.

B. Prime Shut-off Valve Disassembly:(Refer to Figure 2)

1. Place the fire protection system out of service.2. Close the priming valve.3. Trip the deluge valve.4. Remove the prime shut-off valve.5. Remove the three cover screws (6).

CAUTION:The assembly is under spring tension.

6. Separate the cover (4) from the lower assembly.7. Separate the lower diaphragm (3), piston (5), upper diaphragm (7), and spring pad (8), from body (1).8. Clean and/or replace dirty or worn parts.9. If required, remove the valve seat (10) from the body (1) and replace.

C. Prime Shut-off Valve Reassembly:1. Reverse the disassembly procedure, making sure that the burr side of the spring pad is toward the

spring, away from the upper diaphragm.2. Purge all trim piping of foreign matter.3. Reinstall prime shut-off valve and trim piping.4. Repeat inspection procedures.5. Check for and repair any leaks.6. Reset the deluge valve per deluge valve re-setting instructions.


33/126


33 Copyright 2005

Figure 23. High Pressure Solenoid Valve

WARNING:Close system control valve, turn off power supply, and depressurize valve before disassemblingvalve. It is not necessary to remove the valve from the pipe line to make inspections.

A. At least annually, the High Pressure Solenoid Valve diaphragms and seats must be inspected and ifnecessary, repaired or replaced.B. When lubricating High Pressure Solenoid Valve components, use a high grade silicone grease (DowCorning 111 Compound Lubricant or equal).C. When reassembling, tighten parts to torque values indicated in ASCOs maintenance instructions (packedwith valve).D. After maintenance is completed, operate the valve a few times to be sure of proper operation. A metallicclick signifies the solenoid is operating.

Every Fifth Year

1. Deluge Valves:1. Internal inspection of deluge valves is recommended every five years unless inspections and tests

indicate more frequent internal inspections are required. Refer to DISASSEMBLY instructions providedbelow.

2. Internal inspection of strainers and restricted orifices is recommended every five years unless inspectionsand tests indicate more frequent internal inspections are required.

3. Record and provide notification of inspection results as required by the Authority Having Jurisdiction.

Deluge Valve Disassembly(Refer to Figure 3)1. Remove the valve from service.

a. Close the Main Water Supply Control Valve and Priming Valve.b. Open the auxiliary drain valve.c. Release the pressure in the priming chamber by opening the emergency release.

2. Remove trim as required to allow removal of cover (3).3. Remove screws (7).

4. Lift cover (3) from body (1).5. Remove clapper assembly (Nos. 2, 4, 5, 6, 8, and 10) by lifting it from the body (1).6. Inspect seat (9). If replacement is necessary, do not attempt to separate seat from body (1). It is not

removable.7. To replace the diaphragm rubber (2), remove the circle of screws (5). Remove the clamp ring (4) and remove

the diaphragm rubber (2).8. To replace the seat rubber assembly (8), clapper assembly (2, 4, 5, 6, 8, and 10) must be removed from the

valve. Remove the circle of screws (10). Seat rubber assembly (5) can be removed.

NOTE:Prior to installing a new clapper rubber or seat rubber assembly, make certain that all surfaces are cleanand free of foreign matter. The plated seat must be smooth and free of nicks, burrs, or indentations.


34/126


34 Copyright 2005

Deluge Valve Reassembly

1. Prior to reassembly flush the valve of all foreign matter.2. To reassemble, reverse disassembly procedure.

Every Seventh Year

A. It is recommended that the High Pressure Solenoid Valve be replaced at seven-year intervals. Shorter intervalsmay be required if the valve is subject to corrosive water supplies or atmospheres.

Figure 3


35/126


35 Copyright 2005

SECTION 8TROUBLESHOOTING

These procedures cover problems that may be experienced during normal operations. Although theserecommendations cover most problems that are experienced, there are some situations that may occur which arenot covered in these instructions.

TABLE 8-1 TROUBLESHOOTING

PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION

NoProportioning

Water Pressure Shutoff Valve 2 not open. Check valve position. Fully open valve ifclosed.

Manual Foam Concentrate Supply Valve 1not open.

Fully open Valve.

Automatic Foam Concentrate Valve 1A notfunctioning properly.

Refer to manufacturers data.

Automatic Foam Concentrate Supply Valve1A closed. (Electrically actuated)

Check that wiring is installed to actuator.

Check that signal from control system isavailable at valve actuator. If voltage is not

present, check control system.

Ifsignal is present at actuator, use manualoverride to cycle valve. If valve cyclesmanually, then valve actuator is probablyinoperative. Remove actuator, check operation,if failed, repair or replace. If valve does notopen, using manual override on actuator, thenthe valve is jammed. Remove valve, determineand correct reason for jam. See actuator data.

Automatic Foam Concentrate Supply Valve1A closed or not functioning properly.

(Water Powered Ball Valve)

Check that cylinder water pressure supplyvalve is fully open.

Check 1/4" Bleeder/vent valve on strainer forclogging which shuts off water supply tocylinder. Open Bleeder/vent valve on strainer,vent and flush ant debris blocking watersupply.

Valve or valves not in proper standbyposition.

Place valve(s) in normal standby position asshown on System Operating Drawing Fig. 6-1.

Blockage in piping between tank and ratiocontroller or the water feed line,

Determine location of blockage, drainconcentrate from tank, remove appropriate runof piping and remove blockage.

System operating below minimumproportioner inlet pressure.

Refer to Section 3 installation for proper inletpressures.

Ratio controller flow below minimum flowrange of proportioner.

Refer to Appendix A Concentrate Ratio FlowController for proper flow range of proportioner.

Control system not functioning properly. Check wiring for correct interconnection andproper connections. See control systemmanual.


36/126


36 Copyright 2005


PROBLEM PROBLEM CAUSE CORRECTIVE ACTION

NoProportioningcontinued

Foam concentrate incompatible with thesystem design.

Use correct concentrate. Drain and clean tankbefore filling with new concentrate.

Bladder tank empty. Refer to Section 5. If empty, follow appropriatefill procedures in Section 5.

Strainer (if installed) blocked. Remove all strainer screens and clean.Reinstall after cleaning. Check for strainerscreen perforation size - strainer mesh shallhave 1/8 openings for all Chemguard foamconcentrates.

LowPercent ofProportioning

Water pressure Shutoff Valve 2 partiallyopen.

Check valve position. Fully open valve.

Manual Foam Concentrate Supply Valve 1partially open.

Fully open valve.

Automatic Foam Concentrate SupplyValve(s) 1A not fully open.

Valve blocked from fully opening or controlsystem problem. Determine cause and correct.

Automatic Foam Concentrate Supply Valve1A opens slowly. (Water powered ball valve)

Cylinder water pressure supply valve partiallyopen. Fully open valve.

Tighten 1/4" Bleeder/vent valve on cylinderstrainer. Snug with wrench to insure closure torated pressure.

1/4" Bleeder/vent valve strainer clogged,obstructing water supply to cylinder. Open 1/4"

Bleeder/vent.

Flow rate below minimum rate of ratiocontroller.

Refer to Appendix A Concentrate Ratio FlowController for proper flow range of proportioner.

Reduced port valve being used instead of fullport type.

Replace reduced port valve with full port valve.

Piping too small or excessive run betweentank and ratio controller causing excessivefriction loss in water and/or foam concentratepiping.

The total friction loss in the water and foamconcentrate lines between the tank and ratiocontroller shall not exceed 2 psi. Redesignpiping accordingly.

Water pressure too high causing excessiveflow, thus exceeding the design limits of thesystem.

Adjust pressure to proportioner to be within theflow and pressure limits of the system.

Drain valve(s) or vent valve(s) open orpartially open.

Fully close or drain all vent valve(s).

Incorrect orifice diameter or adjustment. Check orifice and adjustment settings,verify .01.


37/126


37 Copyright 2005


PROBLEM PROBLEM CAUSE CORRECTIVE ACTION

Low percentproportioningcontinued

Control system not functioning properly. See control system manual. Check wiring forcorrect interconnection and properconnections.

Strainer (if installed) blocked. Remove all strainer screens and clean,Reinstall after cleaning.

System operating below minimumproportioner inlet pressure.

Refer to Section 3 installation for proper inletpressures.

Foam concentrate incompatible with systemdesign.

Drain and clean tank. Fill with correctconcentrate.

HighPercent of

Proportioning

Incorrect orifice diameter or adjustment. Check orifice and adjustment settings,verify .01.

Water pressure source to tank, other thanwater main supplying ratio controller, whichsupplies higher water pressure to tank thandoes water main to ratio controller.

Contact Maintenance Dept. for instructions onlocating water pressure source properly onwater main.

No Flowat Discharge

Zone discharge valve closed or will notopen.

Open valve. If automated, find problem andcorrect.

Blockage in foam solution discharge line ordischarge device.

Find the cause of the blockage and correct.

Low Flow atDischarge

System pressure too low. Check inlet pressure and correct for properoperation.

Partial blockage in water or foam solution line.

Zone valve did not open completely. Valvejammed, determine reason and correct.

No Operation

Water supply source failure. Check source and correct problem.

Control system not functioning properly.(Automated system)

Check wiring for correct interconnection andproper connections. See control systemmanual.

Foam tank empty. Fill tank with proper type foam concentrate.


38/126


38 Copyright 2005

INDEX ASYSTEM COMPONENTS

Deluge Valve And Associated Trim Kit 39Priming Shut-Off Valve (PSOV) 49

High Pressure Solenoid Valve.. 52Bladder Tank 55Concentrate Ratio Flow Controller (Proport ioner). 60Releasing Panel . 62Manual Emergency Release . 107SlowClose, Indicating Butterfly Valves 1101% Synthetic AFFF Foam.. 114

AFFF Foam Sprinkler Nozzle.. 119


39/126


39 Copyright 2005

DELUGE VALVE MODEL E-1AND ASSOCIATED TRIM KIT

1. PRODUCT NAME

Viking Model E-1 Deluge Valve3 (80 mm) Available since 1985

2. PRODUCT DESCRI

Documents

Foam Mix Fire Sup TM HP0296 v2