Industrial Dry Chemical Systems

Certification Training
Chicago, IL
September 2010
Installation and Service
 Safety (EH&S)
• Safety
– Eye protection
– Ear protection, if applicable
– Steady ladders / scaffolding
– Weight bearing structures
• Cylinders
• Personnel
– Electrical
 Installation
• If cylinder not piped and bracketed
– Valve protection plate attached to top of valve
– Diffuser plate attached to valve outlet flange
– Cylinder in location safe from damage
 Installing the System

• Pipe must be secure

• Nozzles cannot be installed where travel of agent is
impeded
• Nozzle must be out of the way
• Cylinder should be easily accessible
 Installing the System
Discharge
g Adapter
p Kit

• Cylinder must be bracketed in

• Leave valve protection plate on top
• Remove nuts and bolts from diffuser / flange
• Lightly lubricate and install O-ring onto adapter
(“S” lube preferred)
• Insert adapter into valve outlet
• Put flange plate over adapter
• Insert and tighten nuts and bolts
Install Discharge Adapter Kit
 Install Cylinder Bracket

Table 4-1. Wall Mounting Bracket

Dimensions
Cyl Wall
Bracket P/N A B C D E F
Size Load
13-1/8 in. 9-3/4 in. 6-3/4 in. 3 in. 9-1/2 in. 3 in. 65 lb.
486487 21, 25
(333 mm) (248 mm) (171 mm) (76 mm) (241 mm) (76 mm) (30 kg)
19-5/8
19 5/8 iin. 9-3/4
9 3/4 iin. 6-3/4
6 3/4 in.
i 3 in.
i 16 in.
i 3 in.
i 130 lb.
lb
486488 45, 50
(498 mm) (248 mm) (171 mm) (76 mm) (406 mm) (76 mm) (59 kg)

21 in. 13-1/4 in. 10-1/4 in. 5-5/8 in. 16-1/8 in. 4 in. 225 lb.
87-100009-001 70, 75
(533 mm) (337 mm) (257 mm) (143 mm) 422 mm) (102 mm) (102 kg)
Install Cylinder Bracket
 Mount the Cylinder

• Load Bearing
Cylinder Wall
Size Support
21 / 25 65 lbs.
45 / 50 130 lbs.
70 / 75 225 lbs.
Install XV/UCH
Install XV/UCH
Install XV/UCH Actuation
Install XV/UCH
Install XV/UCH Actuation
Install XV/UCH Actuation
Install XV/UCH Actuation
Install XV/UCH Detection
Install XV/UCH Detection
Install XV/UCH Detection
Set XV/UCH Detection
Set XV/UCH Detection Line 1

Table 4-2. Cabling Detection Line 1 Only

Item Description
1 Lockout screw pad (shown with one red lockout screw removed)
2 Actuation Latch
3 Spring and beam for Detection Line 2 (locked out)
3A Spring Post for Detection Line 2 (spring removed)
4 Spring and beam for Detection Line 1 (set with cable)
4A Spring Post for Detection Line 1
5 Beam Stop for Detection Line 1
6 Beam Stop for Detection Line 2
7 Lockout pad for Detection Line 1 (not used, line set)
8 Lockout pad for Detection Line 2 (red lockout screw inserted)
Set XV/UCH Detection Line 2, Option 1

Table
ab e 4-3.
3 Cabling
Cab g Detection
etect o Line
e 2 Only
O y - Opt
Option
o 1
Item Description
1 Lockout screw pad (shown with one red lockout screw removed)
2 Actuation Latch
3 Spring and beam for Detection Line 2 (set with cable)
3A Spring Post for Detection Line 2
4 Spring and beam for Detection Line 1 (locked out)
4A Spring Post for Detection Line 1 (spring removed)
5 Beam Stop for Detection Line 1
6 Beam Stop for Detection Line 2
7 Lockout pad for Detection Line 1 (red lockout screw inserted)
8 Lockout pad for Detection Line 2 (not used, line set)
Set XV/UCH Detection Line 2, Option 2

T bl 4
Table 4-4.
4 Cabling
C bli D
Detection
t ti Li
Line 2 Only
O l - Option
O ti 2
Item Description
1 Lockout screw pad (shown with one red lockout screw removed)
2 Actuation Latch
3 Spring
p g and beam for Detection Line 2 ((set with cable))
3A Spring Post for Detection Line 2
4 Spring and beam for Detection Line 1 (locked out)
4A Spring Post for Detection Line 1 (spring removed)
5 Beam Stop for Detection Line 1
6 Beam Stop for Detection Line 2
7 Lockout pad for Detection Line 1 (red lockout screw inserted)
8 Lockout pad for Detection Line 2 (not used, line set)
Microswitches – High Mount
Microswitches – Deep Mount
Microswitches
Microswitches

Table 4-6. Electrical Ratings for Microswitch

P/N 87-120047-001
250 Vac 15 Amps

250 Vac 1/2 HP

125 Vac 1/2

/ HP
Wiring Solenoid
Locking Out Lines 1 & 2 UCH/XV

g
Item Description

1 Lockout screw pad (shown with red lockout screws removed)

2 Actuation Latch
3 Spring and beam for Detection Line 2 (locked out)
3A Spring Post for Detection Line 2 (spring removed)
4 Spring and beam for Detection Line 1 (locked out)
4A Spring Post for Detection Line 1 (spring removed)
5 Beam Stop for Detection Line 1
6 Beam Stop for Detection Line 2
7 Lockout pad for Detection Line 1 (red lockout screw inserted)
8 Lockout p
pad for Detection Line 2 ((red lockout screw inserted))
Locking Out Detection Lines
Wiring Release
 Wiring Alarm

ATTACH ONE SIDE OF ALARM CIRCUIT

AND EOL TO TERMINAL 2 OF MICROSWITCH

ATTACH EOL TO TERMINAL 4

OF MICROSWITCH
 Wiring a Magnetic Contactor
ADDITIONAL
MAGNETIC CONTACTOR
MAGNETIC CONTACTOR* (IF REQUIRED)

BLACK L1 T1

WHITE L2 T2

RED L3 T3
LINE LOAD
LOAD
LINE

BLUE & WHITE RED & WHITE

CONTROL HEAD
MICROSWITCH N.C. C N.O.

ALARM
* MAGNETIC CONTACTOR
UL LISTED ENCLOSED
INDUSTRIAL CONTROL
EQUIPMENT OR MAGNETIC
SWITCH OF APPROPRIATE
RATING; CONTACTS CLOSED
WHEN COIL IS ENERGIZED

WHITE (GROUND)
BLACK & WHITE (HOT)
POWER
115 VAC
60 HERTZ
Cabling PTT RMR
Cabling PTT RMR
Cabling PTT RMR
Cabling PTT Combo RMR
Cabling PTT Combo RMR
Cabling PTT Combo RMR
Cabling PTT Combo RMR
Installing the Mechanical Gas Valve
Cabling Mechanical Gas Valve
Cabling Mechanical Gas Valve
Cabling Mechanical Gas Valve
 Post Installation Check Out

• See Industrial DIOM Section 4-5

– Kidde 220423
– Badger 60-900000-001

• See Auto Paint Booth DIOM Section 5-3

– Kidde 83-100036-001
– Badger 60-900007-001
 Functional Tests

• See Section 4-6.2 of 220423 / 60-900000-001

• See Section 5-4.2 of 83-100036-001 / 60-900007-001
– Mechanical link line(s)
– Remote manual release(s)
– Solenoid
– Actuation tubing
g
– Actuation test
• Use test cartridge for industrial systems
• Use system cartridge for systems with time delay
– Loosen swivel fitting at control head to relieve pressure before
resetting the control head
Functional Tests

To test actuation delay on

automotive paint booth,
booth
use system cartridge

¼” drive
Commissioning the System
Check Beam Stops
Check Beam Stops
Check Microswitches
Check Microswitches
Check gasket inside
Attaching Cover
 Owner Sign Off

• Owner’s Manual!
– Get signature that owner has it

• Systems must be regularly inspected & maintained

• Monthly owner’s inspection
• No less than 6 month maintenance intervals
• Links should be replaced semi-annually
– Can
C d depend
d on amountt off contamination
t i ti b build
ild up
 Inspection

• During inspection
– Has hazard changed?
– Is there any damage to the system?
– Nozzle
N l caps
– Weight and gauge
– Mountings remain secure
• Pipe
• Cylinder
 Inspection

• During
g inspection
p
– Nozzle aim
– Functional test(s)
• Detection
– Links, cables
– Manual
Man al release(s)
– Detect-A-Fires
• Alarms
• Control heads
• Control panel
 Inspection

• During inspection
– Copper tubing integrity
– Wiring integrity
– Battery
B tt integrity
i t it
– Record dates
• Keep in customer file
– Record serial numbers
• Keep in customer file
 Inspection

• Be thorough on your inspection report / certificate

• Report EVERYTHING
• Owner’s Manual
– Get signature that there is one on the premises
 Servicing & Maintaining the System

Table 5-1. Preventative Maintenance Schedule

Schedule Requirement Paragraph
Monthly Owner’s Inspection Paragraph 5-2.1
Semi-Annual System Inspection by an Paragraph 5-2.2
Authorized Distributor
Every Six Years System Inspection by an Paragraph 5-2.4
5 24
Authorized Distributor
Every 12 Years Detailed System Inspection by an Paragraph 5-2.7
Authorized Distributor
 Servicing & Maintaining the System
Monthly
Table 5-2. Owner’s Monthly Inspection
Checkbox Procedure

Inspect all system components, agent distribution pipe, and conduit runs for physical damage and/or
displacement.
displacement
Inspect all nozzles to see if protective caps (if applicable) are in place. Check for possible
obstructions to the discharge of the dry chemical.
Inspect all detectors (Fusible-links and Thermo-bulbs) for contamination. If contamination is found,
contact an authorized Pre-Engineered Distributor for service.
Inspect each Cylinder and Valve Assembly. The pointer on the pressure gauge should be in the
“green” range. The cylinder should not show evidence of corrosion or damage.

Inspect manual pull stations are unobstructed and in clear view and labeled for intended use.

Inspect all tamper seals are intact and the system is in a ready condition.

Verify the inspection tag or certificate is in place and current.

A record of the monthly inspection is to be kept reflecting the date inspected, initials of the person
performing the inspection, and any corrections required.
If wall mounted, the XV/UCH Control System must be tightly bolted to the wall. If cylinder mounted,
the XV/UCH Control System must be tightly bolted to the SVA. The Cam/Flag on the XV/UCH Control
System indicator should point to the ‘Set’ position. The safety pin and seal wire on the local manual
release handle should be in place. Refer to Figure 5-1. If no Remote Manual Release is installed, the
path to the local manual release on the cylinder should be clear and unobstructed and within reach.
If any discrepancies are noted while making this inspection, DO NOT CONTINUE OPERATING
HAZARDOUS PROCESSES OR TURN ON PROTECTED EQUIPMENT. Immediately contact an authorized
Distributor for service and/or repair.
 Servicing & Maintaining the System
Semi Annual
Semi-Annual
Table 5-3. Semi-Annual Service Procedure
Checkbox Procedure
Preparation for Servicing and Testing
Functional Testing of the System
Clean Out Agent Distribution Piping
Test Mechanical Detector Lines
Test Remote Manual Release (if applicable)
Test Solenoid (if applicable)
Inspection of High-Pressure
High Pressure Nitrogen Tubing
Perform Actuation Tests
Disposal of Cartridge
 Servicing & Maintaining the System
Six Year

Table 5-5. Dry Chemical Cylinder Inspection

Checkbox Procedure
Determine date of cylinder manufacture. See CGA pamphlet C-1 for
hydrostatic test requirements.
Depressurize the Cylinder and Valve Assembly.
Remove the valve and siphon tube.
Remove and discard the dry chemical from the cylinder.
Visually inspect the entire inside surface of the cylinder, per CGA
pamphlet C-6.
Hydrostatically test the cylinder if appropriate. See Paragraph 5-2.4.2 on
page 5-21.
Rebuild valve with new stem/O-ring and new valve/cylinder O-ring. See
Paragraph 5-2.5.4 on page 5-22.
Recharge the cylinder as described in See Paragraph 5-2.6
5 2 6 on page 5-24.
5 24

• Rebuild Actuation Delay

Rebuilding Actuation Delay

• Rebuild Kit
83-100038-001
 Servicing & Maintaining the System
Twelve Year
Table 5-6. Twelve-Year Service Procedure
Checkbox Procedure
XV/UCH Control System: - Replace the XV/UCH System Nitrogen
Cartridge - Rebuild the XV/UCH Control System Valve
Hydrostatically Test the Dry Chemical Cylinders
g Cylinders
Recharge y
Installing Valve Rebuild Kit
 Maintenance
• According to NFPA, cylinders are due for hydrostatic
retest everyy 12 yyears
– Discharge and replace chemical
– Replace all gaskets and stems
• Valve Rebuild Kit
 Servicing
• Secure cylinder while working on it
– Discharging,
Discharging especially
• Do not keep the chemical

• Hydrostatic testing
– Check cylinder for integrity before pressure test
• Visual check
• Hammer test
– Water jacket method is the best
– Make sure cylinder is quickly dried out
• Mild steel rusts quickly
 Servicing

• Always
y use manufacturer’s dryy chemical
– UL tests performed with our own dry chemicals
– UL takes samples
– Always use new chemical
 Rebuilding the Valve

• Rebuild Kit
87-120067-001
Twelve-year Maintenance

• Rebuild Kit
87 120046 001
87-120046-001
Completing the Installation
 The Exam
ƒ Put your name & company name on the answer sheet
ƒ Open book / open notes
ƒ Write answers on exam AND answer sheet
ƒ Pass in Answer Sheet only
ƒ 80% passing grade