RECHARGE MANUAL FIKE CLEAN AGENT SUPPRESSION SYSTEMS W/ DOT & EN CONTAINERS IMPULSE VALVES & GCA VALVES HFC-125 & HFC-227EA AGENTS P/N 06-290 (Rev. 4 / December, 2016) REVISION HISTORY Original Release Date............................................................................................................................ January, 2003 Revision / Description of Change Revision Date Revision 1 .......................................................................................................................................... November, 2008 1) Re-formatted manual 2) Added recharge information on HFC-227ea Revision 2 .............................................................................................................................................. January, 2010 1) Added 3” Threaded GCA wrench to Section 2 Equipment, Item 12 on page 3 2) Added Important Note to Section 3, paragraph 3.2.3 on page 7 . . . When removing hold-down nut on container with 3” threaded valve, use 3” Threaded GCA Wrench (P/N 02-12734) to stop valve from turning. 3) Added Important Note to Section 4.4.2 on page 16 . . . All containers with threaded GCA valves can be super-pressurized in the upright position. 4) Added Section 3.2.4 on page 9 Valve reconditioning procedures and fill / super-pressurization procedures for containers with Impulse Valves. Revision 3 ................................................................................................................................................... April, 2016 1) Remove all references to FM-200 and replace with HFC-227ea 2) Added Waysmos USA SDS to Appendix material 3) Added EN container information Revision 4 .......................................................................................................................................... December, 2016 1) Changed title from “Recharge Procedure” to “Recharge Manual.” 2) Removed “Corporation Model HR-1301” under “Pump” in Section 2.0. 3) Updated equipment calibration frequency in Section 2.1 and added thermometer calibration requirement. 4) Added Section 6.0 for Container Identification. 5) Updated maximum leak rates in Table 5.1. 6) Updated pressure values in Pressure vs. Temperature table in Appendix A.1.2. 7) Corrected SI units for fill density in Appendices A.1.3 and A.2.3. 8) Update publication and document information in Appendices B.5. 9) Removed Appendix C and replaced with Appendix B.6. 10) Replaced “ECARO-25” with “HFC-125” throughout. 11) General error corrections throughout. Manual P/N 06-290 TABLE OF CONTENTS 1.0 GENERAL ........................................................................................................................................................ 1 1.1 SCOPE ............................................................................................................................................................. 1 1.2 PURPOSE ........................................................................................................................................................ 1 1.3 SAFETY PRECAUTIONS ................................................................................................................................. 1 2.0 EQUIPMENT ..................................................................................................................................................... 2 2.1 EQUIPMENT CALIBRATION ........................................................................................................................... 3 3.0 CONTAINER PREPARATION ......................................................................................................................... 4 3.1 TEST AND INSPECTION ................................................................................................................................. 4 3.2 VALVE RECONDITIONING .............................................................................................................................. 4 3.2.1 1" (25MM) GCA VALVE RECONDITIONING PROCEDURE .................................................................................. 4 3.2.2 2.5" (65MM) GCA VALVE RECONDITIONING PROCEDURE ............................................................................... 6 3.2.3 3" (80MM) GCA VALVE RECONDITIONING PROCEDURE .................................................................................. 7 3.2.4 1" (25MM) & 3" (80MM) IMPULSE VALVE RECONDITIONING PROCEDURE .......................................................... 9 4.0 CONTAINER RECHARGING ......................................................................................................................... 12 4.1 CONTAINER CAPACITY ................................................................................................................................ 12 4.2 CONTAINER FILL DENSITY .......................................................................................................................... 12 4.3 AGENT TRANSFER ....................................................................................................................................... 12 4.4 RECHARGE (FILL) PROCEDURE ................................................................................................................. 13 4.4.1 AGENT FILL PROCEDURE – GCA CONTAINERS............................................................................................. 13 4.4.2 NITROGEN SUPER-PRESSURIZATION PROCEDURE – GCA CONTAINERS ........................................................ 16 4.4.3 AGENT FILL PROCEDURE – IMPULSE VALVE CONTAINERS ............................................................................. 18 4.4.4 NITROGEN SUPER-PRESSURIZATION PROCEDURE – IMPULSE VALVE CONTAINERS ........................................ 19 5.0 LEAK DETECTION ........................................................................................................................................ 20 5.1 LEAK TESTING PROCEDURE ...................................................................................................................... 20 6.0 CONTAINER IDENTIFICATION ..................................................................................................................... 21 APPENDIX A – SUPPORT INFORMATION ............................................................................................................ 22 A.1 HFC-125 INFORMATION ............................................................................................................................... 22 A.1.1 CYLINDER FILL RANGE TABLE ..................................................................................................................... 22 A.1.2 PRESSURE / TEMPERATURE CHART ............................................................................................................. 23 A.1.3 APPROXIMATE NITROGEN W EIGHT CHART ................................................................................................... 23 A.2 HFC-227EA INFORMATION .......................................................................................................................... 24 A.2.1 CYLINDER FILL RANGE TABLE ..................................................................................................................... 24 A.2.2 PRESSURE / TEMPERATURE CHART ............................................................................................................. 26 A.2.3 APPROXIMATE NITROGEN W EIGHT CHART ................................................................................................... 26 A.3 SAMPLE LOG BOOK ..................................................................................................................................... 27 Manual P/N 06-290 TABLE OF CONTENTS APPENDIX B – REFERENCED AND CONTRIBUTING PUBLICATIONS ............................................................. 28 B.1 NFPA PUBLICATION ..................................................................................................................................... 28 B.2 U.S. GOVERNMENT PUBLICATION ............................................................................................................. 28 B.3 CGA PUBLICATION ....................................................................................................................................... 28 B.4 FIKE PUBLICATION ....................................................................................................................................... 28 B.5 MISCELLANEOUS PUBLICATION ................................................................................................................ 28 B.6 SAFETY DATA SHEETS (SDS) ..................................................................................................................... 28 Manual P/N 06-290 RECHARGE MANUAL 1.0 GENERAL 1.1 SCOPE This manual contains the minimum requirements and procedures for recharging clean agent suppression containers (HFC-125 or HFC-227ea) in the field. The information contained herein is prepared for the use and guidance of Fike authorized Sales Outlets and shall be strictly adhered to so that the clean agent suppression container will function properly throughout its life. 1.2 PURPOSE After a system discharge, it is imperative that the clean agent suppression containers be recharged and returned to service as soon as possible (24 hours maximum) to ensure continued protection. By participating in Fike’s Field Recharge Program, the sales outlet can eliminate the time associated with shipping the containers to Fike for recharge. The sales outlet can remove the container from service, perform the recharge at their shop and return the container to service in a relatively short period of time. 1.3 SAFETY PRECAUTIONS An understanding of the physical properties of the clean agent (HFC-125 or HFC-227ea), and the safe and proper use of techniques for handling liquefied compressed gasses, will allow the agent to be safety transferred from bulk containers to clean agent system containers. Prior to handling the agent (HFC-125 or HFC-227ea), the Safety Data Sheet (SDS) specified in this manual and the safety precautions listed below shall be read and understood by all individuals handling the product. WARNING: Containers associated with this procedure will be filled with a liquefied gas under pressure. Safe handling procedures associated with pressurized containers must be observed at all times. CAUTION: Suitable pressure relief devices shall be incorporated into the charging system to prevent accidental over pressurization of the system. In pipe sections where agent could become trapped, suitable pressure relief devices shall be provided. CAUTION: Container filling areas must be well ventilated at all times. CAUTION: HFC-125 and HFC-227ea have a relative low toxicity level in its natural state. However, agent products of decomposition can be toxic. Therefore, smoking shall be prohibited at all times in container filling areas. CAUTION: Safety glasses, a full-face shield and gloves shall be worn at all times when handling HFC-125 or HFC-227ea. Liquid agent coming into contact with skin or eyes will cause sever cryogenic burns. The liquid temperature for these agents is as follows: HFC-125 – approximately -55°F (-48°C) HFC-227ea – approximately -300°F (-185°C) CAUTION: Before filling, all containers shall be inspected for evidence of weak or corroded areas and the date of the last hydrotest or inspection. See Section 3.1 for testing details. CAUTION: The quantity of agent transferred to a receiving container must not allow the container to become liquid-full below the following: HFC-125 – 120°F (49°C) pursuant to DOT regulations HFC-227ea – 130°F (54°C) Refer to Appendix A for the minimum/maximum fill ranges of Fike clean agent containers. Revision Date: December, 2016 Manual P/N 06-290 (Rev 4) Page: 1 RECHARGE MANUAL 2.0 EQUIPMENT This section defines the minimum recommended equipment required for the proper filling of Fike Clean Agent containers from bulk storage cylinders. Item 1: Bulk supply of extinguishing agent: a) HFC-125 – UL component recognized clean agent for extinguishing system units also known as 1,1,1,2,3,3,3-Heptafluoropropane. Chemical formula: CF3CHFCF3. b) HFC-227ea – UL component recognized clean agent for extinguishing system units also known as 1,1,1,2,2-Pentafluoroethane. Chemical formula: CHF2CF3. NOTE: The Clean Agents are to be UL Component Recognized Clean Agents for Extinguishing System Units (GARZ2) and are to bear the UL Component Recognized Marking, along with a marking designating the agent as either HFC-227ea or HFC-125. All records and markings of such shall be maintained by the sales outlet, and shall be readily available for review by the UL representative. Item 2: Pump – Any pump system compatible with HFC-227ea and HFC-125 that meets the operating criteria for each pump station setup or configuration. Suggest Getz, Haskel, Goulds, Corken, Dravco pump systems, or equal. Item 3: Recharge Adapter/Core Removal Tool – Impulse Valve (P/N 70-282) / GCA Valve (P/N 02-1900) Required to facilitate reconditioning of the container by removing/adding the valve core from the brass fill valve. Item 4: Core Depressor Tool – Impulse Valve (P/N 70-281) / GCA Valve (P/N 02-2031) Required to super-pressurize the containers by depressing the valve core in the brass fill valve and allowing the nitrogen to flow through. Item 5: Fittings, Valves and Hoses, as required – Each shall be suitable for refrigeration service and have a minimum working pressure of 600 psi (4137 kPa). NOTE: Connection of the supply container to the receiving vessel/container is made through the use of 3/4” (20 mm) refrigerant drum adapters, on drum valves, and one or more lengths of refrigeration charging hoses. The charging hose is a flexible, fiber-reinforced, rubber hose fitted with female tubing connectors at each end and is rated at 2250 psi (15513 kPa). The drum adapters, charging hoses, and misc. valves, fittings, etc. can be purchased at local refrigeration supply houses. Item 6: High Quality Thermometer – Thermometer shall be accurate to ±2°F (1.0°C) and shall be located in the container filling area. Item 7: Scale – A scale capable of accurately weighing to within ±0.5 lb. (0.23 kg), with a total range greater than the maximum charged container weight, approximately 2000 lbs / 907.2 kg. Item 8: Nitrogen Supply – Adequate supply of dry nitrogen shall be provided with a pressure regulator and filling adapter. NOTE: Nitrogen supplies must be Grade H, I, J, K, L, M, N, O, or P, as described in Table 1 of the Compressed Gas Assoc. Pamphlet G10.1, having a dew point of -70°F (-56.7°C), or less. Item 9: Leak Detector – A leak detector capable of detecting a minimum leak rate of 0.18 oz (5.1 g) per year. Suggest Yokogawa Series H-10, D-TEK Refrigeration Leak Detector, or equivalent. Item 10: Leak Standard – A Model LS-20 leak standard for calibrating the leak detector and capable of being set to the minimum required leak rate. NOTE: To properly set a leak detector to check HFC-227ea and HFC-125, two different leak standards are required. To obtain LS-20B Leak Standards, calibrated for HFC-227ea and HFC-125, contact Bacharach Inc. Revision Date: December, 2016 Manual P/N 06-290 (Rev 4) Page: 2 RECHARGE MANUAL Item 11: Pressure Gauges – Two pressure gauges, as follows: 0-600 psi (0-4137 kPa) calibrated in 20 psig (138 kPa) increments, or less, for the output/discharge side of the pump. 0-600 psi (0-4137 kPa) calibrated in 20 psig (138 kPa) increments, or less, for the output/discharge side of the nitrogen regulator. Item 12: Threaded GCA Wrench – 3" Valve (P/N 02-12734) / 1" Valve (P/N S70-114) – Required to hold threaded GCA valve in place when removing hold-down nut on threaded valve. Item 13: Spanner Wrench (Impulse Valve / P/N 70-2153-100) – Required to remove and tighten Hold-down Nut. Item 14: Body Wrench (P/N 02-12682) – Required to hold Impulse valve in place when removing Hold-down Nut. Item 15: Pressure vs. Temperature Chart – A pressure vs. temperature chart detailing the relationship of super-pressurized agent vs. temperature shall be kept in the container filling area. See Appendix A. Item 16: Log Book – A permanent log book shall be kept containing the following information: Date Pumped Container final pressure Customer Leak test results Container Serial Number Initial fill or recharge Name/initials of person performing the initial fill/recharge procedure Quantity of agent pumped Comments column (See Appendix A.3) 2.1 EQUIPMENT CALIBRATION A program shall be established by the Sales Outlet to assure that testing and measuring equipment used in the production and/or inspection process is kept clean, is maintained in good working order, and in calibration. The following calibration frequencies shall be adhered to at minimum: Scales shall be calibrated at a minimum of once every twelve months. Leak Standard shall be calibrated at a minimum of once every twelve months. Pressure gauges shall be calibrated at a minimum of once every twelve months. Thermometer shall be calibrated at a minimum of once every twelve months. Equipment shall be calibrated when it has been subjected to abuse, such as being dropped or struck with an object or its accuracy is questionable. The sales outlet or an outside laboratory may perform calibration. In either case, it shall be by comparison with a standard that is traceable to the applicable U.S. or foreign National Standard. Certification of calibration shall be maintained by the sales outlet until the next succeeding calibration and shall be readily available. Revision Date: December, 2016 Manual P/N 06-290 (Rev 4) Page: 3 RECHARGE MANUAL 3.0 CONTAINER PREPARATION 3.1 TEST AND INSPECTION Fike clean agent containers shall not be recharged without retest if more than 5 years have elapsed since the date of the last test and inspection. For halocarbon agent containers, the retest shall be permitted to consist of a complete visual inspection as described in the Code of Federal regulations (CFR), Title 49, Section 173.34 (e) (10). The CFR requirements also refer to the Compressed Gas Association (CGA) pamphlet C-6, Section 3. A certified CGA inspector shall perform inspections. Containers that fail to pass the visual inspection shall be subjected to additional strength tests before recharging. NOTE: Transporting charged containers that have not been tested within 5 years could be illegal. Federal and local regulations should be consulted (reference NFPA 2001, Section 4-2.1). 3.2 VALVE RECONDITIONING After a system discharge, the container valve must be reconditioned using the appropriate reload kit before it can be recharged with agent. If the valve is leaking and needs to be reconditioned, the contents of the container must be transferred to another container before reconditioning the valve. WARNING: Container contents are under high pressure. Never attempt to rebuild the container valve until the contents have been transferred and the pressure gauge reads 0 psig (0 kPa). CAUTION: Care should be taken, when handling valve components, to avoid damage of any kind. Do not bend, poke or otherwise distort the valve’s rupture disc as its service may be adversely affected. 3.2.1 1" (25mm) GCA VALVE RECONDITIONING PROCEDURE The 1" (25mm) valve is provided on the 10, 20, 35, 60 and 100 lb (4, 8, 15, 27 and 44 L) containers and requires a Reload Kit (P/N 85-023-1 for HFC-227ea or P/N 85-044-1 for HFC-125) to rebuild the valve. To recondition the 1" valve, refer to Figure 3.2.1 for pictorial clarification and identification of valve parts while performing the following steps: Step 1: Remove 1" adapter nut (Item 2) and baffle plug (Item 1). IMPORTANT: When removing adapter nut on container with 1" threaded valve, use 1" Threaded GCA Wrench (P/N S70-114) to prevent valve from turning. Step 2: CAUTION: Remove 1" valve assembly (Item 3) and O-ring (Item 4). Discard both. Valve assembly has sharp edges. Handle carefully to avoid injury. Step 3: Remove retainer nut (Item 7). Step 4: Remove actuator housing assembly (Item 6) and Teflon washer (Item 5). Discard both. Step 5: Remove pressure gauge and discard. Step 6: Clean all debris from the seating surfaces for the Teflon washer (Item 5) and the O-ring (Item 4) with fine emery cloth, or similar material. Surfaces must be dirt and rust free. Clean all threads and blow out all valve areas with an air gun. Step 7: Coat new Teflon washer (Item 5) with a clear silicon vacuum grease (Molykote 55 or equivalent) and place on new actuator housing assembly (Item 6). Install actuator housing assembly in valve actuator boss. Step 8: Reinstall retainer nut (Item 7) and torque to 90-150 inch-pounds (10-17 N-m). DO NOT OVERTIGHTEN. Revision Date: December, 2016 Manual P/N 06-290 (Rev 4) Page: 4 RECHARGE MANUAL Step 9: Coat new O-ring (Item 4) and valve body seating surface with a light film of clear silicon vacuum grease (Molykote 55 or equivalent). 1 1" (25mm) VALVE ASSEMBLY No. Description 2 Part Number 3 4 SEATING SURFACES 1 Baffle Plug 80-1046 2 Adapter Nut 80-1034 3 Valve Assembly 70-1049 4 "O" Ring 02-1223 5 Teflon Washer 70-1059 6 Actuator Housing Assembly 70-1054 7 Retainer Nut 70-1044 5 6 7 VALVE BODY ACTUATOR BOSS FIGURE 3.2.1 Step 10: Install new O-ring (Item 4) on new valve assembly (Item 3). Install valve assembly (Item 3) in valve body and tighten until it bottoms out. Step 11: Remove and replace valve core (P/N 02-4161) in brass fill valve (not shown). Fill valve is located on the valve body, opposite the pressure gauge. Step 12: Install adapter nut (Item 2) and baffle plug (Item 1). Step 13: Install new pressure gauge (P/N 02-3594 for HFC-227ea or P/N 02-10279 for HFC-125). Apply PTFE thread tape to male threads of gauge before installing. THE CONTAINER IS NOW READY FOR RECHARGING. Revision Date: December, 2016 Manual P/N 06-290 (Rev 4) Page: 5 RECHARGE MANUAL 3.2.2 2.5" (65mm) GCA VALVE RECONDITIONING PROCEDURE The 2.5" (65mm) valve is provided on the 125i and 215i lb (51 and 90 L) containers and requires a Reload Kit (P/N 85-024-1 for HFC-227ea or P/N 85-045-1 for HFC-125) to rebuild the valve. To recondition the 2.5" valve, refer to Figure 3.2.2 for pictorial clarification and identification of valve parts while performing the following steps: Step 1: Remove Victaulic coupling (Item 2) and baffle plate (Item 1) from the valve outlet. Step 2: Remove hold-down nut (Item spanner wrench (P/N 70-1152). Step 3: Remove hold-down ring (Item 4), O-ring (Item 6), and rupture disc (Item 5). Discard O-ring and rupture disc. CAUTION: 3) using left-hand Rupture disc has sharp edges. Handle carefully to avoid injury. Step 4: Remove retainer nut (Item 9). Step 5: Remove actuator housing (Item 8), and Teflon washer (Item 7). Discard both. Step 6: Remove pressure gauge and discard. Step 7: Clean all debris from the seating surfaces for the Teflon washer (Item 7) and the O-ring (Item 6) with a fine emery cloth, or similar material. Surfaces must be dirt and rust free. Clean all threads and blow out all valve areas with an air gun. 2.5" (65mm) VALVE ASSEMBLY No. Description 1 Part Number 2 1 Baffle Plate 70-1123 3 2 Victaulic Coupling, Style #77 02-1376 4 3 Hold-down Nut 70-1094 5 SEATING SURFACES 7 8 6 4 Hold-down Ring 70-1104 5 Rupture Disc D1383-1 6 "O" – Ring 02-1375 7 Teflon Washer 70-1059 8 Actuator Housing Assembly 70-1054 9 Retainer Nut 70-1044 9 VALVE BODY ACTUATOR BOSS FIGURE 3.2.2 Step 8: Coat new Teflon washer (Item 7) with a clear silicon vacuum grease (Molykote 55 or equivalent) and place on new actuator housing assembly (Item 8). Install actuator housing assembly in valve actuator boss. Step 9: Reinstall retainer nut (Item 9) and torque to 90-150 in-lbs (10-17 N-m). DO NOT OVERTIGHTEN. Step 10: Coat new O-ring (Item 6) and valve body seating surface (groove) with a light film of clear silicon vacuum grease (Molykote 55 or equivalent). Install new O-ring into groove. Revision Date: December, 2016 Manual P/N 06-290 (Rev 4) Page: 6 RECHARGE MANUAL Step 11: Install new rupture disc (Item 5) with convex (domed) side up. Install the hold-down ring (Item 4), centered over rupture disc. Step 12: Install hold-down nut (Item 3). Spin hold down nut on and hand tighten. Further tighten with right hand spanner wrench (P/N 70-1153), 1/3 turn minimum. Step 13: Remove and replace valve core (P/N 02-4161) in the brass fill valve (not shown). Fill valve is located on the valve body, opposite the pressure gauge. Step 14: Install baffle plate (Item 1) and Victaulic coupling (Item 2). Step 15: Install new pressure gauge (P/N 02-3594 for HFC-227ea or P/N 02-10279 for HFC-125). Apply PTFE thread tape on male threads of gauge before installing. THE CONTAINER IS NOW READY FOR RECHARGING. 3.2.3 3" (80mm) GCA VALVE RECONDITIONING PROCEDURE The 3" (80mm) valve is provided on the 215, 375, 650 and 1000 lb (90, 153, 267 and 423 L) containers and requires a Reload Kit (P/N 85-024-1 for HFC-227ea or P/N 85-045-1 for HFC-125) to rebuild the valve. To recondition the 3" (80mm) valve, refer to Figure 3.2.3-2 for pictorial clarification and identification of valve parts while performing the following steps: Step 1: Remove Victaulic coupling (Item 2) and baffle plate (Item 1) from the valve outlet. Step 2: Remove hold-down nut (Item 3) using left hand spanner wrench (P/N 70-1152). IMPORTANT NOTE: When removing Hold-down Nut on container with 3" threaded valve, use 3" Threaded GCA Wrench (P/N 02-12734) to prevent valve from turning (see Figure 3.2.3-1). 3” Threaded GCA Wrench Machined Slots (Typical 2) FIGURE 3.2.3-1 Step 3: Remove hold-down ring (Item 4) and disc assembly (Item 5). Discard both. Step 4: Remove siphon tube assembly (Item 7) and O-rings (Item 6). Discard O-rings. Step 5: Remove pressure gauge (P/N 02-10279) and discard. Step 6: Clean all debris from the seating surfaces for the O-ring (Item 6) with a fine emery cloth, or similar material. Surfaces must be dirt and rust free. Clean all threads and blow out all valve areas with an air gun. Step 7: Apply a light film of clear silicone vacuum grease to bottom O-ring (Item 6), groove, and flat seating surface in valve body. Revision Date: December, 2016 Manual P/N 06-290 (Rev 4) Page: 7 RECHARGE MANUAL Step 8: Coat new bottom O-ring (Item 6) and siphon tube seating surface (bottom groove) with a light film of clear silicon vacuum grease (Molykote 55 or equivalent). Install new O-ring into bottom groove and reinstall siphon tube into container making sure it rests squarely on the flat seating surface of the valve. 1 3" (80mm) VALVE ASSEMBLY 2 No. Description 3 Part Number 1 Baffle Plate 70-1294 2 Victaulic Coupling, Style # 77 02-1987 3 Hold-down Nut 70-1323 4 Hold-down Ring 70-1331 5 Disc Assembly 70-1661 6 "O" – Ring 02-2114 7 Siphon Tube Assembly N/A 4 5 6 SEATING SURFACES 7 VALVE BODY FIGURE 3.2.3-2 Step 9: Coat new top O-ring (Item 6) and siphon tube seating surface (top groove) with a light film of clear silicon vacuum grease (Molykote 55 or equivalent). Install new O-ring into top groove. NOTE: Steps 8 and 9 do not apply to 3" Threaded GCA valves. Step 10: Install new disc assembly (Item 5) with convex (domed) rupture disc facing up. Actuator boss on disc assembly must protrude through slot in top of container body. Step 11: Center hold-down nut over top of rupture disc on valve assembly. Spin hold-down nut on hand tight. Further tighten with right hand spanner wrench 1/3 turn minimum, or until it will no longer turn. (Wrench, P/N 70-1153, available from Fike) Step 12: Install new pressure gauge (P/N 02-3594 for HFC-227ea or P/N 02-10279 for HFC-125). Place PTFE thread tape on the male threads of gauge before installing. Step 13: Remove and replace the valve core in the brass fill valve located on the side of the discharge valve. Step 14: Reinstall the baffle plate and grooved coupling. THE CONTAINER IS NOW READY FOR RECHARGING. Revision Date: December, 2016 Manual P/N 06-290 (Rev 4) Page: 8 RECHARGE MANUAL 3.2.4 1" (25mm) & 3" (80mm) IMPULSE VALVE RECONDITIONING PROCEDURE The 1" (25mm) valve is provided on the 5, 10, 20, 35, 60 and 100 lb (2, 4, 8, 15, 27 and 44 L) containers and require Reload Kit P/N 85-047 (for both HFC-227ea and HFC-125) to rebuild the valve. The 3" (80mm) valve is provided on the 150, 150i, 215, 375, 650 and 1000 lb (61, 61i, 88, 153, 267 and 423 L) containers and require Reload Kit P/N 85-048 (for both HFC-227ea & HFC-125) to rebuild the valve. Item No. Description 1" (25mm) Reload Kit (P/N 85-047) includes the following: 3" (80mm) Reload Kit (P/N 85-048) includes the following: Part Number Part Number 1 Friction Ring 70-2060 70-2063 2 Disc Assembly 70-247 70-248 3 O-Ring 02-11987 02-11989 4 Valve Core-Fill Port 02-4161 02-4161 Baffle Plate Victaulic Coupling Hold-down Nut Item 1 – Friction Ring Item 2 – Disc Assembly Item 3 – O-Ring Valve Body Item 4 – Valve Core Item 4 – Valve Core 1" Impulse Valve Revision Date: December, 2016 FIGURE 3.2.4-1 Manual P/N 06-290 (Rev 4) 3" Impulse Valve Page: 9 RECHARGE MANUAL To recondition the 1" or 3" valve, refer to Figure 3.2.4-1 for pictorial clarification and identification of valve parts while performing the following steps: Step 1: Remove Victaulic coupling and baffle plate from the valve outlet (if installed). Step 2: Remove Hold-down nut (Item 3) using spanner wrench (P/N 70-2153-100). IMPORTANT NOTE: When removing Hold-down Nut, use Body Wrench (P/N 02-12682) to stop valve from turning (see Figure 3.2.4-2). Spanner Wrench P/N 70-2153-100 w Body Wrench P/N 02-12682 This side of tools used on 1" Impulse Valve s 3” Impulse Valve FIGURE 3.2.4-2 Step 3: Remove Friction Ring (Item 1), Disc assembly (Item 2), and O-ring (Item 3). Discard all 3 items. Step 4: Reset the Actuation Pin to the set position (see Figure 3.2.4-3). WARNING: Disc can be damaged and rendered inoperable if the actuator pin is NOT pushed in to the set position before installing the disc assembly. Actuator Pin O-Ring Groove in Valve Body Operated Position Set Position FIGURE 3.2.4-3 Step 5: Clean all debris from the seating surfaces for the O-ring (Item 3). Surfaces must be dirt free. Clean all threads and blow out all valve areas with an air gun (see Figure 3.2.4-4). Step 6: Apply a light film of clear silicone vacuum grease (Molykote 55 or equivalent) to O-ring (Item 3), groove, and flat seating surface in valve body. Revision Date: December, 2016 Manual P/N 06-290 (Rev 4) FIGURE 3.2.4-4 Page: 10 RECHARGE MANUAL Step 7: Install new O-ring (Item 3) into bottom groove in valve body. Step 8: Install new Disc assembly (Item 2) with concave (domed) rupture disc facing down. Use the alignment tap to ensure disc assembly is installed correctly (see Figure 3.2.4-5). Alignment Tabs Item 2 Disc Assembly Step 9: Install new Friction ring (Item 1) over top of rupture disc on valve assembly (see Figure 3.2.4-6). IMPORTANT: Friction ring MUST be installed with raised face pointing down on top side of disc assembly. Valve may leak or burst at a lower temperature if friction ring is installed with raised face pointing up. Valve Body FIGURE 3.2.4-5 Friction Ring Friction Ring Raised Face on Friction Ring FIGURE 3.2.4-6 Step 10: Spin Hold-down Nut on hand-tight. Further tighten with spanner wrench 1/3 turn minimum, or until it will no longer turn. (Wrench, P/N 70-2153-100, available from Fike) Step 11 Remove and replace the valve core (Item 4) in the fill port located on the side of the discharge valve. Step 12: Reinstall the baffle plate and grooved coupling. THE CONTAINER IS NOW READY FOR RECHARGING Revision Date: December, 2016 Manual P/N 06-290 (Rev 4) Page: 11 RECHARGE MANUAL 4.0 CONTAINER RECHARGING 4.1 CONTAINER CAPACITY The amount of agent that a vessel or container can safely contain depends upon the volume of the vessel/container, and upon the maximum temperature to which the vessel/container is exposed. For small pressure vessels/containers, DOT (Department of Transportation) regulations require that the vessel/container 3 shall not become liquid-full below 130°F (54.4°C). Since the density of HFC-227ea is approximately 79 lb/ft 3 (1265.6 kg/m ), a maximum quantity of 79 lbs (1265.6 kg) of HFC-227ea can be placed in each cubic foot (cubic 3 3 meter) of container volume and the density of HFC-125 is approximately 75 lb/ft (1189.7 kg/m ), a maximum quantity of 75 lbs (1189.7 kg) of HFC-125 can be placed in each cubic foot (cubic meter) of container volume. 4.2 CONTAINER FILL DENSITY The fill density of a container is defined as the total weight of product, per unit of internal volume of the container. Fike containers for a fill density between: 3 3 3 3 HFC-227ea – 40 lbs/ft to 70 lbs/ft (640 kg/m to 1121 kg/m ) of container volume. 4.3 3 3 3 3 HFC-125 – 25 lbs/ft to 56 lbs/ft (400 kg/m to 896 kg/m ) of container volume. AGENT TRANSFER The transfer of liquid agent from the bulk storage container to a container is accomplished by using a suitable pump approved for use with HFC-227ea and/or HFC-125 (see Section 2.0). The receiving container should be evacuated to eliminate contamination by air and to facilitate transfer of liquid agent. However, evacuation is only practical if evacuation equipment is available within the recharge area. To accelerate the filling process, the following methods can be used: A. Container Chilling – Chilling the container prior to filling facilitates the transfer of agent. This involves placing the container in a cold environment to allow the pressure in the container to be lower than that in the supply container during the transfer process. Packing in ice, immersion in chilled fluids, placement in a freezer or placing outside in cold climates are all suitable methods for chilling the receiving container. WARNING: Below -20°F (-28.9°C), many metals become brittle so caution must be exercised if temperatures of this range, or lower, are anticipated or employed. B. Chilled Transfer Line – This method entails chilling the agent in the transfer line as it flows from the supply container to the receiving container. For example, a coil of copper refrigeration tubing can be placed in the transfer line between the supply and the receiving container and immersed in a cold bath. Revision Date: December, 2016 Manual P/N 06-290 (Rev 4) Page: 12 RECHARGE MANUAL 4.4 RECHARGE (FILL) PROCEDURE The following is the Fike recommended step-by-step procedure for the filling of clean agent containers. Refer to Appendix A for the minimum/maximum fill ranges of Fike clean agent containers: Appendix A.1 for HFC-125 fill ranges Appendix A.2 for HFC-227ea fill ranges NOTE: Containers to be recharged must be rebuilt in accordance with the methods and procedures outlined in Section 3.0 of this manual. CAUTION: Suitable precautions must be taken to prevent contamination of the agent supply when it is transferred from the bulk storage cylinder to the container. Suitable precautions may include any combination of the following: Purging the fill line with nitrogen before it is connected to each container. Using a fill line fitted at the end with a quick-disconnect type fitting connected to the container. If the fill line is kept pressurized up to the quick disconnect fitting, it only need to be purged with nitrogen prior to being connected to the bulk agent storage container. Installing a moisture meter or indicator in the fill line between the bulk agent storage container and the container to monitor the agent. The moisture content of the agent shall not exceed 10 ppm. Wearing of protective equipment such as safety glasses and gloves. 4.4.1 AGENT FILL PROCEDURE – GCA CONTAINERS The steps for filling a Fike GCA container with HFC-227ea or HFC-125 are as follows (see Figure 4.4 for item numbers): Step 1: Inspect container (Item 2) per CGA pamphlet C6 for damage and verify that all container components are in good condition. Leak check container before filling (see Section 5.1). Step 2: Place container (Item 2) on scale (Item 12) and verify tare weight by subtracting baffle plate, Victaulic coupling, and any other material used (e.g. dolly, cart, etc.) from the value indicated on the scale. Enter tare weight in log book (see Appendix A.3). Step 3: Attach the core removal tool (P/N 02-1900) (Item 3) with extractor rod to the brass fill valve on the container. With the core removal tool (Item 3) valve open completely, push extractor rod in and engage the core. Turn the extractor rod counterclockwise to unscrew the core. Pull the extractor rod back as far as possible. Close core removal tool (Item 3) valve completely. Remove the extractor rod and save core for reinsertion. Step 4: Ensure that the 1/4 turn ball valve (Item 14), used for pressure bleed off, is closed. Step 5: Attach fill hose to the core removal tool (Item 3) and open the valve on the core removal tool. Step 6: Note weight of container with core removal tool (Item 3) and fill hose attached. Step 7: Calculate final gross weight by adding the weight determined in Step 6, to the amount of agent required, or zero out scale if feature is available. Step 8: Open shutoff valve(s) (Item 4) on bulk storage tank (Item 10) to allow flow to pump (Item 5). Step 9: Open main valve (Item 1) on fill line. Step 10: Turn on pump (Item 5) to begin filling. Step 11: Turn off pump (Item 5) when scale (Item 12) indicates the calculated weight in Step 7, or when zeroed out scale reaches agent weight. CAUTION: Small containers will fill very rapidly. DO NOT fill containers beyond their rated capacities. Refer to Appendix A for the minimum/maximum fill ranges of Fike clean agent containers. Revision Date: December, 2016 Manual P/N 06-290 (Rev 4) Page: 13 RECHARGE MANUAL Step 12: Turn off main valve in fill line (Item 1) and close core removal tool valve (Item 3). Step 13: Open 1/4 turn ball valve (Item 14) to remove pressure from core removal tool. Step 14: Disconnect fill hose from core removal tool (Item 3). Step 15: Place valve core on end of extractor rod. Step 16: Attach extractor rod to core removal tool (Item 3). Step 17: Open valve on core removal tool (Item 3). Step 18: Push in extractor rod and screw valve core into valve body clockwise. DO NOT OVERTIGHTEN. Step 19: Remove extractor rod from core removal tool (Item 3). Step 20: Remove core removal tool (Item 3) from brass fill valve. Step 21: Replace brass fill valve cap. Step 22: Etch or stamp final information onto container label, if applicable. See Section 6.0. Step 22: Enter information in log book. NOTE: It is recommended that a running total log be maintained documenting the quantity of agent removed from the bulk supply container. See Appendix A.3 for Log Sheet example. WARNING: If the valve core has been removed for filling, it must be re-installed before disconnecting the fill line. Failure to do so can result in serious injury to personnel as well as loss of agent. Revision Date: December, 2016 Manual P/N 06-290 (Rev 4) Page: 14 RECHARGE MANUAL 13 12 3 14 10 7 6 4 SCALE 16 15 1 8 9 5 2 11 IN OUT FIGURE 4.4 TYPICAL FILL STATION ARRANGEMENT Item Description 1 Shutoff Valve, Agent Fill Valve 2 Fike Storage Container 3 Recharge Adapter / Valve Core Removal Tool 4 Bulk Agent Tank Shutoff Valve 5 Agent Pump 6 Bypass/Vapor Return (Set at 40 psig / 276 kPa) 7 Pressure Gauge, Agent Fill Line 8 Pressure Gauge, Nitrogen Fill Line 9 Pressure Regulator, Nitrogen Fill Line 10 Bulk Agent Tank 11 Dry Nitrogen Container 12 Scale (2000 lb./900 kg) Minimum 13 Hoist (2000 lb./ 900 kg) Minimum 14 1/4 Turn Ball Valve 15 3 Port Ball Valve 16 Core Depressor Tool Revision Date: December, 2016 Manual P/N 06-290 (Rev 4) Page: 15 RECHARGE MANUAL 4.4.2 NITROGEN SUPER-PRESSURIZATION PROCEDURE – GCA CONTAINERS The following is the Fike recommended step-by-step procedure for super-pressurizing Fike clean agent containers with a GCA operated valve. Containers must be super-pressurized with nitrogen, which is the propellant for the agent. In order to do this properly, the nitrogen must be thoroughly mixed with the agent. Differences in the containers cause nitrogen to be introduced differently. The small 10, 20, 35, 60 and 100 lb (4, 8, 15, 27 and 44 L) containers can be pressurized in the upright position, then agitated or shaken to adequately mix the agent and the nitrogen gas. They contain a fixed siphon / pickup tube and a brass fill valve. The fill valve located on the side of the container valve assembly, discharges directly into the pickup tube and directs the flow of nitrogen down the tube and up, through the liquid agent. This action allows the nitrogen gas to be absorbed into the agent, completing the super-pressurization process. The inverted 125i and 215i lb (51 and 90 L) containers do not contain a siphon / pickup tube and must be pressurized in the “valve down” position. These containers can be agitated, as well, but doing so can be a difficult task. The action of the nitrogen “bubbling” through the liquid agent is generally sufficient to complete the superpressurization process. The large 215, 375, 650 and 1000 lb (87, 153, 267 and 423 L) containers must be inverted to super-pressurize them with nitrogen. These containers have a siphon tube, but the fill valve is not attached. The nitrogen “bubbling” through the liquid is absorbed by the agent. IMPORTANT: All containers with threaded GCA valves can be super-pressurized in the upright position because the nitrogen is introduced directly in the siphon tube. For all containers, care must be taken to observe the container pressure gauge during this process, as the agitation will cause the absorption of the nitrogen gas thereby reducing the container pressure. Continue to supply nitrogen into the container and agitating until the container pressure stabilizes at 360 psi at 70°F (2482 kPa at 21°C). CAUTION: Appropriate safeguards MUST be taken to avoid over-pressurization of the container(s), as well as avoiding nitrogen contact with skin. Only dry nitrogen, as described in Section 2.0, of this procedure may be used. Step 1: Invert container if necessary. Fike’s 10, 20, 35, 60 and 100 lb containers must be filled with the valve outlet upright. All other containers with welded valves are filled with the valve outlet down. Containers should be inverted to no less than a 30° angle (see Figure 4.5). NOTE: Placing a large piece of cardboard, carpet or rubber matting on the floor before inverting the large clean agent container(s) will help avoid damage to the container’s surface. Step 2: Remove fill valve cap. Step 3: Close bleed valve (Item 15) in nitrogen line. Step 4: Attach core depressor tool (P/N 02-2031) (Item 16) to fill valve on neck of cylinder. Step 5: Depress fill valve core by turning knob on core depressor tool (Item 16) clockwise. Step 6: Open pressure regulator valve (Item 9). CAUTION: Step 7: Do not leave cylinder unattended while pressurizing. Periodically check pressure on gauge (Item 8) as pressurizing. Revision Date: December, 2016 Manual P/N 06-290 (Rev 4) Page: 16 RECHARGE MANUAL NOTE: The gauge installed on the clean agent container, or the gauge on the nitrogen regulator, should not be used to determine the clean agent container charging pressure. The 0-600 psi (0-4137 kPa) test gauge, installed between the nitrogen pressure regulator and the container being charged, shall be used to determine the container charging pressure (see Figure 4.4). Step 8: Pressurize container to appropriate level. See Appendix A. Step 9: Agitate container to mix nitrogen. NOTE: Nitrogen is soluble in clean agent. Therefore, nitrogen will “settle” or mix with the agent over a short period of time. This time frame can be reduced by agitating the container, whenever possible, or “bubbling” the nitrogen gas upward through the liquid agent. Over-pressurizing the container to compensate for nitrogen settlement is not recommended. Step 10: Close pressure regulator valve (Item 9). Step 11: Release valve core by turning knob on core depressor tool (Item 16) counter-clockwise. Step 12: Open bleed valve (Item 15) in nitrogen line. Step 13: Remove core depressor tool (Item 16) from fill valve. Step 14: Replace fill valve cap. Step 15: If container is inverted, carefully turn container upright. STRUCTURAL BEAM HOIST DRY NITROGEN CYLINDER NITROGEN FILL LINE FIKE STORAGE CONTAINER 30° MIN. FILL ADAPTER CARPET, CARDBOARD, OR RUBBER MAT. FLOOR SURFACE FIGURE 4.5 TYPICAL LARGE CAPACITY CONTAINER PRESSURIZATION ARRANGEMENT Revision Date: December, 2016 Manual P/N 06-290 (Rev 4) Page: 17 RECHARGE MANUAL 4.4.3 AGENT FILL PROCEDURE – IMPULSE VALVE CONTAINERS The steps for filling a Fike Impulse Valve container with HFC-227ea or HFC-125 are as follows (see Figure 4.4 for item numbers): Step 1: Inspect container (Item 2) per CGA pamphlet C6 for damage and verify that all container components are in good condition. Leak check container before filling (see Section 5.1). Step 2: Place container (Item 2) on scale (Item 12) and verify tare weight by subtracting baffle plate, Victaulic coupling, and any other material used (e.g. dolly, cart, etc.) from the value indicated on the scale. Enter tare weight in log book (see Appendix A.3). Step 3: Attach the core removal tool (P/N 70-282) (Item 3) with extractor rod to the brass fill valve on the container. With the core removal tool (Item 3) valve open completely, push extractor rod in and engage the core. Turn the extractor rod counter clockwise to unscrew the core. Pull the extractor rod back as far as possible. Close core removal tool (Item 3) valve completely. Remove the extractor rod and save core for reinsertion. Step 4: Ensure that the 1/4 turn ball valve (Item 14), used for pressure bleed off, is closed. Step 5: Attach fill hose to the core removal tool (Item 3) and open the valve on the core removal tool. Step 6: Note weight of container with core removal tool (Item 3) and fill hose attached. Step 7: Calculate final gross weight by adding the weight determined in Step 6, to the amount of agent required, or zero out scale if feature is available. Step 8: Open shutoff valve(s) (Item 4) on bulk storage tank (Item 10) to allow flow to pump (Item 5). Step 9: Open main valve (Item 1) on fill line. Step 10: Turn on pump (Item 5) to begin filling. Step 11: Turn off pump (Item 5) when scale (Item 12) indicates the calculated weight in Step 7, or when zeroed out scale reaches agent weight. CAUTION: Small containers will fill very rapidly. DO NOT fill containers beyond their rated capacities. See Appendix A.1, for container minimum/maximum fill ranges. Step 12: Turn off main valve in fill line (Item 1) and close core removal tool valve (Item 3). Step 13: Open 1/4 turn ball valve (Item 14) to remove pressure from core removal tool. Step 14: Disconnect fill hose from core removal tool (Item 3). Step 15: Place valve core on end of extractor rod. Step 16: Attach extractor rod to core removal tool (Item 3). Step 17: Slowly open valve on core removal tool (Item 3). Step 18: Push in extractor rod and screw valve core into valve body clockwise. DO NOT OVERTIGHTEN. Step 19: Remove extractor rod from core removal tool (Item 3). A small amount of pressure will be released. Step 20: Remove core removal tool (Item 3) from brass fill valve. Step 21: Replace brass fill valve cap. Step 22: Etch or stamp final information onto container label, if applicable. See Section 6.0. Step 23: Enter information in log book. NOTE: It is recommended that a running total log be maintained documenting the quantity of agent removed from the bulk supply container. See Appendix A.3 for Log Sheet example. Revision Date: December, 2016 Manual P/N 06-290 (Rev 4) Page: 18 RECHARGE MANUAL 4.4.4 NITROGEN SUPER-PRESSURIZATION PROCEDURE – IMPULSE VALVE CONTAINERS The following is the Fike recommended step-by-step procedure for super-pressurizing Fike clean agent containers with an Impulse Valve. Containers must be super-pressurized with nitrogen, which is the propellant for the agent. In order to do this properly, the nitrogen must be thoroughly mixed with the agent. Differences in the containers cause nitrogen to be introduced differently. All containers (except 150i) can be pressurized in the upright position, then agitated or shaken to adequately mix the agent and the nitrogen gas. They contain a fixed siphon / pickup tube and a fill port. The fill valve located on the side of the container valve assembly, discharges directly into the pickup tube and directs the flow of nitrogen down the tube and up through the liquid agent. This action allows the nitrogen gas to be absorbed into the agent, completing the super-pressurization process. The inverted 150i lb (60 L) container does not contain a siphon / pickup tube and must be pressurized in the “valve down” position. This container can be agitated as well, but doing so can be a difficult task. The action of the nitrogen “bubbling” through the liquid agent is generally sufficient to complete the super-pressurization process. Care must be taken to observe the nitrogen pressure gauge during this process, as the agitation will cause the absorption of the nitrogen gas thereby reducing the container pressure. Continue to supply nitrogen into the container and agitating until the container pressure stabilizes at 360 psi at 70°F (2482 kPa at 21°C). CAUTION: Appropriate safeguards MUST be taken to avoid over-pressurization of the containers, as well as avoiding nitrogen contact with skin. Only dry nitrogen as described in Section 2.0 may be used. Super-pressurize containers using the following steps (see Figure 4.4 for item numbers): Step 1: Invert 150i container (valve outlet down) before filling. Containers should be inverted to no less than a 30° angle (see Figure 4.5). All other containers must be filled with the valve outlet upright. NOTE: Placing a large piece of cardboard, carpet, or rubber matting on the floor before inverting the container(s) this will help avoid damage to the container’s surface. Step 2: Remove brass plug on the container fill port. Step 3: Close bleed valve (Item 15) in nitrogen line. Step 4: Attach core depressor tool (P/N 70-281) (Item 16) with ball valve closed, to fill valve port on Impulse Valve of container. Step 5: Thread in until core depressor tool (Item 16) bottoms out. Step 6: Attach nitrogen line to core depressor tool (Item 16). Step 7: Open pressure regulator valve (Item 9), bleed valve (Item 15) and core depressor tool (Item 16). CAUTION: Do not leave container unattended while pressurizing. Step 8: Periodically check pressure on gauge (Item 8) while pressurizing. NOTE: The gauge installed on the clean agent container, or the gauge on the nitrogen regulator, should not be used to determine the clean agent container charging pressure. The 0-600 psi (0-4137 kPa) test gauge, installed between the nitrogen pressure regulator and the container being charged, shall be used to determine the container charging pressure. Step 9: Pressurize container to appropriate level. See Appendix A. NOTE: Nitrogen is soluble in clean agent. Therefore, nitrogen will “settle” or mix with the agent over a short period of time. This time frame can be reduced by agitating the container, whenever possible, or “bubbling” the nitrogen gas upward through the liquid agent. Revision Date: December, 2016 Manual P/N 06-290 (Rev 4) Page: 19 RECHARGE MANUAL Step 10: Close pressure regulator valve (Item 9). Step 11: Close core depressor tool (Item 16) by turning handle counter clockwise. Step 12: Open bleed valve (Item 15) in nitrogen line. Step 13: Remove core depressor tool (Item 16) from fill port. There will be a popping sound when removing from fill port. Step 14: Replace brass plug into fill port. Step 15: If container is inverted, carefully turn container upright. 5.0 LEAK DETECTION After the container has been filled with the required quantity of agent and super-pressurized with nitrogen, it must be carefully checked for leaks. All potential leak points must be carefully inspected with a leak detector (see Section 2.0). The leak detector MUST be checked against a leak standard (see Section 2.0) prior to each use and after every five units tested or every half-hour, whichever comes first. For calibration purposes, the leak standard shall be set to the minimum leakage rate for the specific container being filled. Refer to Section 5.1 for details on calibrating and using the leak detector and maximum leak rates per container. 5.1 LEAK TESTING PROCEDURE The following is the Fike recommended step-by-step procedure for leak testing all recharged clean agent containers. This procedure is based on the use of the D-TEK Refrigerant Leak Detector and the LS-20 Leak Standard for the specific clean agent. Although the procedure should be virtually the same for any other brand of leak detector, the manufacturer’s manual should be consulted for operating details. NOTE: See Table 5.1 for the maximum allowable leakage rates for clean agent containers. To perform a leak test on a clean agent container, proceed as follows: Step 1: Turn on the leak detector unit and allow it to stabilize for a minimum of 5 minutes prior to conducting any leak testing. Step 2: Allow the leak standard to condition at a temperature of 70°F ± 10°F (21°C ± 12°C), while set at the maximum leak rate, for a minimum of 5 minutes prior to calibrating the leak detector. Step 3: After the initial warm-up period, set the leak standard to the maximum allowable leak rate for the size container being checked. Table 5.1 details the maximum leakage rate allowed for each container size. If the maximum leak rate for the container exceeds the maximum leak rate for the leak standard, use the maximum rate of the leak standard. Step 4: Use the leak standard to calibrate the leak detector to the required leak rate for the clean agent container being tested. This is done by slowly passing the leak detector probe past the leak capillary and adjusting the leak detector balance knob until the leak detector responds to the appropriate setting. Refer to the manufacturer’s manual for detector calibration directions. Step 5: Slowly check all openings, seams, weld joints and container components (i.e. pressure gauge, fill valve, low pressure switch, liquid level device, etc.). The inspection area should be well ventilated and separate from the fill station area, preferably in a positive pressure room. Step 6: If a leak is detected, it is recommended that the container be blown off with an air gun or dry nitrogen to remove any possible “pockets” of agent that may have accumulated during the fill process. Then retest the container for leakage. Step 7: Containers that have NO indication of leakage are acceptable for shipment and system use. Step 8: Record container acceptance date, any comments or remarks, and the inspector’s initials in the fill station logbook. Step 9: Containers that have an unacceptable leakage rate shall be emptied, inspected, and repaired or rebuilt in accordance with the procedures outlined in Section 3.0 of this manual and in the appropriate Fike Design, Installation and Maintenance Manual. Revision Date: December, 2016 Manual P/N 06-290 (Rev 4) Page: 20 RECHARGE MANUAL TABLE 5.1 – MAXIMUM LEAK RATES, HFC-227ea AND HFC-125 6.0 DOT Container Size Maximum Leak Rate oz/year (g/year) 5 – 20 lb (2 – 8.5 L) 0.09 (2.5) 35 lb (15 L) 0.30 (8.5) 60 – 1000 lb (27 – 423 L) 0.50 (14.2) EN Container Size Maximum Leak Rate oz/year (g/year) 5–9L 0.10 (2.8) 16 L 0.30 (8.5) 26 – 150 L 0.50 (14.2) CONTAINER IDENTIFICATION Upon completion of the previous procedures and if applicable, stamp or etch using a permanent marker the following information onto the container identification label in the appropriate spaces (see Figure 6.0): Fill station code number assigned by Fike Container gross weight (agent weight + tare weight + nitrogen weight) Agent (HFC-227ea or HFC-125) weight added to container The following information shall be stamped or etched on the container identification label by Fike personnel before the container is shipped from the factory: Container assembly number (e.g. 70-156) Container serial number (assigned by Fike) Container tare weight (weight of container when empty) Manufactured date (date container was filled) An X in the “Container Shipment Vertical Only” box only if the container cannot be shipped in the horizontal (lying down) position. Fill Station Code Number FPS-XXXX FIGURE 6.0 – CONTAINER IDENTIFICATION LABEL Revision Date: December, 2016 Manual P/N 06-290 (Rev 4) Page: 21 RECHARGE MANUAL APPENDIX A – SUPPORT INFORMATION This appendix contains tables and charts, which were referred to throughout this manual. A.1 HFC-125 INFORMATION A.1.1 CYLINDER FILL RANGE TABLE GCA CONTAINER DATA TABLE – HFC-125 Container Fill Range Tare Weight DOT Specification Minimum Maximum lb (L) Part Number Valve Size lbs (kg) lbs (kg) in (mm) lbs (kg) 10 (4) 70-108 4BA500 4 (2.0) 8 (3.5) 1 (25) 15 (6.8) 20 (8.5) 70-098 4BA500 8 (3.5) 16 (7.5) 1 (25) 21 (9.5) 35 (15) 70-089 4BA500 14 (6.5) 30 (13.5) 1 (25) 31 (14.1) 60 (27) 70-152 4BW500 25 (11.5) 54 (24.5) 1 (25) 52 (23.6) 100 (44) 70-153 4BW500 39 (18.0) 87 (39.0) 1 (25) 77 (34.9) 125i (51) 70-041 4BA500 46 (21.0) 120 (46.0) 2.5 (65) 141 (64.0) 215i (90) 70-077 4BA500 80 (36.5) 178 (81.0) 2.5 (65) 200 (90.7) 215 (88) 70-154 4BW500 136 (61.5) 302 (137.0) 3 (80) 225 (102.1) 375 (153) 70-155 4BW500 136 (61.5) 302 (137.0) 3 (80) 225 (102.1) 650 (267) 70-156 4BW500 236 (107.0) 528 (239.5) 3 (80) 385 (174.6) 1000 (423) 70-157 4BW500 374 (169.5) 836 (379.5) 3 (80) 550 (249.5) Size IMPULSE VALVE, DOT CONTAINER DATA TABLE – HFC-125 Container Size Fill Range Minimum Maximum Valve Size Tare Weight lbs (kg) lbs (kg) in (mm) lbs (kg) 1 (25) 11 (5.0) lb (L) Part Number DOT Specification 5 (2) 70-272 3AA2015 10 (4) 70-273 3AA2015 4 (2.0) 8 (3.5) 1 (25) 15 (6.8) 20 (8.5) 70-263 4BW500 8 (3.5) 16 (7.5) 1 (25) 21 (9.5) 35 (15) 70-264 4BW500 14 (6.5) 30 (13.5) 1 (25) 31 (14.1) 60 (27) 70-265 4BW500 25 (11.5) 54 (24.5) 1 (25) 52 (23.6) 100 (44) 70-266 4BW500 39 (18.0) 87 (39.0) 1 (25) 77 (34.9) 150 / 150i (61) 70-267 4BW500 54 (24.5) 120 (54.5) 3 (80) 150 (68.0) 215 (88) 70-268 4BW500 78 (35.5) 173 (78.5) 3 (80) 155 (70.3) 375 (153) 70-269 4BW500 136 (61.5) 302 (137.0) 3 (80) 225 (102.1) 650 (267) 70-270 4BW500 236 (107.0) 528 (239.5) 3 (80) 385 (174.6) 1000 (423) 70-271 4BW500 374 (169.5) 836 (379.5) 3 (80) 550 (249.5) Revision Date: December, 2016 4 (2.0) Manual P/N 06-290 (Rev 4) Page: 22 RECHARGE MANUAL IMPULSE VALVE, EN CONTAINER DATA TABLE – HFC-125 Container Fill Range Container Approval Minimum Maximum (L) Part Number Valve Size (kg) (kg) in. (mm) (kg) 5 70-348 EN-1964 2.5 4.0 1 (25) 11 9 70-349 EN-1964 4.0 7.0 1 (25) 13 16 70-350 EN-1964 6.5 12.5 1 (25) 16 26 70-278 EN-1964 10.5 20.5 1 (25) 23 45 70-255 EN-1964 18.5 36.0 1 (25) 35 83 70-256 EN-1964 33.5 66.0 3 (80) 62 150 70-257 EN-1964 60.5 120.0 3 (80) 82 Size A.1.2 NOTE: A.1.3 NOTE: Tare Weight PRESSURE / TEMPERATURE TABLE – HFC-125 CONTAINERS The pressures shown do not vary with fill density. The pressure versus temperature curve for HFC3 3 3 3 125, at fill densities between 25 lbs/ft to 56 lbs/ft (400 kg/m to 896 kg/m ), is a straight line for temperatures less than 120°F (49°C). Temperature °F / °C Pressure psig / kPa 32 / 0 261 / 1800 40 / 4 279 / 1924 50 / 10 303 / 2089 60 / 16 330 / 2275 70 / 21 360 / 2482 80 / 27 393 / 2710 90 / 32 428 / 2951 100 / 38 466 / 3213 110 / 43 507 / 3496 120 / 49 551 / 3800 APPROX. NITROGEN WEIGHT ADDED TO A CONTAINER TO REACH 360 PSIG – HFC-125 Fill Density 3 3 lb/ft (kg/m ) Amount of Nitrogen per lb of HFC-125 oz (g) 25 (400) 0.424 (12.0) 30 (481) 0.395 (11.2) 35 (561) 0.365 (10.4) 40 (641) 0.346 (9.8) 45 (721) 0.303 (8.6) 50 (801) 0.269 (7.2) These nitrogen weights are approximate. The final check should always be the pressure gauge reading 360 psi at 70°F (2482 kPa at 21°C). Revision Date: December, 2016 Manual P/N 06-290 (Rev 4) Page: 23 RECHARGE MANUAL A.2 HFC-227ea INFORMATION A.2.1 CONTAINER FILL RANGES GCA CONTAINER DATA TABLE– HFC-227ea Container Fill Range DOT Specification Minimum Maximum lb (L) Part Number Valve Size lbs (kg) lbs (kg) in (mm) lbs (kg) 10 (4.5) 70-108 4BA500 6 (3.0) 10 (4.5) 1 (25) 15 (6.8) 20 (8.5) 70-098 4BA500 12 (5.5) 21 (9.5) 1 (25) 21 (9.5) 35 (16) 70-089 4BA500 22 (10.0) 38 (17.0) 1 (25) 31 (14.1) 60 (27) 70-152 4BW500 39 (18.0) 68 (30.5) 1 (25) 52 (23.6) 100 (45) 70-153 4BW500 63 (28.5) 108 (48.5) 1 (25) 77 (34.9) 125i (51) 70-041 4BW500 73 (33.5) 126 (57.0) 2.5 (65) 141 (64.0) 215i (90) 70-077 4BW500 128 (58.5) 223 (101.0) 2.5 (65) 200 (90.7) 215 (97.5) 70-154 4BW500 124 (56.5) 216 (98.0) 3 (80) 155 (70.3) 375 (170) 70-155 4BW500 217 (98.5) 378 (171.5) 3 (80) 225 (102.1) 650 (295) 70-156 4BW500 378 (171.5) 660 (299.0) 3 (80) 370 (167.8) 1000 (454) 70-157 4BW500 598 (271.5) 1045 (474.0) 3 (80) 520 (235.9) 60 (27) 70-022 4BA500 37 (17.0) 64 (29.0) 1 (25) 80 (36.3) 100 (45) 70-088 4BA500 58 (26.5) 100 (45.0) 1 (25) 90 (40.8) 215 (97.5) 70-087 4BA500 123 (56.0) 215 (97.5) 3 (80) 285 (129.3) 375 (170) 70-086 4BA500 215 (97.5) 375 (170.0) 3 (80) 375 (170.1) 650 (295) 20" Dia. 70-083 4BA500 372 (169.0) 650 (294.5) 3 (80) 455 (206.4) 650 (295) 24" Dia. 70-083a 4BA500 372 (169.0) 650 (294.5) 3 (80) 430 (195.1) 1000 (454) 70-090 4BA500 573 (260) 1002 (454.5) 3 (80) 673 (305.3) Size Revision Date: December, 2016 Manual P/N 06-290 (Rev 4) Tare Weight Page: 24 RECHARGE MANUAL IMPULSE VALVE / DOT CONTAINER DATA TABLE– HFC-227ea Container Size Fill Range Maximum Valve Size Tare Weight lb (L) Part Number DOT Specification Minimum lbs (kg) lbs (kg) in (mm) lbs (kg) 5 (2) 70-272 3AA2015 4 (2.0) 5 (2.0) 1 (25) 11 (5.0) 10 (4) 70-273 3AA2015 6 (3.0) 10 (4.5) 1 (25) 15 (6.8) 20 (8.5) 70-263 4BW500 12 (5.5) 21 (9.5) 1 (25) 21 (9.5) 35 (15) 70-264 4BW500 22 (10.0) 38 (17.0) 1 (25) 31 (14.1) 60 (27) 70-265 4BW500 39 (18.0) 68 (30.5) 1 (25) 52 (23.6) 100 (44) 70-266 4BW500 63 (28.5) 108 (49.0) 1 (25) 77 (34.9) 150 / 150i (61) 70-267 4BW500 87 (39.5) 150 (68.0) 3 (80) 150 (68.0) 215 (88) 70-268 4BW500 124 (56.5) 216 (98.0) 3 (80) 155 (70.3) 375 (153) 70-269 4BW500 217 (98.5) 378 (171.5) 3 (80) 225 (102.1) 650 (267) 70-270 4BW500 378 (171.5) 660 (299.0) 3 (80) 385 (174.6) 1000 (423) 70-271 4BW500 598 (271.5) 1045 (474.0) 3 (80) 550 (249.5) IMPULSE VALVE / EN CONTAINER DATA TABLE– HFC-227ea Container Size Fill Range Maximum Valve Size Tare Weight L Part Number Container Approval Minimum kg kg in (mm) kg 5 70-348 EN-1964 3.5 5.5 1 (25) 11 9 70-349 EN-1964 6.0 10.0 1 (25) 13 16 70-350 EN-1964 10.5 17.5 1 (25) 16 26 70-278 EN-1964 17.0 29.0 1 (25) 23 45 70-255 EN-1964 29.0 50.0 1 (25) 35 83 70-256 EN-1964 53.5 93.0 3 (80) 62 150 70-257 EN-1964 96.5 168.0 3 (80) 82 Revision Date: December, 2016 Manual P/N 06-290 (Rev 4) Page: 25 RECHARGE MANUAL A.2.2 NOTE: A.2.3 NOTE: PRESSURE/TEMPERATURE TABLE – HFC-227ea CONTAINERS Temperature °F / °C Pressure psig / kPa 30 / 1.11 284 / 1958 40 / 4.44 303 / 2089 50 / 10.0 321 / 2213 60 / 15.5 340 / 2344 70 / 21.1 360 / 2482 80 / 26.7 381 / 2627 90 / 32.2 402 / 2772 100 / 37.8 425 / 2938 110 / 43.3 449 / 3096 120 / 48.9 475 / 3275 130 / 54.4 502 / 3461 The pressures shown do not vary with fill density. The pressure versus temperature curve for HFC3 3 3 3 227ea, at fill densities between 40 lb/ft and 70 lb/ft (640 kg/m and 1121k/m ), is a straight line for temperatures less than 130°F (54.4°C). APPROX. NITROGEN WEIGHT ADDED TO A CONTAINER TO REACH 360 PSIG – HFC-227ea Fill Density 3 3 lb/ft (kg/m ) Amount of Nitrogen per lb of HFC-227ea oz (g) 40 (641) 0.534 (15.1) 45 (721) 0.463 (13.1) 50 (801) 0.407 (11.5) 55 (881) 0.361 (10.2) 60 (961) 0.323 (9.2) 65 (1041) 0.291 (8.2) 70 (1121) 0.263 (7.5) These nitrogen weights are approximate. The final check should always be the pressure gauge reading 360 psi at 70°F (2482 kPa at 21°C). Revision Date: December, 2016 Manual P/N 06-290 (Rev 4) Page: 26 RECHARGE MANUAL A.3 SAMPLE LOG BOOK – ENGLISH & METRIC ENTRIES Cylinder Serial No Customer Date Initial or Recharge Agent Fill Wt. Pressure (psi/kPa) Leak TestPass/Fail 375-1000 Chrysler 6/20/99 Initial 370 lbs. 360 Pass 650-1103 KAF Mfg. Co. 7/13/99 Recharge 598 lbs. 360 Pass 60-1571 ABCO Co. 8/2/99 Recharge 57 lbs. 360 Pass 100-1233 Sprint 1/13/00 Initial 100 lbs. 360 Pass 1000-1234 Kolten Corp. 1/13/00 Initial 975 lbs. 360 Pass 375-1000 Chrysler 6/20/99 Initial 168.0 kg 2482 Pass 650-1103 KAF Mfg. Co. 7/13/99 Recharge 271.5 kg 2482 Pass 60-1571 ABCO Co. 8/2/99 Recharge 26.0 kg 2482 Pass 100-1233 Sprint 1/13/00 Initial 45.5 kg 2482 Pass 1000-1234 Kolten Corp. 1/13/00 Initial 442.5 kg 2842 Pass Revision Date: December, 2016 Manual P/N 06-290 (Rev 4) Comments Page: 27 RECHARGE MANUAL APPENDIX B – REFERENCED AND CONTRIBUTING PUBLICATIONS This appendix lists the publications, which were used for a basis for, or substantiation of, the data and procedures contained in this manual. B.1 NFPA PUBLICATION National Fire Protection Association, 1 Batterymarch Park, P.O. Box 9101, Quincy, MA 02269-9101 B.2 B.3 B.4 B.5 NFPA No. 2001 – Standard on Clean Agent Fire Extinguishing Systems – Current Edition U.S. GOVERNMENT PUBLICATION Superintendent of Documents, U.S. Government Printing Office, Washington, DC 20401 Title 29, Code of Federal Regulations, Part 1910, Subpart “S” DOT Title 49, Code of Federal Regulations, Parts 170 – 190 Federal Register, Volume 59, Page 13044, EPA SNAP Program CGA PUBLICATION Compressed Gas Association, 1235 Jefferson Davis Highway, Arlington, VA 22202 Pamphlet C-6, Standard for the Visual Inspection of Steel Compressed Gas Cylinders Pamphlet G10.1, Table 1 – Quality of nitrogen Supplies FIKE PUBLICATION Fike Corporation, 704 S. 10th Street, P.O. Box 610, Blue Springs, MO 64013 P/N 06-215 – Design, Installation, and Maintenance Manual for HFC-227ea Clean Agent Extinguishing Systems P/N 06-433 – Equipment, Design and Service Manual for Clean Agent Fire System w/ Impulse Valve & HFC-227ea Agent P/N 06-285 – Design, Installation, and Maintenance Manual for HFC-125 Clean Agent Extinguishing Systems P/N 06-431 – ECARO-25 Equipment, Design and Service Manual for Clean Agent Fire System w/ Impulse Valve & HFC-125 Agent MISC. PUBLICATION Several other sources of publications and information used in the preparation of this manual follow: B.6 FM-200™ – Properties, Uses, Storage & Handling, DuPont Fluoroproducts, Chestnut Run Plaza 7021274E, P.O. Box 80702, Wilmington, DE 19880-0702, 1-800-473-7790, www.chemours.com FE-25™ – Properties, Uses, Storage & Handling, DuPont Fluoroproducts, Chestnut Run Plaza 7021274E, P.O. Box 80702, Wilmington, DE 19880-0702, 1-800-473-7790, www.chemours.com Yokogawa H-10 Pro Refrigerant Leak Detector and Model LS-20 Leak Standard, Central States Consulting Company, 109 Lynn Drive, Battle Creek, MI 49017, 1-800-272-7022 D-TEK Refrigerant Leak Detector, Leybold Inficon Inc., 2 Technology Place, East Syracuse, NY 13057 SAFETY DATA SHEETS (SDS) FM-200™ – SDS, The Chemours Company, 1-844-773-2436, www.chemours.com MH227 – SDS, Waysmos USA Inc., 646-593-8882, www.waysmosusa.com FE-25™ – SDS, The Chemours Company, 1-844-773-2436, www.chemours.com Nitrogen, Compressed – SDS, Praxair Inc., 1-800-772-9247, www.praxair.com ® Revision Date: December, 2016 Manual P/N 06-290 (Rev 4) Page: 28 th 704 SW 10 Street P.O. Box 610 Blue Springs, Missouri 64013 Tel: (816) 229-3405 Fax: (816) 229-0314 www.fike.com
