Amerex vs Manual 16400a Pneum Op

INSTALLA TION TION,, OPE OPE R ATION ATION A ND MA I N TE N A N C E MA NUA NU A L No. 16400 Rev. A

J un une e 2012 MOD UL A R DRY CHEMICAL CHEM ICAL VEHICLE VEHICLE FIRE FI RE SUPPRE SU PPRE SS I O N SYS T EMS EM S PNE UMA UMA TIC TIC A C TUA TUA TION TION

Models V13ABC & V13PK (13 lbs. / 5.9 kg ABC or Purple K) V25ABC & V25PK (25 lbs. / 11.3 kg ABC or Purple K) VH25ABC & VH25PK (Horizontal Mounting Only) V50ABC & V50PK (50 lbs. / 22.7 kg ABC or Purple K) VS50ABC & VS50PK (50 lbs. / 22.7 kg ABC or Purple K) Amerex Corporation An ISO 9001 quality and ISO 14001 environmental, r egistered firm.

Post Office Box 81 – 81 – 7595 7595 Gadsden Highway Trussville, Alabama 35173-0081 Phone: (205) 655-3271 Fax: (205) 655-3279 Email: [email protected] Home Page: http://www.amerex-fire.com

THE PURPOSE OF THIS MANUAL This manual is intended for use with models of AMEREX Vehicle Fire Suppression and Overheat Warning Systems that are equipped with pluggable pluggable modular wiring components. These are referred referred to as “Modular Systems” throughou throughoutt this manual. manual. It is intended intended for use as a reference reference manual and does not take the place of AMEREX factory training. This manual must be used in conjunction with NFPA Standard No. 17, Dry Chemical Extinguishing Systems, as well as all other standards deemed applicable to an installation installa tion by local authorities having jurisdiction. jurisdicti on. Individuals who design, install, operate, inspect, recharge or maintain these systems shall read this entire entire manual. manual. It is the the responsibility responsibility of the the installer of these systems to make certain that the owner of the equipment on which these systems are installed receives and reads the Owner's Manual, which is packaged with each agent cylinder. As with all electrical and mechanical equipment, all AMEREX systems require periodic care to provide maximum assurance that they will operate effectively and safely. safely. Inspection frequency should be based on the the requirements of the equipment on which the system is installed and the environment in which the equipment will operate. operate . Inspection and maintenance schedules are shown in this manual and must be followed to insure reliable system performance. Equipment operating continually and/or in harsh environments will require more frequent inspection and maintenance. You will receive additional and updated pages for this manual as they are published. It is important that that these changes and additions additions be added to this this manual according to the instructions that will accompany them. By doing this, you are assured of always having the latest information information concerning your system from the AMEREX factory. The application and use of the AMEREX Vehicle Fire Suppression Systems are limited to the applications and uses described in this manual. Technical Technica l data contained herein is based on controlled laboratory testing deemed appropriate by Factory Mutual Research Corp. and other listing agencies, and is intended for informational purposes only. The data presented is accurate for the testing performed, but is published with no guarantee relative to a given hazard where factors are different from those encountered during during actual tests. AMEREX disclaims disclaims any liability for any use of the data and information information contained herein herein by any and all other parties. Please direct questions concerning information in this manual to:

AMEREX CORPORATION Vehicle Systems Group P.O. Box 81 Trussville, AL 35173-0081 205-655-3271

Thank you for choosing AMEREX.

THE PURPOSE OF THIS MANUAL This manual is intended for use with models of AMEREX Vehicle Fire Suppression and Overheat Warning Systems that are equipped with pluggable pluggable modular wiring components. These are referred referred to as “Modular Systems” throughou throughoutt this manual. manual. It is intended intended for use as a reference reference manual and does not take the place of AMEREX factory training. This manual must be used in conjunction with NFPA Standard No. 17, Dry Chemical Extinguishing Systems, as well as all other standards deemed applicable to an installation installa tion by local authorities having jurisdiction. jurisdicti on. Individuals who design, install, operate, inspect, recharge or maintain these systems shall read this entire entire manual. manual. It is the the responsibility responsibility of the the installer of these systems to make certain that the owner of the equipment on which these systems are installed receives and reads the Owner's Manual, which is packaged with each agent cylinder. As with all electrical and mechanical equipment, all AMEREX systems require periodic care to provide maximum assurance that they will operate effectively and safely. safely. Inspection frequency should be based on the the requirements of the equipment on which the system is installed and the environment in which the equipment will operate. operate . Inspection and maintenance schedules are shown in this manual and must be followed to insure reliable system performance. Equipment operating continually and/or in harsh environments will require more frequent inspection and maintenance. You will receive additional and updated pages for this manual as they are published. It is important that that these changes and additions additions be added to this this manual according to the instructions that will accompany them. By doing this, you are assured of always having the latest information information concerning your system from the AMEREX factory. The application and use of the AMEREX Vehicle Fire Suppression Systems are limited to the applications and uses described in this manual. Technical Technica l data contained herein is based on controlled laboratory testing deemed appropriate by Factory Mutual Research Corp. and other listing agencies, and is intended for informational purposes only. The data presented is accurate for the testing performed, but is published with no guarantee relative to a given hazard where factors are different from those encountered during during actual tests. AMEREX disclaims disclaims any liability for any use of the data and information information contained herein herein by any and all other parties. Please direct questions concerning information in this manual to:

AMEREX CORPORATION Vehicle Systems Group P.O. Box 81 Trussville, AL 35173-0081 205-655-3271

Thank you for choosing AMEREX.

Part Number 16400 Rev. A

June 2012

TABLE OF CONTENTS: Forward

About This Manual

Section 1

Introduction

1.A 1.B 1.C

What Can Be Protected, Use and Limitations Limitation s Testing Performed Operating Temperature Extremes

1-1 1-2 1-2

Component Description and Operating Details Method of Operation Pneumatic Actuation Individual Components - An Installer's Glossary How the System Works - A Typical Fire Scenario Some Typical Installations Installation s In Case of Fire - Actions to Take

2-1 2-1 through 2-17 2-18 through 2-20 2-21 through 2-22 2-23

Section 3 3.A 3.B 3.C 3.D 3.E

Hazard Analysis Identifying the Potential for Fire Assessing the Consequences of Fire Determining the Need for Fire Protection Selecting the Appropriate Fire Suppression Options Selecting Fire Suppression System Hardware

3-1 3-2 3-2 3-3 3-3 through 3-5

Section 4 4.A 4.B 4.C 4.D 4.E 4.F 4.G 4.H

System Layout and Design Single Discharge Dischar ge Nozzle Coverage Ratings Multiple Discharge Discha rge Nozzle Coverage Discharge Network Hose Limitations Stainless Steel Rigid Tubing in Discharge Network Actuation Network Hose Limitations Multiple Agent Cylinder Networks (Pneumatic (Pneumatic Actuation) Hose Coupling and Fitting Specifications Detection Network

4-1 4-2 through 4-3 4-4 through 4-12 4-13 4-14 4-15 4-16 4-17

Section 5 5.A 5.B

Electrical Controls Modular Control Panel III SafetyNet Control Systems

5-1 5-1

Section 6 6.A

Installation Installation of System Mounting and Installing Components Agent Cylinder Cylinder Brackets Brackets Agent Cylinder Cylinder Mechanical Control Head Pneumatic Control Head Vent Check

6-1 6-1 through through 6-2 6-3 6-3 6-3 6-3

Check Valve Distributor Nozzle Brackets Nozzles Actuator Bracket Manual Actuator Pressure Operated Switch Circuit Monitor III or Control Panel III SafetyNet Control Systems Spot Thermostats Linear Heat Detection Cable Assemblies

6-3 6-4 6-4 6-4 6-5 6-5 6-5 6-6 6-6 6-7 6-8 through 6-9

Section 2 2.A 2.B 2.C 2.D


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Table of Contents – Continued 6.B 6.C

6.D

6.E 6.F

Section 7

Connection of Hoses Connection of Electrical Circuits Wiring Material Routing Wiring Connections Color Coding Heat Sensor Connections Agent Cylinder Pressure Switch Pressure Operated Switch Electric Actuator Connection Lead Wiring Schematics Engine Shutdown and Auxiliary Devices Placing the System In Service Connect The Discharge Network Connect Agent Cylinder Pressure Switch Test Engine Shutdown Systems The Electrical Networks Agent Cylinder Pressure Switch Circuit Battery Back-Up Circuit Install the Electric Actuator Manual Actuators Documentation Final Inspection Provide Owner / Operator Training Warranty Statement

Inspection Servicing the Amerex Systems Daily Inspection Monthly Inspection

Section 8

9-1 9-1 through 9-4 9-4 through 9-6 9-6

Component Rebuild Diagrams & Spare Parts Agent Cylinders V13, V25, V50, VS50 Agent Cylinders VH25 Horizontal Discharge Valve Assembly Pneumatic Control Head Manual Actuator Electric/Nitrogen Actuator Nitrogen Cylinder Additional Parts Not Pictured

Section 11

8-1 through 8-6

Recharge Clean Up Recharge Recharge Nitrogen Cylinders Recharge Completion

Section 10

7-1 7-1 7-1

Maintenance Semi Annual / 1000 Hour Maintenance

Section 9

6-9 6-10 6-10 6-10 6-10 6-10 6-11 6-11 6-12 6-12 6-12 6-13 through 6-14 6-15 6-15 6-15 6-15 6-15 through 6-16 6-16 6-16 6-17 6-17 6-17 6-17 6-17 through 6-18 6-18 through 6-19

10-1 10-2 10-3 10-4 10-5 10-6 10-7 10-8

System Specifications Weight of Components

11-1


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Section 1 Introduction 1.A. What can Be Protected The AMEREX Models V13, V25, VH25, VS50 and V50 are pre-engineered dry chemical fire suppression systems. These systems have predetermined flow rates and nozzle discharge quantities dispensed through specific flexible hose and/or stainless steel tubing sizes of designated minimum and maximum lengths, connected with specific numbers and sizes of fittings and couplings. These models are intended for use of both mobile and self-propelled equipment such as off-road earth moving, land clearing, forestry, landfill and farming vehicles, over –the-road buses, maintenance and refuse collection vehicles, and mobile equipment such as pumps, compressors or generators. The Models V13ABC, V25ABC, VH25ABC, VS50ABC and V50ABC use Amerex ABC multipurpose, ammonium phosphate base dry chemical which is effective at suppressing fires involving both Class A (ordinary combustibles) and Class B (flammable liquids), and is safe for use on Class C fires (involving energized electrical equipment). This ABC capability is particularly well suited to vehicle applications since solid debris (wood chips, coal dust, paper refuse, farm vegetation), flammable liquids (hydraulic fluid, diesel fuel or gasoline, battery acid, ethylene glycol) and electrical current (batteries, starters, winches, and charging systems) normally coexist in these cases. The Models V13PK, V25PK, VH25PK, VS50PK and V50PK use Amerex Purple K Class BC potassium bicarbonate base dry chemical which is effective at suppressing Class B fires (involving flammable liquids), and is safe on Class C fires (involving energized electrical equipment). This BC capability is well suited to vehicles where flammable liquids are the primary hazard. CAUTION: Extinguishing of flowing flammable liquid fires may result in a reflash unless all sources of ignition have been removed. Flammable gases present a potential explosion hazard if the flow of gas is not stopped before or during extinguishment. The Models V13, V25, VH25, VS50 and V50 shall not be considered satisfactory protection for the following: (a) Chemicals containing their own oxygen supply, such as cellulose nitrate. (b) Combustible metals such as lithium, sodium, potassium, magnesium, titanium, and zirconium. (c) Deep-seated or burrowing fires in ordinary combustibles where the dry chemical cannot reach the point of combustion. (d) Explosion suppression. (e) Other purposes for which the system was not designed. Use of the Models V13, V25, VH25, VS50 and V50 can help protect major vehicle components such as engines, transmissions, charging systems, hydraulic systems, and braking and control systems avoiding costly equipment loss, equipment downtime, product loss, and most importantly, operator injury. CAUTION: The discharge of large amounts of dry chemical may create hazards to personnel such as reduced visibility and temporary breathing difficulty. The dry chemical is completely non-toxic, and considered only a nuisance dust by O.S.H.A. standards. MSDS information is available online via the Amerex website: www.amerex-fire.com.


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1.B Testing Performed: AMEREX Models V13, V25, VH25, VS50 and V50 have been rigorously tested by Factory Mutual Research Corporation to ANSI/UL 1254 and found to meet or exceed all requirements applicable to vehicle fire suppression systems. Testing includes but is not limited to: 240 hr. salt fog test, vibration and shock testing, repetitive cycling test, bracket loading tests, hydrostatic pressure testing, temperature extremes tests, temperature cycling, pressure retention, and fire tests. The fire tests for Models V13ABC, V25ABC, VH25ABC, VS50ABC and V50ABC were conducted on both Class A and Class B hazards while fire tests for Models V13PK, V25PK, VH25PK, VS50PK and V50PK were conducted only on Class B hazards. All fire tests were conducted in both total flooding and overhead application scenarios. Diagrams of the fire test methods and apparatus are shown in Figures 1-1 & 1-2. The AMEREX system is Factory Mutual Research Corp. approved as a pre-engineered vehicle fire suppression system. All fire testing was conducted under controlled laboratory conditions. Fires by nature are unpredictable and Amerex does not claim that all fires will be extinguished or effectively suppressed. Warning: Use of any component not of AMEREX manufacture other than specifically mentioned in this manual or the incorrect installation of components will void the AMEREX warranty and the Factory Mutual listing, and will negatively affect the functionality of the system.

1.C. Operating Temperature Extremes AMEREX Vehicle Fire Suppression Systems are suitable for use in the temperature range of -40 oF (-40 oC) to 150 oF (66 oC). Installers must not place systems on any vehicle that functions outside of these temperature limits. Also, care must be taken not to place system components in areas or enclosures of a vehicle where temperatures outside this range are experienced. For example, agent cylinders must never be placed inside an area where temperatures can exceed 150 oF (66 oC) such as an engine compartment.


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Section 2 Component Description and Operating Details NOTE: Bracketed item numbers in component descriptions correspond to identification numbers used in Figure 2_1V and Figure 2_1H, installation components for pneumatic actuated sys tems, following in this section. See page 2-12 and 2-13. A utomatic pneumatically actuated systems make use of one or more small Nitrogen Cylinders P/N 09956 (Item 5). These cylinders contain pressurized gas which is released by means of an Electric Nitrogen Actuator P/N 20775 (Item 7) through installer provided supply hose to a Pneumatic Control Head P/N 10147 (Item 4) mounted on the Agent Cylinder Valve. The Pneumatic Control Head contains a piston that opens the Agent Cylinder Valve and releases the fire suppression agent. Automatic pneumatically actuated systems may be manually actuated by pulling the safety ring pin on the Manual Actuation Switch P/N 14053 and pressing the red “FIRE” button, or automatically through the use of heat sensing devices. Electric Power is provided by the vehicle battery (12 to 24 VDC) to operate the system. Manual only pneumatically actuated s ys tems do not require the use of electricity and operate solely on the nitrogen pressure released by use of the Manual Actuator P/N 10210 (Item 6) to release the nitrogen. The Manual Actuator is operated by pulling the safety ring pin on the Actuator and pressing down on the red “Fire” button.

2.A. Individual Components - An Installer's Glossary Agent Cylinder Assembly (Item 1): The agent cylinder is available in five configurations and two fire suppression agents. Models V13ABC, V25ABC, VH25ABC, V50ABC, and VS50ABC are charged with AMEREX multi-purpose ABC dry chemical agent. Models V13PK, V25PK, VH25PK, V50PK, and VS50PK are charged with AMEREX Class BC "Purple K" dry chemical agent. All assemblies are stored pressure designs with an operating pressure of 350-psi (2413 KPa). The cylinders are constructed of welded steel to DOT 4BW specifications. The V13 models are 7 inches (17.8 cm) in diameter. The V25 and V50 models are 9 inches (22.9 cm) in diameter. The VS50 is 14 inches (35.6 cm) in diameter. The VH25 Horizontal models are always mounted horizontally, thus their height as installed horizontally including mounting bracket is significantly less than their vertically mounted counterparts of the same volume. Horizontal models are recommended where vertical space is limited. The discharge valve, which is common to all agent cylinders, is of rugged forged brass construction. The valve is equipped with a 350 psi (2413 KPa) pressure gauge protected by a forged brass gauge guard, a pressure monitoring switch and a pressure relief device. The valve controls agent discharge via a spring loaded, internal sealing stem that must be depressed from the top of the valve to initiate agent discharge. Agent cylinders are shipped from the AMEREX factory fully charged with a shipping plate installed on the top of the valve to help prevent accidental agent discharge and an anti-recoil plate on the valve outlet to redirect


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chemical flow should an accidental discharge occur. installation.

Page 2-2 Both of these plates must be removed at

All agent cylinders cylinders are equipped with with a pressure monitoring monitoring switch. The agent cylinder cylinder pressure switch is an electrical device that is factory installed installed on the agent cylinder discharge valve. valve. The switch allows allows for the monitoring of the agent cylinder charge pressure by providing a closed circuit when the pressure is within the proper operating range, and an open circuit when the pressure d rops below the proper operating range. Example: The switch sends a signal to the Control Panel illuminating the service system LED when the pressure falls below the acceptable range. The switch is factory installed with a plug-type connector installed on the leads. At installation, installation, the free end of this plug is permanently permanently connected to the suppression system wiring. The agent cylinder pressure switch must must be factory installed. Therefore, when the agent cylinder is removed for recharging, the switch remains on the valve and is simply unplugged from the wiring harness. The following agent cylinders are available with factory installed agent cylinder pressure switches: V13ABC Agent Cylinder w/ Pressure Switch……P/N Switch……P/N 15647 V25ABC Agent Cylinder w/ Pressure Switch……P/N Switch……P/N 15591 VH25ABC Agent Cylinder w/ Pressure Switch….P/N 15524 V50ABC Agent Cylinder w/ Pressure Switch……P/N Switch……P/N 15590 VS50ABC Agent Cylinder w/ Pressure Switch…..P/N Switch…..P/N 16979 V13PK Agent Cylinder w/ Pressure Switch……....P/N Switch……....P/N 15650 V25PK Agent Cylinder w/ Pr essure essure Switch………P/N 15651 VH25PK Agent Cylinder w/ Pressure Switch…….P/N Switch…….P/N 15652 V50PK Agent Cylinder w/ Pressure Switch………P/N Switch………P/N 15653 VS50PK Agent Cylinder w/ Pressure Switch……..P/N Switch……..P/N 16980 Agent Cylinder Brackets (Item 2): The agent cylinder brackets are constructed from 3/16 inch (4.7mm) and 1/4 inch (6.4mm) welded steel & painted to resist corrosion. corrosion. The part numbers for available agent cylinders cylinders are shown shown below. All brackets are equipped with thick rubber pads to protect protect the agent cylinders. The mating agent cylinder must be used with with the corresponding agent cylinder bracket selected. The mounting brackets are not interchangeable with other agent cylinder sizes.


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Mechanical Control Head (Item 3) P/N 10134:On 10134:On installations where neither automatic nor remote actuation is required, the mechanical control head, P/N 10134 can be used. This device is a T-handle design constructed of brass and stainless steel and bolts directly to the top of the agent cylinder discharge discharge valve. The handle is locked in the safety position by a ring pin, which which is pulled out at the time time of actuation. The T-handle is spring loaded and detented to lock in place only in the FULL OPEN or FULL CLOSED positions to discourage incomplete valve opening opening in a fire situation. situation. The Mechanical Control Head is also used as a service tool to open the discharge valve during agent cylinder recharging.

Pneumatic Control Head (Item 4) P/N 10147: On installations where remote and/or automatic pneumatic actuation is required, the pneumatic control head, P/N 10147 must be used. This device is constructed of extruded brass brass and bolts directly to the top of the agent cylinder discharge discharge valve. When supplied with actuation pressure, the piston inside the pneumatic control head extends and locks down to depress the stem of the agent cylinder valve releasing the fire suppression agent. Actuation pressure (compressed nitrogen gas) enters the Pneumatic Control Head through 1/4 NPT threaded ports on either side.

Nitrogen (N2) Cylinder (Item 5) P/N 09956 : The N2 cylinder, P/N 09956, 09956, supplies nitrogen gas pressure to the pneumatic control head through the actuation lines for the purposes of opening the agent cylinder cylinder valve. This cylinder is charged charged to 1800 psig o (12410 KPa) at 70 F (21º C) and contains enough nitrogen to actuate up to eight agent cylinder valves at a maximum distance of 125 feet (21.3 meters) to the last control head. Pressure is retained in the N2 cylinder by a gold plated rupture disc. Replacement rupture discs are available available as P/N P/N 09958. Only genuine AMEREX rupture discs may be used when recharging nitrogen nitrogen cylinders. Proper charge charge pressure is indicated by a pressure gauge located on the cylinder bottom and protected by an impact resistant plastic gauge guard. The N2 cylinder is shipped fully charged from the AMEREX factory with a protective shipping cap installed on the outlet threads. The cap must be removed at installation but must remain in place at all other times. (Retain the shipping cap to reuse reuse when recharging the cylinders) cylinders) Construction of the N2 cylinder is per DOT 3E. The cylinder is rechargeable rechargeable by certified AMEREX AMEREX installers and does not require periodic hydrotesting.

Manual Actuator (Item 6) P/N 10210: 10210 : The manual manual actuator, P/N 10210, is used for manually releasing nitrogen gas pressure from the N2 cylinder to power the pneumatic pneumatic control head. The body of the actuator is chrome chrome plated brass and contains a stainless steel puncture point that is connected to a palm button and locked in place by a stainless stainless steel ring pin. pin. The diameter diameter of the pull ring has been made large for for ease of operation when wearing wearing gloves. The exposed shaft of the stem is shielded from the elements by a rubber dust boot. To use the actuator, the operator pulls the ring pin and strikes down hard on the palm button. This strike pushes the puncture puncture stem into the rupture disc disc of the N2 cylinder, which releases releases the nitrogen. Released nitrogen gas enters the actuation lines through a 1/4 NPT NPT exhaust port. The manual actuator and N2 cylinder assembly are mounted to an actuator bracket by two stainless steel 1/4-inch screws, which are included with the assembly. assembly. The manual actuator may be installed installed inside or outside the vehicle cab in any orientation that facilitates easy access to the ring pin and palm button.


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Electrical/Nitrogen Actuator (Item 7) P/N 20775: The electrical/nitrogen actuator, P/N 20775, is used to release nitrogen gas gas pressure from the N2 cylinder to power the the pneumatic control head. The body of the electrical/nitrogen actuator is constructed of chrome plated brass and contains a stainless steel steel puncture point. The puncture stem is free to travel against the return spring into the rupture disc of the N2 cylinder (Item 5), which which is installed at the the outlet port port end. There is a brass adapter threaded into the other end that accepts an Electric Actuator P/N 14036 (Item 8). This threaded adapter is removable for disassembling and cleaning the control head during maintenance. When a heat detection device detects heat beyond its actuation point, it completes an electrical circuit sending sending an electrical charge to to the electric actuator. The actuator fires and extends a shaft to propel the puncture stem into the rupture disc of the the N2 cylinder releasing releasing the nitrogen gas. The electrical/nitrogen actuator and N2 cylinder assembly are mounted to an actuator bracket by two stainless steel 1/4-inch screws, which are included with the assembly.

Electrical Actuator (Item 8) P/N 14036: The Electrical Actuator must be used to operate the electric/nitrogen electric/nitrogen actuator. The Electrical Electrical Actuator is a device that when electrically activated extends a stainless steel shaft that mechanically operates the electric/nitrogen electric/nitrogen actuator. Once activated it cannot be reused and must be replaced. replaced. Service life of the Electric Actuator is 6 years after which it must be replaced. Shelf life of the the Electric Actuator Actuator is 10 years after which it must be replaced whether whether it has been placed placed in service or not. For this item to function reliably the Circuit Monitor or Control Panel must have direct power from the vehicle battery and the the backup battery must must be fully charged. An O-ring seal is provided with each electric electric actuator to keep keep contamination from entering the actuator body (Item 7). This O-Ring must be used. Vent Check (Item 9) P/N 10173: 10173 : The vent check, P/N 10173, is a safety device device that installs in the pneumatic pneumatic control head. Its function is to bleed any slowly slowly accumulating pressure pressure that could cause cause the pneumatic control head to open the agent cylinder valve prematurely. Examples of possible pressure sources include a slow leak in the rupture disc of an N2 cylinder, or normal temperature induced expansion of the air and moisture moisture trapped in the actuation lines. A vent check must be used on all pneumatically pneumatically actuated systems. Use of a pipe plug or other type of "stopper" is unacceptable unacceptable and can lead to system malfunctions. The body of the vent check is constructed of machined brass. The inside of the vent check contains a spring and nylon ball. Slowly accumulating accumulating gas can pass around the nylon ball and bleed to the atmosphere. atmosphere. However, the rapid accumulation accumulation of actuation pressure from the N2 cylinder causes the ball to compress the spring and seal on a tapered seat, blocking the bleed hole. Following an actuation, the vent check can be used to exhaust residual residual actuation pressure by unseating the nylon ball (typically with a small piece of wire or the tip of a ball point pen). In installations using multiple agent cylinders, the vent check is installed only in the last pneumatic control head at the end of the actuation actuation network. The Vent Check is supplied with with a plastic dust cap, which should be re-installed after assembly into the Pneumatic Control Head. Actuation Lines (Item 10) : The function of the actuation actuation line is to carry high-pressure nitrogen gas from the N2 cylinder to the pneumatic pneumatic control head. Actuation lines consist of 1/4 inch (6.4 mm) ID, wire braided braided rubber hydraulic hose, and corresponding fittings. fittings. Actuation hose and fittings are installer supplied. Various manufacturers’ specifications specifications for these hoses are given given in Section 4G. Care must be taken to always use only the brand of fittings specified by each hose manufacturer manufacturer for their hose. Substitution of unapproved hose or that of a different size will void the Factory Mutual listing, and will adversely affect system performance. See important hose routing procedures in Section 4.


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Check Valve (Item 11) P/N 10262: The check valve, P/N 10262, is used in various locations in the actuation network to ensure that the nitrogen gas follows the correct path to the pneumatic control head. Although there is no limit to the number of manual actuator/N2 cylinder assemblies that can be used on an installation, the path from each one of these actuators to the last pneumatic control head must not exceed 125-ft. (21.3 meters) maximum. Therefore, one check valve must be installed on both inlets of any 1/4-inch tee where two actuators are connected. This plumbing consideration is explained in Section 4. The P/N 10262 check valve must be used as a safety device to trap nitrogen actuation pressure in the pneumatic control head. One check valve must be installed on the inlet side of each pneumatic control head. When sufficient nitrogen pressure accumulates to force the agent cylinder valve open, the check valve will keep the valve open for the duration of the discharge, even if the actuation line is subsequently damaged to the point of rupture.

Actuator Brackets (Item 12) P/N 10354 and 10355: The manual actuator and electrical/nitrogen actuator and N2 cylinders are mounted to the vehicle on an indoor, P/N 10355, or an outdoor, P/N 10354 actuator bracket. Both brackets are constructed of steel and painted to inhibit corrosion. The outdoor actuator bracket includes a steel guard to protect the actuator and N2 cylinder. Front accessible, 1/4 inch, stainless steel cap screws are provided to mount the cover to the outdoor bracket.

Discharge Fitting Kit (Item 13) P/N 10199 : The discharge fitting kit, P/N 10199, consists of a brass fitting with an o-ring seal on one end and 3/4 NPT male pipe threads on the other, and a stainless steel flange for locking the fitting in place. The flange is placed over the threaded end of the fitting before connection to a discharge hose. Discharge Hoses (Item 14): The function of the discharge hoses is to carry the dry chemical agent to the discharge nozzles. These hoses consist of 1/2 inch (12.7 mm) and 3/4 inch (19.1 mm) ID, wire braided rubber hydraulic hose, and/or stainless steel tubing and the corresponding fittings. Discharge hose and fittings are installer supplied. Detailed specifications for these hoses by manufacturer are given in Section 4. Care must be taken to always use only the brand of fittings specified by each hose manufacturer for their hose. Substitution of unapproved hose or that of a different size will void Factory Mutual listing, and will adversely affect system performance. If you wish to use hose other than that specifically approved in this manual, please call AMEREX Vehicle Systems (205-655-3271) for prior written approval.

Distributor (Item 15) P/N 10178: The distributor, P/N 10178, is constructed of steel and is used as a manifold for the discharge hoses. The distributor is epoxy coated to inhibit corrosion. A single 3/4 NPT inlet connects internally to four 1/2 NPT outlets. Distributors are required in all 6 and 8 nozzle networks, and some 4 nozzle networks. Precise locations are given in section 4.


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Discharge Nozzle (Item 16) P/N 10250: The discharge nozzle, P/N 10250, is constructed of brass and distributes dry chemical agent in a cone shaped pattern. It is machined with a 1/2-inch NPT pipe thread for assembly into 1/2-inch distribution hoses. It is shipped complete with a heat and weather resistant rubber blow-off cap that prevents debris from lodging in the nozzle outlet. The blow off cap is molded with a retaining loop that assembles over the 1/2 inch pipe threads before the nozzle is installed. In this way, when the blow off cap is displaced from the nozzle tip by the chemical discharge pressure, it will not drop into the fire. Replacement blow-off caps are available separately as P/N 10167. If blow-off caps become worn, damaged, lost or brittle they must be replaced. Nozzle Bracket (Item 17) P/N 10780: The nozzle bracket, P/N 10780, is constructed of a 1/2 inch steel pipe coupling welded to an angled steel bracket. The bracket is epoxy coated to inhibit corrosion. After welding or bolting the bracket to the vehicle, a 1/2-inch ID distribution hose is plumbed to one end of the coupling. The other end of the coupling can accept the discharge nozzle directly, or a nipple and elbow followed by a discharge nozzle if required for aiming purposes.

Circuit Monitoring Panels & Control Panels, Modular (Item 18) : See Amerex Manual 19680 for complete details, dimensions, specifications and installation instructions for the Modular Circuit Monitors and Control Panels. See Amerex Manual 16601 for complete details, dimensions, specifications and installation instructions for the Amerex SafetyNet Electronic Control System and related components. Power Supply Lead, Modular (Item 19) : The power supply lead (color coded red) is used to supply electrical power from the vehicle battery to any one of the five circuit monitoring and control panels. This assembly is constructed of 16 gauge, two conductor, abrasion resistant jacketed wire, assembled to a fuse holder and terminated with two 3/8" (9.5 mm) ID. round eye battery connection terminals on one end. The other end has an Amerex click lock connector (color coded red) for connection to the mating connector at the circuit monitor or control panel (color coded red). The fuse holder is of a weatherproof rubber construction and is equipped with a rubber retaining loop. A 10 amp, Type AGC fast acting fuse is provided in the fuse holder for protection of the control panels and the related circuits. WARNING: USE OF THE AMEREX SUPPLIED POWER LEAD IS CRITICAL TO PROPER FUNCTIONING AND PROTECTION OF ALL SYSTEM ELECTRICAL COMPONENTS. USE OF POWER SUPPLY LEADS OTHER THAN OF AMEREX MANUFACTURE OR USE OF A FUSE OTHER THAN THE TYPE AND RATING SPECIFICALLY SPECIFIED IN THIS MANUAL VOIDS THE FACTORY MUTUAL LISTING .


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The power supply lead is available in the following lengths: 10 feet ( 3 meters) = P/N 14016 15 feet (4.6 meters) = P/N 14799 25 feet (7.6 meters) = P/N 14017 40 feet (12.2 meters) = P/N 14018 50 feet (15.2 meters) = P/N 14019 60 feet (18.3 meters) = P/N 14915 75 feet (22.9 meters) = P/N 15150 Power Lead Extension 1 foot (.3 meter) = P/N 18161 Power Lead Extension 10 feet (3 meters) = P/N 14800 Power Lead Extension 18 feet (5.5 meters) = P/N 20174 Power Lead Extension 20 feet (6 meters) = P/N 16527 Power Lead Extension 40 feet (12.2 meters) = P/N 14801. Replacement fuse = P/N 15779 Electrical Actuator Connector Lead, Modular (Item 20) : The Electrical Actuator Connector Lead Assembly must be used to connect the Electrical Actuator to the Circuit Monitor or Control Panel. The Actuator Connector Lead is an armor jacketed, abrasion resistant, high temperature 16 gauge, two-conductor wire equipped with yellow color-coded Amerex Click Lock connectors. These connectors mate with the Actuator plug at the Control Panel and the plug at the Electrical Actuator. The following lengths are available: 1 foot (.3 meters) = P/N 18160 3 feet (.9 meters) = P/N 14723 6 feet (1.8 meters) = P/N 14724 7 feet (2.1 meters) = P/N 16512 10 feet (3 meters) = P/N 14123 15 feet (4.6 meters) = P/N 17418 18 feet (5.5 meters) = P/N 20173 20 feet (6.1 meters) = P/N 14124 25 feet (7.6 meters) = P/N 16945 30 feet (9.1 meters) = P/N 14125 35 feet (10.7 meters)=P/N 17194 36 feet (10.9 meters)=P/N 17284 37 feet (11.3 meters)=P/N 17545 40 feet (12 meters) = P/N 14126 41 feet (12.5 meters)=P/N 14546 46 feet (14.0 meters)=P/N 17230 50 feet (15 meters) = P/N 14127 53 feet (16.2 meters)=P/N 16513 55 feet (16.8 meters)=P/N 20622

An additional line of heavy-duty actuation lead wire assemblies is now available for the Amerex Modular Fire Suppression Systems. The new lead assemblies come with a solid heat and abrasion resistant outer sleeve installed over the standard red hazard area wire and sealed over the modular pluggable connectors at each end. This shielded cable offers additional protection against heat and abrasion and must be used as standard wiring harness for the Amerex Fire Suppression System in all off road applications. Shielded Actuation Lead Assemblies are available in the following lengths: 3 foot (.9 meters) = P/N 16470 24 inches (0.61 meters) = P/N 17780 6 feet (1.8 meters) = P/N 16471 44 inches (1.12 meters) = P/N 19674 10 feet (3 meters) = P/N 16472 20 feet (6 meters) = P/N 16473


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Local Sensing Heat Actuated Thermostat Assembly, Modular (Item 21) : The "spot" thermostat is a normally open, self-resetting contact closure device. At least one heat sensing device must be installed in each protected area of the vehicle. The four-wire configuration allows continuous electrical supervision of all circuits connecting the thermostats. During a fire, the thermostat is heated to its factory preset actuation temperature. Upon reaching the preset temperature, the thermostat electric contacts are designed to close sending a fire alarm condition to the electrical panel. When the thermostat cools, the contacts reset to their original open condition. The thermostats are equipped with Amerex green color coded click lock electrical connectors to connect to green color coded Jumper Leads (Item 30) which connect to the circuit monitor or control panel. Section 3, Hazard Analysis, gives instructions for thermostat selection. Local sensing heat actuated thermostats are available in weather resistant miniature models. The 450º thermostat is only available is the bulkhead mount configuration. Thermostats and any part of the Amerex detection circuit if exposed to fire conditions or showing evidence or scorching or flame contact must be replaced. Spot thermostats are available in the following preset temperatures. Weatherproof Thermostats P/N (Deg. F.) 14087 280 14088 350 16615 450

(Deg. C) 138 177 232

Linear Heat Detection Cable Assemblies (Item 22): Linear Heat Detection Cable Assemblies consist of two steel conductors inside a heat sensitive insulated modular wiring harness. The two internal steel conductors are twisted into a spring loaded normally open condition. The heat sensitive cable is terminated at each end with green color coded Amerex Click Lock connectors for connection to Hazard Wire Modular Leads. When heated to a specific pre-determined temperature (356ºF.), the external conductor insulating jacket melts causing the conductors to short together and close the detection circuit. The Linear Heat Detector can be used as a stand-alone detector or downstream of spot thermostats if required. One P/N 14010 End Of Line Module must be plugged into the end of the detection circuit to complete the circuit and provide electrical supervision. The Linear Heat Detection Cables are available in various lengths with our without a stainless steel spring outer covering for added abrasion and impact protection. The following lengths are available. Note: The use of the 173XX series of Control Panels or SafetyNet is required when Linear Heat Detection is used! Without outer spring cover: 5 feet (1.5 meters) = P/N 20075-05 10 feet (3.1 meters) = P/N 20075-10 16 feet (4.5 meters) = P/N 20075-16 20 feet (6.1 meters) = P/N 20075-20 25 feet (7.6 meters) = P/N 20075-25 With outer protective spring cover: 5 feet (1.5 meters) = P/N 20083-05 10 feet (3.1 meters) = P/N 20083-10 16 feet (4.8 meters) = P/N 20083-16 20 feet (6.1 meters) = P/N 20083-20 25 feet (7.6 meters) = P/N 20083-25 Linear Heat Detection Assemblies may be combined as needed. Total length per system must not exceed 100 feet.


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Page 2-9

Pressure Operated Switch (Item 23) P/N 11615: The pressure operated switch, P/N 11615, is a device THAT can be used to send an electrical signal. The pressure operated switch is equipped with a single pole double throw switch to facilitate normally open or normally closed wiring. This SPDT switch is capable of handling 10 Amps (resistive) at 24 VDC. The pressure operated switch is installed in the 1/4-inch actuation lines. In this manner, Nitrogen actuation gas, whether released from the N2 Cylinder by the manual strike of a palm button or by the automatic release from a thermostat and electric actuator, will pressurize the switch causing it to transfer from the "normal" position to the "actuated" position. The switch will remain in its actuated position until the nitrogen actuation pressure is relieved, and the manual reset button, located on the top of the switch enclosure, is depressed. Electrical connection points are provided inside a water resistant enclosure. A 1/4 NPT threaded fitting is provided for plumbing to the actuation (nitrogen) line. Hazard Wire Modular Lead Assembly (Item 24): Hazard wire is armor jacketed, abrasion resistant, two conductor wire. In all installations, Hazard Wire Modular Lead Assemblies must be used on all leads routing from control panel to thermostats, and between thermostats. The assemblies are available in various lengths and are equipped with suitable green color coded, male and female Amerex Click Lock pluggable connectors on each end. The following lengths are available: 3 feet (.9 meters) = P/N 13981 6 feet (1.8 meters) = P/N 13982 7 feet (2.1 meters) = P/N 16512 10 feet (3 meters) = P/N 13983 15 feet (4.5 meters) = P/N 13984 18 feet (5.5 meters) = P/N 20172 20 feet (6.1 meters) = P/N 13985 22 feet (6.7 meters) = P/N 16511 25 feet (7.6 meters) = P/N 17195 30 feet (9.1 meters) = P/N 13986 32 feet (10.1 meters)= P/N 17281 37 feet (11.2 meters)= P/N 17282 40 feet (12.2 meters)= P/N 13987 42 feet (12.8 meters)= P/N 17229 43 feet (13.1 meters)= P/N 17547 50 feet (15.2 meters)= P/N 13988 60 feet (18.3 meters)= P/N 1 7063 Heavy-duty hazard lead wire assemblies come with a solid heat and abrasion resistant outer sleeve installed over the red hazard area wire. They are sealed over the modular pluggable connectors at each end. This shielded cable offers additional protection against heat and abrasion and are recommended for high vibration and off road applications. Shielded Hazard Lead Assemblies are available in the following lengths: 3 foot (.9 meters) = P/N 16457 59 inches (1.5 meters) = P/N 19675 6 feet (1.8 meters) = P/N 16458 196 inches (5.0 meters) = P/N 19676 10 feet (3 meters) = P/N 16459 256 inches (6.5 meters) = P/N 19677 15 feet (4.5 meters) = P/N 16460 386 inches (9.8 meters) = P/N 19678 20 feet (6 meters) = P/N 16461 355 inches (9.0 meters) = P/N 19687


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End Of Line Electric Module (Item 25): P/N 14010 completes the thermostat wiring circuits. Two are furnished with each Circuit Monitor or Control Panel.

Modular Fire Alarm Test Module (Item 26) P/N 21447: The Fire Alarm Test Module, P/N 21447 is used to test the function of the heat detection devices and actuation circuit when placing the system in service or performing routine maintenance See Sections 6 and 8 Manual Actuation Switch (Item 27) P/N 14053: All modular automatic pneumatically actuated systems require at least one Manual Actuation Switch. Multiple Manual Actuation Switches may be used if more than one manual actuation station is required or they may be used in conjunction with one or more Manual Actuators (P/N 10210 Item 6) if exterior mounting is required. To use the switch, the operator pulls out the safety ring pin breaking the plastic lock wire seal, and presses the red “FIRE” button. This action provides a signal to the display panel which actuates the fire alarm signal. The Manual Actuation Switch is also used as a test tool for systems utilizing Modular Linear Heat Detection. This test method is described in Section 6 and 8. The Manual Switch has green color coded Amerex Click Lock Connectors for connection to the detection circuit wiring. NOTE: Plastic lock wire seal included. Pressure Switch Modular Lead Assembly (Item 28) Pressure Switch Lead Assemblies are used to connect the blue color coded pressure switch leads at the Control Panel to the plugs provided on the Agent Cylinder Pressure Switch in order to monitor agent cylinder pressure at the Control Panel. On systems that use a single agent cylinder, a two connector Pressure Switch Lead can be used to connect both the male and female plugs at the Control Panel and the agent cylinder. On multiple agent cylinder systems a single connector lead is used to make connections between agent cylinders and then back to the two conductor lead to complete the circuit back to the Control Panel. The assemblies are available in various lengths and are equipped with suitable blue color coded, male and female Amerex Click Lock pluggable connectors on each end. The following lengths are available: Two connector lead assemblies 6 feet (1.8 meters) =P/N 21539-6 10 feet (3 meters) =P/N 21539-10 14 feet (4.2 meters) =P/N 21539-14 20 feet (6 meters) =P/N 21539-20 25 feet (7.6 meters) =P/N 21539-25 30 feet (10.1 meters) =P/N 21539-30 35 feet (11 meters) =P/N 21539-35 40 feet (12.2 meters) =P/N 21539-40 45 feet (13.5 meters) =P/N 21539-45 50 feet (15.2 meters) =P/N 21539-50 60 feet (18.3 meters) =P/N 21539-60

Single connector lead assemblies 1 foot (.3 meters) =P/N 22207-1 3 feet (.9 meters) = P/N 22207-3 5 feet (1.5 meters) = P/N 22207-5 10 feet (3 meters) = P/N 22207-10 15 feet (4.5 meters) = P/N 22207-15 20 feet (6.1 meters) = P/N 22207-20


June 2012

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Figure 2_1V System Schematic V13, V25, VH25, V50 & VS50 Systems Manual & Pneumatic Actuation


June 2012

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Figure 2_1H V13, V25, VH25, VS50 & V50 Agent Cylinder and Mounting Bracket Detail


June 2012

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Amerex Pre-Engineered Dry Chemical Vehicle Fire Suppression System Components as Shown in Fig 2_1V and Fig 2_1H. For Manual & Pneumatic Actuation Systems Only Sheet one of four Item No. Part No. Description _________________________________________________________________________________ 1

Agent Cylinders with Agent Cylinder Pressure Switch: 15647 V13ABC Agent Cylinder w/ Pressure Switch 15591 V25ABC Agent Cylinder w/ Pressure Switch 15524 VH25ABC Agent Cylinder w/ Pressure Switch 15590 V50ABC Agent Cylinder w/ Pressure Switch 16979 VS50ABC Agent Cylinder w/ Pressure Switch 15650 V13PK Agent Cylinder w/ Pressure Switch 15651 V25PK Agent Cylinder w/ Pressure Switch 15652 VH25PK Agent Cylinder w/ Pressure Switch 15653 V50PK Agent Cylinder w/ Pressure Switch 16980 VS50PK Agent Cylinder w/ Pressure Switch _______________________________________________________________________________ 2 12156 Bracket, Agent Cylinder - V13 10180 Bracket, Agent Cylinder - V25 11338 Bracket, Agent Cylinder - VH25 (Horizontal Model) 10181 Bracket, Agent Cylinder - V50 16974 Bracket, Agent Cylinder – VS50 _________________________________________________________________________________ 3 10134 Mechanical Control Head (T-Handle) _________________________________________________________________________________ 4 10147 Pneumatic Control Head _________________________________________________________________________________ 5 09956 Nitrogen (N2) Cylinder - 15 Cu. In.(246 ml.) _________________________________________________________________________________ 6 10210 Manual Actuator _________________________________________________________________________________ 7 20775 Electric/Nitrogen Actuator _________________________________________________________________________________ 8 14036 Electric Actuator _____________________________________________________________________________ ____ 9 10173 Vent Check _________________________________________________________________________________

10 XXXXX Actuation Hose (Installer Supplied) _________________________________________________________________________________ 11 10262 Check Valve _________________________________________________________________________________ 12

10355 10354

Bracket, Actuator - Indoor Bracket, Actuator - Outdoor (With Cover)


June 2012

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Amerex Pre-Engineered Dry Chemical Vehicle Fire Suppression System Components as Shown in Fig 2_1V and Fig 2_1H. For Manual & Pneumatic Actuation Systems Only Sheet two of four Item No. Part No. Description 13 10199 Discharge Fitting Kit _________________________________________________________________________________ 14 XXXXX Discharge Hoses (Installer Supplied) _________________________________________________________________________________ 15 10178 Distributor _________________________________________________________________________________ 16

10250 Cone Nozzle with Blow-off Cap 10167 Replacement Blow-off Cap Only _________________________________________________________________________________ 17 10780 Bracket, Nozzle Ass’y- 90 Degree _________________________________________________________________________________ 18 17308 Circuit Monitor III Panel, Modular Leads Exit Bottom 17309 Circuit Monitor III Panel, Modular Leads Exit Back 17310 Control Panel III Modular, Leads Exit Bottom 17311 Control Panel III Modular, Leads Exit Back 18-A 16389 SafetyNet Operator Display 16390 SafetyNet Driver Panel 16391 SafetyNet Detection Module 16392 SafetyNet Releasing Module 16395 SafetyNet Detection and Releasing Module _________________________________________________________________________________ 19

14016 Power Connector Lead, Modular - 10 Feet (3.0 Meters) 14799 Power Connector Lead, Modular - 15 Feet (4.6 Meters) 14017 Power Connector Lead, Modular - 25 Feet (7.6 Meters) 14018 Power Connector Lead, Modular - 40 Feet (12.2 Meters) 14019 Power Connector Lead, Modular - 50 Feet (15.2 Meters) 14915 Power Connector Lead, Modular - 60 Feet (18.3 Meters) 15150 Power Connector Lead, Modular – 75 Feet (22.9 Meters) __________________________________________________________ 14800 Power Lead Extension, Modular – 10 Feet (3.0 Meters) 16527 Power Lead Extension, Modular – 20 Feet (6.0 Meters) 14801 Power Lead Extension, Modular – 40 Feet (12.2 Meters) 15779 Replacement Fuse 10 AMP ___________________________________________________________________________________ 20 Electrical Actuator Modular Connector Lead Assemblies 14723 3 Feet (1 Meter) 14724 6 Feet (1.8 Meters) 16512 7 Feet (2.1 Meters) 14123 10 Feet (3.0 Meters) 17418 15 Feet (4.6 Meters) 14124 20 Feet (6.1 Meters) 16945 25 Feet (7.6 Meters) 14125 30 Feet (9.1 Meters) 17194 35 Feet (10.7 Meters) 17284 36 Feet (10.9 Meters)


June 2012

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Amerex Pre-Engineered Dry Chemical Vehicle Fire Suppression System Components as Shown in Fig 2_1V and Fig 2_1H. For Manual & Pneumatic Actuation Systems Only 17545 14126 17285 14127 16513

Sheet three of four 37 Feet (11.3 Meters) 40 Feet (12 Meters) 41 Feet (12.5 Meters) 50 Feet (15 Meters) 53 Feet (16.2 Meters)

Heavy Duty Abrasion Resistant Shielded Modular Thermostat Lead Assemblies 16470 3 Feet (0.9 Meters) 16471 6 Feet (1.8 Meters) 16472 10 Feet (3 Meters) 16473 20 Feet (6.1 Meters) _____________________________________________________________________________ 21

14087 14088 14090

Weather Proof Miniature Thermostat 280º F (138º C) Weather Proof Miniature Thermostat 350º F (177º C) Weather Proof Miniature Thermostat 450º F (232º C)

_________________________________________________________________________________ 22

20083-05 20083-10 20083-16 20083-20 20083-25

Linear Heat Detection (With Spring Cover) 5 Feet (1.5 Meters) Linear Heat Detection (With Spring Cover) 10 Feet (3.1 Meters) Linear Heat Detection (With Spring Cover) 16 Feet (4.8 Meters) Linear Heat Detection (With Spring Cover) 20 Feet (6.1 Meters) Linear Heat Detection (With Spring Cover) 25 Feet (7.6 Meters)

20075-05 20075-10 20075-16 20075-20 20075-25

Linear Heat Detection (W/O Spring Cover) 5 Feet (1.5 Meters) Linear Heat Detection (W/O Spring Cover) 10 Feet (3.1 Meters) Linear Heat Detection (W/O Spring Cover) 16 Feet (4.8 Meters) Linear Heat Detection (W/O Spring Cover) 20 Feet (6.1 Meters) Linear Heat Detection (W/O Spring Cover) 25 Feet (7.6 Meters)

________________________________________________________________________________ 23 11615 Pressure Operated Switch _________________________________________________________________________________ 24

Hazard Zone Wire Modular Thermostat Lead Assemblies: 13981 3 Feet (0.9 Meter) 13982 6 Feet (1.8 Meters) 16512 7 Feet (2.1 Meters) 13983 10 Feet (3.0 Meters) 13984 15 Feet (4.5 Meters) 13985 20 Feet (6.1 Meters) 16511 22 Feet (7.6 Meters) 17195 25 Feet (7.6 Meters) 13986 30 Feet (9.1 Meters) 17281 32 Feet (10.1 Meters) 17282 37 Feet (11.2 Meters) 13987 40 Feet (12.2 Meters) 17229 42 Feet (12.8 Meters) 17547 43 Feet (13.1 Meters) 17230 46 Feet (14.0 Meters) 13988 50 Feet (15.2 Meters) 17063 60 Feet (18.3 Meters)


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Amerex Pre-Engineered Dry Chemical Vehicle Fire Suppression System Components as Shown in Fig 2_1V and Fig 2_1H. For Manual & Pneumatic Actuation Systems Only Sheet four of four Heavy Duty Abrasion Resistant Shielded Modular Thermostat Lead Assemblies 16457 3 Feet (0.9 Meter) 16458 6 Feet (1.8 Meters) 16459 10 Feet (3.0 Meters) 16460 15 Feet (4.5 Meters) 16461 20 Feet (6.1 Meter _________________________________________________________________________________ 25

14010

End of Line Module, Replacement, Detection Circuit (Two Supplied With Each Panel _________________________________________________________________________________ 26

21447

Alarm Test Module

27 14053 Manual Actuation Switch ____________________________________________________________________________________ 28

Pressure Switch Modular Lead Assemblies Two connector lead assemblies 21539-6 6 feet (1.8 meters) 21539-10 10 feet (3 meters) 21539-14 14 feet (4.2 meters) 21539-20 20 feet (6 meters) 21539-25 25 feet (7.6 meters) 21539-30 30 feet (10.1 meters) 21539-35 35 feet (11 meters) 21539-40 40 feet (12.2 meters) 21539-45 45 feet (13.5 meters) 21539-50 50 feet (15.2 meters) 21539-60 60 feet (18.3 meters)

Single connector lead assemblies 22207-1 1 foot (.3 meters) 22207-3 3 feet (.9 meters) 22207-5 5 feet (1.5 meters) 22207-10 10 feet (3 meters) 22207-15 15 feet (4.5 meters) 22207-20 20 feet (6.1 meter) ___________________________________________________________________________________ Not Pictured

14840 14841

Replacement Cord-set for Modular Circuit Monitor Replacement Cord-set for Modular Control Panel

Part Number 16400 Rev.

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Only Genuine Amerex Tools Should Be Used For Servicing The Amerex System .

Amerex Fire Suppression System Service Tools


June 2012

2.B. How the System Works - A Typical Fire Scenario The following is a typical fire scenario for an installation utilizing manual only fire detection and remote pneumatic fire suppression system actuation.

(1)

A fire starts in a protected area.

(2) Equipment operator (1) pulls the ring pin & (2) strikes the palm button on the manual actuator, releasing nitrogen gas into the actuation lines leading to the pneumatic control head on top of the agent cylinder valve.

(3) The nitrogen pressure entering the pneumatic control head opens the agent cylinder valve allowing pressurized dry chemical to flow into the distribution hoses leading to the discharge nozzles. The pressure of the entering dry chemical causes the protective dust caps located on the nozzles to be blown off.

(4) Dry chemical suppression agent discharges through fixed nozzles into protected areas, suppressing the fire.

Page 2-18


June 2012

The following is a typical scenario for an installation utilizing manual/electrical system actuation. This example shows the method of manually actuating the electrically actuated fire suppression system. (1)

A fire starts in a protected area.

(2) Equipment operator (1) pulls the ring pin & (2) presses the red “FIRE” button on the Manual Actuation Switch, thereby completing an electrical circuit form the vehicle battery to the electric actuator located on the electric/nitrogen actuator.

(3) The completed circuit energizes the electric actuator on the electric/nitrogen actuator. The electric/nitrogen actuator opens the nitrogen cylinder which pressurizes the pneumatic actuator on the agent cylinder valve allowing pressurized dry chemical to flow into the distribution hoses leading to the discharge nozzles.

(4) Dry chemical fire suppression agent discharges through fixed nozzles into the protected areas, suppressing the fire.

Page 2-19


June 2012

The following is a typical scenario for an installation utilizing automatic fire detection and pn eumatic system actuation. This example shows the method of automatically actuating the system through the use of spot heat sensors or linear he at detection cable assemblies.

(1) A fire starts in a protected area.

(2) Heat and flames cause the temperature to rise to the set point of the spot heat sensors or linear detection cable. Upon reaching temperature, the contacts of the spot sensors close or the insulation of the linear heat sensor cable melts allowing the conductors to touch, thereby completing an electrical circuit.

(3) The completed circuit energizes the electric actuator on the electric/nitrogen actuator. The electric/nitrogen actuator opens the nitrogen cylinder which pressurizes the pneumatic control head and open the ag ent cylinder valve. Once opened dry chemical flows into the distribution hoses leading to the discharge nozzles. The pressure of the entering dry chemical causes the protective dust caps located on the nozzles to be blown off.

(4) Dry chemical fire suppression agent discharges through fixed nozzles into protected areas, to suppress the fire. Simultaneously, the relay switches the auxiliary contacts (if so equipped) and stops the engine.

Page 2-20


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2.C. Some Typical Installations of Manual and Pneumatically Actuated Systems Example 1: Mechanical Control Head with 4 Nozzle Installation: The most basic combination of hardware to the pressurized agent cylinder. In this case, detection of fire and actuation of the suppression system rely solely on the vehicle operator. Care must be taken to locate the agent cylinder in convenient proximity to the vehicle operator. Actuation is accomplished by pulling a ring pin, then pulling a T-handle lever (P/N 10134) to open the agent cylinder valve. This combination is ideal for small vehicles where fires can be quickly spotted by operators and where only one actuation location is required. Figure 2_2 shows a V25 - 4 nozzle system, however the Mechanical Control Head will work with any size agent cylinder. NOTE: To comply with NFPA 17, installation of a "manual only" suppression system must be approved by the local authorities having jurisdiction.

Example 2: Remote Pneumatic Manual Only Actuation with Dual 4 Nozzle Installation: In some installations, multiple actuation locations are required even though automatic detection and automatic actuation is not. In these cases, Amerex pressurized agent cylinders should be fitted with a P/N 10147 pneumatic control head and connected to one or more P/N 10210 manual actuators. Detection of the fire and actuation of the suppression system rely solely on the equipment operator or other personnel who may be close by. Actuation is accomplished by pulling a ring pin on any one of the manual actuators, and striking down hard on the palm button. Depressing the palm button releases nitrogen pressure which powers the pneumatic control head to open the agent cylinder valve(s). If engine shutdown, fuel shutoff, or remote alarm actuation is desired, the Pressure Operated Switch, P/N 11615 should be plumbed into the actuation network between the agent cylinder(s) and the closest manual actuator. Nitrogen pressure released by any manual actuator will activate the switch. NOTE: To comply with NFPA 17, installation of a "manual only" suppression system must be approved by the local authorities having jurisdiction.


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Example 3: Automatic or Manual Actuation (Pneumatic): Per NFPA 17, most installations will require automatic fire detection and suppression. In these cases, the pressurized agent cylinders will be fitted with a P/N 10147 pneumatic control head connected to at least one P/N 10210 manual actuator located in the path of egress. In addition, the pneumatic control head will be connected to one P/N 20775 Electric/Nitrogen Actuator which is combined with a P/N 14053 Manual Actuation Switch located within the operator's reach i n the vehicle cab. This Electric/Nitrogen Actuator contains an Electric Actuator P/N 14036 that is the device used to actuate the Nitrogen Cartridge. When the Nitrogen Cartridge is opened, high pressure nitrogen gas is used to open the agent cylinder valve.


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2.D. In Case of Fire Actions To Take: BRING TO A SAFE & CONTROLLED STOP AND SET BRAKES. TURN OFF THE EQUIPMENT. ACTUATE THE AMEREX FIRE SUPPRESSION SYSTEM BY PULLING THE RING PIN AND DEPRESSING THE "RED" FIRE BUTTON. GET ANY PASSENGERS AWAY FROM THE EQUIPMENT. TAKE A HAND PORTABLE EXTINGUISHER ALONG IF POSSIBLE OR OBTAIN ONE FROM ANOTHER LOCATION. STAND BY WITH PORTABLE EXTINGUISHER AND WATCH FOR SOURCES OF RE-IGNITION. NOTIFY LOCAL FIRE DEPARTMENT. Reasons Behind The Actions: A running piece of equipment can continue to pump fuel or hydraulic fluid adding to the fire. Its cooling fan creates wind currents that can reduce the effectiveness of the suppression system discharge. Its electrical system or other hot spots can continue to re-ignite the fire. Powering the vehicle down reduces the possibility of re-ignition. By getting away from the equipment, the operator, as well as others, is protected from possible explosions or heat injuries. A successful fire suppression event is the suppression of the vehicle fire long enough to allow all personnel and passengers to exit the vehicle to safety. Because residual heat could cause a re-ignition of the fire, or because the fire may be deep seated (vehicle fire suppression systems are not intended to extinguish deep-seated fires) it is important to stand by with a portable extinguisher. Maintain the standby until all possibility of re-flash is eliminated and all residual heat has dissipated or professional fire fighters arrive on the scene.

What To Expect: Discharge of an Amerex Fire Suppression System is noisy and can produce a large cloud of fire suppression agent temporarily obstructing vision. Breathing the extinguishing agent is unpleasant and may cause some irritation. M.S.D.S. information for Amerex ABC and "Purple K" dry powder fire suppression agent available at www.amerex-fire.com.

After The Fire Is Out: DO NOT restart the equipment until it has been serviced and cleaned. Use a water stream or compressed air to remove dry chemical residue immediately to avoid corrosion. DO NOT return the equipment to service until the suppression system has been serviced and recharged and until the source of the fire has been located and neutralized.


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Section 3 Hazard Analysis WARNING: A THOROUGH HAZARD ANALYSIS PRIOR TO LOCATING COMPONENTS IS CRUCIAL TO PROPER SYSTEM PERFORMANCE. AN IMPROPER OR INCOMPLETE HAZARD ANALYSIS CAN LEAD TO FALSE SYSTEM DISCHARGES OR FAILURE TO SUPRESS A FIRE. A COMPLETE AND THOROUGH HAZARD ANALYSIS, INCLUDING DETAILED DOCUMENTATION MUST BE COMPLETED PRIOR TO FINALIZING THE SYSTEM DESIGN AND COMPLETING THE SYSTEM INSTALLATION. Any fire suppression system design and any response to a fire situation must strive to accomplish the following objectives listed in order of priority: 1. Protect the lives and health of the vehicle operator and occupants by allowing them time to bring the vehicle to a stop and escape from the fire. 2. Curtail the spread of the fire by isolating it, keeping it small and limiting its exposure to other sources of fuel. 3. Limit property damage from the fire. The accomplishment of the first priority (item (1) above) is considered a successful suppression. Accomplishing all three items listed above represents the maximum positive outcome that can be expected from any fire situation. The potential for fire involving a vehicle exists nearly everywhere on or around the vehicle and within the vehicle itself, due to the environment in which it operates. A proper Hazard Analysis will address those risks that are most likely to occur. The Vehicle Hazard Analysis consists of five phases: A. B. C. D. E.

Identifying the potential for fire Assessing the consequences of fire Determining the need for fire protection Selecting the fire suppression option(s) Selecting the appropriate fire suppression system hardware

3.A. Identifying the Potential for Fire Ignition Sources 



High temperatures are usually found in the engine compartment areas, exhaust systems, turbocharger areas, and some emissions equipment and fluid heaters. Other ignition sources are pumps, batteries, electrical wiring, switches, electrical motors, generators and sources of friction such as bearings, brakes and gears. Electrical ignition sources include batteries, battery cables, transformers, fuse panels, splices, electrical wiring, switches, electrical motors, generators and auxiliary motors such as winches and starters. Please note: Lithium-ion batteries cannot be protected with this system.



Smoking materials, chemical reactions and spontaneous ignition sources.

Fuel Sources 



Class A Materials: wood, paper, rags, coal dust, electrical insulation, combustible debris, hoses, tires, seats. Class B Materials: flammable & combustible liquids such as gasoline, diesel fuel, natural gas (LNG / CNG), cleaning fluids, propane, methane, methanol, hydraulic fluids, grease, ethylene glycol, battery acid, alcohol and oil. The additional hazard of explosion may exist if no safety devices are employed to stop the flow of fuel at the time of the fire. The Amerex System is NOT designed to function as an explosion suppression system.

Part Number 16400 Rev. A 

June 2012

Page 3-2

Class C Items: Class C items describe sources of electrical current that may energize a fire making it more hazardous to personnel & inextinguishable using conductive agents such as water.

Coexistence of Fuel & Ignition Sources 



Vehicle Design. Check existing areas where fuel sources come into close proximity to high temperature engine surfaces, manifolds, turbocharger and starter. Other areas may include equipment articulation points, engine (belly) pan area and battery compartments. On larger equipment, check roller path collector areas, electrical switch gears, electrically driven wheels and transformer compartments. During hazard analysis note areas where combustible liquids may spray (as in the case of a broken line) or drip onto hot surface areas or splatter from a battery or an electrical switch short which would carry heat to another area of the vehicle.

Previous Experiences 

Past experiences may indicate where special hazards exist. Assistance from vehicle owner/operator, or service person should be carefully considered in determining hazard areas. Examples might include a hydraulic hose that frequently loosens in the same place or a component of the vehicle that frequently fails. Inquire if machines have a similar history of fires. Many machines have fires in the same areas. These areas should be protected.

3.B. Assessing the Consequences of Fire Personnel Exposure 



Determine the number of persons included and their locations during routine vehicle operations. This would include vehicle operator as well as passenger, if any. Determine the exposures to potential fires for each person and whether fire & smoke could impair safe egress from the vehicle.

Economic Risk 

Consider the cost of repairs or replacement of vehicle.



Consider the cost of vehicle downtime to production loss.



Consider the cost of the product that could be lost should fire spread from the vehicle.

3.C. Determining the Need for Fire Protection Identify Mandatory Requirements

Company policy, insurance companies and government agencies mandate certain fire protection and fire suppression requirements. Contact your local authority having jurisdiction (AHJ) to find protection requirements. Identify Additional Requirements The need for fire precautions, in addition to those mandated may be discovered as a result of this Hazard Analysis. One or more portable fire extinguishers of the appropriate type and rating per vehicle should also be used.


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Evaluate If the Hazard Analysis has disclosed unacceptable personnel risks, economic risks, or both, appropriate fire protection options must be determined.

3.D. Selecting the Appropriate Fire Suppression Options Risk Reduction 





Vehicle design. Assist in determining if the risk could be reduced by minor changes in vehicle designs. Examples: thermal shield could be added or hoses could be re-routed. If unacceptable risk still exists then further actions such as the installation of portable fire extinguishers, a fixed fire suppression system, or both is required to remove the hazards. If the hazard is larger or can spread to a larger area than can be covered with a single extinguisher, or if the hazard is expected to grow in intensity faster than can be detected visually and suppressed by a person with a single fire extinguisher, then a suppression system is needed.

Fire Detection & Suppression Systems Alternatives 





Portable Protection which includes both hand portable and wheeled extinguishers. Detection. Fire detection devices may be used to provide early warning of fire & activate a fire suppression system. Fixed Fire Suppression System. Fixed system protection can be accomplished by a combination of both local application and total flooding. The effects of the system may also be enhanced with the addition of a liquid agent based cooling system.

3.E. Selecting Fire Suppression System Hardware Locating High Risk Area(s) 

Assess all vehicle areas and compartments as outlined in Section 3.A. Pay particular attention to engine, fuel transfer, and hydraulic pump compartments. Remember, these potential fire hazard areas are similar in many vehicles.

Determine Agent to be Used 

Review the "Fuel Sources" identified in Section 3.A. If any of the fuel sources qualify as Class A materials, or if any fuel sources are in the proximity of other Class A materials, then the Models V13ABC, V25ABC, VH25ABC (Horizontal) VS50ABC and/or V50ABC must be selected. If there are no Class A fuel sources or there are no Class A fuel sources in the proximity but Class B and/or Class C fuel sources are present, then the Models V13PK, V25PK, VH25PK (Horizontal) VS50PK and/or V50PK may be used.

Determine Magnitude of Hazard in Each Risk Area 



Determine how many nozzles are required to adequately deliver agent to all hazard areas by means of total flooding, local application, or a combination of both. Refer to Section 4.A of this manual concerning nozzle coverage. Refer to NFPA 17, for further assistance in matching nozzle coverage to the hazard. After determining the exact number of nozzles required to cover all hazard areas, assessment of agent cylinder size can be determined, i.e. if 2 nozzles use V13, if 4 nozzles use V25 or VH25 (Horizontal), 6 or 8 use V50 or VS50, or combinations of two or more sizes.


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Page 3-4

Determine Method of Fire Detection 



For the suppression system to be used, fires or conditions likely to produce fire must first be detected by visual (human senses) or by means of a thermal or flame sensor. Automatic detection will be needed. NFPA 17 requires that each protected area or compartment must be provided with at least one fire detection device. Proceed as follows:

Determining Degree Rating and Type of Sensor(s) To Be Used 











Use a temperature probe and/or take thermocouple measurements to measure engine ambient temperature as well as temperature in specific areas of the vehicle. For example, the area near the turbocharger will normally have higher temperature than surrounding areas. Take into consideration natural changes affecting ambient temperature due to seasonal climatic changes. For example; if you are measuring temperatures during the winter time when it is 0 deg. F. (-18 deg. C.) and the system will see service during the summer when temperatures may reach 100 deg. F. (38 deg. C.) or more, your ambient temperature should be adjusted upward at least 100 deg. F. to compensate. After ambient temperatures are identified, select detection devices rated at least 100 deg. F above identified ambient temperatures. Spot thermostats, linear heat detection cable or a combination of both may be used. In situations where extreme vibration, extremely corrosive or wet conditions, or a large area needs to be monitored, use of the linear heat detector(s) in lieu of spot detector(s) should be considered. Also, if vehicle components block accessibility to the detectors for maintenance, use of the linear detection is preferred. If extremely rapid detection of fire and deployment of the fire suppression system is desired, SafeIR Optical Flame Detection may be used. See Amerex SafetyNet Manual P/N 16601. When Optical Flame Detection is used, one spot thermostat or linear pneumatic heat detection device must be used as a back-up fire detection method. Since the Optical Flame Detector is a line of sight device, and may be “blinded” by extreme dust, grease, mud, etc. a back -up detection method must be used in all cases.

Determine Methods of Actuation 





Consult local authorities having jurisdiction. detection/actuation must be used.

For compliance with NFPA 17, automatic

Selection of automatic detection and actuation systems will require an electrical manual activation switch mounted in the vehicle cab. Additional electric buttons and/or pneumatic actuation points may also be needed. Requirements for manual actuation, remote from the agent cylinder will require use of one or more manual actuation switches. NFPA 17 requires that at least one manual control for actuation shall be located no more than 5 ft. (1.5m) above the floor and be convenient and easily accessible at all times including time of the fire. The equipment operator shall provide one easily accessible manual system actuation button for use. A second manual actuator shall be located so that it is in the path of egress and operable from ground level away from potential hazard areas. The combination Electric / Pneumatic Control Head and Nitrogen Cartridge actuation is ideal for off road and severe service application as it allows manual actuation of the Fire Suppression System even with a complete loss of electrical power (including the i nternal back-up battery).


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Control Panel 





Type of control panel required should be determined by assessment of features required. There are two types of control panels available. The Circuit Monitor III allows for automatic activation but has no shutdown feature. The Control Panel III adds a timed relay for shutdown. See Manual P/N 19680 for complete feature details of Control Panel III and Circuit Monitor III. SafetyNet provides supervision, automatic activation, timed relays as well as other programming options. See Manual P/N 16601 for complete feature details. All control panels must be located in vehicle cab within the operator's audible and visual range. All control panels must be located within reach of operator so an operator has access to reset button, alarm silence button, engine shutdown delay button, etc. while seated.

Special Options 

If monitoring of agent cylinder pressure is required select an agent cylinder that has the Agent Cylinder Pressure Switch attached. A control panel is required when utilizing this option.


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Section 4 System Layout and Design To properly design the agent distribution, actuation, and detection networks, an installer must first complete a hazard analysis of the vehicle on which the suppression system will be installed. Refer to Section 3 for instructions on hazard analysis. Once this task is completed and documented, the following sections will provide the required nozzle coverage and nozzle spacing information necessary for choosing the number and size of agent cylinders, for choosing the required number of agent discharge nozzles and for designing the hose networks that connect the system components.

4.A. Single Discharge Nozzle Coverage Ratings Each discharge nozzle (P/N 10250) is rated for a specific area or volume of protection based upon testing with static air flow and minimal or no obstructions. Because each nozzle may be used to distribute dry chemical using either a total flooding method for enclosed spaces, or a local application method for unenclosed spaces, this area or volume of protection is described using t wo measures of coverage. As shown in Figure 4.1, each nozzle has a maximum total flooding volume of protection of 244 cu. ft. (6.9 Kiloliters). This volume represents a single nozzle placed in the center of the top plane of a 6-ft. - 3 in. (1.9 meter) cube with no obstructions or air flow. Alternately, as shown in figure 4.2, each nozzle has an overhead local application maximum area of protection of 900 sq. in. (.7 sq. meters). This area reflects a single nozzle centered above a 30-inch (76.2-cm) square fuel pan at a height of 35 to 46 inches (89 to 117 cm) above the surface of the fuel with no obstructions or air flow. Table 4.1 summarizes these values. Coverage Type

Rated Protection

Nozzle Placement

Total Flooding Overhead Local Application

244 cu. ft. (6.9 Kl) 6' - 3" (1.9 meter) cube 900 sq. in. (.6 sq. meter) 30 inch (76.2 cm) square

Center of Top Plane

Table 4.1: Single Nozzle Coverages

Center of Area 35 to 46" 89 to 117 cm) above fuel


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4.B. Multiple Discharge Nozzle Coverages AMEREX vehicle suppression system models V13, V25, VH25 (Horizontal) V50 and VS50 offer five multiple nozzle configurations. The model V13 must use 2 nozzles. The model V25 and VH25 (Horizontal) must use 2, 3, or 4 nozzles, while the V50 and VS50 models must use either 4, 6, or 8 nozzles. With all systems, single nozzles are combined in installations to yield a total maximum protected volume or area based upon no obstructions or air flow. This total equals the number of nozzles used multiplied by the single nozzle coverage ratings. Volumes and areas may be arranged in any configuration, as long as total maximum coverages and hose limitations are not exceeded, and as long as nozzles are spaced so as to duplicate the placement used in the single nozzle ratings. Figures 4.3 and 4.4 show examples of multi-nozzle maximum coverages. Neither the volumes nor the areas need to be adjacent to one another. Table 4.2 summarizes the total multi-nozzle coverage for each model. Model

V13ABC/PK V25ABC/PK VH25ABC/PK

Number of Nozzles

2 2 3 4 4 6 8

V50ABC/PK VS50ABC/PK V50ABC/PK VS50ABC/PK Table 4.2: Total System Coverages by Model

Total Maximum Volume Protected by Total Flooding Application 488 cubic feet 488 cubic feet 732 cubic feet 976 cubic feet 976 cubic feet 1464 cubic feet 1952 cubic feet

Total Maximum Area Protected by Local Application 12.5 square feet 12.5 square feet 18.75 square feet 25 square feet 25 square feet 37.5 square feet 50 square feet


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While the nozzles have been tested to determine maximum area for Local Application and both maximum area and maximum volume for Total Flood application, vehicle fire hazards do not specifically qualify 100% as either Total Flood or Local Applications due to vehicle variations, obstructions, air flow and other factors. All the AMEREX Vehicle Fire Suppression System Models were exhaustively tested to establish minimum and maximum discharge hose lengths. These lengths must be strictly observed when designing and installing the agent discharge network to ensure proper agent distribution to each nozzle. Failure to observe hose length limitations can cause failure to suppress a fire. A total of seven discharge distribution networks are available for the four models. The V13 system is arranged using all 1/2" (12.7 mm) I.D. hose split with one tee fitting to distribute agent to the two nozzles. The V13 system is the only system using all 1/2" hose. The V25, VH25 (Horizontal), VS50 and V50 models all use 3/4" (19mm) I.D. hose from the valve to the distributor or tee fittings, but must be reduced to 1/2" (12mm) I.D. hose to the nozzles. No other hos e sizes are tes ted or approved. The V25 and VH25 (Horizontal) two, three and four nozzle systems can be arranged using plumbing tees at hose junctions, or using the distributor. Hose length limitations are identical for the V25 and VH25 (Horizontal) systems in all cases. The V50 and VS50 are arranged using a combination of tees and distributors in both the four, six, and eight nozzle systems. The configurations of each model, together with the required hose diameters are illustrated and specified on the following pages. Notice in the tables that many hose sections allow a minimum length of zero feet from the agent cylinder to the first tee. It is important to realize that even with these zero length allowances all configurations still require an agent cylinder to nozzle distance of 5 ft. minimum (1.5 meters). Also note that the length of hose extending from one outlet of a tee or distributor may be 3 times as long or as short (3:1 imbalance) as the section(s) leading from the other outlet(s) of the tee of distributor. In most cases a zero hose length is used only in a total flooding application. Finally, notice that all sections allow for the use of two elbows. When calculating hose length and hose imbalance, the effect of the elbow should be ignored. The length of a hose section is therefore defined by the sum of the lengths of the individual hoses between two tees, distributors, nozzles or discharge valve outlet fittings only.

Part Number 16400 Rev. A 4.C Discharge Network Hose Limitations: Hose Limitations for V13 and Systems:

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June 2012

Hose Limitations for V25 and VH25 Horizontal Systems Using Tees:

Page 4-5


June 2012

Hose Limitations for V25 and VH25 Horizontal Systems Using Distributor:

Page 4-6


June 2012

Hose Limitations for V25 and VH25 Horizontal Systems Systems Using Distributor Optional Three Nozzle Configuration: Configuration:

Page 4-7


June 2012

Hose Limitations Limitations for V25 and VH25 Horizontal Systems Using Tee Optional Two Nozzle Configuration: Configuration:

Page 4-8


June 2012

Hose Length Limitations for V50 Using Distributors Distributors

Page 4-9


June 2012

Hose Limitations for V50 Systems Using Distributors and Tees:

Page 4-10


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Hose Limitations for V50 and VS50 Systems Using Tee’s Optional Four Nozzle Configuration


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Hose Limitations for V50 and VS50 Systems Using Distributor Optional Four Nozzle Configuration


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4.D. Stainless Steel Rigid Tubing in Discharge Network The discharge network of the AMEREX Vehicle Fire Suppression System may be constructed using certain types of rigid tubing in place of some or all sections of the SAE 100R1 or 100R5 wire braid hose. While discharge networks constructed completely from rigid tubing may make assembly and maintenance procedures difficult and awkward, use of rigid tubing in areas of a vehicle that are difficult to access during inspection procedures or may be subject to extreme heat may prove to be beneficial in the long run. To design a discharge network using portions of rigid tubing, observe the following rules: 1. The design must comply fully with the specifications for overall hose lengths, hose diameters, number of elbows and imbalances shown in section 4.C. 2.

A change from flexible hose to rigid tubing (or from tubing to hose) may be made only once per hose section. (A hose section is defined as that length connecting any two flow dividing fittings.)

3.

Tables for hose limitations found in section 4.C. specify a maximum allowable imbalance of 3:1 for the lengths of sections of hose exiting from any given tee or distributor. When using a combination of hose and tubing, within one network, two additional imbalance requirements must be met: The individual lengths of each piping material, tubing and hose, used to plumb a section on one branch of any tee or distributor must be within a 3:1 ratio of the length of the same piping material used to plumb each of the sections on the other branches of that tee or distributor. As with the overall 3:1 imbalance, these individual imbalances must be determined for a distributor using the minimum vs. maximum piping lengths.

The illustration at right shows proper observance of these rules. The example network is designed for a V25 system using a distributor. Note the following: (1) The 15 foot (4.6 meters) maximum length for each section has been observed. (2) The imbalance between the longest section of 15 feet (4.6 meters) and the shortest section of 5 feet (1.5 meters) is within 3:1. (3) The imbalance between the longest flexible hose section of 6 feet (1.8 meters) and the shortest hose section of 2 feet ( .6 meter) is within 3:1. (4) The imbalance between the longest section of rigid tubing of 9 feet (2.7 meters) and the shortest length of tubing of 3 feet ( .9 meter) is also within the required 3:1 imbalance ratio. Also note that if a section of rigid tubing is used on one branch of a distributor or tee, then a section of rigid tubing must be used on all branches to keep the number of flow restrictions created by transition from flexible hose to tubing equal on all side of the distributor or tee.

Material Rigid tubing used in discharge networks must be Type 304 or Type 31 6 Seamless Stainless Steel conforming to ASTM-A-269. Only 3/4 inch (19mm) outside diameter (wall thickness .065/.035) tubing may be used in place of 3/4 inch (19mm) inside diameter flexible hose. Only 1/2 inch (12mm) outside diameter (wall thickness .035/.028)thin wall tubing may be used in place of 1/2 inch (12mm) inside diameter flexible hose.

Fittings Fittings for connection of rigid tubing must be constructed of Type 316 Stainless Steel, must be of welded or compression fitting type, and must be recommended by their manufacturer for use with ASTM-A-269 tubing. Swagelok and CPI Parker comprise a partial list of manufacturers for stainless steel tube fittings. Always follow manufacturer's instructions and specifications for proper fitting assembly.


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4.E. Actuation Network Hose Limitations (Pneumatic Actuation Applications) When an AMEREX pneumatically activated fire suppression system is installed, a pneumatic control head, check valve and vent check, along with one or more pneumatic Manual Actuators must be installed. In addition, if the system is equipped with automatic fire detection and system actuation, one Electric/Nitrogen Actuator must be installed. The system actuation network is a series of 1/4 inch (6mm) I.D. hoses, tees, and check valves used to carry nitrogen pressure from the actuators to the pneumatic control head(s) located on the agent cylinder valve(s). The hose used is 1/4 inch (6mm) hydraulic hose and is specified in detail in Section 4.G. Figure 4.9 shows a typical system actuation network.

In designing a system actuation network, there are five very important factors to consider: The first is that two check valves must be used, one on each inlet of any tee where the hoses leading from any two actuators join together. This ensures that only the direct route from an actuator or electric/nitrogen actuator to the pneumatic control head is pressurized by the nitrogen actuation pressure. Without the check valves, the entire network would have to be pressurized before the pneumatic control head could open the discharge valve. The second factor is that the total hose length along a direct path from any one actuator or electric/nitrogen actuator to the pneumatic control head must be not more than 125 feet (38 meters). In the example network in Figure 4.9, the total length of hose in the network is 178 feet (54.3 meters) which includes the 3 foot ( .9 meter) section routing to the Pressure Operated Switch. However, the hose distances from the actuators to the control head are 83 ft. (25.3 meters), 68 ft. (20.7 meters) and 88 ft. (26.8 meters). Because check valves must be used at the inlet sides of T1 and T2 which limits the flow of nitrogen pressure to the shortest path from actuator to control head, the network is acceptable. Third, one check valve must always be used as a safety device at the inlet of each pneumatic control head. By using this valve, nitrogen actuation pressure is trapped in the pneu matic control head, thereby keeping the discharge valve open for the duration of the discharge.


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Fourth, if a Pressure Operated Switch is used in the actuation network, the distance from the tee to the s witch pressure inlet must not exceed 3 feet ( .9 meter), and the amount of hose used to connect the Pressure Operated Switch must be included in the 125 ft. (38 meters) maximum hose length allowance. The switch must be plumbed into the actuation line after the last actuator junction to insure pressure will reach the switch from any actuator location. Always mount the Pressure Operated Switch vertically with the manual reset button on top. Do not use a check valve in the hose directly before the Pressure Operated Switch, as it will trap pressure in the switch and make manual reset of the b utton very difficult. Fifth, is that the actuation hose must not be routed through the hazard area. If the actuation hose is routed through the hazard area there is a risk that the hose may be damaged by a fire before the system is actuated thus preventing Nitrogen pressure reaching the Pneumatic Control Head and opening the Agent Cylinder Valve.

4.F. Multiple Agent Cylinder Networks (Pneumatic Actuation Applications) The size of the vehicle and its hazards often require that more than one agent cylinder be used. The models V13, V25, VH25 (Horizontal), VS50 and V50 can be used in multiples and in any combination as long as the following rules are strictly observed: 





The agent distribution network of each agent cylinder must be piped completely independent of all other agent distribution networks and each network must comply with the hose limitations as specified in section 4.C. No “manifolding” of cylinders on a single distribution network is normally allowed. A maximum of eight agent cylinders may be actuated by a single pneumatic actuation network. The hose length along a direct path from any one remote actuator to the last pneumatic control head does not exceed 125 ft. (38 meters). A vent check, P/N 10173, is installed in only the last pneumatic control head in the actuation network.


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4.G Hose Coupling and Fitting Specifications Hose: The flexible hose used to construct the discharge and actuation networks on the AMEREX Vehicle Fire Suppression System must meet or exceed either SAE 100R5 or SAE 100 R1 hose specifications. Further details may be obtained from the following standards: SAE Hydraulic Hose Fitting Standard J516A SAE Hydraulic Hose Standard J517A SAE Standard J343 A list of hose manufacturers and corresponding part numbers is given in Table 4.6. It is not intended to be a complete list. The hoses listed meet the SAE standards given as well as USBM Flame Resistance Requirements. Any hose meeting the above specifications is acceptable. Some Installations will require the use of hose that is rated for use at -65 deg. F. (-54 C.). Several hoses are listed that are suitable for the se installations.

Couplings: Couplings used on any hose must be only those specified by the hose manufacturer for the hose in use. Most hose manufacturers provide a wide selection of both crimp-on or reusable type couplings in solid and swivel configurations. The use of swivel type couplings will facilitate an easier and more efficient installation of hoses.

Fittings: Fittings such as elbows and tees used to plumb coupled hose assemblies must be galvanized malleable or ductile iron, black or galvanized steel, stainless steel, copper or brass. Cast iron fittings shall not be used. Fittings used to connect discharge hoses shall be rated for used at 600 WOG (41.4 bars). Fittings used to connect actuation hoses shall be rated for use at 1800 psi. (124 bars) minimum. Table 4.6: Vendor

Size

(>>>>>>>>>>>>>>>>>>>>>> -40 F. [-40 C.]<<<<<<<<<<<<<<<<<<<<<<<<<) (-65 F. [-54 C.) 100R5 100R5 100R1A 100R1AT MIL-H-13531 Rubber Cover Reduced O.D. 1503-5 2651-5 2681-4 2663-4 2766-4 1503-10 2651-10 2681-8 2663-8 2766-8 ----------------2681-12 2663-12 2766-12

AeroQuip

1/4" 1/2" 3/4"

Dayco

1/4" 1/2" 3/4"

5D 10D ---------

5DR 10DR ---------

4M 8M 12M

4MX 8MX 12MX

-------------------------

Gates

1/4" 1/2" 3/4

5C5C 10C5C ---------

-------------------------

-------------------------

4CIT 8CIT 12CIT

MIL#-4 MIL#-8 MIL#-12

Goodyear

1/4" 1/2" 3/4"

9050-5 9050-10 ---------

-------------------------

9010-4 9010-8 9010-12

9015-4 9015-8 9015-12

9201-4 9201-8 9201-12

Parker

1/4" 1/2" 3/4"

201-5 201-10 ---------

221-5 221-10 ---------

-------------------------

421-4 421-8 421-12

245-4 245-8 245-12

Swagelok

1/4" 1/2" 3/4"

8R-4 8R-8 8R-12

-------------------------

-------------------------

-------------------------

-------------------------

1/4 inch = ( 6mm). 1/2 inch = (12mm). 3/4 inch = (19 mm).


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4.H. Detection Network The detection network consists of a number of thermostats and/or linear heat detection cables connected together in a continuous electrical circuit beginning at the Circuit Monitor or Control Panel and ending with an End of Line Module (P/N 14010). The use of the End of Line Module allows the integrity of the wire, the thermostats, and/or linear heat detection cables and the wiring connections to be monitored. Thermostats and/or linear heat detection cables are placed above or as near as practical to the hazard areas as determined by the hazard analysis (See Section 3). The objective is to position the thermostats and/or linear heat detection cables so that they experience the shortest possible delay between fire ignition and contact closure. Care must be taken to position the thermostats and/or linear heat detection cables so that they will not easily be damaged during regular vehicle use and maintenance. They should also be positioned so that they may be easily accessed during the required maintenance procedure. Thermostats should be rated 100ºF above the ambient operating temperature where each will be placed. Any thermostat or thermostat lead exposed to a fire condition must be replaced. See Section 3.E. for information regarding thermostat temperature selection. (remainder of page left intentionally blank)


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Section 5 Electrical Controls On any Model V13, V25, VH25 (Horizontal) VS50 or V50 system installed with automatic detection and electric actuation, any one of the following circuit supervision control panel units is required. All Circuit Monitors, Control Panels and SaftyNet contain an internal Back-Up Battery which must be replaced every two years. The purpose of the Back-Up Battery is to provide brief temporary power, for a maximum duration of 24 hours, to the Fire Suppression System in the event of interruption of vehicle battery power. The unit should be selected on the basis of the features required by the user, and/or any local authorities having jurisdiction. Features of each unit are described in detail below.

5.A Modular Control Panel III SEE MANUAL 19680 FOR COMPLETE OPERATING, INSTALLATION, TROUBLE SHOOTING AND MAINTENANCE INFORMATION.

5.B SafetyNet Electronic Control System SEE MANUAL 16601 FOR COMPLETE OPERATING, INSTALLATION, TROUBLE SHOOTING AND MAINTENANCE INFORMATION. (remainder of page left intentionally blank)


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Section 6 Installation THE PRIMARY CAUSE OF SYSTEM MALFUNCTIONS IS POOR INSTALLATIONS! Installation of the AMEREX Fire Suppression System can begin only after a complete hazard analysis (Section 3) has been performed and documented, and a complete system layout design (Section 4) has been made and documented. Failure to complete these two steps prior to system installation can lead to false system discharges or failure to adequately suppress a fire. At no time should an AMEREX Fire Suppression System be installed without first completing the above steps. Upon completion of these two prerequisites, installation should be performed as follows: A. MOUNT HARDWARE AND INSTALL COMPONENTS    

  

Mount the agent cylinder brackets and install the agent cylinders. Mount the manual or pneumatic control heads on the discharge valves. Mount the distributors, thermostats and nozzle brackets. Install and aim nozzles. Mount the pneumatic actuator brackets and install electric/nitrogen control head and manual actuators. Do not install N2 cylinders yet. Mount pressure operated switch, bench test then mount circuit monitor or control panel. Mount thermostats, optical flame sensors, and/or linear heat detection cables. Connect Agent Cylinder Pressure Switch wiring to Control Panel circuit.

B. C. D. E. F.

CONNECT DISCHARGE AND ACTUATION HOSE NETWORKS. CONNECT DETECTION, ACTUATION AND POWER SUPPLY WIRING. TEST THE SYSTEM. PLACE SYSTEM IN SERVICE. INSTALL NITROGEN CYLINDER(S). PROVIDE TRAINING FOR THE EQUIPMENT OWNER/OPERATOR.

6A. Mounting Hardware and Installing Components Agent Cylinder Brackets must be fastened to the vehicle either by welding or by bolting using SAE grade 5 or better 1/2 inch (12mm) bolts. As a safety precaution, never weld on fuel or combustible material storage tanks. If brackets are welded in place, all metal left exposed by welding heat must be repainted. Locate the Agent Cylinder Brackets observing the following guidelines. Before welding on any surface, consult with vehicle owner / maintenance personnel to verify that it is acceptable and safe to weld on the surface in question. Welding is prohibited on many vehicle surfaces. [1.] Locate near the hazard or hazards being protected, but not where they will be exposed to a fire in the hazard area. Do not mount the agent cylinder in the hazard area or where temperatures exceed 150ºF. [2.] Locate where the Agent Cylinder will be protected from physical damage or abuse. [3.] Locate where the Agent Cylinder will be easily accessible for inspection and service. [4.] Locate where the Agent Cylinder will not be exposed to temperatures above 150 degrees F. (66 C.) or below -40 degrees F. (-40 C.). [5.] Locate where discharge and actuation hose lengths will conform to the hose limitations as specified in Section 4. [6.] Locate on a flat and rigid surface capable of supporting the weight of the Agent Cylinder and its bracket as it vibrates under operating conditions. [7.] Locate in a vertical or near vertical (15 degree angle offset maximum) orientation relative to the ground for the V13, V25, and V50 models. See Figure 6.1. When installing any horizontal agent cylinder bracket P/N 11338, the long side of the bracket must always be mounted horizontally or near horizontally (5 degree angle offset maximum) orientation relative to the ground. (See FIG. 6.1A) [8.] On Mechanical Control Head installations, locate where T-handle will be within easy reach of the equipment operator and can be actuated with a pull of the T-handle towards the operator.


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The Agent Cylinders can be installed once the agent cylinder brackets are secure. Install agent cylinders with the discharge outlet facing in the direction that will be required to connect to the discharge hoses. The discharge opening is the 1 1/4-inch opening opposite the gauge. When installing the VH25 (Horizontal) Agent Cylinders, extreme care must be taken to insure that the Agent Cylinder is mounted in its bracket horizontally (parallel with the ground) and with the orientation arrow engraved on top of the valve pointing straight down. See Figure 6.1B.

Warning! Mounting of the VH25 (Horizontal Model P/N 15525 for ABC, P/N 12318 for PK) agent cylinders otherwise will result in incomplete discharge of the suppression agent. Bolt the two padded straps in place using the stainless steel bolts, washers, and self-locking nuts provided. Tighten the nuts until the rubber pads are firmly compressed against the agent cylinders but not bulging from under the straps. Note: the straps will not fully contact the bracket back when tightened. Figure 6.1A. Correct VH25 (Horizontal) Agent Cylinder Bracket Orientation.

WARNING: DO NOT ATTEMPT TO USE THE V25 VERTICAL MOUNTING BRACKET, P/N 10180, WITH THE VH25 (HORIZONTAL) AGENT CYLINDER. IT WILL FIT, BUT THE V25 BRACKET LACKS THE END PLATE TO KEEP THE VH25 (HORIZONTAL) AGENT CYLINDER FROM SLIPPING OUT. ALWAYS USE A VH25 HORIZONTAL BRACKET P/N 11338 WHEN THE VH25 AGENT CYLINDER IS USED.


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Figure 6.1B. Correct VH25 (Horizontal) Agent Cylinder Orientation.

Note in Figure 6.1B cut-away side view, orientation of the internal right angle down tube. Proper orientation of the tank is necessary so the pick-up opening is always against the bottom side of the agent cylinder. If agent cylinder is oriented other than as shown, incomplete fire suppression agent discharge will result.

The Mechanical Control Head (T-Handle) or Pneumatic Control Heads should be mounted only after the agent cylinders are in place. Remove the discharge valve shipping plate and use its two 5/16" stainless bolts (and nuts if installing the T-Handle) to secure the control head to the discharge valve. Warning: Make sure that the stem of either control head is retracted before bolting it to the valve. Otherwise, the extended stem will open the valve and agent discharge will result. Apply medium grade thread locking compound to the threads, and tighten the two bolts securely using a 1/2" wrench. On mechanical control head installations, always orient the T-handle lever so that a pull towards the operator is required to actuate the system. Apply the instruction label, P/N 10891, on a smooth flat surface near the Agent Cylinder where it will be obvious to the operator it a fire situation. See Figure 6.2.

On all pneumatic control head installations, assemble a vent check P/N 10173 into the 1/4-inch port of the outlet side of the control head and a check valve P/N 10262 on the inlet side of the pneumatic control head. Improper installation could cause the agent cylinder to fail to operate. Wrap the male threads of the vent check and check valve with Teflon tape before installing. Tighten the vent check and check valve into the control head 2 1/2 to 3 full turns past hand tight using a 9/16" wrench.


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The Distributor (P/N 10178) can be mounted to the vehicle in any orientation as long the five threaded ports are accessible and not obstructed. Before mounting, make sure that the hose lengths leading to and from the distributor are within the hose limitations specified in Section 4. The distributor may be attached either by welding or by using SAE grade 2 or better 1/4" (6mm) bolts. The distributor is painted to prevent corrosion. If the distributor is welded to the vehicle, it should be repainted where welding heat has removed the paint. As a safety precaution, never weld on a fuel or combustible storage tank. See Figure 6.3. Note: Welding can change the physical properties of metal. Consult with vehicle owner prior to welding to verify proper location to weld on the vehicle. Nozzle Brackets (P/N 10780) must be securely mounted for the fire suppression system to properly protect those high risk items identified in the hazard analysis. (See Section 3). They may be mounted in any orientation by welding or by using SAE grade 2 or better 1/4-inch (6mm) bolts. If bolts are used, apply one or two drops of thread locking compound to the bolt threads before tightening. The nozzle brackets are painted to prevent corrosion. If they are attached by welding, they should be repainted where welding heat has removed the paint. As a safety precaution, never weld on a fuel or combustible storage tank. Hazards at which the nozzle is directed are determined in the Hazard Analysis. (See section 3.) Locate the nozzle brackets observing the following guidelines; [1.] Locate where nozzles will be protected from mechanical, environmental, or other conditions that could render them inoperable. [2.] Locate where nozzles will not readily be put out of alignment by normal vehicle operation, or vehicle maintenance. [3.] Locate where, at the time of discharge, each blow-off cap encounters no obstructions that may hinder its displacement from the nozzle or affect discharge of the dry chemical. [4.] Locate where the nozzle can deliver fire suppression chemical directly on the hazard in an uninterrupted cone pattern. There should be no obstructions present between the nozzle orifice and hazard. The cone pattern is approximately 3 feet ( .9 meter) in diameter at 3 feet from the nozzle. A small adjustable bea m "Mag-Light" type flashlight is handy to use in positioning and aiming nozzles. Adjust the flashlight beam so it is approximately 3 feet in diameter 3 feet from the flashlight lens. The light beam will now roughly duplicate the chemical dispersion pattern. Hold the flashlight where you think the nozzle should be placed and observe where the light beam shines. [5.] Locate where the nozzle will deliver its fire suppression agent with (instead of against) the flow of air from the radiator fan after determining the direction of flow from the fan (push vs. pull). The Nozzles (P/N 10250) can be installed directly into the nozzle brackets, or i nto elbow fittings and then into the nozzle brackets. In all cases, the nozzles and fittings should first be tightened a minimum of one wrench flat past hand tight, then tightened to the desired orientation to insure proper aiming is maintained. Several examples of proper nozzle installations are given in Figure 6.4. After installing the nozzles, install the nozzle blow-off caps. Slip the retaining loop of the blow-off cap over the hex on the nozzle, wipe a thin coating of silicone grease around the inside of the cap, push the cap onto the nozzle until it bottoms, rotate the blow-off cap as needed until the retaining loop is arching downward so that when it is blown off it will hang clear of the nozzle outlet.


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Actuator Brackets (P/N 10354 / Outdoor & P/N 10355 / Indoor) can be mounted in any orientation as lo ng as easy access to the pull pins and actuator palm buttons are provided. When placing either bracket, consideration should be given to access for removing the nitrogen cylinder and viewing the nitrogen cylinder gauge. Use SAE grade 2 or better 1/4-inch (6mm) bolts or weld the brackets to the vehicle. If the brackets are welded in place all metal left exposed by the welding heat should be repainted. As a safety precaution, never weld on a fuel or combustible storage tank. When installing the outdoor actuator bracket, it is a good practice to thread the four 1/4 inch X 1/2 inch stainless steel cover screws loosely into the bracket to prevent their being lost until time to "Place the System in Service." (Section 6) Locate the actuator brackets observing the following guidelines: [1.] Locate where actuators will not be subject to mechanical, environmental, or other conditions that could render them inoperable. [2.] Locate at least one manual actuator no more than 5 ft. above the ground convenient and easily accessible to the vehicle operator in route of egress. [3.] Cab mounted actuators must be in reach of the equipment operator while operating the equipment. [4.] Locate all actuators where the Nitrogen cylinders will not be exposed to temperatures above 150 degrees F. (66 C.) or below -65 degrees F. (-54 C.). [5.] Locate on a rigid flat surface capable of supporting the weight applied by the actuator assemblies as they vibrate under vehicle operating conditions. [6.] Locate where the Nitrogen cylinders and actuators will be easily accessible for inspection and servicing. [7.] Locate where the actuation hose lengths will not exceed the 125 ft. (38 meters) maximum. The Manual Actuator and the Electric/Nitrogen Actuator are held in the Actuator Brackets by two 1/4-inch stainless steel Allen head cap screws, which are provided. These screws thread into square nuts held in place on the actuator bracket by spring steel cages. The nuts float loosely to aid in alignment until the tightened 1/4-inch screws clamp them firmly in place. Use a 3/16 Allen (hex) wrench to secure the mounting screws. Do not install the Nitrogen cylinders until time to "Place the System in Service" as described in section 6.D to prevent accidental system discharge. Last, apply the instruction label, P/N 10574, furnished with the Manual Actuator, on a smooth flat surface near the actuator where it will be obvious to the operator in a fire situation. The Pressure Operated Switch (P/N 11615) must be bolted to the vehicle using (4) number 10 screws through the four mounting feet provided on the switch enclosure box. The enclosure is water resistant and can be mounted inside the vehicle cab or elsewhere on the vehicle. The Pressure Operated Switch is activated by nitrogen pressure tapped from the actuation network of the pneumatically actuated system and can be used to initiate engine shutdown or activation of auxiliary alarms. The switch actuates automatically


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upon suppression system discharge. To reset the switch, a reset button on top of the switch enclosure is pressed after actuation system pressure subsides. A 1/4-inch NPT fitting is provided on the bottom of the switch enclosure for connection into the actuation hose network. An opening with an electrical wire strain relief for up to 14-gauge wire is provided for wire entry. When used in pneumatic actuated systems that have multiple manual or electrical/manual actuators, it must be plumbed (using a Tee) in the actuation network between the last actuation point and the agent cylinder (See Section 4.E., Figure 4.9) to insure that nitrogen pressure will reach the switch from any actuator location. Electrical connections are covered in section 6.C. The Pressure Operated Switch may be mounted anywhere along the actuation hose network as long as the following guidelines as observed: [1.] Locate where it will not be subjected to mechanical, environmental, or other conditions that could render it inoperable. [2.] Locate on a flat rigid surface capable of supporting the weight applied by the switch as it vibrates under vehicle operating conditions. [3.] Locate where the reset button and front access panel will be easily accessible for inspection and servicing. Mount vertically with the manual reset button on top. [4.] Locate where the actuation hose running from the main actuation network to the switch does not exceed 3 feet ( .9 meter). The length of the actuation hose used to connect the pressure operated switch must be included in the 125 ft. (38 meter) maximum hose length allowance as specified in section 4. [5.] Do not install a check valve in the hose running from the main actuation hose network to the pressure operated switch as it will trap nitrogen pressure in the switch and make pressing the reset button very difficult. [6.] Wrap the male threads of the hose fittings used for hose connections with Teflon tape before tightening.

The Circuit Monitor III, Control Panel III or SafetyNet Display Panel must always be mounted in the vehicle cab protected from the weather. To maintain the environmental integrity of the enclosures of these units, use only the mounting holes provided. All units must be mounted in the immediate visual field and within reach o f the vehicle operator while operating the vehicle. The Panels are shipped with End of Line Modules attached to the terminals of the detection circuit leads (Color-coded green). Do not discard the End of Line Modules when installing the panels. They must be removed later and installed at the end of each thermostat lead. SEE AMEREX MANUAL 19680 FOR COMPLETE INSTALLATION AND INSTRUCTIONS FOR CIRCUIT MONITOR III AND CONTROL PANEL III. SafetyNet Control Systems

SEE AMEREX MANUAL P/N 16601 FOR COMPLETE SAFETYNET DETAILS AND INSTRUCTIONS. The Amerex Vehicle SafetyNet System (AVSN) is a natural evolution of the Amerex AMGaDS Mobile Gas Detection System and the Modular Fire Suppression System electronic control system. The SafetyNet System consists of a self-configuring, proprietary, microprocessor based Vehicle Safety Network that gives added flexibility to the proven Amerex Vehicle System Design. Modular components allow for custom tailored Fire Suppression and Gas Detection Applications. Simplicity, Flexibility and Reliability are key features of the SafetyNet System. The SafetyNet System automatically recognizes other SafetyNet components and self-configures for proper operation. For the intermediate user needing additional system flexibility, SafetyNet offers easy to use Windows based pulldown menu screens for application specific programming. A more advanced feature of SafetyNet allows the user to gather data in real-time from system sensors (event / data logging). The Amerex Vehicle SafetyNet has been tested to FM, SAE, and CE standards and is the n ext step in Vehicle Fire Suppression Safety.


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Fixed Temperature Detection Devices; The Fixed Temperature Detection Devices, whether “spot” type or “linear” are critical to the performance of the automatic fire suppression system. It is the detection device’s sole function to signal the system to discharge in the event of a fire. Failure to select the correct devices can result in false system discharges or failure to suppress a fire. The local sensing or "Spot-type” fixed temperature detectors (Spot Thermostats) must be mounted in each protected compartment or area of the vehicle as determined by the Hazard Analysis described in Section 3. When the ambient temperature around the thermostat reaches the rated temperature of the device, internal contacts inside the device close completing an electrical circuit to fire the electric actuator. When the device cools, the contacts reopen and reset the device to its normal operating condition. The status of the detection circuit is monitored for faults by the electrical circuit from the Circuit Monitor III, Control Panel III or SafetyNet Display Panel. Detection devices must be installed in such a way and in locations that will be protected from physical damage and from environmental damage. Complete wiring instructions are given in Amerex Manual P/N 19680 for Circuit Monitor III or Control Panel III Installation, Operation and Instruction Manual. Modular Spot Fixed Temperature Devices (Spot Thermostats) are equipped with steel mounting brackets and color-coded Amerex Click Lock electrical connectors as shown in figure 6-6A. The mounting brackets may be fastened to the vehicle in any orientation by bolting using SAE grade 2 or better 1/4 inch (6mm) bolts. Always apply one or two drops of thread locking compound to the bolt threads before tightening. DO NOT WELD THE BRACKETS TO THE VEHICLE, AS HEAT FROM WELDING WILL DAMAGE THE DETECTOR ASSEMBLY. DO NOT PAINT ANY DETECTION DEVICE.

Locate and mount the Spot Thermostats observing the following rules: [1.] Locate where the Spot Thermostats will be protected from mechanical, environmental, or other conditions that could render them inoperable. [2.] Locate near the hazard as determined by the hazard analysis (See Section 3). Verify the temperature setting of the chosen Spot Thermostat at each location by referring to the hazard analysis ambient temperature measurements taken. [3.] Locate where they are accessible for maintenance and service. [4.] Do not paint Spot Thermostats as paint acts as a heat shield. [5.] Do not locate Spot Thermostats on any component of a vehicle that is likely to be removed or moved during maintenance or service. Examples would include; hatches air cleaner housings, engine carriage brackets, removable guards or shields, brackets holding other components such as alternators and pumps, [6.] Locate spot sensor above the hazard area. [7.] Do not attach the Spot Thermostat directly on a “hot” component such as an exhaust manifold, turbocharger, engine block or radiator as heat will be transmitted to the Spot Thermostat through conductivity. Remember to choose a detection device that is rated 100º F above the ambient operating temperature of the hazard area.


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Heat Detection Cable Assemblies: The Linear Heat Detection Cable Assembly consists of two steel conductors inside a heat sensitive insulated modular wiring harness. When the insulation is exposed to temperatures in excess of 356ºF the insulation melts and allows the two conductors inside to short together and send an alarm signal to the Control Panel to discharge the fire suppression system. The Cable Assembly is equipped with green color coded Amerex click lock connectors at each end to plug into the detection circuit wiring. When the Linear Heat Detection Assembly is the last device on either detection circuit it must be terminated with an End Of Line Module (P/N 14010) to complete the circuit. The entire section of Linear Detection Assembly must be replaced if exposed to heat in excess of 357ºF or is involved in a fire. No splicing of the wire is permissible. Doing so will void the Amerex system warranty and could adversely affect the devices ability to detect a fire.

To be most effective the Linear Heat Detection Cable Assembly should be routed above the hazards identified during the hazard analysis (See Section 3). It should be secured at least every 18 inches with padded p-clamps, weather and UV resistant Nylon Zip Ties or similar methods. Both of the terminated ends should be secured. Locate and mount the Linear Heat Detection Cable Assembly observing the following rules: [1.] Locate where all components will be protected from mechanical, environmental, or other conditions that could render them inoperable. [2.] Locate the End of Line Module (P/N 14010) installed at the end of the last cable, where it can be accessed for service and removed for testing. [3.] Locate the Linear Detection Assembly above the hazard as determined by the hazard analysis (See Section 3). The melting point of the cable insulation is 356º F (180º C). Verify that the normal ambient temperature in areas where the sensing cable is to be located is 256º F (124º C) or less by referring to the hazard analysis ambient temperature measurements taken. [4.] Locate the Linear Detection Cable where it is accessible for replacement and service. Maximum amount of Linear Detection Cable permitted is 100 feet total. Do not exceed 100ft. [5.] Do not locate Linear Detection Cable where in will be subject to damage from abrasion, sharp edges or moving parts. Avoid pinching by observing a minimum bend radius of 6 inches (15 cm). Locate retaining pclamps every 18 inches (45 cm) along the Linear Detection Cable and 1 inch from the end of the Cable Assembly plug. Rubber grommets must be used when cable is routed through a bulkhead or panel to protect the tubing from abrasion. Leave a slight amount of slack in the cable to allow for contraction and expansion. [6.] If mounting with cable ties, do not over tighten and pinch the cable. Do not paint the cable. [7.] Do not locate the Linear Detection Cable or End Of Line Module (P/N 14010) on any component of a vehicle that is likely to be removed during maintenance or service.


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[8.] Locate the Linear Detection Cable above the hazard area. If possible locate in cavities or under bulkheads where heat from a fire will be trapped in order to minimize sensor response time. [9.] NEVER attach the Linear Detection Cable directly on a “hot” component such as exhaust manifold, turbocharger, engine block or radiator. Maintain a minimum distance of 18 inches (45 cm) above such hot components.

6.B. Connection of Hoses When all components are secured to the vehicle, the distribution and actuation hoses may be built and connected. Using a flexible tape, measure from component to component. Route the hose along the same paths as existing hoses on the vehicle. Do not cross the hoses through open areas where vehicle maintenance will be obstructed. Avoid running hoses through pinch points and articulating joints. If a hose must reach a component located on a movable surface, such as to a nozzle located on an engine cowling or tilt cab, route the hose first to the pivot hinge, then to the component so that movement of the vehicle surface will not be impeded. Once the hose lengths are determined, make a final check that they are within the hose limitations given in Section 4. In connecting discharge hoses to tees, make certain that the supply hose attaches to the tee at the middle port, and that the two end ports are used as outlets. Figure 6..7 illustrates the correct and incorrect methods. Make sure that the actuation hoses are fitted with the required number of check valves as specified in Section 4. Secure hoses to the vehicle every few feet using UV resistant wire ties or "P" clamps. Also apply anti-tamper labels, P/N 10787 to hoses running near vehicle high maintenance areas to help to discourage inadvertent disconnection. If holes were cut in vehicle bulkheads to facilitate hose routing, line those holes with a grommet or automotive welting to prevent abrasion of the hose. Actuation hose must not be run through the hazard area to avoid damage by fire before system actuation. If routing other than through the hazard area is not possible, the actuation hose must be protected by the addition of a heat resistant wrap and extreme high temperature hose must be used. Tighten all hoses in place. On discharge hoses, tighten all pipe threaded connections to nozzle brackets, fittings, distributors, and discharge outlet fittings a minimum of one full turn past hand tight. Connect the main 3/4-inch (19mm) agent supply hose to the agent cylinder discharge fitting. Slip the retaining flange over the discharge fitting first, then tighten the fitting into the hose coupling. On actuation hoses, tighten all pipethreaded connections at actuators, check valves, fittings and pneumatic control heads three full turns past hand tight. Follow hose and coupling manufacturer recommendations on tightening other types of connectors. The use of Teflon thread tape or pipe thread sealant is recommended. Do not allow thread tape or thread sealant to enter hose I.D.


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6.C. Connection of Electrical Circuits WARNING: THE PRIMARY CAUSE OF FIRE SUPPRESSION SYSTEM MALFUNCTIONS HAS BEEN TRACED TO POOR INSTALLATION OF ELECTRICAL COMPONENTS AND POOR WIRING PRACTICES. THEREFORE, ONLY THOSE WIRING CONNECTION SCHEMATICS, WIRING PRACTICES, ROUTING METHODS, AND CONNECTION METHODS AS SPECIFIED IN THIS MANUAL ARE APPROVED FOR USE WITH THE AMEREX SYSTEM. ANY OTHER METHODS ARE NOT PERMITTED! The following pages show instructions and wiring diagrams for proper connection of all electrical components. Wiring Material: Only genuine Amerex wire assemblies may be used in wiring of the Amerex Fire Suppression System. Routing: Route wires along the same paths as used by the existing vehicle wiring harnesses. Do not stretch the wires across open areas where vehicle maintenance will be obstructed. Avoid routing wires through pinch points and articulating joints. If the wires must be routed to a component located on a moveable surface, such as to a thermostat on an engine cowling or tilt cab, route the wires first to the pivot hinge and then to the component so that movement of the surface will not be impeded. Allow enough slack in the wire so that this movement will not put a strain on the wiring or components. Use Amerex Hazard Wire Lead Assemblies throughout. If holes are cut in vehicle bulkheads to facilitate routing wires, line the holes with a grommet or automotive welting to prevent abrasion of the wires. Secure wires to the vehicle or to existing wiring harnesses using heavy duty UV resistant wire ties or padded metal “P” clamps at least e very 24 inches (61 cm). Also apply anti-tamper labels, P/N 10787 to all wiring identifying it as Fire Suppression System wiring to discourage inadvertent disconnection or cutting. If additional protection from heat or abrasion is deemed necessary by the installer, or by the authority having jurisdiction, it is recommended that the wires be encased in commercially available convoluted tubing or vinyl coated fabric weave loom. Wiring Connections: Amerex wiring harnesses provide the most convenient, durable and weather resistant wiring system available and are specified to insure the utmost in reliability of the Fire Suppression System. All modular wiring components are supplied with color coded Amerex Click Lock pluggable wiring connections for ease of installation. Splicing of wire is unnecessary and is strictly forbidden under the terms of the Amerex Warranty and Factory Mutual Listing. All wiring connections are made at the Circuit Monitor or Control Panel, main power, electric actuator, thermostats, and interconnections of these circuits via color coded Amerex Click Lock connectors and Amerex Modular Lead Assemblies of appropriate length. (See Section 2.) . There is no need to open or make any wire connections inside either the Circuit Monitor or Control Panel as all connections are made outside the panel enclosures. When connecting wires to the engine shutdown relay or agent cylinder pressure switch circuits, the connections must be made inside a weather proof junction box, or the use of crimp-on butt splice connectors protected by adhesive wall shrink tubing is required. Color Coding: All Click Lock Connectors are color coded to indicate the circuits they mate with. When the wiring is correctly installed, the color coding of the male and female Click Lock Connectors will match. Color Codes are as follows: Red = Main Power Circuit Yellow = Electric Actuator Circuit Green = Thermostat, Heat Detection Circuit Blue (Single Wire Loop) = Agent Cylinder Pressure Switch Circuit Timed Relay 3 Conductor Lead – Gray outer jacket surrounding the following conductors: Red = Common Black = Normally Closed Contact point White = Normally Open Contact Point


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Connect the various circuits in the following sequence: Heat Sensor Connections: The Local Sensing Spot Thermostats, and the Linear Heat Sensing Cable Assemblies are connected in a Class B circuit with an end of line module for monitoring purposes. Two wires with a green color coded Amerex Click Lock connector are provided at the Circuit Monitor III, Control Panel III or SafetyNet Electronic Controls for connection to a green color coded Hazard Wire Lead Assembly. Either or both wires may be used for heat sensor connection leads or for connection of manual actuation switches. The Hazard Wire Lead Assembly then connects to the first Modular Thermostat or Linear Heat Detection Cable Assembly. Shorter lengths of the Hazard Wire Lead Assembly are used to connect between additional Thermostat Assemblies and/or Linear Heat Sensors until all heat sensing devices are connected. A maximum length of 100 feet of Linear Heat Detection Cable is permitted. Do not exceed 100 feet. Finally, an End of Line Module is plugged in after the last Thermostat or Linear Heat Sensor Cable. This completes the thermostat wiring Class B circuit to allow for monitoring of the circuit.

Manual Actuation Switch (P/N 14053): On installations using the Electric/Nitrogen Actuator, P/N 20775, a Manual Actuation Switch P/N 14053 may be used to fire the electric actuator in addition to the heat detection circuits. The Manual Actuation Switch is installed into either detection circuit using the green color coded Amerex Click Lock connectors provided on the switch assembly. In all installations using the P/N 14053 Manual Actuation Switch(es) at least one must be installed in the detection circuit BEFORE THE FIRST HEAT DETECTION DEVICE. Installing the Manual Actuation Switch BEFORE the first heat detection device insures that the Manual Actuation Switch will actuate the fire suppression system even in the event the remainder of the detection circuit is cut or damaged. All detection circuits can be used with multiple P/N 14053 Manual Actuation Switches combined with other heat detection devices such as spot heat detectors or linear heat detection cables.

Agent Cylinder Pressure Switch: An Agent Cylinders equipped with this switch (or switches in the case of multiple agent cylinders) is wired in a series loop from the Control Panel III or SafetyNet Panel to the switch and back. (The Circuit Monitor Panel has no provisions for use of the Agent Cylinder Pressure Switch). Pressure inside the Agent Cylinder holds electrical contacts normally closed inside the Agent Cylinder Pressure Switch. Use Amerex Modular Pressure Switch Leads (See Section 2) for connection purposes. The pressure switch circuit is color coded blue at the Control Panel. To connect, unplug the blue color coded jumper plug at the Control Panel connection lead, plug in the corresponding male and female plugs on the Modular Pressure Switch Leads, then connect the other end of the Pressure Switch Leads at the Agent Cylinder into the male and female plugs provided on the Agent Cylinder pressure switch. In this way, the switch needs only to be unplugged to facilitate agent cylinder recharge. The Control Panel is shipped from the factory with a blue jumper plug installed in the event that a pressure switch is not used. Leave this plug in place at the pa nel if not using the agent cylinder pressure switch option.


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Pressure Operated Switch: (Optional) The Pressure Operated Switch (Fig. 2-1X) has no wiring routing to the control panel as it is operated by nitrogen pressure from the actuation network. When the cover of the pressure operated switch is removed, three connection points for a single pole - double throw switch will be found. One connection point is labeled "Normally Closed," the second is "Normally Open," and the third is "Common." These connection points can be used to initiate engine shutdown or operate auxiliary safety equipment such as air dampers or warning horns. This is an immediate action device and thus does not have a time delay feature. It is the responsibility of the installer to gain sufficient understanding of vehicle operation to properly select, install, and connect any auxiliary equipment. In particular, the installer must determine: 1) if the device or equipment is "Energized to run" (Power supplied to sustain normal operation) or "Energized to Stop" (Power supplied to terminate normal operations) 2) are the current requirements for the shutdown or safety device 10 amps or less 3) are the voltage requirements for the device between12 and. 24 VDC The contacts of the pressure operated switch are rated for a maximum of 10 amps at 24 volts DC. This value must not be exceeded. Electrical Actuator Connection Lead: On all automatic electrically actuated systems the Electric Actuator Connection Lead (Fig. 2-1E5) must be used to connect the Electric Actuator to the actuation lead routing from the Control Panel. A yellow color coded male Amerex Quick Lock connector is provided at one end for mating to the matching connector at the Circuit Monitor III, Control Panel III or SafetyNet Panel. A yellow color coded female Amerex Quick Lock connector is provided at the other end for connection to the Electrical Actuator. DO NOT CONNECT THE ACTUATOR LEAD TO THE ACTUATOR AT THIS TIME!

Wiring Schematics: SEE AMEREX MANUAL P/N 19680 FOR COMPLETE INSTALLATION AND INSTRUCTIONS FOR CIRCUIT MONITOR III AND CONTROL PANEL III. OR SEE AMEREX MANUAL P/N 16601 FOR COMPLETE SAFETYNET DETAILS AND INSTRUCTIONS.


June 2012

Engine Shutdown and Auxiliary Safety Equipment: and SafetyNet Controls:

Page 6-13

Installations equipped with a Modular Control Panel III

P/N 17310, 17311 and SafetyNet Panels will include a connection lead for engine shutdown equipment or auxiliary safety equipment such as air dampers, warning horns or lights. It is the responsibility of the installer to gain sufficient understanding of vehicle operation to properly select, install, and connect any auxiliary equipment. In particular, the installer must determine: [1] if the device or equipment is “Energized to Run” (Power supplied to sustain normal operations) or “Energized to Stop” (Power supplied to terminate normal operations). [2] What are the current requirements for the shutdown or safety device. The panel relay is rated for 5 amp maximum. [3] How long a time delay should occur prior to engine shutdown. The timer relay is factory set to initiate immediately. To increase the delay, refer to manual P/N 19680 for Control Panel III or manual P/N 16601 for SafetyNet Electronic Controls. Minimum delay is 0 seconds; maximum delay is 15 seconds. Engine shutdown delay of 15 seconds must not be exceeded as fifteen seconds also represents the discharge time of the system suppression system. Exceeding fifteen second through the use of auxiliary devices will adversely affect the system’s performance.

The auxiliary contacts of the Control Panel III and SafetyNet Controls are sized for a maximum of 5 amps. This value must not be exceeded. The auxiliary contacts of the Control Panel III may be used with either 12 or 24 VDC systems. Any device that is wired to the auxiliary contacts of the Control Panel must draw its current from an independent power lead fused with a 10 amp type AGC fast blow fu se. In addition, the internal relay “common” contact is also protected with an internal self-resetting circuit breaker. Figure 6-20 gives only a few examples of the many common auxiliary devices encountered in these installations.


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Example Wiring Diagrams for Typical Auxiliary and Engine Shutdown:

Page 6-14


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6.D. Placing the System in Service

1. Connect The Discharge Network -Remove the anti-recoil plate from agent cylinder. Lightly and sparingly lubricate the discharge fitting O-ring if necessary with water only and insert the fitting into the discharge valve. Bolt the retaining flange securely in place using the 5/16 inch stainless steel bolts provided with the anti-recoil plate. WARNING: Do not apply or spray lubricant of any type into the valve discharge opening! This includes oils, grease, WD40 etc. 2. Connect Agent Cylinder Pressure Switch - On installations so equipped, plug the connector together at the pressure switch to complete the circuit to the Control Panel III or SafetyNet Panel. 3. Test the Engine Shutdown System - Connect the Fire Alarm Module P/N 21447 to the electric actuator lead connector. Push the reset button on the Alarm Module. The panel should now indicate a normal condition with the green "System OK" LED illuminated. Start the equipment or vehicle and allow it to idle. Request assistance from the equipment owner/operator if necessary. CAUTION: Do not attempt to operate equipment on which proper training has not been given or that you are not familiar with. Push and hold the "Push To Test" button, located behind the Amerex logo, on the front of the Control Panel III and mark the "start time" on a stop watch. An audible "click" will occur when the auxiliary relay is energized. Confirm that the delay period is as required and that the vehicle is powered down, or that other safety devices are properly actuated as applicable. Release the "Push To Test" button and observe that the panel returns to normal condition. The vehicle should now be able to be restarted. 4. The Electrical Networks - With the Alarm Module P/N 21447 still connected to the electric actuator lead connector, press and release the reset button. The Circuit Monitor III or Control Panel III should now indicate a normal condition. Only the "System OK" green LED should be illuminated. Test the function of each spot heat sensor. Hold an electric heat gun near the thermostat until the contacts close. WARNING: Do not use a propane torch or any other uncontrolled flame heat source to test the Spot Heat Sensors as permanent damage to the heat sensor will result! Test each individual spot thermostat using the following procedure: Perform a visual inspection of the heat detector. During the visual inspection, verify that the sensing shell is free from dents, dings, cracks, scorch marks from flames, or any other physical damage. If the shell has experienced any of these symptoms, replace immediately. If the shell has been painted, the unit should be replaced immediately. If a build-up of grease, dust, or any other foreign matter has accumulated on the unit, it may be cleaned with a vacuum or soft dry cloth. Care should be used to not damage the unit in any way! 



Perform an operational verification of the heat detector. The fire suppression system must be disabled with use of the 21447 test module/simulator prior to doing any operational verification tests of the heat detector! a. Set-point temperature for each heat detector are: i. 280°F closes at 280°F +/- 14°F ii. 350°F closes at 350°F +/- 17°F iii. 450°F closes at 450°F +/- 22°F b. It is acceptable to use a controlled heat source such as a radiant heat gun that is adjustable for appropriate temperature test settings. Milwaukee 8978-20 variable temperature heat gun would be a good selection that has adjustable temperature settings. The heat gun must be held a minimum of ½” away from the tip of the detector body. Remove heat immediately following activation of the unit.


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c. Do not overheat the set-point of the unit by more than 100°F (55°C) (example: 280°F unit must not be heated beyond 380°F). Overheating the unit beyond recommended limitations can cause the unit to change set-point temperature rating. d. DO NOT CONTACT THE SENSING SHELL WITH HEATING DEVICES SUCH AS PENCIL TORCHES, SOLDERING IRONS, OR OPEN FLAME. Radical sources of heat can change the set-point temperature rating of the unit and shall not be used. While the thermostat is a repeatable device, replacement is mandatory should the unit be subjected to an open flame or a fire event. WARNING: DO NOT PERFORM THIS TEST ON THE SYSTEM IF THE ELECTRIC ACTUATOR AND ELECTRIC/NITROGEN ACTUATOR ARE INSTALLED AND CONNECTED! SYSTEM DISCHARGE WILL RESULT! WARNING: USE EXTREME CARE WHEN FOLLOWING THIS PROCEDURE. MAKE CERTAIN THAT NO HAZARDS EXIST THAT COULD BE IGNITED BY THE HEAT SOURCE. When the thermostat contacts close, the Circuit Monitor III or Control Panel III will enter the alarm mode. The green LED will turn off, the red "Fire" LED and “Service System” LED will illuminate and an audible alarm will sound. Also, on installations using the Control Panel, the time delayed relay will begin to count down. Remove the heat source. After the thermostat cools and the contacts reopen, the red “Fire” LED will remain illuminated and the alarm will continue to sound. If the yellow LED on the Alarm Module is off, then the detector has reopened or is reset. Press the reset button on the Alarm Module. The Circuit Monitor or Control Panel will return to the normal mode. The system will not reset until the thermostats are cool and reset. Repeat this test for each thermostat. Test the function of each Linear Heat Detection Cable Assembly by attaching a Manual Actuation Switch P/N 14053 to the male end plug. Replace the End of Line Module on the male end plug of the Manual Actuation Switch and observe that the green “SYSTEM OK” LED is illuminated on the Circuit Monitor or Control P anel III. Press the “FIRE” button on the Manual Actuation Switch. The panel must go into alarm. Remove Manual Switch and re-install the End of Line Module Check each Manual Actuation Button by pressing and releasing. The Control Panel must go into alarm when each Manual Actuation Button is pressed and released. When all thermostats, heat detection cables and manual actuation buttons have been tested and the green "System OK" LED has again illuminated, remove the Alarm Module from the electric actuator lead connector. 5. Agent Cylinder Pressure Switch Circuit - On installations so equipped, test the function of the agent cylinder pressure switch circuit by unplugging the switch at its socket. This duplicates loss of agent cylinder pressure, which would open the switch. The Control Panel will enter the fault mode (Green OK LED off, red “Service System” LED on). Reconnect the pressure switch and the panel will return to normal. 6. Battery Back- Up Circuit - All Modular Circuit Monitors and Control Panels are equipped with a Back Up Battery. To test the function of the internal back-up battery, disconnect the vehicle power supply to the panel by unplugging the fuse holder in the power supply lead. Only the “Service System” LED should be illuminated on t he panel. Reconnect the power supply lead. With vehicle power restored, the green “System OK” LED should again be illuminated.


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7. Install the Electric Actuator - Screw the electric actuator into the Electric/Nitrogen Actuator at the threaded hole provided. Firmly finger tighten actuator into Control Head body until the body of the actuator is securely in contact with Control Head body. Do not over tighten by using pliers. Plug in the click lock connector to the mating connector on the actuator lead assembly. Check that the green “System OK” LED is illuminated and the red “Fire” LED is off on the Circuit Monitor or Control Panel. Screw the N2 cylinder into the open end of the Control Head. Tighten securely by hand, 1 1/2 to 2 turns past contact with the sealing gasket. See Fig. 2_1V on page 2-11 for assembly example. 8. Manual Actuators - With N2 cylinder removed, depress the palm button several times to confirm free travel. Screw the N2 cylinder into the open end of the actuator. Tighten securely by hand, 1 1/2 to 2 turns past contact with the sealing gasket. On remote actuators mounted on outdoor brackets, install covers using the four 1/4 stainless steel cap screws provided. Install the pull pin and secure with the plastic lock wire provided or a leaded wire seal. Make sure that the pull pin is accessible through the slotted opening in the cover. Tighten the cap screws securely using a 3/16 inch T-handle Allen wrench. 9. Documentation - Make a final check to confirm that all details of the installation match the design documentation made earlier when the hazard analysis and system design was performed. Make any necessary revisions to the documentation and store as a permanent record. Photographs are perhaps the best form of documentation of all and can be referred to later to confirm the original system layout as well as the original configuration of the machine when the system was installed. 10. Final Inspection - Perform an "Inspection" as per Section 7. 6.E. Provide Owner / Operator Training The OWNERS MANUAL shipped with each agent cylinder contains operating instruction, system description, housekeeping requirements, and system inspection requirements. Make sure the equipment owner/operator receives this manual. Make an INSTALLATION REVIEW with the equipment owner/operator. Show them the location of all system components on the vehicle. Point out the high risk/hazard areas and explain that those areas must be of particular concern during housekeeping operations. Explain how to use the system. If the installation is equipped with engine shutdown features, explain the use of this feature and the steps that must be taken to bring the vehicle to a complete stop or to move the vehicle to a service area after system discharge. WARNING: IF THE VEHICLE HAS BEEN EQUIPPED WITH THE VEHICLE ENGINE SHUTDOWN CAPABILITY, ALL POTENTIAL OPERATORS MUST BE TRAINED IN SAFETY PROCEDURES TO BE TAKEN IN THE EVENT OF LOSS OF POWER AND/OR STEERING AND BRAKES. ONCE A FIRE CONDITION IS DETECTED, THE “ENGINE SHUTDOWN TIMER - PUSH TO DELAY” BUTTON ON THE PANEL MAY BE PRESSED AS MANY TIMES AS NEEDED TO DELAY ENGINE SHUTDOWN AND ALLOW MORE TIME TO BRING THE VEHICLE TO A SAFE AND CONTROLLED STOP. OPERATORS SHOULD ALSO REALIZE THAT PUSHING THE “DELAY” BUTTON WILL NOT DELAY DISCHARGE OF THE FIRE SUPPRESSION SYSTEM. ALL POTENTIAL OPERATORS MUST BE TRAINED THOROUGHLY IN THE USE OF THIS FEATURE. Explain the sensitivity of the thermostats in that extreme shock, welding torches, steam cleaning, or other outside heat sources may create an unwanted discharge. Explain that cutting the system wiring anywhere along the electrical circuits especially, the detection circuits, will cause an unwanted discharge. Give a brief description of system inspection including: 1) that all components are in place and unobstructed.

Part Number 16400 Rev. A June 2012 Page 6-18 2) all pressure gauges are in operable (green pie) range. 3) all hoses are connected and tight. 4) Control Panel "System OK" LED is illuminated. 5) Supplementary hand portable fire extinguisher(s) locations and use. 6) Owner inspection of the vehicle and the suppression system does not take the place of factory trained inspection and service, but should be encouraged as an added measure of safety. Complete the WARRANTY REGISTRATION with the equipment owner/operator. Explain the terms of the warranty and the services that must be performed on the system to keep the warranty valid. Tear off the back page of the Owners Manual P/N 10722. Fill in all requested information including the owner's name, address, etc., installer's name, address etc., description of the vehicle and the vehicle identification number (VIN #) of the vehicle on which the system was installed. Note that the serial number(s) of the agent cylinder(s) found on the agent cylinder top dome(s) have already been filled in at the Amerex Factory. Insure that the form is signed by both the owner and the installer, and returned the form to Amerex Corporation, Systems Division Warranty Department, P.O. Box 81, Trussville, Alabama, 35173. 6.F. Warranty Statement Warranty and Limitation of Liabilities, Buyers Remedies, and Indemnification Amerex Corporation (Seller) warrants that Vehicle Fire Suppression System components (Goods) delivered are free from defects in material and workmanship under conditions of normal use for a period of three (3) years from the date of purchase except Small Vehicle Fire Suppression System components and AMGADS gas sensors which are warranted for a period of one (1) year. Nonstandard products manufactured by Seller to customer specifications are warranted for a period of one (1) year. Contact Amerex Corporation for warranty statements for other Amerex Corporation products. Seller reserves the right to make any modifications required by production conditions to the information set forth in the Seller’s catalogues and advertising literature. Seller shall not be liable or responsible, however, for (A) any defects attributed to normal wear and tear, erosion or corrosion or improper storage, use or maintenance, or (B) defects in any portion or part of the Goods manufactured by others. If (B) above is applicable, Seller will, as an accommodation to Buyer, assign to Buyer any warranties given to it by any such other manufacturers. Any claim by Buyer with reference to the Goods for any cause shall be deemed waived by Buyer unless submitted to Seller in writing within ten (10) days from the date Buyer discovered, or should have discovered, any claimed breach. Buyer shall give Seller an opportunity to investigate. Provided that Seller is furnished prompt notice by Buyer of any defect and an opportunity to inspect the alleged defect as provided herein, Seller shall, at its option and in its sole discretion either: (i) repair the defective or non-conforming Goods, (ii) replace the nonconforming Goods, or part thereof, which are sent to Seller by Buyer within sixty days after receipt of the Goods at Buyer's plant or storage facilities, or (iii) if Seller is unable or chooses not to repair or replace, return the purchase price that has been paid and cancel any obligation to pay unpaid portions of the purchase price of nonconforming Goods. In no event shall any obligation to pay or refund exceed the purchase price actually paid. This warranty does not cover defects resulting from modification, alteration, misuse, exposure to corrosive conditions or improper installation or maintenance. Repair and/or replacement as provided above shall be at Seller's plant and shipped F.O.B. Plant unless otherwise agreed to by Seller. Transportation charges for the return of the Goods or part thereof to Seller shall be prepaid by Buyer, unless otherwise agreed to in writing by Seller. Seller shall, in no event, be responsible for any labor, removal or installation charges that may result from the abovedescribed repair and/or replacement of any Goods. The foregoing warranty does not cover failure of any part or parts manufactured by others, the failure of any part or parts from external forces, including but not limited to earthquake, installation, vandalism, vehicular or other impact, application of excessive torque to the operating mechanism or frost heave. The exclusive remedy of Buyer and the sole liability of Seller, for any loss, damage, injury or expense of any kind arising from the manufacture, delivery, sale, installation, use or shipment of the Goods and whether based on contract, warranty, tort or any other basis of recovery whatsoever, shall be, at the election of Seller, the remedies described above. The foregoing is intended as a complete allocation of the risks between the parties and Buyer understands that it will not be able to recover consequential


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damages even though it may suffer such damages in substantial amounts. Because this Agreement and the price paid reflect such allocation, this limitation will not have failed of its essential purpose even if it operates to bar recovery for such consequential damages. THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES WHETHER EXPRESS OR IMPLIED BY LAW. THERE IS NO IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT, WHETHER AS A RESULT OF BREACH OF CONTRACT, WARRANTY, TORT (INCLUDING NEGLIGENCE) OR STRICT LIABILITY, SHALL SELLER BE LIABLE FOR ANY PUNITIVE, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING, BUT NOT LIMITED TO, LOSS OF PROFIT, LOSS OF USE OF THE GOODS OR OTHER PROPERTY EQUIPMENT, DAMAGE TO OTHER PROPERTY, COST OF CAPITAL, COST OF SUBSTITUTE GOODS, DOWNTIME, OR THE CLAIMS OF BUYER'S CUSTOMERS FOR ANY OF THE AFORESAID DAMAGES. SELLER SHALL NOT BE LIABLE FOR AND BUYER AGREES TO DEFEND AND INDEMNIFY SELLER AGAINST ALL CLAIMS OR LOSSES (INCLUDING ATTORNEYS’ FEES), INCLUDING PERSONAL INJURY, PROPERTY DAMAGE OR OTHER LIABILITY, RESULTING IN WHOLE OR IN PART FROM (1) THE NEGLIGENCE OF BUYER OR ITS CUSTOMERS; (2) BUYER’S OR ITS CUSTOMER’S MISUSE , damage, alteration or modification of Seller’s Goods; (3) Buyer’s OR ITS CUSTOMER’S use of the Goods in any product or system designed, manufactured or sold by Buyer OR ITS CUSTOMERS; OR (4) ANY BREACH OF THIS AGREEMENT; provided, however, that Buyer shall have no obligation to indemnify Seller for claims or losses that arise solely from the negligence or misconduct of Seller. In any contract by Buyer for resale of the Goods, Buyer shall effectively disclaim, as against Seller, any implied warranty of merchantability and all liability for property damage or personal injury resulting from the handling, possession or use of the Goods, and shall exclude, as against Seller, any liability for special or consequential damages.


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Servicing the Amerex Systems: The following sections (7, 8 and 9) deal with inspection, maintenance, and recharge of the Amerex Vehicle Fire Suppression Systems. Per NFPA Code 17, Inspection is defined as a Quick check that requires minimal knowledge to perform. NFPA 17 defines Maintenance and Recharge as tasks that are required to be performed by, a trained person who has undergone instruction necessary to perform those functions, and has the manufacturer’s service manual. Amerex has based the servicing requirements for Vehicle Fire Suppression Systems on NFPA 17 and other specific information particular to the Amerex System design. It is the responsibility of the equipment owner to provide minimum service as required by NFPA, Amerex Corp., and all authorities having jurisdiction. Since the application and usage of the Amerex Systems can vary, some systems may require mor e frequent service to insure reliable operation.

Section 7 Inspection Daily Inspection Check the Circuit Monitor III or Control Panel III LED's to see if the system has power and that the green "SYSTEM OK" LED is illuminated. No other LED’s should be illuminated under normal conditions. Monthly Inspection NFPA 17 requires the following minimum quick check inspection on a monthly basis: [1] Check that all components are present and in their original location. [2] Check that all manual actuation switches and remote actuators are unobstructed by vehicle modifications or clutter. [3] Check that tamper indicators, lock wire seals, and pull pins and “In Case Of Fire” instruction labels are intact. [4] Check that the maintenance tag or certificate is in place. Record date of inspection and initials of inspector. [5] Check the physical condition of all components for damage or conditions that may prevent operation. [6] Check the nozzles. All blow-off caps must be intact and in place. Nozzle outlets must be unobstructed and properly aimed. There should be no obstructions between the nozzle and the hazard it is protecting. In addition, Amerex requires the following inspections on a monthly basis: [ 7 ] Check that all components, agent cylinders, control heads, actuators, hose systems, wiring, and detectors are securely mounted, and that all wiring connections are sealed from the weather. [ 8 ] Check that all agent cylinder labels are intact, clean and legible.


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Section 8: Maintenance Semi Annual maintenance: NFPA 17 requires the following minimum maintenance on a semi-annual basis. Any deficiencies that are found and corrected should be documented with one copy provided to the equipment owner and a second copy kept for permanent record. Maintenance may be performed only by Amerex factory trained personnel. [1] Check that the hazards have not changed. Look for changes in vehicle operation or cleaning procedures that may have increased the hazard. Compare with the original vehicle hazard analysis. [2] Examine all spot heat sensors, linear heat detection cable, agent cylinders, valves, piping/hose assemblies, nozzles, alarms, and auxiliary equipment. [3] Verify that the actuation and discharge network hoses are not obstructed. In addition, Amerex requires the following minimum maintenance on a semi-annual basis. [4] Service the agent cylinders. Clean cylinder to remove dirt, grease or foreign material. Check to make sure that the instruction nameplate is securely fastened and legible. Inspect the cylinder for corrosion, abrasion, and dents or weld damage. Hydro test the cylinder if any of these conditions are found or you doubt the integrity of the cylinder. (See Section 9) WARNING: ALWAYS INSTALL SHIPPING PLATE AND ANTI-RECOIL PLATE WHEN TRANSPORTING A PRESSURIZED AGENT CYLINDER. NOTE: When cleaning, avoid use of solvents around the pressure gauge. Solvents can seriously damage the plastic gauge face. [5] Servicing the Discharge Valve. a. Check the pressure relief to confirm that it is free of corrosion and has not been altered. b. Remove control head and check the valve stem return spring and retaining washer in the top of the valve for corrosion or debris. The valve stem spring retainer in the top of the valve body should be centered in its recess. Depressurize cylinder and rebuild valve if defects are found. (See valve rebuild instruction is Section 9 )

[6] Inspect the pressure gauge on the discharge valve: a. If bent or damaged, depressurize and follow recharge instructions. (Section 9) b. If pressure is low, check for leaks, or partial discharge. Depressurize the agent cylinder and follow recharge instructions. c. If over pressurized (overcharged), depressurize the agent cylinder and follow recharge instructions. [7] Servicing the discharge networks. a. Disconnect discharge hose from agent cylinder by unbolting retaining flange. Inspect discharge outlet for extinguishing chemical residue, dirt, debris and lubricant contamination. The discharge throat should be free from any contamination. After inspecting discharge throat install P/N 10646 AntiRecoil Plate on valve discharge opening. b. Remove all nozzle blow-off caps. c. Attach an Amerex P/N 12129 Discharge Network test adapter to the discharge fitting and connect to a compressed air source. d. Blow compressed air through the hose. e. Confirm that the compressed air is flowing through each nozzle with no obstructions. f. Verify all hoses have no damage, and each connection point is properly secured in the network. g. Service the nozzles. Orient all blow off caps with the retaining loop arching down. Replace any that are damaged.


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h. Remove the anti-recoil cap from the agent cylinder and reconnect the discharge fitting to the discharge valve. Bolt the retaining flange securely in place using the 5/16 inch stainless steel provided with the anti-recoil plate. If necessary a few drops of water can be used to lubricate the discharge fitting o-ring for insertion. WARNING: Do not apply or spray lubricant of any type into the valve discharge opening! This includes oils, grease, WD40 etc. In time this lubricant will migrate onto the sealing surface and can cause the valve to stick. [8] Service the T-handle mechanically operated control head P/N 10134. (See Section 10 for exploded drawing). a. Remove the head from the discharge valve. b. Clean the assembly to remove dirt, grease and foreign material. c. Pull out the ring pin and operate the lever several times to confirm free movement and full travel. d. Replace complete assembly if operation is impeded, or if corrosion is present. e. Bolt mechanical control head in place and install pull pin and tamper indicator. Make sure that the mechanical control head is properly oriented relative to the equipment operator so that a "pull" of the T-handle is necessary to actuate the suppression system. [9] Service the P/N 10147 pneumatic control head. Exploded view of internal components of the (10147) assembly:

Service Procedure: a) Assembly must be disassembled, cleaned, and reassembled after each use per the following guidelines: i. Bleed residual nitrogen from system by using a paper clip to press white vent check ball until all pressure is relieved. ii. Carefully disconnect nitrogen hose at control head inlet iii. Remove vent check (10173) and inspect for damage or debris inside of it. iv. Remove 5/16” bolts that fasten the control head to the agent cylinder discharge valve.


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v. Use retaining ring pliers for removal of the retaining ring (Note: use eye protection for this step). vi. Remove safety lock washer (17637), (10148) o-ring, and (17635) piston assembly. vii. Use a flat head screwdriver to force the locking plunger down on (17635) piston assembly shaft in order to remove the safety lock washer (17637). viii. Inspect cylinder bore of body (11669). If scarring has occurred inside body, it will prevent travel of O-ring (10148) during actuation. Replace (11669) body if this is found. Replace any other components that compromise the functioning of the pneumatic control head assembly. ix. Make sure that the locking plunger is spring-loaded and can be forced in and out of the piston shaft. Note: Do not remove plunger from piston assembly! If this part is compromised, replace the entire piston assembly. x. Replace O-Ring (10148) if it is damaged. xi. Lubrication: O-Ring (10148) must be lubricated with L0172 lubricant. Inside bore of the control head is to be lubricated with L0172 lubricant also. xii. Reinstall piston assembly (17635) as shown above. xiii. Reinstall safety lock washer (17637) as shown above. xiv. Reinstall retaining ring (10149) (note: eye protection required!). xv. Reinstall vent check valve (10173) ** See installation manual (16400) for cleaning/diagnosing and reinstalling the vent check. xvi. Test the assembly by using shop air less than 90 PSI to force the piston through the safetylocking washer. After it is acknowledged that the piston locks, use a flathead screwdriver to force the locking plunger mechanism down so that the piston assembly can be recessed into the control head assembly again. xvii. Fasten the control head assembly to the agent cylinder with the Amerex supplied 5/16” bolts. Use 2 drops of the medium grade blue Locktite to secure the bolts in place to prevent vibration from loosening the control head assembly from the agent cylinder. xviii. Refer to installation manual 16400 for pneumatic hose plumbing installation. [10] Service the manual actuator on installations so equipped. (See Section 10 for exploded drawing). a. Remove the N2 cylinders from all manual actuators after first removing covers from outdoor actuator brackets as required. b. Pull the ring pin from each actuator. c. Operate the palm button of each several times to confirm free movement and complete travel and return. d. Inspect all actuators for signs of corrosion and replace any actuator whose travel is impeded or whose integrity is in doubt. e. Inspect the N2 cylinder rubber sealing gasket in the bottom of each actuator and replace if worn or cracked. f. Re-install ring pin into actuator with lockwire tamper seal indicator. [11] Pressure test the actuation network on pneumatically actuated systems. a. Connect an Amerex P/N 10895 actuation network test adapter to one manual actuator in place of the N2 cylinder.

CAUTION: This test must be performed only with the pneumatic control head removed from the agent cylinder discharge valve or discharge will occur. b. Pressurize the actuation network to 80 p.s.i. minimum and inspect as follows: i. Verify that no pressure escapes around the palm button shaft (strike stem). Replace the actuator if leaks are detected.


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ii.

Inspect all ¼” hose network and components for damage or leaks. Repair any leaks and replace and damaged components. iii. Check that the piston on the pneumatic control head is fully extended 1/2 inch (12 mm) and that no pressure is escaping around the piston. Piston must be held in the down and locked position by the detent ball. iv. Examine the vent check to confirm the internal nylon ball is sufficiently seated. Replace vent check if improper seating is detected. v. Examine all other actuators in the network. Pressure escaping from any of their N2 cylinder inlets indicates a malfunctioning check valve in the hose currently under test. Replace any check valves found defective. vi. When testing the electric/nitrogen actuator, momentarily remove the electric actuator and confirm that no pressure escapes from the electric actuator inlet hole. Pressure from the actuator hole indicates worn o-rings on the puncture stem. Disassemble and rebuild or replace the electric/nitrogen control head if leakage is detected. Reinstall the electric actuator. vii. When all actuators have been checked, remove test adapter and pressure source. Depress the detent ball and make sure piston on pneumatic control head is fully retracted and bolt head securely on top of discharge valve. Replace pull pins and tamper indicators on all actuators. viii. If system is equipped with a pressure operated switch P/N 11615, check to see that switch has activated. Verify activation of auxiliary devices controlled by the pressure operated switch. Reset by pressing the reset button on top of the switch enclosure after bleeding off pressure. [12] Service the Nitrogen Cylinders on systems so equipped. Clean all N2 cylinders to remove dirt, grease, and foreign material. Make sure that the nameplate is in place and fully legible. Inspect the cylinders for corrosion, abrasion, or dents. Relieve pressure and discard if integrity of a cylinder has been compromised. NOTE: When cleaning N2 cylinders, avoid use of solvents. Solvents can seriously damage the gauge face, the gauge guard, or the nameplate. Visually inspect the pressure gauge. The pressure must be in the operable "green pie" zone. Follow instructions for N2 cylinder recharge if pressure i s below operable range or replace the nitrogen cylinder. Visually inspect the rupture disc. Check for signs of rupture or corrosion. Check that the disc is not a substitute. Only an Amerex factory supplied rupture disc marked with A7 or AX is acceptable. Follow instructions for N2 CYLINDER RECHARGE if disc is corroded or otherwise unacceptable or replace the nitrogen cylinder. WARNING: Always install shipping cap when transporting a pressurized N2 cylinder. Install nitrogen cylinders into actuators and electric/nitrogen actuator. Tighten cylinders by hand 1 -1/2 to 2 turns past contact with rubber sealing gasket. Replace covers on outdoor a ctuator brackets as required. [13] Service the detection network. (Automatic system installations only). Clean all spot heat sensors and linear heat detection cables if so equipped. Also clean the Circuit Monitor, Control Panel or SafetyNet Panels to remove dirt, grease and foreign material. Spot heat sensors and linear heat detection cable assemblies may be pressure washed. Control Panel surfaces should be cleaned with a damp cloth and mild soap and water solution. Check spot heat sensors for dents, punctures, or other damage. Spot heat sensors and linear heat detection cable assemblies must not be painted. Replace if damaged or painted. Check all exposed wiring for cuts, abrasion, or heat damage. Check power supply (battery) connections for tightness, corrosion and wire fatigue. Check that all other wiring connections are tight and sealed from the weather. Correct any deficiencies discovered. [14] Test the detection network. Unplug the electric actuator and attach actuation lead (color coded yellow) to the Alarm Test Module, Amerex P/N 21447. Check that the reset button on the alarm module is depressed. When the alarm test module is connected, the display panel should indicate a normal condition. Only the green "System OK" LED should be illuminated. Test the function of each spot heat sensor. Hold an electric heat gun near the thermostat until the contacts close. WARNING: Do not use a propane torch or any other uncontrolled flame heat source to test the Spot Heat Sensors as permanent damage to the heat sensor will result!


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WARNING: DO NOT PERFORM THIS TEST ON THE SYSTEM IF THE ELECTRIC ACTUATOR AND ELECTRIC/NITROGEN ACTUATOR ARE INSTALLED AND CONNECTED! SYSTEM DISCHARGE WILL RESULT! WARNING: USE EXTREME CARE WHEN FOLLOWING THIS PROCEDURE. MAKE CERTAIN THAT NO HAZARDS EXIST THAT COULD BE IGNITED BY THE HEAT SOURCE. Test each individual spot thermostat using the following procedure: Perform a visual inspection of the heat detector . During the visual inspection, verify that the sensing shell is free from dents, dings, cracks, scorch marks from flames, or any other physical damage. If the shell has experienced any of these symptoms, replace immediately. If the shell has been painted, the heat detector must be replaced immediately. Care should be used to not damage the heat detector in any way!



Perform an operational verification of the heat detector. The fire suppression system must be disabled with use of the 21447 test module/simulator prior to doing any operational verification tests of the heat detector!



a.

Set-point temperature for each heat detector are: i. 280°F closes at 280°F +/- 14°F ii. 350°F closes at 350°F +/- 17°F iii. 450°F closes at 450°F +/- 22°F

b.

It is acceptable to use a controlled heat source such as a radiant heat gun that is adjustable for appropriate temperature test settings. Milwaukee 8978-20 variable temperature heat gun would be a good selection that has adjustable temperature settings. The heat gun must be held a minimum of ½” away from the tip of the detector body. Remove heat immediately following activation of the unit.

c.

Do not overheat the set-point of the heat detector by more than 100°F (55°C) (example: 280°F heat detector must not be heated beyond 380°F). Overheating the heat detector beyond recommended limitations can cause the unit to change set-point temperature rating.

d.

DO NOT CONTACT THE SENSING SHELL WITH HEATING DEVICES SUCH AS PENCIL TORCHES, SOLDERING IRONS, OR OPEN FLAME. Radical sources of heat can change the set-point temperature rating of the unit and shall not be used.

While the heat detector is a repeatable device, replacement is mandatory should the heat detector be subjected to an open flame or a fire event. When the thermostat contacts close, the Circuit Monitor III, Control Panel III or SafetyNet Panel will enter the alarm mode. The green LED will turn off, the red "Fire" LED and “Service System” LED will illuminate and an audible alarm will sound. Also, on installations using the Control Panel or SafetyNet, the time delayed relay will begin to count down. Remove the heat source. After the thermostat cools and the contacts reopen, the red “Fire” LED will remain illuminated and the alarm wil l continue to sound. If the yellow LED on the Alarm Module is off, then the detector has reopened or is reset. Press the reset button on the Alarm Module. The Panel will return to the normal mode. The system will not reset until the thermostats are cool and reset. Repeat this test for each thermostat. Test the function of each Linear Heat Detection Cable Assembly by attaching a Manual Actuation Switch P/N 14053 to the male end plug. Replace the End of Line Module on the male end plug of the Manual Actuation Switch and observe that the green “SYSTEM OK” LED is illuminated on the Circuit Monitor III, Control Panel III or SafetyNet Panel. Press the “FIRE” button on the Manual Actuation Switch. The panel must go into alarm. Remove Manual Switch and re-install End of Line Module at the end of the circuit. Check each Manual Actuation Switch by pressing and releasing. The Control Panel must go into alarm when each Manual Actuation Switch is pressed. Verify that all thermostats have cooled as indicated by an illuminated green "SYSTEM OK" LED on the front of the Circuit Monitor III, Control Panel III or SafetyNet Operator Display Panel and reconnect the actuation lead to the Electric Actuator.


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P/N 21447 Alarm Test Module: [15.] Test the agent cylinder pressure switch circuit. On installations so equipped, unplug the switch at its plug socket. The Control Panel or SafetyNet Operator Display will enter the fault mode (red “Service System” LED illuminated) as previously described. Reconnect the pressure switch when testing is complete. Repair any circuits and replace any switches that do not function properly. [16.] Check the last recharge date on the agent cylinder inspection tag. As required by NFPA 17, the dry chemical in stored pressure systems such as the Amerex system must be examined every 6 years to confirm that the chemical is free flowing. If 6 years have elapsed, follow instructions in SYSTEM RECHARGE (Section 9) for proper depressurization and chemical reclaim. Check the date of manufacture stamped on the agent cylinder dome. Cylinder must be hydrostatic (proof pressure) tested every 12 years to the test pressure indicated on the nameplate (700 psi, 4827 KPa). If hydrotest is due, see Section 9.


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Section 9: Recharge Clean Up 1.

Following a system discharge IMMEDIATELY CLEAN ALL SURFACES contacted by dry chemical to avoid corrosion.

2.

If the dry chemical has not been heated and is dry, it may be swept, vacuumed, or blown from any surface it has contacted. If it has been wetted or come in contact with heat, scrubbing, power washing with a soap solution, or steam cleaning will be necessary.

3.

The dry chemical extinguishing agent is completely non-toxic in all forms. It is considered a "Nuisance Dust" if inhaled, and may have a slightly salty taste in the mouth.

4.

It is slightly corrosive to metals after being wetted similar to a mild salt-water solution. A complete MSDS sheet is available on the Amerex website at www.amerex-fire.com.

Recharge CAUTION: Always completely depressurize the a gent cylinder before attempting to recharge. Never have any part of your body over the agent cylinder while removing the valve assembly. Always use a protective shield between you & the pressure gauge while charging an agent cylinder. Do not stand in front of the gauge if a shield is not available. Always use a REGULATED pressurizing source of dry nitrogen only with a minimum dew point of minus 70 oF (minus 57oC). Calibrate the pressure regulator gauge at frequent intervals. The pressure regulator gauge should be used to determine when the intended charging pressure has been reached. Do not use the agent cylinder gauge for this purpose. Never leave an agent cylinder connected to the regulator of a high-pressure source for an extended period of time. A defective pressure regulator could cause the agent cylinder to rupture due to excessive pressure. Always use a quality 24 hour cure epoxy such as Armstrong C-7 two part epoxy, when replacing items such as gauge, pressure switch, gauge guard, etc. Insure epoxy is fully cured before pressurizing agent cylinder. Do not mix types of dry chemicals in agent cylinders, recharge or recovery systems. Mixing ABC (acidic base) with Regular, Purple-K, Super-K or Monnex (alkaline base) dry chemicals may result in a chemical reaction capable of developing a dangerous pressure buildup. 1.

Remove the Pneumatic Control Head. Caution: On pneumatic control head installations, first verify that all pressure has been relieved from actuation lines by unseating ball in vent check. After the control head has been removed, install a protective shipping plate (P/N 10099) on top of valve.

2.

Disconnect discharge fitting & retaining flange from valve body. Install an anti-recoil plate (P/N 10646) on the valve discharge opening.

3.

On units equipped with an agent cylinder pressure switch, disconnect switch from wiring harness by unplugging at connector socket. Do not attempt to unscrew switch from valve body. If switch must be replaced seal the threaded pressure connection with a 24 hour epoxy. Insure epoxy is fully cured before pressurizing agent cylinder.


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4.

Remove agent cylinder from bracket.

5.

Relieve agent cylinder of all residual pressure or discharge all chemical and pressure as dictated by recharge requirements. To empty cylinder of pressure and chemical, install P/N 10134 Manual control head. Remove anti-recoil plate and connect valve outlet to a "Closed" dry chemical recovery system.

Page 9-2

NOTE: A "closed" recovery system is designed to prevent loss of the chemical "fines". Loss of the "fines" could result in reduced extinguisher efficiency. 6.

Remove discharge valve assembly from cylinder using a 2 1/2-inch open end pump wrench. Place wrench on wrench boss of valve and tap with a mallet in a counter-clockwise direction until valve is freed.

7.

Disassemble valve by removing downtube. Do not remove gauge, pressure switch or rupture disc unless replacement is required. Thoroughly clean all parts with a soft bristle brush or soft cloth. Clean the valve and downtube with air or nitrogen.

8.

Disassemble the valve stem by using a 1/8 inch Allen hex wrench on top of the stem screw. On the bottom of the valve is the other end of the valve stem assembly. Use a 5/16 inch open end wrench to aid in removal of the valve stem assembly.

9.

Replace the collar O-ring (P/N 05239) and valve stem assembly (P/N 10095), with Amerex factory replacements.

10.

Inspect all other parts and replace with factory new parts if worn or damaged. Inspect sealing area in valve body. Discard valve body if sealing seat is damaged. Lubricate the collar Oring and small O-ring on the valve stem with Visilox V-728 or synthetic motor oil. WARNING! DO NOT LUBRICATE THE VALVE STEM SEALING AREA. Lubrication on sealing surface will degrade over time and cause the valve to stick. Sealing area must be dry and free of any lubricant or foreign material.

11.

Apply a medium grade thread locking compound to downtube retainer threads and reassemble downtube in valve body and torque 75 ft.-lbs.


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Page 9-3

WARNING: DISASSEMBLE AND REASSEMBLE THE VH25 (HORIZONTAL) DOWNTUBE ONLY AS FOLLOWS REFERRING TO FIGURE 9-2 BELOW: i. Clamp valve in vise at the wrench boss area. ii. Loosen only the downtube retainer with a 13/4" wrench leaving the downtube nut undisturbed. iii. Unscrew downtube retainer, downtube nut, and downtube as a single unit. DO NOT LOOSEN DOWNTUBE NUT. iv. To reassemble, screw downtube assembly into valve, and torque retainer into valve to 125 ft.lbs. Alignment of downtube and valve must be as shown with pickup opening facing away from green pie area in pressure gauge, and downtube alignment arrows (stamped on side of downtube and under valve discharge opening) pointing to each other.

v. If downtube and valve alignment is not correct; loosen downtube nut, realign downtube as detailed in step 4, and retighten downtube nut into downtube retainer to 110 ft. lbs. WARNING: IF THE VH25 (HORIZONTAL) DOWNTUBE AND VALVE ARE NOT ALIGNED AS SHOWN ABOVE IN FIGURE 9-2, THE SYSTEM MAY FAIL TO FUNCTION PROPERLY. LOCATION OF THE DOWNTUBE PICKUP OPENING RELATIVE TO THE VALVE IS CRITICAL FOR PROPER SYSTEM FUNCTION. vi. Clean Horizontal Agent Cylinder valve collar o-ring seating surface and threads with a small brush, then wipe surfaces clean with a clean damp cloth to remove dust. Lightly brush the 0-ring seat with Visolox V-728. Install discharge valve assembly and tighten using thin head 2 1/2-inch open-end pump wrench. vii. Remove fill cap from opposite valve end of agent cylinder using 2 1/2-inch open end wrench. Replace the O-Ring (P/N 05239) with a factory new unit. Refill agent cylinder per steps (g.), (h.), (i.), and (j.) below using Amerex ABC model 555 or Amerex Purple K model 515. viii. Clean the Horizontal Agent Cylinder fill cap collar o-ring seating surface and threads with a small brush, then wipe surfaces clean with a damp cloth. Lightly brush o-ring seat with Visolox V-728 or synthetic motor oil. Install fill cap and tighten. WARNING: UNDER NO CIRCUMSTANCES SHOULD THE HORIZONTAL VALVE AND DOWNTUBE ASSEMBLY BE REINSTALLED WITH POWDER IN THE AGENT CYLINDER. ALWAYS ASSEMBLE THE VALVE IN AN EMPTY TANK, AND THEN FILL THROUGH THE FILL OPENING IN THE OPPOSITE END. 11.

Examine chemical that is removed from the agent cylinder. If chemical is contaminated or caked, it must be discarded.


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Page 9-4

12.

Service the agent cylinders. Clean cylinder to remove dirt, grease or foreign material. Make sure that the instruction nameplate is securely fastened and legible. Inspect the cylinder for corrosion, abrasion, dents or weld damage. If any of these conditions are found and you doubt the integrity of the cylinder, hydrostatically test to factory test pressure (700 p.s.i., 4827 KPa) with P/N 05152 Hydrotest Adapter using the proof pressure method in accordance with CGA Pamphlet C-6 and NFPA Pamphlet 17. Always thoroughly dry cylinders following hydrotest. Interior of agent cylinder should be inspected following CGA visual inspection standard Pamphlet C-6. Hydrostatic testing may only be done by individuals certified to perform hydrostatic testing by those having jurisdiction in your area.

13.

Fill Agent Cylinder with the proper amount of new, free flowing Amerex ABC model 555 or Amerex Purple K Dry Chemical model 515 by weight as specified on the agent cylinder nameplate.

14.

Clean Agent Cylinder collar o-ring seating surface and threads with a small brush, then wipe surfaces with a clean damp cloth to remove dust. Lightly brush the o-ring seat with Visolox V-728. Install discharge valve assembly and tighten using a 2 1/2-inch open end thin head pump wrench and torque to 30 to 40 ft.-lbs. Tapping on the side of the cylinder with a rubber mallet as the downtube is inserted will aid in assembly.

15.

Pressurize the Agent Cylinder: Bolt a P/N 10136 pressurizing adapter to the discharge outlet and a P/N 10134 manual control head to the top of the valve. Connect the adapter to a regulated nitrogen supply. Rotate the manual control head lever to "open" position and pressurize the cylinder to 350 p.s.i. (at 70 oF). When the desired pressure has been reached, rotate the operating lever to the "closed" position. Shut off nitrogen supply and disconnect the supply line. pressurizing adapter and the T-handle control head.

Remove the

16.

Check the agent cylinder for leaks: Apply leak detect fluid (soapy water) to the collar seal, discharge outlet, pressure relief device threads, gauge and gauge guard threads, and cylinder welds. Look for bubbles in the leak detect fluid. Bubbles may take several minutes to appear. Dry all areas contacted by leak detect fluid when complete.

17.

Install shipping plate to top of valve and anti-recoil plate to valve outlet. Record date of recharge on inspection tag. Reinstall agent cylinder per instructions in Section 6.

Recharging Nitrogen Cylinder. NOTE: The nitrogen, as it compresses into the 15 cu. in. N2 cylinder may experience a significant temperature rise. This temperature rise must be compensated for by pressurizing to the value corresponding to 1800 p.s.i. at the higher temperature. The best method to accomplish proper pressurization is to attach a commercially available magnetic base thermometer to the side of the N2 cylinder. (Make sure there are no leaks in the nitrogen supply plumbing). 18.

Pressurize and hold the cylinder pressure at 1800 p.s.i. for two minutes to allow the temperature to stabilize. Read the temperature on the thermometer. Refer to Figure 9.1. Locate the temperature on the "Cylinder Temperature" (horizontal) axis of the graph. Draw a line vertically upward from that temperature until it crosses the "nominal pressure" line. Draw a second line horizontally from the point of intersection to the "charge pressure" (vertical) axis of the graph. Increase the pressure from the regulated nitrogen supply to match the value read from the "charge pressure" axis of Figure 9.1.

NOTE: Nitrogen used for pressurizing must be dry with a dew point of -70 oF (-57 oC) or lower.


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Page 9-5

19.

When the determined pressure is reached, tighten the rupture disc by applying a torque wrench to the recharge adapter wrench and tightening (clockwise) to 40 ft. lbs. Remove nitrogen supply. Relieve the pressure of the supply hose and disconnect it. Remove nitrogen cylinder from recharge adapter.

20.

Check for leaks by applying leak detect fluid (soapy water) to the rupture disc, the threads on the rupture disc fitting where it joins the cylinder, and the pressure gauge threads. Look for bubbles in the leak detect fluid. Bubbles may take several minutes to appear. Dry fluid from all surfaces and inside of rupture disc following leak detect. Install shipping cap.

21.

Reinstall N2 cylinder in actuator per instructions in Section 6. Make certain that puncture pin of actuator is fully retracted before installing cylinder.


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Page 9-6

REBUILD ELECTRIC/NITROGEN ACTUATOR: If the system discharged automatically, the Electric/Nitrogen Actuator must be serviced. See Section 10 for parts diagram. 22.

Remove spent Electric Actuator (P/N 14036), retaining nut, puncture stem, and return spring. Find and discard the small brass disc which was displaced from the end of the Electric Actuator upon actuation. It is normally found on top of the puncture stem assembly. Thoroughly clean all parts. Replace any worn o-rings or backup rings. Clean bore of Control Head body and inspect for damage. If bore of body is gouged, discard and replace. Lubricate all o-rings and bore. Reassemble and check for proper operation.

23.

PURGE DISCHARGE NETWORK: Connect P/N 12129 Discharge Network Blow Out Adapter to the discharge fitting. Blow pressurized dry nitrogen or compressed air through until no dry chemical residue is visible escaping at any nozzle.

24.

SERVICE DISCHARGE NOZZLES: Clean and inspect nozzles and nozzle blow-off caps. Replace blow-off caps P/N 10167, if damage is detected. Wipe inside of skirt of nozzle blow-off cap with a light coating of silicone grease. Reinstall caps onto nozzles with retaining loops arching downward in the proper orientation.

25.

REPLACE HARDWARE: Reinstall agent cylinder and E/M actuator per procedures in Section 6, "System Installation". Be sure to replace all tamper indicators, and lock wire seals.

26.

RETURN THE SYSTEM TO "Ready": Reinstall and reconnect linear actuator; then reinstall N2 cylinders. Use the procedures given in Section 6, "Placing the System in Service" to avoid accidental discharge.


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Section 10 Component Rebuild and Spare Parts Agent Cylinder V13, V25, VS50 and V50

Page 10-1


Agent Cylinder VH25 Horizontal

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Page 10-2

Part Number 16400 Rev. A Discharge Valve Assembly

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Page 10-3

Part Number 16400 Rev. A Pneumatic Control Head P/N 10147

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Page 10-4

Part Number 16400 Rev. A Manual Actuator P/N 10210

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Page 10-5


Electric/Nitrogen Actuator P/N 20775

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Page 10-6


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Nitrogen Cylinder Assembly 15 Cu. In. P/N 09956

Page 10-7


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Page 10-8

Additional Parts Not Pictured:

Bracket Components:

S trap, Ag ent Cylinder B racket For V25, VH25 and V50 Strap Bolts & Nuts V50/V25

14782 10244

Strap, Agent Cylinder Bracket V13 Strap Bolts & Nuts V13

14781 12305

Strap, Agent Cylinder Bracket VS50 Strap Bolts & Nuts VS50

22220 17085

Discharge Components: Discharge Fitting O-ring Blow-of Cap, Discharge Nozzle

10140-006 10167-006

Miscellaneous: Owner’s Manual Anti-Tamper Label 50 lb. ABC Chemical 50 lb. PK Chemical 25 lb. PK Chemical “In Case of Fire” Label Pull Pin Lock wire Seal

10722 10787 CH 555 CH 515 CH 553 10574-001 01387

Amerex vs Manual 16400a Pneum Op

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