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System
PRODUCT MANUAL
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FOREWARD
This Kidde Fire Protection High Pressure Carbon Dioxide Product Manual (MA-59812-100) is to
be used by qualified and trained personnel, with knowledge of the applicable standard as
dictated by the authority having jurisdiction, such as BS 5306 or NFPA 12 together with any other
applicable standards in effect.
This manual is intended to clearly and accurately reflect the Kidde Fire Protection High Pressure
Carbon Dioxide Fire Suppression System. This publication describes the design, operation,
installation and maintenance of the High Pressure Carbon Dioxide (CO2) System.
Kidde Fire Protection assumes no responsibility for the application of any systems other than
those addressed in this manual. The technical data contained herein is limited strictly for
informational purposes only. Kidde Fire Protection believes this data to be accurate, but it is
published and presented without any guarantee or warranty whatsoever. Kidde Fire Protection
disclaims any liability for any use that may be made of the data and information contained herein
by any and all other parties.
Any questions concerning the information presented in this manual should be addressed to:
SAFETY SUMMARY
Kidde Engineered Systems use pressurised equipment; therefore personnel responsible for fire
suppression systems must be aware of the risks associated with the improper handling,
installation or maintenance of this equipment. Fire suppression system service personnel shall
be thoroughly trained in the proper handling, installation and service of Kidde Fire Protection
High Pressure CO2 Fire Suppression System equipment and follow the instructions used in this
manual.
Kidde Fire Protection has provided warnings and cautions at appropriate locations throughout the
text of this manual. These warnings and cautions are to be adhered to at all times. Failure to do
so may result in serious injury or fatality to personnel.
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TABLE OF CONTENTS
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2. INTRODUCTION
This manual describes the design, installation, commissioning and maintenance to be used on all
Kidde Fire Protection (KFP) High Pressure Carbon Dioxide (CO2) Systems.
General requirements and design criteria are based on British Standard (BS) 5306 part 4, but on
some occasions National Fire Protection Association (NFPA) 12 may be used as the base document.
Detailed information on components is given in the individual CO2 Engineering Data Sheets.
The importance of proper design cannot be over stressed as design concentrations and application
rates are critical for successful extinguishing. The recommendations given in this document represent
the best known technical data, but while the aim has been to anticipate all considerations, the
recommendations should be applied in practical situations with discretion and due regard to local
circumstances.
Full requirements for the design of CO2 fire fighting systems are given in BS5306 part 4.
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• Care should be taken in locating the extinguishing agent containers as close as possible to the
hazard to minimise the time for the agent to reach the fire.
• Electrical system schematics in accordance with the relevant standard showing safety interlocks
and a description of the sequence of operation.
• Full sets of drawings and technical submittals, as required, shall be submitted to the client and the
consultant for approval prior to installation.
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System design shall be verified using the Kidde Fire Protection CO2 calculation program. A full print
out shall be submitted for approval.
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direction corner pulleys K1122 shall be used. The cable shall be run in ½" O.D. galvanised
conduit for mechanical protection.
12. Pressure Operated Direction Valves (various sizes available) – These are used to control the flow
of CO2 to a specific hazard in a system designed to protect multiple risks from a common bank of
cylinders. The valve shall be capable of opening under full CO2 pressure. A manual lever shall be
supplied for emergency control. An optional switch can be fitted to the valve which indicates
whether the valve is open or closed. POD valves can be supplied in the following sizes: ¾", 1",
1¼", 1½", 2", 3", and 4" with or without the switch.
13. Safety Relief Device (K921) - Shall be used where gas may be trapped between two closed
valves to prevent a dangerous rupture of the pipework e.g. when directional valves or isolating
valves are used.
14. Pressure Switch (K60218) - Shall be used to provide electrical contacts rated at 10amp providing
the following facilities:
• Plant shut down
• Remote alarm signalling
• Discharged indication
• Gas in manifold - should direction valve not open.
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The CO2 fire suppression system shall be designed based upon accurate drawings of the hazard or in
the absence of drawings a detailed site survey. The hazard analysis shall define the design
concentration used and temperature applicable.
NOTE: Warning signs shall be fitted to all appropriate doors into the hazard area and any areas
where CO2 may build up and form a hazardous concentration.
All equipment shall be installed to the manufacturer's manuals and due consideration for service and
maintenance of the system shall be given.
The system shall meet the requirements of BS 5306 part 4 or NFPA 12 as determined by the
client/consultant or their insurers.
System temperature ranges:
• Total flooding systems: Minimum -18 Maximum 55°C.
• Local Application flooding Systems: Minimum 0°C Ma ximum 46°C.
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4. GENERAL
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5. SYSTEM COMPONENTS
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WARNING: The valve will close immediately once the force is removed from the actuator rod.
Each cylinder valve incorporates a safety disc designed to rupture and discharge the CO2 cylinder
contents when the ambient temperature reaches approximately 60°C (Figure 5-2).
Specification
Body Material: Brass
Seals: Silicone Rubber Shore 70° - 90°
Actuator Rod: St. Steel
Safety Burst Disc: Ruptures at 179 to 196 bar
K24509 - DIN 477 (25E) Klem valve is used with all cylinder sizes.
Refer to data sheet DS K24509 for further information on Klem cylinder valve such as
dimension/thread details.
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WARNING: This device is NOT self-resetting. After operation the piston MUST be manually
reset by pushing the piston back onto its seating.
NOTE: If manually operated the lever must be returned to its original position and secured
before re-setting.
Specification
Body Material: Brass
Seals: Nitrile
Lever: Plated Steel
Securing Pin: Stainless Steel
Safety Pin: Stainless Steel
Weight: 0.4kg
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5.4 Racking
CO2 cylinders should be located as near as possible to the hazard they protect, but should not be
exposed to the fire in a manner that is likely to impair performance. They should not be exposed to
weather conditions or put in a location where they can be subjected to chemical or other damage.
Suitable guards or enclosures should be provided when necessary.
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Weight
Part No Material Finish
(kg)
Steel Back
2 Cylinder K17238 MS Angle Paint Black 1.8
Racks
Steel Front
2 Cylinder K13744 MS Strap 2.7
Straps Nylon Dipped
Black
3 Cylinder K13745 MS Strap 4.5
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Table 5-6 1” NB (25mm) Manifold Details Table 5-7 1¼” NB (32mm) Manifold Details
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NOTE: Manifold pipe clips and manifold pipe clip bolts are supplied with the brackets.
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Specification
Hose Material: Reinforced Rubber
Connectors: Mild Steel Zinc Plate and Chromate Passivated
Coupling Nuts: Mild Steel Zinc Plate and Chromate Passivated
Test Pressure: 210 bar
Weight: 0.5kg
Adaptor K62755: Brass
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There are various options available for automatically or manually operating the control head as
illustrated in Figure 5-11.
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Specification
Water Capacity: 0.4 Litres CF-CD01 Issue 2
Body Material: Steel
Test Pressure: 250 bar
Valve: Brass
Charge: Dry nitrogen to 65 bar at 20 (Recharge required at 55 bar)
Weight: 1.7kg
Finish: Grey Paint
* K62462 and K62462A are not listed for use with an FM Approved System.
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Specification
Sensor Capacity: Max System Pressure 207 bar
Proof Pressure 621 bar
Electrical Rating: 28vDC 5 Amp resistive
3 Amp inductive
Connections: Common Earth
Open under pressure - 1
Closed under pressure - 2
Temperature Range: -54 to +107°C
Construction: ST.ST Housing, Black Nylon Cap
Operating Pressure: Factory set at 50 bar – decreasing
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Specification
Body Material: Brass
Weight: 2.35kg
Rating: IP55
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Electrical Rating
250v AC 7A Resistive, 7A Inductive
30v DC 4A Resistive, 3A Inductive
50v DC 1A Resistive, 0.25A Inductive
125v DC 0.4A Resistive, 0.3A Inductive
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Specification
Body Material: Steel
Weight: 0.1kg
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Unscrew the port plug on the control head and screw the button fully home (Figure 5-19).
Port Plug
Figure 5-19 Control Head Showing Port Plug and Safety/Reset Pin
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Specification
Material: Mild Steel
Finish: Painted Black
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Specification
Material: Black Mild Steel
Finish: Nylon Dipped Black
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Specification
Box: Box-Steel painted signal red BS 381C/537
Front Cover: Plastic
Weight: 1.65kg
Rating: IP40
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Specification
Materials: Brass (natural)
Weight: 0.5kg
Specification
Material: Mild Steel Box Painted Black
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The long 527mm pilot loop (K93434) is used to interconnect the release head where the cylinders are
installed in a double row. It is also used to convey the pilot nitrogen gas from a system actuator to the
inlet port of the first release head.
Specification
Hose Material: Polyamide inner tube, synthetic branding/polyamide cover
End Fittings: Brass - Natural Finish
Minimum Bend Radius: 50mm
Test Pressure: 207 bar
Weight: 50 grams
Specification
Body Material: Brass
Weight: 0.02kg
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Figure 5-30 Typical 2 Cylinder Configuration with Nitrogen Pilot Cylinder Actuation
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Gas pressure from the nitrogen cylinder drives the pneumatic time delay.
Specification
Cylinder Capacity: 1.77L
Safety relief device Burst Range: 183 bar to 207 bar at 21°C
Cylinder Contents: nitrogen BB-n-411b, Grade A, Type 1 124 bar
The pressure operated control head (Figure 5-32) allows for pneumatic actuation of nitrogen pilot
cylinder and is mounted directly on top of the nitrogen pilot cylinder valve. The pressure operated
control head is self-venting to prevent accidental system discharge in the event of a slow build up
of pressure in the pilot line.
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The lever operated control head (Figure 5-33) is installed on the 30 or 60 second time delay unit
(Figure 5-34) and will act as an emergency override should the time delay period need to be
bypassed. It is equipped with an operating lever secured in the closed position by a safety pull pin
and seal wire. The lever can be rotated to the open position by removing the safety pin.
WARNING: DO NOT ADJUST - Tampering with this unit could cause failure.
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¾ ” BS PT
Figure 5-36 CO2 Operated pressure Switch
Specification
Housing: Cast Aluminium
Finish: Red Enamel
Testing: 2KV tested
Inductive Rating
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DC Rating
Specification
Body Materials: Gunmetal
Finish: Nickel Plate
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NOTE: The valve remains open until the pilot gas pressure is vented from the pilot gas line.
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WARNING: These devices should be fitted so that the discharge in the event of operation will
not injure or endanger personnel. If necessary the discharge should be vented to an area
where it will not become a hazard to personnel (as per the requirements of BS 5306 part 4).
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Specification
Burst/Opening Pressure: 150 bar ± 5%
Material: Brass
Finish: Natural
Weight: 0.35 kg
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.
Figure 5-44 Lock Out Valve
Lever Operated stainless steel ball valve with 2-SPDT limit switches W/BY Beacon, NEMA 4, 4X with
Lock Open/Close Feature.
The lockout valve consists of a stainless steel ball valve with union ends. The ball valve has a 2,500
PSIG pressure rating. A NEMA4 enclosure, housing two SPDT limit switches with a 15A rating, sits at
the top of the valve. Limit switch No.2 shall be wired in series with the electric control head in the
releasing circuit. Limit switch No.1 may be wired to provide positive indication that the valve is fully
closed.
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Valve Size Part Number Dim ‘A’ (mm) Dim ‘B’ (mm) Dim ‘C’ (mm)
¼” 10611106 40 70 235
½” 10611107 40 70 235
¾” 10611108 50 89 243
1” 10611109 50 92 243
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Figure 5-46 All CO2 Cylinders Discharging to Either Space Incorporating the Assembled Time
Delay Unit Kit
Figure 5-47 Two Spaces Requiring Differing CO2 Cylinders Space Incorporating the
Assembled Time Delay Unit Kit
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Specification
Environment: Industrial/Offshore/Marine
Material: Horn - mild steel
Nozzle - brass
Finish: Horn - black paint.
Nozzle - Natural
Weight: K61792 N13 - N18:- 0.8kg approx.
K61793 N3 - N12:- 0.6kg approx.
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Specification
Material: Horn: Stainless Steel Nozzle: Stainless Steel
Finish: Body: Natural Nozzle: Natural
Weight: 0.9 kg approx.
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Specification
Mounting Plate Material: mild steel
Mounting Plate Finish: Zinc plated and passivated.
Nozzle Material: brass
Nozzle Finish: natural
Weight: 0.4kg approx.
Specification
Body Material: Bronze
Rotor: Brass
Hood: Steel
Nozzle & Filter: Monel
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Each unit contains 10cc of odorant which is sufficient to produce a positive and identifiable lemon
smell in a protected space. One odourising device will be sufficient for 1000 Kg/ CO2 max.
Specification
Body Material: Brass
NOTE: This unit MUST be installed downstream and MUST NOT be installed in the inverted
position (see section 9.33). If odouriser is removed, the opening is to be plugged off
IMMEDIATELY.
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Specification
Material: 22 SWG Aluminium
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Specification
Material: 22 SWG Aluminium
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The components of the weight indicator mechanism with a cylinder hanging are shown in Figure 5-55.
The device is supplied in a kit form, for assembly onto the mounting frame, and comprises: the body,
two hanger rods, neck collar, weight, four off M10 nuts and washers, and one off M12 nut and
washer.
The mounting frame will be supplied by others. Figure 5-55 shows the dimensions of the weight
monitoring device.
5.29.1 Operation
When the weight indicator mechanism is set up, the downward force of the cylinder is greater than the
leverage provided by the weight on the weight rod.
As the contents of the cylinder drops through a pre-determined amount, the downward force of the
cylinder becomes less than the leverage of the weight, therefore the weight rod drops and trips the
microswitch sending a signal to a control panel.
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Microswitch Specification
Type: Single-pole, volt-free, change-over
Rating: Maximum current 3A at 125v or 250v AC
Sealing: Rated at IP67 to BS 5490
Connections: RED - common
BLUE - normally open (N/O)
YELLOW - normally closed (N/C)
The customer is to provide protective flexible conduit (rated at IP65 minimum), wire and insulated
crimp pin or blade terminal connectors.
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The weight monitoring device is available without the switch E8731-403 which has been designed and
certified as non-electric equipment for compliance to the following hazardous area classification:
Group II category 3 GD c T6 X
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Figure 5-59 Typical 2 Cylinder System Configuration with Direct Acting Solenoid
Specification
Environmental Protection: BS EN 60529 1991 IP6
Nominal Coil Resistance: 53.2 ohms
Minimum Firing Pulse: 60ms
Maximum Firing Pulse: unlimited
Electrical Connection: DIN Plug type DIN 43650A
Storage Temperature Range: -30°C to +55°C
Operating Temperature Range: -20°C to +55°C
Maximum Working Pressure: 152.5 bar G
NOTE: The master cylinder can actuate maximum 5 slave cylinders in any one system.
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6. SYSTEM DESIGN
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NOTE:
Table 6-1 Volume Factors MUST ONLY be used for surface fires. For deep seated fires refer to
section 6.3
Example
Room: 6m x 9m x 3m = 162m3
162m3 x 0.80kg/m3 = 129.6kg
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6.2.4 Compensation
Additional CO2 needs to be applied at 5kg/m2 of the opening. Where necessary this quantity should
be multiplied by the appropriate Material Conversion Factor (refer to Section 6.2.5).
The additional quantity should be discharged through the regular pipework system and the flow rate
increased accordingly so that the additional quantity is discharged within the time specified in BS
5306 Part 4.
Example
Room: 6m x 9m x 3m high = 162m3
162m3 x 0.80kg/m3 = 129.6kg
Uncloseable opening = 1.0m2 = 5.0kg
Basic quantity = 134.6kg
If room contains butadiene as the most hazardous material: MCF = 1.3
134.6kg x 1.3 = 175kg
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Table 6-2 Minimum Carbon Dioxide Design Concentration and Material Conversion Factors
NOTE: For materials not listed please contact Kidde Fire Protection.
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Example
Oven: 3m x 1.5m x1.8m = 8.1m³
If the normal working temperature is 204°C:
204-100 = 104/5 = 20.8
20.8 x 2% = 41.6%
8.1m3 x 1.07 kg/m3 = 8.66 (basic quantity) x 1.416 (temp correction) = 12.26kg
Where the normal temperature of the enclosure is below -20°C, add 2% of CO2 for each 1°C below
-20°C. CO2 has a lower expansion ratio at lower tem peratures so it will be denser and leakage would
be greater than normal therefore the additional quantity of carbon dioxide shall be discharged within
the design discharge period.
Example
Refrigerated Space: 3m x 6m x 3m = 54m3 with a normal operating temperature of -23°C
23°C - 20°C = 3°C x 2% = 6%
54m3 x 0.90kg/m3 = 48.6kg (basic quantity) x 1.06 (temp correction) = 51 .5kg
If an addition has been made to the basic CO2 quantity to compensate for openings or application of
an MCF, the total quantity should be used in place of the basic quantity in the above examples.
Example
Starting with the example in Section 6.2.5, assume the room has 30m3 of air removed by the
ventilation system in one minute.
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Services such as heating, fuel supplies, paint spraying, conveyors etc. must also be shutdown before
or simultaneously, with the CO2 discharge.
Example
Paper documents storage room: 6m x 6m x 3m high = 108m3
108m3 x 2 kg/m3 CO2 = 216kg
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6.3.2 Openings
Total flooding systems protecting solid materials cannot tolerate the degree of openings permitted for
surface fire protection.
The design concentration must be maintainable over a long period; low level openings are not
practicable. Small openings at or near the ceiling are ideal because:
a) Compensation for losses involves only reasonable quantities of additional CO2.
b) They allow the escape of hot gases.
c) They prevent pressure increases that can stress the enclosure structure.
Any openings that cannot be closed shall be compensated for by the addition of CO2 equal in volume
to the expected loss during the extinguishing and holding time.
Example
Assume the room has 30m3 of air removed by the ventilation system in one minute:
30m3 x 2kg/m3 = 60kg + 216kg (original) = 276kg
Services such as heating, fuel supplies, paint spraying, conveyors etc. must also be shutdown before
or simultaneously, with the CO2 discharge.
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NOTE: Flooding factors for other deep seated fires should be agreed with Kidde Fire
Protection.
Table 6-1 (Volume Factors) is NOT applicable for deep seated fires and must not be used.
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Two separate banks of CO2 containers and distribution piping are used in this case, the ‘initial’ bank
discharging at a fast rate and the ‘extended’ bank discharging at a slow rate.
Table 6-4 is used to determine the quantity of CO2 to maintain minimum concentration.
The quantities are based on the nett internal volume of the machine and the deceleration time
assuming average leakage.
For non re-circulating machines with relief vents add 35% to the quantities shown in
Table 6-4.
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CO2 Required 5 min 10 min 15 min 20 min 30 min 40 min 50 min 60 min
kg lb m3 ft3 m3 ft3 m3 ft3 m3 ft3 m3 ft3 m3 ft3 m3 ft3 ft3
45 100 34 1 200 28 1 000 23 800 17 600 14 500 11 400 9 300 6 200
68 150 51 1 800 43 1 500 34 1 200 28 1 000 21 750 17 600 14 500 11 400
91 200 68 2 400 55 1 950 45 1 600 37 1 300 28 1 000 24 850 18 650 14 500
113 250 93 3 300 69 2 450 57 2 000 47 1 650 37 1 300 30 1 050 23 800 17 600
136 300 130 4 600 88 3 100 68 2 400 57 2 000 47 1 650 37 1 300 28 1 000 20 700
159 350 173 6 100 116 4 100 85 3 000 71 2 500 57 2 000 47 1 650 34 1 200 26 900
181 400 218 7 700 153 5 400 108 3 800 89 3 150 71 2 500 57 2 000 45 1 600 34 1 200
204 450 262 9 250 193 6 800 139 4 900 113 4 000 88 3 100 74 2 600 60 2 100 45 1 600
227 500 306 10 800 229 8 100 173 6 100 142 5 000 110 3 900 93 3 300 79 2 800 62 2 200
250 550 348 12 300 269 9 500 210 7 400 173 6 100 139 4 900 119 4 200 102 3 600 88 3 100
272 600 394 13 900 309 10 900 244 8 600 204 7 200 170 6 000 147 5 200 127 4 500 110 3 900
295 650 436 15 400 348 12 300 279 9 850 235 8 300 200 7 050 176 6 200 156 5 500 136 4 800
319 700 479 16 900 385 13 600 314 11 100 266 9 400 230 8 100 204 7 200 181 6 400 159 5 600
340 750 524 18 500 425 15 000 350 12 350 297 10 500 259 9 150 232 8 200 207 7 300 184 6 500
363 800 566 20 000 464 16 400 385 13 600 329 11 600 289 10 200 261 9 200 232 8 200 207 7 300
386 850 609 21 500 503 17 750 421 14 850 360 12 700 320 11 300 289 10 200 258 9 100 229 8 100
408 900 651 23 000 541 19 100 456 16 100 391 13 800 350 12 350 317 11 200 285 10 050 255 9 000
431 950 697 24 600 581 20 500 491 17 350 422 14 900 379 13 400 346 12 200 312 11 000 278 9 800
454 1 000 739 26 100 620 21 900 527 18 600 453 16 000 411 14 500 374 13 200 337 11 900 303 10 700
476 1 050 782 27 600 666 23 300 564 19 900 484 17 100 442 15 600 402 14 200 364 12 850 326 11 500
499 1 100 824 29 100 697 24 600 596 21 050 515 18 200 470 16 600 430 15 200 389 13 750 351 12 400
522 1 150 867 30 600 736 26 000 632 22 300 547 19 300 501 17 700 459 16 200 416 14 700 374 13 200
544 1 200 912 32 200 773 27 300 667 23 550 578 20 400 532 18 800 487 17 200 442 15 600 399 14 100
567 1 250 954 33 700 813 28 700 702 24 800 609 21 500 562 19 850 515 18 200 467 16 500 422 14 900
590 1 300 1 000 35 300 852 30 100 738 26 050 641 22 650 592 20 900 544 19 200 494 17 450 447 15 800
612 1 350 1 042 36 800 889 31 400 773 27 300 673 23 750 623 22 000 572 20 200 521 18 400 472 16 650
635 1 400 1 087 38 400 929 32 800 809 28 550 705 24 900 654 23 100 600 21 200 548 19 350 496 17 500
658 1 450 1 130 39 900 968 34 200 844 29 800 736 26 000 685 24 200 629 22 200 575 20 300 520 18 350
680 1 500 1 172 41 400 1 008 35 600 879 31 050 767 27 100 715 25 250 657 23 200 600 21 200 544 19 200
Table 6-4 Extended Discharge Gas Quantities for Enclosure Circulation - Rotating Electrical Machines
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Example
A Room requires 1,000kg of CO2.
This would be the basic quantity calculated, plus all additions but not including any special addition for
cooling purposes (refer to Section 6.4)
1000kg of CO2 ÷ by one minute
Flow rate = 1000kg/min
Example
Paper documents storage room:
6m x 6m x 3m high = 108m3
108m3 x 2kg/m3 of CO2 = 216kg
30% vol = 32.4m3
32.4 in3 ÷ 0.56m3/kg (expansion 30°C) = 57.85kg ÷ 2
Flow rate = 29kg/min
Flow time = 216 ÷ 29 = 7.45 minutes
To ensure a flow time of 7 minutes
Use 216 ÷ 7 = 31kg per minute
Most calculations produce a flow time of between four and seven minutes, the last step shows
what to do if seven minutes is exceeded.
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6.6.2 General
The important point is that the hazard shall be isolated from other hazards and the entire hazard
protected simultaneously, so that fire is prevented from spreading to unprotected areas and a re-flash
from unprotected areas is not possible.
For example, in a six stand printing press simultaneous protection would be given to all printing
stands, the drying boxes, the ink supply containers, and the flammable vapour extract duct. Similarly
in an industrial food processing environment, simultaneous protection is given to the cooking oil
surfaces, the burner compartment, the fume hood and extraction duct.
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Any service likely to affect the efficiency of the CO2 discharge must be interlocked with the system so
as to automatically shut down. This would include ventilating fans, conveyors, flammable liquid
pumps, mixers, heaters, dryers, sprayers etc.
Example
Local application portion:
Flow rate (kg/min) x discharge time (min) x 1.4 x MCF = kg of CO2 required.
E.g. 100kg/min x 0.5 x 1.4 x 1.5 (Ethyl Ether) = 100 x 0.7x 1.5 = 105kg
Plus 150kg for a 90 second discharge for cooling = 315kg in total and discharged at a rate of
150kg/min.
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e.g. 14kg of CO2 is for a total flooding portion of a combined local application minus total flooding
system (discharge time 0.5min)
Flow rate = 14kg / (1.4 x0.5) = 20kg/min
See Table 6-5 for details of horn height, area coverage and CO2 quantity combinations.
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The aiming point is measured from the near side of the area protected and is located by multiplying
the fractional aiming factor in Table 6-6 by the width of the area protected by the horn.
It is important that horns are located so that the discharge is not obstructed and their alignment is not
easily disturbed.
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Discharge horns must be located so as to develop an extinguishing concentration over coated stock
that may be extending over a protected surface, e.g. freshly dipped items hanging on a conveyor line.
In these circumstances additional horns may be required for this specific purpose, particularly if stock
extends more than 600mm above a protected surface.
Note the increase in area coverage that is given in Table 6-5 for coated surfaces compared with
liquid surfaces.
The effects of severe air currents and draughts shall be compensated for by adjusting horn locations
or by providing additional horns to suit the expected conditions.
Example
Hazard: Quench Tank
Material: Quench Lube Oil
MCF: 1
Surface dimensions: 0.92 m x 2.13m
Horn Location: The site survey has shown that discharge horns can be positioned anywhere from
0.92m to 1.83m above the liquid surface without interfering with plant operations.
Design Aim: To select a combination of horn height, area coverage and flow rate to adequately cover
the area with the minimum CO2 quantity.
Procedure: Consider the size to be protected. What is the minimum number of horns that could be
used to cover a length of 2.13m of liquid surface?
Answer: Two horns with a side of square each of 1.08m. This selection also satisfies a width of 0.92m
since it is less than 1.08m, and also an area of 1.95m² since it is less than can be protected by the
two horns selected.
Horns required: Two located centrally above the liquid surface pointing down from a height of 1.14m.
CO2 required. 50.4 x (1.4/2) (liquid flow for 0.5 min) = 50.4 x 0.7 = 35.3kg
This provides the basic CO2 quantity for the minimum permitted length of time but the discharge time
at the calculated flow rate could be increased for cooling to prevent re-ignition.
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Examples
If horn P/N K61792, with a flow rate of 52.3 kg/min, was selected it should be located approximately
2.44 m from the surface it is protecting.
Example 1
Hazard: Paint Spray Booth (ignoring extract duct for this calculation)
Actual dimensions: 2.44m wide (open front) x 2.13m high x 1.83m deep
Assumed volume: 2.44m x 2.13m x 2.43m (1.83m deep + 0.6m) = 12.63m3
Percent Perimeter enclosed =
(2.44 + 1.83 + 1.83) / (2.44 + 2.44 + 1.83 + 1.83) = (6.1/ 8.54) = 71%
Discharge rate for 71% enclosure: from Figure 6-2= 7.5kg/min m3
Discharge rate: 12.63m3 x 7.5 kg/min m3 = 94.73kg/min
CO2 required: 94.73kg/min x 0.7 = 66.3kg x MCF (1.0)
Example 2
Hazard: Printer with 4 sides and top open (no continuous solid walls and ignoring extract duct for this
calculation).
Actual dimensions:
1.22m wide x 1.52m long x 1.22m high (this is the maximum hazard outline)
Assumed volume:
2.42m (1.22 + 0.6 + 0.6) x 2.72m (1.52 + 0.6 + 0.6) x 1.82m (1.22 + 0.6) = 11.98m3
Percent perimeter enclosed: Zero
Discharge rate for 0% enclosure: 16kg/min m3
Discharge rate: 11.98m3 x 16 kg/min m3 = 191.7kg/min
CO2 required: 191.7kg/min x 0.7 = 134.2kg x MCF (1.0)
NOTE: The assumed volume method of system design always needs more gas than the rate
by area method, so to be competitive it is always worth considering if the risk can be protected
by the area method. Example 2 can, but Example 1 cannot.
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Metric Imperial
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Examples
A surface fire where the design concentration has to be achieved in one minute. If a space requires
300kg of CO2, the flow rate from the main manifold would be 300kg/min and the size of the feed pipe
would be 32mm bore.
If the system used 4 discharge horns in a balanced distribution system, the feed pipe would branch
into two pipes each flowing at 150kg/min and would be sized 25mm bore.
NOTE: The design concentration would include any extra CO2 for losses through openings
and that demanded by the MCF but would not include any extra CO2 allowed for cooling. This
would be allowed to discharge at the same rate and would extend the discharge time beyond
one minute.
The same philosophy applies in a local application system except that the minimum discharge time is
30 seconds, which may be extended beyond this time to discharge any extra CO2 added for cooling.
A deep seated fire where the design concentration has to be achieved within seven minutes, but a
concentration of 30% (must be achieved within) two minutes.
When an order has been received, the Contract Engineer would calculate the flow rate accurately. For
estimating purposes it is sufficient to adopt a short cut method.
Table 6-4, it is simply necessary to divide the quantity of CO2 required by the length of time of the
extended discharge to determine the flow rate.
These are determined by use of the Calculation Program, and nozzle orifice sizes are drilled in
accordance to the range stated on the relevant data sheets.
A point to bear in mind is that the maximum number of discharge horns that can be fed by one
container is 11 – N3.
The larger the nozzle orifice the smaller the number of horns that can be used, i.e. only one N11
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Containers shall be located as near as possible to the space they protect. They may be located
within the protected space, but must not be exposed to a fire in a manner that is likely to impair
system performance. If located within the protected space the manual/pneumatic actuator can be
used to provide a means of mechanically operating the system from outside the protected space. The
chosen location should provide protection from mechanical, chemical, electrical and other types of
damage. Suitable guards or enclosures should be provided when necessary, as required by an
appropriate risk analysis. The floor at the container location must be suitable for withstanding the
loading exerted by the containers.
The containers must not be exposed to the direct rays of the sun. When excessive temperature
variations are expected, suitable enclosures shall be provided.
The general ambient storage temperatures should not exceed the following:
a) For total flooding systems: not greater than 55ºC or less than -18ºC.
(b) For local application systems: not greater than 46ºC or less than 0ºC.
NOTE: The minimum storage temperature for local application is higher than that allowed for
total flooding systems because the discharge area limit tests were carried out at a minimum
temperature of 0ºC and to operate at lower temperatures would cause the figures in Table 6-5
to be incorrectly applied.
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6.14 Alarms
System condition indicators should be provided as appropriate to the surroundings.
a) A total flooding systems should have indicators located outside the entrance doors to show:
• CO2 Discharged - Red Lamp
• Manual Control Only - Green Lamp
• Automatic and Manual Control - Amber Lamp
These indications may not always be necessary for a local application system.
NOTE: Warning labels are required to be located alongside manual release points and located
on all entrance doors.
Depending upon the size and complexity of the site or system, instructional wall charts may be
required.
Audible alarms should be provided as appropriate to the type of system and protected area, but at
least to the requirements of BS 5306 part 4.
Where BS 5839 is not a requirement, local alarms may be mains operated provided the supply can be
guaranteed.
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When applying CO2 into potentially explosive atmospheres, in particular those containing explosive
vapours and gases, the following should be taken into account:
Electrostatic charging of steel piping not bonded to earth may occur during the discharge of carbon
dioxide – therefore pipework shall be bonded and earthed in accordance with BS 7430 and BS 7671.
The discharge of carbon dioxide is known to generate an electrostatic charge in the hazard. Under
certain conditions, impingement of the CO2 on isolated conducting surfaces over time can lead to a
build-up of charge which could generate an electrical spark which could pose as an ignition risk.
6.16 Detection
Automatic detection systems used with CO2 extinguishing systems should comply with appropriate
Codes of Practice, these include:
• BS 5839 - Fire Detection and Alarm Systems in Buildings.
• BS 6266 - Data Processing Installations.
• FOC rules.
• This manual.
FM Approved systems are required to be installed with FM Approved detection and release devices.
NOTE: Attention is drawn to the considerably higher concentration of detectors required by
BS6266 when protecting computer suites.
This philosophy should not be extended into other areas of protection without prior consultation with
Kidde Fire Protection.
Suitable safeguards are required to protect people in areas where the atmosphere may become
hazardous by the presence of carbon dioxide gas from a fixed fire extinguishing system. Carbon
dioxide at atmospheric pressure is a colourless, odourless and electrically non-conducting inert gas
which is nearly 1.5 times denser than air resulting in possible migration of carbon dioxide travelling to
lower levels. These hazards to personnel have to be taken into account in the design and installation
of the systems. Consideration to the possibility of carbon dioxide collecting in pits, wells, shafts or
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any other potential lower lying areas where carbon dioxide might escape too which fall outside the
protected enclosure and/or the cylinder storage area.
WARNING: Carbon dioxide extinguishes fire by reducing the oxygen content from the normal
21% in air to ~15% or lower which are levels that are lethal to personnel.
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The Kidde Fire Protection Carbon Dioxide Flow calculation program has been divided into three main
areas:
1. Commands Available
2. Output
3. File Utilities.
NOTE: The calculation information can be entered and displayed in metric or imperial units. It
can be converted at any time upon command by simply using the metric check box.
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7.1.4 Revision
This data field is used to track versions/changes on a specific data file and/or submittal.
Distance Factor
0 – 15m
1.10
(0-50ft)
15 – 30m
1.20
(50-100ft)
30 – 90m
1.30
(101-300ft)
90 – 120m
1.40
(301-400ft)
120 – 150m
1.50
(401-500ft)
Table 7-1 Pipe Length Factors
• Exclude Pipe Size: Occasionally, it is desirable to exclude or inhibit specific pipe sizes from
being selected and used by the calculation program. To exclude a pipe size from being selected,
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simply choose the specific size or “None”. Only a maximum of 2 sizes may be excluded from the
calculation. The sizes in this list represent all the pipe sizes possible for both steel pipe and
tubing.
NOTE: The user should be aware as to which pipe sizes are applicable to the pipe type that
will be utilized in the piping network.
Pipe Temperature: The initial pipe temperature should be entered here to accurately calculate
the vapour portion of the discharge.
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• Area
• Area Nozzle List
• Area Name: Enter the name of the specific area - commas are not accepted.
• Type: Select the appropriate hazard type (see Figure 7-5) and the calculation module will perform
the necessary cross checks needed to determine if the calculated system’s discharge
performance is satisfactory. See Table 7-2 for some examples of the cross checks performed.
The latest edition of BS 5306 part 4 / NFPA 12 should be consulted prior to determining the fire type
for each hazard.
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1. Dry Electrical Hazard: A typical hazard of this kind is anything that requires a 30% concentration
held for some period of time, i.e., a transformer room or a compartmentalised gas turbine. If this
option is chosen, simply fill in the volume, choose a loss factor per minute (usually between 1%
and 3% is sufficient for enclosures that have average leakage), and type in the cool-down (or
hold) time in minutes. After supplying these three pieces of information, press the Compute
button.
Next an ‘Extended Discharge Wizard’ dialog box will be shown (Figure 7-7); fill in the design criteria
for the ‘Initial Discharge’. Based upon the information supplied, the program will be able to compute
the extended discharge CO2 quantity and the rate of discharge per minute. If the initial discharge
design criteria needs to be modified, simply depress the ‘Edit Initial Discharge Information’ and the
program will re-compute the requirements for the extended discharge. When finished, simply press
the ‘Close’ button and the information from this form will automatically transfer to the Hazard Data
screen. Next add the required amount of discharge nozzles.
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2. Hydroelectric Generator: If this option is chosen, simply type in the volume and select the cool-
down time from the drop-down list. After completing this, press the ‘Compute’ button. The
software will use
3. Table 6-4 to calculate the amount of gas required and then calculate the appropriate rate of
discharge per minute. After this is complete, press the ‘Close’ button and the information from this
form will automatically transfer to the Hazard Data Screen. Then add the required amount of
discharge nozzles.
4. Job Specification: Sometimes manufacturers supply a specification for how the extended
discharge shall perform. In this case, select this option and fill in all the fields, i.e., volume, CO2
quantity, rate, and the cool-down time. Next, press ‘Compute’ so the program can compute/set
the necessary values needed for the calculation module. When this is complete, press the ‘Close’
button and the information from this form will automatically transfer to the Hazard Data Screen.
Next, add the required number of discharge nozzles.
• CO2 % (Design Concentration): For Total Flooding Systems only, this is the minimum
percentage of CO2 concentration required for this specific area. Refer to BS 5306 part 4 / NFPA12
for further information.
• Temperature: For Total Flooding Systems only, enter the normal ambient temperature for the
area. If the area has a temperature in excess of 100°C (212°F) or below -18°C (0°F), the program
will automatically compensate an additional 2% CO2 gas for every 5°C above 100°C and 2% CO 2
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7.1.10 Area
Enter the appropriate values in the Length, Width and Height field and the program will compute the
correct room volume and amount of agent required automatically. Please note, the Width and Height
fields are both set to a default of 1. If the volume is known, enter it into the Length data field and leave
the Width and Height fields as 1. Once the data has been entered, clicking on the ‘Add’ button will
assign this data to the current hazard.
• Number the terminal points consecutively to the end of each distribution section. Do not duplicate
numbers on the same calculation.
• Multi-hazard systems (utilising POD valves) demand close attention. The hazard requiring the
greatest flow rate (not necessarily the greatest quantity of CO2) should be calculated first, since it
will establish the size of the manifold and main discharge header. These sizes must be used in
calculations for the other hazards.
End: This indicates the end of the same section. If this line is a nozzle, clicking the button that
appears in this cell will cause a ‘Nozzle Reference’ box to be visible. Here the user can scroll through
the hazards and select the desired nozzle, or simply type in the nozzle number into the end cell.
Cylinder Qty: The quantity of cylinders flowing through this specific section of manifold piping. Enter
a quantity of zero (0) to indicate distribution piping.
Pipe Len: Length of pipe in feet or meters as applicable, including all elevation changes.
Elev: Change of elevation within the pipe section, expressed in feet or meters.
• A positive number indicates a rise in elevation.
• A negative number indicates a drop in elevation.
• A zero indicates no change in elevation.
Type: Type of pipe to be installed. There are several types available, accessible through the pop-
down, for use:
• 40T: Schedule 40 pipe with threaded fittings. Select for BS5306 systems using BS1387 pipe, up
to and including 40mm.
• 40W/V Schedule 40 pipe with welded or grooved / Victaulic fittings. Select for BS5306 systems
using BS1387 pipe, up to and including 40mm.
• 80T: Schedule 80 pipe with threaded fittings. Select for BS5306 systems using BS3601 or API5L
pipe.
• 80W/V: Schedule 80 pipe with welded or grooved / Victaulic fittings. Select for BS5306 systems
using BS3601 or API5L pipe.
1/4 8 0.065
5/16 9 0.065
3/8 10 0.065
1/2 15 0.065
5/8 18 0.065
3/4 20 0.095
7/8 22 0.095
1 25 0.095
1-1/4 32 0.188
1-1/2 40 0.188
2 50 0.188
All tubing to be either:
• Grade 304 seamless (ASTM A-213, A-269)
• Grade 304 welded (ASTM A-129, A-269)
• Grade 316 seamless (ASTM A-213, A-269)
• Grade 316 welded (ASTM A-249, A-269)
NOTE: Grade 304L and 316L tubing is NOT permitted.
Size: The size of pipe in the section. When a pipe size of “0" is chosen, the program will
automatically calculate the pipe size required. Depending on the type of pipe chosen under the pipe
type column, the appropriate pipe sizes will be displayed in the pipe size drop down list i.e. if 40T is
chosen, a size of 22cm (7/8") will not be available.
Fittings 90's: Indicates the number of 90° elbows in the pipe sec tion. When 45° elbows are used,
they are treated as an equivalent number of 90° elb ows. In this case, 0.5 would be inserted for each
45° elbow and included in the 90's field.
Tees/Valves: The default for this section is ‘None’. For sections where tees or selector valves are
used, the following choices are available:
• Thru: The beginning of the pipe section begins with a thru tee. If the side branch of a tee is used
to provide pressure for tripping a pressure switch or pressure release, it is treated as an
equivalent number of elbows. In this case, 0.6 would be included in the 90's field.
• Side: The beginning of the pipe section begins with side tee. If one of the thru branches of a tee
is used to provide pressure for tripping a pressure switch or pressure release, it is treated as an
equivalent number of elbows. In this case, 2.0 would be included in the 90's field.
• Dirt Trap or Blow-Out (Figure 7-13): The equivalent length of the dirt trap fittings will
automatically be included in the calculation program.
• Pressure Operated Directional Valve (POD): The beginning of the pipe section begins with a
POD valve. The equivalent length of the valve will automatically be included in the calculation
program. If a pipe type of ‘Tubing’ was chosen, it will be automatically changed to 40T.
• Thru & POD: To save time by avoiding additional lines of piping data input, if the pipe section
begins with a thru tee and is followed by a POD selector valve, the pipe modelling can be
configured as one line of input. All fitting equivalent lengths will automatically be included with the
input. If a pipe type of ‘Tubing’ was chosen, it will be automatically changed to 40T.
• Side & POD: Same as above but using a side tee instead of a thru tee.
• Ball Valve: When the section of piping contains a ball valve for purposes such as lockout or
isolation, the equivalent length of the valve will automatically be included in the calculation
program. If a pipe type of ‘Tubing’ was chosen, it will be automatically changed to 40T.
• Check Valve: When the section of piping contains a check valve, i.e., a main with reserve
system, the equivalent length of the check valve will automatically be included in the calculation. If
a pipe type of ‘Tubing’ was chosen, it will be automatically changed to 40T.
• Fix Code: This default button should be on when the values in the ‘Kgs Required’ column indicate
the actual nozzle code or drill diameter in inches for a particular nozzle.
Flow Rate: This default button should be on when the values in the last column indicate the
discharge rate in kgs (pounds) per minute to be discharged from a nozzle. To set the rate for a
particular nozzle, select the far right cell, click the ‘Flow Rate’ default button, and then either type the
flow rate in or use the drop down list and select the “Get Rate” option. The computer will automatically
calculate and display the required flow rate needed for that particular nozzle. Alternatively, the flow
rates can be all set simultaneously after finishing the piping model by following the above steps, but
instead of selecting ‘Get Rate’ select ‘Set All’ (Figure 7-14).
NOTE: The ‘Get Rate’ and ‘Set All’ functions only work for total flooding hazards and for
hazards that utilize the ‘ext’d discharge’. The rate must be determined by the local application
nozzle selector slide rule and inputted manually.
Unless a low rate orifice nozzle is selected for a hazard, all flow rates will default to a minimum
of 4.54kg/min (10lbs/min). This is to insure that the nozzle will not freeze up and clog the
discharge pipe.
Add: The ‘Add’ button works similarly to the Add buttons on the previous screens. Clicking the ‘Add’
button will add a blank line to the bottom of the data grid. Other ways to add data: Function key ‘F5’,
the ‘Right Arrow’ key (if positioned in the last column of the last row), or depressing the ‘Shift’ and
‘Insert’ keys simultaneously.
Copy & Paste: To copy information in the row(s) select the desired cell(s) to be copied and press
‘Copy’ (F9 function key). To copy multiple rows at one time, simply click on any cell in the first row to
be copied and while continuing to depress the mouse button, highlight the remaining rows and select
‘Copy’ (F9 function key). Select a cell in the row where the copied rows are to be pasted. Press the
‘Paste’ button (F10 function key).
NOTE: Only consecutive rows can be copied at once. The lines will be inserted starting at the
row of the cell that is highlighted. This information can be pasted at any time and as many
times as necessary without reselecting the rows to be copied.
Insert: The ‘Insert’ button is used to insert a line of data into the data grid in a specific location other
than at the next available position at the bottom of the grid. In order to insert a line, click onto the
highest line in the data grid that must be moved down and depress the ‘Insert’ button (F7 function
key).
Delete: The ‘Delete’ function (F8 function key) is used to delete a line of data in the data grid.
Highlight the data line within the data grid by highlighting it with the mouse and click the ‘Delete’
button. A verification message will appear to validate the request. Confirm the request, the data line
will be deleted and any data lines below it will be moved up to compensate for the deleted line of data.
After running a calculation, it is always recommended to ‘Fix Results’ (Figure 7-16). After this is done,
the input data can be fixed to represent the pipe sizes, pipe schedules, and actual nozzle codes that
were determined by the calculation program. This is useful for ‘as-built’ modifications etc.
NOTE: This option is only available after a ‘fix results’ calculation has been performed.
Piping: This section of the Results screen displays the following information:
• Section Nodes - The starting and ending nodes for a particular section of the pipe model.
• Nominal Pipe Size - The computed or inputted pipe size and schedule.
• Length - Length of pipe within the section, including elevation changes.
• Elev - The length of an elevation change within the section of pipe.
• EQL - Total equivalent length of the section of pipe, including pipe, elbows, tees, couplings
unions, valves, and additional information inputted into the equivalent length column of the data
file.
• Section Flow - The flow rate through the pipe section.
• BAR - The pressure at the termination of the section.
• Nozzle Flow - The flow rate through the pipe section and nozzle.
• Nozzle Code - The calculated/ideal nozzle code.
NOTE: If tubing was chosen rather than pipe, the calculation results printout will give
information on the minimum wall thickness (in inches) that is required for each size of tubing.
Fix Results: This will run one additional calculation using the pipe sizes and actual nozzle sizes
available. It is recommended to always use this feature to ensure that the system will be acceptable
and utilising actual available nozzle codes.
Calculation Results: The selection of this option will output the results of the calculation.
BOM: The mechanical high pressure CO2 system BOM, including pipe and pipe fittings. Once this has
been printed, the system must be recalculated before printing the BOM again.
Print CO2 Requirements: Selecting this option will print the CO2 requirements for each individual
hazard (not applicable to LA Rate by Area and LA Rate by Volume hazard types). A step by step
walk-through of how the requirement was calculated will be printed. This information can be sent
directly to a printer to obtain a hard copy (useful for submitting to authorities having jurisdiction, etc.)
or it can be printed to a text file, which can then be entered into AutoCAD or a word processing
program.
NOTE: If no total flooding hazards are defined, this option will not be available.
7.4.4 Print
Clicking on this command will start the printing or writing of the selected data.
8. FLOW CALCULATION
ION SOFTWARE
Copy F9 Key
GENERAL FUNCTIONS
Move One Cell To The Left Left Arrow Key Shift + Tab
Move One Cell To The Right Right Arrow Key Enter Or Tab
9. INSTALLATION
9.1 Purpose
The following installation procedures, in combination with the commissioning procedures, are
intended to ensure that the system satisfies the required designed properties and ensure the correct
functionality/operation of the installed Kidde Fire Protection High Pressure Carbon Dioxide Fire
Suppression System.
The Installation Engineer of a Kidde Fire Suppression System shall be familiar with this product
manual.
WARNING: All pressurised cylinders can be extremely hazardous. CO2 Klem cylinder valves
are capable of producing a high discharge thrust from the valve outlet when opened.
9.2.1 UTC Fire & Security Cardinal Rules and General Rules
9.2.1.1 Intent
The purpose of the UTCFS EH&S Standard Work: Gaseous Suppression System Standard is to
establish minimum safe requirements for use of compressed gas cylinders as related to suppression
systems. For businesses operating outside UTCFS, we recommend compliance to this guidance as it
represents current best safe practice.
9.2.1.2 Applicability
This UTCFS EH&S Standard Work Gaseous Suppression System Standard applies to all UTCFS
business units worldwide including those joint ventures, partnerships or other business arrangements
where UTCFS holds a majority ownership interest, majority voting control, or where UTCFS, by
contract, has agreed to manage the company. Each operation will comply with all applicable legal
EH&S requirements, UTC EH&S requirements and with this UTCFS EH&S Standard Work.
This standard applies to any activity or process where a fire suppression system is installed,
upgraded, serviced, or tested by a UTCFS Employee(s) or Contractor.
A. Employees shall never transport cylinders without approved /suitable valve assembly
protection (i.e. protective cap, transport cap, discharge and actuation port cap, locking pins,
metal sleeving).
B. Employees shall never remove the protection cap(s) or locking pin before a cylinder is
secured.
C. Employees shall never leave cylinders unsecured.
D. No work is to be undertaken on a suppression system unless: (a) the means for activation has
been rendered safe, electrically, pneumatically and mechanically; and (b) any stored pressure
in the manifold or distribution and/or actuation pipe-work has been safely discharged.
E. Employees shall never use cylinders which have signs of damage, corrosion and or have
exceeded their next required proof pressure test date.
A. Employees shall never install, maintain, modify or repair compressed gas system without a
permit to work system and or clear detailed safety control methods in place.
B. Employees shall never work with valves or regulators unless trained and competent / licensed
to do so and a permit to work and or risk assessment for the task is in place.
C. Employees shall store cylinders in a defined ventilated compressed gas cylinder storage area.
The storage area must be suitable and sufficient to protect the cylinders from damage,
interference and have adequate means to secure the cylinders.
D. All transportation of cylinders shall only be undertaken when the cylinder(s) are secured and
fitted with approved valve assembly protection (i.e. protective cap, transport cap, discharge
and actuation port cap, locking pins, metal sleeving).
E. All vehicles used for transportation of cylinders must be suitable for the load, possess
sufficient means of securing the cylinders, have a separate designated compartment in which
to transport the cylinders from the personnel area (cab), this may be by segregation (steel
compartment) or open area. If a local requirement, vehicles should be fitted with the relevant
signs indicating that compressed gas is being carried and the local requirements for
transportation regulations complied with.
F. All personnel transporting cylinders must be trained in the safe handling and transportation of
compressed gas, where required have applicable licenses/permits, posses suitable
mechanical aids to transport them safely and be familiar with the MSDS and Emergency
Procedures for the type of gas they are transporting.
G. All unrelated works within the vicinity of the cylinder bank location must be either completed
or well controlled prior to the installation, maintenance, modification or repair of the
compressed gas cylinders and all related works must be subject to the permit to work system
or risk assessment and suitable controlled (e.g. warning barriers and warning notices).
H. All Personal Protection Equipment (PPE) is clearly defined and used when required. When
installing or removing pressurized actuation equipment, suitable safety glasses and gloves
must be worn.
Figure 9-1 Cylinder and Klem Valve Assembly with Protection Cap Fitted
Specification
Cylinder Body: 1999/36/EC (TPED)
Material: Steel
Test Pressure: 250 bar
Fill Ratio: 0.661kg/litre
Standard Point Finish: Red
WARNING: The valve will close immediately once the force is removed from the actuator rod.
Each cylinder valve incorporates a safety disc designed to rupture and discharge the CO2
cylinder contents when the ambient temperature reaches approximately 60°C.
Refer to Data Sheet DS K24509 for further detail on Klem Cylinder Valve such as
dimensions/thread details.
weather conditions or put in a location where it can be subjected to chemical or other damage.
Suitable guards or enclosures should be provided when necessary.
1. Offer strap up to a suitable structure or wall and mark the hole centres for drilling at an elevation
from ground level.
2. Drill appropriate fixing holes (
3. Figure 9-2).
4. Place and clamp the container in position.
4. Place the cylinders in position against the cut-outs in the back rack.
5. Hook the rack bolts through the 17.5mm diameter hole(s) in the back rack.
6. Locate the straight end of the rack bolts through the 17.5mm diameter holes in the front strap and
clamp the containers firmly in place using the nuts and washers supplied with the rack bolts.
Single Row Rack Bolt Assembly K62752 MS Rod Paint Black 0.4
7. Place the front straps in position and clamp the cylinders firmly in position using the nuts and
washers supplied.
45kg Cylinders
22.6kg Cylinders
9.10.1 Piping
The pipe and fittings materials must conform to the requirements of BS 5306 part 4, as shown in the
following tables:
*Fittings conforming to BS EN 10242 may be used on open section pipework greater than 20mm
provided that they are suitable certified by the manufacturer for the anticipated pressure.
Table 9-1 Closed and Open Ended Pipework Section – High Pressure Systems
BS1387 BW - Heavy
BS 3601 S 430
API 5L S or ERW B
ASTM A106-77 HF or CD A or B
BS 3601 S 430
ASTM A106-77 HF or CD A or B
API 5L S or ERW B
Abbreviations: HF-Hot Finished, CFS-Cold Finished Seamless, CD-Cold Drawn, HFS-Hot Finished Seamless,
S-Seamless, ERW-Electric Resistance Welded & Induction Welded.
Flange bolts, studs, nuts and washers: Bolts and studs shall conform to BS EN 1515-1. Nuts shall
conform to BS EN 1515-1. Washers shall conform to BS 3410 or BS 4320.
NOTE: Plain washers should be fitted under bolt head and nut. A minimum of two threads
should project above the nut when fully tightened
Gasket for flanged joints: Flanges joints shall be fitted with a gasket. The recommendation of
the gasket manufacturer should be followed in selecting the grade, specification and thickness to
be used.
Nominal Pipe Size Conforms to: Type of Pipe Grade of Steel Minimum Wall Thickness*
BS 3601 S 430
API 5L S or ERW B
API 5L S or ERW B
*Schedule numbers determine the minimum wall thickness in accordance with BS 1600. Where
the specified pipe is not obtainable in these dimensions, the next largest thickness should be used.
Max Spacing (m) 1.5 1.8 2.1 2.4 2.7 3.4 3.7 4.3 5.2
Note: Test Report/statement of completion must be issued, see example shown in Table 9-4. It is
recommended that the calibrated flow meter used is listed on the Test Report.
2) The installation has been visually inspected and found to be in good order
It is recommended that the pressure applied during the test is 1.5 times the maximum operating
pressure (normally 60 bar, test pressure equal to approx. 90 bar).
The recommended holding time is 10 minutes to ensure that both the pipe and fittings used and the
overall assembly will withstand the operating pressure as well the "water hammer" effect which occurs
at the start of the discharge. A pressure drop of more than 5 bar shall not be accepted.
If the required pressure cannot be maintained for the minimum hold time, all connections shall be
checked for leakage. Any connection found to be leaking shall be tightened and the procedure is
repeated until a successful test has been completed.
The pipe from the manifold to the distribution pipe inlet will need to be fitted with a test valve which
incorporates a hose connection to the pressure testing equipment (union/flanged connection to be
supplied locally).
If no union/flanged connection with the distribution inlet is available, one of the manifold check valve
connections may be used. Disconnect all discharge hoses from the manifold. Connect the pressure
testing equipment to the check valve (3/4” BSP).
Warning: It shall be ensured that water does not enter the cylinder valves or remains in the
manifold arrangement after the pressure testing. Piping shall then be blown through with
compressed air, an inert gas such as nitrogen until all moisture has been removed from all
components (e.g. pipe work, manifolds, diverter valves etc.)
2) The installation has been visually inspected and found to be in good order
9.12.3 Precautions
Pneumatic testing involves the hazard of energy stored in compressed gas. Particular care must
therefore be taken to minimise the chance of failure of brittle components during a pneumatic test.
In areas where water cannot be accepted as the media for pressure testing (i.e. operating computer
rooms etc) compressed air, or an inert gas (e.g. nitrogen) may be used. All due precautions shall be
taken to prevent injury to personnel while the pipes are under pressure (i.e. maintaining a safe
distance from the pipe work and a total evacuation of all areas affected prior to and during the
pressure test).
During the pressure test, the test gas pressure must be applied slowly through a pressure regulator.
When a pressure of approx. 2 bar is attained, a preliminary check shall be made, including
examination of joints/fittings etc. After the inspection (if all joints/fittings etc. are found to be tight) the
pressure shall be gradually increased in steps until the test pressure is reached, holding the pressure
at each step long enough to equalise piping strains.
Test Report
Pipe Work Installation
Date: Client:
Installer:
System Description
Pipe Flushing
Leakage Test
Pressure Test
Remarks:
Witnessed/Approved by
Table 9-4 Example Test Report for the installation and verification of pipe work
Metres 2.5 2.5 2.7 2.7 2.8 3.0 3.2 3.3 3.5 3.8 4.2 4.57
9 9 4 4 9 5 0 5 0 1 7
To the nearest part not at earth potential of an insulator supporting a live
conductor ('ground clearance')
Metres 2.44
Max rated Voltage 11 15 22 33 44 66 88 110 132 165 220 275
(XY)
NOTE: The term insulator includes all forms of insulating supports, such as pedestal and
suspension insulators, bushings, cable sealing ends and the insulating supports of certain
types of circuit breaker etc.
IMPORTANT: See qualifying notes of clause 34 and definitions 30 and 31 of BS 7354: 1990
from which this table is taken.
NOTE: All dirt, swarf and cutting oil must be removed from each section of pipe before
installation. CO2 pressure will remove any debris and may deposit it on valuable equipment.
NOTE: Use PTFE tape on all pipe screw threads (or other approved thread sealant).
3” & 4” Inch Pod Valves – See section 5.22.2 for component details
3” & 4” Companion Flange, Bolts and Gasket – See section 5.22.3 for component details
Pressure Operation for POD valves ¾” to 4” – See section 5.22.4 for component details
Valve Open Indicator Switch – See section 5.22.6 for component details
• With the Safety Lock pin removed check that the indicator switch clicks into operation.
After the checks have been carried out satisfactorily install the POD valve as follows:
1. Install the POD valve in the main feed line at a position where access for manual operation of
maintenance/service is unhindered by other obstacles. Where possible install the POD valve at a
height of approximately (1.5 meters) 5’- 0” (maximum). Make sure that the arrow shown on the
valve body to indicate the direction of flow faces away from the CO2 manifold.
2. Connect a nipple and socket union to the outlet side of the POD valve for ease of installation to
the main CO2 feed line.
3. Use PTFE pipe tape on all screwed pipe fittings.
4. To prevent accidental discharge of fire fighting systems during installation work check the
following before connecting the pilot gas lines:
• That the Safety and Reset pin is screwed fully home in the control head.
• That all safety pins are fully inserted in the cylinder release heads, and POD valves.
5. Using 3/16” bundy tubing and fittings, connect the nitrogen pilot cylinder valve to the pilot gas inlet
port of the POD valves and from the POD valve gas outlet port to the CO2 cylinder pressure
release head as shown in Figure 5-46 and Figure 5-47.
NOTES:
• Clip the bundy tube to the wall at approx 457mm centres.
• ¾ to 2 inch POD valves require adaptors K90220 and K90219 fitted in the pilot gas inlet port and
adaptor K90219 fitted to the pilot gas outlet port.
• 3 and 4 inch POD valves require adaptor K90219 fitted to both inlet and outlet pilot gas ports.
• A POD valve indicator switch, if fitted, must be wired as shown in
1. That the hose is clean and free from dirt before installation.
2. That the hose is free from damage
3. That all screw threads are clean and free of any damage.
NOTES: Do NOT use PTFE pipe tape on discharge or Pilot line hoses. Do NOT over-tighten
fittings.
45.0 E7194-004
1800 ± 100
45.0 E7194-001
Table 9-6 Manifold Heights, all dimension in mm.
WARNING: Always connect the loop to the manifold inlet or pipework if single cylinder, before
connecting to the cylinder valve outlet.
Nitrogen Pilot Gas Cylinder and Valve – See section 5.9 for component details
Optional Pressure Monitoring Switch – See section 5.9.1 for component details
Control Head with Switches – See section 5.10.2 for component details
When carrying out servicing or maintenance, screw the safety / reset pin fully home to inhibit
(isolate) the system.
Specification
Body Material: Steel
Weight: 0.1kg
NOTE: Check the distance to the 1st cylinder valve release head to ensure that the long pilot
gas flexible hose K93434 can be easily coupled to the nitrogen pilot gas cylinder valve outlet.
2. Lower the control head so that its swivel nut projects through the hole in the mounting
bracket and bolt onto the bracket.
WARNING: Do NOT fit the nitrogen pilot gas cylinder at this time.
and push the pin in. Ensure that no dirt or foreign matter falls into the control head while the
port is open; reconnect the port plug.
8. Verify that as the Safety and Reset pin is screwed in, the actuating pin retracts, reverting to
its original position when the Safety and Reset pin is FULLY IN.
WARNING: Ensure that the nitrogen pilot gas cylinder has NOT been fitted.
5. Remove the Safety and Reset pin and energise the solenoid causing the firing pin to operate
(Figure 5-15 and Figure 5-16).
6. To reset de-energise the solenoid and re-insert the Safety and Reset pin.
Solenoid designed in accordance with BS 5490 IP55. The unit is prewired and supplied complete
with flexible conduit.
Mechanical Specification
Case Material: Aluminium Alloy.
Finish: Grey Anodise.
Weight: 0.77kg.
Electrical Specification
Cable: PVC
Coil resistance at 20°C: 64.5 Ohms ± 5% 24v DC (Nom inal) 8.5 Watts.
Solenoid designed in accordance with ATEX directive: ATEX 94/9/EC classification: for potentially
explosive atmospheres flameproof enclosure EX II 2 G EEx d II C T6 to T4
II 2 D IP65 T 85 to T135ºC
Mechanical Specification
Case material: Aluminium Alloy
Finish: Epoxy Gloss Grey/Green
Weight: 1.4kg
Electrical Specification
Coil resistance at 20°C: 16 Ohms ± 10% 24v DC (Nomi nal), 16.8Watts
Remove the Safety and Reset pin and energise the solenoid causing the firing pin to operate (Figure
5-15 and Figure 5-16).
To Reset de-energise the solenoid and re-insert the Safety and Reset pin.
After the control head (K62304) has been operated, the actuation signal is removed if the solenoid is
wired as shown in Figure 9-8.
The user of this equipment should make sure they are aware of the following information.
2. Placing the device into service
These Control Heads may be installed in an area classified as Zone 2 or Zone 22 or unclassified.
3. Safe use of Control Heads
Control Heads are for use only as a component of a pneumatic activation system for
extinguishers compatible with the activation pressure (65bar at 20°C). The Control Head solenoid
activation option is limited to certified version K93206/AX.
The switched version is to be used with an intrinsically safe supply suitable for the hazard area.
Control Heads are supplied with a resetting tool that also acts as a disable device to allow
maintenance on the extinguishing system.
4. Assembling and dismantling
Control Heads are supplied complete and ready to install in accordance with chapter 6:
Installation.
5. Installation
Control Head installation shall be in accordance with Section 9.19.1, except that for zone 2 or
zone 22 compliance solenoid K62422B is not to be used.
6. Maintenance (service and emergency repair)
The Safety and Reset Pin must be used to disable the control head before any system
maintenance is performed. For maintenance refer to Section 11.
7. Adjustment
Control Heads have no adjustable components.
8. Limitations of use
Control Heads must only be used within areas specified by the hazardous area certification as
indicated on the equipment label.
9. Special Parameters
The ambient temperature for this equipment is –18°C to 55°C.
Unscrew both blanking plugs from the control head body (use a ¼” A/F hex wrench).
4. Feed in the inner cable through the blanking plug port on the ‘Safety and Reset’ pin side of
the control head, through the top hole of the cable pull-ring inside the control head and out
through the blanking plug port on the other side of the control head.
5. Slide the outer Bowden cable, complete with box, onto the free end of the inner cable and
screw cable into the blanking port and tighten.
6. Attach the cable box to the wall at a point convenient to the remote pull cable conduit.
7. Make sure that the control head cable is not forced to bend through a radius of less than
45mm (approximately 1 ¾”) along its length (Figure 9-10).
8. Slide the cable clamp into the inner cable, loop the inner cable end and feed back through
the clamp as illustrated in Figure 9-11.
NOTE: With ‘Safety and Reset’ pin screwed fully home make sure that there is approximately
3mm of slack cable between the cable clamp and the cable attachment nut inside the box.
Adjust if necessary.
Feed remote pull cable into the cable clamp and secure with the two locking screws.
Test for satisfactory operation with the pilot valve and cylinder assembly removed and adjust tension
of remote cable if necessary. Refit the box lid and gasket.
1. Attach the pull box using the single 7/16 (11.1mm) diameter fixing hole.
2. With front plate and glass removed, use a slotted screwdriver to remove the 7/16” Whitworth
grub screw from the centre of the pull handle.
3. Feed the 1/8” diameter bronze cable through the pull handle, steel conduit and pulley
assemblies, up to the cable clamp located inside the cable release box.
4. With the cable protruding inside the cable release box slacken the two cable-clamp locking-
screws and attach the bronze cable as shown for single release mechanism.
5. With approximately 76mm of cable protruding out through the pull handle, tie a single knot in
cable. Solder the knot completely.
6. Slide the cable into the handle recess, tighten and then cut-off excess cable.
7. Re-fit the 7/16” Whitworth grub screw to the pull handle.
8. With the pilot gas cylinder detached from the control head, remove the Safety and Reset pin,
pull the handle in the pull box and test the system for each operation.
9. Check that the control head operates.
10. Insert the Safety and Reset pin.
11. Refit the pilot cylinder.
12. When satisfied with the operation re-locate glass and front plate and tighten using the four
long 2½” long x 2BA round head screws.
13. Remove the Safety and Reset pin and hand it to a responsible person.
NOTE: All cable runs must be straight. Changes in direction must only be accomplished by
the use of pulleys; bends and dog legs must not be used.
After these checks have been carried out satisfactorily install as follows:
1. Remove the securing pin.
2. Slide the release head onto the cylinder valve and refit the securing pin, lightly tap fully home.
9.23.1 Assembly
1. Tubing must be cut off square and all burrs and swarf removed as loose particles could damage
any seals used elsewhere in the pipeline.
Where an inaccessible fitting would make the assembly of a sound joint difficult, it is recommended
that the sleeve is pre-assembled onto the tubing. This can be done by following the above procedure
but using a fitting of the correct size clamped in a vice. The tubing assembly can then be done and
released and transferred to the final union with the sleeve already correctly positioned.
WARNING: Do NOT use Loctite®, adhesive or tape on any part of this assembly.
1. Install the correct length pilot gas flexible loops as shown in Figure 9-12 for single row cylinders or
Figure 9-13 for double row cylinders.
2. Install a pilot gas vent in the last open port of the pressure/lever actuator.
NOTES: Do NOT use PTFE or any other pipe sealant. Do NOT over tighten fittings.
Figure 9-14 Pneumatic Time Delay Unit with the Lever/Manual Control Head
2) Install the pressure operated control head using a suitable wrench. Tighten securely. Connect
the actuation line to the pressure port using the appropriate adapter.
WARNING: Ensure that the pilot line is non-pressurized and the actuating pins are in the
retracted (SET) position. Failure to follow this procedure will cause the cylinder to discharge
accidentally when the control head is installed on the cylinder valve.
• The time delay may be installed in the discharge piping or the actuation line.
NOTE: The time delay period is preset at the factory; however the actual time delay period may
vary up to 100% depending on the ambient conditions and/or variations in installation.
NOTE: Valve should be locked in the ‘open’ position using a padlock. Installation must be
electrically supervised.
NOTE: The switches and the corresponding cams are preset by the valve assembly supplier to
the configurations indicated below; no adjustment to the cams is required. When the cam is
engaged with the switch, the switch contacts are closed, thus closing the normally open
contacts.
NOTE: The limit switch assembly consists of 2 single pole, double throw (SPDT) mechanical
switches, which are rated to 15 amps.
After the above checks have been satisfactorily carried out, install the pressure switch as follows:
1. A ¾” BSP screwed connection is required on the end of the manifold, attach a ¾” BSP galvanised
hexagon nipple.
2. Attach the pressure switch or, wall mount the switch, make up all pipework to suit the site location
of the pressure switch making sure that there is a ¾” BSP galvanised union in this line for each of
installation and/or removal of equipment.
3. To the ¾” BSP outlet connection on the pressure switch attach a ¾ BSP galvanised hexagon
nipple and one half of the union as mentioned in (2) above.
4. Connect the pressure switch to the pipework via the union and hand-tighten.
5. Mark the two pressure switch fixing holes on the wall or framework.
6. Loosen the union nut and remove the pressure switch.
7. Drill the two holes.
8. Reconnect the pressure switch to the pipework and tighten the union nut.
9. Fix the pressure switch to the wall or framework.
NOTE: Alternatively, the switch may be wall mounted by adapting the ¾ threads to 3/16” ENOT
and using bundy tube to connect.
CAUTION: The frame must be fixed and all floors and walls must capable of supporting overall
weight loadings.
The weight of the weight indicator mechanism is heavy and may operate at any time. It is
therefore recommended that the weight indicator mechanisms and the CO2 cylinders are
installed in unoccupied areas.
To install the weight indicator mechanism carry out the following procedure:
1. Assemble the mounting frame (supplied by others).
2. If the weight indicator mechanism is outside or in a damp environment, it is recommended
that the threads are sprayed with oil to keep them free of rust.
3. Using the mounting rod fit the body to the mounting frame using the M12 nut and washer.
4. Remove the terminal box cover, by undoing the four M4x16mm screws.
5. Connect the flexible conduit to each terminal box (Figure 9-19).
NOTE: Make sure that the flexible conduit, rated at IP65 minimum, passes underneath the
weight when it is in the down (operated) position and that it does obstruct the movement of
the weight.
NOTE: It is recommended to connect the microswitch in SERIES. This enables the wires to
monitor continuously.
Normally Closed
If the microswitch contacts are to be wired in the ‘Normally Closed’ (N/C) positions, i.e. in series,
carry out the following procedure:
1. Remove the BLUE wire from the terminal block, cut 10 mm from it and electrically insulate
the end with an insulating cap or tape.
2. Thread the two core cable through the flexible conduit and connect to the terminal box
(Figure 9-20). Use an insulated crimp pin connector for each wire.
3. Replace the terminal box cover.
4. On the end/last terminal box, the spare exit hole from the terminal box must be sealed or
blanked off to maintain IP 65 rating.
NOTE: A simpler ‘Series’ installation using a single wire is shown in Figure 9-21. However, the
wire will not be monitored continuously.
Normally Open
If the microswitch contacts are to be wired in the ‘Normally Open’ (N/O) positions, i.e. in parallel,
carry out the following procedure;
1. Remove the YELLOW wire from the terminal block, cut 10 mm from it and electrically
insulate the end with an insulating cap or tape.
2. Thread the two core cable through the flexible conduit and connect to the terminal box
(Figure 9-22). Where two wires are to be connected into same terminal outlet, use an
insulated blade terminal connector.
3. Replace the terminal box cover.
4. On the end/last terminal box, the spare exit hole from the terminal box must be sealed or
blanked off to maintain IP 65 rating.
6. Make sure that the protection cap is fitted and inspect the cylinder for external damage.
7. Weigh the cylinder for correct contents using a scale weighing device and record the weight.
WARNING: If the cylinders are to be moved in a skid assembly, they must be securely
wedged in position to prevent movement.
8. Transport the cylinder to its position at the mounting frame using a suitable trolley. Remove
the securing wedge from the cylinder.
9. Remove the protection cap from the cylinder and store in a safe place.
10. Screw the neck collar fully onto the cylinder ensuring that all threads are engaged. Make sure
that the cylinder valve outlet is in the correct position.
11. Connect the flexible discharge hose to the manifold and torque to between 30 and 40Nm.
12. Remove the anti-recoil cap from discharge outlet of the cylinder valve and store in a safe
place.
13. Connect the other end of the flexible discharge hose to the discharge outlet of the cylinder
valve and torque to between 30 and 40Nm.
14. Fit the two hanger rods through the holes in the body and the neck collar. Secure with an M10
nut and washer on each hanger rod.
15. Make sure that the M10 nuts are screwed evenly onto the hanger rods by the same amount.
16. Tighten the M12 nut, on the mounting rod, until the cylinder is 20mm from the floor or
mounting frame base.
NOTE: Make sure that the cylinder is hanging vertically. If not, carefully adjust the nuts on
the hanger rods until the cylinder is hanging vertically
17. Fit an M10 nut to the weight rod and wind halfway down. Fit an M10 washer to the weight rod,
followed by the weight, another M10 washer and finally an M10 nut. DO NOT TIGHTEN.
18. With the weight rod in the “full” (uppermost) position, slowly wind the nuts and weight up the
rod away from the body, until a position is reached where the weight rod will just begin to drop
from its stop.
19. From this set point, wind the inner nut towards the body by five turns. Hold this position and
lock the other nut against the weight. With the weight in the ‘full’ position, the indicator is now
set.
20. If required, carry out the testing procedure (Section 11.7).
21. Repeat steps 1 to 19 for each weight indicator mechanism and cylinder.
The user of this equipment should make sure they are aware of the following information;
These Weight Indicator Mechanisms may be installed in an area classified as Zone 2 or Zone 22 or
unclassified.
Weight Indicator Mechanisms are for use only as a contents indicator system for CO2 45kg
extinguishers.
The switched version is to be used with an intrinsically safe supply suitable for the hazard area.
9.29.1.7 Adjustment
After Installation adjustment of the Weight Indicator Mechanism is not required. For initial set up
follow instructions provided in installation chapter.
Specification
Environment: Industrial/Offshore/Marine
Material: Horn – Mild Steel
Nozzle – Brass
Filter – St. St. (N3-N5 only)
Finish: Horn – Black Paint & Nozzle – Natural
NOTE: Ensure that the frangible discs are not dented or damaged during installation.
The flanged horn may be fitted to ductwork by the addition of the appropriate adaptor.
Specification
Material: Body: Aluminium Nozzle: Brass Filter: St. St. (N3-N5 Only)
Finish: Body: Natural Nozzle: Natural
Weight: 0.9 kg approx.
NOTE: 4 - 5/16" Whitworth Hex Head screws c/w nuts and washers together with joint sealing
tape supplied with each adaptor.
Each unit contains 10cc of odorant which is sufficient to produce a positive and identifiable lemon
smell in a protected space. One odourising device will be sufficient for 1000 Kg/CO2 max.
NOTES:
This unit must be installed downstream in the advised positions (Figure 9-26).
If odouriser is removed, the opening is to be plugged off immediately.
Odouriser must NOT be installed in the inverted position as shown in diagram 4 below.
Specification
Label Material: 22 SWG Aluminium
10. COMMISSIONING
This chapter describes the commissioning procedure in terms of both visual and mechanical function
checks:
10.2.1 General
If the control head is connected to the pilot gas cylinder check as follows:-
1. Make sure that the ‘Safety and Reset’ pin is screwed fully home.
2. Unscrew the pilot gas cylinder from the control head.
3. Remove the ‘Safety and Reset’ pin.
4. Check the distance moved by the firing pin.
5. Energise the solenoid, if fitted, from the control panel. The solenoid operates the control head
thereby causing the control head firing pin to be moved downwards by a minimum distance of
3mm thus giving a total projection of 6mm. This insures that the solenoid and control head are
both operable and have functioned correctly.
6. After the test has been carried out satisfactorily reset the control head by screwing the ‘Safety and
Reset’ pin fully home and checking that the firing pin does not project more than 3mm.
1. Remove the ‘Safety and Reset’ pin from the control head.
2. Remove the front cover and glass from the pull box unit.
3. Pull the handle in the pull box unit and manually fire the control head.
4. When satisfied, reset the control head by screwing the ‘Safety and Reset’ pin fully home.
5. Reset the cable arrangement as described in Section 9.21.
6. Relocate the glass and front cover plate to pull box unit.
NOTE: If the POD valves are fitted with switches check that the indication has been given at
the control panel that the POD valve is open.
5. When satisfied with the manual operations of the POD valves reset and re-insert the Safety
Lock pins.
6. With the pressure/manual release heads still removed, depress the Push-to-Fire button on
the control head thereby releasing the pilot gas (nitrogen) into the pilot line causing the
pressure/manual release heads to operate.
NOTE: If POD valves are installed in the system check that these have been opened before
checking the pressure/lever actuator.
7. After the POD valves and/or pressure/lever actuator have functioned correctly re-set each
control head by screwing the ‘Safety and Reset’ pin fully home.
8. Push piston inside pressure/lever actuator back to set position.
9. Remove the pilot gas (nitrogen) test cylinder from the control head.
10. Visually check that the plunger assembly has returned to its normal position. When satisfied,
re-connect the pilot cylinder and the pressure/lever actuator to the container valves. Tighten
the running nut at the control head/pilot cylinder interface.
WARNING: Do NOT discharge CO2 while there are personnel present in the area. The engineer
carrying out the test MUST observe the safety regulations governing the use of CO2
4. If POD valves are installed in the main distribution line, remove the Safety Lock pins and
manually open.
5. Discharge the CO2 cylinder and check that the trip assemblies have all functioned correctly.
6. Re-insert the Safety Lock pin to the CO2 container.
7. Re-set the pressure trip assemblies.
8. Reconnect cylinders and replace discharged cylinder.
11. MAINTENANCE
This part of the manual describes procedures which enable a proficient Service Engineer to undertake
the regular inspection and testing of a Kidde Fire Protection CO2 System safely in accordance with
the recommendation of BS 5306 part 4.
Before going to site the Service Engineer should obtain the relevant details and drawings of the
systems to be serviced and refer to report of previous service visits and of fault call-outs since the last
service.
The Engineer’s signature on the Service Report and on the record card after carrying out the work is
confirmation that the system, on that day, is in complete operational order. It is an advantage to have
a witness to this fact, and the Engineer should therefore encourage the customer’s representative to
accompany then whilst the work is completed.
The first action to take, when arriving at site, is to report to the customer’s representative and to ask if
there are any specific instructions with which to comply.
• Ask if any particular problems have arisen since the last service visit.
• Ask if any fires have occurred and how the system performed.
• Record any false or accidental operation and get reasons.
• If it is necessary to take some action which may cause inconvenience to the Customer, ask their
permission first.
• Notify all concerned that the fire protection system is being maintained and may be inoperative.
• Work systematically and in a clean, tidy and professional manner.
• Consider the possibility of genuine fire alarm occurring whilst work in being conducted on the
system and make appropriate arrangements.
• Prepare a service report. Submit a copy to the Client, one to the Service Manager and retain a
copy.
3. Check if doors and windows are being propped open and would not be shut in the event of a
system operation. Report this to the Customer and note it on the report sheet.
4. Check that all manual controls are accessible, correctly identified and have not become obscured.
5. Check that the discharge nozzles are unobstructed and are adequately secured.
6. Check that all warning and instruction labels are clearly visible and legible. Check that all
necessary safety precautions and operational instructions are clearly stated.
7. Check that the paintwork is in good condition.
8. Check that containers are accessible and that the area is clean, dry and ventilated.
9. Check that pipes and fittings are adequately secured. All piping must be rigidly secured at the
nozzle to prevent damage from recoil.
10. Check that all system controls, such as valves, lock-off units, pull boxes, manually or electrically
operated devices are accessible to operating personnel. Any damage must be noted and rectified
after obtaining the customer’s official order number for the additional work. Rectification work
should be recorded on a report sheet separate from the service report sheet.
11.2.1 General
• Check that the manifold bracket fixings are secure.
• Check that the manifold check valve is in good condition and is tight.
• Check that the manifold-to-container discharge valve couplings are tight.
NOTE: The solenoid WILL be damaged if the control head is reset while in the activated mode.
6. After the test has been carried out satisfactorily, reset the control head by screwing the
‘Safety and Reset’ pin fully home and checking that the firing pin does not project by more
than 3mm.
11.2.2.4 Reinstatement
18. Refit the pilot gas cylinder to the control head.
NOTE: If the POD valves are fitted with indicator switched, check that the indication has been
given at the control panel that the POD valve is open.
4. When satisfied with the manual operation of the POD valves reset and re-inserts the Safety
Lock pins.
5. Connect a nitrogen pilot gas test cylinder to the control head and connect the pilot loop. With
the pressure/manual release heads still removed from the CO2 cylinder, operate the control
head thereby releasing the pilot gas (nitrogen) into the pilot causing the pressure/manual
release heads to operate.
NOTE: If POD valves are installed in the system, check that these have opened before
checking the pressure/manual release heads.
6. Check that there are no leaks in the pilot gas system and that the pilot vent bleed (K24051)
operates correctly. Sufficient pressure to operate the pressure/manual release heads, and
POD valves if fitted, should be maintained in the system for a MINIMUM OF 10 MINUTES.
7. After the POD valves and/or pressure/manual release heads have functioned correctly re-set
the control head by screwing the ‘Safety and Reset’ pin fully home.
8. Disconnect the pilot line from the pilot gas cylinder and remove the pilot gas cylinder from the
control head. The pilot gas line will now be vented.
9. Manually reset the piston and visually check the plunger in each pressure/manual release
head.
10. Reset the control head and replace the test pilot gas cylinder with the full pilot gas cylinder.
Tighten the running nut at the control head/pilot cylinder interface.
11. When satisfied, re-connect the pressure/manual release heads to the CO2 container
discharge valves.
WARNING: Do NOT discharge CO2 while there are personnel in the area. The engineer carrying
out the test MUST observe the safety regulations governing the use of CO2
4. If POD valves are installed in the main distribution line, remove the Safety Lock pins and
manually open.
5. Discharge a CO2 cylinder or portable CO2 extinguisher and check that the trip assemblies
have all functioned correctly.
6. Re-set the POD valve and re-insert the Safety Lock pin to the CO2 container.
7. Re-set the pressure trip assemblies.
NOTE: The switch may be pressure tested by connecting a CO2 container onto the distribution
pipework.
If the user wishes to confirm that the weight indicator mechanism is functioning correctly, a test
kit can be built (Figure 11-1).
NOTE: The test weight, 3.2kg to 4.5kg, represents a weight loss of CO2 of 7% to 10%
4. When the weight indicator mechanism is set correctly, the mechanism will trip.
Weighing procedure:
1. Remove the cylinders from the wall brackets and connecting pipes or flexible hoses. Fit anti-
recoil caps to outlet ports.
2. Ensure the cylinders are adequately supported.
3. Transfer cylinders to weighing station.
4. Place cylinder to be weighed directly adjacent to yoke assembly.
5. Slide yoke under valve.
6. On spring balance set dial to zero by means of adjusting screw.
7. To weigh the cylinder, pull handle downwards to raise the cylinder until the weighing beam is in a
horizontal position.
8. Read off the scale and record weight.
9. For establishing the actual gross weight of the cylinder, multiply the recorded weight by 12 (e.g.
weight of 10kg the gross weight 10 x 12 = 120kg).
12. APPENDICES
K24628 3/4" Pressure Operated Direction Valve with Indicator Switch 11m 8m 11m
K24629 1" Pressure Operated Direction Valve with Indicator Switch 11m 8m 11m
K24630 1 1/4" Pressure Operated Direction Valve with Indicator Switch 11.9m 10.4m 11.9m
K24631 1 1/2" Pressure Operated Direction Valve with Indicator Switch 11.9m 10.4 11.9m
K24632 2" Pressure Operated Direction Valve with Indicator Switch 15.6m 13.4m 15.6m
K24775 3" Pressure Operated Direction Valve with Indicator Switch 39m 29.9 39m
K24777 4" Pressure Operated Direction Valve with Indicator Switch 75.6m 54.9m 75.6m
Appendix 1 –CO2 Component List: Those components included in the FM Approved System
Indicated.