Foam Water Spray Vehicle Fire Suppression System · selected fire risks in the risk area to be protected. The Wormald ‘Loss of Pressure’ Vehicle Foam Water Spray Fire Suppression

Revision 1.1 November 2013 Company Confidential Copyright © 2013 Wormald Page 0 of 39

Foam Water Spray Vehicle Fire Suppression System Pressure to Operate Operation & Maintenance Manual


Contents PREFACE ................................................................................................................................................... 3

1.0 INTRODUCTION ............................................................................................................................. 4

2.0 PRESSURE TO OPERATE SYSTEM ............................................................................................. 5 2.1 System Operation ...................................................................................................................................... 5

2.2 Components ............................................................................................................................................... 6

2.2.1 Agent Storage Assembly .......................................................................................................... 6

2.2.1 a) Storage Container ............................................................................................................... 6 2.2.1 b) Refill Plug ............................................................................................................................ 7 2.2.1 c) Container Control Valve – Pressure to Operate System ..................................................... 8 2.2.1 d) Container Brackets .............................................................................................................. 9 2.2.1 e) Base Plate ......................................................................................................................... 10 2.2.1 f) Container Siphon Tube Flexible ........................................................................................ 10

2.2.2 Actuators, Fire Panels and Pressure Switches....................................................................... 11

2.2.2 a) Manual Actuation ............................................................................................................... 11 2.2.2 b) Manual/Electric Actuation .................................................................................................. 12 2.2.2 c) Automatic Actuation – Linear Detection Wire .................................................................... 12 2.2.2 d) Triple Infra Red Detector ................................................................................................... 13 2.2.2 e) Fire Indicator Panel ........................................................................................................... 13 2.2.2 f) Pressure Switch ................................................................................................................ 14 2.2.2 g) Manifold Block ................................................................................................................... 14 2.2.2 h) Stainless Steel Check Valve ............................................................................................. 15

2.2.3 Delivery Network .................................................................................................................... 15

2.2.3 a) Nozzle, Blow Off Cap and Bracket .................................................................................... 15 2.2.3 b) Hydraulic Hose and Stainless Steel Tube ......................................................................... 16 2.2.3 c) Fittings . .......................................................................................................................... 16

3.0 IN CASE OF FIRE ......................................................................................................................... 17 3.1 Explanation .............................................................................................................................................. 17

3.2 What to Expect ......................................................................................................................................... 17

3.3 After the Fire is Out .................................................................................................................................. 17

4.0 RECHARGE PROCEDURE .......................................................................................................... 18 4.1 General .................................................................................................................................................... 18

4.2 VFS Recharge Safety Tools ..................................................................................................................... 18

4.3 Automatic Detection and Actuation Instructions ....................................................................................... 18

4.4 Recharge Instructions – 25, 45, 65 and 106 Litre Systems ...................................................................... 21

4.4.1 General ................................................................................................................................... 21

5.0. INSPECTION AND TESTING PROCEDURE ................................................................................ 25 5.1 Level A – Daily or 8 to 12 Hours Operation .............................................................................................. 25

5.2 Level 1 – Six Monthly ............................................................................................................................... 25

5.2.1 Cabin / Internal / External & Electric Actuation ....................................................................... 25

5.2.2 Container and Valve Assembly .............................................................................................. 26

5.2.3 Hose, Stainless Steel Tube and Fittings ................................................................................. 26

5.2.4 Nozzle and Blow Off Caps ...................................................................................................... 26

5.2.5 Pressure Switch ...................................................................................................................... 26

5.2.6 Fire Indicator Panel ................................................................................................................ 27

5.2.7 Linear Detection Wire ............................................................................................................. 27

5.2.8 Triple IR Detection .................................................................................................................. 27


5.2.9 Ancillary Visual / Audible Alarms ............................................................................................ 28

5.2.10 Record on Record of Service Sheet ................................................................................... 28 5.3 Level 2 – Yearly ....................................................................................................................................... 28

5.3.1 Record on Record of Service Sheet ....................................................................................... 29 5.4 Level 4 – Five Yearly ................................................................................................................................ 29

5.4.1 Record on Record of Service Sheet ....................................................................................... 29

6.0 RECORD OF SERVICE SHEET ................................................................................................... 30

7.0 WARRANTY .................................................................................................................................. 30

8.0 APPENDIX ..................................................................................................................................... 31 8.1 Product ..................................................................................................................................................... 31

8.1.1 Assemblies ............................................................................................................................. 31

8.1.2 Individual Components ........................................................................................................... 33

8.1.3 VFS Safety Tools & Testing Devices ...................................................................................... 36 8.2 Detection Wire Fluid Capability ................................................................................................................ 36

8.3 Sample of Record of Service (ROS) Sheet .............................................................................................. 38


PREFACE

This Manual is intended to provide interpretation on the system componentry / operations, recharge process, and inspection / test procedures of the Wormald “Pressure to Operate” Vehicle Foam Water Spray Vehicle Fire Suppression Systems. Personnel, who, operate, recharge, inspect or maintain these fire suppression systems, should read this entire manual.

As with Fire Protection equipment, the “Pressure to Operate” Foam Water Spray Fire Suppression System requires periodic maintenance to help ensure that it will operate effectively and safely. Inspection frequency should be based on the need of the vehicle on which the System is installed. Maintenance should be conducted at intervals no longer than six months and follow the maintenance (inspect and test) procedures in Section 5 of this Manual.

The Wormald “Pressure to Operate” Vehicle Foam Water Spray Fire Suppression System is limited to the uses described herein. For other applications, contact your Technical Services Group for advice.

As an operation, recharging and maintenance document, this manual is for information purposes only to assist the reader in understanding the operation and maintenance requirements for this type of Fire Suppression System.

Only competent accredited Wormald staff should carry out the recharing and maintenance of a Wormald “Pressure to Operate” Vehicle Foam Water Spray Vehicle Fire Suppression System. Advice and assistance should be sought from Wormald.

COPYRIGHT

The content of this Manual is the exclusive property of Wormald and is protected by copyright laws. No part of this Manual maybe reproduced, photocopied, stored on a retrieval system, or transmitted without the prior written consent of Wormald.


1.0 INTRODUCTION

The Wormald “Pressure to Operate” Vehicle Foam Water Spray Fire Suppression System is a pre-engineered fixed nozzle installation for protection of specialised vehicles and equipment. Typical applications include surface mining equipment, underground mining machines, forestry machines, construction equipment, waste disposal and agricultural machinery.

The Wormald “Pressure to Operate” Vehicle Foam Water Spray Fire Suppression (VFS) System consists of three major components; firstly, a pressurised agent storage container assembly containing 6% Aqueous Film Forming Foam (AFFF) concentrate mixed with potable water and pressurised with dry nitrogen to 1620 kPa at 20oC; secondly, a detection and actuation system to trigger the installation; and thirdly, a delivery network to carry the foam solution from the pressurised container to the nozzles and onto the fire. The VFS System is effective on Class A (carbonaceous materials) and Class B (flammable liquid) Fires and limited Class E Fires.

The system would be expected to perform effectively in environmental temperatures between 2°C and 60°C.

The VFS System can be actuated manually by the cabin actuator or the ground/external level actuator. Automatic Detection and Actuation are also available.

The extinguishing agent, AFFF foam solution, is delivered from a container pressurised with dry nitrogen through the hydraulic hose / stainless steel tube network and pre-set (non - aspirating) nozzles onto the fire prone surfaces/areas. The foam nozzles provide direct impingement and coverage at the selected fire risks in the risk area to be protected.

The Wormald ‘Loss of Pressure’ Vehicle Foam Water Spray Fire Suppression System is Activfire listed to be compliant with Australian Standard AS5062-2006: Fire protection for mobile and transportable equipment.

Note that NO substitution of any components is allowed as it will will void the Activfire listing.


2.0 PRESSURE TO OPERATE SYSTEM

2.1 System Operation

The system operates when pressure is applied to the container control valve.

The container control valve (4) is a spring assisted pressure seat type valve, which requires a force to depress a piston to push the valve stem off the seat to open the valve. This is achieved by releasing an external pressure source such as a nitrogen cartridge (1) or (2) to open the control valve (4) and discharge the Foam Water Spray solution from the Foam Water Spray storage container through the system discharge nozzles (6).

The external pressure is released from the nitrogen cartridge (1) or (2) by manually depressing an actuator knob or automatically by an electrically operated pyrotechnic actuator (1) connected to the fire detection system (3) which can consist of linear detection wire and flame detectors.

The pressure switches (5) that operate with a rise in pressure are fitted to the container control valve and the actuation manifold block (7).

(4) Control Valve

(1) Cabin Actuator

(2) Ground Actuator

(2) Ground Actuator

(5) Pressure Switches

(3) Detection Wire 180°C

(6) Nozzles

Stainless Steel

Tube Ringmain

Fire Indicator Panel

(7) Manifold Block


2.2 Components

2.2.1 Agent Storage Assembly

2.2.1 a) Storage Container

The storage containers are manufactured to AS 2030.1 (SAA Gas Container Code, Part 1: Containers for compressed gases other than acetylene). The Containers are constructed of grade 316 stainless steel and externally powder coated red (shade R13 of AS 2700). They are available in four sizes of water capacity (25, 45, 65 and 106 litres) designed to contain 19, 35, 50 and 80 litres respectively of foam solution.

Container Design Registration WorkSafe Victoria - Approval Numbers V13011635, V13011636, V1301637.

Storage Containers

Note: Maximum number of containers allowable on any mobile or transportable equipment is ten (10) container assemblies. The container sizes cannot be mixed.


Container Details

Container Size Container Part Number

Height Diameter Foam Solution

Label Part Number

106 Litre Container FO106LCYL 1210 mm 360 mm 80 litre FO106LABEL



45 Litre Container FO45LCYLHP 760 mm 318 mm 35 litre FO45LABEL


2.2.1 b) Refill Plug

The refill plugs are manufactured from brass for all the container sizes. On the 45, 65 and 106 Litre Containers, an 'O' Ring is fitted to the Plug to obtain an effective seal between the Container and the Plug.

Part Number: FO50PLUG

Refill Plug (complete with ‘O’ Ring) for 45, 65 and 106 Litre Containers

Part Number: FO20PLUG

Refill Plug for 25 litre Container


2.2.1 c) Container Control Valve – Pressure to Operate System

This Container Control Valve is a high flow, single action pressure operated piston valve. The actuation of the container control valve is dependent on the pressure from the nitrogen gas expelled from either the Manual or Automatic/Manual Cartridge Actuator. This valve will operate in all vertical and horizontal positions.

Incorporated into the container control valves are a pressure gauge, a burst disc and a Schrader pressurising valve. The valve stem has a 32nb BSP parallel thread fitted with a nitrile “O” Ring that seals in the container neck ring. The Container Control Valve is factory assembled and set, and must be returned to the manufacturer for any repairs.

The control valve is available as a combination of 304 Stainless Steel and Brass Valve, or as a fully 316 Stainless Steel Valve for regions where the water has a high saline content.

Valve Specification Valve Body 304 or 316 Stainless Steel Valve Cap Brass or 316 Stainless Steel Sealing Piston Assy Stainless Steel with Nitrile 'O'-ring seals Mass (Valve Assy) 1.5 kg Valve Operating Pressure 1620 kPa @ 20°C Burst Disc Rated Pressure 3100 kPa - 3500 kPa Discharge Outlet Thread 1 1/16” JIC Male Actuation Inlet Thread 1/4” BSP Female parallel Valve Stem Thread 32nb BSP Male parallel

Container Control Valve

Part Number Description

FOAMPHEAD Control Valve - Type P – Brass Cap

FOSSPHEAD Control Valve - Type P– Stainless Steel Cap

FOLIQGAUGE Liquid Filled Pressure Gauge

FOSCHVAL Schrader Valve

FO50ORING Container Valve 'O' Ring

BURDISASS Bursting Disc Assembly

FOCHKVAL Check Valve


2.2.1 d) Container Brackets

Container brackets are of the saddle type with a front clamp. The brackets are constructed of mild steel for each container size and are powder coated red to match the container. Brackets may be either welded or bolted to the vehicle structure. Specially designed brackets are available on request.

Part Number: FO106BKTS 106 Container Shielded Bracket




Brackets that are shown include the 106L and 65L. The 65L Bracket typically represents the 45L and 25L Bracket with a single clamp which fits around the Container.

A bracket is not available for the 45L HP - High Profile Container. This container was developed for the Forestry Industry and is supplied and installed within a fully enclosed box complete with a cover plate.

Part Number: FO45BOX 45 High Profile Container Box


2.2.1 e) Base Plate

The base plate is available for mounting under the 45L, 65L and 106L Brackets. The base plate is manufactured from mild steel and has five (5) x 10 mm tapped holes in the plate. Two base plates are available. The shaped base plate has the same configuration of the container bracket base and should be utilised on Dozers, Loaders, Graders, etc. The round base plate should be utilised on the ‘deck’ of trucks or excavators to prevent any ‘stressing’ of the ‘deck’ plate.

Part Number: FOBASEPL Shaped Base Plate for 45L, 65L and 106L

Part Number: FOBASEPL-R Round Base Plate for 45L, 65L and 106L

2.2.1 f) Container Siphon Tube Flexible

The siphon tube has a ball joint fitted to the adaptor to enable the siphon to swivel within the container. This allows “pick up” of all the foam solution when the vehicle is on sloping terrain. The end of the siphon tube has a brass insert with an ‘O’-Ring fitted so the siphon tube will not wear on the inside wall of the stainless steel container.

Part Number Component

FODNTU106 Siphon Tube, 106L


FODNTU45HP Siphon Tube, 45LHP




2.2.2 Actuators, Fire Panels and Pressure Switches

Each System requires at least one manual actuator. Options include the Cabin type for installation in the vehicle's operator compartment, as well as an internal / external actuator for access outside the vehicle and at ground level. Optional visual and audible alarms are available for discharge of Fire Suppression System.

2.2.2 a) Manual Actuation

The cabin and internal and external actuators are supplied with a gas pressure cartridge (to be installed on site).

The Manual Actuator is manufactured from brass with a stainless steel centre puncture pin. (An all stainless steel unit is available for more aggressive environments). The Knob mounted on top of the centre pin is coloured red for easy identification. A Safety Pull Pin is inserted in the actuator shaft and secured with an Anti-Tamper Tie, locking the actuator in the set position.

The Actuator can be mounted directly onto the machine, or the actuator can be mounted onto a bracket designed for this actuator. The ‘L’ Bracket is for areas where the Nitrogen Cartridge is not prone to damage. The ‘S’ Bracket is normally utilised for exterior locations. The bracket is pre-drilled for ease of mounting.

Cabin or Ground Actuator

(Stainless Steel Model shown)

A system which has more than one actuator 'in line' requires a check valve to be installed to prevent loss of pressure through other actuator lines. This will improve the systems reliability and speed of operation.


FOMANVALVE Actuator Valve – Brass

FOSSMANVAL Actuator Valve – Stainless Steel

7013 Actuator Cartridge

FOACTBKT Actuator Bracket


FOACTLABEL Actuator Label


2.2.2 b) Manual/Electric Actuation

An automatic electrical fire detection and operating system can be supplied as an option to supplement the manual operation by adding the electrical operated actuator.

The Manual/Electric Actuator can be utilised in conjunction with the Automatic Fire Panel or can be interconnected with a Radio Transmitter / Receiver for Remote Control Operation.

2.2.2 c) Automatic Actuation – Linear Detection Wire

The linear detection wire consists of two spring steel conductors that are separated by a heat sensitive insulator. At the temperature rating of the wire (180°C) the insulator melts, allowing the two conductors to make contact. This contact provides electrical continuity between the two conductors.

The linear detection wire is positioned throughout the risk area. When a fire occurs, the linear detection wire activate, completing an electrical circuit and releasing the Wormald Foam Fire Suppression System.


24479 PAD Actuator Valve – Brass

437286 PAD Actuator Valve – Stainless Steel


436302 Protract Actuation Device (PAD)

436242 PAD Connector Cable – 510mm


419772 Actuator Bracket




71230 Linear Detection Wire 30.4 Metres

71231 Linear Detection Wire 152.4 Metres

FODETGROM Detection Grommet

426520 E.O.L Resistor each


2.2.2 d) Triple Infra Red Detector

The Triple Infra Red Detector is not intended for a 'standalone system' but is coupled with the Linear Detection Wire. The Triple IR Flame Detector is high performance and high reliability self-contained triple spectrum flame detector. The Detector has a sensitive range for 10 metre with three Infra-Red Bands. The Detector can detect fires from fuel such as petrol, diesel fuel and hydraulic fluids.

2.2.2 e) Fire Indicator Panel

The Fire Panel is used with either the Linear Detection Wire and incorporates both visual and audible alarms to indicate a fire in the protected area. The Fire Panel initiates the electrical actuator that activates the automatic manual actuator releasing the Foam Water Spray through the distribution system.

The Self-Contained Fire Panel features:-

• High intensity L.E.D. front panel indicators

• Internal lithium battery backup

• Audible alarm and fault condition beeper

• Front panel Delay/Rest switch.

• Engine Shutdown and Timer Functions


432480 Triple IR Detector / Bracket

434106 Y-Connector Cable

434103 3.0m Plug Cable Assembly



434107 E.O.L. Triple IR Cable Assembly


432670 ASC-N Check Fire Panel

434675 Reset Tool

427308 3.6 VDC Battery

423525 Combined Bracket


2.2.2 f) Pressure Switch

Every system is fitted with a pressure switch that shuts down the engine (where applicable) when the Foam Water Spray VFS System is activated (either manually or automatically) reducing the supply of fuel to the fire. The switch has an IP65 rating, and can be interconnected with the Fire Indicator Panel to provide visual and audible alarms.

Two pre-set pressure switches are used on a single container application. One is pre-set to operate at 900 kPa for system discharge / engine shutdown; the other pre-set at 1200 kPa for container low pressure.

The pressure switch has three (3) terminals. One connector is neutral, while the other connections are for normally ‘open’ (NO) or normally ‘closed’ (NC) connections.

Machine shuts down on system discharge and a low-pressure signal is activated by the pressure switch.

Part Number: FOPRESSW9 Pressure Switch – 900 kPa

Part Number: FOPRESSW12 Pressure Switch–1200 kPa

2.2.2 g) Manifold Block

The brass manifold block is fitted with a mounting plate for attaching the manifold block to the machine through welding, tapping or bolting.

The manifold block has six 1/4” BSP (F) inlets which allow the actuation hose to be connected within the actuation system, and a top port for the 900kPa Pressure Switch.

The manifold block for the actuators can be located at a central point outside the risk or adjacent to the Container Bracket/s. All manifold blocks have the same fittings for ease of mounting. This manifold has five 1/4” BSP (F) inlets which allows up to four actuators to connect.

Part Number: FOMANIFOLD Manifold Block for Actuators


2.2.2 h) Stainless Steel Check Valve

The check valve is manufactured from stainless steel, and has been designed so that the valve can only be installed in the correct direction of flow. The inlet of the check valve is ¼” BSP (F) and the outlet is 7/16” JIC (M). This design allows the ¼” hydraulic hose to be connected onto the JIC connection. The check valve shall be fitted on all actuators at the manifold block and onto the top control valve port. The check valve blocks the flow of gas from other actuators and the actuation gas from escaping to an open actuator that may have had the cartridge removed. The check valve also keeps the gas from pressurising the actuator hoses.

Part Number: FOCHKVAL Stainless Steel Check Valve

2.2.3 Delivery Network

2.2.3 a) Nozzle, Blow Off Cap and Bracket

The nozzle is a full cone, non-aspirating spray type nozzle manufactured from brass (a stainless steel model is available for corrosive environments). The conical spray pattern is achieved with internal swirl plates. The nozzles are located in a closed ring main and directed to discharge onto the fire prone surfaces/areas, such as turbo chargers, exhaust manifolds, starter motors and any other areas that could be a source of ignition.

A blow off cap is supplied with the each nozzle to prevent external foreign matter from blocking the nozzle orifice. The Blow Off Cap is manufactured of stainless steel and includes a stainless steel wire connection fitted around the nozzle. Dow Corning #4 Silicon Grease should be applied to the nozzle to assist the blow off cap in the prevention of external foreign matter blocking the nozzle.

On system discharge the blow off cap is thrown free of the nozzle, and the wire connection retains the blow off cap for further use.

The nozzle bracket is manufactured from 3 mm thick mild steel and secured to the vehicle structure by welding, self-tapping screws or nuts and bolts. The nozzle bracket is adjusted to aim the nozzle at the target. Corrosion protection (cold galvanising or similar) is to be applied after installation.


FOBNM16NOZ Nozzle– Brass

FOSS16NOZ Nozzle– Stainless Steel

FOSSCAP Blow Off Cap

FONOZBKT Nozzle Bracket


2.2.3 b) Hydraulic Hose and Stainless Steel Tube

The minimum pressure rating for hydraulic hose and fittings is SAE 100R1. For underground mining applications, the hydraulic hose must comply with VSBM, MSHA 2G-11C and all other SAE requirements including an operating temperature ranging from -54°C (-65°F) to 121°C (250°F). The stainless steel tubing meets the appropriate minimal ratings of DIN 17440, 2391 and 2413.

2.2.3 c) Fittings .

Only Hose fittings, tees and connectors that are manufactured from steel and zinc dichromate electro plated for corrosion protection can be used in the VFS System.


3.0 IN CASE OF FIRE

When a fire event occurs, the response of the operator is very important. As soon as a fire is observed, the following actions should be taken:

1. Turn the machine engine off.

2. Actuate the Wormald foam water spray VFS System by pulling the ring pin and pushing down the plunger knob on the actuator. If the machine is fitted with an automatic detection system, system discharge may have already been initiated.

3. Move away from the vehicle/machine. Take a portable extinguisher if available.

4. Stand by with a portable extinguisher.

3.1 Explanation

If vehicle/machine is left running, it may add fuel to the fire and or the fire may re-ignite. React quickly so the fire is caught before it grows too large. Leave the fire area immediately to gain protection from windblown flames, potential explosions or other dangers created by the fire. Heat remaining from the fire could cause re-ignition after the Wormald VFS System has discharged. It is important that operator or colleague stand by, at a safe distance, with a portable extinguisher. This stand-by should be maintained until all possibility of re-ignition is assured.

3.2 What to Expect

When the Wormald VFS System discharges, there is a spray of foam solution over the protected area(s). The agent is non-toxic, wets, cools and forms a film of foam over the protected surfaces.

3.3 After the Fire is Out

The vehicle or machinery should not be restarted until the cause of the fire has been determined and it is deemed safe to move the vehicle/machinery without further protection by an operational fire suppression system. Once the cause of the fire is determined and repaired, immediately arrange to have the fire suppression system recharged.


4.0 RECHARGE PROCEDURE

4.1 General

Prior to the recharging of any System, the system pressure status of the System Container must be established.

The Container will require periodic internal and external examination and hydrostatic pressure testing by an authorised Gas Container Test Station. The test interval should not exceed five (5) years after the latest test date stamped on the container.

Many Systems have Automatic Detection and Actuation. Section 3 provides procedures for the Automatic Detection and Actuation and Section 5 for recharging the fire suppression systems.

4.2 VFS Recharge Safety Tools

To carry out Recharging of the fire suppression system correctly and safely, personnel require the VFS Safety Tools as a minimum. See detail in Appendix on Safety Tools.

Tools shall include:-

Vehicle System Charging Rig Part Number: FOCHARGERIG30

Pressure Test Tool for 1/4" Actuation Hose Part Number: FOPRESTESTC7031

Safety Cap with Isolation Valve and

Safety Vent Plug Part Number: FOSAFECAP7031

Overfill Tubes for each size container Part Numbers are: 106L:FOFILTUB106

65L: FOFILTUB65

45L: FOFILTUB45

25L: FOFILTUB25

4.3 Automatic Detection and Actuation Instructions

1. Check the Fire Indicator Panel to determine if the fire suppression system has discharged. This can be identified by pressing the ‘Delay’ button for approximately two seconds at which time the front panel LED’s (Light Emitting Diode) will display a combination of LED’s that represent the diagnostic code.

The diagnostic code may provide you with one of the following events

- Power Faults

- Circuit Faults


Power Faults

External Power External Power Internal Battery Internal Battery Fault Low Fault Low

Circuit Faults

Detection Circuit Low Agent Release Circuit Release Circuit Fault Container Fault Fault Isolated

If further troubleshooting of the Fire Panel is required please see Table 5.1 on page 46.

2. The Fire Panel will be displaying an audible alarm where the system has activated manually or automatically. If this has occurred, insert the Isolate Key into the Fire Panel and turn ninety degrees to isolate the panel.

3. Before performing the recharge steps, determine the cause of the system discharge.

4. Then remove control module cover screws and replace internal 3.6 VDC lithium battery. Record date of new battery installation on label located adjacent battery. Reinstall control module cover.

5. If fire suppression system has actuated automatically, unscrew the empty 10R cartridge from the PAD Actuator.

6. PAD Actuator recharge steps:-

a) Back out the two (2) screws holding the Terminal Housing and Cable Assembly to the actuator body assembly disconnect the actuation cable from the Protracting Actuation Device (PAD) leads and remove the terminal housing (the screws are captive screws and should remain secured in the terminal housing cover).

b) Unscrew the upper portion of the actuator body to expose the bore in the top of the puncture pin.


c) Remove the PAD from the actuator body by lifting the PAD out of the puncture pin and actuator body, while pulling the PAD leads back through the port in the side of the actuator.

d) After the PAD has been removed, tip the actuator body upside down, being careful not to drop the actuator pin, to remove the small brass septum that was ejected from the PAD during discharge.

e) Before inserting the new PAD into the bore in the top of the pin, route the PAD connector from inside of the actuator to the outside of the actuator through the port in the actuator body. Then as the connector is being pulled through the port, insert the PAD into the bore in the top of the actuation pin.

f) When the PAD is fully seated inside the bore in the actuator pin, carefully pull on the PAD leads that are extending outside the actuator body to take up the remaining slack in the PAD lead wires.

Note: Do not pull on the connector.

g) Position the upper body so that the slot in the stem base straddles the PAD lead wires.

h) Thread the upper actuator body back into the lower body.

i) Mate the PAD Connector that is extending from the port in the actuator body the connector located on the inside of the Terminal Housing and Cable Assembly, and using the two (2) captive screws, reattach the Terminal Housing and Cable Assembly to the actuator body.

j) Rotate the actuator so that the gas outlet port is facing the front and Terminal Housing and Cable Assembly is facing right (facing the left side of the control module) and tighten the jam nut firmly.

k) Install the ring pin, and attach the anti-tamper tie.

7. In case of a fire or accidental discharge of the system, inspect linear detection wire and connect a multimeter to confirm what has occurred on the circuit.

a) Where the linear detection wire has been damaged, if this is a small section has been damaged, the linear detection wire can be spliced together using an in-line splicing kit; however we recommend that there are no more than two (2) connections in the linear detection wire or,

b) If Triple IR Detectors are utilised, inspect detectors and verify that they have not been damaged. Confirm that all detectors have been reset to their normal operational condition.

Note: Where leaks could occur, and components, adaptors, and /or stems on actuation hoses, remove any Lochtite on threads, clean threads and reapply with Lochtite 577 on the NPT, BSP, and JIC (M) threads


Table 4.1

4.4 Recharge Instructions – 25, 45, 65 and 106 Litre Systems

4.4.1 General

Prior to the recharging of any System, the container pressure indicator / gaugemust be established.

The Container will require periodic internal and external examination and hydrostatic pressure testing by an authorised Gas Container Test Station. The test interval should not exceed five (5) years after the latest test date stamped on the container.


1. Disconnect the actuation system hose to relieve any residual pressure.

2. Pull up the Red Konob on the Actuator and insert a Ring Pin into Actuator stem to retain the Actuator in the closed position.

3. Unscrew and remove the empty LT-5-L or LT-10-R Gas Cartridge, check weigh the fully charged replacement cartridge and install in the actuator (Return the empty cartridge to a Wormald Distributor for recharging).

4. Ensure that the system Actuators have been reset, Safety Ring Pins fitted and the Anti-Tamper Ties are installed.

5. Flush the Fire Suppression System by disconnecting the Discharge Hose from the lower port of the Container Control Valve and flushing water through discharge hose

6. During the discharge of water from the system, check the discharge from all nozzles to ensure that they are not blocked, and have a uniform spray pattern.

7. Inspect the Automatic Systems as per maintainence schedules (see Section 7)

8. Carefully remove the Fill Plug from the shoulder of the extinguishing container.

Note: If audible release of gas is oberserved, do not fully remove the plug from the container until all pressure is released. This will be indicated when the audible release of gas ceases.

9. Recharge the Container through the control valve inlet.

10. Fit the correct overfill tube into the control valve inlet.

11. Add the appropriate quantity of potable water into the overfill tube. Once the correct amount of water has been filled into the container, remove the overfill tube and add the Ansul ICAO-B 6% AFFF foam concentrate to the container through the control valve inlet, as per Table 4.2.

Volume of Agent Foam

Solution (litres)

Container Volume (litres)

Potable Water (litres)

6% AFFF Concentrate

(litres)

19 25 17 2

35 45 31.5 3.5

50 65 45 5

80 106 72 8

Table 4.2


10. Once the water and foam concentrate has been added, check the siphon tube is properly connected to the control valve; that there is no wear and tear on or near the ball joint and that the o-ring on the end of the siphon tube is in place and not worn.

11. Remove the overfill tube and refit the Control Valve and siphon tube to the control valve port, tighten as required and re-connect the Discharge Hose to the outlet port of the Control Valve.

12. Lightly lubricate the Fill Plug ‘O’ ring with #4 Dow Corning silicon lubricant, refit the Fill Plug to the Container, then “nip up” to ensure that it has made face to face contact with the Container collar fitting.

13. Pressurise the Container with dry nitrogen to 1620 kPa @ 20°C (Refer to Table 5.3) via the Schrader valve fitted to Container Control Valve.

Note: Use the Vehicle Systems Charging Rig (which has independent gauges, regulator and pressure relief valve) to pressurise system. A calibrated pressure gauge of the charge rig must be used in the nitrogen supply line to determine that the system pressure is 1620kPa @ 20°C. Do Not use the pressure gauge fitted to the Container Control Valve or pressure gauges on the Nitrogen Cylinder. When applying pressure to Container fitted with Control Valves through the Schrader valve, adjust the regulator so the gauge reads 1000 kpa and wait for bubbling reaction to settle in the container. Increase pressure rates at 200kpa intervals and do not exceed 2200kpa. At each 200kpa interval, wait to the bubbling reaction settles before proceeding to the next interval. After system has been pressurised to the correct pressure / temperature (see temperature chart – table 4.3), check that the Container Control Valve pressure gauge is reading within the green zone and to the nearest 50kpa increment on the high side.

14. Test all of the System connections for leaks using AFFF in water solution or ‘Blue’. Ensure all Hose and Detection fittings, Fill Plug, Control Valve connections, Schrader Valve and Gauge are tested.

15. Refit the dust cap to the Schrader valve.

16. Lubricate the nozzles with Dow Corning #4 silicon grease and refit the Blow Off Caps to all system nozzles.

17. Record details on Record of Service Sheet. See sample in the Appendix


Settled Pressure for AFFF VFS System Containers

Temperature (°C) Pressure (kPa)

-20 1385

-15 1414

-10 1444

- 5 1473

0 1503

5 1532

10 1561

15 1591

20 1620

25 1649

30 1679

35 1708

40 1737

45 1767

50 1796

55 1826

60 1855

65 1884

Table 4.3


5.0. INSPECTION AND TESTING PROCEDURE

Maintenance of the fire suppression system shall be undertaken as per the Inspection, Test, and Preventative Maintenance Schedules of AS 5062-2006 and the following:-

5.1 Level A – Daily or 8 to 12 Hours Operation

1. Check container pressure gauge are within the operating range.

2. Ensure the safety pin and anti tamper tie are intact.

3. Inspect and ensure manual actuators are clean, undamaged and accessible.

4. The Fire Panel must be checked the system daily by visually verifying that the GREEN power LED is flashing and no other LED is illuminated or audio alarm sounding. If any other conditions exist, contact the local authorized WORMALD distributor or whoever has been trained and authorized by WORMALD to perform inspection and maintenance checks.

5.2 Level 1 – Six Monthly

5.2.1 Cabin / Internal / External & Electric Actuation

1. Inspect general condition of each actuator.

2. Ensure the safety pin and anti tamper tie are intact.

3. Ensure labels are visible and legible.

4. Where cartridge actuators are fitted, weigh the cartridge and check against the stamped weight.

5. Check actuation cartridge is secure and undamaged.

6. Where Manual / Electric actuators are fitted, weigh the cartridge and check against the stamped weight.

7. Check actuation system including the check valves for blockages.

8. Check the Pyrotechnic Detonator Lead for proper connection onto the Manual / Electric Actuator.

9. Check the Pyrotechnic Detonator for connection into the Manual / Electric Actuator.

10. Ensure that the Check-valves are correctly fitted.


5.2.2 Container and Valve Assembly

1. Check condition of container assembly in accordance with Australian Standard AS 2030.1 and AS2337.1.

2. Inspect the mounting bracket for any damage and ensure the container is tightly secured.

3. Check the pressure gauge on the container control valve to ensure it is in the operating range.

4. Check the Schrader valve cap is in place.

5. Ensure the check valve is fitted correctly and in the correct direction.

5.2.3 Hose, Stainless Steel Tube and Fittings

1. Check nozzle caps are in place, if not replace cap.

2. Inspect all hoses and stainless steel tube for any abrasion or excessive wear.

3. Ensure that all hoses and stainless steel tube are firmly fastened.

4. Inspect all fittings for any damage or excessive wear.

5. Ensure that all fittings are firmly tightened.

a) Flush all hoses (except the 1/4" actuation hoses), stainless steel tube and nozzles with water.

b) Check 1/4” actuation hoses for any leaks.

5.2.4 Nozzle and Blow Off Caps

1. Inspect each nozzle bracket and nozzle direction is pointing to its aim point.

2. Remove the nozzle caps and check all nozzle outlets for debris and foreign materials.

3. Lubricate each nozzle with “Dow Corning #4” silicon grease and refit the nozzle caps - replace any damaged nozzles or caps.

5.2.5 Pressure Switch

1. Check the condition of the Pressure Switch.

2. Check that all wiring is properly connected.


3. Check the condition of all wiring.

5.2.6 Fire Indicator Panel

1. Check the operational functions of the Fire Indicator Panel.

2. Check the condition of Fire Indicator Panel.

3. Carry out a system test on Fire Indicator Panel.

5.2.7 Linear Detection Wire

1. Check the condition of the Linear Detection Wire.

2. Check for continuity of Linear Detection Wire.

3. Check that the Linear Detection Wire does not have more than two connections otherwise replace all Linear Detection Wire.

4. Check that the Linear Detection Wire is properly clamped.

5.2.8 Triple IR Detection

1. Disconnect power to the detector before proceeding with any maintenance including lens cleaning.

2. Clean dust, dirt or moisture with a soft optical cloth and detergent.

3. Clean the viewing window using water and detergent and rinse with clean water.

4. Perform additional recommended service activities in accordance with the manufacturers VFS System Manual.


5.2.9 Ancillary Visual / Audible Alarms

1. Where fitted check the condition of the visual and audible alarms.

2. Test the audible and visual to confirm that they are in good working order.

3. Check that the wiring between the audible and visual and the Fire Indicator Panel and the un-isolated power supply are securely mounted and there is no damage to the cables.

5.2.10 Record on Record of Service Sheet

5.3 Level 2 – Yearly

1. Carry out Level 1 - Six monthly checks.

2. See Note below for Remote Control Function, if fitted, before carrying out the following procedures.

3. a) Discharge Test the Fire Suppression System and time the discharge to ensure it does not exceed, where the maximum permissible number of nozzles are fitted for a standard discharge of 60 seconds +/- 10%.

b) Discharge Test the Fire Suppression System and time the discharge to ensure it does not exceed, where the maximum permissible number of nozzles are fitted for a extended discharge of 90 seconds +/- 10%.

4. Replace foam solution in container. (Refer to Recharge Instructions).

5. Check and lubricate the 'O' Rings on the Filler Plug and Control Valve using Dow Corning #4 silicon grease.

6. Remove the Control Valve, lubricate ‘O’ Rings using Dow Corning #4 silicon grease and check the operation.

7. Check Engine Shutdown operation, discharge to release and the override switch functions.

8. Lubricate all nozzles using Dow Corning #4 silicon grease and refit the nozzle blow-off caps.

9. Replace Battery in Fire Indicator Panel

10. Perform additional recommended service activities in accordance with the manufacturer’s VFS System Manual.



Note: If the Remote Control Function is interconnected with the Foam Fire Suppression System through a transmitter/receiver adaptor or cable connection, check and test the fire system by actuating the Fire System by Remote Control Operation and simulate a test of discharge utilising the Test Control Module.

CAUTION

Cartridge must be removed before continuing with the following steps or accidental system actuation will take place when PAD is actuated.

CAUTION

Do not actuate PAD unless it‘s installed in actuator body. If the PAD is actuated outside of actuator body, it will detonate causing possible personal injury.

CAUTION

Make certain the cartridge is removed from the actuator. Failure to do so will cause system discharge when PAD is actuated.

5.4 Level 4 – Five Yearly

1. Carry out a Level 2 service.

2. In accordance with AS 2030.1, hydrostatic pressure test containers every five (5) years at an Australian Standards approved pressure test station container.

3. Where fitted, replace Linear Detection Wire every five (5) years, or in an aggressive environment, as required.

4. Replace the Protract Actuation Device (P.A.D.)


Refer to sample in Appendix.


6.0 RECORD OF SERVICE SHEET

It is important that each six monthly, twelve monthly and five yearly inspections, along with system discharges and hydrostatic container tests, be recorded on the Record of Service Sheet.

7.0 WARRANTY

The components of the Wormald Vehicle Foam Water Spray Fire Suppression System supplied by the Wormald are warranted to you as the original purchaser for one year from the date of delivery against defects in workmanship and materials. Wormald will replace or repair any Wormald supplied component which, in its opinion, is defective and has not been tampered with or subjected to misuse, abuse, exposed to highly corrosive conditions or extreme high temperature provided that written notice of the alleged defect shall have been given to the Wormald within 30 days after discovery thereof and prior to the expiration of one year after delivery, and further provided that if Wormald so instructs, such article or part thereof is promptly returned to Wormald with shipping charges prepaid.

Disclaimer of Liability and Limitation of Damage

The above warranty is the only one given by Wormald concerning this system and applies only to the Wormald Vehicle Foam Water Spray Fire Suppression Systems that have been installed and maintained in accordance with all directions and requirements provided by Wormald in the Manual created for the type of system in operation. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES WHETHER EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO FITNESS OR PURPOSE AND MERCHANTABILITY, AND WORMALD DOES NOT ASSUME, OR AUTHORISE ANY OTHER PERSON TO ASSUME FOR IT, ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OF ITS PRODUCTS. WORMALD SHALL NOT BE LIABLE FOR CONSEQUENTIAL OR SIMILAR DAMAGES.

For repairs, parts and service of the Wormald Vehicle Fire Suppression System, contact your local Wormald representative, or Wormald, Unit 1, 2-8 South Street, Rydalmere, NSW Australia 2116.


8.0 APPENDIX

8.1 Product

8.1.1 Assemblies

106LCYLASSP 106L Assembly with 'P' Valve & Flex Tube

PART NUMBER ASSEMBLY

FO106LCYL 106L Container

FO106LABEL 80L Label

FO106BKTS 106L Shielded Bracket

FODNTU106 Flex Syphon Tube - 106

FO50PLUG 50mm Plug for 45/65/106L Container

FOAMPHEAD Control Valve PTO

FOBAND3 Vivid Blue Band - Suit 106L Container

FOINCASE Label - In Case of Fire

FOWARNFOAM Foam Warning Label




FO65LABEL 50L Label


FODNTU65 Flex Syphon Tube - 25/65



FOBAND2 Vivid Blue Band - Suit 25L, 45HP & 65L Container






FO45LABEL 35L Label





FOBAND1 Vivid Blue Band - Suit 16L & 45L Container




45LHPASSP 45L Assembly with 'P' Valve & Flex Tube


FO45LCYLHP 45L Container High Profile

FO45LABEL 35L Label

FO45BOX 45L Box for HP 45L Container


FODNTU45HP Flex Syphon Tube - 45 High Profile








FO25LABEL 19L Label



FO20PLUG 20mm Plug for 16/25L Container





NOZMETCAP Nozzle with Metal Cap


FOBNM16NOZ Nozzle

FOSSCAP Metal Blow Off Cap -Stainless

NOZASS Nozzle Ass with Metal Cap (Angle Bracket)


FOBNM16NOZ Nozzle

FOSSCAP Metal Blow Off Cap -Stainless

FONOZBKT Nozzle Bracket

ACTASSP-L Manual Actuator Assembly with L Bracket



FOMANVALVE Actuator Valve


FOACTBKT Actuator Bracket – L Type

7013 Nitrogen Cartridge


ACTASSP-S Manual Actuator Assembly with S Bracket



FOMANVALVE Actuator Valve


FOACTBKT Actuator Bracket – S Type

7013 Nitrogen Cartridge

AUTOACTASSP-L Automatic Actuator Assembly with L Bracket


24479 PAD Actuator Valve – Brass


436302 Protract Actuation Device (PAD)


419772 Actuator Bracket



8.1.2 Individual Components

PART NUMBER COMPONENT

ANTITAMPER Anti Tamper Ties AXATSEAL Service Tag Seal Ambi Tach 75 BURDISASS Bursting Disc Assembly FO106BKTS 106L Shielded Bracket FO106LABEL 80L Label for 106L Container FO106LCYL 106L Container FO106STABIL Stabiliser Bracket Suit 106L Container FO20PLUG 20mm Plug for 16/25L Container FO25BKTS 25L Shielded Bracket FO25LABEL 19L Label for 25L Container FO25LCYL 25L Container FO45BKTS 45L Shielded Bracket FO45BOX 45LBox for HP 45L Container FO45LABEL 35L Label for 45L Container FO45LCYL 45L Container FO45LCYLHP 45L Container High Profile FO50ORING O'RING - Spare - Suit FO50PLUG FO50PLUG 50mm Plug for 45/65/106L Container FO50PLUGMS Mild Steel 50mm Plug FO65BKTS 65L Shielded Bracket FO65LABEL 50L Label FO65LCYL 65L Container FOACTBKT Actuator Bracket - L Type FOACTBKT-S Actuator Bracket - S Type FOACTBOOT Actuator Dust Boot



FOAMPHEAD Control Valve PTO FOAMPORING Kit, O-Ring x 5 for FOAMPHEAD FOAMPTOOL Service Tool for Control Valves FOBAND1 Vivid Blue Band - Suit 16L & 45L Containers FOBAND2 Vivid Blue Band - Suit 25L, 45HP & 65L Containers FOBAND3 Vivid Blue Band - Suit 106L Container FOBASEPL Base Plate - Shaped FOBASEPL-R Base Plate - Round FOBNM16NOZ Nozzle FOCLAMP Clamp Suit 45L 65L 106L Bracket 428375 Splice Kit Shipping Assembly, 10/pkg FODETGROM Detection Wire Grommet 71230 Detection Wire 30.5 Metres 71231 Detection Wire 152.4 Metres FODNTU45 Flex Syphon Tube - 16/45 FODNTU45HP Flex Syphon Tube - 45 High Profile FODNTU65 Flex Syphon Tube - 25/65 FODNTUORING O'ring - Spare - Suit Siphon Tubes FOHEADCAP Brass Cap to suit Control Valve FOMANVALVE Actuator Valve - Brass FOINCASE Label - In Case of Fire FOKNOB Actuator Knob & Pull Pin FOLIQGAUGE 1620kpa Liquid Filled Gauge FOMANIFPTO Manifold Block PTO FOMANIFOLD Manifold Block1/4 BSPT x 6 Way FONOZBKT Nozzle Bracket FONOZBKTF Nozzle Bracket - Flat FOPRESSW12 Pressure Switch 1200KPA FOPRESSW9 Pressure Switch 900 kpa 434670 Checkfire ASCN Control Module Assembly 426520 End of Line (EOL) Resistor Assembly 427308 Battery Checkfire SC-N 3.6V 436026 Protracting Actuation Device 435479 PAD Actuator Shipping 436242 PAD Connector Cable – 510mm 436114 PAD Connector Cable – 6100mm 24479 PAD Actuator Manual / Automatic – Brass 437286 PAD Actuator Manual / Automatic – Stainless Steel 432480 IR Detector/Bracket Shipping Assembly 434108 Interface Module 434106 Y-Connector Cable 434103 Receptacle-Plug Cable Assembly, 3.0 m 432320 Receptacle-Plug Cable Assembly, 6.1 m 432324 Receptacle-Plug Cable Assembly, 9.1 m 432321 Receptacle-Receptacle Cable Assembly, 304 mm 419772 Actuator Bracket 434107 E.O.L. Triple IR Cable Assembly 423525 Combined Bracket 13193 LT-10-R Cartridge 6979 Actuator Cartridge (LT-5R) 7013 Actuator Cartridge (LT-5L)



FOSCHVAL Schrader Cap with Valve FOSS16NOZ Nozzle - 316 Stainless FOSS20PLUG 20mm Stainless Steel Plug for 16/25L Cyl FOSSMANVAL S/S Actuator Valve FOSSACTVNN S/S Actuator Valve without Gauge FOSSCAP Metal Blow Off Cap -Stainless FOSSPHEAD Control Valve PTO 316 Stainless FOSYSACTLABEL Fire Suppression System Activation Label FOWARNFOAM Foam Warning Label G1620 1620kpa Gauge 79559 Alarm Horn – Audible Alarm 419208 Alarm Strobe – Visual Alarm 430042 AFFF 6% ICAO-B 20 Litre Drum NZFO106LABEL 106L Label - New Zealand with FERN Approval NZFO25LABEL 25L Label - New Zealand with FERN Approval NZFO45LABEL 45L Label - New Zealand with FERN Approval NZFO65LABEL 65L Label - New Zealand with FERN Approval

NZFO45HPLABEL 45L High Profile Label - New Zealand with FERN Approval

PART NUMBER TESTING DEVICES 423541 Test Module, Release Circuit 434675 ASC-N Reset Tool


Independent Charge Rig complete with 1 x 3 metre hose and schrader valve adaptor & 1 x 10 or 30 metre hose. This Charge Rig provides a method to assist in pressurising the fire suppression containers

Safety Cap to assist in the prevention of accidental discharge when carrying out recharge / maintenance

Pressure Test Actuation Device for testing the integrity of the 1/4" actuation hose

Overfill Tube to assist in filling the correct amount of water required for the Fire Suppression Container

8.1.3 VFS Safety Tools & Testing Devices

PART NUMBER SAFETY TOOLS

FOCHARGERIG10 Vehicle Systems Charging Rig c/w 10 Metres Hose FOCHARGERIG30 Vehicle Systems Charging Rig c/w 30 Metres Hose FOPRESTESTC7031 Pressure Test Jig for 1/4" Actuation Lines FOSAFECAP7031 Safety Cap with Isolation Valve & Safety Vent Plug FOFILTUB106 Fill Tube for 106L Containers - 72L Water Fill FOFILTUB25 Fill Tube for 25L Containers - 17L Water Fill FOFILTUB45 Fill Tube for 45L Containers - 31.5L Water Fill FOFILTUB65 Fill Tube for 65L Containers - 45L Water Fill


8.2 Detection Wire Fluid Capability


8.3 Sample of Record of Service (ROS) Sheet



FOR NOTES

Wormald Australia Pty Ltd Wormald ABN 80 008 399 004

Wormald Phone: 133 166 Email: [email protected] Website: www.wormald.com

Documents

Foam Water Spray Vehicle Fire Suppression System · selected fire risks in the risk area to be protected. The Wormald ‘Loss of Pressure’ Vehicle Foam Water Spray Fire Suppression