THE PURPOSE OF THIS MANUAL

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2 THE PURPOSE OF THIS MANUAL This manual is intended for use with models of AMEREX Vehicle Fire Suppression and Overheat Warning Systems that are equipped with plugable modular wiring components. These are referred to as Modular Systems throughout this manual It is intended for use as a reference manual and does not take the place of AMEREX factory training. This manual must be used in conjunction with NFPA Standard No. 17, Dry Chemical Extinguishing Systems, as well as all other standards deemed applicable to an installation by local authorities having jurisdiction. Individuals who design, install, operate, inspect, recharge or maintain these systems shall read this entire manual. It is the responsibility of the installer of these systems to make certain that the owner of the equipment on which these systems are installed receives and reads the Owner s Manual which is packaged with each agent cylinder. As with all electrical and mechanical equipment, all AMEREX systems require periodic care to provide maximum assurance that they will operate effectively and safely. Inspection frequency should be based on the requirements of the equipment on which the system is installed and the environment in which the equipment will operate. Inspection and maintenance schedules are shown in this manual and must be followed to insure reliable system performance. Equipment operating continually and/or in harsh environments will require more frequent inspection and maintenance. You will receive additional and updated pages for this manual as they are published. It is important that these changes and additions be added to this manual according to the instructions that will accompany them. By doing this, you are assured of always having the latest information concerning your system from the AMEREX factory. The application and use of the AMEREX Vehicle Fire Suppression Systems are limited to the applications and uses described in this manual. Technical data contained herein is based on controlled laboratory testing deemed appropriate by Factory Mutual Research Corp. and other listing agencies, and is intended for informational purposes only. The data presented is accurate for the testing performed, but is published with no guarantee relative to a given hazard where factors are different from those encountered during actual tests. AMEREX disclaims any liability for any use of the data and information contained herein by any and all other parties. Please direct questions concerning information in this manual to: AMEREX CORPORATION Vehicle Systems Group P.O. Box 81 Trussville, AL Thank you for choosing AMEREX.

3 Part Number Rev. B January 1997 TABLE OF CONTENTS: Forward Section 1 1.A 1.B 1.C Section 2 2.A 2.B 2.C 2.D Section 3 3.A 3.B 3.C 3.D 3.E Section 4 4.A 4.B 4.C 4.D 4.E 4.F 4.G 4.H 4.I Section 5 5.A 5.B 5.C Section 6 6.A About This Manual Introduction What Can Be Protected, Use and Limitations Testing Performed Operating Temperature Extremes Component Description and Operating Details Methods of Operation Individual Components - An Installer s Glossary How the System Works - A Typical Fire Scenario Some Typical Installations In Case of Fire - Actions to Take Hazard Analysis Identifying the Potential for Fire Assessing the Consequences of Fire Determining the Need for Fire Protection Selecting the Appropriate Fire Suppression Options Selecting Fire Suppression System Hardware System Layout and Design Single Discharge Nozzle Coverage Ratings Multiple Discharge Nozzle Coverage Discharge Network Hose Limitations Stainless Steel Rigid Tubing in Discharge Network Actuation Network Hose Limitations Multiple Agent Cylinder Networks (Pneumatic Actuation) Multiple Agent Cylinder Networks (Electric Actuation) Hose Coupling and Fitting Specifications Detection Network Electrical Controls Modular Circuit Monitor Plus Modular Control Panel Back -Up Battery Installation of System Mounting and Installing Components Agent Cylinder Brackets Agent Cylinder Mechanical Control Head Pneumatic Control Head Vent Check Agent Cylinder Pressure Switch Distributor Nozzle Brackets Nozzles Actuator Bracket Manual Actuator Electrical / Manual Actuator Electrical Manual Actuation Switch through through through through through through through through Table of Contents - Continued

4 Part Number Rev. B January 1997 Pressure Operated Switch Modular Circuit Monitor or Control Panel Spot Thermostats Firetrace Thermostats 6.B Connection of Hoses 6.C Connection of Electrical Circuits Wiring Material Routing Wiring Connections and Splicing Color Coding Thermostat Connections Electrical Manual Actuation Switch Multiple Control Head Adapter Agent Cylinder Pressure Switch Squib Connector Lead Pressure Operated Switch Electrical Connection Schematics: Index Circuit Monitors with Spot Detectors - Pneumatic Actuation Circuit Monitors with Spot Detectors - Electric Actuation Control Panels with Spot Detectors - Pneumatic Actuation Control Panels with Spot Detectors - Electric Actuation Multiple Electrically Actuated Control Heads Engine Shutdown and Auxiliary Devices 6.D Placing the System In Service Connect The Discharge Network Connect Agent Cylinder Pressure Switch Test Engine Shutdown Systems The Electrical Networks Agent Cylinder Pressure Switch Circuit Battery Back-Up Circuit Install the Squib Install the Electric Actuator Install the Nitrogen Cylinders Documentation Final Inspection 6.E Provide Owner / Operator Training through through through through 6-27 Section 7 Section 8 Section 9 Inspection Servicing the Amerex Systems Daily Inspection Monthly Inspection Maintenance Semi Annual Maintenance Recharge Clean Up Recharge Recharge Nitrogen Cylinders Recharge Completion through through through Section 10 Component Rebuild Diagrams & Spare Parts Agent Cylinders V13, V25, V50 Agent Cylinders VH13 and VH25 Horizontal Discharge Valve Assembly Mechanical Control Head T-Handle Assembly Pneumatic Control Head Manual Actuator Electrical - Manual Actuator Table of Contents - Continued

5 Part Number Rev. B January 1997 Nitrogen Cylinder Electric Control Head Additional Parts Not Pictured Section 11 Section 12 System Specifications General Extinguishing Agents Agent Cylinders Nozzles Hose and Fittings System Actuation Detection Electrical Controls Nozzle Coverages Weight of Components Electrical Power Consumption Warranty Information 11-1 through through

6 Part Number Rev. C October 1997 Page 1-1 SectionN1 Introduction 1.A What Can Be Protected, Use and Limitations The AMEREX Models V13, V25 VH25 and V50 are pre-engineered dry chemical extinguishing systems. These systems have predetermined flow rates and nozzle discharge quantities dispensed through specific flexible hose and/or stainless steel tubing sizes of designated minimum and maximum lengths, connected with specific numbers and sizes of fittings and couplings. These models are intended for use on both mobile and self-propelled equipment. Examples include mobile and semi-mobile equipment such as offroad earth moving, land clearing, forestry, landfill and farming vehicles; over-the-road buses, maintenance and refuse collection vehicles; and mobile equipment such as pumps, compressors or generators. The Models V13ABC, V25ABC, VH25ABC and V50ABC use Amerex ABC multipurpose, ammonium phosphate base dry chemical which is effective on fires involving both ordinary combustibles and flammable liquids, and is safe for use on fires involving energized electrical equipment. This ABC capability is particularly well suited to vehicle applications since solid debris (wood chips, coal dust, paper refuse, farm vegetation), flammable liquids (hydraulic fluid, diesel fuel or gasoline, battery acid, ethylene glycol) and electrical current (batteries, starters, winches, charging systems) normally coexist in these cases. The Models V13PK, V25PK, VH25PK and V50PK use Amerex Purple K Class BC potassium bicarbonate base dry chemical which is effective on fires involving flammable liquids, and is safe on fires involving energized electrical equipment. This BC capability is well suited to vehicles where flammable liquids are the primary hazard. CAUTION: Extinguishing of flowing flammable liquid fires, may result in a reflash unless all sources of ignition have been removed. Flammable gases present a potential explosion hazard if the flow of gas is not stopped before or during extinguishment. The Models V13, V25, VH25 and V50 shall not be considered satisfactory protection for the following: (a) Chemicals containing their own oxygen supply, such as cellulose nitrate. (b) Combustible metals such as sodium, potassium, magnesium, titanium, and zirconium. (c) Deep-seated or burrowing fires in ordinary combustibles where the dry chemical cannot reach the point of combustion. Use of the Models V13, V25, VH25 and V50 can help protect major vehicle components such as engines, transmissions, charging systems, hydraulic systems, and braking and control systems avoiding costly equipment loss, equipment downtime, product loss, and most importantly, operator injury. CAUTION: The discharge of large amounts of dry chemical may create hazards to personnel such as reduced visibility and temporary breathing difficulty. The dry chemical is completely non-toxic, and considered only a nuisance dust by O.S.H.A. standards.

7 Part Number Rev. C October 1997 Page B Testing Performed: AMEREX Models V13, V25, VH25 and V50 have been rigorously tested by Factory Mutual Research Corporation and found to meet or exceed all requirements applicable to vehicle fire suppression systems. Testing includes but is not limited to: 240 hr. salt fog test, vibration and shock testing, repetitive cycling test, bracket loading tests, hydrostatic pressure testing, temperature extremes tests, temperature cycling, pressure retention, and fire tests. The fire tests for Models V13ABC, V25ABC VH25ABC and V50ABC were conducted on both Class A and Class B hazards while fire tests for Models V13PK, V25PK, VH25PK and V50PK were conducted only on Class B hazards. All fire tests were conducted in both total flooding and overhead application scenarios. Diagrams of the fire test methods and apparatus are shown in Figures 1-1 & 1-2. The AMEREX system is Factory Mutual Research Corp. approved as a pre-engineered vehicle fire suppression system. Warning: Use of any component not of AMEREX manufacture other than specifically mentioned in this manual or the incorrect installation of components will void the AMEREX warranty and the Factory Mutual listing. Additionally, all AMEREX models have been independently laboratory tested to meet or exceed standards set forth in SAE-J1211. FLAMMABLE LIQUID (CLASS B) HAZARD. ALL 8 CORNERS I AGENT CMINDER Total Flooding Fire Tests COMBUSTIBLE SOLID (CLASS A) HAZARD. WORST CASE LOCATIONS USED IN TESTS FOR MODELS V25ABC AND V5DABC ONLY. Figure l-2 Local Application Fire & Splash Tests

8 Part Number Rev. C October 1997 Page C. Operating Temperature Extremes AMEREX Vehicle Fire Suppression Systems are suitable for use in the temperature range of -65 F (-54 C) to 150 F (66 C). Installers must not place systems on any vehicle that functions outside of these temperature limits. Also, care must be taken not to place system components in areas or enclosures of a vehicle where temperatures outside this range are experienced. For example, agent cylinders must never be placed inside engine compartments where temperatures regularly exceed 150 F (66 C).

9 Part Number Rev. C October 1997 Page 2-1 Section 2 Component Description and Operating Details NOTE: Bracketed item numbers in component descriptions correspond to identification numbers used in Figure 2_ 1 V and Figure 2_1 H, installation components for pneumatic actuated svstems, following in this section. See page 2-12 and Bracketed item numbers in component descriptions for electrically actuated systems are shown in Figure 2_1E. See page Installer should familiarize himself thorough/y with the two different methods of actuation prior to specifying components. Pneumatically actuated systems make use of one or more small Nitrogen Cylinders (Item 5). These cylinders contain pressurized gas which is released by means of an actuator (Item 6 or 7) through installer provided supply hose to a Pneumatic Control Head (Item 4) mounted on the Agent Cylinder Valve. The Pneumatic Control Head contains a piston that opens the Agent Cylinder Valve and releases the extinguishing agent. Pneumatically actuated systems may be manually actuated by pulling the safety ring pin on the Actuator and pressing down on the red FIRE palm button, of automatically through the use of heat sensors on automatic systems. Electrically actuated systems do not use Nitrogen Cylinders. Electrical power is provided by the vehicle battery to operate the system. An Electric Control Head (Item 30) is mounted on the Agent Cylinder Valve. This Electric Control Head contains an Electric Actuator (Item 37) that extends a shaft when energized which opens the Agent Cylinder Valve and releases the extinguishing agent. Electrically actuated systems may be manually actuated by pulling the safety ring pin on the Manual Actuation Switch (Item 32) and pressing the red "Fire" button, or automatically through the use of heat sensors. 2.A. Individual Components - An Installer s Glossary Agent Cylinder Assembly (Item 1): The agent cylinder is available in four configurations and two extinguishing agents. Models V13ABC (P/N 11345), V25ABC (P/N 10103), VH25ABC (P/N 12252) and V50ABC (P/N 10104) are charged with AMEREX multi-purpose ABC dry chemical agent. Models V13PK (P/N 11346), V25PK (P/N 10981), VH25PK (P/N 12318) and V5OPK (P/N 10982) are charged with AMEREX Class BC Purple K" dry chemical agent. All assemblies are stored pressure designs with an operating pressure of 350 psi (2413 KPa). The cylinders are constructed of welded steel to DOT 4BW specifications. The V13 models are 7 inches (17.8 cm) in diameter. The V25 and V50 models are 9 inches (22.9 cm) in diameter. The VH25 Horizontal models are always mounted horizontally, thus their height as installed horizontally including mounting bracket is significantly less than their vertically mounted counterparts of the same volume. Horizontal models are recommended where vertical space is FIG. 2-1A limited. The discharge valve, which is common to all agent cylinders, is of rugged forged brass construction. The valve is equipped with a 350 psi (2413 KPa) pressure gauge protected by a forged brass gauge guard, a fusible element pressure relief plug and a refrigeration grade air valve and cap. The valve controls agent discharge via a spring loaded, internal sealing stem that must be depressed from the top of the valve to initiate agent discharge. Agent cylinders are shipped from the AMEREX factory fully charged with a shipping plate installed on the top of the valve to help prevent accidental agent discharge and an anti-recoil plate on the valve outlet to redirect chemical flow should an accidental discharge occur. Both of these plates must be removed at installation.

10 Part Number Rev. C October 1997 Page 2-2 Agent Cylinder Brackets (Item 2): The agent cylinder brackets are constructed in four sizes from 3/16 inch (4.7mm) and 1/4 inch (6.4mm) welded steel & painted to resist corrosion. The part numbers for available agent cylinders are shown below. All brackets are equipped with thick rubber pads to protect the agent cylinders. The mating agent cylinder must be used with the corresponding agent cylinder bracket selected. The mounting brackets are not interchangeable for other agent cylinder sizes. FIG2-1B 9 1/2 VI 3 VH25 V25 V50 P/N P/N P/N P/N FIG. 2-1C Mechanical Control Head (Item 3): On installations where neither automatic nor remote actuation is required, the mechanical control head, P/N can be used. This device is a T-handle design constructed of brass and stainless steel and bolts directly to the top of the agent cylinder discharge valve. The handle is locked in the safety position by a ring pin which is pulled out at the time of actuation. The T-handle is spring loaded and detented to lock in place only in the FULL OPEN or FULL CLOSED positions to discourage incomplete valve opening in a fire situation. The Mechanical Control Head is also used as a service tool to open the discharge valve during agent cylinder recharging. Pneumatic Control Head (Item 4): On installations where remote and/or automatic pneumatic actuation is required, the pneumatic control head, P/N must be used. This device is constructed of extruded brass and bolts directly to the top of the agent cylinder discharge valve. When supplied with actuation pressure, the piston inside the pneumatic control head extends to depress the stem of the agent cylinder valve releasing the extinguishing agent. Actuation pressure (compressed nitrogen gas) enters the Pneumatic Control Head through 1/4 NPT threaded ports on either side.

11 Part Number Rev. C October 1997 Page 2-3 Nitrogen (N2) Cylinder (Item 5): The N2 cylinder, P/N 09956, supplies nitrogen gas pressure to the pneumatic control head through the actuation lines for the purposes of opening the agent cylinder valve. This cylinder is charged to 1800 psig (12410 KPa) at 70 F (21 C) and contains enough nitrogen to actuate up to eight agent cylinder valves at a maximum distance of 125 feet (21.3 meters) to the last control head. Pressure is retained in the N2 cylinder by a gold plated rupture disc.. Replacement rupture discs are available as P/N Only genuine AMEREX rupture discs may be used when recharging nitrogen cylinders. Proper charge pressure is indicated by a pressure gauge located on the cylinder bottom and protected by an impact resistant plastic gauge guard. The N2 cylinder is shipped fully charged from the AMEREX factory with a protective shipping cap installed on the outlet threads. The cap must be removed at installation but must remain in place at all other times. (Retain the shipping cap to reuse when recharging the cylinders) Construction of the N2 cylinder is per DOT 3E. The cylinder is rechargeable by FIG. 2-1E certified AMEREX installers and does not require periodic hydrotesting. Manual Actuator (Item 6): The manual actuator, P/N 10210, is used for manually releasing nitrogen gas pressure from the N2 cylinder to power the pneumatic control head. The body of the actuator is chrome plated brass and contains a stainless steel puncture point that is connected to a palm button and locked in place by a stainless steel ring pin. The diameter of the pull ring has been made intentionally large for ease of operation by large gloved hands. The exposed shaft of the stem is shielded from the elements by a rubber dust boot. To use the actuator, the operator pulls the ring pin and strikes down hard on the FIG. 2-1F palm button. This strike pushes the puncture stem into the rupture disc of the N2 cylinder which is installed into the actuator body through mating threads. Released nitrogen gas enters the actuation lines through a 1/4 NPT exhaust port. The manual actuator and N2 cylinder assembly are mounted to an actuator bracket by two stainless steel 1/4 inch screws. The manual actuator may be installed inside or outside the vehicle cab in any orientation that facilitates easy access to the ring pin and palm button. lectical/mechanical Actuator (Item 7): Like the manual actuator, the electrical/manual (E/M) actuator, P/N 09984, is used for releasing nitrogen gas pressure from the N2 n cylinder to power the pneumatic control head. The body of the E/M Actuator is also constructed of chrome plated brass and contains a stainless steel puncture point. However, the E/M Actuator body also contains a stainless steel strike stem and return spring, and a threaded port to accept an electrical squib cartridge. The strike stem is connected to a palm button on one end of the actuator and locked in the safety position by a ring pin. The puncture stem is free to travel against the return spring into the rupture disc of the N2 cylinder which is installed at the other end. To manually discharge the system, pull out the ring pin FIG. 2-1G and strike down hard on the palm button. This will force the puncture stem into the rupture disc of the N2 cylinder releasing the nitrogen gas into the actuation lines through a 1/4 NPT exhaust port. The E/M actuator can also release the nitrogen gas in the event of automatic fire detection without manually depressing the palm button. When a heat detection device detects a fire, it completes an electrical circuit sending an electrical charge to the squib cartridge. The cartridge fires and the expanding gasses produced propels the puncture stem into the rupture disc of the N2 cylinder releasing the nitrogen gas. The E/M actuator and N2 cylinder assembly are mounted to an actuator bracket by two stainless steel 1/4 inch screws. The electrical manual actuator must be installed inside the vehicle cab to protect it from the weather, but it may also be mounted in any orientation that facilitates easy access to the ring pin and palm button.

12 Part Number Rev. C October 1997 Page 2-4 Squib (Item 8): The squib, P/N 10883, is an electrically detonated, gas generating pyrotechnic device used in the electrical manual actuator to initiate the release of nitrogen actuation pressure in automatic fire detection and actuation scenarios. One end is threaded to screw into the electrical manual actuator body and is equipped with an o-ring for sealing. The other end is threaded and keyed to mate with the modular squib connector lead (Item 22). The squib is shipped with a ground or shunt wire surrounding the electrical pins on the connector end. THIS SHUNT WIRE SHOULD NEVER BE REMOVED UNTIL THE SQUIB IS READY TO BE MATED TO THE CONNECTOR LEAD, AT WHICH TIME THE SHUNT WIRE MUST BE REMOVED. Upon detonation the squib momentarily drains a maximum 5 amperes. The squib has a field service life of 3 years and must be replaced following that time period. Also, the squib must be replaced following each automatically actuated system discharge. The shelf storage PINS life of a squib is 5 years after which it must be replaced regardless if it has FIG. 2-1H been placed into service or not. Vent Check (Item 9): The vent check, P/N 10173, is a safety device that installs in the pneumatic control head. Its function is to bleed any slowly accumulating pressure that could cause the pneumatic control head to open the agent cylinder valve prematurely. Examples of possible pressure sources include a slow leak in the rupture disc of an N2 cylinder, or normal temperature induced expansion of the air and moisture trapped in the actuation lines. A vent check must be used on all pneumatically actuated systems. Use of a pipe plug or other type of stopper is unacceptable and can lead to system malfunctions. The body of the vent check is constructed of machined brass. FIG. 2-1I The inside of the vent check contains a spring and nylon ball. Slowly accumulating gas can pass around the nylon ball and bleed to the atmosphere. However, the rapid accumulation of actuation pressure from the N2 cylinder causes the ball to compress the spring and seal on a tapered seat, blocking the bleed hole. Following an actuation, the vent check can be used to exhaust residual actuation pressure by unseating the nylon ball (typically with a small piece of wire or the tip of a ball point pen).ln installations using multiple agent cylinders, the vent check is installed only in the one pneumatic control head at the end of the actuation network. Actuation Lines (Item 10): The function of the actuation line is to carry high pressure nitrogen gas from the N2 cylinder to the pneumatic control head. Actuation lines consist of 1/4 inch (6.4 mm) ID, wire braided rubber hydraulic hose, and corresponding fittings. Actuation hose and fittings are installer supplied. Various manufacturer s specifications for these hoses are given in Section 4G. Care must be taken to always use only the brand of fittings specified by each hose manufacturer for their hose. Substitution of unapproved hose or that of a different size will void the Factory Mutual listing AMEREX warranty, and will adversely affect system performance. If you wish to use hose other than that specifically approved in this manual, please call AMEREX Vehicle Systems ( ) for prior written approval. Check Valve (Item 11): The check valve, P/N 10262, is used in various locations in the actuation network to ensure that the nitrogen gas follows the correct path to the pneumatic control head. Although there is no limit to the number of manual actuator/n2 cylinder assemblies that can be used on an installation, the path from each one of these actuators to the last pneumatic control head must not exceed 125 ft. (21.3 meters) maximum. Therefore, one check valve must be installed on both inlets of any 1/4 inch tee where two actuators are connected. This plumbing consideration is explained in Section 4. The P/N check valve must be used as a safety device to trap nitrogen actuation pressure in the pneumatic control head. One check valve is installed on the inlet side of each pneumatic control head. When FIG. 2-1J sufficient nitrogen pressure accumulates to force the agent cylinder valve open, the check valve will keep the valve open for the duration of the discharge, even if the actuation line is subsequently damaged to the point of rupture.

13 Part Number Rev. C October 1997 Page 2-5 Actuator Brackets (Item 12): The manual and electical/manual actuators and N2 cylinders are mounted to the vehicle on an indoor, P/N 10355, or an outdoor, P/N actuator bracket. Both brackets are constructed of steel and painted to prevent corrosion. The outdoor actuator bracket includes a steel guard to protect the actuator and N2 cylinder. Front accessible, 1/4 inch, stainless steel cap screws are provided to mount the cover to the outdoor bracket. The outdoor bracket can be used to discourage unauthorized tampering with the nitrogen cylinder P/N either indoors or outdoors as necessary. FIG 2-1K 3/4-NPT Discharge Fitting Kit (Item 13): The discharge fitting kit, P/N 10199, consists of a brass fitting with an o-ring seal on one end and 3/4 NPT male pipe threads on the other, and a stainless steel flange for locking the fitting in place. The flange is placed over the threaded end of the fitting before connection to a discharge hose. FIG. 2-1L Discharge Hoses (Item 14): The function of the discharge hoses is to carry the dry chemical agent to the discharge nozzles. These hoses consist of 1/2 inch (12.7 mm) and 3/4 inch (19.1 mm) ID, wire braided rubber hydraulic hose, and/or stainless steel tubing and the corresponding fittings. Discharge hose and fittings are installer supplied. Detailed specifications for these hoses by manufacturer are given in Section 4. Care must be taken to always use only the brand of fittings specified by each hose manufacturer for their hose. Substitution of unapproved hose or that of a different size will void Factory Mutual listing, AMEREX warranty. and will adversely affect system performance. If you wish to use hose other than that specifically approved in this manual, please call AMEREX Vehicle Systems ( ) for prior written approval. Distributor (Item 15): The distributor, P/N 10178, is of steel construction and is used as a manifold for the discharge hoses. The distributor is painted to retard corrosion. A single 3/4 NPT inlet connects internally to four 1/2 NPT outlets. Distributors are required in all 6 and 8 nozzle networks, and some 4 nozzle networks. Precise locations are given in section 4. The distributor is also available without the mounting flange and unpainted for weld-on applications as P/N Discharge Nozzle (Item 16): The discharge nozzle, P/N 10250, is constructed of brass and distributes dry chemical agent in a cone shaped pattern. It is machined with a 1/2 inch NPT pipe thread for assembly into 1/2 inch distribution hoses. It is shipped complete with a heat and weather resistant rubber blow-off cap that prevents debris from lodging in the nozzle outlet. The blow off cap is molded with a retaining loop that assembles over the 1/2 inch pipe threads before the nozzle is installed. In this way, when the blow off cap is displaced from the nozzle tip by the chemical discharge pressure, it will not drop into the fire. Replacement blow-off caps are available RETAINING LOOP ARCHING DOWNWARD separately as P/N If blow-off caps become worn, damaged, lost or brittle they should be replaced.

14 Part Number Rev. C October 1997 Page 2-6 Nozzle Bracket (Item 17): The nozzle bracket, P/N 10780, is constructed of a 112 inch steel pipe coupling welded to an angled steel bracket. The bracket is painted to retard corrosion. After welding or bolting the bracket to the vehicle, a 1/2 inch ID distribution hose is plumbed to one end of the coupling. The other end of the coupling can accept the discharge nozzle directly, or a nipple and elbow followed by a discharge nozzle if required for aiming purposes. The nozzle bracket is also available unpainted without the 1/2 inch pipe coupling (hole only) as P/N Nipple, 90 Elbow, 45 Elbow (Items & 20): The nipple P/N 10888, 90 elbow P/N 10886, and 45 elbow P/N 10887, are all constructed of wrought steel. The nipple is made from hex stock so that it is easily assembled using an adjustable or opened end wrench. FIG. 2-1O These three fittings can be used as required in conjunction with the nozzle bracket to aim the discharge nozzles. Assembly and tightening instructions are provided in more detail in Section 6.A. NOTE: As an alternate, these fittings may be installer supplied as long as the fittings chosen comply with the requirements specified in Section 4. G. Circuit Monitoring Panels & Control Panels, Modular (Item 21): These panels are offered in four configurations. All panels may be either surface mounted or flush mounted via external mounting feet. All panels are internally prewired for connection to other system electrical components via Amerex Click Lock plug connectors. All panels are factory sealed. Opening panels voids Amerex warranty. All electrical connections are made outside the panel enclosure via cables exiting the rear or the bottom of the panel enclosure depending on selected model, through water tight plugable connectors. All panel electric circuitry is protected by a self resetting internal circuit breaker against shorts, grounds and over current conditions. /- 3/16 DIA. HOLES CIRCUIT MONITOR Enclosure Dimensions: Height=2.65 (6.2cm) Width= 4.00 (10cm) Depth= 2.00 (5cm) CONTROL PANEL I FIG. 2-1P 67 See section 6 of this manual for installation instructions. The Circuit Monitor, Modular, P/N 14008, is the most basic of the four and provides dashboard monitoring of the detection, squib firing, and power supply circuits. The status of these circuits is communicated to the vehicle operator by high contrast red and green LEDs and a continuous tone audible warning buzzer. All wire leads are brought out the bottom of the panel enclosure, and equipped with color coded, weather proof, Click Lock connectors. Leads with click lock connectors are provided for power input, squib firing, and heat detection circuits. The Circuit Monitor. Modular. P/N is the same as the except the leads exit out the back of the panel to facilitate dash mounting.

15 Part Number Rev. C October 1997 Page 2-7 The Control Panel, Modular P/N 14011, features a Push to Test button, and adds a time delayed 10 amp relay circuit that can be used to actuate vehicle shutdown controls such as a fuel shut-off solenoid, or peripheral safety or warning equipment such as a strobe light, horn or etc. All leads exit out the bottom of the panel. The Control Panel also gives the option for the monitoring of the agent cylinder pressure by using the agent cylinder pressure switch P/N (see item 28). The Control Panel, Modular P/N is the same as the except the leads exit out the back of the panel to facilitate dash mounting. All Circuit Monitor and Control Panels have an internal self recharging 24 hour battery back-up in the event that the vehicle power supply should fail. WARNING: AT NO TIME SHOULD THE BACK-UP BATTERY BE USED AS THE MAIN POWER SOURCE. THE SYSTEM MUST BE CONNECTED DIRECTLY TO THE VEHICLE BATTERY AS A MAIN POWER SOURCE. THE BACK-UP BATTERY IS RATED FOR SERVICE ABOVE 0 F (-18 C), AND MUST NOT BE RELIED UPON IN AREAS WHERE TEMPERATURES CAN BE LOWER FOR RELIABLE OPERATION. All units are housed in watertight enclosures with external electrical connections provided via click lock connectors. Two End Of Line Modules, P/N 14010, are provided on each detection circuit lead connection. These must be retained for use at the end of each detection circuit. All units are intended to act as the main junction box for all detection, actuation, pressure monitoring, and power circuits. A detailed description of the features and function of each panel is given in Section 5. Connection diagrams and installation instructions are shown in Section 6. Squib Connector Lead, Modular (Item 22): The squib connector lead is used on automatic detection and actuation installations to carry electrical current to the squib cartridge. This assembly consists of high temperature cable attached on one end to a keyed Bendix connector which mates to the threaded pin socket on the squib, and an Amerex click lock connector on the other end which mates to the control panel click lock connector. The squib connector lead is available in the following lengths; FIG. 2-1Q 5 feet (0.9 meter) = P/N feet (3.0 meters) = P/N feet (4.6 meters) = P/N Power Supply Lead, Modular (Item 23): The power supply lead is used to bring electrical power from the vehicle battery to any one of the five circuit monitoring and control panels.. This assembly is constructed of 16 gauge, two conductor, abrasion resistant jacketed wire, assembled to a fuse holder and terminated with two 3/8" (9.5 mm) ID. round eye battery connection terminals on one end. The other end has an Amerex click lock connector for connection to the mating connector at the circuit monitor or control panel. The fuse holder is of a weather-proof rubber construction and is equipped with a rubber retaining loop. A 10 amp, Type AGC fast acting fuse is provided in the fuse holder for protection of the control panels and the related circuits. WARNING: USE OF THE AMEREX SUPPLIED POWER LEAD IS CRITICAL TO PROPER FUNCTIONING AND PROTECTION OF ALL SYSTEM ELECTRICAL COMPONENTS. USE OF POWER SUPPLY LEADS OTHER THAN OF AMEREX MANUFACTURE OR USE OF A FUSE OTHER THAN THE TYPE AND RATING SPECIFICALLY SPECIFIED IN THIS MANUAL VOIDS AMEREX WARRANTY ON ALL ELECTRICAL SYSTEM COMPONENTS. Replacement fuses are available as P/N The power supply lead is available in the following lengths: 10 feet ( 3 meters) = P/N feet (7.6 meters) = P/N feet (12.2 meters) = P/N feet (15.2 meters) = P/N 14019

16 Part Number Rev. C October 1997 Page 2-8 Local Sensing Heat Actuated Thermostat Assembly, Modular (Item 24): The spot thermostat is a normally open, self-resetting contact closure device. At least one thermostat must be installed in each protected, area of the vehicle. Prior to a fire, the four conductor configuration allows continuous integrity monitoring of all WEATHER PROOF MINIATURE THERMOSTAT RISE THERMOSTAT FIG. 2-1S 1 d miniature or rate of rise compensated models. set temperatures: circuits connecting the thermostats. During a fire, the thermostat is heated to its factory preset actuation temperature. Upon reaching the preset temperature, the thermostat electric contacts close and actuate the fire suppression system. When the thermostat cools, the contacts reset to their original open condition. The thermostats are equipped with Amerex click lock electrical connectors to connect to Jumper Leads (Item 30) which connect to the circuit monitor or control panel. Section 3, Hazard Analysis, gives instructions for thermostat selection. Local sensing heat actuated thermostats are available in either weather proof Both types of thermostats are available in the following pre Rate of Rise Thermostats: Weather Proof Miniature Thermostats P/N (Deg. F.) (Deg. C) P/N (Deg. F.) (Deg. C) I Firetrace Linear Pneumatic Heat Actuated Thermostat (Item 25): The Firetrace heat detector, P/N 13886, is a linear,. pneumatic operated, heat actuated, four wire contact closure device. It uses a 35 foot (IO.6 meters), 1/4 inch (6 mm), O.D. heat sensitive flexible polymer tube which is pressurized with compressed air to 70 p.s.i. from a small reservoir cylinder at one end of the tube. Pressure contained in the tubing holds a contact switch in the open position. When the tube reaches a temperature of 400 F anywhere along it s length, it ruptures and releases the compressed air which allows electrical contacts in the switch to close. The tube must be replaced after a fire. The thermostats are equipped with Amerex click lock electrical connectors to connect to Jumper Leads (Item 30) which connect to the circuit monitor or control panel. A FIG. 2-1S1 gauge is provided on the reservoir cylinder to check air pressure, and air can be added to the cylinder as needed through a valve stem with a common air hose. The air cylinder includes a mounting bracket, and mounting clips are provided for the tubing. Firetrace Detector System is P/N Replacement 35 ft. tubing is P/N 14122

17 Part Number Rev. C October 1997 Page 2-9 Agent Cylinder Pressure Switch (Item 26): The agent cylinder pressure switch, P/N 10914, is an electrical device that mounts to the air valve on the agent cylinder discharge valve. The switch allows for the monitoring of the agent cylinder charge pressure by providing a closed circuit when the pressure is within the proper operating range, and an open circuit when the pressure drops PLUG CONNECTOR below the proper operating range. Additionally, the switch FREE END FOR allows for the function of the time delayed relay following manual system actuation. It may be used on all installations where the Control Panel or Control Panel Plus is selected. The switch is supplied with a plug-type connector installed on the leads. At installation, the free end of this plug is permanently connected to the suppression system wiring. Therefore, when the agent cylinder is removed for recharging, the switch remains on the valve and is simply unplugged from FIG 2-1W the wiring harness. Pressure Operated Switch (Item 27): The pressure operated switch, P/N 11615, is an optional device which can be used to switch an electrical signal from the actuation of any pneumatically operated vehicle suppression system whether actuation be manual or automatic. The pressure operated switch is equipped with a single pole double throw switch to facilitate normally open or normally closed wiring. This SPDT MANUAL RESET BUTTON switch is capable of handling 10 Amps (resistive) at 24 VDC. The pressure operated switch is installed in the 1/4 inch actuation lines. In this manner, Nitrogen actuation gas, whether released from the N2 Cylinder by the manual strike of a palm button or by the automatic release from a thermostat and squib, will pressurize the P/N switch causing it to transfer from the normal position to the actuated position. 1/4 NPT FITTING- AND WIRE ENTRY FIG.2-1X The pressure operated switch will remain in its actuated position until the nitrogen actuation pressure is relieved, and the manual reset button, located on the top of the switch enclosure, is depressed. Electrical connection points are provided inside a water tight enclosure. A 1/4 NPT threaded fitting is provided for plumbing to the actuation (nitrogen) line. Hazard Wire Modular Lead Assembly (Item 28): Hazard wire is an armor jacketed, abrasion resistant, high temperature 392 F - (200 C), 16 gauge, two conductor wire. In all installations, Hazard Wire Modular Lead Assemblies must be used on all leads running from control panel to thermostats, and between thermostats. The assemblies are available in various lengths and are equipped with suitable color coded, male and female Amerex Click Lock pluggable connectors on each end. The following lengths are available: 3feet (.9 meters) = P/N feet (1.8 meters) = P/N feet (3 meters) = P/N feet (4.5 meters) = P/N feet (6.1 meters) = P/N feet (9.1 meters) = PIN feet (12.2 meters)= P/N feet (15.2 meters)= P/N If additional lengths or special requirements exist, contact Amerex Vehicle Systems Group (205)

18 Part Number Rev. C October 1997 Page 2-10 Modular Fire Alarm Conversion Module (Item 29): The Fire Alarm Conversion Module, P/N is used to convert the AMEREX automatic fire detection and fire suppression system into an automatic fire detection and fire alarm system. The Fire Alarm Conversion Module replaces the modular squib or electric actuator connector lead when used with either the modular circuit monitors or control panels. Elimination of the squib or electric actuator requires that discharge of the fire suppression agent must be done manually, or the fire suppression system components omitted completely. The Fire Alarm Conversion Module can also be used to test the function of the heat detection devices when placing the system in service or performing routine maintenance. See Sections 6 and 8.. FIG. 2-1Z Please contact the AMEREX factory for further details on designing systems using the Fire Alarm Conversion Module. Q Electric Control Head (Item 30): On installations where remote and/or automatic actuation is required and the use of the palm button type of Manual Actuator (Item 6) or Electrical/Mechanical Actuator (Item 7) and Pneumatic Control Head (Item 4) are NOT desired, the Electric Control Head, P/N must be used. This device is constructed of machined brass and bolts directly to the top of the agent cylinder &a discharge valve. The top of the Electric Control Head has a hole which is threaded 0 to accept the Electrical Actuator, P/N The bottom plate retains the valve actuator piston and locking ring. When the system is actuated electrically, either manually or automatically, the Electrical Actuator pushes the valve actuator piston FIG.2-1E1 down to its extended and locked position which opens the agent cylinder valve. Note: The backup battery contained in the Circuit Monitor of Control Panel must be used when panels are used with the electric control head. WARNING: AT NO TIME SHOULD THE BACK-UP BATTERY BE USED AS THE MAIN POWER SOURCE. THE SYSTEM MUST BE CONNECTED DIRECTLY TO THE VEHICLE BATTERY AS A MAIN POWER SOURCE. THE BACK-UP BATTERY IS RATED FOR SERVICE ABOVE 0 F (-18 C), AND MUST NOT BE INSTALLED IN AREAS WHERE TEMPERATURES CAN BE LOWER FOR RELIABLE OPERATION. Electrical Actuator (Item 31): On all installations using the Electric Control Head (Item 30), the Electrical Actuator, P/N 14036, must be used. The Electrical Actuator is an electrically fired device that when activated extends a control shaft which mechanically opens the agent cylinder valve. Service life of the Electric Actuator is 4 years after which time it must be replaced. Shelf life of the Electric Actuator is 10 years after which time it must be replaced whether it has been placed in service or not. Note: The backup battery contained in the Circuit Monitor or Control Panel must be used when panels are used with the Electric Control Head. FIG. 2-1E2 WARNING: AT NO TIME SHOULD THE BACK-UP BATTERY BE USED AS THE MAIN POWER SOURCE. THE SYSTEM MUST BE CONNECTED DIRECTLY TO THE VEHICLE BATTERY AS A MAIN POWER SOURCE. THE BACK-UP BATTERY IS RATED FOR SERVICE ABOVE 0 F (-18 C), AND MUST NOT BE INSTALLED IN AREAS WHERE TEMPERATURES CAN BE LOWER FOR RELIABLE OPERATION.

19 Part Number Rev. C October 1997 Page 2-11 Manual Actuation Switch (Item 32): On all installations using the Electric Control Head (Item 33), at least one Manual Actuation Switch P/N is required. Multiple Manual Actuation Switches may be used if more than one manual actuation station is required. To use the switch, the operator pulls out the safety ring pin breaking the plastic lockwire seal, and presses the red "FIRE" button. This action provides electrical power to the Electrical Actuator which then discharges the fire extinguishing system. Electrical Actuator Connector Lead, Modular (Item 33):On all installations using the Electric Control Head, an Electrical Actuator Connector Lead Assembly must be used to wire the Electrical Actuator to the Circuit Monitor or Control Panel. The Actuator Connector Lead is an armor jacketed, abrasion resistant, high temperature 16 gauge, two conductor wire equipped with color coded Amerex Click Lock connectors. These connectors mate with the Squib / Actuator plug at the Control Panel and the plug at the Electrical Actuator. The following lengths are available: 10 feet (3 meters) = P/N feet (6.1 meters) = P/N feet (9.1 meters) = P/N feet (12 meters) = P/N feet (15 meters) = P/N Multiple Electric Control Head Adapter (Item 34): The Multiple Electric Control Head Adapter, P/N 14128, is required when more than one Electrical Control Head is used to control additional agent cylinder valves. It is a junction box adapter that allows multiple Electrical Actuators to be wired in series. The Multiple Control Head Adapter will actuate from two to four control heads simultaneously: It uses color coded Amerex Click Lock Connectors for all electrical connections, and comes with jumper plugs (not shown) for use on any un-used connector leads. The enclosure is 4 inches (10 cm) wide, 2 1/2 inches (6.4 cm) tall, and 1 1/4 inches (3.2 cm) deep. Mounting holes are provided at each corner for number 8 screws. End Of Line Electric Module (Item 35): P/N completes the thermostat wiring circuits. Two are furnished with each Circuit Monitor or Control Panel. ADAPTER FOR MULTI PLE ELECTRIC CONTROL ieads FIG. 2-1E4

20 Part Number Rev. C October 1997 Page 2-12 Figure 2_1V System Schematic V13, V25, VH25 8 V50 Systems Manual & Pneumatic Actuation FIGURE 2_1V COMPONENTS VERTICAL AGENT CYLINDERS

21 Part Number Rev. C October 1997 Page 2-13 Figure 2_1 H V13, V25, VH25 & V50 Agent Cylinder and Mounting Bracket Detail FIGURE 2_1H AGENT CYLINDER AND MOUNTING BRACKET DETAIL

22 Part Number Rev. C October 1997 Page 2-14 Amerex Pre-Engineered Dry Chemical Vehicle Fire Suppression System Components as Shown in Fig 2_1V and Fig 2_1H. For Manual & Pneumatic Actuation Systems Only Sheet One of Two Item No. Part No. Description Agent Cylinder Ass y - V13ABC Agent Cylinder Ass y - V13PK Agent Cylinder Ass y - V25ABC Agent Cylinder Ass y - V25PK Agent Cylinder Ass y - V50ABC Agent Cylinder Ass y - V50PK Agent Cylinder Ass y - VH25ABC (Horizontal Model) Agent Cylinder Ass y - VH25PK (Horizontal Model) Bracket, Agent Cylinder - V Bracket, Agent Cylinder - V Bracket, Agent Cylinder - V Bracket, Agent Cylinder - VH25 (Horizontal Model) Mechanical Control Head (T-Handle) Pneumatic Control Head Nitrogen (N2) Cylinder - 15 Cu. ln.(246 ml.) Nitrogen (N2) Cylinder - 15 Cu. In. High Vibration Applications - Special Manual Actuator Electrical / Mechanical Actuator Squib Vent Check Actuation Hose (Installer Supplied) Check Valve Bracket, Actuator Indoor Bracket, Actuator - Outdoor (With Cover) Discharge Fitting Kit - 14 Discharge Hoses (Installer Supplied) Distributor Distributor (Without Flange - Unpainted) Cone Nozzle with Blow-off Cap Replacement Blow-off Cap Only Bracket, Nozzle Ass y- 90 Degree Bracket, Nozzle (No Coupling - Hole Only - Unpainted)

23 Part Number Rev. C October 1997 Page 2-15 Amerex Pre-Engineered Dry Chemical Vehicle Fire Suppression System Components as Shown in Fig 2_1V and Fig 2_1H. For Manual & Pneumatic Actuation Systems Only Sheet Two of Two Item No. Part No. Description Hex Nipple 1/2 Inch Degree Elbow 1/2 Inch Degree Elbow 1/2 Inch Circuit Monitor Panel, Modular Leads Exit Bottom Circuit Monitor Panel, Modular Leads Exit Back Control Panel Modular, Leads Exit Bottom Control Panel Modular, Leads Exit Back Squib Connector Lead, Modular - 5 Feet (1.5 Meters) Squib Connector Lead, Modular - 10 Feet (3 Meters) Squib Connector Lead, Modular - 15 Feet (4.6 Meters) Power Connector Lead, Modular - 10 Feet (3 Meters) Power Connector Lead, Modular - 25 Feet (7.6 Meters) Power Connector Lead, Modular - 40 Feet (12.2 Meters) Power Connector Lead, Modular - 50 Feet (15.2 Meters) Rate of Rise Thermostat, F. (162 C.) Rate of Rise Thermostat, F. (232 C.) Rate of Rise Thermostat, F. (316 C.) Weather Proof Miniature Thermostat 280 F (138 C) Weather Proof Miniature Thermostat 350 F (170 C) Firetrace Linear Pneumatic Thermostat Firetrace Replacement Tubing Ass y. 35 Feet Agent Cylinder Pressure Switch Pressure Operated Switch 28 Hazard Zone Wire Modular Thermostat Lead Assemblies: Feet (0.9 Meter) Feet (1.8 Meters) Feet (3.0 Meters) Feet (4.5 Meters) Feet (6.1 Meters) Feet (9.1 Meters) Feet (12.2 Meters) Feet (15.2 Meters) Modular Fire Alarm Conversion Module End of Line Module, Replacement, Detection Circuit (Two Supplied With Each Panel)

24 Part Number Rev. C October 1997 Page 2-16 Figure 2_1 E System Schematic V13, V25 & V50 Systems - Electric Actuation. (See Figure 2_1 H for complete Agent Cylinder and Mounting Bracket Details) FIGURE 2_1E COMPONENTS ELECTRICAL ACTUATION ONLY

25 Part Number Rev. C October 1997 Page 2-17 Amerex Pre-Engineered Dry Chemical Vehicle Fire Suppression System Components as Shown in Fig 2_1E. For Electrical Actuation Systems Only Sheet One of Two Item No. Part No. Description Agent Cylinder Ass y - V1 3ABC Agent Cylinder Ass y - V1 3PK Agent Cylinder Ass y - V25ABC Agent Cylinder Ass y - V25PK Agent Cylinder Ass y - V50ABC Agent Cylinder Ass y - V50PK Agent Cylinder Ass y - VH25ABC (Horizontal Model) Agent Cylinder Ass y - VH25PK (Horizontal Model) Bracket, Agent Cylinder - V13 Bracket, Agent Cylinder - V25 Bracket, Agent Cylinder - V50 Bracket, Agent Cylinder - VH25 (Horizontal Model) Discharge Fitting Kit Discharge Hoses (Installer Supplied) Distributor Distributor (Without Flange - Unpainted) Cone Nozzle with Blow-off Cap Replacement Blow-off Cap Only Bracket, Nozzle Ass y- 90 Degree Bracket, Nozzle (No Coupling -- Hole Only - Unpainted) Hex Nipple -1/2 Inch Degree Elbow 1/2 Inch Degree Elbow 1/2 Inch Circuit Monitor Panel, Modular Leads Exit Bottom Circuit Monitor Panel, Modular Leads Exit Back Control Panel Modular, Leads Exit Bottom Control Panel Modular, Leads Exit Back Power Connector Lead, Modular - 10 Feet (3 Meters) Power Connector Lead, Modular - 25 Feet (7.6 Meters) Power Connector Lead, Modular - 40 Feet (12.2 Meters) Power Connector Lead, Modular - 50 Feet (15.2 Meters)

26 Part Number Rev. C October 1997 Page 2-18 Amerex Pre-Engineered Dry Chemical Vehicle Fire Suppression System Components as Shown in Fig 2_1E. For Electrical Actuation Systems Only Sheet Two of Two item No. Part Number Description Rate of Rise Thermostat, F. (162 C.) Rate of Rise Thermostat, F. (232 C.) Rate of Rise Thermostat, F. (316 C.) Weather Proof Miniature Thermostat 280 F ( 138 C) Weather Proof Miniature Thermostat 350 F ( 177 C) Firetrace Linear Pneumatic Thermostat Firetrace Replacement Tubing Ass y. 35 Feet Agent Cylinder Pressure Switch Hazard Zone Wife Modular Lead Assemblies: Feet (0.9 Meter) Feet (1.8 Meters) Feet (3.0 Meters) Feet (4.5 Meters) Feet (6.1 Meters) Feet (9.1 Meters) Feet (12.2 Meters) Feet (15.2 Meters) Modular Fire Alarm Conversion Module Electric Control Head Electric Actuator Manual Actuation Switch Electrical Actuator Modular Connector Lead Assemblies Feet (3.0 Meters) Feet (6.1 Meters) Feet (9.1 Meters) Feet (12 Meters) Feet (15 Meters) Multiple Electric Control Head Adapter End of Line Module Replacement, Detection Circuit (Two Supplied With Each Panel)

27 Part Number Rev. C October 1997 Page 2-19 Only Genuine Amerex Tools Should Be Used For Servicing The Amerex System. AMEREX FIRE SUPPRESSION SYSTEM SERVICE TOOLS AGENT CYLINDER RECHARGE ADAPTER NITROGEN CYLINDER RECHARGE ADAPTER AGENT CYLINDER HYDROTEST ADAPTER fsy DISCHARGE HOSE BLOWOUT ADAPTER ACTUATION HOSE TEST ADAPTER SQUIB SIMULATOR FIRE ALARM MODULE, SQUIB & ELECTRIC ACTUATOR TEST DEVICE. FIG. 2_1J SERVICE TOOLS Available as special order only: Nitrogen Recharge Stand Assembly Complete PIN (Not Pictured) Vehicle Systems Training Slide Presentation P/N (Not Pictured)

28 Part Number Rev. C October 1997 Page B. How the System Works - A Typical Fire Scenario The following is a typical fire scenario for an installation utilizing manual only fire detection and remote pneumatic fire suppression system actuation. (1) A fire starts in a protected area. (2) Equipment operator (1) pulls the ring pin & (2) strikes the palm button on the manual actuator, releasing nitrogen gas into the actuation lines leading to the pneumatic control head on top of the agent cylinder valve. (3) The nitrogen pressure entering the pneumatic control head opens the agent cylinder valve allowing pressurized dry chemical to flow into the distribution hoses leading to the discharge nozzles. The pressure of the entering dry chemical causes the protective dust caps located on the nozzles to be blown off. (4) Dry chemical extinguishing agent discharges through fixed nozzles into protected areas, suppressing the fire. FIG. 2-6

29 Part Number Rev. C October 1997 Page 2-21 The following is a typical fire scenario for an installation utilizing automatic fire detection and pneumatic system actuation, and post actuation vehicle shutdown. (1) A fire starts in a protected area. (2) Heat and flames cause the temperature to rise to the set point of the thermostat. Upon reaching temperature, the contacts of the thermostat close, thereby completing an electrical circuit from the vehicle battery to the squib located in the electrical/manual actuator. (3) The completed circuit causes the squib to detonate, releasing nitrogen gas into the actuation lines leading to the pneumatic control head on top of the agent cylinder valve. Simultaneously, the completed electrical circuit causes the auxiliary contact relay, located in the control panel, to begin to countdown. (4) The nitrogen pressure entering the pneumatic control head opens the agent cylinder valve allowing pressurized dry chemical to flow into the distribution hoses leading to the discharge nozzles. The pressure of the entering dry chemical causes the protective dust caps located on the nozzles to be blown off. (5) Dry chemical extinguishing agent discharges through fixed nozzles into protected areas, to suppress the fire. Simultaneously, the relay timer completes its cycle switching the auxiliary contacts and, for example, closes a fuel shutoff solenoid valve stopping the engine. FIG. 2-7

30 Part Number Rev. C October 1997 Page 2-22 The following is a typical scenario for an installation utilizing automatic fire detection and electrical system actuation. This example shows the method of manually actuating the electrically actuated fire suppression system. (1) A fire starts in a protected area (2) Equipment operator (1) pulls the ring pin & (2) presses the red FIRE button on the Manual Actuation Switch which energizes the Electric Control Head on the Agent Cylinder valve. (3) The Electric Actuator opens the Agent Cylinder valve allowing pressurized dry chemical to flow into the distribution hoses leading to the discharge nozzles. The pressure of the entering dry chemical causes the protective dust caps located on the nozzles to be blown off. (4) Dry chemical extinguishing agent discharges through fixed nozzles into the protected areas, suppressing the fire. FIG.2-8

31 Part Number Rev. C October 1997 Page C. Some Typical Installations of Manual, Pneumatic, and Electrically Actuated Systems. Example 1: Mechanical Control Head with 4 Nozzle Installation: The most basic combination of hardware to construct an Amerex Fire Suppression System uses the P/N mechanical control head mounted directly to the pressurized agent cylinder. In this case, detection of fire and actuation of the suppression system rely solely on the vehicle operator. Care must be taken to locate the agent cylinder in convenient proximity to the vehicle operator. Actuation is accomplished by pulling a ring pin, then pulling a T-handle lever to open the agent cylinder valve. This combination is ideal for small vehicles where fires can be quickly spotted by operators and where only one actuation location is required. Figure 2-2 shows a V25-4 nozzle system, however the Mechanical Control Head will work with any size agent cylinder. NOTE: To comply with NFPA 17, installation of a "manual only" suppression system must be approved by the local authorities having jurisdiction. Example 2: Remote Pneumatic Manual Only Actuation with Dual 4 Nozzle Installation: In some installations, multiple actuation locations are required even though automatic detection and automatic actuation is not. In these cases, Amerex pressurized agent cylinders should be fitted with a P/N pneumatic control head and connected to one or more P/N manual actuators. As in Example 1, detection of the fire and actuation of the suppression system rely solely on the equipment operator or other personnel who may be close by. Actuation is accomplished by pulling a ring pin on any one of the manual actuators, and striking down hard on the palm button. Depression of the palm button releases nitrogen pressure which, in turn, powers the pneumatic control head to open the agent cylinder valve(s). If engine shutdown, fuel shutoff, or remote alarm actuation is desired, the Pressure Operated Switch, P/N should be plumbed into the actuation network between the agent cylinder(s) and the closest manual actuator. Nitrogen pressure released by any manual actuator will activate the switch. NOTE: To comply with NFPA 17, installation of a manual only suppression system must be approved by the local authorities having jurisdiction. Figure 2-3: Ore hauler type installation using dual V25 and multi-point remote Manual Actuators. Pneumatic Actuation

32 Part Number Rev. C October 1997 Page 2-24 Example 3: Automatic or Manual Actuation (Pneumatic): Per NFPA 17, most installations will require the previously described remote manual actuator combined with automatic fire detection and suppression system actuation. In these cases, the pressurized agent cylinders will be fitted with a P/N pneumatic control head connected to at least one P/N manual actuator located in the path of egress. In addition, the pneumatic control head will be connected to one P/N electrical/manual actuator located within the operators reach in the vehicle cab. This actuator contains a squib cartridge that, when provided with electrical power, duplicates the palm button action of the manual actuator by releasing nitrogen gas to power the pneumatic control head and open the agent cylinder valve. Electrical current is provided to the squib by thermostats, which are connected to the vehicle battery and placed near potential ignition and fuel sources found on the vehicle. Figure 2-4: Trash truck type installation with automatic fire detection and automatic pneumatic fire system actuation Also, in many automatic detection and actuation installations, a system to automatically shut off the engine, or its fuel flow, or both, will be required. In these situations, an Amerex Modular Control Panel, P/N 14011, should be used. Example 4: Automatic or Manual Actuation (Electric): Many transit and school bus operators have chosen Amerex systems with automatic fire detection and suppression actuation to protect vehicles and passengers. The use of the electrically actuated system has proven to be well suited for this type of vehicle. There is no nitrogen cylinder or electrical mechanical actuator to take up valuable cab space, and the use of the electric activation switch is preferred by operators as it's small size allows it to be mounted in the existing instrument panel within easy reach of the driver. Most state highway governing agencies require engine shutdown in the event of a fire. In these cases, the Figure 2-5: Transit Bus using Modular Control Panel Plus, P/N dual V25's, multiple spot detectors with control panel and electric 14011, is used as it features an actuator switch at driver's area. internal timed relay which can be connected to shut off the engine it the event of a fire. Thermostats in the hazard areas detect the fire and complete a circuit which provides current to the electric control head, or the system can be manually discharged by pressing the manual actuation button on the dash.

33 Part Number Rev. C October 1997 Page D. In Case of Fire Actions To Take: TURN OFF THE EQUIPMENT. BRING TO A SAFE & CONTROLLED STOP AND SET BRAKES. ACTUATE THE AMEREX FIRE SUPPRESSION SYSTEM BY PULLING THE RING PIN AND STRIKING DOWN HARD ON THE PALM BUTTON OR PULLING THE T-HANDLE LEVER TO THE FULL OPEN AND LOCKED POSITION. GET AWAY FROM THE EQUIPMENT. TAKE A HAND PORTABLE EXTINGUISHER ALONG IF POSSIBLE OR OBTAIN ONE FROM ANOTHER LOCATION. STAND BY WITH PORTABLE EXTINGUISHER AND WATCH FOR SOURCES OF RE-IGNITION. NOTIFY LOCAL FIRE DEPARTMENT. Reasons Behind The Actions: A running piece of equipment can continue to pump fuel or hydraulic fluid adding to the fire. Its cooling fan creates wind currents that can reduce the effectiveness of the suppression system discharge. Its electrical system or other hot spots can continue to re-ignite the fire. Shutting the vehicle off reduces the possibility of reignition. By getting away from the equipment, the operator, as well as others, are protected from possible explosions or heat injuries. Because residual heat could cause a re-ignition of the fire, or because the fire may be deep seated (vehicle fire suppression systems are not intended to extinguish deep seated fires) it is important to stand by with a portable extinguisher. Maintain the standby until all possibility of re-flash is eliminated, all residual heat has dissipated or professional fire fighters arrive on the scene. What To Expect: Discharge of an Amerex Fire Suppression System is noisy and can produce a large cloud of extinguishing chemical temporarily obstructing vision. Breathing the dry chemical is unpleasant and may cause some irritation. See M.S.D.S. information for Amerex ABC and "Purple K" dry powder extinguishing agent in Section 11 for further information. After The Fire Is Out: DO NOT restart the equipment until it has been serviced and cleaned. Use a water stream or compressed air to remove dry chemical residue immediately to avoid corrosion. DO NOT return the equipment to service until the suppression system has been serviced and recharged and until the source of the fire has been located and neutralized.

34 Part Number Rev. C October 1997 Page 3-1 Section 3 Hazard Analysis WARNING: A THOROUGH HAZARD ANALYSIS PRIOR TO LOCATING COMPONENTS IS CRUCIAL TO PROPER SYSTEM PERFORMANCE. AN IMPROPER OR INCOMPLETE HAZARD ANALYSIS CAN LEAD TO FALSE SYSTEM DISCHARGES OR FAILURE TO COMPLETELY EXTINGUISH A FIRE. AT NO TIME SHOULD AN AMEREX FIRE SUPPRESSION SYSTEM BE INSTALLED WITHOUT FIRST COMPLETING AND DOCUMENTING A COMPLETE HAZARD ANALYSIS. The Vehicle Hazard Analysis consists of five phases: A. B. C. D. E. Identifying the potential for fire Assessing the consequences of fire Determining the need for fire protection Selecting the fire suppression option(s) Selecting the appropriate fire suppression system hardware 3.A. Identifying the Potential for Fire Ignition Sources [ ] High temperatures are usually found in the engine compartment areas, exhaust systems, and turbocharger areas. Other ignition sources are pumps, batteries, electrical wiring, switches, electrical motors, generators and sources of friction such as bearings, brakes and gears. [ ] Electrical ignition sources include battery box, battery cable, transformers, fuse panels, splices, auxiliary motors such as winches and starters. [ ] Smoking materials, chemical reactions and spontaneous ignition sources. Fuel Sources [ ] Class A Materials: wood, paper, rags, coal dust, electrical insulation, combustible debris, hoses, tires, seats. [ ] Class B Materials: flammable & combustible liquids such as gasoline, diesel fuel, natural gas (LNG/ CNG), cleaning fluids, propane, methane, methanol, hydraulic fluids, grease, ethylene glycol, battery acid, alcohol and oil. The additional hazard of explosion may exist if no safety devices are employed to stop the flow of fuel at the time of the fire. [ ] Class C Items: (Note: Class C items describe sources of electrical current that may energize a fire making it more hazardous to personnel & inextinguishable using conductive agents such as water.) Shorts in electrical system from friction wearing through wire, defective wires, defective wire coverings. Coexistence of Fuel & Ignition Sources [ ] Vehicle Design. Check existing areas where hydraulic fluid or fuel sources come into close proximity to high temperature engine surfaces, manifolds, turbocharger and starter. Other areas may include equipment articulation points, engine (belly) pan area and battery compartments. On larger equipment, check roller path collector areas, electrical switch gears, electrically driven wheels and transformer compartments. [ ] During hazard analysis note areas where combustible liquids may spew or drip onto hot surface areas or splatter from a battery or an electrical switch short which would carry heat to another area of the vehicle.

35 Part Number Rev. C October 1997 Page 3-2 Previous Experiences [ ] Past experiences may indicate where special hazards exist. Assistance from vehicle owner/operator, or service person should be carefully considered in determining hazard areas. Examples might include a hydraulic hose that frequently loosens in the same place or a component of the vehicle that frequently fails. 3.B. Assessing the Consequences of Fire Personnel Exposure [ ] Determine the number of persons included and their locations during routine vehicle operations. This would include vehicle operator as well as passenger, if any. [ ] Determine the exposures to potential fires for each person and whether fire & smoke could impair safe egress from the vehicle. Economic Risk [ ] Consider the cost of repairs or replacement of vehicle, [ ] Consider the cost of vehicle downtime to production loss. [ ] Consider the cost of the product that could be lost should fire spread from the vehicle. Example: Could a skidder burn down the forest? 3.C. Determining the Need for Fire Protection Identify Mandatory Requirements Certain fire protection and fire suppression requirements are mandated by company policy, insurance companies and government agencies. Identify Additional Requirements Evaluate The need for fire precautions, in addition to those mandated, may be discovered as a result of this Hazard Analysis. If the Hazard Analysis has disclosed unacceptable personnel risks, economic risks, or both, appropriate fire protection options must be determined. 3.D. Selecting the Appropriate Fire Suppression Options Risk Reduction [ ] Vehicle design. Assist in determining if the risk could be reduced by minor changes in vehicle designs. Examples: thermal shield could be added or hoses could be re-routed. [ ] If unacceptable risk still exists then further actions such as the installation of portable fire extinguishers, a fixed fire suppression system, or both is required to remove the hazards. [ ] If the hazard is larger or can spread to a larger area than can be covered with a single extinguisher, or if the hazard is expected to grow in intensity faster than can be detected visually and suppressed by a person with a single fire extinguisher, then a suppression system is needed.

36 Part Number Rev. C October 1997 Page 3-3 Fire Detection & Suppression Systems Alternatives [ ] Portable Protection which includes both hand portable and wheeled extinguishers. [ ] Detection. Fire detection devices may be used to provide early warning of fire & activate a fire suppression system. [ ] Fixed Fire Suppression System. Fixed system protection can be accomplished by local application, total flooding, or a combination of both. 3.E. Selecting Fire Suppression System Hardware Locating High Risk Area(s) [ ] Assess all vehicle areas and compartments as outlined in Section 3.A. Pay particular attention to engine, fuel transfer, and hydraulic pump compartments. Remember, these potential tire hazard areas are similar in many vehicles. Determine Agent to be Used [ ] Review the "Fuel Sources" identified in Section 3.A. If any of the fuel sources qualify as Class A materials, or if any fuel sources are in the proximity of other Class A materials, then the Models V13ABC, V25ABC, VH25ABC (Horizontal) and/or V50ABC must be selected. If there are no Class A fuel sources or there are no Class A fuel sources in the proximity but Class B and/or Class C fuel sources are present, then the Models V13PK, V25PK, VH25PK (Horizontal) and/or V50PK may be used. Determine Magnitude of Hazard in Each Risk Area [ ] Determine how many nozzles are required to adequately deliver agent to all hazard areas by means of total flooding, local application, or a combination of both. Refer to Section 4.A of this manual concerning nozzle coverage. Refer to NFPA 17, for further assistance in matching nozzle coverage to the hazard. [ ] After determining the exact number of nozzles required to cover all hazard areas, assessment of agent cylinder size can be determined, i.e. if 2 nozzles use V13, if 4 nozzles use V25 or VH25 (Horizontal), 6 or 8 use V50, or combinations of two or more sizes. Determine Method of Fire Detection [ ] For the suppression system to be used, fires or conditions likely to produce fire must first be detected by visual (human senses) or by means of a thermal sensor. Confer with the equipment owner operator and discuss your recommendations to determine if automatic detection will be needed. [ ] NFPA 17 requires that each protected area or compartment must be provided with a fire detection device. Proceed as follows:

37 Part Number Rev. C October 1997 Page 3-4 Determining Degree Rating and Type of Sensor(s) To Be Used [ ] Use a temperature probe to measure engine ambient temperature as well as temperature in specific areas of the vehicle.for example, the area near the turbocharger will have higher temperature than all other areas. [ ] Take into consideration natural changes effecting ambient temperature due to seasonal climatic changes. For example; If you are measuring temperatures during the winter time when it is 0 deg. F. (-18 deg. C.) and the system will see service during the summer when temperatures may reach 100 deg. F. (38 deg. C.) or more, your ambient temperature should be adjusted upward at least 100 deg. F. to compensate. [ ] After ambient temperatures are identified, select thermostats rated at least 100 deg. F above identified ambient temperatures. [ ] In situations where extreme vibration, extremely corrosive or wet conditions, or a large area needs to be monitored, use of the linear pneumatic heat detector(s) in lieu of spot detector(s) should be considered. Also, if vehicle components block accessibility to the detectors for maintenance, use of the linear pneumatic detector is ideal. Determine Methods of Actuation [ ] Consult local authorities having jurisdiction. For compliance with NFPA 17, automatic detection/actuation must be used except as allowed by local authorities. [ ] Selection of automatic detection and actuation systems will require use of the electrical/manual actuator and squib or electrical manual activation switch, (depending on system configuration), mounted in the vehicle cab. [ ] Requirements for manual actuation, remote from the agent cylinder will require use of one or more manual actuators. NFPA 17 requires that at least one manual control for actuation shall be located no more than 5 ft. (1.5m) above the floor and be convenient and easily accessible at all times including time of the fire. One easily accessible manual system actuator shall be provided for use by the equipment operator. A second actuator shall be located so that it is in the path of egress and operable from ground level away from potential hazard areas. [ ] Single point manual actuation for installations where the agent cylinder can be mounted in reach of the equipment operator can be accomplished by selecting the mechanical (lever operated) control head. Control Panel [ ] Type of control panel required should be determined by assessment of features required. There are two types of control panels available. Circuit Monitor and Control Panel models are available. [ ] All control panels must be located in vehicle cab within the operator's audible and visual range. [ ] All control panels must be located within reach of operator so an operator has access to reset button, alarm silence button, engine shutdown delay button, etc.

38 Part Number Rev. C October 1997 Page 3-5 Special Options [ ] If a manually operated system is deemed satisfactory, but engine shut down is required, the pressure operated switch should be plumbed into the pneumatic actuation network to control ignition or fuel shut off. [ ] If monitoring of agent cylinder pressure and/or certain engine shut down in the event of manual actuation of an automatic system is required, include the agent cylinder pressure switch in the system in combination with the Control Panel or Control Panel Plus.

39 Part Number Rev. C October 1997 Page 4-1 Section 4 System Layout and Design To properly desiqn the agent distribution, actuation, and detection networks, an installer must first complete a hazard analysis of the vehicle on which the suppression svstem will be installed. Refer to Section 3 for instructions on hazard analysis. Once this task is completed and documented, the following sections will provide the required nozzle coverage and nozzle spacing information necessary for choosing the number and size of agent cylinders, for choosing the required number of agent discharge nozzles and for designing the hose networks that connect the system components. 4.A. Single Discharge Nozzle Coverage Ratings Each discharge nozzle whether connected to the V13, V25, VH25 (Horizontal) or the V50 is rated for a specific "zone of protection." Because each nozzle may be used to distribute dry chemical using either a total flooding method for enclosed spaces, or a local application method for unenclosed spaces, this zone of protection is described using two measures of coverage. As shown in Figure 4.1, each nozzle has a total flooding volume of protection of 244 cu. ft. (6.9 Kiloliters). This volume represents a single nozzle placed in the center of the top plane of a 6 ft. - 3 in. (1.9 meter) cube. Alternately, as shown in figure 4.2, each nozzle has an overhead local application area - of protection of 900 sq. in. (.7 sq. meters). This area reflects a single nozzle centered above a 30 inch (76.2 cm) square fuel pan at a height of 35 to 46 inches (89 to 117 cm) above the surface of the fuel. Table 4.1 summarizes these values. Coverage Type Rated Protection Nozzle Placement Total 244 cu. ft. (6.9 KI) Center of Top Plane Flooding 6' - 3"(1.9 meter) cube Overhead 900 sq. in. (.6 sq. meter) Center of Area 35 to 46" Local Application 30 inch (76.2 cm) square 89 to 117 cm) above fuel Table 4.1: Single Nozzle Coverages TOTAL FLOODING VOLUME, ONE NOZZLE EQUALS: 244 CU. FT. (6.9 k.l.) Figure 4.1: Single nozzle total flooding volume. (76 cm.) Figure 4.2: Single nozzle local application area.

40 Part Number Rev. C October 1997 Page B. Multiple Discharge Nozzle Coverages AMEREX vehicle suppression system models V13, V25, VH25 (Horizontal) and V50 offer four multiple nozzle configurations. The model V13 must use 2 nozzles. The model V25 and VH25 (Horizontal) must use 4 nozzles, while the V50 model must use either 6 or 8 nozzles. With all systems, single nozzles are combined in installations to yield a total protected volume or area. This total equals the number of nozzles used multiplied by the single nozzle coverage ratings. Volumes and areas may be arranged in any configuration, as long as total coverages and hose limitations are not exceeded, and as long as nozzles are spaced so as to duplicate the placement used in the single nozzle ratings. Figures 4.3 and 4.4 show examples of multi-nozzle coverages. Neither the volumes or the areas need to be adjacent to one another. Table 4.2 summarizes the total multi-nozzle coverage for each model. Model V13ABC/PK Number of Nozzles 2 Total Volume Total Area Protected by Total Protected by Flooding Application Local Application 488 cubic feet 12.5 square feet (13.8 Kiloliters) (1.2 square meters) V25ABC/PK VH25ABC/PK V50ABC/PK V50ABC/PK cubic feet 25 square feet (27.6 Kiloliters) (2.3 square meters) 1464 cubic feet 37.5 square feet (41.4 Kiloliters) 1952 cubic feet (3.5 square meters) 50 square feet 1 I (55.3 Kiloliters) (4.6 square meters) Table 4.2: Total System Coverages by Model 244 CU. FT. X 8 NOZZLES = 1952 CU. FT. (6 9 KILOLITERS) (55.3 KILOLITERS) Figure 4.3: Example of multi-nozzle total flooding coverage - V50 using (8) nozzles 900 SQ. IN. X 6 NOZZLES = 5400 SO. IN. = 37.5 SQ. FT (.6 so. METER) (3 5 SO. METERS) ;i;f :;I JLf / / - -,/I -- --! +i / / figure 4.4: Example of multi-nozzle local application coverage - V50 using (6) nozzles.

41 Part Number Rev. C October 1997 Page 4-3 All the AMEREX Models V13, V25, VH25 (Horizontal) and V50 are exhaustively tested to establish minimum and maximum discharge hose lengths. These minimums and maximums must be strictly observed when designing and installing the agent discharge network to ensure proper agent distribution to each nozzle. Failure to observe hose length limitations can adversely affect system performance and cause failure to completely extinguish a fire. A total of five discharge distribution networks are available for the four models. The V13 system is arranged using all 1/2" (12.7 mm) I.D. hose split with one tee fitting to distribute agent to the two nozzles. The V13 system is the only system using all 1/2" hose. The V25, VH25 (Horizontal) and V50 models all use 3/4" (19mm) I.D. hose from the valve to the distributor or tee fittings, but must be reduced to 1/2" (12mm) I.D. hose to the nozzles. No other hose sizes are tested or approved. The V25 and VH25 (Horizontal) four nozzle systems can be arranged using plumbing tees at hose junctions, or using the 1 to 4 distributor. Hose length limitations are identical for the V25 and VH25 (Horizontal) systems in all cases. The V50 is arranged using a combination of tees and distributors in both the six and eight nozzle systems. The configurations of each model, together with the required hose diameters are illustrated and specified on the following pages. Notice in the tables that many hose sections allow a minimum length of zero feet. It is important to realize that even with these zero length allowances all configurations still require an agent cylinder to nozzle distance of 5 ft. minimum (1.5 meters). Therefore, all sections leading to a nozzle cannot be zero at once. Also notice that the length of hose extending from one outlet of a tee or distributor may be 3 times as long or as short (3:1 imbalance) as the section leading from the other outlet(s) of the tee or distributor. Because of this maximum imbalance requirement, if a zero hose length is chosen at the outlet of a tee or distributor, a zero hose length must be used at all outlets from that tee or distributor. Finally, notice that all sections allow for the use of two elbows. (Elbows placed directly at the nozzle or distributor can be ignored when calculating the number of elbows in discharge network). When calculating hose length and hose imbalance, the effect of the elbow should be ignored. The length of a hose section is therefore defined by the sum of the lengths of the individual hoses between two tees, distributors, nozzles or discharge valve outlet fittings only.

42 Part Number Rev. C October 1997 Page 4-4 Hose Limitations for V13 and Systems: AMEREX V13 SYSTEMS Cylinder to any one N 50 ft. MAX. (15.2 Met 3 ft. Min. (.9 Meter 1/2 inch = 12 mm) FIG LOCATION HOSE I.D. HOSE LENGTH, feet NUMBER OF ELBOWS / inches (Meters) SECTION of HOSE MAXIMUM MINIMUM MAXIMUM MINIMUM CYLINDER to T1 1/2 40 (12.0) T1 to each NOZZLE 1/2 15 (4.6) CYLINDER to any NOZZLE - - 1/2 50 (15.2) 3 (.9) ALL 1/2 inch HOSE (19.8) 3 (.9) NOTE: This system may be unbalanced in a maximum ratio of 3:1, at the outlets of T1

43 Part Number Rev. C October 1997 Page 4-5 Hose Limitations for V25 and VH25 Horizontal Systems Using Tees: AMEREX V25 and VH25 SYSTEMS Cylinder to any one Nozzle: 60 ft. MAX. (18.2 meters) 5 ft. Min. (1.5 meters) Tl=l,3, T2=+X+-X+ (3/4 inch = 19 mm) (1/2 inch = 12 mm) FIG. 4-7 Hose & Elbow Limitations for V25 & VH25 Using Tee s LOCATION CYLINDER to T1 T1 to each T2 T2 to each NOZZLE CLYINDER to any one NOZZLE ALL a inch HOSE ALL $- inch HOSE HOSE I.D. HOSE LENGTH, feet inches (meters) NO. of ELBOWS/ SECTION of HOSE MAXIMUM MINIMUM MAXIMUM MINIMUM (13.7) I 4 20 ( 6.1) i 15 ( 4.6) (18.3) 5 (1.5) (13.7) 3 (.9) _ (18.2) NOTE: This system may be unbalanced in a maximum ratio of 3:1, at the outlets of any one tee.

44 Part Number Rev. C October 1997 Page 4-6 Hose Limitations for V25 and VH25 Horizontal Systems Using Distributor: AMEREX V25 and VH25 SYSTEMS Cylinder to any one Nozzle: 60 ft. MAX. (18.2 meters) 5 ft. Min. (1.5 meters) DlSTRlBUTOR=jx$x+x+x+ nozzle (3/4 inch = 19mm) (1/2 inch = 12mm) Hose & Elbow Limitations for V25 and VH25 Using Distributor FIG. 4-8 LOCATION CYLINDER to DISTRIBUTOR DISTRIBUTOR to each NOZZLE CYLINDER to any one NOZZLE ALL $ inch HOSE HOSE I.D. inches i - l- HOSE LENGTH, feet (meters) MAXIMUM 45 (13.7) 15 ( 4.6) 60 (182) 45 (13.7) MINIMUM 5 (1.5) 0 5 (1.5) 3 (.9) NO. of ELBOWS/ SECTION of HOSE --I--- MAXIMUM MINIMUM ALL -$ inch HOSE - 60 (18.2) 0 NOTE: This system may be unbalanced in a maximum ratio of 3:1 at the outlets of the distributor. HOWEVER, this ratio must be observed for the minimum vs. maximum hose sections. For example, if the longest hose leading from the distributor is 15 feet, none of the other branches may be less than 5 feet.

45 Part Number Rev. C October 1997 Page 4-7 Hose Limitations for V50 Systems Using Distributors and Tees: AMEREX V50 SYSTEM DISTRIBUTOR=3xixjx~x~ T~z+~+~+ Cylinder to any one Nozzle: 56 ft. MAX. (17.1 meters) 5 ft. Min. (1.9 meters) (3/4 inch = 19mm) (1/2 inch = 12mm) FIG. 4-9 Hose & Elbow Limitations for V50 with 6 nozzles LOCATION CYLINDER to DISTRIBUTOR DISTRIBUTOR to each T1 NO. of ELBOWS/ HOSE I.D. HOSE LENGTH, feet SECTION of HOSE inches (meters) MAXIMUM MINIMUM MAXIMUM MINIMUM I 4 45 (13.7) 2 (.6) T 15 (4.6) T1 to each NOZZLE 3 11 ( 3.3) CYLINDER to any one NOZZLE - 56 (17.1) 5 (1.9) - - ALL $- inch HOSE - 45 (13.7) 2 (.6) - - ALL -$- inch HOSE - 66 (20.1) NOTE: This system may be unbalanced in a maximum ratio of 3: 1, at the outlets of the distributor, or at the outlets of any tee. HOWEVER, at the distributor, this ratio must be observed for the minimum vs. maximum hose sections. For example,if the longest hose leading from the distributor is 15 feet, none of the other branches may be less than 5 feet.

46 Part Number Rev. C October 1997 Page 4-8 Hose Length Limitations for V50 Using Distributors AMEREX V50 SYSTEM Cylinder to any one Nozzle: DISTRlBUTOR=~x3x3xiX$ 60 ft. MAX. (18.2 meters) 5 ft. Min. (1.9 meters) Tl=+x+x+ (3/4 inch = 19mm) L in. 4 (1/2 inch = 12mm) 3 in. 4 nozzle FIG.4-10 LOCATION Hose & Elbow Limitations for V50 with 8 nozzles, HOSE I.D. HOSE LENGTH, feet inches NO. of ELBOWS/ SECTION of HOSE MAXIMUM MINIMUM MAXIMUM MINIMUM CYLINDER to T (12.1) 0 T1 to each DISTRIBUTOR + 20 ( 6.1) DISTRIBUTOR to each NOZZLE NOTE: This system may be unbalanced in a maximum ratio of 3:1, at the outlets of the distributor, or at the outlets of T1. HOWEVER, at the distributor, this ratio must be observed for the minimum vs. maximum hose sections. For example, if the longest hose leading from the distributor is 15 feet, none of the other branches may be less than 5 feet.

47 Part Number Rev. C October 1997 Page D. Stainless Steel Rigid Tubing in Discharge Network The discharge network of the AMEREX Vehicle Fire Suppression System may be constructed using certain types of rigid tubing in place of some or all sections of the SAE 100R1 or 100R5 wire braid hose. While discharge networks constructed completely from rigid tubing may make assembly and maintenance procedures difficult and awkward, use of rigid tubing in areas of a vehicle that are difficult to access during inspection procedures or may be subject to extreme heat may prove to be beneficial in the long run. To design a discharge network using portions of rigid tubing, observe the following rules: 1. The design must comply fully with the specifications for overall hose lengths, hose diameters, number of elbows and imbalances shown in section 4.C. 2. A change from flexible hose to rigid tubing (or from tubing to hose) may be make only once per hose section. (A hose section is defined as that length connecting any two flow dividing fittings.) 3. Tables for hose limitations found in section 4.C. specify a maximum allowable imbalance of 3:1 for the lengths of sections of hose exiting from any given tee or distributor. When using a combination of hose and tubing, within one network, two additional imbalance requirements must be met: The individual lengths of each piping material, tubing and hose, used to plumb a section on one branch of any tee or distributor must be within a 3:1 ratio of the length of the same piping material used to plumb each of the sections on the other branches of that tee or distributor. As with the overall 3:1 imbalance, these individual imbalances must be determined for a distributor using the minimum vs. maximum piping lengths. The illustration a right shows proper observance of these rules. The example network is designed for a V25 system using a distributor. Note the following: (1) The 15 foot (4.6 meters) maximum length for each section has been observed. (2) The imbalance between the longest section of 15 feet (4.6 meters) and the shortest section of 5 feet (1.5 meters) is within 3:1. (3) The imbalance between the longest flexible hose section of 6 feet (1.8 meters) and the shortest hose section of 2 feet (.6 meter) is within 3:1. (4) The imbalance between the longest section of rigid tubing of 9 feet (2.7 meters) and the shortest length of tubing of 3 feet (.9 meter) is also within the required 3:1 imbalance ratio. Also note that if a section of rigid tubing is used on one branch of a distributor or tee, then a section of rigid tubing must be used on all branches to keep the number of flow restrictions created by transition from flexible hose to tubing equal on all side of the distributor or tee. Material Rigid tubing used in discharge networks must be Type 304 or Type 316 Seamless Stainless Steel conforming to ASTM-A-269. Only 3/4 inch (19mm) outside diameter tubing may be used in place of 3/4 inch (19mm) inside diameter flexible hose. Only 1/2 inch (12mm) outside diameter tubing may be used in place of 1/2 inch (12mm) inside diameter flexible hose. Fittings Fittings for connection of rigid tubing must be constructed of Type 316 Stainless Steel, must be of welded or compression fitting type, and must be recommended by their manufacturer for use with ASTM-A-269 tubing. Swagelok and CPI Parker comprise a partial list of manufacturers for stainless steel tube fittings. Always follow manufacturer's instructions and specifications for proper fitting assembly.

48 Part Number Rev. C October 1997 Page E. Actuation Network Hose Limitations (Pneumatic Actuation Applications) When an AMEREX fire suppression system with remote pneumatic actuation capability is installed, a pneumatic control head and vent check, along with one or more pneumatic Manual Actuators must be installed. In addition, if the system is equipped with automatic fire detection and system actuation, one Electrical/Mechanical Actuator must be installed. The system actuation network is a series of 1/4 inch (6mm) I.D. hoses, tees, and check valves used to carry nitrogen pressure from the actuators to the pneumatic control head located on the agent cylinder valve. The hose used is 1/4 inch (6mm) hydraulic hose and is specified in detail in Section 4.G. Figure 4.9 shows a typical system actuation network. Figure Actuator System Actuation Network CHECK VALVE MANUAL ACTUATOR #2 PRESSURE OPERATED MANUAL ACTUATOR #1 DIMINSIONS IN (- -) = METERS In designing a system actuation network, there are four very important factors to consider. The first is that two check valves must be used, one on each inlet, of any tee where the hoses leading from any two actuators join together. This ensures that only the direct route from an actuator to the pneumatic control head is pressurized by the nitrogen actuation pressure. Without the check valves, the entire network would have to be pressurized before the pneumatic control head could open the discharge valve thus wasting nitrogen pressure and possibly increasing the reaction time of the system. The second factor is that the total hose length along a direct path from any one actuator to the pneumatic control head must be not more than 125 feet (38 meters). In the example network in Figure 4.9, the total length of hose in the network is 178 feet (54.3 meters) which includes the 3 foot (.9 meter) section running to the Pressure Operated Switch. However, the hose distances from the actuators to the control head are 83 ft. (25.3 meters), 68 ft. (20.7 meters) and 88 ft. (26.8 meters). Because check valves are used at the inlet sides of Tl and T2 which limits the flow of nitrogen pressure to the shortest path from actuator to control head, the network is acceptable. Third, one check valve must always be used as a safety device at the inlet of each pneumatic control head. By using this valve, nitrogen actuation pressure is trapped in the pneumatic control head, thereby keeping the discharge valve open for the duration of the discharge even if a leak develops somewhere else in the actuation network. Fourth, if a Pressure Operated Switch is used in the actuation network, the distance from the tee to the switch pressure inlet must not exceed 3 feet (.9 meter), and the amount of hose used to connect the Pressure Operated Switch must be deducted from the 125 ft. (38 meters) maximum hose length allowance. The switch must be plumbed into the actuation line after the last actuator junction to insure pressure will reach the switch from any actuator location. Always mount the Pressure Operated Switch vertically with the manual reset button on top. Do not use a check valve in the hose directly before the Pressure Operated Switch, as it will trap pressure in the switch and make manual reset of the button very difficult.

49 Part Number Rev. C October 1997 Page F. Multiple Agent Cylinder Networks (Pneumatic Actuation Applications) The size of the vehicle and its hazards often require that more than one agent cylinder be used. The models V13, V25, VH25 (Horizontal) and V50 can be used in multiples and in any combination as long as the following rules are strictly observed:. The agent distribution network of each agent cylinder must be piped completely independent of all other agent distribution networks and each network must comply with the hose limitations as specified in section 4.C.. A maximum of eight agent cylinders may be connected to operate from a single pneumatic actuation network. The hose length along a direct path from any one remote actuator to the last pneumatic control head does not exceed 125 ft. (38 meters).. A vent check, P/N 10173, is installed in only the last pneumatic control head in the actuation network. E/M ACTUATOR TO DISTRIBUTION NETWORK # TO DISTRIBUTION Figure 4 10: Typical multi-agent cylinder installation.

50 Part Number Rev. C October 1997 Page G Multiple Agent Cylinder Networks (Electrical Actuation Applications) The size of the vehicle and its hazards often require that more than one agent cylinder be used. The models V13, V25, VH25 (Horizontal) and V50 can be used in multiples and in any combination as long as the following rules are strictly observed: The agent distribution network of each agent cylinder must be piped completely independent of all other agent distribution networks and each network must comply with the hose limitations as specified in section 4.C. A maximum of four agent cylinders may be connected to operate from a single electric actuation network. The wire length along all paths from the Circuit Monitor or Control Panel to all Electric Control Heads does not exceed 125 ft. (38 meters). Circuit Monitor / Control Panel To Thermostats and/or End of Line Module / Manual Actuatio f-.- Multiple Control Head Adapter o vehicle Battery Figure 4_10A: Typical

51 Part Number Rev. C October 1997 Page H Hose Coupling and Fitting Specifications Hose: The flexible hose used to construct the discharge and actuation networks on the AMEREX Vehicle Fire Suppression System must meet or exceed either SAE loor or SAE 100 R1 hose specifications. Further details may be obtained from the following standards: SAE Hydraulic Hose Fitting Standard J516A SAE Hydraulic Hose Standard J517A SAE Standard J343 A list of hose manufacturers and corresponding part numbers is given in Table 4.6. It is not intended to be a complete list. The hoses listed meet the SAE standards given as well as USBM Flame Resistance Requirements. Any hose meeting the above specifications is acceptable. Some Installations will require the use of hose that is rated for use at -65 deg. F. (-54 C.). Several hoses are listed that are suitable for these installations. Couplings: Couplings used on any hose must be only those specified by the hose manufacturer for the hose in use. Most hose manufacturers provide a wide selection of both crimp-on or reusable type couplings in solid or swivel configurations. Fittings: Fittings such as elbows and tees used to plumb coupled hose assemblies must be galvanized malleable or ductile iron, black or galvanized steel, stainless steel, copper or brass. Cast iron fittings shall not be used. Fittings used to connect discharge hoses shall be rated for used at 600 WOG (41.4 bars). Fittings used to connect actuation hoses shall be rated for use at 1800 psi. (124 bars) minimum. Table 4.6: (>>>>>>>>>>>>>>>> -40 F. [-40 C.]~<<<<<C<CC~CCC~<<~~)(~~ F. [-54 C.] ) Vendor Size 100R5 100R5 100R1A 100R1AT MIL-H Rubber Cover Reduced O.D. 1/4 inch = (6mm). l/2 inch = (12mm). 3/4 inch = (19 mm).

52 Part Number Rev. C October 1997 Page I. Detection Network The detection network consists of a number of thermostats wired together in a continuous electrical circuit beginning at the Circuit Monitor or Control Panel and ending with an End of Line Module. The use of the End of Line Module allows the integrity of the wire, the thermostats, and the wiring connections to be monitored. Thermostats are placed above or as near as practical to hazard areas as determined by the hazard analysis (See Section 3). The objective is to position the thermostats so that they experience the shortest possible delay between fire ignition and contact closure. Care must be taken to position the thermostats so that they will not easily be damaged during regular vehicle use and maintenance. See Section 3.E. for information regarding thermostat temperature selection.

53 Part Number Rev. C October 1997 Page 5-1 Section 5 Electrical Controls On any Model V13, V25, VH25 (Horizontal) or V50 system installed with automatic detection and pneumatic actuation, any one of the following circuit supervision control panel units is required. On systems using electric actuation, any one of the following circuit supervision control panel units may also be used. All Circuit Monitor and Control Panels contain a permanent internal Back-Up Battery. The purpose of the Back-Up Battery is to provide temporary power to the Fire Suppression System in the event of interruption of vehicle battery power. The particular unit to use should be selected on the basis of the features needed by the user, and by any local authorities having jurisdiction. Features of each unit are described in detail below. 5.A. Modular Circuit Monitor The Modular Circuit Monitors P/N and P/N provide color coded pluggable connections for all fire suppression system electrical circuits. The P/N has the lead wires exiting out the bottom of the panel enclosure. The P/N has the lead wires exiting out the back of the panel enclosure. The units provide supervision of the System Power, Squib or Electric Actuator, and two Class B Heat Detector circuits. In the event of fire or component failure, the Circuit Monitor provides a warning via LED system status indicators, and an audible alarm. The unit is designed to operate using either 12 or 24 volt DC vehicle power. The Modular Circuit Monitor Plus must always be connected directly to the vehicle battery usinq only an AMEREX manufactured power supply lead. Power must always be drawn directly from the vehicle battery and never from any other source. The Circuit Monitor then provides continuity supervision by passing a small amount of electrical current through the squib or electric actuator, and heat detector circuits. The Modular Circuit Monitor is provided with a self charging internal Back-Up Battery which will keep the Fire Suppression functional for 24 hours if vehicle battery power is lost. During Back-Up Battery operation, the functions of the LED's and audible alarms are suspended to conserve power. WARNING: AT NO TIME SHOULD THE BACK-UP BATTERY BE USED AS THE MAIN POWER SOURCE. THE SYSTEM MUST BE CONNECTED DIRECTLY TO THE VEHICLE BATTERY AS A MAIN POWER SOURCE. THE BACK-UP BATTERY IS RATED FOR SERVICE ABOVE 0 F (-18 C), AND MUST NOT BE INSTALLED IN AREAS WHERE TEMPERATURES CAN BE LOWER FOR RELIABLE OPERATION. In a normal situation, all circuits are intact. A Green LED indicating "System OK" is illuminated on the front of the circuit monitor. In a fire situation, contacts in a heat detector close providing an electrical short circuit through the squib or electric actuator to vehicle ground. This short circuit causes the squib or electric actuator to fire thereby actuating the fire suppression system. Upon system actuation, the Circuit Monitor green "System OK" LED goes out, the audible alarm sounds and a red "Fire" LED illuminates. When the fire is extinguished and the heat detector contacts reopen, the green "System OK" LED will again illuminate. Both red and green LED s will remain on until the system is serviced. The audible alarm mav be silenced by pressing the "Push to Silence" button.

54 Part Number Rev. C October 1997 Page SYSTEM OK [FIRE (SYSTEM ACTIVATED) 0 Si I ence Engaged OSERVICE SYSTEM Figure 5_1: Modular Circuit Monitor Plus Figure 5_2: Modular Control Panel

55 Part Number Rev. C October 1997 Page B. Modular Control Panel The Modular Control Panels provide color coded pluggable connections for all fire suppression and warning system electrical circuits. The P/N has the lead wires exiting out the bottom of the panel enclosure. The P/N has the lead wires exiting out the back of the panel enclosure The units provide supervision of the System Power, Squib / Electric Actuator, Heat Detection, Fire Warning System and is capable of accepting input from the Agent Cylinder Pressure Switch circuits. The Control Panel provides warning in the event of fire or failure of any of these circuits. If equipped with the Agent Cylinder Pressure Switch, a warning will also be given if pressure in the agent cylinder is lost. The Modular Control Panel features visual LED system status indicators, a silencable audible alarm, a "Push to Test" button, a time delayed relay rated for 10 amps at 24 volts DC containing both normally open and normally closed functions, and internal Back-Up Battery. The time delayed relay is adjustable for a zero to thirty (0 to 30) second countdown and may be connected to the vehicle electric fuel pump, fuel shut off solenoid, or other device for engine shutdown or warning purposes as long as the current draw on that circuit does not exceed the 10 amp rating. As with the other electric panels, power must always be drawn directly from the vehicle battery usinq only an AMEREX manufactured Power supply lead. The Control Panel then provides circuit supervision by passing a small amount of electrical current through the Squib / Electric Actuator, Heat Detector, and Agent Cylinder Pressure Switch (if so equipped) circuits. WARNING: IF THE VEHICLE HAS BEEN EQUIPPED WITH THE VEHICLE ENGINE SHUTDOWN CAPABILITY, ALL POTENTIAL OPERATORS MUST BE TRAINED IN SAFETY PROCEDURES TO BE TAKEN IN THE EVENT OF LOSS OF POWER AND/OR STEERING AND BRAKES. ONCE A FIRE CONDITION IS DETECTED, THE ENGINE SHUTDOWN TIMER PUSH TO DELAY BUTTON ON THE PANEL MAY BE PRESSED AS MANY TIMES AS NEEDED TO DELAY ENGINE SHUTDOWN AND ALLOW MORE TIME TO BRING THE VEHICLE TO A SAFE AND CONTROLLED STOP. THE ENGINE SHUTDOWN TIMER LED ILLUMINATES JUST BEFORE THE TIMER REACHES ZERO. OPERATORS SHOULD ALSO REALIZE THAT PUSHING THE DELAY BUTTON WILL NOT DELAY DISCHARGE OF THE FIRE SUPPRESSION SYSTEM EXTINGUISHERS. ALL POTENTIAL OPERATORS MUST BE TRAINED THOROUGHLY IN THE USE OF THIS FEATURE. In a Normal situation, all circuits are intact. A green LED indicating "System OK" is illuminated on the front of the Control Panel. In a fire situation, the Control Panel enters an "alarm mode." This alarm mode is normally activated when a fire is detected by any one of the thermostats and actuates the suppression system automatically. (See case one below.) However if the system is equipped with an agent cylinder pressure switch, the alarm mode will also be activated when the suppression system is actuated manually. (See case two below.) Fire Situation, Case One: If the fire system is actuated automatically, heat detector contacts close providing a circuit through the squib or electric actuator to vehicle ground. This circuit causes the squib or electric actuator to fire and actuate the fire suppression system. When the squib or electric actuator fires, the Control Panel red "Fire" LED is illuminated, the alarm sounds, and the zero to thirty second timer begins countdown to relay transfer. The audible alarm may be silenced by pushing the Push to Silence button on the Control Panel. This will light the "Silence Engaged" LED. The alarm must first sound before the silence button becomes operational. The alarm cannot be made to silence prior to a fire or fault condition. The engine shutdown "Shutdown Reset" button may be pushed at any time before the countdown timer reaches zero. This resets the timer to its original pre-set time. Releasing the delay button resumes the countdown. When the timer reaches zero, the relay contacts switch and he Relay Engaged LED remains on. The Control Panel remains in alarm (red "Fire" LED and audible alarm on) until system maintenance is performed.

56 Part Number Rev. C October 1997 Page 5-4 Fire Situation, Case Two: When the fire suppression system is equipped with an agent cylinder pressure switch and the system is activated manually with a manual actuator or manual actuation switch, the normally closed agent cylinder pressure switch opens. When the pressure switch opens, the Control Panel red "Fire" LED lights up, the audible alarm sounds, and the zero to thirty second engine shutdown timer starts. The "Alarm Silence" and engine shutdown "Shutdown Reset" buttons both function the same as before in "Case One." The Control Panel will remain in alarm (red "fire" LED and audible alarm on) until system maintenance is performed. If a fault situation occurs in the squib, electric actuator or agent cylinder pressure switch circuits, the red "Fire" LED will illuminate, the audible alarm will sound, and the zero to thirty second engine shutdown timer will start. The red "Fire" LEDs will remain lit until the fault condition is repaired. A tvpical fault condition in the squib or electric actuator circuit would be: squib / actuator lead broken or missinq. disconnected squib connector, blown squib or electric actuator, squib or actuator lead shorting to ground etc. A tvpical fault in the aqent cvlinder pressure switch circuit would be a broken wire. disconnected pressure switch. agent cvlinder has lost pressure. missinq jumper in panel on systems not usinq the agent cvlinder pressure switch, etc. IF a fault situation occurs in the heat detector or power supply circuits, the green "System OK" LED will turn off, but the audible alarm and shutdown timer will not be activated. This can be an indication that the internal circuit breaker has opened due to an over current condition (voltage higher than 30 VDC and/or over 10 amps). The breaker will not reset as long as the problem exists. A tvpical fault in the detector circuit would be a broken or shorted wire, wiring connections loose, thermostat faultv or stuck in contact closed position or manual actuation switch in on position. A fault in the power supply circuit usually means power has been lost to the panel. Check power supply fuse and wiring connections at battery and control panel. To verify the proper function of the Control Panel, press and hold the push to test button on the panel. The test button is located behind the Amerex Diamond. Holding this button down simulates a closed thermostat and a fired squib. The red "Fire" light comes on, the audible alarm sounds, the green "System OK"led turns off, and the timed relay countdown begins. Holding the button down until the engine shutdown timer reaches zero will cause engine shutdown. Release of the test button returns the Control Panel to normal operation. Pushing the test button will not cause discharge of the fire extinguishers. 5.C. Back-Up Battery All Circuit Monitor and Control Panels are provided with an internal Back-Up Battery. The backup battery is kept fully charged by an internal battery charging unit. In the event of vehicle power failure (removal of vehicle battery, electrical fire, accident, etc.) the backup battery provides power to operate the fire suppression system automatically for 24 hours. All auxiliary functions (System Status LEDs, audible alarm, engine shutdown, etc.) are suspended in order to provide extended battery life. The red "Service System" LED indicator is illuminated when the system is running off of backup battery power. The battery charging unit is also supervised by the control panel. If a fault occurs (back-up battery unplugged, battery dead, charging system trouble) the Control Panel green System OK LED and the "Service System" LED will not be illuminated. WARNING: AT NO TIME SHOULD THE BACK-UP BATTERY BE USED AS THE MAIN POWER SOURCE. THE SYSTEM MUST BE CONNECTED DIRECTLY TO THE VEHICLE BATTERY AS A MAIN POWER SOURCE. THE BACK-UP BATTERY IS RATED FOR SERVICE ABOVE 0 F (-18 C), AND MUST NOT BE INSTALLED IN AREAS WHERE TEMPERATURES CAN BE LOWER FOR RELIABLE OPERATION.

57 Part Number Rev. C October 1997 Page 6-1 Section 6 Installation THE PRIMARY CAUSE OF SYSTEM MALFUNCTIONS IS POOR INSTALLATIONS! Installation of the AMEREX Fire Suppression System can begin only after a complete hazard analysis (Section 3) has been performed and documented, and a complete system layout design (Section 4) has been made and documented. Failure to complete these two steps prior to system installation can lead to false system discharges or failure to completely extinguish a fire. At no time should an AMEREX Fire Suppression System be installed without first completing the above steps. Upon completion of these two prerequisites, installation should be performed as follows: A. MOUNT HARDWARE AND INSTALL COMPONENTS Mount the agent cylinder brackets and install the agent cylinders. Mount the manual or pneumatic control heads on the discharge valves. Mount the electric control heads on the discharge valves (electrically actuated systems only) Mount the distributors, thermostat brackets, and nozzle brackets. Install and aim nozzles. Mount the actuator brackets and install actuators. Do not install N2 cylinders yet. (Pneumatic Actuated Systems Only) Mount manual actuation switches (Electrically Actuated Systems) Mount pressure operated switch, circuit monitor or control panel. Mount thermostats. Install agent cylinder pressure switch. B. CONNECT DISCHARGE AND ACTUATION HOSE NETWORKS. C. CONNECT DETECTION, ACTUATION AND POWER SUPPLY WIRING. D. PLACE SYSTEM IN SERVICE. E. PROVIDE TRAINING FOR THE EQUIPMENT OWNER/OPERATOR. 6A. Mounting Hardware and Installing Components Agent Cylinder Brackets must be fastened to the vehicle either by welding or by bolting using SAE grade 5 or better 1/2 inch (12mm) bolts. If brackets are welded in place, all metal left exposed by welding heat must be repainted. Locate the Agent Cylinder Brackets observing-the following guidelines. [1.] Locate near the hazard or hazards being protected, but not where they will be exposed to a fire or explosion in the hazard area. [2.] Locate where the Agent Cylinder will be protected from physical damage or abuse. [3.] Locate where the Agent Cylinder will be easily accessible for inspection and service. [4.] Locate where the Agent Cylinder will not be exposed to temperatures above 150 degrees F. (66 C.) or below -65 degrees F. (-54 C.). [5.] Locate where discharge and actuation hose lengths will conform to the hose limitations as specified in Section 4. [6.] Locate on a flat and rigid surface capable of supporting the weight of the Agent Cylinder and its bracket as it vibrates under operating conditions. [7.] Locate in a vertical or near vertical (15 degree Figure 6.1: Mounting options - V50 Agent Cylinder Bracket. angle offset maximum) orientation relative to the ground for the V13, V25, and V50 models. See Figure 6.1. When installing any horizontal agent cylinder bracket P/N or P/N 13930, the long side of the bracket must always be mounted horizontallv or near horizontallv (5 deqree anqle offset maximum) orientation relative to the qround. See Figure 6.1A on the next page.

58 Part Number Rev. C October 1997 Page 6-2 [8.] On Mechanical Control Head installations. locate where T-handle will be within easy reach of the equipment operator and can be actuated with a pull of the T-handle towards the operator. The Agent Cylinders can be installed once the agent cylinder brackets are secure. Install agent cylinders with the discharge outlet facing in the direction that will be required to connect to the discharge hoses. The discharge opening is the 1 1/4 inch opening opposite the gauge. When installing the VH25 (Horizontal) Agent Cylinders, extreme care must be taken to insure that the Agent Cylinder is mounted in its bracket horizontally (parallel with the ground) and with the orientation arrow engraved on top of the valve pointing straiqht down. See Figure 6.1 B. Warning! Mounting of the VH25 (Horizontal Model) agent cylinders otherwise will result in incomplete discharge of the extinguishing agent. Bolt the two padded straps in place using the stainless steel bolts, washers, and self locking nuts provided. Tighten the nuts until the rubber pads are firmly compressed against the agent cylinders but not bulging from under the straps. Figure 6.1A. Correct VH25 (Horizontal) Agent Cylinder Bracket Orientation. BASE BOTTOM OK DOWN BASE BOTTOM TO SIDE OK BASE BOTTOM SUSPENDED OK END VIEW END VIEW EASE MAY BE MOUNTED AT ANY ANGLE AS LONG AS BASE BOTTOM IS PARALLEL TO THE GROUND BASE MOUNTED VERTICALLY NOT OK! GR.(-J-JJND :. I.:.: :.:.:.:. 1. I.:.: WARNING: DO NOT ATTEMPT TO USE THE V25 VERTICAL MOUNTING BRACKET, P/N 10180, WITH THE VH25 (HORIZONTAL) AGENT CYLINDER. IT WILL FIT, BUT THE V25 BRACKET LACKS THE END PLATE TO KEEP THE VH25 (HORIZONTAL) AGENT CYLINDER FROM SLIPPING OUT. ALWAYS USE A VH25 HORIZONTAL BRACKET P/N 11338

59 Part Number Rev. C October 1997 Page 6-3 Figure 6.1B. Correct VH25 (Horizontal) Agent Cylinder Orientation. GAUGE FACING \ GREEN PIE IN GAUGE AT TOP j POINT DOWN ~R~~~~~-...-~...--.~ Note in Figure 6.1B cut-away side view, orientation of the internal right angle down tube. Proper orientation of the tank is necessary so the pick up opening is always aqainst the bottom side of the aaent cylinder. If aaent cylinder is oriented other than as shown, incomplete extinquishinq agent discharge will result. The Mechanical Control Head (T-Handle) or Pneumatic Control Heads should be mounted only after the agent cylinders are in place. Remove the discharge valve shipping plate and use its two 5/16" stainless bolts (and nuts if installing the T-Handle) to secure the control head to the discharge valve. Warning: Make sure that the stem of either control head is retracted before bolting it to the valve. Otherwise, the extended stem will open the valve and agent discharge will result. Apply thread locking compound to the threads, and tighten the two bolts securely using a 1/2" wrench. On mechanical control head installations, always orient the T-handle lever so that a pull towards the operator is required to actuate the system. Apply the instruction label, P/N 10891, on a smooth flat surface near the Agent Cylinder where it will be obvious to the operator it a fire situation. See Figure 6.2. On pneumatic control head installations, assemble a vent check P/N into the 1/4 inch port of the outlet side of the control head. Wrap the male threads of the vent check with Teflon tape before installing. Tighten the vent check into the control head 2 1/2 to 3 full turns past hand tight using a 9/16" wrench. Figure 6.2: Agent cylinder oriented for pull of Mechanical Control Head lever.

60 Part Number Rev. C October 1997 Page 6-4 On Electric Control Head installations, bolt the Electric Control Head to the top of the Agent Cylinder Valve after verifying the piston inside the Electric Control Head is free to travel to it's upward position. Do not install the Electric Actuator at this time. The Agent Cylinder Pressure Switch can be used on all installations where the AMEREX Modular Control Panel is used. To install the switch, remove the cap from the air valve on the agent cylinder valve. Make sure the male flare on the air valve and the female threads and the female flare on the pressure switch are free of debris that could cause leakage. Apply sealant sparingly to male threads, and thread the switch onto the air valve and tighten 1/8 turn past hand tight using a 9/16 open end wrench.once the threading of the switch onto the air valve has bequn, it should be completed quickly to prevent extinguishinq chemical from leakinq onto the flare connection and partial (or complete) loss of agent cylinder pressure. After assembly, check for leakage at the pressure switch to air valve connection using a suitable water-based detecting fluid. The Distributor can be mounted to the vehicle in any orientation as long as access to the five threaded ports is not obstructed. Before mounting, make sure that the hose lengths leading to and from the distributor will not fall outside the hose limitations specified in Section 4. The distributor may be attached either by welding or by using SAE grade 2 or better 1/4" (6mm) bolts. The distributor is painted to prevent corrosion. If the distributor is welded on, it should be repainted where welding heat has removed the paint. See Figure 6.3. Nozzle Brackets must be securely mounted for the fire suppression system to properly protect those high risk items identified in the hazard analysis. They may be mounted in any orientation by welding or by using SAE grade 2 or better 1/4 inch (6mm) bolts. If bolts are used, apply one or two drops of thread locking compound to the bolt threads before tightening. The nozzle brackets are painted to prevent corrosion. If they are attached by welding, they should be repainted where welding heat has removed the paint. Hazards at which the nozzle is directed are determined in the Hazard Analysis. (See section 3.) Locate the nozzle brackets observing the following guidelines; [1.] Locate where nozzles will be protected from mechanical, environmental, or other conditions that could render them inoperable. [2.] Locate where nozzles will not readily be put out of alignment by normal vehicle operation, or vehicle maintenance. [3.] Locate where, at the time of discharge, each blow-off cap encounters no obstructions that may hinder its displacement from the nozzle or affect discharge of the dry chemical. [4.] Locate where the nozzle can deliver extinguishing chemical directly on the hazard in an uninterrupted cone pattern. The cone pattern is approximately 3 feet (.9 meter) in diameter at 3 feet from the nozzle. A small adjustable beam "Mag-Light" type flashlight is handy to use in positioning and aiming nozzles. Adjust the flashlight beam so it is approximately 3 feet in diameter 3 feet from the flashlight lens. The light beam will now roughly duplicate the chemical dispersion pattern. Hold the flashlight where you think the nozzle should be placed and observe where the light beam shines. [5.] Locate where the nozzle will deliver its extinguishing chemical with (instead of against) the flow of air from the radiator fan.

61 Part Number Rev. C October 1997 Page 6-5 The Nozzles can be installed directly into the nozzle brackets, or into elbow fittings and then into the nozzle brackets. In all cases, the nozzles and fittings should first be tightened a minimum of 3 turns past hand tight, then tightened to the desired orientation to insure proper aiming is maintained. "Fine tuning" of a nozzle's aim may be accomplished by bending the nozzle bracket using locking pliers or an adjustable wrench Several examples of proper nozzle installations are given in Figure 6.4. After installing the nozzles, install the nozzle blow-off caps. Slip the retaining loop of the blow-off cap over the hex on the nozzle, wipe a thin coating of silicone grease around the inside of the cap, push the cap onto the nozzle until it bottoms, rotate the blow-off cap as needed until the retaining loop is arching downward so that when it is blown off it will hang clear of the nozzle outlet NOZZLE BRACKET WITH Figure 6 4. Nozzle HEX NIPPLE & and Nozzle Bracket ' ELBOW mounting options NOZZLE BRACKET ONLY -I NOZZLE BRACKET WTIH \ HEX NIPPLE &

62 Part Number Rev. C October 1997 Page 6-6 Actuator Brackets (pneumatic actuated systems) can be mounted in any orientation as long as easy access to the pull pins and actuator palm buttons are provided. When placing either bracket, consideration should be given to access for removing the nitrogen cylinder and viewing the nitrogen cylinder gauge. Use SAE grade 2 or better 1/4 inch (6mm) bolts or weld the brackets to the vehicle. If the brackets are welded in place. all metal left exposed by the welding heat should be repainted. When installing the outdoor actuator bracket, it is a good practice to thread the four 1/4 inch X 1/2 inch stainless steel cover screws loosely into the bracket to prevent their being lost until time to Place the System in Service. (Section 6) Locate the actuator brackets observing the following guidelines: [1.] Locate where actuators will not be subject to mechanical, environmental, or other conditions that could render them inoperable. [2.] If the bracket will be used for an Electrical / Mechanical Actuator, it must be located inside the vehicle cab out of the weather. [3.] Locate at least one manual actuator no more than 5 ft. above the ground convenient and easily accessible to the vehicle operator in route of egress. [4.] Cab mounted actuators must be in reach of the equipment operator while operating the equipment. [5.] Locate all actuators where the Nitrogen cylinders will not be exposed to temperatures above 150 degrees F. (66 C.) or below -65 degrees F. (-54 C.). [6.] Locate on a rigid flat surface capable of supporting the weight applied by the actuator assemblies as they vibrate under vehicle operating conditions. [7.] Locate where the Nitrogen cylinders and actuators will be easily accessible for inspection and servicing. [8.] Locate where the actuation hose lengths will not exceed the 125 ft. (38 meters) maximum. The Manual Actuator and the Electrical Manual Actuator are held in the Actuator Brackets by two 1/4 inch stainless steel Allen head cap screws which are provided. These screws thread into square nuts held in place on the actuator bracket by spring steel cages. The nuts float loosely to aid in alignment until the tightened 1/4 inch screws clamp them firmly in place. Use a 3/16 Allen (hex) wrench to secure the mounting screws. Do not install the Nitrogen cylinders until time to Place the System in Service as described in section 6. to prevent accidental system discharge. Last, apply the instruction label, P/N 10574, furnished with the actuator, on a smooth flat surface near the actuator where it will be obvious to the operator in a fire situation..

63 Part Number Rev. C October 1997 Page 6-7 Manual Actuation Switches can be mounted in any orientation as long as easy access to the pull pins and actuator button are provided. Use SAE grade 2 or better 1/4 inch (6mm) bolts. Do not attempt to weld the switch housing to the vehicle as damage to the switch will occur. Locate the Manual Actuation Switches observing the following guidelines: [1.] Locate the manual actuation switches where they will not be subject to mechanical, environmental or other conditions that could render them inoperable. [2.] Locate at least one manual actuation switch no more than 5 ft. above the ground convenient and easily accessible to the vehicle operator in route of egress. [3.] Cab mounted manual actuation switches must be in reach of the equipment operator while operating the equipment. [4.] Locate all manual actuation switches where they will not be exposed to temperatures above 150 degrees F. (66 C.) or below -65 degrees F. (-54 C.). [5.] Locate on a rigid flat surface capable of supporting the weight of the switch and housing. [6.] Insure that wiring running to and from the actuation switches is protected from abrasion and damage and is secured to the vehicle Make certain the pull pin and lock wire seal are in place. Connect wiring as shown in the schematic shown in section 6C of this manual. Last, apply the instruction label, P/N 10574, furnished with the actuator, on a smooth flat surface near the actuator where it will be obvious to the operator in a fire situation. r

64 Part Number Rev. C October 1997 Page 6-8 The Pressure Operated Switch must be bolted to the vehicle using (4) number 10 screws through the four mounting feet provided on the switch enclosure box. The enclosure is waterproof and can be mounted inside the vehicle cab or elsewhere on the vehicle. The Pressure Operated Switch is activated by nitrogen pressure tapped from the actuation network of the pneumatically actuated system and can be used to initiate engine shutdown or activation of auxiliary alarms. The switch actuates automatically upon suppression system discharge. To reset the switch, a reset button on top of the switch enclosure is pressed after actuation system pressure subsides. A 1/4 inch NPT fitting is provided on the bottom of the switch enclosure for connection into the actuation hose network. An opening with an electrical wire strain relief for up to 14 gauge wire is provided for wire entry. When used in pneumatic actuated systems that have multiple manual or electrical/manual actuators, it must be plumbed (using a Tee) in the actuation network between the last actuation point and the agent cylinder (See Section 4.E., Figure 4.9) to insure that nitrogen pressure will reach the switch from any actuator location. Electrical connections are covered in section 6.C. The Pressure Operated Switch may be mounted anywhere along the actuation hose network as long as the following guidelines as observed: [1.] Locate where it will not be subjected to mechanical, environmental, or other conditions that could render it inoperable. [2.] Locate on a flat rigid surface capable of supporting the weight applied by the switch as it vibrates under vehicle operating conditions. [3.] Locate where the reset button and front access panel will be easily accessible for inspection and servicing. Mount vertically with the manual reset button on top. [4.] Locate where the actuation hose running from the main actuation network to the switch does not exceed 3 feet (.9 meter). The length of the actuation hose used to connect the pressure operated switch must be deducted from the 125 ft. (38 meter) maximum hose length allowance as specified in section 4. [5.] Do not install a check valve in the hose running from the main actuation hose network to the pressure operated switch as it will trap nitrogen pressure in the switch and make pressing the reset button very difficult. [6.] Wrap the male threads of the hose fittings used for hose connections with Teflon tape before tightening. The Modular Circuit Monitor or Control Panel must always be mounted in the vehicle cab protected from the weather. To maintain the environmental integrity of the enclosures of these units, use only the mounting holes provided. All units must be mounted in the immediate visual field and within reach of the vehicle operator while he is operating the vehicle. The Panels are shipped with End of Line Modules attached to the terminals of the thermostat leads (Color coded green). Do not discard the End of Line Modules when installing the panels. They must be removed later and installed at the end of each thermostat lead. Thermostats; The thermostats are the Decision making device of the automatic fire suppression system. it is the thermostat s sole function to signal the system to discharge in the event of a fire. Their selection and installation must be done with the utmost care. Failure to do so can result in false system discharges or failure to completely extinguish a fire. The local sensing or Spot Thermostats must be mounted in each protected compartment or area of the vehicle as determined by the Hazard Analysis described in Section 3. When the ambient temperature around the thermostat reaches the rated temperature of the thermostat, internal contacts inside the thermostat body close completing an electrical circuit to fire the squib or electric actuator. When the thermostat cools, these contacts reopen and reset the thermostat to its normal operating condition. The condition of the spot detector is monitored for faults by the electrical circuit from the Circuit Monitor or Control Panel. They must be installed in such a way and in a location that they will be protected from physical damage and from environmental damage due to moisture. Complete wiring instructions are given in section 6.C.

65 Part Number Rev. C October 1997 Page 6-9 Modular Spot Thermostats are equipped with steel mounting brackets and color coded Amerex Click Lock electrical connectors as shown in figure 6.6A. The mounting brackets may be fastened to the vehicle in any orientation by bolting using SAE grade 2 or better 1/4 inch (6mm) bolts. Always apply one or two drops of thread locking compound to the bolt threads before tightening. DO NOT WELD THE BRACKETS TO THE VEHICLE AS HEAT FROM WELDING WILL DAMAGE THE DETECTOR ASSEMBLY. DO NOT PAINT THERMOSTATS. L-J Figure 6.6A Example Thermostat Mountings Locate and mount the thermostats observing the following rules: [1.] Locate where thermostats will be protected from mechanical, environmental, or other conditions that could render them inoperable. [2.] Locate near the hazard as determined by the hazard analysis. Verify the temperature setting of the chosen thermostat at each location by referring to the hazard analysis ambient temperature measurements taken. [3.] Thermostat brackets must be positioned so as not to shield the thermostat from the heat source of the protected area. [4.] Locate where they are accessible for maintenance and service. [5.] Do not paint thermostats as paint acts as a heat shield. [6.] Do not locate thermostats on any component of a vehicle that is likely to be removed during maintenance or service. Examples would include; air cleaner housings, engine carriage brackets, removable guards or shields, brackets holding other components such as alternators and pumps, [7.] Locate spot sensor above the hazard area.if possible locate in cavities or under bulkheads where heat from a fire will be trapped in order to minimize sensor response time. [8.] Do not attach the thermostat directly on a hot component such as an exhaust manifold, turbocharger, engine block or radiator as heat will be transmitted to the thermostat through it s metal mounting bracket.

66 Part Number Rev. C October 1997 Page 6-10 Firetrace Linear Pneumatic Heat Actuated Thermostats The Firetrace heat detector, P/N 13886, is a linear, pneumatic operated, heat actuated, four wire contact closure device. It uses a 35 foot (10.6 meters), 1/4 inch (6 mm), O.D. heat sensitive flexible polymer tube which is pressurized with compressed air to 70 p.s.i. from a small reservoir cylinder at one end of the tube. Pressure contained in the tubing holds a contact switch in the SENSING TUBING & CLAMPS Figure 6.6B Example of Firetrace placement. open position. wnen tne tune reaches a temperature of 400 F (200 C) anywnere along it's length, it ruptures and releases the compressed air which allows electrical contacts in the switch to close. The entire length of tube must be replaced after a fire. No splicing of the tubing is permissible, and doing so will void the Amerex system warranty. Replacement tubing is available as P/N and comes with all mounting and attachment hardware included. The thermostats are equipped with Amerex click lock electrical connectors to connect to Jumper Leads which connect to the circuit monitor or control panel. A gauge is provided on the reservoir cylinder to check air pressure, and air can be added to the cylinder as needed through a valve stem with a common air hose. The air cylinder includes a mounting bracket, and mounting clips are provided for the tubing. The cylinder mounting bracket and tubing mounting clips can be bolted to the vehicle using 1/4 inch (6 mm) bolts. Apply a drop of thread locking compound to bolt threads before tightening. Figure 6.6B shows a typical Firetrace installation. Locate and mount the Firetrace Heat Detector observing the following rules: [1.] Locate where all components will be protected from mechanical, environmental, or other conditions that could render them inoperable. [2.] Locate the air reservoir cylinder where it can be accessed for service and in a position that the gauge is visible to service personnel. The air cylinder may be mounted in any orientation. Insure the air cylinder is pressurized to 70 p.s.i. [3.] Locate the tubing near the hazard as determined by the hazard analysis. The melting point of the tubing is 325 F (163 C). Verify that the normal ambient temperature in areas where the sensing tubing is to be located is 225 F (107 C) or less by referring to the hazard analysis ambient temperature measurements taken.

67 Part Number Rev. C October 1997 Page 6-11 [4.] Locate the tubing where it is accessible for replacement and service. [5.] Do not locate tubing where in will be subject to damage from abrasion, sharp edges or moving parts. Avoid pinching by observing a minimum bend radius of 6 inches (15 cm). Locate retaining clips every 18 inches (45 cm) along the tubing and 1 inch from the end of the tube. Rubber grommets must be used when tubing is routed through a bulkhead or panel to protect the tubing from abrasion. [6.] Do not paint the tubing as paint acts as a heat shield. [7.] Do not locate air reservoir cylinder or tubing on any component of a vehicle that is likely to be removed during maintenance or service. If the reservoir cylinder must be located in the engine compartment, mount it as low, and as far away from heat sources as possible. [8.] Locate the tubing above the hazard area. If possible locate in cavities or under bulkheads where heat from a fire will be trapped in order to minimize sensor response time. [9.] NEVER attach the Firetrace tubing directly on a "hot" component such as exhaust manifold, turbocharger, engine block or radiator. Maintain a minimum distance of 18 inches (45 cm) above such hot components

68 Part Number Rev. C October 1997 Page B. Connection of Hoses With all components secured to the vehicle, the distribution and actuation hoses may be built and connected. Using a flexible tape, measure from component to component. Route the hose along the same paths as existing hoses on the vehicle. Do not cross the hoses through open areas where vehicle maintenance will be obstructed. Avoid running hoses through pinch points and articulating joints. If a hose must reach a component located on a movable surface, such as to a nozzle located on an engine cowling or tilt cab, route the hose first to the pivot hinge, then to the component so that movement of the vehicle surface will not be impeded. Once the hose lengths are determined, make a final check that they are within the hose limitations given in Section 4. Cut and couple all hoses. It is a good practice to mark the hose length on each hose as it is built to avoid confusion. Assemble all hoses to components along the predetermined routes. In connecting discharge hoses to tees, make certain that the supply hose attaches to the tee at the middle port, and that the two end ports are used as outlets. Figure 6..7 illustrates the correct and incorrect methods. Make sure that the actuation hoses are fitted with the required number of check valves as specified in Section 4. Secure hoses to the vehicle every few feet using UV resistant wire ties or "P" clamps. Also apply anti-tamper labels, P/N to hoses running near vehicle high maintenance areas to help to discourage inadvertent disconnection. If holes were cut in vehicle bulkheads to facilitate hose routing, line those holes with a grommet or automotive welting to prevent abrasion of the hose. CORRECT INLET 1 Figure 6.7: Proper vs Improper Tee connections for discharge hoses I P I ii 1 i- L-----i PLUMBING TEE OUTLET A OUTLET INCORRECT Tighten all hoses in place. On discharge hoses, tighten all pipe threaded connections to nozzle brackets, fittings, distributors, and discharge outlet fittings a minimum of one full turn past hand tight. Connect the main 3/4 inch (19mm) agent supply hose to the agent cylinder discharge fitting. Slip the retaining flange over the discharge fitting first, then tighten the fitting into the hose coupling. On actuation hoses, tighten all pipe threaded connections at actuators, check valves, fittings and pneumatic control heads three full turns past hand tight. Follow hose and coupling manufacturer recommendations on tightening other types of connectors.

69 Part Number Rev. C October 1997 Page C. Connection of Electrical Circuits WARNING: THE PRIMARY CAUSE OF FIRE SUPPRESSION SYSTEM MALFUNCTIONS HAS BEEN TRACED TO POOR INSTALLATION OF ELECTRICAL COMPONENTS AND POOR WIRING PRACTICES. THEREFORE, ONLY THOSE WIRING CONNECTION SCHEMATICS, WIRING PRACTICES, ROUTING METHODS, AND CONNECTION METHODS AS SPECIFIED IN THIS MANUAL ARE APPROVED FOR USE WITH THE AMEREX SYSTEM. ANY OTHER METHODS ARE NOT PERMITTED! The following pages show instructions and wiring diagrams for proper connection of all electrical components. Wiring Material: Only genuine Amerex Power Supply Leads, Amerex Squib Connector Leads, Amerex Linear Thermostat Connector Assemblies, and Amerex Hazard Wire Modular Lead Assemblies may be used in wiring of the Amerex Fire Suppression System. Routing: Route wires along the same paths as used by the existing vehicle wiring harnesses. Do not stretch the wires across open areas where vehicle maintenance will be obstructed. Avoid routing wires through pinch points and articulating joints. If the wires must be routed to a component located on a moveable surface, such as to a thermostat on an engine cowling or tilt cab, route the wires first to the pivot hinge and then to the component so that movement of the surface will not be impeded. Allow enough slack in the wire so that this movement will not put a strain on the wiring or components. Use Amerex Hazard Wire Lead Assemblies throughout. If holes are cut in vehicle bulkheads to facilitate routing wires, line the holes with a grommet or automotive welting to prevent abrasion of the wires. Secure wires to the vehicle or to existing wiring harnesses using heavy duty UV resistant wire ties or padded metal P clamps at least every 24 inches (61 cm). Also apply anti-tamper labels, P/N to all wiring identifying it as Fire Suppression System wiring to discourage inadvertent disconnection or cutting. If additional protection from heat or abrasion is deemed necessary by the installer, or by the authority having jurisdiction, it is recommended that the wires be encased in commercially available convoluted tubing or vinyl coated fabric weave loom. Wiring Connections and Splicing: As previously stated, only genuine Amerex wiring components are to be used for the connection of all Fire Suppression System Components. These wiring components provide the most convenient, durable and weather proof wiring system available for the connection of system electrical components, and are specified to insure the utmost in reliability of the Fire Suppression System. All modular wiring components are supplied with color coded Amerex Click Lock pluggable wiring connections for ease of installation. Splicing of wire is unnecessary and is strictly forbidden under the terms of the Amerex Warranty and Factory Mutual Listing except as noted in this manual. Connections: All wiring connections are made at the Circuit Monitor or Control Panel, main power, squib or electric actuator, thermostats, manual actuation switch and interconnections of these circuits via color coded Amerex Click Lock connectors and Amerex Modular Lead Assemblies of appropriate length. (See Section 2.). There is no need to open or make any wire connections inside either the Circuit Monitor or Control Panel as all connections are made outside the panel enclosures. When connecting wires to the engine shutdown relay or agent cylinder pressure switch circuits, the connections must be made inside a weather proof junction box, or the use of crimp-on butt splice connectors protected by adhesive wall shrink tubing is required. Color Coding: All Click Lock Connectors are color coded to indicate the circuits they mate with. When the wiring is correctly installed, the color coding of the male and female Click Lock Connectors will match. Color Codes are as follows: Red = Main Power Circuit Yellow = Squib or Electric Actuator Circuit Green = Thermostat, Heat Detection and Manual Actuation Switch Circuit Blue (Single Wire Loop) = Agent Cylinder Pressure Switch Circuit Timed Relay 3 Conductor Lead: Red = Common Black = Normally Closed Contact point White = Normally Open Contact Point

70 Part Number Rev. C October 1997 Page 6-14 Connect the various circuits in the following sequence: Thermostat Connections: The Local Sensing Spot Thermostats, P/N 14020, P/N 14021, P/N 14022, P/N 14087, P/N and the Firetrace Linerar Detector P/N are connected in a two wire continuous loop to enable circuit monitoring. Two wires with a green color coded Amerex Click Lock connector are provided at the Circuit Monitor or Control Panel for connection to a green color coded Hazard Wire Lead Assembly. Either or both wires may be used for Thermostat connection leads or for connection of manual actuation switches. The Hazard Wire Lead Assembly then runs and connects to the first Modular Thermostat Assembly. Shorter lengths of the Hazard Wire Lead Assembly are used to run between additional Thermostat Assemblies until all Thermostats are connected. Finally, an End of Line Module is plugged in after the last Thermostat. This completes the thermostat wiring loop. Figures 6-8, 6-9, 6-12 and 6-13 show connection diagrams for systems using any of the above Thermostat Assemblies. A system need not necessarily use only one type of heat detector as any of these detectors are interchangeable as needed as long as the male and female electric plugs and wiring color codes match. Electrical Manual Actuation Switch: On all installations using the Electric Control Head, P/N 14032, at least one Manual Actuation Switch P/N 14053, is required. Multiple Manual Actuation Switches may be used if more than one manual actuation station is desired. The Manual Actuation Switch is wired into either thermostat wiring loop using the green color coded Amerex Click Lock connectors provided on the Switch assembly. In all installations, the Manual Actuation Switch(es) must be wired in the thermostat wiring loop BEFORE THE FIRST THERMOSTAT. Example wiring schematics are provided later in this section. Wiring the Manual Actuation Switch BEFORE the first thermostat insures that the Manual Actuation Switch(es) will actuate the fire suppression system even in the event the remainder of the thermostat wiring is cut or damaged. Also, the second thermostat lead wire at the panel can be used only for the Manual Actuation Switch as a dedicated circuit. In this way one circuit provides connection for the thermostats while the other provides connection for the Manual Switch. Multiple Control Head Adapter: On all installations using two or more agent cylinders and Electric Control Heads, P/N 14032, the Multiple Control Head Adapter, P/N is required. This adapter allows the simultaneous actuation of up to four Electric Control Heads. It has an input line which has a yellow coded male Amerex Click Lock connector for attachment to the Electrical Actuator Connector Lead bringing electric current from the Circuit Monitor or Control Panel. The current is then split through four channels by the Multiple Control Head Adapter. Channels one and two have lead wires with yellow coded Click Lock Connectors for attachment to Connector Leads to deliver electric current to remotely located Electric Control Heads. Channels three and four are equipped with jumper plugs which must remain in place if these channels are not used. If channels three and/or four are to be used, remove the jumper plugs and attach the lead wire cables provided with the control head adapter. LINE OUT 3 LINE OUT 4 INPUT LEAD ADAPTER FOR MULTIPLE ELECTRIC CONTROL HEADS FIG. 2-1E4

71 Part Number Rev. C October 1997 Page 6-15 Aqent Cylinder Pressure Switch: (Optional) This switch (or switches in the case of multiple agent cylinders) is wired in a series loop from the Circuit Monitor / Control Panel to the switch and back. Pressure inside the Agent Cylinder holds electrical contacts normally closed inside the Agent Cylinder Pressure Switch. Use Amerex Hazard Wire or other insulated wire of 18 gage minimum I for connection purposes. To connect, cut the blue Agent Cylinder Pressure Switch jumper loop wire at the Circuit Monitor / Control Panel, and using weather proof type butt PLUG CONNECTOR splices, connect wires to each of the wires at the free ends of the female plug socket at the Agent Cylinder Pressure Switch. In this way, the switch need only to be unplugged to facilitate agent cylinder recharge. The Control Panel and Control Panel Plus are shipped from the factory with a blue jumper wire installed in the event that a pressure FREE END FOR switch is not used. When connecting the optional pressure switch, cut and connect the Agent Cylinder Pressure switch wiring to the blue lead wires. See Fig. 2-1W FIG 2-1W Squib Connector Lead: On all automatic pneumatically actuated systems the Squib Connector Lead (Fig. 2-1Q) must be run from the Electrical/Manual Actuator directly to the Circuit Monitor or Control Panel without splices, and is provided in three lengths. P/N is a 5 foot (0.9 Meter) length. P/N is a 10 foot (3.0 Meter) length, and P/N is a 15 foot (4.6 Meter) length. A yellow color coded male Amerex Quick Lock connector is provided at one end for mating to the matching connector at the Circuit Monitor / Control Panel. A keyed four pin circular connector is provided at the other end for connection to the Squib. DO NOT CONNECT THE SQUIB CONNECTOR LEAD TO THE SQUIB AT THIS TIME! I FIG. 2-1Q Electrical Actuator Connection Lead: On all automatic electrically actuated systems the Electric Actuator Connection Lead (Fig 2-1E5) must be run from the Electrical Actuator directly to the Circuit Monitor or Control Panel without splices, and is provided in five lengths. P/N is a 10 foot (3 meters) length. P/N is a 20 foot (6.1 meters) length. P/N is a 30 foot (9.1 meters) length. P/N is a 40 foot (12 meters) length, and P/N is a 50 foot (15 meters) length. A yellow color coded male Amerex Quick Lock connector is provided at one end for mating to the matching connector at the Circuit Monitor / Control Panel. A yellow color coded female Amerex Quick Lock connector is provided at the other end for connection to the Electrical Actuator. DO NOT CONNECT THE ACTUATOR LEAD TO THE ACTUATOR AT THIS TIME!

72 Part Number Rev. C October 1997 Page 6-16 Pressure Operated Switch: (Optional) The Pressure Operated Switch (Fig. 2-1X) has no wiring running to the control panel as it is operated by Nitrogen pressure from the actuation network. When the cover of the pressure.. operated switch is removed, three connection points for a single pole - double throw switch will be found. One connection point is MANUAL RESET labeled "Normally Closed," the second is "Normally Open," and the third is "Common." These connection points can be used to initiate immediate engine shutdown (no time delay) or operate auxiliary safety equipment such as air dampers or warning horns. It is the responsibility of the installer to gain sufficient understanding of vehicle operation to properly select, install, and connect any auxiliary equipment. In particular, the installer must determine: 1) if the device or equipment is "Energized to run" FIG 2-1X \ 1/4 NPT FITTING - AND WIRE ENTRY (Power supplied to sustain normal operation) or "Energized to Stop" (Power supplied to terminate normal operations) 2) what are the current requirements for the shutdown or safety device 3) what are the voltage requirements for the device (12 vs. 24 volts DC). The contacts of the pressure operated switch are rated for a maximum of 10 amps at 24 volts DC. This value must not be exceeded. Wiring Schematics; The following pages show wiring schematics for proper connection of all electrical components. Diagrams are given showing connection of Circuit Monitors and Control Panels using both spot thermal detectors and linear thermal detectors. Refer to Figure 6-8, Figure 6-9, Figure 6-10, Figure 6-11, Figure 6-12, Figure 6-13 and Figure 6-14 for this information. See guide below: + For systems using spot detectors or Firetrace detectors and pneumatically operated valve(s), refer to Figure 6-8 for Circuit Monitor connections or Figure 6-12 for Control Panel connections. + For systems using spot detectors or Firetrace detectors and electrically operated valve(s), refer to Figure 6-9 for Circuit Monitor connections or Figure 6-13 for Control Panel connections. + For systems using electric actuation and multiple agent cylinders, refer to Figure Three common connection diagrams for engine shutdown and engagement of auxiliary warning devices are shown in Figure For applications outside of these examples, please contact Amerex Vehicle Systems Group Factory Engineering. (205)

73 Part Number Rev. C October 1997 Page 6-17 Circuit Monitors With Spot Detectors - Pneumatic Actuation: Figure 6-8 SPOT THERMOSTATS Qty. as Required HAZARD WIRE LEAD ASSEMBLIES. Length as Needed. Color Code = Green SQUIB-LEAD-ASS'Y Color-Code = Yello E/M ACTUATOR - PN WITH -SQUIB - PN VEHICLE BATTERY 12 OR 24 VOLTS DC Figure 6-8: Wiring Diagram for Automatic, Pneumatic Actuated Systems Using Circuit Monitor or Circuit Monitor Plus with Spot Detectors

74 Part Number Rev. C October 1997 Page 6-18 Circuit Monitors With Spot Detectors - Electric Actuation: Figure SPOT THERMOSTATS Qty. as Required i HAZARD WIRE LEAD ASSEMBLIES Lenqth as Needed. Color Code = Green MANUAL ACTUATION SWITCH P/N ELECTRIC CONTROL HEAD with ACTUATOR

75 Part Number Rev. C October 1997 Page 6-19 Control Panels With Spot Detectors - Pneumatic Actuation: Figure 6-12 SPOT THERMOSTATS Qty. as Required AGENT CYLINDER PRESSURE SWITCH CONNECTION LOOPI RELAY CONNECTION 3 CONDUCTOR LEAD E/M ACTUATOR - PN WITH SQUIB - PN VEHICLE BATTERY 12 OR 24 VOLTS DC Figure 6-12: Wiring Diagram for Automatic Pneumatic Actuated Systems Using Control Panel with Spot Detectors

76 Part Number Rev. C October 1997 Page 6-20 Control Panels With Spot Detectors - Electric Actuation: Figure 6-13 SPOT u THERMOSTATS Qty. as Required AGENT CYLINDER PRESSURESWITCH LOOP ONNECTION 3 CONDUCTOR LEAD ELEC. ACTUATOR LEAD - ASS' Color Code = Yellow ELECTRIC CONTROL HEAD with ACTUATOR (NEG) VEHICLE BATTERY 12 OR 24 VOLTS DC Figure 6-13: Wiring Diagram for Automatic Electrically Actuated Systems Using Control Panel with Spol Detectors.

77 Part Number Rev. C October 1997 Multiple Electrically Actuated Control Heads: Page 6-21 Figure 6-16 Color Code=Green TS Qty. as Requ ired SHUTDOWN RELAY CONNECTION 3 CONDUCTOR LEAD CONTROL HEAD AD ELECTRIC HEAD wit (P+oS) (NEG) VEHICLE BATTERY 12 OR 24 VOLTS DC Figure 6-16: Wiring Diagram for Automatic Electrically Actuated Systems Using Multiple Electric Control Heads and Agent Cylinders

78 Part Number Rev. C October 1997 Page 6-22 Engine Shutdown and Auxiliary Safety Equipment: Panel Installations equipped with a Modular Control P/N and P/N will include a connection lead for engine shutdown equipment or auxiliary safety equipment such as air dampers, warning horns or lights. It is the responsibility of the installer to gain sufficient understanding of vehicle operation to properly select, install, and connect any auxiliary equipment. In particular, the installer must determine: [1] if the device or equipment is "Energized to Run" (Power supplied to sustain normal operations) or Energized to Stop (Power supplied to terminate normal operations). [2] What are the current requirements for the shutdown or safety device. [3] How long a time delay should occur prior to engine shutdown. The shutdown delay is factory set to initiate after a time delay of 30 seconds. To reduce the delay, turn the labeled white nylon adjustment screw inside the back-up battery compartment which is located in the back of the Control Panel P/N or Minimum delay is 0 seconds; maximum delay is 30 seconds. Do not attempt to turn the adjustment screw past it s stop, or damaqe will occur. The auxiliary contacts of the Control Panel are sized for a maximum of 10 amps. This value must not be exceeded. The auxiliary contacts of the Control Panel may be used with either 12 or 24 VDC systems. Any device that is wired to the auxiliary contacts of the Control Panel must draw its current from an independent power lead fused with a 15 amp type AGC fast blow fuse. In addition, the internal relay common contact is also protected with an internal self resetting circuit breaker. Figure 6-20 gives only a few examples of the many common auxiliary devices encountered in these installations.

79 Part Number Rev. C October 1997 Page 6-23 SCENARIO 1: NORMALLY OPEN, ENERGIZE TO STOP EXAMPLE - 12 VDC EXTERNAL SIREN CONTROL PANEL NOTE: RELAY CONNECTION LEAD COLOR CODE RED = COMMON BLACK = NORMALLY CLOSE0 CONTACT WHITE = NORMALLY OPEN CONTACT ltiz FBLACK = NORMALLY CLOSED (NOT USED) SCENARIO 2: NORMALLY CLOSED ENERGIZE TO RUN EXAMPLE - 12 VDC VEHICLE IGNITION BLACK = CONTROL PANEL NORMALLY CLOSED WHITE = NORMALLY OPEN (NOT USED) r- EXISTING WIRING TO VEHICLE FUEL PUMP, IGNITION COIL, ETC I f+?--l- L-.-l - WIRE AND CONNECT TO CONTROL PANEL SCENARIO 3: NORMALLY CLOSED ENERGIZE TO RUN EXAMPLE - 24 VOC FUEL PUMP CONTROL PANEL ii1_ BLACK = NORMALLY CLOS WHITE = NORMALLY OPEN (NOT USED) /--RED = COMMON DISCONNECT EXISTING - ff. WIRE AND CONNECT + - KEY TO CONTROL PANEL - SWITCH - Figure 6-20: Example Wiring Diagram for Some Typical Auxiliary and Engine Shutdown Devices

80 Part Number Rev. C October 1997 Page D. Placing the System in Service 1. Connect The Discharge Network -Remove the anti-recoil plate from agent cylinder. Lubricate the discharge fitting o-ring and insert the fitting into the discharge valve. Bolt the retaining flange securely in place using the 5/16 inch stainless steel bolts provided with the anti-recoil plate. On installations fitted only with a mechanical control head, install the pull pin and secure with a leaded wire seal or the plastic lock wire provided. Proceed to section 6.D.7. On installations fitted only with remote manual actuation, proceed to Section 6.D Connect Aqent Cylinder Pressure Switch - On installations so equipped, plug the connector together at the pressure switch to complete the circuit to the Control Panel. 3. Test the Engine Shutdown System -- Connect the Squib Simulator P/N to the squib or Fire Alarm Module P/N to electric actuator lead connector where the squib or actuator would normally be connected. Push the red reset button on the Squib Simulator or Alarm Module. The panel should now indicate a normal condition with the green System OK LED illuminated. Start the equipment or vehicle and allow it to idle. Request assistance from the equipment owner/operator if necessary. CAUTION: Do not attempt to operate equipment on which proper training has not been given or that you are not familiar with. Push and hold the Push To Test button, located behind the Amerex logo, on the front of the Control Panel and mark the start time on a stop watch. An audible click will occur when the auxiliary relay is energized. Confirm that the delay period is as required and that the vehicle is shut down, or that other safety devices are properly actuated as applicable. Release the Push To Test button and observe that the panel returns to normal condition. The vehicle should now be able to be restarted. 4. The Electrical Networks - With the Squib Simulator or Alarm Module still connected to the squib or electric actuator lead connector, press and release the red reset button. The Circuit Monitor or Control Panel should now indicate a normal condition. Only the System OK green LED should be illuminated. Test the function of each spot thermostat. Hold an electric heat gun or a trigger operated propane torch near the thermostat until the contacts close. Test the function of each Firetrace detector by depressing the valve stem pin until all air has been released from the air reservoir. WARNING: DO NOT PERFORM THIS TEST ON THE SYSTEM IF THE SQUIB AND N2 CYLINDER OR ELECTRIC ACTUATOR AND CONTROL HEAD ARE INSTALLED AND CONNECTED! SYSTEM DISCHARGE WILL RESULT! WARNING: USE EXTREME CARE WHEN FOLLOWING THIS PROCEDURE. MAKE CERTAIN THAT NO HAZARDS EXIST THAT COULD BE IGNITED BY THE HEAT SOURCE. When the thermostat contacts close, the Circuit Monitor or Control Panel will enter the alarm mode. The green LED will turn off, the red Fire LED will illuminate and, on installation equipped with an audible alarm, the alarm will sound. Also, on installations using the Control Panel, the time delayed relay (engine shutdown) will begin to count down. Remove the heat source. After the thermostat cools and the contacts reopen or the Firetrace air cylinder has been repressurized to 70 psi., the red Fire LED will remain lit and the alarm will continue to sound. If the yellow LED on the Squib Simulator or Alarm Module is off, then the detector has reopened or is reset. Press the button on the Squib Simulator or Alarm Module. The Circuit Monitor or Control Panel will return to the normal mode. The system will not reset until the thermostats are cool and reset. Repeat this test for each thermostat. When all thermostats have been tested and the green System OK LED has again illuminated, remove the Squib Simulator or Alarm Module from the squib or electric actuator lead connector.

81 Part Number Rev. C October 1997 Page 6-25 Agent Cylinder Pressure Switch Circuit - On installations so equipped, test the function of the agent cylinder pressure switch circuit by unplugging the switch at its socket. This duplicates loss of agent cylinder pressure which would open the switch. The Control Panel will enter the alarm mode as previously described. Reconnect the pressure switch and the panel will return to normal. 5. Batterv Back- Up Circuit - All Modular Circuit Monitors and Control Panels are equipped with a Back Up Battery. To test the function of the internal back-up battery, disconnect the vehicle power supply to the panel by unplugging the fuse holder in the power supply lead. Only the Service System LED should be illuminated on the panel. Reconnect the power supply lead. With vehicle power restored, the green System OK LED should again be illuminated. 6. Install the Squib - On installations equipped with automatic detection and pneumatic actuation, install and connect the squib. Screw the squib into the Electrical/Mechanical Actuator at the port closest to the palm button marked "SQUIB." Tighten using a 5/8 inch wrench until the hex on the squib contacts the actuator body. Remove the protective cap and the shunt wire from the squib and attach the squib connector lead. Make sure that the pins and key in the connector align properly in the squib and connector as assembly is made. Tighten the connector clockwise until firmly hand tight. Check that the green System OK LED is illuminated and the red Fire LED is off on the Circuit Monitor or Control Panel. Install the Electric Actuator - On installations equipped with automatic detection and electric actuation, install and connect the electric actuator. Apply one drop of low strength thread locking compound to the threads of the actuator. Screw the electric actuator into the Electric Control Head at the threaded hole provided. Firmly finger tiqhten actuator into Control Head body until the hex of the actuator is securely in contact with Control Head body. Do not over tighten by using a wrench. Plug in the click lock connector to the mating connector on the actuator lead assembly. Check that the green System OK LED is illuminated and the red Fire LED is off on the Circuit Monitor or Control Panel. 7. Install the Nitroqen Cylinder(s) (Pneumatically actuated systems) Manual Actuators - With N2 cylinder removed, depress the palm button several times to confirm free travel. Screw the N2 cylinder into the open end of the actuator. Tighten securely by hand, 1 1/2 to 2 turns past contact with the sealing gasket. On remote actuators mounted on outdoor brackets, install covers using the four 1/4 stainless steel cap screws provided. Install the pull pin and secure with the plastic lock wire provided or a leaded wire seal. Make sure that the pull pin is accessible through the slotted opening in the cover. Tighten the cap screws securely using a 3/16 inch T-handle Allen wrench. Electrical/Manual Actuators - With N2 cylinder removed, depress the palm button several times to confirm free travel. Install pull pin and secure with the plastic lock wire provided or a leaded wire seal. Screw the N2 cylinder into the open end of the actuator. Tighten cylinder securely by hand, 1 1/2 to 2 turns past contact with the sealing gasket. If the electrical/manual actuator was installed in the vehicle cab using an outdoor bracket, install the bracket cover as previously described above.

82 Part Number Rev. C October 1997 Page Documentation - Make a final check to confirm that all details of the installation match the design documentation made earlier when the hazard analysis and system design was performed. Make any necessary revisions to the documentation and store as a permanent record. Photoqraphs are perhaps the best form of documentation of all and can be referred to later to confirm the oriqinal system layout as well as the oriqinal configuration of the machine when the system was installed. Photographs are highly recommended. 9. Final Inspection - Perform an Inspection as per Section 7. 6.E. Provide Owner - Operator Training The OWNERS MANUAL shipped with each agent cylinder contains operating instruction, system description, housekeeping requirements, and system inspection requirements. Make sure the equipment owner/operator receives this manual. Make an INSTALLATION REVIEW with the equipment owner/operator. Show them the location of all system components on the vehicle. Point out the high risk/hazard areas and explain that those areas must be of particular concern during housekeeping operations. Explain how to use the system. If the installation is equipped with engine shutdown features, explain the use of this feature and the steps that must be taken to bring the vehicle to a complete stop or to move the vehicle to a service area after system discharge. WARNING: IF THE VEHICLE HAS BEEN EQUIPPED WITH THE VEHICLE ENGINE SHUTDOWN * CAPABILITY, ALL POTENTIAL OPERATORS MUST BE TRAINED IN SAFETY PROCEDURES TO BE TAKEN IN THE EVENT OF LOSS OF POWER AND/OR STEERING AND BRAKES. ONCE A FIRE CONDITION IS DETECTED, THE ENGINE SHUTDOWN TIMER - PUSH TO DELAY BUTTON ON THE PANEL MAY BE PRESSED AS MANY TIMES AS NEEDED TO DELAY ENGINE SHUTDOWN AND ALLOW MORE TIME TO BRING THE VEHICLE TO A SAFE AND CONTROLLED STOP. OPERATORS SHOULD ALSO REALIZE THAT PUSHING THE DELAY BUTTON WILL NOT DELAY DISCHARGE OF THE FIRE SUPPRESSION SYSTEM EXTINGUISHERS. ALL POTENTIAL OPERATORS MUST BE TRAINED THOROUGHLY IN THE USE OF THIS FEATURE. Explain the sensitivity of the thermostats in that welding torches, steam cleaning, or other outside heat sources may create a false discharge. Explain that cutting the system wiring anywhere along the electrical circuits especially, the detection circuits, will cause a false discharge. Give a brief description of system inspection including: 1) that all components are in place and unobstructed, 2) all pressure gauges are in operable (green pie) range, 3) all hoses are connected and tight, 4) Circuit Monitor/ Control Panel System OK LED is illuminated, and 5) supplementary hand portable fire extinguisher(s) locations and use. Owner inspection of the vehicle and the suppression system does not take the place of factory trained inspection and service, but should be encouraged as an added measure of safety.

83 Part Number Rev. C October 1997 Page 6-27 Complete the WARRANTY REGISTRATION with the equipment owner/operator. Explain the terms of the warranty and the services that must be performed on the system to keep the warranty valid. Tear off the back page of the Owners Manual P/N Fill in all requested information including the owner s name, address, etc., installer s name, address etc., description of the vehicle and the vehicle identification number (VIN #)f the vehicle on which the system was installed.note that the serial number(s) of the agent cylinder(s) found on the agent cylinder top dome(s) have already been filled in at the Amerex Factory. Insure that the form is signed by both the owner and the installer, and returned the form to Amerex Corporation, Systems Division Warranty Department, P.O. Box 81, Trussville, Alabama,

84 Part Number Rev. C October 1997 Page 7-1 Servicing The Amerex Systems: The following sections deal with inspection, maintenance, and recharge of the Amerex Vehicle Fire Suppression Systems. Per NFPA Code 17, "Inspection" is defined as a "Quick check that requires minimal knowledge to perform." NFPA 17 defines "Inspection" and "Recharge" as tasks that are required to be performed by, "A trained person who has undergone instruction necessary to perform those functions, and has the manufacturer's service manual."amerex has based the servicing requirements for Vehicle Fire Suppression Systems on NFPA 17 and other specific information particular to the Amerex System design. It is the responsibility of the equipment owner to provide minimum service as required by NFPA, Amerex Corp., and all local authorities having jurisdiction. Since the application and usage of the Amerex Systems can vary, some systems may require more frequent or less frequent service to insure reliable operation. If service schedules other than specified as follows are desired, contact the Amerex Vehicle Systems Engineering Department for a service schedule review (205) Section 7 Inspection Daily lnspection On systems with either the Circuit Monitor or Control Panel, check the panel LED's to see if the system has power and that the "SYSTEM OK" LED is illuminated. Monthly Inspection NFPA 17 requires the following minimum quick check inspection on a monthly basis: [A] Check that all components are present and in their original location. [B] Check that all manual actuators are unobstructed by vehicle modifications or clutter. [C] Check that tamper indicators, lock wire seals, and pull pins are intact. [D] Check that the maintenance tag or certificate is in place. Record date of inspection and initials of inspector. [E] Check the physical condition of all components for damage or conditions that may prevent operation. [F] Check the Agent Cylinder Pressure Gauge(s) for proper operating pressure. On systems with remote actuation, the Nitrogen cylinder pressure gauge(s) should be checked for proper operating pressure. [G] On systems equipped with the Firetrace heat detection system, insure that the gauge on the air reservoir cylinder indicates proper operating pressure of 70 p.s.i. [H] Check the nozzles. All blow-off caps must be intact and in place. Nozzle outlets must be unobstructed and properly aimed. In addition, Amerex requires the following inspections on a monthly basis: [ I ] Check that all components, agent cylinders, control heads, actuators, hose systems, wiring, and detectors are securely mounted, and that all wiring connections are sealed from the weather. [J ] Check that all "In Case of Fire" instruction labels and agent cylinder and N2 labels are intact, clean and legible.

85 Part Number Rev. C October 1997 Page 8-1 Section 8 Maintenance Semi Annual Maintenance: NFPA 17 requires the following minimum maintenance on a semi-annual basis. Any deficiencies that are found and corrected should be documented with one copy provided to the equipment owner and a second copy kept for permanent record. Maintenance may be performed only by Amerex factory trained personnel. [1] Check that the hazards have not changed. Look for changes in vehicle operation or cleaning procedures that may have increased the hazard. Compare with the original vehicle hazard analysis. [2] Examine all detectors, Nitrogen cylinders, agent cylinders, releasing devices, piping/hose assemblies, nozzles, alarms, and auxiliary equipment. [3] Verify that the actuation and discharge network hoses are not obstructed. (Specific tests follow in the Amerex semi-annual maintenance instructions) In addition, Amerex requires the following minimum maintenance on a semi-annual basis. [4] Consult vehicle operating and maintenance personnel to determine if any problems with the extinguishing system, or with the vehicle itself have been encountered that may have affected the extinguishing system. [5] Service the agent cylinders. Clean cylinder to remove dirt, grease or foreign material. Check to make sure that the instruction nameplate is securely fastened and legible. Inspect the cylinder for corrosion, abrasion, dents or weld damage. Hydrotest the cylinder if any of these conditions are found or you doubt the integrity of the cylinder. (See Section 9) WARNING: ALWAYS INSTALL SHIPPING PLATE AND ANTI-RECOIL PLATE WHEN TRANSPORTING A PRESSURIZED AGENT CYLINDER. NOTE: When cleaning, avoid use of solvents around the pressure gauge. They could seriously damage the plastic gauge face. [6] Service the Discharge Valve. Inspect the discharge valve for damaged, missing, or substitute parts. Only factory replacement parts are approved for use on Amerex fire suppression systems. Check the air valve cap or Agent Cylinder Pressure Switch as applicable to make sure they are tight and providing a good seal. Check the fusible plug pressure relief to confirm that it is free of corrosion and has not been altered. Remove control head and check the valve stem return spring and retaining washer in the top of the valve for corrosion. Depressurize cylinder and rebuild valve if defects are found. See proper method of depressurizing and reclaiming chemical in System Recharge procedures in Section 9. System rebuilding and recharging may only be done by individuals certified by Amerex and those having jurisdiction in your area. [7] Visually inspect the pressure gauge on the discharge valve: a. If bent or damaged, depressurize and replace. b. If pressure is low, check for leaks, or partial discharge. Depressurize the agent cylinder and recharge if gauge pressure is low. c. If over pressurized (overcharged), depressurize the agent cylinder and follow recharge instructions. If any of the above conditions are found, contact your Amerex servicing distributor for corrective action.

86 Part Number Rev. C October 1997 Page 8-2 [8] Service the discharge networks. Clean the discharge fitting and all nozzles to remove dirt, grease or foreign material. Disconnect discharge hose from agent cylinder by unbolting retaining flange. Inspect discharge outlet for extinguishing chemical residue. Extinguishing chemical residue is often the sign of an unreported discharge. Confirm that all hoses are free of obstructions: Remove all nozzle blow-off caps. Attach an Amerex P/N Discharge Network test adapter to the discharge fitting and connect to a compressed air source. Blow air through the hose. Confirm that free flow is present at each nozzle. Follow each discharge hose along its entire length checking for cuts or abrasions. Replace any damaged sections of hose. Check all hose connections for tightness. Repair any loose joints. I Fig 8_2 Confirm that all nozzles are properly aimed. Inspect all blow-off caps with the retaining loop arching downward. Discard any caps that are worn or cracked, or that have lost their flexibility. Reapply silicone grease sparingly to the inside of skirt of each blow-off cap and replace all blow-off caps. Inspect discharge fitting o-ring and replace if worn. Reconnect discharge fitting to discharge valve. Bolt retaining flange securely in place. Service the mechanical control head. See Section 10 for exploded drawing. On installations equipped with a mechanical (T-Handle lever operated) control head, remove the head from the discharge valve. Clean the assembly to remove dirt, grease and foreign material. Pull out the ring pin and operate the lever several times to confirm free movement and full travel. Disassemble and rebuild if operation is impeded, or if corrosion is present. Bolt mechanical control head in place and install pull pin and tamper indicator. Make sure that the mechanical control head is properly oriented relative to the equipment operator so that a pull of the T-handle is necessary to actuate the suppression system. -or- [10] Service the pneumatic control head. See Section 10 for exploded drawing. On installations so equipped remove the pneumatic control head from the agent cylinder discharge valve by removing the two 5/16 in. bolts. Inspect the retaining ring, the retaining ring groove, the control head body, and the vent check for signs of damage or corrosion. Disassemble and rebuild if the integrity of the control head is in doubt. -or- Service the electric control head. See Section 10 for exploded drawing. On installations so equipped remove the electric control head from the agent cylinder discharge valve by removing the two 5/16 in. bolts. Inspect the retaining ring, piston and control head body. Remove the electric actuator from the top of the control head by unplugging the wiring connector and then unscrewing it from the control head. Inspect all items for damage or corrosion. The retaining ring should be loose and visible from the bottom side of the Electric Control Head. Replace if the integrity of any component is in doubt. [11] Service the manual and electrical/manual actuator on installations so equipped. See Section 10 for exploded drawing. Remove the N2 cylinders from all manual and electrical/manual actuators after first removing covers from outdoor actuator brackets as required. Pull the ring pin from each actuator. Operate the palm button of each several times to confirm free movement and complete travel and return. Inspect all actuators for signs of corrosion. Disassemble and rebuild any actuator whose travel is impeded or whose integrity is in doubt. Inspect the N2 cylinder rubber sealing gasket in the bottom of each actuator and replace if worn or cracked. [12] Pressure test the actuation network on pneumatically actuated systems. Connect an Amerex P/N actuation network test adapter to one actuator in place of the N2 cylinder on systems so equipped and connect a regulated air or nitrogen source to the adapter.

87 Part Number Rev. C October 1997 Page 8-3 CAUTION: This test must be performed only with the pneumatic control head removed from the agent cylinder discharge valve or discharge will occur. I Fig. 8_ ACTUATION NETWORK TEST ADAPTER Pressurize the actuation network to 80 psi minimum and inspect as follows: a. Check that no pressure escapes around the palm button shaft (strike stem). Rebuild actuator if leaks are detected. b. Check all 1/4 inch hoses and hose connections along the direct path to the pneumatic control head. Replace any hose sections found to be leaking or abraded. Repair any connections found to be leaking. c. Check that the piston on the pneumatic control head is fully extended 1/2 inch (12 mm) and that no pressure is escaping around the piston. Disassemble and rebuild the control head if required. d. Examine the vent check to confirm the internal nylon ball is sufficiently seated. Replace vent check if improper operation is detected. e. Examine all other actuators in the network. Pressure escaping from any of their N2 cylinder inlets indicates a malfunctioning check valve in the hose currently under test. Replace any check valves found defective. f. When testing the electrical/manual actuator, momentarily remove the squib and confirm that no pressure escapes from the squib inlet hole. Pressure from the squib hole indicates worn o- rings on the puncture stem. Disassemble and rebuild the electrical/manual actuator if leakage is detected. Replace the squib immediately. Repeat steps (a) through (f) for all manual or electrical/manual actuators, relieving pressure from the network by unseating the nylon ball in the vent check following each test. h. When all actuators have been checked, remove test adapter and pressure source. Make sure piston on pneumatic control head is fully retracted and bolt head securely on top of discharge valve. Replace pull pins and tamper indicators on all actuators. i. If system is equipped with a pressure operated switch P/N 11615, Check to see that switch has activated. Verify activation of auxiliary devices controlled by the pressure operated switch. Reset by pressing the reset button on top of the switch enclosure after bleeding off pressure. [13] Service the Nitrogen Cylinders on systems so equipped. Clean all N2 cylinders to remove dirt, grease, and foreign material. Check to make sure that the nameplate is in place and fully legible. Inspect the cylinders for corrosion, abrasion, or dents. Relieve pressure and discard if integrity of a cylinder has been compromised. NOTE: When cleaning N2 cylinders, avoid use of solvents. They could seriously damage the gauge face, the gauge guard, or the nameplate. Visually inspect the pressure gauge. The pressure must be in the operable green pie zone. Follow instructions for N2 cylinder recharge if pressure is below operable range.

88 Part Number Rev. C October 1997 Page 8-4 Visually inspect the rupture disc. Check for signs of rupture or corrosion. Check that the disc is not a substitute. Only an Amerex factory supplied rupture disc marked with A7 or AX is acceptable. Follow instructions for N2 CYLINDER RECHARGE if disc is corroded or otherwise unacceptable. WARNING: Always install shipping cap when transporting a pressurized N2 cylinder. Install nitrogen cylinders into actuators. Tighten cylinders by hand 1-1/2 to 2 turns past contact with rubber sealing gasket. Replace covers on outdoor actuator brackets as required. [14] Service the detection network. (Automatic system installations only). Clean all thermostats and Firetrace tubing if so equipped. Also clean the Circuit Monitor or Control Panel to remove dirt, grease and foreign material. Thermostats may be pressure washed. Control Panel surfaces should be cleaned with a damp cloth and mild soap and water solution. Check thermostats for dents, punctures, or other damage. Thermostats must not be painted. Replace if damaged or painted. Check all exposed wiring for cuts, abrasion, or heat damage. Check power supply (battery) connections for tightness and wire fatigue. Check that all other wiring connections are tight and sealed from the weather. Correct any deficiencies discovered. [15] Test the detection network. Remove the squib connector lead from the squib and attach it to the Squib Simulator Module, Amerex P/N 10781, or unplug the electric actuator and attach it to the Alarm Test Module, Amerex P/N Check that the reset button on the squib simulator or alarm module is depressed. With the connection of the squib simulator or alarm test module, the circuit monitor or control panel should now indicate a normal condition. Only the green "System OK" LED should be illuminated. Test the function of each spot thermostat. Hold an electric heat gun, trigger operated propane torch, or other suitable heat source near the spot thermostat until the contacts close. For Firetrace detectors, relieve air pressure from the air cylinder by pressing the valve stem pin. Do not heat Firetrace sensor. tubing to test. After testing re-tighten the valve stem cap once re-pressurized, and check that the ferrule nut holding the tubing to the cylinder is wrench tight.. Warning: Do not perform this test on the system if the squib and N2 cylinder or electric actuator and control head is installed and connected. System discharge will result. Warning: Exercise extreme care when following this procedure. Make certain that no hazards exist that could be ignited by the heat source. When the thermostat or detector contacts close, the circuit monitor or control panel will enter alarm mode. The green "System OK" LED on the Circuit Monitor/Control Panel will turn off, the red "Fire" LED will illuminate and, on installations so equipped, the audible alarm will sound and the time delayed relay (engine shut down) will begin to count down. Remove the heat source or repressurize the Firetrace air cylinder to 70 p.s.i. as applicable. When the thermostat cools and the contacts reopen, or the Firetrace air cylinder has been repressurized to 70 psi., the red "Fire" LED will remain lit and the alarm will continue to sound. If the yellow LED on the Squib Simulator is off, then the detector has reopened or is reset. Press the button of the Squib Simulator. The Circuit Monitor or Control Panel will return to the normal mode. The system will not reset until the thermostats are cooled or reset. Repeat this test for each thermostat. Repair any circuits and replace any thermostats that do not function properly. Verify that all thermostats have cooled as indicated by an illuminated green "SYSTEM OK" LED on the front of the circuit monitor or control panel and reconnect squib connector lead to squib.

89 Part Number Rev. C October 1997 Page 8-5 Detail of Squib Simulator and Alarm Test Module: SQUIB SIMULATOR FIRE ALARM MODULE, SQUIB & ELECTRIC ACTUATOR TEST DEVICE [16] Test the agent cylinder pressure switch circuit. On installations so equipped, unplug the switch at its plug socket. The control panel will enter alarm mode as previously described. Reconnect the pressure switch when testing is complete. Repair any circuits and replace any switches that do not function property. [17] Test the function of the internal back-up battery. Insure that the system has been powered by the vehicle battery for at least 24 hours. This insures that the back-up battery is fully charged. Remove the squib connector lead from the squib or unplug the electric actuator, and attach it to the Squib Simulator Module, Amerex P/N Check that the reset button on the Squib Simulator is depressed. With the connection of the Squib Simulator, the Circuit Monitor or Control Panel should now indicate normal condition. Remove the vehicle power supply to the panel by unplugging the fuse holder on the power supply lead. Only the "Service System" LED should be illuminated on the panel. Hold an electric heat gun, trigger operated propane torch, or other suitable heat source near the spot thermostat until the contacts close. For Firetrace detectors, relieve air pressure from the air cylinder by pressing the valve stem pin. Do not heat Firetrace sensor tubing to test. After testing re-tighten the valve stem cap once re-pressurized, and check that the ferrule nut holding the tubing to the cylinder is wrench tight. Do not press the red button on the Squib Simulator at this time. Restore vehicle battery power to the system by plugging in the fuse holder on the power lead. The system should come up in alarm condition when vehicle battery power is restored. This indicates that the back-up battery has actuated the system. Press the reset button on the Squib Simulator and the panel should return to normal condition. Reconnect the squib or electric actuator lead. [1 8] Check the last recharge date on the agent cylinder inspection tag. As required by NFPA 17, the dry chemical in stored pressure systems such as the Amerex system must be examined every 6 years to confirm that the chemical is free flowing. If 6 years have elapsed, follow instructions in SYSTEM RECHARGE (Section 9) for proper depressurization and chemical reclaim. Check the date of manufacture stamped on the extinguisher cylinder dome. Cylinder must be hydrostatic (proof pressure) tested every 12 years to the test pressure indicated on the nameplate (700 psi, 4827 kpa). If hydrotest is due. See Section 9.