Fire Safety prevent | detect | contain | escape ™

Maintenance Manual
(Part Number 61432)
(CSIRO ActivFire Listing Number: afp-2118)
 PEFS Maintenance Manual 2

PRE-FACE
Document History

Version Summary of Change

2.0 Original CSIRO listed manual
2.1 Changed: LOP valve cap modified to provide 2 ports
Changed: Manual release unit changed to strike knob arrangement similar to LOP manual actuatos
Changed EOL assembly changed to brass housing with metal gland.
Remeved: Triple nozzle kit assembly.

This manual is an uncontrolled document. Chubb Fire Safety reserves the right to alter this manual at any
time in accordance with our policy of continuous development. Chubb Fire Safety welcomes feed back
regarding this manual and associated equipment. For further information or feedback, contact Chubb Fire
Safety on 1300 369 309.

PEFS Maintenance Manual, version 2.1, September 2007

© Copyright 2007 Chubb Fire Safety Limited
 PEFS Maintenance Manual 3

GENERAL INFORMATION

Contents
PRE-FACE ...........................................................................................................................................................2
Document History...........................................................................................................................................2
GENERAL INFORMATION .......................................................................................................................................3
Contents .........................................................................................................................................................3
About this manual ……………………………………………………………………………………………………4
Warranty ………………………………………………………………………………………………………………4
Intended use..…………………………………………………………………………………………………………5
Introduction …………………………………………………………………………………………………………...5
Recommended tool list...................................................................................................................................6
MAINTENANCE SCHEDULE ....................................................................................................................................7
Daily................................................................................................................................................................9
6 Monthly......................................................................................................................................................11
Yearly ...........................................................................................................................................................15
5 yearly.………………………………………………………………………………………………………………23
MAINTENANCE REPORT ......................................................................................................................................24
SPARE PARTS ....................................................................................................................................................25
Cylinders & Cylinder Assemblies .................................................................................................................25
Discharge Components................................................................................................................................31
Detection & Actuation Components .............................................................................................................37
Monitoring & Control Components ...............................................................................................................50
VS CONTROL SYSTEM OPERATION & FAULT FINDING..........................................................................................55

PEFS Maintenance Manual, version 2.1, September 2007

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 PEFS Maintenance Manual 4

About This Manual

This manual is written for those who maintain PEFS systems. It contains maintenance information for the
system.

Chubb Fire Safety Limited (“Chubb”) assumes no responsibility for the application of any systems other than
those addressed in this manual. The technical data contained herein is limited strictly for informational
purposes only. All information contained in this manual is based on the latest product information available
at the time of preparation and Chubb reserves the right to make changes at any time without notice. Chubb
believes this data to be accurate, but it is published and presented without any guarantee or warranty.
Chubb disclaims any liability for any use that may be made by the data and information contained herein by
any party.

PEFS systems are to be designed, installed, commissioned, inspected, maintained, and tested only by
qualified, trained personnel.

No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by
any means, electronic, mechanical, photocopying, or otherwise without the prior approval of Chubb Fire
Safety.

IMPORTANT

Please note this manual contains warnings and cautions against some specific service methods which could
cause personal injury. It must be understood that these warnings cannot cover all ways in which service
might be done. Anyone using service procedures whether or not recommended by Chubb Fire Safety must
satisfy himself thoroughly that neither personal safety nor equipment safety will be jeopardised. All
information contained in this manual is based on the latest product information available at the time of
preparation. Chubb Fire Safety reserves the right to make changes at any time without notice.

Warranty
Chubb warrants to the original system purchaser (“Customer”) that each new PEFS system is free from
defects in material and workmanship under normal use for a period of twelve (12) months from the date of
commissioning. This warranty does not cover damage resulting from a party’s negligence, fault, misuse,
neglect or incorrect use of the product, abuse or fair wear and tear. In addition, the warranty does not cover
work required to be done to repair a defect or damaged caused by vandalism, fire, water, damage, power
surge or other circumstance outside of Chubb’s control. This warranty is conditional upon documented
evidence of proper maintenance, performed in accordance with the PEFS Owner’s Manual and Maintenance
Manual by qualified and trained personnel, using replacement parts that conform to original design
specifications. This warranty will be voided upon modification of the (i) installed and commissioned PEFS
system; (ii) use, condition and environment of the Customer’s equipment. Chubb will have no liability for any
statements, representations, guarantees, conditions or warranties not expressly stated in writing by Chubb.

Nothing in this warranty excludes, restricts or modifies the application of the provisions of any statute
(including the Trade Practices Act 1974 (Cth)) where to do so would contravene that statute or cause any
part of this warranty to be void.

Where Chubb breaches its obligations under this warranty, Chubb agrees at its sole discretion to elect to re-
supply the PEFS system again or to the replacement or repair of the PEFS system. To the extent
permitted by law the aggregate liability of Chubb to the Customer whether in contract, tort (including
negligence) or otherwise, will be limited to the value of the payment received by Chubb from the purchaser
in respect of the purchase of PEFS.

Notwithstanding anything else in this document, Chubb will not be liable for:

(a) any indirect, consequential or special or economic loss, cost, liability, damage or expense howsoever
arising; or
(b) loss of profit, loss of use, loss of income, loss of rental or other benefit, loss of production, loss of actual
or potential business opportunity or loss of reputation.

PEFS Maintenance Manual, version 2.1, September 2007

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Intended use
The PEFS system is a fire suppression system, installed as part of a fire risk reduction strategy, as defined
in the PEFS Risk Assessment. As such, it is designed to suppress a fire occurring in the specified risk area
only.

Introduction
Mining, Off-Road, Forestry and Construction equipment operating in harsh outdoor environments can be
subjected at any time to the threat of fire, which may spread rapidly through the equipment endangering life
and resulting in damage to major capital equipment and loss of production. The installation of a fire
detection and suppression system is essential to minimise the risk to both operator and equipment.

PEFS is a Pre-Engineered Foam Spray system designed specifically to cope with the harsh operating
conditions experienced by mobile and transportable equipment. PEFS systems consist of pressurised
cylinders containing foam solution, actuation devices to initiate discharge and a discharge network
containing nozzles to direct the foam spray on the hazard. PEFS systems may be configured for both
manual and automatic operation.

PEFS systems offer impressive fire suppression capabilities through the combination of FOAM discharged in
the form of a finely atomized SPRAY. Strategically positioned nozzles direct the high velocity foam spray
and provide “three dimensional” fire fighting properties, allowing the system to suppress pressure fires such
as might occur from a ruptured fuel or hydraulic line. The small droplets of foam are extremely efficient at
absorbing large amounts of heat and turn to steam which further enhances the three dimensional fire
fighting properties of the PEFS system. Once discharged, the foam is also effective in suppressing spill or
pool fires which may result from the collection or leakage of fuel. The resulting foam blanket provides post
fire securement.

Australian Standard AS5062 Fire Protection of Mobile and Transportable Equipment details the
requirements for fire protection systems used in these applications. Chubb’s PEFS system has been tested
and approved by CSIRO and, when installed and commissioned in accordance with the requirements of this
manual, complies with AS 5062.

Glossary of terms

LOP – Loss of Pressure

ROP – Rise of Pressure

EOL – End of Line resistor

LHD – Linear Heat Detection

PEFS Maintenance Manual, version 2.1, September 2007

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 PEFS Maintenance Manual 6

Recommended Tool List

The following tools are recommended to carry out installation and maintenance of PEFS systems.

Description
Tape measure 25mm
Portable tube bender (suit 6.0mm & 12.7mm OD tube)
Flaring tool – 45° 1/8” – 3/4" tube sizes
Angle grinder 100 mm
Drill (Heavy duty) - 12.7 mm chuck
Socket set - metric 4mm – 19mm, A/F 3/16” – 15/16”
Spanner Set - metric 7mm – 22mm, A/F 1/4" – 1”
Files - Round and Flat (medium bastard) 250mm
Hand / Drill type deburring tool 2-14mm
Hex Wrench set (Allen keys) Metric & Imperial
Portable drop saw and spare discs
Ultra Bi Hacp Cobalt 12Dx32Tx10mm Tap
Hacksaw and spare blades
Stanley knife and spare blades
Pressurising unit with lockable chuck
Nitrogen cylinder c/w regulator
15 metre extension lead (10 amp)
Thread tape M6x1.0 (x2), M8x1.25 & M10x1.5
Shifters 250mm & 450mm
Tee handle wrenches 5mm
Screwdriver set 13 Piece
Hammer - Ball Pein
Side cutters 250mm
Funnel and measuring jug
Deutsch connector crimping tool.
Multimeter
Cable Stripper
Crimp Pliers (Automotive lug type)
Drill Set 1mm – 13mm x 0.5mm (high speed)
Holesaw set
Step ladder
Digital scales
Pliers (combination) 225mm
Multigrips 250mm
Cable cutters
Cutting compound
Loctite 567 hydraulic thread sealant
Molykote 111 lubricant
Thread tape
Assortment of high tensile bolts, nuts and Nylok type nuts
Assortment of flat and spring washers
Nitrogen cylinders and regulator
Pressure packs of Zinc based primer
Assortment of electrical lug connectors.
Assortment of Deutsch connectors. (3, 4 & 12 Pin)
Assortment of cable glands
Assortment of screws (self taping)
Radox fire retardant cable twin and 4 core .75mm
Portable Welder (VRD Inverter)
Welding Rods
Welding safety equipment
Grinding face shield

PEFS Maintenance Manual, version 2.1, September 2007

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 PEFS Maintenance Manual 7

MAINTENANCE SCHEDULE
The following maintenance schedule is a guide and sets out minimum requirements only. In all cases, local
conditions where the system is fitted should be taken into consideration when setting maintenance
frequencies. For example, in harsh environments the yearly service may need to be carried out every 6
months.

Inspection & Testing

Daily 6 Monthly Yearly

1 System Pressure – check 9 9 9

4 Manual Actuators – check 9 9 9

3 VS Display Panel - test 9 9 9

6 Distribution System – check 9 9

7 Actuation System - check 9 9

8 Detection System - check 9 9

9 Instruction labels - check 9 9

10 Cylinders & Brackets – check 9 9

11 Manual Actuators – test 9 9

12 Battery Condition (VS control system) - check 9

12 VS Control System – functional test 9

14 Actuation systems – test 9

16 Detection systems - test 9

13 Distribution system - discharge test 9

17 Equipment shutdown - test 9

22 Refill and Pressurise System 9

23 System Leaks – Test 9

The daily inspection items should be completed by the operator prior to equipment start-up or shift change.

PEFS Maintenance Manual, version 2.1, September 2007

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Preventative Maintenance & System Survey

6 Monthly Yearly
1 Nozzles - clean 9 9

4 Pneumatic detectors - replace 9

3 Manual Actuators - service 9

2 Filters & check valves – service 9

6 Cylinder valves – service 9

7 Foam solution - replace 9

8 Nozzle – check orientation & coverage 9

9 Detectors – check coverage 9

System performance – check system
10 9
configuration
11 Internal battery replace – VS control system 9

12 Cylinders - hydrotest 9 5 yearly

PEFS Maintenance Manual, version 2.1, September 2007

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Daily

System Pressure
Check the reading on the pressure indicator located on the cylinder valve. The pressure should be 1350kPa
as indicated in the green segment of the indicator.

On LOP systems, check the reading on the pressure indicator located on the manual LOP actuators. The
pressure should show 1350kPa in the green segment of the indicator.

If system is low on pressure, the source of the leak should be identified and rectified prior to re-pressurising
the system. If the system pressure shows 0 kPa, it is likely the system has been discharged and will need to
be refilled.

Manual Actuators
Check that all actuators are secure, clean, undamaged, clearly visible and accessible.

LOP Systems

Check that the pull pins are in place on all LOP manual actuators.

If a pull pin is not in place, check the System Pressure to ensure

that the system has not been activated.

ROP Systems

Check that the pull pins are in place on all ROP manual actuators. Check that the pull pin is in place on all
ROP cylinder valves.

If a pull pin is not in place, check the cylinder pressure to ensure that the system has not been activated.
If the system has been activated, all the CO2 Cartridge should need to be inspected and replaced if
necessary.

PEFS Maintenance Manual, version 2.1, September 2007

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 PEFS Maintenance Manual 10

VS Control Systems
Check that the pull pins are in place on all VS Control System manual
release units.

If a pull pin is not in place, check the cylinder pressure to ensure that the
system has not been activated

VS Display Panel - Test

Check that the display panel is secure, clean, undamaged and accessible.

Test the VS Display Panel for correct operation:

a. Inspect the VS display panel and check that only the green
POWER LED is illuminated
b. Press and hold the “TEST” button and confirm that:
• All LED’s on the display illuminate.
• Audible alarm sounds.
c. Release the “TEST” button and check that only the green
POWER LED is illuminated.

If either the FAULT LED or amber POWER LED is illuminated after

releasing the TEST button a fault exists. Further details on fault finding
for the VS control system can be found further on in this document.

PEFS Maintenance Manual, version 2.1, September 2007

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 PEFS Maintenance Manual 11

Six Monthly
The following items are required to be completed in addition to the daily service items.

Distribution System

• Check that all nozzle seals are in place and are clean.
• Check that nozzles are correctly aimed and aligned.
• Check that all discharge hose, tubes and fittings are undamaged and secure.

Actuation System

• Check that all pneumatic actuation hoses, tubes and fittings are undamaged and secure.
• Check that all electrical actuation wiring and connections are undamaged and secure.

Note: Care must be taken when inspecting LOP actuation detection tubing, hose and fittings. Loosening
of any connections may cause the PEFS system to discharge.

Detection System

• Check that all pneumatic detection hoses, tubes and fittings are undamaged and secure.
• Check that all electrical detection wiring, LHD (Linear Heat Detection) cable and connections are
undamaged and secure.

Instruction Labels

• Check that all manual release, system warning and instruction and cylinder labels are in place,
visible and legible.

Cylinders and Brackets

• Check that all cylinder valves are clean and undamaged.

• Inspect cylinders and brackets for damage and that they are properly secured.
• Check cylinder test date is within last 5 years.

WARNING: The cylinder is a pressure vessel. Do not remove any parts from the cylinder unless
the cylinder is depressurised first.

To safely depressurise the cylinders the following procedure should be followed: New LOP picture
needed
2

1. Remove Schrader valve cap from filler port assembly (1).

2. Depress schrader valve core to release cylinder pressure.
3. Check that the pressure indicator on cylinder valve shows 0kPa.
4. On LOP systems, check that the pressure indicators on manual LOP actuators also shows 0kPa.
5. Reinstall schrader valve cap.
6. Remove actuation pipework (2) from cylinder valve.
7. Remove discharge hose (3) from cylinder valve.
8. Disconnect the electrical connectors fitted to the cylinder low pressure and discharge pressure switches
9. Remove cylinder from cylinder bracket.
PEFS Maintenance Manual, version 2.1, September 2007
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 PEFS Maintenance Manual 12

Manual Actuators

• Check that all manual actuators are secure, clean, undamaged and accessible.
• Test the operation of each actuator.

LOP Systems

• Remove the cover from each LOP actuator and check that the SureSpray nozzle seal is in tact.

Note: Care must be taken when inspecting LOP actuation detection tubing, hose and fittings. Loosening
of any connections may cause the PEFS system to discharge.

ROP Systems

Check the contents of the CO2 cartridge fitted in each ROP manual actuator.

Large Hex Nut

CO2 Cartridge

1. Ensure safety pin is in place.

2. Unscrew large hex nut and remove top assembly.
WARNING: Unscrew nut slowly to ensure that any pressure build-up within actuator has time
to purge through vent slot on side of thread.
3. Remove CO2 Cartridge, O-ring and washer.
WARNING: The CO2 Cartridge is a sealed pressure vessel. Care must be taken when
handling. Avoid any impacts, this may rupture CO2 Cartridge and cause personal injury or
damage to other equipment.
4. Clean CO2 Cartridge with a clean cloth
5. Check mass of CO2 Cartridge is within ±5% of mass stamped on CO2 Cartridge. Replace CO2 Cartridge
if underweight.
6. Check CO2 Cartridge manufacturing date. Replace if more than 5 years old.
7. Remove pull pin from top assembly.
8. Check piston assembly moves freely. Clean and re-lubricate piston o’rings with Molykote 111 if needed.
9. Refit pull pin to top assembly.
10. Reinstall CO2 Cartridge, O-ring and washer.
11. Check housing O-ring. Replace if damaged.
12. Reinstall top assembly. Tighten large hex nut.
13. Cartridges which are damaged or out of test date should be removed from site and depressurised in the
workshop using a dedicated actuator piped into the CO2 discharge vent.

PEFS Maintenance Manual, version 2.1, September 2007

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VS Control Systems

1. Check that all electrical manual release units incorporated into the VS control system are accessible
and in good condition.

2. For those systems using solenoid activation, remove the solenoid coil from the solenoid valve and place
the coil on a spare solenoid valve or valve stem.

3. Remove the back cover from the VS display panel and move the Maintenance Isolate DIP switch
(switch 7) to the ON position. Confirm the ISOLATED LED on the VS display panel is illuminated.

System Reset

DIP Switches

VS Display Panel Circuit Board

The isolate switch isolates the actuation, auxiliary alarm and shutdown outputs from the VS control
module. All VS control module inputs remain enabled along with the audible alarm unit output, fault
output and VS display panel LED’s. In this state the ISOLATED LED on the VS display will remain
illuminated and the audible alarm unit will beep once per minute. This switch allows testing of manual
release and detection inputs as well as fault conditions without causing discharge of the PEFS system,
initiating equipment shutdown or auxiliary alarm outputs.

4. With the system isolated, operate each electrical manual release incorporated in the VS control system
and confirm the ALARM LED on the VS display panel illuminates and audible alarm unit operates.

5. Reset the VS control system after operating each manual release by pressing and holding the RESET
button (located on the display panel circuit board) for 2 seconds.

6. After all manual release units have been tested return the Maintenance Isolate DIP switch to the OFF
position and confirm the ISOLATED LED on the VS display panel is extinguished.

7. One final test should be completed without the system being isolated to ensure the solenoid coil is
energised by the VS control system when in alarm. Operate one of the electric manual releases and
confirm that the solenoid coil is energised.

Note: As the coil is only energised by the control system for 30 seconds, it may be necessary to
have two people complete this task.

8. Reset the VS control system by pressing and holding the RESET button (located on the display panel
circuit board) for 2 seconds.

9. Refit the back cover to the VS display panel.

10. Re-fit the solenoid coil to the solenoid valve on the PEFS system.

PEFS Maintenance Manual, version 2.1, September 2007

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 PEFS Maintenance Manual 14

Battery Condition

Check the condition of the internal battery in the VS control module.

The VS control system monitors the usage of the internal battery during operation. A visual indication of the
remaining battery capacity can be obtained by following the procedure below.

1. Remove the cover from the VS Control Module.

2. Press and hold both the “fault” and “battery reset” push buttons on the VS control module circuit
board.
3. The remaining battery capacity is shown visually by illumination of the fault LED’s (all LED’s lit =
battery full). The internal battery should be replaced when two or less amber LED’s are illuminated.
Fault push button Fault LED’s

RS232
connection

Real time clock

battery

Battery reset

VS Control Module Circuit Board

Replacing the internal battery

To replace the internal battery it is necessary to remove the circuit board from the control module housing.

1. Remove the cover from the VS Control Module.

2. Remove the screws which hold the connectors to the control module housing
3. Carefully remove the circuit board and unplug the battery pack from the rear of the circuit board
4. Install a new battery pack and re-connect the battery lead to the circuit board
5. Refit the circuit board into the housing
6. Reset the battery life monitor:
a. Ensure the system real time clock is correctly set for the current time and date
b. Press and hold the “battery reset” push button on the control module circuit board.
c. Press and hold the “system reset” push button
d. Wait 3 seconds
e. Release the “reset” push button
f. Wait 2 seconds
g. Release the “battery reset” push button

7. Confirm the battery life has been reset by pressing and holding the “fault” and “battery life reset”
push buttons on the circuit board. All LED’s should illuminate. More detailed battery usage
information can be obtained using the control module’s RS232 interface and “get battery info”
command.

NOTE: As the internal battery is used to energize the actuation output, it is critical that the battery
life monitor only be reset when installing a new battery pack.
PEFS Maintenance Manual, version 2.1, September 2007
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 PEFS Maintenance Manual 15

Yearly
VS Control System – Function Test
1. For those systems using solenoid activation, remove the solenoid coil from the solenoid valve and place
the coil on a spare solenoid valve or valve stem.
2. Operate a manual release unit.
3. Confirm the ALARM LED and amber SHUTDOWN LED on the VS display panel is illuminated and the
audible alarm unit sounds.
4. Confirm the solenoid coil is energised by checking for a magnetic field.
Note: As the coil is only energised by the control system for 30 seconds, it may be necessary to
have two people complete this task.
5. Reset the VS control system by removing the back cover from the VS display panel and pressing the
RESET button (located on the display panel circuit board) for 2 seconds.
6. Confirm the ALARM and SHUTDOWN LED’s on the display are extinguished.
7. Repeat Steps 3 to 6 by introducing a short circuit on the detection circuit.
8. Refit the back cover on the display panel.
9. Check all actuation wiring supports and connections are secure.

In conjunction with the test detailed above, complete the following items to confirm the correct operation of
the VS control system.

Equipment Shutdown

Record the time delay between the VS control system registering an alarm and the shutdown output being
energised. Confirm the equipment shutdown operates and interfaces correctly. Confirm this time matches
that specified on the commissioning documentation for the system.

Shutdown Delay

Confirm the DELAY button becomes enabled during the final ten seconds of the shutdown delay period and
record the shut delay extension period. Confirm this time matches that specified on the commissioning
documentation for the system.

Discharge delay

Record the time delay between the VS control system registering an alarm and the solenoid output being
energised. Confirm this time matches that specified on the commissioning documentation for the system.

Detection mode

Confirm the detection mode setting (single circuit or dual circuit) of the VS control system is correct.

Auxiliary outputs

Test and confirm the correct operation of any auxiliary alarm and fault indicators fitted to the auxiliary alarm
and auxiliary fault outputs.

Cylinder Low Pressure Switch

Test and confirm the correct operation of the cylinder low pressure switch input by disconnecting the
electrical connector on the pressure switch. Confirm the FAULT LED on the VS display panel and audible
fault alarm unit operates.

Discharge Pressure Switch

Test and confirm the correct operation of the cylinder low pressure switch input by disconnecting the
electrical connector on the pressure switch. Confirm the DISCHARGED, FIRE and SHUTDOWN LED’s
illuminate and the audible alarm sounds.

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Replace internal Battery

At the completion of function testing, replace the internal battery with a new unit and reset the battery life
counter as detailed in the previous section.

NOTE: Detailed information on the configuration and operation of the VS control system can be
found at the end of this manual.

Distribution System - Discharge Test

An annual discharge test is important to confirm the complete PEFS system operates and performs to the
same standard as when originally commissioned.

1. Discharge the PEFS system using one of the available actuation or detection options.
2. Confirm all nozzle seals release and nozzles discharge.
3. Check that the nozzle discharge patterns cover the fire hazard area as specified in the commissioning
documentation.
4. Confirm the DISCHARGED LED on the VS display panel illuminates.
5. Record the Effective Discharge Time (EDT) and compare it to the EDT recorded during commissioning.
6. Check that all alarms, actuation and shutdown functions operate as intended.
7. Service PEFS cylinder valves.
8. Refill and Pressurise system.
9. Reset the VS control system by pressing the RESET button on the display panel printed circuit board
and refit the back cover to the display panel.

Distribution System – Clear Passage Test

After completing the discharge test:

1. Disconnect discharge hose from cylinder valve
2. Flush discharge network with water and/or compressed air/nitrogen
3. Check distribution network is clear of any blockages
4. Remove nozzles and replace with new/serviced nozzles c/w with seals
5. Reconnect discharge hose to the cylinder valve

PEFS Maintenance Manual, version 2.1, September 2007

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Cylinder Valve - Service

WARNING: The cylinder is a pressure vessel. Do not remove any parts from the cylinder prior to
depressurising the cylinder.

LOP Valve Service

New LOP picture
needed
5

6
2
7

4
3 8

1. Remove schrader valve cap from filler port assembly (1).

2. Depress schrader valve core to release cylinder pressure.
3. Check that the pressure indicator on cylinder valve shows 0kPa.
4. If fitted, check that the pressure indicators on manual LOP actuators read 0kPa.
5. Reinstall schrader valve cap.
6. Remove actuation hose (2) from top of cylinder valve (4).
7. Remove discharge hose (3) from cylinder valve (4).
8. Remove cylinder valve (4) from cylinder.
9. Remove the 4 screws and washers (5).
10. Remove the cap (6) and o’ring (7).
11. Remove the piston assembly (8).
12. Replace damaged components and o’rings.
13. Clean and re-lubricate all o’rings and outside diameter of piston assembly (8) with Molykote 111.
14. Re-install piston assembly (8).
15. Re-install o-ring (7) to cap (6).
16. Re-install cap (6), washers and screws (5) to cylinder valve.
17. Inspect syphon tube (9). Replace if tube has become stiff or is damaged.
18. Check cylinder valve neck o-ring is clean. Replace o-ring if damaged.
19. Re-lubricate o-ring with Molykote 111.
20. Re-install cylinder valve (4) to cylinder.
21. Refill cylinder and pressurise system.

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ROP Valve Service

4 7

12 8
2

9
3
1

10

11

1. Remove schrader valve cap from filler port assembly (1).

2. Depress schrader valve core to release cylinder pressure.
3. Check that the pressure indicator on cylinder valve shows 0kPa.
4. Reinstall schrader valve cap.
5. Bleed pressure from actuation network through bleed valve (12).
6. Remove actuation hose (2) from cylinder valve (4).
7. Remove discharge pipework (3) from cylinder valve (4).
8. Remove cylinder valve (4) from cylinder.
9. Remove syphon tube from cylinder valve (4).
10. Remove piston assembly (10) and spring (11).
11. Remove the 4 screws and washers (5).
12. Remove the manual actuator cap (6).
13. Remove the pneumatic actuator body (7).
14. Remove the pneumatic piston assembly (8) and spring (9).
15. Replace damaged components and o’rings.
16. Clean and re-lubricate all o’rings and the outside diameter of the piston assemblies (8) and (10) with
Molykote 111.
17. Re-install piston assembly (8) and spring (9).
18. Re-install pneumatic actuator body (7).
19. Re-install manual actuator cap (6), washers and screws (5) to cylinder valve.
20. Check cylinder valve neck o’ring is clean. Replace o’ring if damaged.
21. Re-lubricate o-ring with Molykote 111.
22. Re-install piston assembly (10) and spring (11).
23. Re-install syphon tube to cylinder valve (4).
24. Re-install cylinder valve (4) to cylinder.
25. Refill and pressurise cylinder.

PEFS Maintenance Manual, version 2.1, September 2007

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Pneumatic Detectors – Replace

LOP Systems

Prior to replacing any LOP detection tubing ensure the system is depressurised by depressurising the PEFS
cylinders using the schrader valve fitted to the cylinder valve fill port.

NOTE: Do not loosen any hose connections or fittings in the LOP actuation system while the system is
pressurised. This will cause the system to discharge.

After having depressurised the PEFS cylinders, replace each length of LOP detection tubing leak test the
detection network and re-pressurise the system to 1,350 kPa.

ROP Systems

Replace the wick in each Pyrotube detector using the procedure detailed below. Alternatively, each
Pyrotube detector can be completely replaced if it is not possible to remove the wick from the installed
Pyrotube detectors.

1
2

1. Disconnect pyrotube (1) from Filter (2).

2. Remove Filter (2) and clean with compressed air.
3. Reinstall Filter (2).
4. Remove end connectors from Pyrotube (1)
5. Remove Pyrotube wick from stainless steel tubing. Dispose of Pyrotube wick in a safe manner as
detailed below.
6. Clean inside of stainless steel tubing.
7. Install new Pyrotube wick.
8. Reinstall end connectors to Pyrotube (1).
9. Reinstall Pyrotube (1) to Filter (2).
10. Test actuation pipework.

Disposal of Pyrotube Wick

WARNING: Pyrotube Wick is a flammable item. Treat its disposal with caution.

Pyrotube Wick should be destroyed only by competent personnel. Do not place in rubbish bins or with
commercial waste for disposal until Pyrotube Wick has been rendered safe by completing the procedure
below.

1. Ensure that a portable Dry Chemical Fire Extinguisher is positioned close by.
2. Unwind the wick on a non-flammable surface in an outdoor area away from any flammable items.
3. Cut thread connector from one end
4. Light the cut end of the wick. The wick will burn progressively along its entire length at approximately 5
seconds per metre.

Notice: Water will not extinguish burning wick. Pyrotube Wicks do not require oxygen to burn.
PEFS Maintenance Manual, version 2.1, September 2007
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 PEFS Maintenance Manual 20

Manual LOP actuators – Service

Prior to servicing any LOP actuators ensure the system is depressurised by depressurising the PEFS
cylinders using the schrader valve fitted to the cylinder valve fill port.

NOTE: Do not loosen any hose connections or fittings in the LOP actuation system while the system is
pressurised. This will cause the system to discharge.

After having depressurised the PEFS cylinders, service each LOP actuator as follows.

1. Remove the actuator cover plate.

2. Remove actuation hose from actuator connection (2).
3. Check the SureSpray nozzle to ensure its foil seal is in place.
4. Remove Surespray nozzle and check that the internals of actuator and
nozzle are clean and unobstructed. Replace nozzle pintle and foil if
damaged or missing.
5. Remove and inspect actuator piston and seals.
6. Clean and lubricate all seals using Molykote 111 (or equivalent o-ring
lubricant). 2
7. Replace any damaged components or seals.
8. Refit piston to actuator body
9. Ensure that the actuation mechanism moves freely.
10. Refit Surespray nozzle SureSpray
11. Refit pull pin nozzle
12. Reconnect actuation hose to actuator connection (2).

Actuation Systems – Leak Test

Test pneumatic actuation circuits for leaks. Check that all pneumatic actuation hoses, tubes and fittings are
undamaged and secure. The leak testing procedure required for ROP systems is detailed below.

ROP Systems

3
1
3
2
4 3
1
4

1. Remove actuation hose/fitting from check valve fitted to the ROP cylinder valve (1).
2. Fit a plug to the actuation hose/fitting removed from the check valve.
3. One section at a time, connect a source of nitrogen or compressed air to the end of each actuation
network section (3).
4. Remove the actuation hose from each check valve (4) in the manifold block (other than the section
being tested).
5. Pressurise the section being tested to 1,350kPa and inspect for leaks. Leak test all connections and
check valves with liquid leak detection solution (allow to sit for at least 5 minutes).
6. Repeat steps 3 – 6 until section of the ROP actuation and detection system has been tested.
7. Release pressure in actuation network and re-instate all actuation hose connections to their original
state.
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Refill and Pressurise System

Cylinders must only be filled using potable water. The fill quantities for each size cylinder are detailed in the
table below.
Cylinder Size Total Water AFFF Storage
Fill quantity quantity Pressure
C23 cylinder assembly 18 lt. 16.5 lt. 1.5 lt. 1350kPa
C30 cylinder assembly 24 lt. 22.0 lt. 2.0 lt. 1350kPa
C45 cylinder assembly 35 lt. 32.5 lt. 2.5 lt. 1350kPa
C65 cylinder assembly 50 lt. 47.0 lt. 3.0 lt. 1350kPa
C106 cylinder assembly 85 lt. 79.0 lt. 6.0 lt. 1350kPa

ROP cylinder LOP cylinder

1. Remove schrader valve cap from filler port assembly (1).
2. Depress schrader valve core to release cylinder pressure.
3. Check that the pressure indicator on cylinder valve reads 0kPa.
4. On LOP systems, check that the pressure indicators on manual LOP actuators shows 0kPa.
5. Reinstall schrader valve cap.
6. Remove filler port assembly (1).
7. Fill cylinder with approximately 90% of the water contents required.
8. Fill cylinder with required quantity of AFFF foam concentrate.
9. Slowly fill cylinder with the remainder of the water contents required. A fill tube is fitted to the cylinder to
prevent overfilling the cylinder.
10. Refit filler port assembly.

Pressurising

LOP Systems

LOP systems are pressurised using the schrader valve fitted on any of the manual LOP actuators.

NOTE: Do not pressurise LOP systems using the schrader valve on the filler port assembly (1) of the PEFS
cylinders. This will cause the cylinder to discharge.

To pressurise the system using a manual LOP actuator:

1. Ensure the pull pin is in place on the actuator piston

2. Remove the cover from the LOP actuator.
3. Connect a source of compressed nitrogen, regulated to 1350kpa, to the schader valve on the LOP
manual actuator (2).
4. Fill with nitrogen until the pressure indicator on the actuator shows 1,350 kPa
5. Check the pressure indicator on the cylinder valves also shows 1,350 kPa.
6. Disconnect the source of compressed nitrogen.
7. Test the actuation system for leaks.
8. Check that the seal on the nozzle fitted to the actuator outlet is in place.
9. Refit the cover on the LOP actuator.
10. Test the cylinder for leaks, using leak detection solution. Pay special attention to the filler port
assembly, burst disk, cylinder valve and all valve fittings.
11. Leak test all LOP detection and actuation hoses and fittings and manual LOP actuators.

Note: LOP systems may also be pressurised from using a “recharging point” fitted anywhere in the LOP
actuation network and following steps 3 – 7 detailed above.
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ROP Systems

ROP cylinders can be pressurised using the schader valve fitted to either the filler port Assembly (1) or the
cylinder valve.

1. Connect a source of compressed nitrogen, regulated to 1350kpa, to the schrader valve.

2. Fill with nitrogen until the pressure indicator on the cylinder valve shows 1,350 kPa
3. Disconnect the source of compressed nitrogen.
4. Test the cylinder for leaks, using leak detection solution. Pay special attention to the filler port
assembly, burst disk, cylinder valve and all valve fittings.

WARNING: Do not pressurise a cylinder that is not in test date.

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5 Yearly
PEFS cylinders must be hydrotested every five years at a licensed test station. Following hydrotesting of
each cylinder complete the following service items:

1. Install burst disk to cylinder. Apply Loctite 567 thread sealant to threads prior to installation.
2. Check o-rings on fill tube and filler plug assembly (1) are clean. Replace damaged o-rings.
3. Install fill tube and filler plug assembly to cylinder.
4. Check cylinder valve neck o-ring is clean. Replace o-ring if damaged. Lubricate o-ring with Molykote
111.
5. Fit syphon tube to cylinder valve
6. Fit cylinder valve and syphon tube to cylinder.
7. Install new label to cylinder or clean existing label.
8. Install cylinder to cylinder bracket.
9. Install and connect pressure switches.
10. Connect discharge hose to cylinder valve.
11. Connect actuation hoses to cylinder valve.
12. Refill and pressurise cylinder.

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MAINTENANCE REPORT
Inspection and Maintenance Report for PEFS Pre-Engineered Foam Spray Systems
Work Order Number: Date:

Client Information
Customer Name: Contact Name:
Customer Address:
Telephone: Mobile: Fax:

Equipment Information
Equipment Type: Equipment Make:
Equipment Model: Equipment Serial No.:
Equipment Location:

AFFF System
Operating Mode: LOP ‰ ROP ‰
Cylinder Size: Qty: Serial Numbers: Manufacture Date:
Qty Nozzles: Qty Manual Actuators: Fire Alarm Panel: Standard ‰ Shutdown ‰ None ‰

Service
THIS INSPECTION IS TO BE CONDUCTED IN ACCORDANCE WITH PEFS MAINTENANCE & PARTS LIST MANUAL (P/N: 61416)
Item Service 6 Mnth 12 Mnth Defect Report

1 System Pressure – Check

2 Fire Alarm Panels – Test

3 (ROP) Pull Pins – Check

4 (LOP) Manual LOP Actuator Security Ties – Check

5 (LOP) Manual LOP Actuators – Inspect

6 Cylinder Valves – Inspect

7 Nozzle Caps – Inspect

8 Pipework, Hoses and Fittings – Check

9 Cylinders – Check

10 Cylinder Brackets – Check

11 Labels – Check

12 Discharge Pipework – Clean

13 (ROP) Manual CO2 ROP Actuators – Inspect

14 (ROP) Actuation Pipework (ROP) – Test

15 Discharge Test Discharge Time:

16 Cylinders – Inspect

17 (ROP) Cylinder Valve (ROP) – Refurbish

18 (ROP) Pyrotube Wick – Replace

19 (LOP) Cylinder Valve (LOP) – Refurbish

20 (LOP) Manual LOP Actuators – Inspect

21 (LOP) LOP Detection Tubing – Replace

22 Refill and Pressurise System

23 System Leaks – Test

24 Stamp maintenance date on Service Tag

Record of all repairs:

Record of parts used:

Does system meet original Design Specifications: YES ‰ NO ‰

If No, Changes:

Name of Technician: Signature:

Name of Customer: Signature:

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SPARE PARTS
Cylinders

PEFS cylinders are manufactured from 304 stainless steel to the requirements of AS3509. PEFS cylinders
have a fill ratio of 80% of their water capacity and are pressurised to 1,350kPa.

Part No. Description Water Design Test Approval No.

Capacity Pressure Pressure VIC DOL
(MPa) (MPa)
16091 C23 Cylinder 23 lt. 4 6 V1061-84
16092 C30 Cylinder 30 lt. 4 6 V1061-84
16093 C45 Cylinder 45 lt. 2.2 3.6 V376-84
16094 C65 Cylinder 65 lt. 2.2 3.6 V376-84
16095 C106 Cylinder 106 lt. 2.2 3.6 V376-84

Table 1 – PEFS cylinder specifications

Cylinder C23 C30 C45 C65 C106

Diameter 216 318 360 360 360
Height 726 512 572 772 1188

H
H
H
H

Table 2 – PEFS cylinder dimensions

Cylinder Assemblies

Two types of cylinder assemblies (Rise of Pressure [ROP] and Loss of Pressure [LOP]) are available for use
in PEFS systems depending upon the detection and actuation mode selected.

Rise Of Pressure (ROP) Cylinder Assemblies

Part Total Water AFFF Storage Height

Number Fill quantity quantity Pressure (mm)
C23 ROP cylinder assembly 6011/12 18 lt. 16.5 lt. 1.5 lt. 1350kPa 960
C30 ROP cylinder assembly 6012/12 24 lt. 22.0 lt. 2.0 lt. 1350kPa 740
C45 ROP cylinder assembly 6013/12 35 lt. 32.5 lt. 2.5 lt. 1350kPa 820
C65 ROP cylinder assembly 6014/12 50 lt. 47.0 lt. 3.0 lt. 1350kPa 1020
C106 ROP cylinder assembly 6015/12 85 lt. 79.0 lt. 6.0 lt. 1350kPa 1440

Table 3 – ROP cylinder assembly details

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Loss Of Pressure (LOP) Cylinder Assemblies

Part Total Water AFFF Storage Height

Number Fill quantity quantity Pressure (mm)
C23 LOP cylinder assembly 6016/12 18 lt. 16.5 lt. 1.5 lt. 1350kPa 910
C30 LOP cylinder assembly 6017/12 24 lt. 22.0 lt. 2.0 lt. 1350kPa 690
C45 LOP cylinder assembly 6018/12 35 lt. 32.5 lt. 2.5 lt. 1350kPa 770
C65 LOP cylinder assembly 6019/12 50 lt. 47.0 lt. 3.0 lt. 1350kPa 970
C106 LOP cylinder assembly 6020/12 85 lt. 79.0 lt. 6.0 lt. 1350kPa 1390

Table 4 – LOP cylinder assembly details

CYLINDER VALVE
118554
CYLINDER VALVE
110269
New LOP picture
needed
O’RING
107656

FILLER PLUG
ASSY
23100

FILL TUBE

SIPHON TUBE
ASSY

CYLINDER

BURST DISC
112255

Rise of Pressure Loss of Pressure

Cylinder Assembly Cylinder Assembly

Figure 1 – ROP & LOP cylinder assemblies

Cylinder Sub-assemblies

Cylinder sub-sssemblies come with burst disk, fill tube and filler plug assembly

Cylinder Sub-Assembly
Cylinder Size
Part Number
C23 109508
C30 109510
C45 109511
C65 109512
C106 111045

Table 5 – cylinder sub-assemblies

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Fill Tubes

Cylinder assemblies are fitted with a fill tube to assist in the correct filling of cylinders. The cylinders are
filled to the correct volume when the foam solution level reaches the bottom of the fill tube. Each cylinder
size has a different length fill tube.

Cylinder Fill Tube

Size Part Number
C23 30247
C30 30215 O’RING
C45 30248 90127
C65 30249
C106 30250

Table 6 – Fill tube details

Siphon Tubes

PEFS cylinder assemblies are fitted with flexible siphon tubes to allow the cylinders to be mounted either
vertically or horizontally. The siphon tubes are manufactured from reinforced flexible hose with brass end
fittings.

Figure 2 – Siphon tube

Cylinder Siphon Tube Syphon Tube

Size Part Number Length (±2mm)
C23 109298 719
C30 110281 485
C45 110282 546
C65 110283 745
C106 112040 1156

Table 7 – Siphon tube details

Foam Concentrate

Only Chubb 3% AFFF foam concentrate (20 litre drum part number 86280) is to be used for filling PEFS
systems. Tables 3 & 4 detail the correct fill quantities for each size PEFS cylinder. PEFS systems are
suitable for use in suppression of class A (ordinary combustible) and class B (flammable liquid) fires.

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ROP Cylinder Valve

The ROP valve consists of a chrome plated brass body and incorporates an integral manual and pneumatic
actuator.
SOCKET HEAD
SCREW
110265

SPRING
WASHER
103194 CAM
110249

GRUB SCREW
CHECK VALVE 110264
103222

PULL PIN
104657 MANUAL ACTUATOR BODY
110245

PNEUMATIC ACTUATOR BODY

O’RING
110247
107238
SCHRADER VALVE
LEVER
94001
110251
CAP
40503
KNOB
107555 PNEUMATIC PISTON
O’RING 110253
110254

SPRING PLUG
110255 118551
(Port for 127379 200kPa Fire
Alarm/Discharge Pressure
Switch)
CAP
40503 PLUG
118551
(Port for 127361 900kPa
SCHRADER VALVE Cylinder Low Pressure Switch)
94001

PRESURE
INDICATOR VALVE BODY
103850 110243

PLUG
VALVE STEM 103604
ASSEMBLY
110263

SPRING
110273

Figure 3 – ROP valve assembly (part number 110269)

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Cylinder Valve LOP

The LOP valve consists of a stainless steel valve body with brass piston.

SOCKET HEAD
SCREW
SCHRADER VALVE 118537
94001
SPRING
CAP WASHER
40503 118538

NIPPLE
128817
CAP O’RING
XXXXX 90022

PISTON
118534

O’RING BS211
118548

O’RING BS005
103856
CHECK VALVE
118536

O’RING BS208
118549

RETAINER
PLUG 118535
118551
(Port for 127361 900kPa Cylinder
Low Pressure Switch)

PLUG
118551
(Spare port for 127379
200kPa Fire Alarm/Discharge
Pressure Switch)

PRESURE
INDICATOR
103850 BODY
118532

Figure 4 – LOP valve assembly (part number 118554)

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Cylinder Brackets

PEFS cylinder brackets are manufactured from welded carbon steel and painted black.

Figure 5 - C23 cylinder bracket Figure 6- C30 cylinder bracket

(part number 128735) (part number 128736)

Figure 7 – C45 & C65 cylinder bracket Figure 8 – C106 cylinder bracket
(part number 128737) (part number 128738)

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DISCHARGE COMPONENTS
Stainless Steel Tube

½”’ Stainless Steel tube should be used in the fire hazard areas to supply the PEFS discharge nozzles. The
tube is 12.7mm outside diameter x 0.9mm wall thickness annealed seamless type 304 or 316 stainless steel
tubing (part number 112108 for 2m lengths).

Figure 9 – Stainless steel tube and fittings

Discharge Hose

All hose used in PEFS discharge systems must be flame resistant to U.S.MSHA 2G requirements. Use of
hose in fire risk areas should be kept to a minimum and avoided if possible. In areas where discharge hose
may be subjected to abrasion or impact, hose protection spiral guards should be used.

Hose Part Description

Size Number
Red ‘FIRE SUPPRESSION’ branded
½” 118097
discharge hose. Oil resistant with high
tensile steel wire braid reinforcement.
Meets SAE 100R1AT specifications and
¾” 118098
U.S.MSHA 2G flame resistance
requirements.

Table 8 – Discharge hose

Nozzles

SureSpray discharge nozzles are non-aspirated, solid cone, spray nozzles with a 1/4” BSP inlet thread.
Surespray nozzles are of all brass construction and comprise 4 parts, including a brass foil seal.

1 1. nozzle body
4 2. pintle
3. foil seal
4. foil retaining cap

3 2

Figure 10 – SureSpray nozzle assembly

Upon system discharge, the foil seal is designed to rupture and the support pintle will be displaced from the
nozzle outlet allowing the nozzle to discharge foam solution. Replacement of the foil and pintle is required
following discharge.

NOTE: As the foils are very thin, care must be taken to ensure that only a single foil is installed when
servicing SureSpray nozzles.
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Two types of SureSpray nozzles, BM17N and BM16W, are available. The BM17N has a narrow discharge
pattern and is suitable for applications where the nozzle is mounted up to 1,000mm from the target, whilst
the BM16W has a wider discharge pattern for close range applications where the nozzle is mounted less
than 450mm from the target.

(part number 46111) (part number 46112)

Figure 11 – SureSpray nozzle range and coverage details

Part Number Description

46113 Foil cap
46114 Foil cap assembly tool
46115 Foil seal
46116 Pintle – BM 16 & BM 17

Table 9 – SureSpray nozzle spare parts

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Nozzle Kits

A range of standard nozzle discharge configurations are available in the form of nozzle kits.

Nozzle kit single straight (part number 115371) Nozzle kit single end 90° (part number 115151)
ELBOW
SOCKET 112138
112143

Nozzle kit single straight 90°(part number 115152) Nozzle kit double straight 90° (part number 115153)
TEE
112132
TEE
112132
ELBOW
112139

ELBOW
119336
TEE
REDUCING 112183
BUSH
112144
SOCKET
112143

Nozzle kit double straight 90°/45° (part number 125316)

ELBOW
119336 TEE
112132

SOCKET ELBOW
112143 TEE 114632
112183

Nozzle Kit Triple Straight 45°/90°/45° (part number 125317)

Figure 12 – Standard nozzle kit configurations

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Discharge Hose and Tube fittings

The hose and tube fittings supplied by Chubb meet minimum levels of quality and corrosion resistance.
Fittings from non-approved suppliers may not offer the same levels of quality and corrosion resistance and
could result in blockage of hose or tubing due to corrosion.

Type Part No. Description

Hose 40136 Suitable for hose sizes 3/8” to 5/8”.
Protector 40152 Suitable for hose sizes ¾” to 1”.
118099 1/2” Hose x 3/4” JIC (f) swivel
118100 3/4” Hose x 1 1/16” JIC (f) swivel
118101 90° Elbow 1/2” Hose x 3/4” JIC (f) swivel
Couplings 118102 90° Elbow 3/4” Hose x 1 1/16” JIC (f) swivel
(Field
Attachable)
115963 90° Bend 1/2” Hose x 3/4” JIC (f) swivel

128744 1/2” Hose x 3/4” JIC (m)

Cap/Nut 112145 3/4” JIC Nut & Sleeve to suit 1/2” Tube

Adaptor/ 112146 3/4” JIC (m) x 1 1/16” JIC (f)

Reducing
Bushes 112144 3/8” BSP (m) x 1/4” BSP (f)

114545 3/4” JIC

112962 3/4” JIC x 1/2” BSP

112128 3/4” JIC x 3/4” BSP
Nipples 112129 1 1/16” JIC x 3/4” BSP
128766 3/4” JIC Bulkhead

112142 1 1/16” JIC Bulkhead

Socket 112143 3/8” BSP (f) x 1/4” BSP (f)

Plug/Cap 128745 3/4” JIC (m)

112130 3/4” JIC (m)
112131 1 1/16” JIC (m)
114609 1 1/16” JIC (m) x ¾” JIC (m) x ¾” JIC (m)
112132 3/4” JIC (m) x 3/4” JIC (m) x 3/8” BSP (m)

112183 3/8” BSP (f)

117381 3/4” JIC (m) bulkhead

Tees
115371 3/4” JIC (m) x 1/4” BSP (f) x ¾” JIC (m)
115815 3/4” JIC (m) x 1/2” BSP (f) x ¾” JIC (m)

128748 3/4” JIC (m) x 3/4” JIC (f)swv x 3/4” JIC (m)

3/4” JIC (f)swv x 3/4” JIC (m) x 3/4” JIC (m)

128747

Table 10 – PEFS discharge hose & tube fittings

(continues over.)
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112136 3/4” JIC (m & f) swivel

112436 1 1/16” JIC (m & f) swivel

112138 3/8” BSP (m) x 3/4” JIC (m)

112134 3/4” JIC (m)

112135 1 1/16” JIC (m)
117322 ¼” BSP (f) x ¾” JIC (m)

112140 3/8” BSP (m) x 3/8” BSP (f)

Elbows 112139 3/8” BSP (f) x 3/8” BSP (f)

128743 45° 1 1/16” JIC (m & f) swivel

114567 45° 3/4” JIC (m & f) swivel

114632 45° 3/8” BSP (m)

119336 3/8” BSP (m)

128741 3/4” JIC (f)

Table 10 – PEFS discharge hose & tube fittings

(continued)

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Single, Elbow End

Nozzle Assy.

115151

Stainless Steel Tube

Nozzle Assy.
Double, Tee
115153

112108
Nozzle Assy.
Single, Tee
115150

114609
Tee

Nut & Sleeve

112145
Coupling
118098

118100
Hose

112129
Nipple

Figure 13 – Typical Discharge System – (ROP Cylinder Valve shown)

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DETECTION & ACTUATION COMPONENTS

Rise Of Pressure (ROP) Detection & Actuation
Pyrotube Detector

The Pyrocord has an installed life of 1 year and must be replaced annually as part of the regular
maintenance routine.

Length (m) Pyrotube

Part Numbers
1.0 36646
1.5 36647
2.0 36648
2.5 36649
3.0 36650
3.5 36651
4.0 36652
4.5 36653
5.0 36654
5.5 36655
6.0 36656

Table 11 – Pyrotube (Pyrotubes are supplied with JIC flared fittings without the Pyrocord.)

Pyrocord

Pyrocord (part number 93501) is supplied separately to the Pyrotube Assemblies and needs to be cut to size
and inserted into the Pyrotube Assemblies at the time of installation.

Pyrotube Filter

A Pyrotube filter must be fitted in each Pyrotube detection circuit to prevent debris from the burnt Pyrocord
element fouling other actuation system components. The filter is to be fitted at the junction of the Pyrotube
detector and the connecting tube or hose directing pressure to the pneumatic actuator on the cylinder valve.
The Pyrotube Filters have a 230µm mesh element that may be removed for cleaning or replacement.

7/16” JIC
Male Flare

Figure 14 – Pyrotube filter (part number 128762)

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ROP Manual Actuator

ROP manual actuators are manufactured from stainless steel and contain a CO2 cartridge. When the strike
button on the actuator is struck, the CO2 cartridge is pierced and the pressure released is used to operate
the cylinder valve’s pneumatic actuator.

BOLT
SPRING WASHER 91314
94234
ORING
90011 NUT
O’RING 92327
90222
CO2 CARTRIDGE ORING
16004 94814

BUTTON
26172
SLEEVE
26170 BODY
26171

PISTON
26173 LABEL
(NOT SHOWN)
66517

WASHER PULL PIN

36404 41010

BRACKET
76818

Figure 15 – Remote manual ROP actuator (part number ES9106-B Surface/Flush Mounted)
(Bracket 76818 removed for flush mount application)

CO2 cartridge (part Number 16004)

Capacity 95 cc
Service life 5 Years
Charge weight 60g +/- 3 g
Pressure ~5.6Mpa @ 20°C
material Cold Rolled Carbon Steel
Cylinder approval 6865P87

Table 12 – CO2 Cartridge specification

Check Valve

The check valve comes with 1/4” tube JIC flare and 1/4” NPT male thread designed to fit into actuation
manifold blocks.

Figure 16 – ROP Check Valve (part number 103222)

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Loss Of Pressure (LOP) Detection & Actuation

Loss of Pressure Detection Tubing (part number 118837)

LOP detection tubing has an installed life of 1 year and must therefore be replaced annually as part of the
regular maintenance routine.

LOP Detection Tubing must be securely mounted using pipe clips with a synthetic sheathed surface to avoid
chafing. The distance between support clips should be 500mm or less. The LOP Detection Tubing has a
minimum internal bend radius of 50mm.

Manual LOP Actuator

The manual LOP actuator is suitable for internal and external vehicle mounting. Manual LOP actuators are
manufactured from red powder coated stainless steel housing and incorporates a pressure gauge. It is
designed for mounting on a vertical surface, using 4 x M6 fasteners.

Figure 17 –LOP Actuator (part number 47124)

NOTE: Care must be taken when fitting manual LOP actuators to a LOP Detection System. These
actuators must be fitted before pressurising the cylinder.

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Actuation System Fittings

Listed below are fittings required to assemble most configurations of LOP and ROP detection and actuation
networks.

ROP Actuation Hose & Fittings

Part No. Description
3/16” ROP actuation hose, red coloured,
‘FIRE SUPPRESSION’ branded, oil resistant
3/16” ROP synthetic rubber with high tensile steel wire
128756
actuation hose braid reinforcement meeting SAE 100R1AT
specifications and U.S.MSHA 2G and AS2660
flame resistance requirements.
3/16” Hose x 7/16” JIC (f) swivel. Field
117811
attachable
Hose Fittings
Bend 90° 3/16” Hose x 7/16” JIC (f) swivel.
Field attachable

Tube 36603 6.35mm OD 304 Stainless Steel

Table 13 – ROP detection & actuation fittings

LOP Actuation Hose & Fittings

Part No. Description
¼” red coloured, ‘FIRE SUPPRESSION’
branded, oil resistant synthetic rubber with
¼” LOP
high tensile steel wire braid reinforcement
actuation 9344220356
meeting SAE 100R1AT specifications and
hose
U.S.MSHA 2G and AS2660 flame resistance
requirements.
118839 1/4” Hose x 1/4” ORFS(f) Field Attachable

Hose Fittings 9344220357 1/4” Hose x 7/16” JIC (f)swv Field Attachable

128742 90° Elbow 1/4” Hose x 7/16” JIC (f) swivel

LOP Tubing 119237 119235 118837 119234 119236

Includes the following fitting:

Connection ¼" O-RING FACE
SEAL MALE 119225
128763 x1, 128764 x1 and 119226 x2
Kit 119226

1/4” LOP tube x 7/16”JIC (m) Compression

Coupling 128763
AN Union

Cap 128764 1/4” LOP Tube EOL Compression Cap

Support
119226 LOP Tubing internal support spigots
Spigots

Table 14 –LOP detection & actuation fittings

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Common LOP & ROP Actuation Fittings

Part No. Description

128760 6 x ¼” NPT(f), 2 x 1/8” NPT(f)

Manifold Block

128761 4 x ¼” NPT(f), 2 x 1/8” NPT(f)

128752 7/16” JIC (m)

128753 7/16” JIC (f) x 7/16” JIC (m) x 7/16” JIC (m)

Tee
128749 7/16” JIC (m) x 7/16” JIC (f) x 7/16” JIC (m)

112149 1/4” NPT (f)

114608 7/16” JIC (m)

114544 7/16” JIC (m & f) swv

Elbow
114568 45° 7/16” JIC (m & f) swv

128751 7/16” JIC (m) x 1/8” NPT (m)

128746 7/16” JIC

Plug
118551 1/8” NPT
119568 1/4” NPT

128767 7/16” JIC

112150 7/16” JIC Bulkhead

Nipple
112148 1/4” NPT x 7/16” JIC
128817 1/8” NPT x 7/16” JIC

118542 1/8” NPT

Nut/Sleeve 128750 7/16” JIC Nut & 1/4” Sleeve

Table 15 – fittings common to both ROP & LOP detection & actuation systems

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Manual Actuator Location Signs

Actuator location and instruction signs are required to be located adjacent to each manual action point.

Figure 18 – Manual actuator location label - self adhesive, 150mm x 70mm (Part number 66133)

Figure 19 – Manual actuator instruction sign - PVC, 75mm x 200mm (Part number 66509)

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Electrical Detection & Actuation

Linear Heat Detection (LHD) Cable (part number 87000)

Linear heat detection (LHD) cable may be used to automatically activate both ROP and LOP PEFS systems.

Figure 20 LHD Cable (part number 87000)

LHD cable is non-resettable. Once the insulation has melted, the melted section must be replaced. Either
the entire length of cable or just the melted section can be replaced.

Electric Actuation

Electric actuation of both ROP and LOP PEFS systems is achieved using a 12V DC10W solenoid operated
valve. The solenoid valve is connected VS Control System and when energised will initiate discharge of the
PEFS cylinders.

EARTH

1 2
NEUTRAL ACTIVE
ACTUATION ACTUATION
SOURCE SOURCE

Figure 21 – Solenoid valve (part number 94092)

ROP and LOP solenoid valve assemblies are available, complete with the necessary fittings required to fit
them. The LOP solenoid valve assembly may be fitted anywhere in the LOP actuation network and includes
a SureSpray nozzle fitted to the solenoid valve outlet to prevent blockage of the valve outlet by
contaminants. Care should be taken to direct the outlet of the solenoid valve so that its discharge does not
cause a hazard to personnel.

The ROP solenoid valve assembly is to be fitted to the check valve located on the pneumatic actuator body
of the ROP cylinder valve. A suitable length hose must be assembled to connect the inlet of the solenoid
valve to the cylinder filler valve port (see figure 25).

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LOP actuation
network

Figure 22 - LOP solenoid valve assembly (part number ES9014-D)

Connect to
hose from
cylinder filler
port

Connect to
check valve on
pneumatic
actuator body

Figure 23 - ROP solenoid valve assembly (part number ES9014-E)

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128756
Hose

128817
Nipple
Manual CO2 Actuator
ES9106-B

118551
Plug
128762

Manifold Block
Filter

Check Valve

119568

128760
103222

128817

Plug
Nipple
Pyrotube Assy
& Wick

Coupling
117811

Figure 24 – Typical ROP pneumatic detection & actuation arrangement

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ES9014-E ROP
solenoid valve
assy.

Figure 25 – Solenoid actuation of a single ROP cylinder

Check valves
103222

ROP solenoid
valve assy
ES9014-E ROP actuation hose

Tee 128749

Figure 26 – Combined solenoid and pneumatic actuation of single ROP cylinder

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 Manual LOP Actuator
47124

LOP Detection Tubing

118837

Coupling 128763
Spigot 119226

Cap 128764 Nipple

Spigot 119226 128817

Hose Nipple
Coupling 9344220356 112148
9344220357

Plug
118551
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© Copyright 2007 Chubb Fire Safety Limited

PEFS Maintenance Manual, version 2.1, September 2007
Manifold Block
128761
47

Figure 27 – Typical LOP combined solenoid and pneumatic detection & actuation arrangement
LOP Solenoid valve Assy. ES9014-D
Note: may be located at any point in
the LOP actuation network
 PEFS Maintenance Manual 48

Check valve
103222

Check valves
103222

From ROP actuation

network manifold block

Figure 28 - multiple ROP cylinder - combined solenoid and pneumatic actuation arrangement

To LOP actuation network

manifold block

Figure 29 - LOP multiple cylinder actuation arrangement

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Hose and Tube Supports

Hose and tubing used on PEFS actuation and discharge systems must be properly supported and a range of
supports for use with hose and stainless steel tubing are detailed in table 16. Any bolts or welding used for
installation must be in accordance with the customers or vehicle manufactures specifications.

Support Type Part No. Tube Size Hose Size Maximum

Spacing (m)
128819 6mm (1 x M6) - 0.5
103161 8mm (1 x M8) 3/16” 0.5
Insulated P-Clip 103197 12.7mm (1 x M8) 1/4” 0.5
103198 19mm (1 x M8) 1/2” 0.7
103199 29mm (1 x M8) 3/4” 0.7

M6 Weld Lug c/w bolt and washer for mounting

Weld Lug 128755
P-Clips

112270 6.4mm - 0.5

Welded Clamp 112114 12.7mm ¼” 0.5
Block 112113 19.0mm ½” 0.7
128181 25.0mm 3/4” 0.7
128841 20mm ctr to ctr (to suit 6 port Manifold Block)
Weld Clamp Plates
128842 33mm ctr to ctr (to suit 8 port Manifold Block)
91310 M6 x 20mm Hex Head
91317 M6 x 25mm Hex Head
Bolts 91318 M6 x 30mm Hex Head
91319 M6 x 35mm Hex Head
91320 M6 x 40mm Hex Head
Washer 94207 M6 Flat Washer

Nut 92345 M6 Nylok Nut

Nozzle Bracket 104592 Size: 76x51x5 angle, 50mm width, Zinc plated

Table 16 – PEFS discharge and actuation system brackets/supports

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MONITORING & CONTROL COMPONENTS

Pressure Switches

Two pressure switches available for use in PEFS systems:

• “Cylinder low pressure”, 1,200kPa setting (part number 127361)

• “Fire Alarm/Discharge”, 200kPa setting (part number 127379)

The pressure switches have a 1/8”NPT connection, are configurable for NO or NC, and are provided with a
IP65 rated Deutsch DTM series connector.

Figure 30 – Pressure Switch

The pressure switches are connected directly to the cylinder valve as shown on figure 29.

New LOP picture

Fire Alarm/Discharge needed
NC 200kPa

Cylinder Low Pressure

NO 1,200kPa

ROP Cylinder Valve LOP Cylinder Valve

Figure 31 – Pressure switches mounting location on cylinder valves

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VS Control System

The VS Control System comprises a control module, a remote display panel and audible alarm unit. The
display panel provides visual indication of system status, alarms, and faults and also allows manual
extension of the equipment shutdown delay.

VS Display Panel

Figure 32 – VS display panel (part number 87006)

VS Control Module

The control module comprises an IP67 rated enclosure and IP69 rated Deutsch DT series connectors.

Figure 33 – VS control module (part number 87007)

Battery Pack

The VS control system uses a 15 volt, supervised internal battery back-up.

Figure 34 – battery pack (part number 87010)

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Audible Alarm Unit

The audible alarm unit is IP65 rated and comprises buzzer, c/w end of line components required for the
supervision of the buzzer circuit, fitted in a metal enclosure.

Figure 35 – Audible alarm unit (part number 87009)

Manual Release Unit

The manual release unit consists of an IP65 rated metal enclosure with a glanded cable entry. It
incorporates a switch fitted with a series and a parallel EOL resistor to allow it to be monitored for both open
and short circuit faults.

Figure 36 – Manual release unit (part number 47125)

EOL Resistor (part number 87003)

The EOL resistor is used to terminate LHD cable detection circuits. The EOL allows the VS control system
to monitor the integrity of the detection circuit. The EOL resistor is inside a brass housing fitted with metal
cable gland.

Figure 37 – EOL resistor (part number 87003)

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Jiffy Splice cable connector kit (part number 87004)

Jiffy splice cable connectors are used to join field wiring (e.g. radox cable to LHD cable). The connectors
are IP65 rated and are suitable for use with Deutsch connector pins and sockets. Where Jiffy Splice
connectors are used to join to separate lengths of radox cable, the connectors must only be installed outside
the fire hazard area.

Need to set-up new

cable connector

Figure 38 – Jiffy splice connector kit (part number 87004)

Dual Lock Tape (part number 87005)

Two strips of 3M dual lock tape are used to mount the VS display panel.

Connector Kit (part number 87008)

The connector kit is used to terminate and connect field cabling, and
that from the VS display panel, to the VS control module.

The kit includes:

• 2 x 12 pin Deutsch female connectors
• 1 x 4 pin Deutsch female connector
• 28 x connector pins

Figure 39 – Connector kit

(part number 87008)
VS Control System Kit (part number 87001)

The VS control system kit comprises:

• VS control module
• VS display panel
• Connector kit
• Audible alarm unit

RS232 Cable (part number 87012)

The VS control module includes an RS232 connection to allow interrogation and download of event history.
Firmware updates can also been uploaded using the RS232 connection.

Figure 40 – RS232 cable connected to VS Control Module Circuit Board

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Figure 41 – VS Control System – line diagram of typical system configuration

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VS Control System Operation & Fault Finding

A brief overview of the VS Control System’s operation is detailed in this section.

Fault Conditions

Audible and visual fault indications, consisting of illumination of Fault LED and sounding of the buzzer once
every 10 seconds, will be generated by any of the following conditions:
• Open circuit on either detection circuit input
• Open or short circuit on manual discharge input
• Open or short circuit on actuation circuit
• Open or short circuit on the buzzer circuit
• Open circuit on cylinder low pressure switch input (default configuration)
• Primary power supply failure
• Internal battery power supply failure
• A communications fault between the control box and display panel
• Real Time Clock not set
• Real Time Clock battery failure
• Shutdown over-ride DIP switch activated

When the control system is in a fault condition, the fault output relay will also be energized to allow auxiliary
remote fault indications. Faults within the VS control system can be displayed using either the VS control
module circuit board FAULT LED’s or alternatively using the LED’s on the VS display panel. A total of 14
fault conditions can be displayed and these are split into 2 sets of 7 faults. Each set of (7) faults is displayed
at a 2 seconds intervals. The fault set being displayed is indicated by the status of Green fault LED on the
controller (or the green Power LED on the display panel, when using the display panel to display active fault
conditions).

Fault Indications using VS Control Module Fault LED’s

To facilitate fault finding, a set of eight (1 x green, 7 x amber) fault indicating LED’s are provided on the
circuit board inside the VS control module. To view the fault indicators, hold down the pushbutton located
next to the fault LED’s. The fault conditions indicated by these LED’s are shown in table 17.

Amber Fault LED GREEN FAULT LED STATUS

Number. (LED 1)
ON OFF ON

2 Manual release circuit fault Keypad memory error

3 Display/control module Controller memory error

communications fault

4 Primary power fault Internal Battery low

5 Internal battery fault Detection circuit 2 fault

6 Cylinder low pressure Shutdown override activated

7 Detection circuit 1 fault Real Time Clock fault

8 Solenoid actuation circuit Audible alarm circuit fault

fault
Table 17 - VS Control Module fault indications
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Fault indications using VS Display LED’s

In its normal operating mode, the VS display panel will indicate a primary power supply fault by illuminating
the amber “Power” LED whilst all other faults are indicated as a common fault by illuminating the amber
“fault” LED.

However, to improve fault finding, the LED’s on the display unit can temporarily be set to show individual
active system faults by holding down both the ‘DELAY’ and ‘TEST’ buttons on the keypad. Faults are shown
one at a time and at a 2 seconds intervals. The fault conditions indicated by the LED’s are shown in table
18.

DISPLAY LED’S GREEN POWER LED STATUS

ON OFF ON

Power - Amber Manual release circuit fault Keypad memory error

Alarm Display/control module Controller memory error

communications fault

Discharged Primary power fault Internal Battery low

Shutdown - Red Internal battery fault Detection circuit 2 fault

Shutdown - Cylinder low pressure Shutdown override activated

Amber

Fault Detection circuit 1 fault Real Time Clock fault

Isolated Solenoid actuation circuit Audible alarm circuit fault

fault

Table 18 - VS Display Fault indications

Event Log

The VS control system incorporates a Real Time Clock (RTC) which allows up to 65 fault, alarm, shutdown,
isolation and other maintenance events to be date and time stamped and stored in system non-volatile
memory for later retrieval and analysis.

Real Time Clock Fault

A RTC fault occurs when the system detects an incorrect date setting. This could indicate that the time and
date haven’t been set correctly or that the RTC battery (small battery on the VS control module PCB) is
faulty. The RTC fault is latching and to clear it, the system must be reset.

To diagnose the cause of the RTC fault it is necessary to utilize the RS232 interface and the Terminal
program installed on a laptop computer; follow the instructions below:

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Terminal program line settings:

Baud rate 38400 bps

Data bit 8
Parity None
Stop bit 1
Flow control none

a. Use the ‘T’ command to check the current time and date.
b. If the time and date is incorrect, use the ‘ST’ command to set the current time and date.
c. Verify that the time and date are now correct by again using the ‘T’ command.
d. Isolate the primary and internal battery power by unplugging the power connector from the
control module.
e. Wait 10 seconds
f. Plug in the power connector to the control module and wait for the system to initialize.

NOTE: if the RTC has defaulted to the date of “01/01/00” it is necessary to replace the RTC battery and
then follow the steps detailed above.

Fire Alarm

Audible and visual fire alarm indications, consisting of illumination and latching of the Alarm LED and
sounding of the buzzer once per second will be initiated by any of the following conditions:

• Electrical fire detection

o If single circuit detection is selected, a closed contact on detection circuit input 1. Detection
circuit 2 is disabled in single circuit detection mode.
o If dual circuit detection is selected, closed contacts on either detection circuit inputs 1 and 2.

• Electrical manual release

o Operation of an electrical manual release connected to the manual release input.

• System Discharge, via open circuit on discharge pressure switch input (default configuration)
caused by either:
o Manually initiated system discharge.
o Automatically initiated system discharge by either Pyrotube or LOP detection tubing.

When in an alarm condition, the auxiliary alarm output relay will be energised and equipment shutdown
sequence commenced. If the alarm condition was initiated by operation of either electrical manual release
input or fire detection input(s) the actuation output will also be energised. The actuation output is not
energised in the case of pneumatic (LOP or Pyrotube detection) operation or manual mechanical operation
of the PEFS system.

System Discharge

The default (and recommended) discharge configuration for the VS control system is for immediate
discharge when a fire alarm condition is detected. Immediate discharge gives the suppression system the
best chance of suppressing the fire in its early stages. In special circumstances, however, delaying the
discharge of the suppression system may be desirable. To cater for such circumstances, (such as operator
safety) a discharge delay timer is provided with selectable delay periods of 0, 15, 30 and 60 seconds.

When the PEFS system cylinders are actuated, a pressure switch in the discharge network is used to
confirm that agent has been released from the cylinders by illuminating and latching the Discharged LED.
Operation of the discharge pressure switch provides the following functions:

• In the case of electrical actuation of the PEFS cylinders:

o Confirms that the cylinders have discharged.

• In the case of manual (mechanical) or automatic pneumatic (ROP or LOP detection) actuation of the
cylinders:
o Operates the fire alarm visual and audible indications and initiates equipment shutdown.
o Confirms that the cylinders have discharged.

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Equipment Shutdown

A shutdown time delay is incorporated in the VS control system to allow the equipment operator to
safely bring the equipment to rest before the shutdown is activated. The shutdown time delay
countdown is initiated by:

• If single circuit detection is selected, a closed contact on detection circuit input 1.

• If dual circuit detection is selected, closed contacts on both detection circuit inputs 1 & 2.
• Manual (mechanical or electrical) actuation.
• Automatic actuation by ROP or LOP pneumatic detection.

Once the equipment shutdown countdown is initiated the following functions occur:

• The Amber shutdown LED will illuminate.

• The Shutdown timer will begin to count down. The default shutdown delay period is 30 seconds,
however shutdown delay periods of 0, 5, 10, 15, 20, 30, 40 – 180 in 20 second intervals, 210 and
240 seconds can be selected.
• At 10 seconds from end of the count down (this applies also if 5 or 10 second delay period are
selected):
o Amber Shutdown LED will flash,
o Buzzer will sound continuously and
o Delay pushbutton will become enabled

If the Delay push button is pressed before the countdown period expires the following functions will
occur:

• The shutdown period will be extended by a selectable delay extension period (0, 5, 10, 15, 20, 30,
40 – 180 in 20 second intervals, 210 and 240 seconds). The default shutdown delay extension
period is 30 seconds.
• The Amber shutdown LED will change back from flashing to continuous indication.
• The extended delay period will commence counting down.

NOTE: The PEFS VS control system is configured to allow only one time delay extension period to
the equipment shutdown. However, the initial and extended delay periods can be
independently set to different values. Both delay periods should be kept as short as safely
possible.

Once the shutdown period has expired the following functions will occur:

• The shutdown output relay will be energized

• The Red shutdown LED will illuminate
• The buzzer will beep once every 10 seconds.

These functions will continue until the control panel is reset.

System Reset

A system reset button is mounted on the circuit board in both the VS display panel and VS control box. The
system reset will reboot the VS control system and clear all outputs (alarm, shutdown etc). To reset the
system hold down the either reset button for 2 seconds.

A system reset can also be activated using the “TEST”, “DELAY” and “DIM” push buttons on the VS display
panel. To prevent accidental operation, the ‘delay’ push button must be pressed prior to the other two
buttons:
g. Press and hold the ‘DELAY’ button
h. Press and hold the ‘TEST’ and ‘DIM’ buttons
i. Wait 1 seconds
j. Release all three buttons

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Figure 42 - VS control module connector pin configuration

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Remove resistor R1 from

the circuit board on all but
the last manual release
unit in the circuit

Figure 43 – VS control module - input field wiring schematic

Figure 44 – VS control module - output field wiring schematic

PEFS Maintenance Manual, version 2.1, September 2007

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