Co2 Operation & Installation PDF

Issue B December 2004 Manual No 59812-400
High Pressure
Carbon Dioxide
Fire Protection Equipment
INSTALLATION,
COMMISSIONING &
MAINTENANCE MANUAL
K.F.P.S. Ltd December 2004 Manual No 59812-400
ii
PROPRIETARY RIGHTS NOTICE
This document and the information that it contains are the property of Kidde Fire Protection. Rights to
duplicate or otherwise copy this document and rights to disclose the document and the information
that it contains to others and the right to use the information contained therein may be acquired only
by written permission signed by a duly authorised officer of Kidde Fire Protection.
Copyright Kidde Fire Protection Services Ltd.
iii
TABLE OF CONTENTS
Chapter Page
FOREWORD.........................................................................................................1
1 GENERAL....................................................................................................2
1.1 SAFETY PRECAUTIONS ....................................................................2
1.2 PRELIMINARY CHECKS.....................................................................3
PART 1 INSTALLATION......................................................................................4
2 CO
2
CYLINDERS AND RACKING...............................................................4
2.1 CO
2
CYLINDERS.................................................................................4
2.1.1 Klem Cylinder Valves K23521 and K24509.............................5
2.2 INSTALLATION....................................................................................6
2.2.1 Single Cylinder ........................................................................6
2.2.2 Single Row Cylinders ..............................................................7
2.2.3 Double Row Cylinders.............................................................8
3. CO
2
MANIFOLD PIPE................................................................................10
3.1 MANIFOLD BRACKETS, SINGLE ROW...........................................11
3.2 MANIFOLD BRACKETS, DOUBLE ROW..........................................11
4. DISTRIBUTION PIPING.............................................................................12
4.1. PIPING...............................................................................................12
4.2 ELECTRICAL CLEARANCES............................................................15
4.3 INSTALLATION..................................................................................16
5. PRESSURE OPERATED DIRECTION VALVES.......................................17
5.1 TO 2 INCH POD VALVES..............................................................18
5.1.1 Pressure Operation ...............................................................19
5.1.2 Manual Operation..................................................................19
5.1.3 Valve Open Indication ...........................................................19
5.2 3 AND 4 INCH POD VALVES............................................................20
5.2.1 Pressure Operation ...............................................................21
5.2.2 Manual operation...................................................................21
5.2.3 Valve Open Indication ...........................................................21
5.3 3 AND 4 INCH COMPANION FLANGE, BOLTS AND GASKET........22
5.4 SAFETY OUTLETS K 921 AND K22968 ..........................................23
5.5 INSTALLATION..................................................................................26
iv
6. DISCHARGE LOOPS K21578 AND K97112.............................................27
6.2. RIGID DISCHARGE LOOP K21578...................................................27
6.2 FLEXIBLE DISCHARGE LOOP K97112............................................28
6.3 INSTALLATION..................................................................................29
7. SYSTEM ACTUATOR ASSEMBLY...........................................................30
7.1 NITROGEN PILOT GAS CYLINDER AND VALVE............................31
7.2 OPTIONAL PRESSURE MONITORING SWITCH.............................32
7.3 CONTROL HEAD K62303 .................................................................33
7.4 CONTROL HEAD WITH SWITCHES K62304 ...................................34
7.5 CONTROL HEAD MOUNTING BRACKET K62487...........................35
7.6 SAFETY AND RESET PIN K62401 ...................................................36
Retain reset pin in safe location for future use. ..................................36
7.7 INSTALLATION..................................................................................37
8. CONTROL HEAD ACTUATING DEVICES................................................39
8.1 MANUAL PUSH-TO-FIRE BUTTON K62412.....................................40
8.2 SOLENOID ACTUATORS K62422B AND K93206/AX ......................41
8.3 FLAMEPROOF 24V D.C SOLENOID K93206/AX .............................42
8.4 INSTALLATION..................................................................................43
8.4.1 Standard Solenoid.................................................................43
8.4.2 Flameproof Solenoid .............................................................44
8.4.3 Control Head and Solenoid Wiring ........................................45
8.4.4 Special Instructions to comply with 94/9/EC (ATEX) .............46
8.5 PNEUMATIC DIAPHRAGM ACTUATOR K62459 .............................47
8.6 PNEUMATIC BREATHER VENTS K62895 .......................................48
8.7 INSTALLATION..................................................................................49
8.8 CABLE RELEASE ASSEMBLY K62478 ............................................49
8.8.1 Installation.................................................................................50
8.9 PULL BOX K 1114 .............................................................................52
8.9.1 Corner Pulley K 1122 ................................................................53
8.9.2 Installation .............................................................................53
9. CYLINDER VALVE PRESSURE/LEVER ACTUATOR K62341 ................55
9.1 INSTALLATION..................................................................................56
10. PILOT GAS FLEXIBLE LOOPS K93433 and K93434..............................57
10.1 PILOT GAS VENT K24051 ................................................................57
10.2 PILOT GAS RIGID TUBING AND FITTINGS.....................................59
10.3 INSTALLATION..................................................................................61
11. TIME DELAY UNIT K23650.......................................................................62
v
11.1 INSTALLATION..................................................................................63
11.2 TESTING............................................................................................63
11.3 TIME DELAY BY-PASS VALVE K60736 ...........................................67
12. CO
2
OPERATED PRESSURE SWITCH K60218.......................................69
12.1 INSTALLATION..................................................................................71
13. CO
2
OPERATED PRESSURE TRIP K17554.............................................72
13.1 INSTALLATION..................................................................................73
14. CO
2
DISCHARGE NOZZLES.....................................................................74
14.1 MULTIJET NOZZLE K61792 AND K61793........................................74
14.2 FLANGED MULTIJET NOZZLE K5814..............................................75
14.3 FLANGED NOZZLE DUCT ADAPTORS K61420A-D........................76
14.4 DUCT NOZZLE K13045.....................................................................77
14.5 FAN TYPE NOZZLE K6490 ...............................................................78
15. PNEUMATIC DETECTION - HEAT ACTUATED DEVICES ......................79
15.1 PNEUMATIC RATE OF RISE DETECTOR K18724 ..........................79
15.2 PNEUMATIC FIXED TEMPERATURE DETECTOR K18689.............80
15.3 PNEUMATIC CHECK UNIT K24412..................................................81
15.4 PNEUMATIC LOCK-OFF UNIT K24300 ............................................82
15.5 BELLOWS AND MICROSWITCH ASSY K20057 ..............................83
15.6 PNEUMATIC CAPILLARY TUBE, CONDUIT AND FITTINGS...........84
15.7 CO
2
OPERATED SIREN K18307.......................................................85
16. ODORISER ASSEMBLY K62586..............................................................86
17. CO
2
WARNING LABELS ...........................................................................87
PART 2 COMMISSIONING ................................................................................89
18. COMMISSIONING......................................................................................89
18.1 VISUAL CHECKS ..............................................................................89
18.2 MECHANICAL FUNCTION................................................................90
18.2.1 General..................................................................................90
18.2.2 Manual Push-to Fire ..............................................................90
18.2.3 Pull Box .................................................................................90
18.2.4 Pneumatic System.................................................................91
18.2.5 Pressure/Lever Actuator and POD Valves ............................96
18.2.6 Pressure Trip.........................................................................96
18.2.7 Pressure Switch.....................................................................97
PART 3 MAINTENANCE....................................................................................98
19. MAINTENANCE.........................................................................................98
19.1 PRELIMINARY CHECKS...................................................................98
vi
19.2 COMPONENT FUNCTION TESTS....................................................99
19.2.1 General..................................................................................99
19.2.2 Control Head .........................................................................99
19.2.3 Pressure/Manual Release Heads and POD Valves.............100
19.2.4 Pressure Trip.......................................................................101
19.2.5 Pressure Switch...................................................................102
19.3 INSTRUCTIONS FOR COMMISSIONING THE SYSTEM AFTER ITS
OPERATION....................................................................................102
PART 4 TERMS AND CONDITIONS................................................................103
20. TERMS AND CONDITIONS.....................................................................103
vii
LIST OF ILLUSTRATIONS
Figure Page
Figure 1 CO
2
Cylinder ................................................................................................4
Figure 2 Klem Cylinder Valves ...................................................................................5
Figure 3 Single Cylinder Racking ...............................................................................6
Figure 4 Single Row Cylinders ...................................................................................7
Figure 5 Additional Centre Racks for Two Rows of Cylinders ....................................9
Figure 6 CO
2
Manifold Pipes ....................................................................................10
Figure 7 Manifold Brackets, Single Row...................................................................11
Figure 8 Manifold Brackets, Double Row .................................................................11
Figure 9 POD Valve System.....................................................................................17
Figure 10 to 2 inch POD Valves ...........................................................................18
Figure 11 Indicator Switch........................................................................................19
Figure 12 3 & 4 inch POD Valves.............................................................................20
Figure 13. 3 and 4 inch Companion Flange, Bolts and Gasket ................................22
Figure 14 Safety Outlets ..........................................................................................23
Figure 15 All CO
2
Cylinders discharging to either space ..........................................24
Figure 16 Two Spaces Requiring differing CO
2
cylinders .........................................25
Figure 17 Rigid Discharge Loop...............................................................................27
Figure 18 Flexible Discharge Loops.........................................................................28
Figure 19 System Actuator Assembly ......................................................................30
Figure 20 Nitrogen Pilot Gas Cylinder and Valves ...................................................31
Figure 21 Pressure Monitoring Switch......................................................................32
Figure 22 Control Head............................................................................................33
Figure 23 Control Head with Switches .....................................................................34
Figure 24 Standard Mounting Bracket ......................................................................35
Figure 25 Safety and Reset Pin................................................................................36
Figure 26 Control Head Mounting Bracket ...............................................................38
Figure 27 Control Head Actuating Devices...............................................................39
Figure 28 Manual Push-to-Fire Button .....................................................................40
Figure 29 Standard 24V d.c Solenoid.......................................................................41
Figure 30 Flameproof ATEX approved 24V d.c. Solenoid........................................42
Figure 31 Control Head and Solenoid Wiring ...........................................................45
Figure 32 Pneumatic Diaphragm Actuator ...............................................................47
Figure 33 Pneumatic Breather Vents .......................................................................48
Figure 34 Cable Release Assy.................................................................................49
viii
Figure 35 Cable Pull Ring Connection .....................................................................50
Figure 36 Curvature of Cable ...................................................................................51
Figure 37 Cable Release Assembly, Cover Removed .............................................51
Figure 38 Pull Box....................................................................................................52
Figure 39 Corner Pulley ...........................................................................................53
Figure 40 Cylinder Valve Pressure/Lever Actuator...................................................55
Figure 41 Pilot Gas Flexible Loops...........................................................................57
Figure 42 Pilot Gas Vent ..........................................................................................58
Figure 43 Pilot Gas Rigid Tubing and Fittings ..........................................................59
Figure 44 Single Cylinder Row Pilot Gas Operation.................................................61
Figure 45 Double Cylinder Row Pilot Gas Operation ...............................................61
Figure 46 Time Delay Unit........................................................................................62
Figure 47 Single Protected Space System...............................................................64
Figure 48 Two Protected Spaces System................................................................65
Figure 49 Two Protected Spaces Requiring Different CO
2
Quantities......................66
Figure 50 Time Delay By-Pass Valve.......................................................................67
Figure 51 Installation................................................................................................68
Figure 52 CO
2
Operated Pressure Switch................................................................69
Figure 53 Pressure Trip............................................................................................72
Figure 54 Installation................................................................................................73
Figure 55 Multijet Nozzle..........................................................................................74
Figure 56 Flanged Multijet Nozzle............................................................................75
Figure 57 Flanged Nozzle Duct Adaptor ..................................................................76
Figure 58 Duct Nozzle..............................................................................................77
Figure 59 Fan Type Nozzle ......................................................................................78
Figure 60 Pneumatic Rate of Rise Detector .............................................................79
Figure 61 Pneumatic Fixed Temperature Detector...................................................80
Figure 62 Pneumatic Check Unit..............................................................................81
Figure 63 Pneumatic Lock-Off Unit ..........................................................................82
Figure 64 Bellows and Microswitch Assembly..........................................................83
Figure 65 Pneumatic Capillary Tube, Conduit and Fittings ......................................84
Figure 66 CO
2
Operated Siren..................................................................................85
Figure 67 Odoriser Assembly...................................................................................86
Figure 68 Odoriser Check Valve ..............................................................................86
Figure 69 Entrance Door Warning Label ..................................................................87
Figure 70 Manual Control Point Label ......................................................................88
Figure 71 Manometer Test System..........................................................................91
ix
LIST OF TABLES
Table Page
Table 1 CO
2
Cylinder Specification............................................................................4
Table 2 Closed and open ended pipework section High pressure systems..........12
Table 3a Open Ended Pipework................................................................................13
Table 3b Closed Section Pipework 13
Table 4 Pipe Support Spacing.................................................................................14
Table 5 Safety Clearances for Pipework .................................................................15
K.F.P.S. Ltd November 2004 Manual No 59812-400
1
FOREWORD
Kidde Fire Protection recognises its responsibility to ensure that the products it manufactures are, as far
as is reasonably practical, without risk to the health and safety of the users. The following information
should be disseminated to all persons using such products.
The information is furnished in good faith based upon technical data and tests, which are believed to be
reliable. Products undergo rigorous quality control checks during manufacture to ensure that they
present no hazards in the use and application for which they are intended.
Technical data and literature which may assist customers in the discharge of their general duties are
available on request. Should you require further information on this context please contact our sales
office.
Nothing contained in this publication shall form part of any contract made between a customer and
Kidde Fire Protection.
It is of vital importance that the CO
2
equipment should be correctly installed. The Installation Engineer
should become fully conversant with the contract files and all installation drawings before going to site.
2
1 GENERAL
1.1 Safety Precautions
Characteristics of Carbon Dioxide
Carbon Dioxide (CO
2
)

at atmospheric pressure is a colourless, odourless and electrically non-conducting
inert gas which is almost 1.5 times as dense as air.
CO
2
extinguishes fire by reducing the oxygen content of the atmosphere to a point where it will not support
combustion. Reducing the oxygen content from the normal 21% in air to 15% will extinguish most surface
fires, though for some materials a greater reduction is necessary. In some applications the cooling effect of
CO
2
may assist extinction.
Hazards to personnel
Exposure to atmospheres containing about 5% CO
2
leads to shortness of breath and slight headache. At
the 10% level, headache, visual disturbance, ringing in the ears (tinnitus) and tremor are followed by loss of
consciousness.
Fire extinguishing concentrations of CO
2
, which are normally in excess of 30%, especially near to the point
of discharge from total flooding or local application systems, carry a risk of almost immediate asphyxiation.
The gas is also more dense than air and will drift and accumulate in low spaces, such as cellars, pits and
floor voids, which may be difficult to ventilate effectively.
The rapid expansion of large quantities of CO
2
results in a substantial localised cooling of the installation
and of the air surrounding the point of discharge. This can present a frostburn hazard.
Handling and storage of CO
2
cylinders
Observe the following precautions to prevent accidental discharge of CO
2
:
On despatch, all cylinder and valve assemblies are fitted with transport caps which must not be removed
until after the cylinders have been securely restrained, store the transport caps for future use.
Never use the cylinder valve to turn or move the cylinder, this could cause damage or leakage: use a
transport trolley.
Never store cylinders in direct sunlight or in location where the cylinder temperature is likely to exceed
55C.
3
Never depress the cylinder valve actuating pin as this action will open the valve and discharge its contents
causing the cylinder, unless securely restrained, to act as a projectile.
Never fit any release device to a cylinder valve until it has been secured in the cylinder rack and connected
to the discharge pipework.
Re-entry into a flooded area
Never enter an area after a CO
2
discharge until it has been thoroughly ventilated to external atmosphere.
If it is necessary to enter an area containing CO
2
always use self-contained Breathing Apparatus, never use
a filter or canister type mask. As an added precaution the person entering should be tethered by a manned
lifeline.
Dismantling and modifications
It is recommended that Kidde Fire Protection be notified of any intention to alter or extend the system or
areas protected in order that advice be given of any effect that this may have on the original design.
1.2 Preliminary checks
Check that all equipment has been delivered, any damaged equipment must be replace.
Check that the area(s) to be protected agree with the installation drawings.
Check the CO
2
cylinder location for ease of access during maintenance; also safety. Check that the
ambient temperature of the cylinder location complies with the following limitations: -
Total flooding systems: -18 to 55C.
Local Application flooding Systems: Minimum 0C Maximum 46C.
4
PART 1 INSTALLATION
2 CO
2
CYLINDERS AND RACKING
2.1 CO
2
Cylinders
CO
2
is stored in solid drawn steel cylinders containing gas in liquid form equal to two thirds of its water
capacity. The pressure within the cylinder varies with changes in ambient temperature, increasing with
rising temperature. At 21C the pressure is 58.6 bar.
The cylinder assembly comprises a cylinder, cylinder valve and rigid syphon tube which must ALWAYS be
installed in an upright position.
Figure 1 CO
2
Cylinder
Table 1 CO
2
Cylinder Specification
Part No Water
Capacity
(Litres)
Fill Weight
(kg)
Total Weight
(kg)
Dimension (mm)
A B
E7194-001 67.5 45 120 Approx 267 1515
K24069/FM 67.5 45 120 Approx 267 1531
K24338 34.0 22.6 81 Approx 229 1102
NOTE: All dimensions B are 10mm
Cylinder Specification: 1999/36/EC (TPED)
Material: Steel
Test Pressure: 250 bar
Fill Ratio: 0.661kg/litre
Standard Point Finish: Red
5
2.1.1 Klem Cylinder Valves K23521 and K24509
The Klem cylinder valve is a compact, horizontal servo-assisted valve which can be operated by either
pressure or use of its integral manual lever.
The valve is opened by depressing the actuator rod by applying a force of between 23 and 27kg.
WARNING
The valve will close immediately the force is removed from the actuator rod.
Each cylinder valve incorporates a safety disc designed to rupture and discharge the CO
2
cylinder contents
when the ambient temperature reaches approximately 60C (140F).
Materials
Body: Brass
Seals: Silicone Rubber Shore 70
-
90
Actuator Rod: St. Steel
Safety Burst Disc: Ruptures at 179 to 196 bar
Figure 2 Klem Cylinder Valves
6
2.2 INSTALLATION
2.2.1 Single Cylinder
Storage containers should be located as near as possible to the hazard they protect, but should not 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.
1. Offer strap up to a suitable structure or wall and mark the hole centres for drilling at an elevation from
ground level, see in Figure 3.
2. Drill appropriate fixing holes.
3. Place and clamp the container in position.
Part No Cyl Size Dim A Fixing
Holes
Materials Weight
(kg)
K16896 6.8 175 9.5mm
1.0
K4881 22.6 292 10.5mm
Mild Steel 25mm x 3mm

1.2
K62943 45.0 320 12.7mm
Nylon Dipped Black 1.5

Figure 3 Single Cylinder Racking
7
2.2.2 Single Row Cylinders
1. Offer the cylinder back rack up to a suitable structure or wall and mark the hole centres for drilling at
an elevation from the ground as shown in Figure 3. Check that the back rack is correctly offset in
relation to the manifold inlet. See Figure 4.
3. Fix the back rack to the suitable structure or wall using the bolts.
4. Place the cylinders in position against the cut-outs in the back rack.
5. Hook the rack bolts through the 17.5mm diameter hole(s) in the back rack.
6. Locate the straight end of the rack bolts through the 17.5mm diameter holes in the front strap and
clamp the containers firmly in place using the nuts and washers supplied with the rack bolts.
Part No Material Finish Weight
(kg)
2 Cylinder K17238 MS Angle Paint Black 1.8 Steel Back
Racks 3 Cylinder K17235 MS Angle Paint Black 2.7
2 Cylinder K13744 MS Strap 2.7 Steel Front
Straps 3 Cylinder K13745 MS Strap
Nylon Dipped
Black 4.5
Single Row Rack Bolt
Assembly
K62752 MS Rod Paint Black 0.4
Figure 4 Single Row Cylinders
8
2.2.3 Double Row Cylinders
1. Offer the cylinder back rack up to the wall and mark the hole centres for drilling at an elevation from
the ground as shown in Figure 5. Check that the back rack is correctly offset in relation to the
manifold inlet. See Figure 5.
3. Fix the back rack a suitable structure or wall using the bolts.
4. Place the cylinders in position against the cut-outs in the back rack.
5. Slide the rack bolt through the wood centre rack and hook onto the back rack.
6. Place the front row of cylinders into position.
7. Place the front straps in position and clamp the cylinders firmly in position using the nuts and
washers supplied.
9
45kg Cylinders
Part No Weight (kg)
2 Cylinder K24334 1.4 Cylinder Centre
Racks 3 Cylinder K24335 2.0
Two Row Rack Bolt K62753 1.1
Two Rack Special Rack Bolt K17327 0.7
22.6kg Cylinders
Part No Weight (kg)
2 Cylinder K22654 1.1 Cylinder Centre
Racks 3 Cylinder K22655 1.8
Two Row Rack Bolt K17245 1.0
Two Rack Special Rack Bolt K17327 0.7
Figure 5 Additional Centre Racks for Two Rows of Cylinders
10
3. CO
2
MANIFOLD PIPE
On multiple cylinder systems manifold pipes are supplied as a complete assembly including factory
installed check valves.
1 (25mm) NB Manifold 1 (32mm) NB Manifold
Assembly
Part No.
Number of
Cylinders
Weight
(kg)
Assembly
Part No.
Number of
Cylinders
Weight
(kg)
K21207 2 2.7 K21215 2 3
K21209 3 3.9 K21217 3 4.5
K21211 4 5.0 K21219 4 5.9
K21213 5 6.3 K21221 5 7.3
Figure 6 CO
2
Manifold Pipes
11
3.1 MANIFOLD BRACKETS, SINGLE ROW
Dimension (mm) Part No Pipe Size
A B
Material - Finish Weight (kg)
K24267D 1 Mild Steel
K24267E 1
101.6 174.5
Painted Black
2.0
Figure 7 Manifold Brackets, Single Row
3.2 MANIFOLD BRACKETS, DOUBLE ROW
Dimension (mm) Part No Pipe Size
A B
Material - Finish Weight (kg)
K24268D 1 Mild Steel
K24268E 1
101.6 479.4
Painted Black
2.5
NOTE: Pipe Clips and Pipe Clip Bolts are supplied with the Brackets.
Figure 8 Manifold Brackets, Double Row
12
4. DISTRIBUTION PIPING
All the pipework sizes shown in the schematic of the installation have been determined using a computer
programme. It is IMPORTANT that these sizes are used to ensure the correct flow of CO
2
within the stated
discharge time.
4.1. PIPING
1. The pipe and fittings materials must conform with the-requirements of BS 5306 Part 4 as shown in
the following tables.
Table 2 Closed and open ended pipework section High pressure systems
Closed section of pipework
Nominal pipe size Type of fitting Grade or Material Conforms to
WPA or WPB BS 3799:1974 Forged steel, screwed,
3000 lb
ASTM A105N ANSI B16.11:1996
Up to and including 40mm
Wrought steel, butt
welded
WPA or WPB BS 1640-3:1968
WPA or WPB BS 3799:1974 Above 40mm up to 50mm Forged steel, socket
welded, 3,000 lb
Open section of pipework
Nominal pipe size Type of fitting Grade or Material Conforms to
Up to and including 20mm Screwed fittings Malleable iron BS EN
10242:1995
a
Screwed fittings Wrought steel BS EN 10241:2000 Up to and including 40mm
Wrought steel, butt
welded
WPA or WPB BS 1640-3:1968
WPA or WPB BS 3799:1974 Forged steel, screwed,
3000 lb
WPA or WPB BS 3799:1974
All sizes up to 150mm
Forged steel, socket
welded, 3,000 lb
a
Fittings conforming to BS EN 10242 may be used on open section pipework greater than 20 mm provided that they are
suitable certified by the manufacturer for the anticipated pressure
13
Table 3a Open Ended Pipework
BS1387 BW - Heavy
BS 3601 S 430
BS 3601 ERW 430
BS 3601 BW 320 or 430
BS 3602-1 HFS or CFS 360 or 430
API 5L S or ERW B
Up to & incl 40mm
ASTM A106-77 HF or CD A or B
Schedule 40
BS 3601 S 430
BS 3601 ERW 430
BS 3602-1 HFS or CFS 360 or 430
ASTM A106-77 HF or CD A or B
Over 40mm up to & incl
50mm
API 5L S or ERW B
Schedule 80
* 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
COMMENTARY AND RECOMMENDATIONS ON 19.4: The recommendation of the gasket manufacturer should be followed in
selecting the grade, specification and thickness to be used.
Table 3b Closed Section Pipework
High pressure carbon dioxide systems
Nominal pipe size Conforms to Type of Pipe
a
Grade of steel Minimum wall thickness
b
BS 3601 S 430
BS 3602-1 HFS or CFS 430
ASTM A106-77 HF or CD B
Up to and including
40mm
API 5L S or ERW B
Schedule 40 (schedule
80 for joints)
BS 3602-1 HFS or CFS 430
ASTM A106-77 HF or CD B
50mm and above
API 5L S or ERW B
Schedule 80
a
For abbreviations see footnote to Table 3 on previous page
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.
14
NOTE: Crosses must not be used.
2. All pipe and fittings shall be galvanised inside and out.
3. Screwed threads shall comply with the dimensions specified in BS21.
4. Use PTFE pipe tape on all pipe screw threads (or other approved thread sealant).
5. The pipework MUST BE FIRMLY SUPPORTED because, in the event of a fire, the discharge will
impose a force on the pipework. If the piping became dislodged, considerable damage could be
caused and the extinguishing system may not function correctly. Allowance must be made for
expansion and contraction of the pipework. See Table 4 for the minimum recommended pipe support
spacing.
Table 4 Pipe Support Spacing
Pipe Size (mm) 15 20 25 32 40 50 80 100 150
Max Spacing (m) 1.5 1.8 2.1 2.4 2.7 3.4 3.7 4.3 5.2
15
4.2 ELECTRICAL CLEARANCES
Where exposed electrical conductors are present, clearance no smaller than those given in Table 5 shall
be provided where practicable, between the electrical conductors and all parts of the CO
2
system that may
be approached during maintenance, where these clearance distances cannot be achieved, warning notices
shall be provided and a safe system of maintenance work shall be adopted.
Minimum clearance from any point on or about the permanent equipment where a man may be required to
stand (measured from position of the feet)
Table 5 Safety Clearances for Pipework
To the nearest
unscreened live
conductor in air
(section clearance)
Metres 2.59 2.59 2.74 2.74 2.89 3.05 3.20 3.35 3.50 3.81 4.27 4.57
To the nearest part
not at earth potential
of an insulator
supporting a live
conductor ('ground
clearance')
Metres 2.44
Max rated Voltage
(XY) 11 15 22 33 44 66 88 110 132 165 220 275
The term insulator includes all forms of insulating supports, such as pedestal and suspension insulators,
bushings, cable sealing ends and the insulating supports of certain types of circuit breaker etc.
IMPORTANT: See qualifying notes of clause 34 and definitions 30 and 31 of BS 7354: 1990 from
which this table is taken.
16
4.3 INSTALLATION
Piping is normally supplied to site in random lengths. Installation of this pipework must be carried out in
accordance with the site fabrication drawings.
Table 5 shows recommended clearances to enable operation, maintenance and repair work to be carried
out safely.
NOTE: All dirt, swarf and cutting oil must be removed from each section of pipe before
installation. CO
2
pressure will remove any debris and may deposit it on valuable
equipment.
Before installation of any pipework check the following:
(a) That all screw threads are clean and free of any damage.
(b) That all flange faces are clean and free of any damage.
(c) That pipe bores are clean and unobstructed.
(d) The route of the piping. Make sure that it is possible to fix the piping securely on the wall and in the
ceiling and floor voids.
(e) That none of the pipe fittings have been used before because of the risk of distortion.
NOTE: Use PTFE pipe tape on all pipe screw threads. (Or other approved thread sealant).
To install the pipework, carry out the following procedure:
(a) Mark the positions of the supports and hangers.
(b) Drill the wall or ceiling and install the required quantity of rawbolts or anchor bolts to suit the type of
support being used.
(C) Install a pipe hangar or clip adjacent to each nozzle in order to prevent movement of the nozzles
during discharge.
(d) All CO
2
pipework should be painted signal red to BS 381C ref 537 (equivalent to BS 4800 Ref
04E53)
(e) All exposed metalwork in CO
2
systems shall be efficiently earthed to prevent the metal work
becoming electrically charged.
17
5. PRESSURE OPERATED DIRECTION VALVES
When two or more areas are to be protected using a central bank of CO
2
cylinders, a Pressure Operated
Direction (POD) valve is installed in each of the CO
2
main feed pipes leading to the designated areas, see
Figure 9.
Figure 9 POD Valve System
18
5.1 to 2 INCH POD VALVES
Part
Number
Size
(inch)
With
Switch
Dimension mm
A
Dimension mm
B
Weight
(kg)
K24004 NO 171 117 3.4
K24628 YES 216 117 3.5
K24005 1 NO 171 100 3.2
K24629 1 YES 216 100 3.3
K24175 1 NO 210 156 5.7
K24630 1 YES 255 156 5.8
K24176 1 NO 210 137 5.4
K24631 1 YES 255 137 5.5
K24177 2 NO 295 191 17.0
K24632 2 YES 340 191 17.1
Figure 10 to 2 inch POD Valves
19
5.1.1 Pressure Operation
Application of Nitrogen pilot gas to the pilot gas inlet port depresses the valve piston. When the valve piston
is at the bottom of its stroke a pilot gas outlet port is uncovered thus allowing the pilot gas to be conveyed,
by the pilot gas line, to the CO
2
cylinder pressure release heads.
NOTE: The valve remains open until the pilot gas pressure is vented from the pilot gas line.
5.1.2 Manual Operation
Remove the safety pin and operate lever fully.
NOTE: The valve can be opened while subjected to CO
2
pressure.
5.1.3 Valve Open Indication
The indicator switch provides means for operating audible/visual alarms to give warning of a partial or fully
open valve.
Figure 11 Indicator Switch
20
5.2 3 and 4 INCH POD VALVES
Dimension (mm) Part
Number
Size
inch
With
Switch
A B C
Flange
Fixing Holes
Weight
(kg)
K24775 3 YES 330 292 203
8-EQUI spaced
21mm Dia On
165mm PCD
43.3
K24777 4 YES 406 340 241
8-EQUI spaced
25 mm Dia On
197mm PCD
69.5
Figure 12 3 & 4 inch POD Valves
21
5.2.1 Pressure Operation
Application of Nitrogen pilot gas to the pilot gas inlet port lifts the valve piston. When the valve piston is at
the top of its inlet stroke an outlet port is uncovered thus allowing the pilot gas to be conveyed, by the pilot
gas line, to the CO
2
cylinder pressure release heads.
NOTE: The valve remains open until the pilot line is depressurised.
5.2.2 Manual operation
Turn the hand wheel fully anti-clockwise to open the valve.
NOTE: The valve can be opened while subjected to CO
2
pressure.
5.2.3 Valve Open Indication
The indicator switch provides means for operating audible/visual alarms to give warning of a partial of fully
open valve, see Figure 11.
22
5.3 3 and 4 INCH COMPANION FLANGE, BOLTS AND GASKET
Dimension (mm) Part
Number
Size
inch
A B C
Bolt Part
Number
Weight
K60103 3 203 165 32 K60101 7 kg
K60104 4 241 197 35 K60102 8.5 kg
NOTE: Use Gasket K60105 (3) or K60106 (4)
Figure 13. 3 and 4 inch Companion Flange, Bolts and Gasket
23
5.4 SAFETY OUTLETS K 921 and K22968
On systems employing normally closed directional/stop valves there is a possibility of CO
2
entrapment in
pipework between the CO
2
cylinders and the valves therefore a safety outlet must always be fitted. The
indicator sleeve is blown-off when the disc ruptures giving a visual indication of operation.
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
PIPED TO AN AREA WHERE IT WILL NOT BECOME A HAZARD TO PERSONNEL (AS PER THE
REQUIREMENTS OF BS 5306 part 4).
K 921 K22968
Figure 14 Safety Outlets
K 921 Specification: K22968 Specification:
Burst/Opening Pressure: 150 bar 5% 126 bar
Material: Brass Brass
Finish: Natural Natural
Weight: 0.35 kg 0.8 kg
Figures 15 and 16 show the Nitrogen pilot gas installation requirements for opening the pressure operated
direction valve prior to operation of the CO
2
cylinders.
24
Figure 15 All CO
2
Cylinders discharging to either space
25
Figure 16 Two Spaces Requiring differing CO
2
cylinders
26
5.5 INSTALLATION
Before installation of POD valves check the following:
1. All screw threads are clean and free of any damage.
2. If using a flanged valve check that all flanges are clean and free of damage.
3. That all flange bolt holes on the valve align with the flange bolt holes on feed pipe.
4. With the Safety Lock pin removed check that the indicator switch clicks into operation.
After the checks have been carried out satisfactorily install the POD valve as follows:-
1. Install the POD valve in the main feed line at a position where access for manual operation 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 CO
2
manifold.
2. Connect a nipple and socket union to the outlet side of the POD valve for ease of installation to the
main CO
2
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:
(i) That the Safety and Reset pin is screwed fully home in the control head.
(ii) That all safety pins are fully inserted in the cylinder release heads, and POD valves.
5. Using 3/16 bundy tubing and fittings, see Figure 44, connect the Nitrogen pilot cylinder valve to the
pilot gas inlet port of the POD valves and from the POD valve gas outlet port to the CO
2
cylinder
pressure release head as shown in Figure 15 and 16.
NOTES
1. Clip the bundy tube to the wall at approx 457mm centres.
2. to 2 inch POD valves require adaptors K90220 and K90219 fitted in the pilot gas inlet port and
adaptor K90219 fitted to the pilot gas outlet port. See Datasheet 841-5036
3. 3 and 4 inch POD valves require adaptor K90219 fitted to both inlet and outlet pilot gas ports.
6. A POD valve indicator switch, if fitted, must be wired as shown in Figure 11.
27
6. DISCHARGE LOOPS K21578 AND K97112
6.2. RIGID DISCHARGE LOOP K21578
The discharge loop is used to convey CO
2
from the gas outlet of the cylinder valve to the check valve
manifold above the cylinders.
Figure 17 Rigid Discharge Loop
Materials:
Tube: 12.7mm x 18 SWG Annealed.
Material: Copper
Coupling Nuts: Brass
Thread: W21.8 x 1/14 DIN 477. 30.5mm A/F
Test Pressure: 152 Bar Approx
Weight: 0.3kg
28
6.2 FLEXIBLE DISCHARGE LOOP K97112
This loop is used when in-situ weighing of the cylinders are required. It is also recommended for use on
single cylinder systems for ease of connection to rigid discharge piping. When used for this purpose a loop
to pipe adaptor K62755 is required.
Figure 18 Flexible Discharge Loops
Materials - K97112
Hose: Reinforced Rubber
Connectors: Mild Steel Zinc Plate and Chromate Passivated
Coupling Nuts: Mild Steel Zinc Plate and Chromate Passivated
Weight: 0.5kg
Adaptor K62755: Brass
29
6.3 INSTALLATION
Manifold Heights
Height To Underside Of Manifold
Cyl Size (kg) Cyl Part No Copper Loop K21578 Flexible Loop K97112
22.6 K24338 1267 1577
45.0 K24069/FM
45.0 E7194-001
1700
1800 100
NOTE: All dimensions in mm
WARNING
ALWAYS CONNECT THE LOOP TO THE MANIFOLD INLET OR PIPEWORK IF SINGLE CYLINDER,
BEFORE CONNECTING TO THE CYLINDER VALVE OUTLET.
30
7. SYSTEM ACTUATOR ASSEMBLY
The system actuator assembly incorporates the source of pilot Nitrogen gas supply and the mechanism to
release it either automatically and/manually.
Figure 19 System Actuator Assembly
31
7.1 NITROGEN PILOT GAS CYLINDER AND VALVE
Figure 20 Nitrogen Pilot Gas Cylinder and Valves
Specification:
Cylinder: CF-CD01 Issue 2
Water Capacity: 0.4 Litres
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 Standard Assy
K62462A Complete with switch (Factory fitted)
32
7.2 OPTIONAL PRESSURE MONITORING SWITCH
This switch provides means of signaling low-pressure within the Nitrogen pilot cylinder.
WARNING
PRESSURE HEAD - DO NOT ATTEMPT TO REMOVE FROM CYLINDER.
Figure 21 Pressure Monitoring Switch
Sensor Capacity: Max System Pressure 207 bar
Proof Pressure 621 bar
Electrical Rating: 28 V d.c 5 Amp resistive
3 Amp inductive
Connections: Common - Earth
Open under pressure - 1
Closed under pressure - 2
Temperature Range: -54 to +107C
Construction: ST.ST Housing, Black Nylon Cap
Operating Pressure: Factory set at 50 bar - decreasing
33
7.3 CONTROL HEAD K62303
The control head is mounted directly onto the Nitrogen pilot gas cylinder valve and is secured by a coupling
nut. When the control head is operated the firing pin shoots out (extends) by approximately 3mm.
Figure 22 Control Head
Materials:
Body: Brass
Weight: 2.35kg
IP55 Rating
34
7.4 CONTROL HEAD WITH SWITCHES K62304
As K62303 plus switches to provide remote indication that the safety and reset pin has been inserted and a
second switch to indicate the condition of the control head.
Figure 23 Control Head with Switches
Safety/Reset Pin Switch
Orange - Common
Red - N.O.
Black - N.C.
Control Head Condition Switch
Grey - Common
White - N.O.
Yellow - N.C.
Electrical Rating
250 V a.c - 7A Resistive 7A Inductive
30 V d.c - 4A Resistive 3A Inductive
50 V d.c - 1A Resistive 0.25A Inductive
125 V d.c - 0.4A Resistive 0.3A Inductive
35
7.5 CONTROL HEAD MOUNTING BRACKET K62487
Figure 24 Standard Mounting Bracket
Material: Mild Steel
Finish: Painted Black
36
7.6 SAFETY AND RESET PIN K62401
This device, supplied with the control head, when screwed fully home will reset the control head causing
the firing pin to retract to its normal position.
WARNING
DO NOT ATTEMPT TO RESET WHILST STILL ELECTRICALLY OR PNEUMATICALLY ENERGISED.
When carrying out servicing or maintenance, screw the safety/reset pin fully home to inhibit (isolate) the
system.
Retain reset pin in safe location for future use.
Figure 25 Safety and Reset Pin
Body Material: Steel
Weight: 0.1kg
37
7.7 INSTALLATION
The installation procedure is as follows:-
1. Install the control head mounting bracket.
NOTE: Check the distance to the 1st cylinder valve release head to ensure that the long pilot gas
flexible hose K93434 can be easily coupled to the Nitrogen pilot gas cylinder valve outlet,
see Figures 44 and 45.
2. Lower the control head so that its swivel nut projects through the hole in the mounting bracket and
bolt onto the bracket.
WARNING
DO NOT FIT THE NITROGEN PILOT GAS CYLINDER AT THIS TIME.
3. Check the operation of the control head safety and reset.
(i) Remove the red plastic dust cap from the control head threads.
(ii) Ensure that the Safety and Reset pin is screwed fully in.
(iii) Verify that the actuating pin, see Figures 22 and 23, does not project by more than 3mm.
(iv) Check that when the Safety and Reset pin is screwed FULLY OUT and the Push-to-Fire
button of the control head is operated the actuating pin extends so that it now projects by a
minimum of 6mm. If a Push-to-Fire button is not supplied, remove the port plug, Section 8.1,
and push the pin in. Ensure that no dirt or foreign matter falls into the control head while the
port is open. reconnect the port plug.
(v) 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.
38
Figure 26 Control Head Mounting Bracket
TORQUE TO 5/5.5 NO
39
8. CONTROL HEAD ACTUATING DEVICES
There are various options available for automatically or manually operating the control head as illustrated
below:-
Figure 27 Control Head Actuating Devices
1. Manual Push-to-Fire Button K62412
2. Pneumatic Diaphragm K62459
3. 24V d.c Solenoid K62422B
4. 24V d.c Flameproof Solenoid K93206/AX
5. Remote Cable Release Assy K62489
40
8.1 MANUAL PUSH-TO-FIRE BUTTON K62412
To manually operate the control head, pull safety pin and operate push to fire button
Figure 28 Manual Push-to-Fire Button
Unscrew the port plug on the control head and screw the button fully home, as shown below.
Port Plug
41
8.2 SOLENOID ACTUATORS K62422B and K93206/AX
Figure 29 Standard 24V d.c Solenoid
K62422B
Designed to meet with BS5490 IP55. The unit is prewired and supplied complete with flexible conduit.
Case Material: Aluminium Alloy.
Finish: Grey Anodise.
Weight: 0.77kg.
Electrical Specification
Cable:. PVC
Coil resistance at 20C: 64.5 Ohms 5% 24V d.c (Nominal) 8.5 Watts.
42
8.3 FLAMEPROOF 24V d.c SOLENOID K93206/AX
Figure 30 Flameproof ATEX approved 24V d.c. Solenoid
K93206/AX
Designed in accordance with ATEX directive: ATEX 94/9/EC classification: for potentially explosive
atmospheres flameproof enclosure EX II 2 G Eex d II C T6 to T4
II 2 D IP65 T 85 to T135C
Case material: Aluminium Alloy.
Finish: Epoxy Gloss Grey/Green
Weight: 1.4kg.
Suitable for offshore and marine conditions.
Electrical Specification
Coil resistance at 20C: 16 Ohms 10% 24V d.c (Nominal), 16.8 Watts.
43
8.4 INSTALLATION
Before installation of the standard or flameproof solenoid check the following:
1. All screw threads are clean and free of damage.
2. The tip of the plunger does not project by more than 3mm.
8.4.1 Standard Solenoid
1. Make sure that the Safety and Reset pin is screwed fully home into the control head before attaching
the solenoid.
2. Attach the solenoid to the 24mm diameter screwed port on the control head by hand, taking care not
to cross thread the unit. When fully home the solenoid can be finally tightened using an open-ended
spanner (27mm A/F thin section).
3. Insert the 20mm screwed thread of the cable gland, which is attached to the loose end of the flexible
cable of the solenoid, through the 20mm diameter hole located in the junction box and, using a
20mm back nut tighten the gland from inside the junction box.
4. Connect the two crimp terminals to their relevant connections inside the junction box.
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, see Figures 22
and 23, to operate.
6. To reset de-energise the solenoid and re-insert the Safety and Reset pin.
44
8.4.2 Flameproof Solenoid
1. Make sure that the Safety and Reset pin is screwed fully home into the control head before attaching
the solenoid.
2. Check the solenoid nameplate for correct voltage, wattage and service. The solenoid must be
installed only in locations covered by group II category 2 G/D enclosures and where the flammable
gases present in the atmosphere have ignition temperatures higher than the temperature
classification stamped on the nameplate. Ambient temperatures must not exceed the value stamped
on the nameplate.
3. Attach the solenoid to the 24mm diameter screwed port on the control head by hand, taking care not
to cross thread the unit. Once fully home the solenoid can be finally tightened using an A/F open-
ended spanner.
4. Connect the solenoid to the control circuit via a ATEX approved junction box or MICC cable gland.
5. Access to the cable terminal connector is achieved by removing the four cap screws and spring
washers and withdrawing the housing cover. It may be necessary to rotate the cover slightly to ease
withdrawal.
6. After the cover has been removed connect the MICC cable into the terminal connector and tighten
the screws.
Operation Check
WARNING
ENSURE THAT THE NITROGEN PILOT GAS CYLINDER HAS NOT BEEN FITTED.
7. Remove the Safety and Reset pin and energise the solenoid causing the firing pin, see Figures 22
and 23, to operate.
8. To Reset de-energise the solenoid and re-insert the Safety and Reset pin.
45
8.4.3 Control Head and Solenoid Wiring
The internal switches of the control head can be used to indicate whether the Safety and Reset pin has
been inserted or the control head has been operated or reset. A suitable junction box should be used for
the connections, see Figure 31. Normally the operate switch is not used to signal to the control panel that
the extinguishing system has operated; the manifold mounted pressure switch is utilised instead.
Figure 31 Control Head and Solenoid Wiring
Colour State Terminal
Reset and Safety
pin switch
Red
Black
Orange
NC
NO
Common
1
2
3
Operate Switch Yellow
White
Grey
NO
NC
Common
4
5
6
FROM
CONTROL
HEAD
From Solenoid 7
8
Recommended terminal connections to be made in a junction box.
NOTE: If a solenoid is used, connect the control panel between terminals 5 and 8, and link 6 and
7.
After the control head, K62304, has been operated, the actuation signal is removed if the solenoid is wired
as shown in Figure 31.
46
8.4.4 Special Instructions to comply with 94/9/EC (ATEX)
1. Area classification
Control Head Basic and Control Head c/w Switches part numbers, K62303 and K62304 respectively.
Control heads are one part of a pneumatic activation system for extinguishers. These Control heads have
been designed and certified as a non-electric equipment for compliance to the following hazardous area
classification:
Group II category 3 GD c T6 X
The user of this equipment should make themselves aware of the following information;
2. Placing the device into service
These Control Heads may be installed in an area classified as Zone 2 or Zone 22 or unclassified.
3. Safe use of Control Heads
Control Heads are for use only as a component of a pneumatic activation system for extinguishers
compatible with the activation pressure (65 bar 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 KFP High Pressure Carbon
Dioxide Fire Protection Equipment Installation, Commissioning and Maintenance Manual 59812-400.
5. Installation
Control Head installation shall be in accordance with KFP High Pressure Carbon Dioxide Fire Protection
Equipment Installation, Commissioning and Maintenance Manual 59812-400, except that for zone 2 or
zone 22 compliance solenoid K62422B SHALL NOT be used.
6. Maintenance (service and emergency repair)
The Safety and Reset Pin must be used to disable the control head before any system maintenance is
performed refer to manual 59812-400. For maintenance of control head refer to this manual.
7. Adjustment
Control Heads have no adjustable components
8. Training
Consult KFP High Pressure Carbon Dioxide Fire Protection Equipment Installation, Commissioning and
Maintenance Manual 59812-400 before use.
9. Limitations of use
Control Heads must only be used within areas specified by the hazardous area certification as indicated on
the equipment label
10. Special Parameters
The ambient temperature for this equipment is 18C to 55C.
47
8.5 PNEUMATIC DIAPHRAGM ACTUATOR K62459
The pneumatic diaphragm actuator is used to operate the control head. The two 1/8 screwed connectors
on the cover plate of the actuator allow connection to a detector line and a breather assembly.
Air pressure from the detectors deflects the diaphragm which moves the firing pin approximately 3mm into
the control head. After operation the firing pin returns to its normal position, assisted by a spring assembly
which is located under the diaphragm.
Figure 32 Pneumatic Diaphragm Actuator
Diaphragm Housing Material: Aluminium Bronze
Finish: Anodised
Connector Material: Brass
Finish: Dull Nickel Plate
Weight: 0.93kg
48
8.6 PNEUMATIC BREATHER VENTS K62895
The pneumatic breather is a calibrated leak used in pneumatic fire detecting systems.
The purpose of the breather is to relieve slight increases or decreases of air pressure within the detector
circuit caused by normal atmospheric temperature changes or heating of the premises. etc.
Part Number Breather Setting
K62895/5 5 Seconds
K62895/10 10 Seconds
K62895/100 100 Seconds
Figure 33 Pneumatic Breather Vents
Vent settings to be used (seconds)
Temperature Variation: For 1 & 2
Detectors
For 3 & 4
Detectors
For 5 & 6
Detectors
NORMAL 15 20 25
CONSTANT
(Thermostatically controlled)
25 30 30
RAPID (Ovens, etc) 5 10 10
NOTES:
1. A 100 second breather is used only if a pneumatic check unit is employed.
2. The breather in a lock-off unit must be rated the same as the breather fitted to the
Pneumatic Diaphragm Actuator see Figure 32.
49
8.7 INSTALLATION
Before installation of the pneumatic diaphragm actuator check the following:
1. That all screw threads are clean and free of damage,
2. The tip of the plunger does not project by more than 3mm,
3. That the Safety and Reset pin is screwed fully home into the control head before attaching the
actuator.
After the above checks have been carried out satisfactorily install the pneumatic actuator as follows:
1. Attach the pneumatic diaphragm actuator to the 24mm diameter screwed port on the control head by
hand, taking care not to cross thread the unit. Once fully home the actuator can be finally tightened
using an open-ended spanner.
2. Attach the breather vent assembly, see Figure 32, to one of the connections on the actuator.
3. Attach the compression coupling on the copper detection tubing to the second connection.
8.8 CABLE RELEASE ASSEMBLY K62478
This device is used in conjunction with a remote pull box and cable system to manually operate the control
head.
Figure 34 Cable Release Assy
Material: Mild steel box painted black
50
8.8.1 Installation
To install the single release assembly, see Figure 35 and proceed as follows:
1. Unscrew and remove the box lid and gasket. Slacken the cable clamp locking screws and slide
clamp off the inner bowden cable (use a 2.5mm A/F hex wrench).
2. Pull out the inner cable from the release assembly.
NOTE: Do not remove top cover from control head.
3. Unscrew both blanking plugs from the control head body (use a A/F hex wrench).
NOTE: A manual Push-to-Fire button, if fitted, should be unscrewed.
Figure 35 Cable Pull Ring Connection
Cable Connection Port, see Figure 35.
4. Feed in the inner cable through the blanking plug port on the Safety and Reset pin side of 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.
51
Figure 36 Curvature of Cable
Curvature of Cable, see Figure 36
7. Make sure that the control head cable is not forced to bend through a radius of less than 45mm
(approximately 1 ) along its length.
Figure 37 Cable Release Assembly, Cover Removed
8. Slide the cable clamp into the inner cable, loop the inner cable end and feed back through the clamp
as illustrated above.
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.
9. Feed remote pull cable into the cable clamp and secure with the two locking screws.
10. Test for satisfactory operation with the pilot valve and cylinder assembly removed and adjust tension
of remote cable if necessary. Refit the box lid and gasket.
11. Leave the system in an operable condition.
52
8.9 PULL BOX K 1114
The pull box is used where remote emergency manual operation of a system is required. The handle is
connected to the gas release device by flexible phosphor bronze cable run in mild steel conduit for
protection. Abrupt changes in direction to the routing of the manual pull line are affected by means of
enclosed brass pulleys. Part No. K 1122.
Pulley can be mounted in 90 increments.
Figure 38 Pull Box
Specification: BS5490 IP40
Materials: Box-Steel painted signal red BS 381C/537
Front Cover - Plastic
Weight: 1.65kg
53
8.9.1 Corner Pulley K 1122
Figure 39 Corner Pulley
Materials: Brass - Natural
Weight: 0.5kg
8.9.2 Installation
To install the pull box proceed as follows:
WARNING
TO PREVENT ACCIDENTAL DISCHARGE OF THE FIRE FIGHTING SYSTEM DURING INSTALLATION
WORK, MAKE SURE THAT THE SAFETY AND RESET PIN IS SCREWED FULLY HOME INTO THE
CONTROL HEAD OR THE COMPLETE PILOT VALVE AND GAS CYLINDER ASSEMBLY IS
UNSCREWED FROM THE CONTROL HEAD.
1. Attach the pull box using the single 7/16 (11.1mm) diameter fixing hole.
2. With front plate and glass removed, use a slotted screwdriver to remove the 7/16 Whitworth
grubscrew 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 grubscrew to the pull handle.
54
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 2
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.
55
9. CYLINDER VALVE PRESSURE/LEVER ACTUATOR K62341
The release head is a piston device which is fitted to the cylinder valve by means of a U pin and can be
operated by means of independent Nitrogen gas pressure and/or by use of the manual lever. Two gas
pressure ports provide the means of interconnecting a series of release heads by using flexible pilot gas
hoses. (K93433 & K93434)
All pilot lines must include a pilot vent (K24051) as part of the assembly.
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.
Figure 40 Cylinder Valve Pressure/Lever Actuator
Materials
Body: Brass
Seals: Nitrile
Lever: Plated Steel
Securing Pin: Stainless Steel
Safety Pin: Stainless Steel
Weight: 0.4kg
56
9.1 INSTALLATION
Before installation check the following:-
1. Remove Safety pin and rotate manual lever for ease of movement of both the lever and piston.
2. Return lever original position and insert Safety pin.
3. Manually reset the piston.
After these checks have been carried out satisfactorily install as follows:
(a) Remove the securing pin.
(b) Slide the release head onto the cylinder valve and refit the securing pin, lightly tap fully home.
Leave safety pin in place until commissioning system. Refer to section 19 Maintenance.
57
10. PILOT GAS FLEXIBLE LOOPS K93433 and K93434
The short pilot loop K93433 is used to interconnect the pressure / lever actuator K62341 pressure inlet
ports on multiple cylinder systems.
The long 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.
Figure 41 Pilot Gas Flexible Loops
Materials
Hose: Polyamide inner tube, synthetic branding/polyamide cover
End Fittings: Brass - Natural Finish
Minimum Bend Radius: 50mm
Weight: 50 grammes
10.1 PILOT GAS VENT K24051
This device is fitted in the last unused pressure inlet port of the release head K62341 allowing the pilot gas
pressure to slowly vent (bleed) to atmosphere. The rate at which the pilot gas is vented is slow enough to
maintain adequate operation pressure in the pilot gas line far in excess of the duration of the main CO
2
discharge for normal flooding systems. See Datasheet 811-9040A
The bleed valve is factory calibrated to vent at 0.8 litres/min at 750psi.
58
Figure 42 Pilot Gas Vent
Materials
Body: Brass
Weight: 0.02kg
59
10.2 PILOT GAS RIGID TUBING AND FITTINGS
On systems where either the system actuator is remote from the CO
2
cylinders or when the system
incorporates directional valves the pilot gas line consists of steel (bundy) tubing and compression fittings.
Figure 43 Pilot Gas Rigid Tubing and Fittings
K
K
K K
K K K
K
K
K
K
60
ASSEMBLY
1. Tubing must be cut off square and all burrs and swarf removed as loose particles could damage any
seals used elsewhere in the pipeline.
2. Place tubing nut and sleeve on tube.
3. Offer the tubing to the coupling, pushing it right home so that the tubing bottoms on the tubing stop
inside the fitting.
* This is important as it ensures that the correct amount of tubing projects beyond the sleeve to
give a sound joint.
4. Hold the tubing square to the coupling and screw the tubing nut up finger tight so that the sleeve is
trapped between the tubing nut and the seating radius of the counterbore.
5. While holding the tube firmly in contact with the tubing stop, screw the tubing nut down to a
reasonable spanner tightness. This varies between 3/4 and one full turn. On fittings for tubing sizes
of 12mm outside diameter and over, a smear of lubricant applied to the sleeve and the threads of the
tubing nut will effect a sound joint with the minimum of effort.
6. Slacken off the assembly about a turn then pinch down once again.
Where an inaccessible fitting would make the assembly of a sound joint difficult, it is 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.
61
10.3 INSTALLATION
Install the correct length pilot gas flexible loops as shown in Figure 44 for single row cylinders or Figure 45
for double row cylinders.
Install a pilot gas vent, see Figure 42, in the last open port of the pressure/lever actuator, Figure 40.
NOTES:
1. Do not use PTFE or other pipe sealant.
2. Do not overtighten fittings.
Figure 44 Single Cylinder Row Pilot Gas Operation
Figure 45 Double Cylinder Row Pilot Gas Operation
62
11. TIME DELAY UNIT K23650
This hydraulic device can be installed in a system to ensure that personnel are given time to evacuate a
protected space following a warning of imminent CO
2
discharge. It is fitted in the Nitrogen pilot gas line from
the System Actuator thus delaying the flow of pilot gas to the CO
2
cylinder pressure release heads and/or
P.O.D valve for a pre-determined time of 15 or 30 seconds.
This unit is factory pre-set do not adjust. Tampering with this unit could cause failure.
Figure 46 Time Delay Unit
63
Spec Factory set at 15 or 30 sec.
Material: Brass - Painted Red
Part No: K23650/15 = 15 secs
K23650/30 = 30 secs
Weight: 1.9 kg
11.1 INSTALLATION
1. Install vertically with the pilot gas inlet at the top.
2. Fit adaptor K90219 to both inlet and outlet pilot gas points.
11.2 TESTING
Wait approximately 1 hour before testing.
64
Figure 47 Single Protected Space System
65
Figure 48 Two Protected Spaces System
66
Figure 49 Two Protected Spaces Requiring Different CO
2
Quantities
67
11.3 TIME DELAY BY-PASS VALVE K60736
This device may be used to by-pass the time delay units.
Figure 50 Time Delay By-Pass Valve
Materials: Box Mild Steel
Finish: Hammer Grey
68
Figure 51 Installation
69
12. CO
2
OPERATED PRESSURE SWITCH K60218
The universal pressure switch is a gas pressure operated device which is connected to the distribution
piping or manifold. A gas pressure of 4 bar - 110 bar is required to operate the piston which makes or
breaks electrical contacts.
When the system is activated, gas pressure forces the piston against the operating rod which moves
across the housing, operating the switch. The switch completes an electrical circuit and illuminates the
system discharged lamp on the indicating lamp panel or operates the alarm etc. The rod extends into the
transparent cover to indicate the switch has operated.
To reset, unscrew re-setting cap (transport cover) from box, - reverse, and screw onto the operating rod.
Press until switch clicks home. Remove resetting cap from rod - reverse and screw back into box.
Refer to Datasheet 811-9119
Figure 52 CO
2
Operated Pressure Switch
Materials
Housing: Aluminium Casting
Finish: Red Enamel
Testing: 2KV tested
BSPT
70
Inductive Rating
Power Factor 250 Volts 440 Volts 600 Volts
1 30 Amps 25 Amps 20 Amps
0.74 25 Amps 20 Amps 16 Amps
0.50 17.5 Amps 14 Amps 11.5 Amps
D.C. Rating
Resistance 220 Volts 500 Volts
Loadings 30 Amps 15 Amps
71
12.1 INSTALLATION
Before installation of the pressure switch (see Figures 52), check the following:
1. The BSP inlet thread is clean and free of any damage.
2. When manually operated, using the visual indicator and re-setting cap, the switch roller is in the
coupler channel and the operation is smooth with no binding.
After the above checks have been satisfactorily carried out, install the pressure switch as follows:-
1. A BSP screwed connection is required on the end of the manifold, attach a BSP galvanised
hexagon nipple.
2. Attach the pressure switch or, wall mount the switch, make up all pipework to suit the site location of
your pressure switch making sure that there is a BSP galvanised union in this line for each of
installation and/or removal of equipment.
3. To the BSP outlet connection on the pressure switch attach a 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.
Alternatively, the switch may be wall mounted by adapting the threads to 3/16 ENOT and using bundy
tube to connect.
72
13. CO
2
OPERATED PRESSURE TRIP K17554
The pressure trip is fitted into the CO
2
distribution piping and is used to automatically release ventilation
shutters, fire curtains, ducting dampers, fuel valves, etc. CO
2
pressure of approximately 2 bar is sufficient to
operate the piston and unlatch -the catch mechanism.
Figure 53 Pressure Trip
Materials: Body - Gunmetal
Finish: Nickel Plate
73
13.1 INSTALLATION
Figure 54 Installation
NOTES:
Always install the pressure trip in a vertical position as shown.
Dimension from top of doorframe is typical & should be adhered to where possible.
Use PTFE tape on all screw threads.
The maximum load that can be suspended from a pressure trip is 100lb (45kg).
Install the pressure trip as follows:-
1. To the BSP male screwed connection on the pressure trip attach a BSP elbow a suitable
length of BSP galvanised pipe and one half of a BSP union.
2. Offer the pressure trip assembly up to the CO
2
distribution piping and hand tighten the union nut.
3. Making sure that the pressure trip is located in the centre of the doorway and at a suitable vertical
dimension above the door frame so as not to hinder the operation of the equipment mark the one off
fixing hole on the wall.
4. Loosen and disconnect the pressure trip assembly.
5. Drill the pressure trip fixing hole on the wall.
6. Reconnect the pressure trip assembly to the CO
2
pipework.
7. Using a adequate wall fixing to attach the pressure trip to the wall.
8. Once attached to the wall finally tighten the union nut.
9. Attached the cable & cable ring to the pressure trip.
74
14. CO
2
DISCHARGE NOZZLES
There are various nozzles suitable for either total flooding and/or local application systems. In all cases it
is essential that they are installed in their correct locations as defined by the code number stamped on the
nozzle body.
14.1 MULTIJET NOZZLE K61792 AND K61793
These nozzles are the standard carbon dioxide discharge nozzles. The horn has been developed to
prevent the scattering of burning material that can take place with a high velocity discharge.
Datasheet 811-9148
Figure 55 Multijet Nozzle
Environment: Industrial/Offshore/Marine
Material: Horn - mild steel
Nozzle - brass
Finish: Horn - black paint.
Nozzle - Natural
Weight: K61792 N13 - N18 :- 0.8 kg approx.
K61793 N3 - N12 :- 0.6 kg approx.
75
14.2 FLANGED MULTIJET NOZZLE K5814
The flanged carbon dioxide horn is designed for use in those areas where the nozzle may become blocked
by dirt or the process being protected. The force of the discharge automatically blows the disc clear. Three
discs are available:-
Refer to Datasheet 811-9139
Figure 56 Flanged Multijet Nozzle
1. Bakelite - temperatures up to 200C and ambient pressures below 50 psig.
2. Tin Foil - temperatures up to 400C and ambient pressures below 25 psig. (used where
fragmented pieces cannot be tolerated)
3. Mica - temperatures above 400C and ambient pressures below 50 psi.
The flanged horn may be fitted to ductwork by the addition of the appropriate adaptor.
Material: Body: Aluminium Nozzle: Brass
Finish: Body: Natural Nozzle: Natural
Weight: 0.9 kg approx.
76
14.3 FLANGED NOZZLE DUCT ADAPTORS K61420A-D
The range of duct adaptors is designed for those situations where it is required to fit the flanged CO
2
nozzle
(K5814 N3 - N8) to circular or square section ductwork.
Figure 57 Flanged Nozzle Duct Adaptor
Material: Cast aluminium.
Finish: Black paint
NOTE: 4 - 5/16" Whit. Hex. Hd. Screws C/W nuts and washers together with joint sealing tape
supplied with each adaptor.
Adaptor Assembly Weight (approx) Ducting Size
K61420A 1.3kg 610mm Dia
K61420B 1.3kg 457mm Dia
K61420C 1.3kg 305mm Dia
K61420D 1.1kg Flat
77
14.4 DUCT NOZZLE K13045
The CO
2
nozzle and duct adaptor is used to protect ductwork in areas where space is limited.
Datasheet 811-9151
Figure 58 Duct Nozzle
Material: Mounting plate : mild steel
Nozzle : brass
Finish: Mounting plate : zinc plated and passivated.
Nozzle : natural
Weight: 0.4kg approx.
78
14.5 FAN TYPE NOZZLE K6490
Fan type nozzles are designed to be mounted at the sides of the protected equipment and to direct carbon
dioxide across the hazard.
Figure 59 Fan Type Nozzle
Material: Body: Grey cast iron. Nozzle: Brass
Finish: Body: Black paint. Nozzle: Natural
Weight: 2.6kg approx.
79
15. PNEUMATIC DETECTION - HEAT ACTUATED DEVICES
The Rate of Rise system is a thermo-pneumatic system consisting of one or more detectors connected to
a release actuator in which there is a diaphragm and a compensating vent.
15.1 PNEUMATIC RATE OF RISE DETECTOR K18724
The pneumatic detector is a hollow copper chamber of 12cc capacity containing air at normal atmospheric
pressure. It is fixed to the ceiling or in any other positions best suited to site conditions. The function of the
detector is to absorb heat thereby increasing the air pressure within it which is then transmitted through
small bore copper capillary tube running in protective steel conduit to a release actuator. Operation of the
diaphragm in the release actuator will discharge the extinguishing agent or initiate an alarm.
Figure 60 Pneumatic Rate of Rise Detector
80
15.2 PNEUMATIC FIXED TEMPERATURE DETECTOR K18689
This detector works on the same principle as the Rate of Rise detector but is fitted with a slug assembly
containing a fusible alloy disc which will melt at a predetermined temperature. These are used to protect
areas which are subjected to rapid increases in ambient temperatures such as ovens, kitchens, boiler
houses, lantern lights, etc.
Be aware that capillary tubing can act as a rate-of rise detector so routes outside the rapid change area
must be found.
K18689 = Pneumatic Fire Detector less slug assembly, washers and identification disc.
Order appropriate slug assembly kit for fitting on site and for spares. (see table)
Slug assembly kit comprises - slug assembly, 2 washers, identification disc with fitting screw
and fitting instructions.
Note: Slug assembly kits are available in a limited range of temperatures. Please contact Kidde Fire
Protection for further details.
Figure 61 Pneumatic Fixed Temperature Detector
81
15.3 PNEUMATIC CHECK UNIT K24412
The pneumatic check is used on pneumatic type fire detection systems incorporating Rate of Rise
detectors.
The checks are used to divide the detectors into groups of no more than six. Each group is, in this way,
isolated, so that air pressure rise caused by a detector sensing fire can pass through the check to the
system actuator etc, without being dissipated into other detector groups.
The pneumatic check is formed by making use of silicone fluid. The unit being filled with fluid at the factory.
No adjustment should be necessary, but check fluid level.
Installation
This unit must be installed in a vertical position as shown above. Fit pneumatic breathers in the two inlet
ports, see Figure 62 for correct setting.
Figure 62 Pneumatic Check Unit
K 6 2 89 5
82
15.4 PNEUMATIC LOCK-OFF UNIT K24300
An extinguishing system utilising non-electrical heat detectors can be fitted with a pneumatic lock-off unit in
order to prevent automatic actuation when the area protected by the system is occupied. With the unit
switched to AUTOMATIC & MANUAL the pneumatic signal from the heat detectors is allowed to pass
through the unit to the extinguishing system.
However, when the unit is switched to MANUAL ONLY the signal is directed to a pneumatic switch fitted
within the Lock-off unit which can thus provide remote indication, and is prevented from actuating the
extinguishing system. A second Pneumatic breather of the same vent setting as the one fitted to the
extinguishing system actuator must be fitted to the pneumatic switch in the Lock-off unit.
Figure 63 Pneumatic Lock-Off Unit
83
15.5 BELLOWS AND MICROSWITCH ASSY K20057
The bellows and microswitch assembly is used to convert an air pressure signal received from a non-
electrical heat detection device into an electric signal for indication or the operation of a release
mechanism.
The assembly consists of a pair of aluminium castings enclosing a diaphragm and connected to a
microswitch. On receipt of an air pressure signal a spindle housed in the upper casting actuates the
microswitch.
The unit is self-resetting when the air pressure signal is removed. No maintenance is required. Order
appropriate Pneumatic Breather for fitting on site, see Figure 64.
Figure 64 Bellows and Microswitch Assembly
84
15.6 PNEUMATIC CAPILLARY TUBE, CONDUIT AND FITTINGS
Figure 65 Pneumatic Capillary Tube, Conduit and Fittings
85
15.7 CO
2
OPERATED SIREN K18307
This device can be fitted into the main CO
2
feed pipe to provide an audible alarm for the duration of the CO
2
discharge.
Figure 66 CO
2
Operated Siren
Material: Body - Aluminium Casting
Finish: Painted Red
86
16. ODORISER ASSEMBLY K62586
At normal atmospheric pressures and temperatures, the extinguishing gas is colourless and odourless. To
enable CO
2
to be detected during and following a discharge an odoriser shall be fitted. The unit must be
fitted in the main pipe run so that the pressure of the gas passing through the pipe bursts a seal in the unit
and releases a liquid odorant into the gas system. Burst pressure range 20 to 40 psi.
Each unit contains 30cc of odorant which is sufficient to produce a positive and identifiable lemon smell in a
protected space of up to 1,400 cubic metres volume.
Figure 67 Odoriser Assembly
Material: Aluminium Alloy
Finish: Black anodise
NOTES:
1. This unit must be installed in the vertical position with the cylinder uppermost.
2. Adaptor K22152 can be supplied as an optional fitting, see Figure 68. This incorporates a
check valve so that in the event of the gas being released while the odoriser is removed
there is no loss of gas from the pipe.
Figure 68 Odoriser Check Valve
Material: Brass
87
17. CO
2
WARNING LABELS
MATERIAL:- 22 SWG ALUMINIUM
Figure 69 Entrance Door Warning Label
Part Number K93681
88
Figure 70 Manual Control Point Label
Part Number K93680
89
PART 2 COMMISSIONING
18. COMMISSIONING
This chapter described the commissioning procedure under the following headings:
1. Visual Checks
2. Mechanical Function
18.1 VISUAL CHECKS
Before commencement of commissioning tests visually check the following:-
1. Check that the installation conforms to the engineering drawings. Any deviations from drawings must
be reported.
2. All work, e.g. electrical wiring, carried out by other contractors has been completed satisfactorily.
3. Check the protected area for confinement of the extinguishing agent, i.e. that no passage is allowed
to other spaces through floor or ceiling voids, ductwork, holes in partitions or vents, unless allowance
has been made.
4. Check that all manual controls are accessible and correctly identified.
5. Check that the discharge nozzles are unobstructed and are adequately secured. Check that the
nozzles comply with sizes shown on the drawings.
6. Check that the container and valve manifolds are correctly sized, and that check valves and POD
valves are installed for correct directional flow.
7. Check the manifold-to-container installation for undue strain on connecting loops because incorrect
installation can cause service problems.
8. Check the containers are installed in an accessible location, that the area is clean, dry and ventilated
and meets the safe temperature requirements.
9. Check that all system controls, such as valves, lock off, pull boxes, manually or electrically operated
devices, are accessible to operating personnel. If located outdoors ensure that they conform to the
required standards and that adequate shelter has been provided.
10. Check that pipes and fittings are sized in accordance with the drawings and are adequately secured.
All piping must be rigidly secured to the nozzle to prevent damage from recoil.
11. Check that all warning labels and notices give correct information for system operation and that they
are suitably located.
12. Check weigh containers to ensure nett content is in accordance with the requirements.
90
18.2 MECHANICAL FUNCTION
WARNING
DO NOT PROCEED WITH ANY FUNCTIONAL TESTS UNTIL EVERY PRECAUTION HAS BEEN
TAKEN TO PREVENT ACCIDENTAL DISCHARGE.
18.2.1 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.
18.2.2 Manual Push-to Fire
2. Remove pin from Push-to Fire button
3. Manually fire the control head by operating the Push-to-Fire button as shown in Section 8.1
4. When the manual operation of the Push-to-Fire button has been proved, reset the control head by
screwing the Safety and Reset pin fully home.
5. Replace pin into Push-to fire button.
18.2.3 Pull Box
WARNING
TAKEN TO PREVENT ACCIDENTAL DISCHARGE.
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 8.8.
6. Relocate the glass and front cover plate to pull box unit.
91
18.2.4 Pneumatic System
If the control head is to be operated using a pneumatic diaphragm actuator and HAD detection system, a
manometer test, see Figure 71, shall be carried out.
Figure 71 Manometer Test System
Specification: Designed for pressure or vacuum up to 8 water gauge.
Material: Base and Cover Al. Alloy
Paint: Red Enamel
Part No: K17523
92
Before testing the pneumatic actuator and HAD system, ensure that the manometer water level is zeroed
and check for leaks as follows:-
1. Compress the rubber bulb slightly and plug both the simplifix coupling and the open end of the glass
tee piece near the bulb - a wetted thumb is usually adequate for this purpose. Release the pressure
on the rubber bulb, thus causing the water to rise up the right hand side of the simplifix coupling tube
until a reading of 6 water gauge is shown and holds level until the pressure is relieved by removing
the thumbs from the open ends.
Test the HADs, if necessary, as follows:-
1. Remove the HAD from the system and immerse it in water the temperature of which is some 10C
above ambient. but does not exceed 50C. There must be no air leaking from the HAD.
2. If satisfactory replace the HAD in the system making sure all water has been removed and
connections are tight.
93
Test that the system is airtight, as follows:-
1. Remove the pneumatic breather from the breather connection on the diaphragm actuator.
2. Connect the manometer to the breather connection on the diaphragm actuator as shown, and create
a vacuum as described above.
94
3. After an initial pressure drop there should be no further drop for one minute.
4. With the manometer still connected, test that the system is free from blockage, by slightly heating
each HAD in turn and observing that a slight pressure is built up in the system each time; a
displacement of water gauge is sufficient.
After this test has been carried out satisfactorily proceed to check the rating of the pneumatic breather as
follows:-
1. Remove the breather from the pneumatic actuator and connect it to a manometer. Set the water
level in line with the top edge of the metal indicator of the manometer.
NOTE: Before testing ensure that the breather is situated above the level of the manometer to
prevent any possibility of water being blown into the breather.
2. Create a small vacuum (approximately 3 difference in water level in the two limbs of the
manometer). As the water returns slowly to its normal position, note the time taken for the water to
pass through the visor space of one inch of the indicator. This is the time taken for the pressure to
drop by 2 of water pressure. The time should be between 5 and 100 seconds depending on the
breather used; the specified time stamped on the breather.
After this test has been carried out satisfactorily re-connect the breather to the pneumatic actuators.
95
The operation of the system is checked as follows:-
1. Disconnect the pneumatic detector line from the actuator.
2. Connect the manometer to the pneumatic connection on the actuator as shown below:
4. Using the rubber hand bulb gently pump until the pneumatic actuator operates the control head.
NOTE: The pneumatic actuator should operate the control head only between 1" and 3" of water
gauge, as shown in the manometer operating range above.
96
5. Re-place the Safety and Reset pin, ensuring that it is screwed fully home.
6. Re-connect the pneumatic detection line to the pneumatic actuator.
WARNING
DO NOT ATTEMPT TO RESET THE SYSTEM UNTIL THE PRESSURE IN THE HAD LINE HAS BEEN
RELEASED.
18.2.5 Pressure/Lever Actuator and POD Valves
Details of the pressure/lever actuator are given in Part 1, Chapter 9.
To check the pressure /lever actuator and POD valves as follows:
1. Remove the pressure/lever actuator complete with pilot loops and vents from the container valves
and secure them, making sure that they are clear of the container valves. The entire pilot gas system
must remain intact.
2. Remove the safety lock pin from each actuator and check the manual operation.
3. When satisfied with the manual operation of the release heads check the POD valves, if installed, by
connecting a pilot gas (Nitrogen) test cylinder to the head.
Remove Safety Lock Pin from each POD valve and check for manual operation (Valves up to 2).
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.
4. When satisfied with the manual operation of the POD valves reset and re-insert the Safety Lock pins.
5. 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
5. 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.
7. Push piston inside pressure/lever actuator back to set position.
8. Remove the pilot gas (Nitrogen) test cylinder from the control head.
9. 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.
18.2.6 Pressure Trip
Check the pressure trip mechanism, if incorporated in the CO
2
system, as follows:-
1. Physically lift the pivoted lever allowing relevant equipment, e.g. fire curtains or dampers, to be
operated.
2. After manual operation of the pressure trip has been carried out successfully, re-set all fire curtains,
dampers etc.
97
3 To demonstrate operation of the pressure trip assembly, release one container from the main bank.
Disconnect all pressure levers actuators and CO
2
outlet hoses from the cylinders not required for the
test.
WARNING
DO NOT DISCHARGE CO
2
WHILE THERE ARE PERSONNEL PRESENT IN THE AREA. THE
ENGINEER CARRYING OUT THE TEST MUST OBSERVE THE SAFETY REGULATIONS GOVERNING
THE USE OF CO
2
.
4. If POD valves are installed in the main distribution line, remove the Safety Lock pins and manually
open.
5. Discharge the CO
2
cylinder and check that the trip assemblies have all functioned correctly.
6. Re-insert the Safety Lock pin to the CO
2
container.
7. Re-set the pressure trip assemblies.
8. Reconnect cylinders and replace discharged cylinder.
18.2.7 Pressure Switch
If a pressure switch assembly is installed in the main CO
2
line check that it has operated as follows:-
1. Check that an alarm signal has been given on the main control.
2. Check that the pressure switch operating rod has extended into the transparent cover.
3. When satisfied re-set the pressure switch.
4. Manually close the POD valves and re-insert the Safety Lock pins.
5. Disconnect the empty CO
2
container and reconnect the remaining cylinder and replacement.
98
PART 3 MAINTENANCE
19. 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 CO
2
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 Engineers 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 he should therefore encourage the Customers representative to accompany him
while he does the work.
The first action to take, when arriving at site, is to report to the customers 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.
Similarly, 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 his 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 while you are working 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.
Service visits should be on a six-monthly (minimum) basis.
19.1 PRELIMINARY CHECKS
Before commencement of maintenance work check the following:-
1. Check the installation for any structural alternation that could affect the efficiency of the system.
2. Check the protected area for confinement of the extinguishant. If the system has been altered in any
way, and/or if the customers building or plant has been modified since the last inspection visit, this
must be noted on the Service Report. The Client must be informed of any factor jeopardizing the fire
protection system.
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.
99
3. Check that all manual controls are accessible, correctly identified and have not become obscured.
4. Check that the discharge nozzles are unobstructed and are adequately secured.
5. Check that all warning and instruction labels are clearly visible and legible. Check that all necessary
safety precautions and operational instructions are clearly stated.
6. Check that the paintwork is in good condition.
7. Check that containers are accessible and that the area is clean, dry and ventilated.
8. Check that pipes and fittings are adequately secured. All piping must be rigidly secured at the nozzle
to prevent damage from recoil.
9. 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 customers official order number for the additional work. Rectification work should
be recorded on a report sheet separate from the service report sheet.
19.2 COMPONENT FUNCTION TESTS
WARNING
TAKEN TO PREVENT ACCIDENTAL DISCHARGE. ENSURE THAT ALL PERSONNEL IN PROTECTED
AREAS KNOW THAT YOU ARE THERE AND OF THE WORK YOU ARE DOING.
19.2.1 General
1. Check that the manifold bracket fixings are secure.
2. Check that the manifold-to-container discharge valve couplings are tight.
19.2.2 Control Head
Check the control head as follows:-
1. Make sure that the Safety and Reset pin is screwed fully home.
2. Unscrew the pilot gas cylinder from the second head.
4. Energise the solenoid from the control panel or operate the HAD detection system. The solenoid
plunger operates the control head causing the firing pin to be moved downwards by a minimum
distance of 3mm, (6mm projection) proving that the solenoid and control head are both operable and
have functioned correctly.
5. Check the distance moved by the firing pin. Reset the control panel and/or HAD system.
NOTE: The HAD or the solenoid would be damaged if the control head is reset whilst either of
them is 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.
100
Push-to-Fire Button
8. Manually fire the control head by operating the Push-to- Fire button.
9. When the manual operation of the Push-to-Fire Button has been proved reset the control head by
screwing the Safety and Reset pin fully home.
Pull Box
Check the operation of the pull box.
11. Remove the front cover and glass from the pull box unit.
12. Pull the handle in the pull box firmly and manually fire the control head.
13. Rest the pull cable arrangement.
14. When satisfied reset the control head by screwing the Safety and Reset pin fully home.
15. Relocate glass and front cover panel to pull box unit.
Pilot Gas Cylinder
16. Screw the Safety and Reset pin fully home.
17. Check the pressure is approx 65 bar. If it is below 55 bar the container should be refilled.
Reinstatement
18. Refit the pilot gas cylinder to the control head.
19.2.3 Pressure/Manual Release Heads and POD Valves
To check the pressure/manual release heads and POD valves proceed as follows:
1. Remove the pressure/manual release heads complete with pilot loops and vents from the CO
2
container discharge valves. The entire pilot gas system must remain intact.
2. Remove the Safety Lock pin from each release head and check the manual operation. Manually
reset the release head piston and refit the Safety Lock pins when satisfied.
3. Remove the Safety Lock pin from each POD valve and check for manual operation.
101
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-insert 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 CO
2
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 TEN 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 CO
2
container discharge
valves.
19.2.4 Pressure Trip
The trip may be operated from the pilot line or from the discharge pipework. Check the pressure trip
mechanism if incorporated in the system as follows:-
1. Physically lift the pivoted lever as shown in Figure 53 etc, allowing relevant equipment, e.g. fire
curtains or dampers, to be operated.
2. After manual operation of the pressure trip has been carried out successfully, re-set all fire curtains,
dampers etc.
3. To demonstrate operation of a pressure trip assembly, which is operated from the discharge
pipework, release one CO
2
cylinder or connect a portable CO
2
extinguisher to the manifold.
Disconnect all other cylinders.
WARNING
DO NOT DISCHARGE CO
2
WHILE THERE ARE PERSONNEL IN THE AREA. THE ENGINEER
CARRYING OUT THE TEST MUST OBSERVE THE SAFETY REGULATIONS GOVERNING THE USE
OF CO
2
.
4. If POD valves are installed in the main distribution line, remove the Safety Lock pins and manually
open.
5. Discharge a CO
2
cylinder or portable CO
2
extinguisher, and check that the trip assemblies have all
functioned correctly.
102
6. Re-set the POD valve and re-insert the Safety Lock pin to the CO
2
container.
7. Re-set the pressure trip assemblies.
19.2.5 Pressure Switch
If a pressure switch assembly is installed in the main CO
2
line, check the correct operation as follows:
1. Remove the clear plastic spindle cover, reverse and screw it onto the spindle.
2. Check that an alarm is given when the spindle is pulled out.
3. When satisfied re-set the pressure switch. Chapter 12.
NOTE: The switch may be pressure tested by connecting a CO
2
container onto the distribution
pipework.
19.3 INSTRUCTIONS FOR COMMISSIONING THE SYSTEM AFTER ITS OPERATION
1. Refit the cylinder transport caps. Remove the empty CO
2
cylinders.
2. Refill the CO
2
cylinders or replace with fully charged cylinder and secure.
3. If distribution valves are fitted check that they are shut.
4. Check nozzles orifices for debris; clean if necessary.
5. Re-set all system ancillaries, including pressure switches, pressure trips, dampers, curtains, door or
window shutters, ventilators, remote lock-off services and pull boxes.
6. Reset each control head by screwing the Safety and Reset pin fully home. Remove the Safety and
Reset pins and leave them in the possession of an authorised person.
7. Replace the empty pilot gas cylinder with a new or refilled assembly.
103
PART 4 TERMS AND CONDITIONS
20. TERMS AND CONDITIONS
Kidde Fire Protection Services LTD
1.0 In these Conditions, the Seller means KIDDE FIRE PROTECTION SERVICES LTD, the Particulars of Contract
are the details of the Contract set out overleaf, the Buyer and the Goods are respectively the person and the
products specified in the Particulars of Contract as such. Appointed Person means a director or appointed
manager of the Seller, and the Contract means the Contract for the sale of the Goods by the Seller to the Buyer
comprising the Particulars of Contract and these Conditions. These Conditions shall apply to all contracts of sale
with the Seller in relation to the goods and services supplied by the Seller.
Formation and Parties
2.0 No express terms other than those contained in these Conditions and the Particulars of Contract shall be part of
the Contract, and the Contract may only be varied in writing by an Appointed Person. No representations or
warranties relating to the Goods or advice or recommendation on the use of the Goods are binding on the Seller
unless confirmed by the Seller in writing in response to a written request of the Buyer specifically referring to this
Condition.
2.1 The Contract may be cancelled by the Buyer only with the Seller's written consent which, if given, shall be on the
express condition that the Buyer shall pay to the Seller a cancellation charge commensurate with the Seller's
costs incurred up to the date of cancellation plus the Seller's loss of profit or, at the Seller's option, a sum equal to
ten per cent of the Contract Price.
2.2 Unless otherwise specified, quotations made by the Seller shall automatically lapse if no order is received by the
Seller within 30 days of the date of quotation. None of the Seller's distributors, agents or employees are
authorised to conclude contracts orally or over the telephone, and quotations, statements in price lists, or sales
literature and advertisements do not constitute offers. No contract for the sale of Goods shall be concluded until
the Seller has accepted an order of the Buyer by sending to the Buyer an Acknowledgement of Order signed by
an Appointed Person.
2.3 The Buyer warrants that all information which it has given to the Seller prior to entering into the Contract is true
and correct and the Seller reserves all its rights where it subsequently discovers such information is incorrect.
Delivery
3.0 If any delivery time is specified in the Particulars of Contract, this period shall commence on the later of the date
of the Seller's written Acknowledgement of Order and the date the Seller receives all the information necessary to
allow it to proceed without interruption, or if the Buyer requests any variation to the Contract, the date of the
Seller's written confirmation of its agreement to such variation.
3.1 Although the Seller will endeavour to complete the Contract within any specified delivery time or by any specified
delivery date, that time or date is an estimate only and the Seller shall not be liable for any reasonable delay in
delivery.
3.2 Any delivery time specified shall (in any event) be extended by any period or periods of Force Majeure during
which the manufacture or delivery of the goods by the Seller under the Contract is delayed owing to fire,
explosion, flood, storm, sabotage, strikes (official and unofficial), riot, acts of war (whether war be declared or not)
shortage of labour, power, or materials, delay by the Seller's suppliers, civil commotion, accidents, plant
breakdowns, technical difficulties connected with the manufacture or adaptation of the Goods to the Buyer's
design or specification, seizure or other action by or compliance with an order of an apparently competent
authority and any other event or circumstance beyond the control of the Seller.
3.3 The Seller shall be entitled to withhold delivery of any Goods if at the time delivery is to be made payment is due
by the Buyer to the Seller on any account whatsoever.
3.4 The delivery of a greater or lesser quantity of the Goods than the quantity ordered, of other Goods not ordered, or
of Goods only some of which are defective, shall not entitle the Buyer to reject Goods that were ordered and are
not defective.
3.5 Unless otherwise stated, delivery shall be deemed to take place when the Goods are delivered to the delivery
address specified in the Particulars of Contract or if not so specified, at the principal place of business of the
Buyer known to the Seller.
3.6 If the Buyer fails to accept delivery of the Goods in accordance with the Contract the Seller may (without prejudice
to its other rights against the Buyer) store the Goods at the sole risk and cost of the Buyer.
3.7 The Buyer shall inspect the Goods immediately on delivery thereof and shall within five days from such delivery
give notice to the Seller of any matter or thing by reason thereof the Buyer may allege that the goods are not in
accordance with the Contract or are defective in material or workmanship. If the Buyer shall fail to give such
notice the Goods shall be conclusively presumed to be in all respects in accordance with the Contract and free
104
from any defect which would be apparent on reasonable examination of the Goods and the Buyer shall, as
between the Buyer and the Seller, be deemed to have accepted the Goods accordingly.
3.8 The Seller reserves the right to make delivery by instalments and invoice and be paid for each installment
separately. Each installment shall be deemed to constitute a separate agreement subject to the terms of the
Contract and no failure of or delay in delivery of any installment nor any defect in the contents thereof shall entitle
the Buyer to treat the Contract as repudiated with regard to any remaining instalments.
Retention of Title
4.0 Notwithstanding delivery, title to the Goods shall not pass to the Buyer until all sums due on any account
whatever by the Buyer to the Seller have been paid in full. Until such time the Buyer will hold the Goods as bailee
of and in a fiduciary capacity for the Seller and will:
(i) keep the Goods marked or stored separately from other goods, so as to be identifiable as the property of the
Seller;
(ii) deliver the Goods up to the Seller on demand; and
(iii) permit the Seller or its agents to enter upon the Buyer's premises in order to retake possession of the
Goods.
4.1 Notwithstanding that the property in all Goods to be delivered to the Buyer by the Seller will remain vested as
aforesaid until the Seller has received payment in full therefor, the risk of damage to or loss of all or any such
Goods will pass to the Buyer upon delivery in accordance with the Contract unless the Buyer shall fail to accept
delivery whereupon the risk shall pass to the Buyer on the earliest date on which the delivery could have been
made but for such failure on the part of the Buyer.
Price
5.0 Unless otherwise stated in the Particulars of Contract, the Contract prices for the Goods shall be:
(i) exclusive of VAT, taxes or duties levied on the Seller in the Buyer's country for which the Seller shall be
entitled to make additional charges, and shall be exclusive of the costs of delivery and associated packaging
and insurance costs which shall be charged separately.
(ii) subject to increase by the Seller to reflect any variation in the delivery schedule for or design, quantities or
specifications of the Goods made at the request of the Buyer or any delay caused by the failure of the Buyer
to provide adequate information or instructions to the Seller.
Payment
6.0 Unless otherwise specified in the Particulars of Contract payment for the Goods shall be made in full within 30
days of the date of invoice. Time of payment shall be of the essence. If the Buyer fails to make any payment on
the due date then, without prejudice to any other right or remedy available to the Seller, the Seller shall be entitled
to suspend any further deliveries to the Buyer, appropriate any payment made by the Buyer to such of the Goods
(or the Goods supplied under any other contract between the Buyer and the Seller) as the Seller may think fit
(notwithstanding any purported appropriation by the Buyer) charge the Buyer interest (both before and after any
judgement) on the amount unpaid at the rate of 4 per cent per annum above Barclays Bank plc base rate from
time to time and exercise a lien over any property of the Buyer then in its possession, until payment in full is
made.
6.1 Save as aforesaid payments shall be applied to invoices in the order in which they were issued and to Goods in
the order in which they are listed in invoices.
6.2 The Buyer shall not be entitled to make any deduction or withhold any sum from the payment from time to time
due from it whether by way of set-off, counter claim or otherwise.
Warranty
7.0 The Seller warrants for a period of 12 months from invoice date that, in so far as the Goods are of its own
manufacture, they shall be free from defects in workmanship or materials at the time of delivery. If any Goods do
not conform to that warranty the Seller will at its option:
(a) replace the Goods found not to conform to the warranty and such replacements shall be supplied subject to
these Conditions; or
(b) take such steps as the Seller deems necessary to bring the Goods into a state where they are free from
such defects; or
(c) take back the Goods found not to conform to the warranty and refund the appropriate part of the purchase
price.
PROVIDED THAT:
(i) the liability of the Seller shall not arise unless the Buyer demonstrates to the Seller's reasonable satisfaction
that the Goods have, prior to use, been properly stored and handled and subsequently have not been used
in any unusual or abnormal way or in a manner contrary to any instructions or recommendations for use
provided by the Seller;
(ii) the liability of the Seller shall in no event exceed the purchase price of the Goods;
(iii) performance of any one of the above options (as limited by (ii) above) shall constitute an entire discharge of
the Seller's liability under this warranty.
105
7.1 The foregoing warranty is conditional upon:
(a) the Buyer giving written notice to the Seller of the alleged defect in the Goods, such notice to be received by
the Seller within 7 days of the time when the Buyer discovers or ought to have discovered the defect and in
any event within one year of delivery of the Goods;
(b) the Buyer affording the Seller a reasonable opportunity to inspect the Goods and, if so requested by the
Seller, returning the allegedly defective Goods to the Seller's works, carriage pre-paid, for inspection to take
place there;
(c) the Buyer making no further use of the Goods that are alleged to be defective after the time at which the
Buyer discovers or ought to have discovered that they are defective.
7.2 The Seller further undertakes that, in so far as the Goods are not of its own manufacture, it will pass on to the
Buyer the benefit of any guarantees or indemnities given to it in respect of such Goods by its own suppliers.
7.3 Save as provided in paragraphs 1 and 3 of this clause, in clause 2 and in section 12 of the Sale of Goods Act
1979:
(i) all conditions and warranties, express or implied, as to the quality or fitness for any purpose of the Goods
are hereby expressly excluded; and
(ii) except in respect of death or personal injury caused by the Seller's negligence, or in respect of liability under
the Consumer Protection Act 1987, the Seller shall not be liable for any loss or damage (whether direct,
indirect or consequential) howsoever arising which may be suffered by the Buyer.
It is hereby expressly declared that any statements as to quality made by the Seller do not form part of the
description of the Goods.
Limits of Liability
8.0 The Buyer must satisfy itself of the suitability of the Goods for the purposes for which they are purchased, and
must comply with any directions, instructions or warnings as to the use storage or handling of the Goods given by
the Seller. The Buyer must also ensure that the Goods comply with all local approvals and standards relating to
the use to which they are to be put, and without prejudice to the generality of paragraph 3 above, all
recommendations and advice given by or on behalf of the Seller to the Buyer as to the methods of storing,
applying or using the Goods the purposes to which the Goods may be applied and the suitability of using the
Goods in any manufacturing process or in conjunction with any other materials are (except when given pursuant
to a request of the Buyer under clause 2) given without liability on the part of the Seller, its servants or agents.
8.1 In the event that, notwithstanding the provisions of paragraphs 7.3 and 8.0 above, the Seller is found liable for any
loss or damage suffered by the Buyer, that liability shall in no event exceed the purchase price of the Goods.
8.2 Nothing in these Conditions or in the Particulars of Contract shall affect or limit the validity or application of any
customer warranty with the benefit of which any of the Goods are sold and if the Buyer, being an end-user, is able
to benefit from such a warranty the terms thereof shall prevail over the terms of these Conditions and the
Particulars of Contract.
Bankruptcy and Liquidation
9.0 This clause applies if the Buyer becomes (or appears to the Seller to be about to become) bankrupt, or goes (or
appears to the Seller to be about to go) into liquidation, has a petition presented or threatened for its winding-up,
suspends payment of debts or makes any arrangement with creditor, fails to pay in accordance with the terms of
the Contract, has an administration order made or a petition for such an order presented or threatened, has a
receiver appointed over all or any part of its assets or is answerable under the law of the country having
jurisdiction over the Buyer or its assets for any of the foregoing, or is in breach of any other term of the Contract.
9.1 If this clause applies, then without prejudice to any other right or remedy available to the Seller, the Seller shall be
entitled to cancel the Contract or suspend any further deliveries under the Contract without liability to the Buyer,
and if the Goods have been delivered but not paid for the price shall become immediately due and payable
notwithstanding any previous agreement or arrangement to the contrary.
Indemnities
10.0 The Buyer shall indemnify the Seller in respect of all damage injury or loss occurring to any person or property
and against all actions, suits, claims, demands, charges or expenses in connection therewith arising from the
condition or use of the Goods in the event that the damage injury or loss shall have been occasioned partly or
wholly by the carelessness of the Buyer and his servants, contractors or agents or by any breach by the Buyer of
either its obligations to the Seller hereunder or of any patent, design or other intellectual property right of a third
party.
10.1 The Buyer undertakes that it shall not solicit purchasers for the Goods outside countries which for the time being
are Member States of the European Economic Area ("EEA State") or sell the Goods to any person who it knows
is intending to use or resell the same outside the EEA States PROVIDED THAT nothing in this clause or
elsewhere in these Conditions shall be construed so as to prevent the Buyer from selling or distributing the Goods
in or to any EEA State to any person intending to use or resell the same in any EEA State.
Notices
11.0 Any notice required or authorised to be given hereunder shall be in writing and shall be served by registered mail
sent to the address given above or any other address notified for the purpose and shall be deemed to be served
106
seven days after proven despatch, provided that any other mode of service shall be valid if the said notice or
other communication is actually received by the addressee.
Force Majeure
12.0 The Seller shall not be liable to the Buyer if unable to carry out any provision of the Contract for any reason
beyond its control including (but without limitation) Act of God, legislation, war, civil commotion, fire, flood,
drought, failure of power supply, lock out, strike, stoppage or other action by employees or third parties in
contemplation or furtherance of any dispute or owing to any inability to procure parts or materials required for the
performance of the Contract.
Waiver
13.0 Any failure by the Seller to enforce any or all of these conditions shall not be construed as a waiver of the Seller's
rights.
Construction and Jurisdiction
14.0 The proper law of the Contract shall be English law and the English courts shall have jurisdiction over any
disputes arising thereunder. This edition of the Conditions of Sale dated October 2002 supercedes all previous
editions.

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