Pre-Engineered Service Manual FD and MD Models
Contents
1. 2 72 107 ae 1250 12 UNF 2B MINOR DIA 1160 1178 PITCH DIA 1195971 2039 MAJOR DIA 1 250 MIN 6 MINIMUM THREADS REG MACHINE DETAIL NOTES CYLINDER TO MEET DOT 3AL TC 3ALM MATERIAL 6061 76 ALUMINUM ALLOY METAL STAMP 1 4 INCH HIGH CHARACTERS LOV STRESS STAMP ON CYLINDER AS SHOWN 4 THREADS AND SEALING SURFACES TO BE PROTECTED FROM NICKING DURING SHIPPING AND STORAGE 5 HETRIC DIM S ARE NOMINAL UNTDLERANCED DIM S 6 ALL DIM S WITH SYMBOL SHOULD 10051 7 CYLINDER DESIGNED TO MEET EUROPEAN SP ATIONS Il E 974 401 re DE M Xs EKN m ma EEE EL o x vE d 38 711737 e TEXT ARVI usn PRESSURE PRESSE Eee 1509 1 1647 PE 2 103 MOM ini fer crea PSINTPEHDucT Rez 2 16 03 bees CT 44 783 Elle i13 F8 1968 BIROR DIA 1160 1178 PITCH Li9e9 12039 4 LESI M M MIMIMUM THREADS NOTES MACHINE DETAIL T B T 34 HATER AL GDGL T amp ALLOY STAMP HIGH CHARACTERS LrTw STRESS STAMP See THREADS AMD SEALING EURFACES BE PROTECTED DURING SHIPPING2. AGENT PRESSURE WEIGHT BAR KGS 21C 6 89 7 38 7 87 O 12 79 13 78 14 27 FILL CHART FD amp MD Manual and Automatics FM 200 CHARGE AGENT PRESSURE MODEL WEIGHT P S I G FD MD LBS 70F 825 3572 850 900 925 37 89 38 97 1025 44 38 1050 4547 47 63 48 71 ETM 1125 _ 1150 49 80 50 88 120 57 37 AGENT PRESSURE WEIGHT BAR KGS 21C FILL CHART FD amp MD Manual and Automatics FM 200 CHARGE CHARGE PRESSURE AGENT PRESSURE FM 200 HFC 227ea Pressure Temperature Chart 360 Psi 70 F 21C 320 I CO NO O I N CO NO O1 Ol CO 09 G I CO G CO CO N Ol O 35 60 N 4 O O O N Ol Co 200 227 Pressure Temperature Chart 360 Psi ue den 70 F 21C 78 3 2 3 4 9 N O 000 09 CO 00 G O CO s En CO 09 W 6 CO 0 100 09 Co Cylinder Data Sheets 425 073 393 71 1550 4 06 ee KRS gt 2 RX 13335 0525 2 015 Kev A STAMP DETAIL 135 462 91 396 32 25 91270
3. 1573 dme 0 FAX 00 80 l To Ren Aetalerarte JAS DRAWING IS TERE TO BE PROPRIETARY AND M Y NOT BE MENE Oe WITHOUT vis Ere UN CYLINDER CORP COLUMBUS 43085 5 1 gt ALL DIMENSIONS IM INCHES AND 22 CYLINDER MANUFACTURED ACCORDANCE WITH E339 AND CFR PART 1 8 61 CYLINDER HEAT TREATED AFTER ALL WELDING OPERATIONS MATERIGL HRP HSLA MIN THICKNESS BASED ON JOINT EFF 9 SPOT INSIDE OF CYLINDER MUST BE CLEAN DRY AND FREE OF SCALE SLAG OIL AND ALL OTHER POWDER COAT PER ORDER CYLINDER TO BE FM APPROVED 32 SPECIFICATION DUT 4Bw200 TC 4BWM34 300 PSI WORKING PRESS 34 BAR 125 037 From Aaron leyers 9 15 11 ore Y lan SPUD 526212 1 1 2 12UN 2B A WRAPPER SEAM SPUD 55621 85 4 MM 0 3 16 FA TOP HEAD 8 058800 1 2 es 1 8 WRAPPER 17 5 8 299968 448 5 38 MM REF LA 24 1 4 REF 616 MM 85 7 16 646 x 7 Ve 8 TT EU d Um A Ti mam
4. 2 STORAGE D HET amp IC DIAS ARE MOHJHAL UHTILERAHCER BALL WIH wa SHO EE 7 CYLINDER EURDFI ELFPERMH HAREDNG EE AWwAILABLE LPO CYLINDER Oe T CLIFF IMPACT DIVISIUN 5 075 Rell 5 f 4 4 Ep 4 44 703 1020 3451 Ihe i083 3225 Buzz Lime UA EE MA 1 1 PIT H 11959712 25 A HAMA 120 KU THREADS NOTES DETAIL oe eS TEER i GY LINGER TD MEET DOT 244 TC hLES I T ALUMINUM ALLOY METAL STAMP 1 4 DUCH HIGH CHARACTERS LOW STRCIS STAMP M CYLIMDER GUN THREADS AM SEALING SURPACES TO ME PROTECTED FROH DURING SHIFFING AMD STORAGE METRIC DRS ARC NOMINAL LMTOLERANCED MH S ALL DIR S WITH SYMBOL SHOULD EYL NMDE PESIOMED TO MEET E DF DCA TION EUROPEAN MARKIMG TO AVAILABLE UPON LYLIHDER MUALIF POAT parue PRESSURE Cama man ri ht aE 45 076 Kew i ee TE TEST seevice DOT TEX ETT 1667 ET ran jiue gigo STAMP DETAIL NOTES L C LIHDEE HEET DUT 35 7C 34LH 2 5451 ALLO 3 METAL STAMP 174 HIGH LOW STRESS STAHP CYLINDER AZ EHDAK H
5. DOT 3AL 1000 amp 4BW 500 Part _ S NOTE For DOT 4BW 360 use pressure temperature tag 123 230 Tools All Models Number Drive Adaptor 7 8 Manifold 128 002 Drive Adaptor 34 Manifold 128 003 1 2 Deep socket 1 2 Drive N A Combination Wrench 7 16 N A Combination Wrench 9 16 N A Torque Wrench 1 2 Drive N A Torque Wrench 3 8 Drive N A Valve Core removal amp Recovery tool N A Infrared Thermometer N A Manifold Glue Up Assembly 131 137 131 138 131 156 131 157 Gauge 360PSI 120 020 O Rings Black 121 224 amp White 121 221 Relief Valve 122 130 Top Tank Valve 121 016 Bottom Switch 124 006 Grey amp 124 007 Blue Release Brackets Standard Pull 130 206 Left 130 207 Right Release Brackets Reverse Pull 130 208 Left 130 209 Right Sea Fire Disassembly and Rebuild Procedure Agent Recovery and Cylinder Disassembly 1 2 Recover the agent from the cylinder using an approved gas recovery system Ensure the cylinder gas is expelled from the system by removing the Schrader valve cap on the rear of the system as shown below with a 9 16 wrench and then depress the core A refrigerant hose with the appropriate fitting and 6 of hose works well Disassembly 1 2 Obtain an Assembly Repair Log Sheet Record the original batch number stamped on the top of the manifold Record the RA date initials of the
6. Leak Test and Pressure Switch check for All 3AL 1000 and 4BW500 cylinders NOTE 4BW360 cylinders are pressurized to 240PSI and are not covered using this process 1 Fill unit with nitrogen to 360 p s i for leak detection purposes 2 Leak test unit with a Leak Detector or by using a bucket tub or tote filled with water that is large enough to submerse the whole unit Submersing the unit and check for any air bubbles that may arise Particular attention needs to be made to each threaded mating joint the glass bulb and piston area It is necessary to rotate the cylinder to focus on each mating joint Even a minor bubble is an indication of leakage This whole process should take 5 minutes per cylinder 3 Check the pressure switch for proper function under pressure Connect the two leads to a voltmeter continuity checker or other circuit tester We have a 12V DC power supply hooked up to a piezo buzzer all in series connecting the pressure switch makes the circuit and the buzzer sounds Agent Fill 1 When you are assured that the unit is leak free release the nitrogen from the unit and fill with the appropriate amount of FM 200 and determine the temperature of the cylinder 2 Use the chart to determine the proper final pressure based on the cylinder temperature Fill unit with nitrogen to that pressure Fill to approximately 10 psi over the rated pressure to allow for absorption of the nitrogen into the agent 3 Shake or roll th
7. claim on the carrier will be filed If so hold the box packing material and cylinder until the claim is closed If no claim is to be filed the packing materials can be discarded and the cylinder can be processed as required Typical damage seen on returned cylinder Identify the cylinder type model and determine the correct parts needed for use in Repair of the cylinder Get the model number off the label EX 0400 If there is no label or the label is damaged and the model number cannot be read more information will be needed Get the agent type from the main label EX FM200 HFC227 Weigh and record the cylinder weight Look at the writing stamped along the top of the cylinder TPED cylinders have markings around the cylinder just above the base to identify the cylinder type EX TC 3ALM69 DOT39 3AL1000 4BW500 and the cylinder manufacture date EX 10 08 October 2008 An alternate method of identification is to match up the dimensions of the cylinder to the cylinder data sheet DOT39 cylinders cannot be serviced they must be replaced 1000 and 4BW500 cylinders are certifiable for 12 years Owners of cylinders in for service that are over 10 years old should be informed and given a choice to repair as is hydrostatic test to extend the service life to 6 more years then repair or to purchase a replacement Service Parts for FD and MD Models Manifold Glue Up Assembly FD 150 1000 131 137 FD 1050 1500 131 13
8. to pump out of it before recovering any more 3 Ensure that the liquid supply valve is closed on the main supply tank Note You do not need to remove the 3 8 hose that is connected from the tank to the pump as long as the valve is closed 4 Remove the 14 fill hose from the gauge assembly completely or use another of the same style hose 5 Remove the cap off the shrader valve on the ball valve on the inlet side of the pump 6 Connect one end of the 14 hose to this shrader valve the other end to bottle that needs to be emptied Bottle Preparation cylinder to be emptied 7 Remove the cap off the shrader valve Option Turn the shrader core to turn counter clockwise This will help the agent flow out of the bottle faster Do not remove it too far or the agent will expel from the valve 8 Lay the bottle horizontal 9 Connect the 14 hose from the pump to the cylinder repeat of step 6 10 Turn on the compressed air supply to the pump and drain until the gauge reads no pressure and the cylinder feels empty Note Rock the cylinder slowly until it feels like no liquid remains The bottle should be empty FILL CHART FD amp MD Manual and Automatics FM 200 CHARGE AGENT PRESSURE MODEL WEIGHT P S I G FD MD LBS 70F 175 7 98 8 66 9 74 N N 14 07 N 17 32 18 40 475 20 57 22 73 N 27 06 N 16 iN 725
9. 8 MD 150 1000 131 156 MD 1050 1500 131 157 Identify model disassemble cylinder select part and cut to match length Install and torque all models to 120 FT LBS O Rings FD 150 1000 121 224 3 N A FD 1050 1500 121 224 3 121 221 1 MD 150 1000 121 224 3 121 221 1 MD 1050 1500 121 224 3 121 221 1 Use 121 221 under Relief Valve 121 224 in all other manifold ports Gauges PSI FD 150 1000 121 020 FD 1050 1500 121 020 MD 150 1000 121 020 MD 1050 1500 121 020 NOTE 3AL 1000 and 4B W500 Cylinders use 360 gauges Old builds using 4B W360 cylinders cannot be pressurized to 360PSI and require a different 240PSI gauge that must be special ordered Relief Valve Install and torque all models to 15 FT LBS Tank Valve FD 150 1000 121 016 FD 1050 1500 121 016 MD 150 1000 121 016 MD 1050 1500 121 016 Switch FD 150 1000 124 006 FD 1050 1500 124 007 MD 150 1000 124 006 MD 1050 1500 124 007 NOTE Switches can have three different connectors Standard Delphi or Deutsch You must match the correct connector Release Brackets Standard Pull Release Brackets Reverse Pull FD 150 1000 130 208 FD 1050 1500 130 209 MD 150 1000 130 208 MD 1050 1500 130 209 Loctite All Models Thread Locker Loctite 554 121 195 Loctite 545 121 071 Tie All Models Part 121 085 Corrosion Inhibitor All Models Part 121 040 Agent FM 200 HFC227 All Models Part 131 100 Tags For
10. ETRIC ARE MOMEHAL UHTDLESAMCED DH E 5 DMS WITH SYHEDL SHOULD amp CYTLIWDES DESDIGHED TD MEET EURDPLAN SP EE AVLARI CYLINDER GLALIFICATIDM CLIFF DIVISION 8400 Ss CPS gd Her STAMP DETAIL NOTES b LINC TD MEET DUT 3AL TC 3ALH 2 1 4161 16 ALLOY X STAMP 174 HGH HIGH CHARACTERS LOW STROSS OR CYLINDER 4 BETE C ARE MOHINA UNTOLERAMCED OES 5 ALL DOW S WITH ZrHEUL SHOULD 0 05 CYLINDER TD MEET SP EUROPEAN EE AVAILABLE UPON CHIERE QUALIFICATION 2 i Lu ao 1788 118 cree 3 Sa BN CLIFF IMPACT DIVISION ga ur ICH de B MIMUH THREADS En NOTES DETAIL ras gis AEP MELE u 4 THREADS SEALIKG SURFACES EE PROTECTES FROM DURING SHIPPING METEIL M LHTOLERAMCEE Dies 5 ALL WITH SYMBOL BE 7 LTL MDE RESIGNED TO HEET IEEE MARKING BE AVAILABLE QUALIFICATION CLIFF ali 1115 MAET
11. Pre Engineered Service Manual al m E B 1 m H 1 l L m i z mm m ri E m FD and MD Models Servicing of SEA FIRE FD and MD Models When a cylinder arrives for service immediately inspect the box for damage before signing to except delivery Document any damage on receiving documents We suggest wearing safety glasses and using extreme care when receiving unpacking and inspecting a returned cylinder Cylinders damaged during shipment may discharge at any time Carefully open the box and save it and the packing material then inspect the cylinder for damage First inspect the manifold release bracket area for any damage Damage in this area can cause the cylinder to discharge prematurely if bumped Be sure the safety pin is in place If it is not and there is no damage to the release bracket and it can be inserted without force insert the safety pin Do not insert the pin if the release bracket is damaged and never attempt to force a safety pin in place If the release bracket is damaged or the pin cannot be easily inserted carefully remove damaged release brackets before further handling of the cylinder After the cylinder is deemed safe to handle complete the inspection of the cylinder If damaged document the damage Use pictures to document damage whenever possible If the damage is determined to have occurred during shipment decide if a damage
12. a Agent i Turn on the air supply to the fill station The pump should cycle a few times and then stop li Place the empty cylinder on the scale Record the tare weight of the cylinder assembly Connect the agent fill hose Red 4 to the cylinder tank valve iv Determine the desired fill weight from the Fill chart Depending on the length of the red fill hose you will have to deduct 0 15 to 0 25 106 from the desired weight This is to account for the agent that remains in the hose before the nitrogen is put into the cylinder v Open the Fill Manifold Cylinder fill valve ball valve or needle valve Agent should begin entering the cylinder and the pump should start cycling vi Carefully watch the scale and close the valve when you have reached the desired weight vii Close the Fill Manifold Agent Inlet valve b Nitrogen Charge i Open the Fill manifold nitrogen inlet valve li Open the Fill Manifold Cylinder fill valve Watch the fill manifold gauge Calibrated as well as the gauge on the cylinder The pressure should stabilize on the previously set pressure ii Close the Fill Manifold Cylinder fill valve Shake agitate or otherwise move the filled cylinder to mix the nitrogen with the agent 1 This is necessary to aid the nitrogen absorption If not done the cylinder pressure will drop out of serviceable condition within a day or two After agitating rolling it will most likely be necessary to re p
13. ach cylinder depending on weld of the cylinder and the precision repeatability of the filling process Label the cylinder properly Send a copy of the completed Assembly Repair Log Sheet FAX or Email to SEA FIRE Quality Dept METALCRAFT SEAFIRE AUTOMATICS DESCRIPTION ASSEMBLY REPAIR LOG TABLE 1 RECORD OF TRACEABILITY AND INSPECTION e DATE MANIFOLD Glue Up Assy Part Part TORQUE TORQUE TORQUE TORQUE TORQUE TORQUE TORQUE TORQUE LBS LBS LBS LBS LBS LBS LBS LBS LOCTITE INITIALS TESTER STAMP ACC Instructions for Using the Fill Station Agent Fill 1 Preparation a Connect the yellow 3 8 agent supply hose from the tank liquid port to the inlet side of the Haskell pump Open the liquid port valve on the tank and any additional valves in the hose setup b Connect a compressed air supply to the air inlet on the Filter Regulator Lubricator c Connect the nitrogen supply from the nitrogen supply cylinder to the nitrogen inlet valve on the fill station manifold Set the nitrogen regulator to the desired pressure of the cylinder you are going to fill d Check the scale for being level Turn it on and ensure its accuracy e Ensure the Fill Manifold Nitrogen inlet valve is closed f Ensure the Fill Manifold Cylinder fill valve is closed Connect a red 1 4 fill hose g Open the Fill manifold Agent inlet valve 2 Fill Operation
14. e filled cylinder to agitate and mix the nitrogen into the agent This is necessary to aid the nitrogen absorption If not done the cylinder pressure will drop out of serviceable condition within a day or two After agitating rolling it will most likely be necessary to re pressurize with nitrogen to attain the rated pressure Repeat until the pressure is stable Fill with nitrogen using a reliable precise regulator and compare to a calibrated gauge and also the gauge on the cylinder as the final reference 4 When complete apply a small amount of Loctite 554 to the shrader valve threads and install the shrader valve cap Tighten the cap Repeat the leak test procedure 1 Repeat the underwater portion of the leak test We have seen shrader valves leak after being filled where they did not leak initially Corrosion Inhibitor 1 Apply a light coat of wax CRC SP 400 to the entire manifold assembly This is done by using a 1 paint brush or by setting up a dip tank and dipping the entire head assembly The dip tank would need to be at least 6 deep and approximately 10 wide We use the bottom portion of a 5 gallon pail cut off For low volume the brushing is probably best 2 Allow the wax to dry for 45 minutes or longer until it is dry to the touch A fan set up to blow across the surface helps shorten the dry time Final Documentation 1 When unit is filled and charged and waxed record the weight This will be different for e
15. n the manifold On FD150 1000 models insert the pin into the unthreaded unused port Tighten the manifold to 120 FT Lbs Insert a black 121 224 o ring into the ports to receive the gauge switch and Schrader valve Insert a white 121 221 o ring into the port to receive the relief valve if required Install the pressure gauge pressure switch shrader valve and relief assembly FD 1050 and larger models only Use loctite 554 for these accessories Do not allow the Loctite to get on the pressure gauge lens It will crack it when it dries Let the loctite dry for 48 hours This is a must Our experience shows anything less will end up leaking Option for Auto Manual models Addition of manual trigger assembly 1 Insert the lever portion of the trigger through the release bracket Locate the bracket on top of the manifold while also aligning the trigger fingers carefully over the glass bulb This is a down from the top and approach from the side maneuver 2 Use two no 10 32 screws and 10 32 stainless steel lock washers to screw down the release assembly The lever should be somewhat loose 1 16 or less movement This is necessary to ensure against the lever being jammed up or tight 3 Install the safety pin through the lever and into the hole on the release assembly 4 Install a nylon tie around the throat of the cylinder Rotate position the tie so that the pin holder hole next to the clamp is aligned for easy pin storage
16. person performing the repair and the Model number off the label When gas is completely expelled remove the Manifold assembly on the cylinder with the spanner wrench provided or large pipe wrench with an extension bar if necessary by turning it counter clockwise A pipe wrench will most likely gouge the manifold making it un usable again Remove any excess material from the inner threads of the cylinder The best method is to use either a toothbrush or a soft wire brush followed by a clean cloth Assembly 1 2 3 Assemble the parts to be used to make the repair Record the part number and PO Number of each part in each space provided Using the O Ring lubricant provided apply a thin coat to the O Ring groove of the cylinder with a clean cloth or tooth brush Apply Loctite 545 to threads of the cylinder putting the loctite bottle into the throat and rotating it Apply a generous amount but don t overdo it Ensure that complete coverage a full ring is achieved It is only necessary to achieve one ring 2 3 threads not all threads Be aware not to get Loctite on the O Ring groove Ensure that the manifold O ring has some lubrication if not apply a small amount around the whole surface Insert manifold siphon tube assembly into the cylinder and tighten with the manifold socket and torque wrench Align the socket over the manifold on the FD and MD 1050 1500 and insert a pin through the socket and into any port i
17. ressurize with nitrogen to attain the rated pressure 2 Fill to approximately 10 psi over the rated pressure to allow for absorption of the nitrogen into the agent c After a potential few cycles of adding nitrogen closing the nitrogen supply and shaking checking the pressure close all valves and remove the fill hose d When complete apply a small amount of Loc Tite 277 to the tank valve threads and install the tank valve cap Tighten the cap DO NOT over tighten the cap to where the tank valve body moves in the manifold If necessary use a wrench on the tank valve to hold it in place when tightening the cap Recycling Recovering Agent 1 Disconnect the yellow 3 8 Feed hose from the inlet side of the pressure gauge assembly 2 Connect the free end of the hose to the tank where you want the recovered agent to go This could be the vapor side of the main source tank you are using to fill out of or another suitably rated pressure tank Note when you recover FM 200 from a filled extinguisher you will also get nitrogen This nitrogen will eventually need to be bled off or otherwise removed That is why we recommend a separate holding tank to recover the FM 200 into After the nitrogen is removed you can then fill out of this tank Another point is if your main source tank is full or near full you will not be able to pump any recovered FM 200 nitrogen into it The same applies to your holding tank if it s full you need
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