Cover Label No.

F-2011137

007227

CARBON DIOXIDE AND

NITROGEN CARTRIDGES
Field Inspection and Refill Manual
 REVISION INDEX
4-15-11        REV. 1

DATE PAGE REV. NO. DATE PAGE REV. NO.

Revision Record page

7-23-10 4-15-11 7-1 2
started at manual revision 2

7-23-10 CGA C-6 – 2001 – Deleted 4-15-11 7-2 New

See Introduction page
for more information 4-15-11 7-3 New

7-23-10 CGA P-22 – 1995 – Deleted 4-15-11 7-4 New

See Introduction page
for more information 4-15-11 8-1 2

7-23-10 49 CFR – See Deleted 4-15-11 8-2 New

See Introduction page
for more information 4-15-11 8-3 New
ANSUL CO2 and N2 Cartridge
7-23-10 Deleted 4-15-11 9-1 New
Recharging Equipment List

4-15-11 Table of Contents New 4-15-11 10-1 New

4-15-11 1-1 2 4-15-11 11-1 New

4-15-11 1-2 Deleted 4-15-11 11-2 New

4-15-11 2-1 1 4-15-11 11-3 New

4-15-11 3-1 2 4-15-11 11-4 New

4-15-11 3-2 2 4-15-11 11-5 New

4-15-11 4-1 2 4-15-11 12-1 New

4-15-11 4-2 Deleted

4-15-11 4-3 Deleted

4-15-11 4-4 Deleted

4-15-11 5-1 2

4-15-11 5-2 2

4-15-11 5-3 Deleted

4-15-11 5-4 Deleted

4-15-11 6-1 2

4-15-11 6-2 New

4-15-11 6-3 New

4-15-11 6-4 New

LEGEND FOR MANUAL PAGE Indicates revised information.

REVISION INDICATORS: Indicates change in page sequence.
 TABLE OF CONTENTS
4-15-11        Page 1

SECTION
________ PAGES
______ SECTION
________ PAGES
______
1. INTRODUCTION 1-1 11. APPENDIX 11-1 – 11-5
Cartridge Specification Table 11-1
2. CARTRIDGE INSPECTION 2-1 – CO2 Expellant
AND REFILL OVERVIEW Cartridge Specification Table 11-2
– N2 Expellant
3. EQUIPMENT 3-1 – 3-2
Temperature Correction Charts 11-3
Cartridge Refilling Equipment 3-1
Cartridge Test Tank – Drawing No. 819 11-4
Inspection Gauges 3-1
Ounces-To-Grams Conversion Table 11-5
Cartridge Test Tank 3-2
Carbon Dioxide Supply 3-2 12. REFERENCES
Nitrogen Supply 3-2 ANSUL Technical Bulletin No. 31, Form No. F-80261,
“Carbon Dioxide Cartridges”
4. SAFETY AND MAINTENANCE 4-1 ANSUL Technical Bulletin No. 34, Form No. 80195,
RECOMMENDATIONS “Use and Refilling of ANSUL Gas Cartridges”
Safety 4-1 ANSUL Technical Bulletin No. 50, Form No. F-81301,
Maintenance 4-1 “Hydrostatic Retest Requirements for ANSUL Hand
Portable and Wheeled Fire Extinguishers”
5. PRE-FILLING INSPECTION PROCEDURES 5-1 – 5-2
Purpose 5-1
General Inspection 5-1
Using Cartridge Gauges 5-1 – 5-2

6. FILLING CARBON DIOXIDE CARTRIDGES 6-1 – 6-4

Equipment Setup 6-1
Cartridge Refill Procedure 6-2 – 6-4

7. FILLING NITROGEN CARTRIDGES 7-1 – 7-4

SMALLER THAN 23 FT3 (0.7 m3)
Equipment Setup 7-1
Cartridge Refill Procedure 7-2 – 7-4
Nitrogen Supply Cylinder 7-4

8. FILLING 23/55 FT3 (0.7/1.6 m3) 8-1 – 8-3

NITROGEN CARTRIDGES
Equipment Setup 8-1
Booster Pump Specifications 8-1
Cartridge Refill Procedure 8-1 – 8-3

9. LEAK TESTING AND PAINTING 9-1

Leak Testing 9-1
Painting Cartridges Smaller Than 9-1
23 ft3 (0.7 m3)
Painting 23/55 ft3 (0.7/1.6 m3) Cartridges 9-1
Final Inspection and Marking 9-1

10. OUT-OF-SPEC- CARTRIDGES 10-1

 SECTION 1 – INTRODUCTION
4-15-11        Page 1-1
REV. 2

INTRODUCTION
This manual is intended to be used by only those companies
which have been authorized by Tyco Fire Protection Products to
refill ANSUL Carbon Dioxide and Nitrogen cartridges. This manual
does not apply to other manufacturersʼ cartridges. This manual
may not be copied or reproduced for any reason.
For safety and quality, this manual is intended for use only by qual-
ified personnel trained and familiar with cartridge filling operations.
The authorized cartridge refilling company is responsible for main-
taining the proper up-to-date technical publications associated
with filling pressure vessels. The technical publications are as
follows:
1. Compressed Gas Association Pamphlets
– CGA C-6: Standards for Visual Inspection of Steel
Compressed Gas Cylinders
– CGA P-15: Filling of Industrial and Medical Nonflammable
Compressed Gas Cylinders
– CGA P-2: The Responsible Management and Disposition
of Compressed Gases and their Cylinders
2. Code of Federal Regulations
– 49 CFR – Transportation
– Transport Canada
3. National Fire Protection Association Standards
– NFPA 10

TYCO FIRE PROTECTION PRODUCTS Copyright ©2011 Tyco Fire Protection Products
ONE STANTON STREET All rights reserved.
MARINETTE, WI 54143-2542 +1-715-735-7411 Form No. F-8986-03
 SECTION 2 – CARTRIDGE INSPECTION AND REFILL OVERVIEW
4-15-11        Page 2-1
REV. 1

CARTRIDGE INSPECTION AND REFILL OVERVIEW

! WARNING

To lessen the risk of serious personal injury and to better

assure the proper results when filling ANSUL cartridges, the
procedures set forth in this manual must be followed in the
proper sequence.

The following procedures have been established to provide a

uniform method for the processing of ANSUL carbon dioxide and
nitrogen cartridges returned for refill. Strict adherence to the
recommended practices and use of the recommended equipment
will help to assure the safety of those handling the cartridges and
the sale of only those cartridges which meet specifications.
The procedure has been divided into eight sections and must be
followed in the sequence listed below:
SECTION 1 – EQUIPMENT
SECTION 2 – SAFETY AND MAINTENANCE
SECTION 3 – INSPECTION PROCEDURES
(Before Filling Cartridges)
SECTION 4 – FILLING CARBON DIOXIDE CARTRIDGES
SECTION 5 – FILLING NITROGEN CARTRIDGES
SMALLER THAN 23 FT3 (0.7 m3)
SECTION 6 – FILLING 23/55 FT3 (0.7/1.6 m3) NITROGEN
CARTRIDGES
SECTION 7 – LEAK TESTING AND PAINTING
SECTION 8 – OUT-OF-SPEC CARTRIDGES
 SECTION 3 – EQUIPMENT
4-15-11        Page 3-1
REV. 2

EQUIPMENT Cartridge Refilling Equipment (Continued)

Cartridge Refilling Equipment Part
Part No.
____ Description
_________
No.
____ Description
_________ 438601 23/55 ft3 (0.7/1.6 m3) Cartridge Filler Block Assembly
2590 CO2 CARTRIDGE RECHARGE UNIT, COMPLETE (RH) (Required to fill 23/55 ft3 (0.7/1.6 m3) cartridges)
(Inspection Gauges and CO2 source not included) Consisting of:
Consisting of: 55723 Filler Block, RH Thread
2157 Filler Block Assembly (LH) Consisting of: 53675 Neck Ring Spacer
793 Filler Block, LH Thread 53676 Neck Ring Spacer
496 Filler Block Stand This assembly does not include filler block stand. Filler
257 Cap Screw 3/8 in. (2) block is attached to cartridge valve while cartridge is
1459 Packaging secured in cylinder vise.
2481 Packing Follower
2480 Packing Nut 77250 LH Shipping Cap
4346 Handwheel, Machined 77251 RH Shipping Cap
906 Lockwasher (2) 24654 CO2 Cartridge Seal
560 Spline Shaft 53803 CO2 Cartridge Seal
1870 Washer (2) 53819 Nitrogen Cartridge Seal
904 Nut (2) 53821 Nitrogen Cartridge Seal
173 Bolt (2) Inspection Gauges
174 Nipple 1 in. x 2 in. (3) 433695 Complete Set of CO2 Cartridge Gauges
175 Tee 1/4 in. NPT (2) Consisting of:
2482 Gas Control Valve (2) Cylindrical Plug Gauge, 3/4-16 N2 No Go Dia. 0.6930
2492 Copper Tubing & Fitting Consisting of: Thread Plug, 3/4-16 N2 Go P.D. 0.7094
2485 Union Thread Plug, 3/4-16 N2 No Go P.D. 0.7139
2486 Nut, Union Thread Ring Gauge, 1-1/16-20 NSLH Go P.D. 1.0285
2487 Tubing, Copper 24 in. Thread Ring Gauge, 1-1/16-20 NSLH No Go
2488 Square P.D. 1.0180
2489 Tailpiece Set Plug, 1-1/16 NSLH P.D. 1.0285
2490 Nut Set Plug, 1-1/16 NSLH P.D. 1.0180
2491 Washer 433696 Complete Set of Nitrogen Cartridge Gauges
Consisting of:
2591 Cartridge (Spline) Wrench  Consisting of: Ring Gauges, 1/2-14-L1 NPT
148 Handle Plug Gauge, 1/2-14-L1 NPT
490 Spline Cylinder Plug Gauge, 3/4-20 No Go Dia. 0.7027
2658 1/4 in. x 1-1/4 in. Rod Stock (Pin) Thread Plug, 3/4-20-NEF-2B Go P.D. 0.7175
4476 Cartridge Vise Assembly (Maximum of 2 in. Thread Plug, 3/4-20-NEF-2B No Go P.D. 0.7221
(5.1 cm) Diameter) Consisting of: Thread Ring, 1 1/16-20-NSRH Go P.D. 1.0285
545 Nut (2) Thread Ring, 1 1/16-20-NSRH No Go P.D. 1.0180
968 Lockwasher (2) Set Plug, 1 1/16-20-NSRH Go P.D. 1.0285
4478 Base Set Plug, 1 1/16-20-NSRH No Go P.D. 1.0180
4479 Screw (2) Other Inspection Equipment includes:
4480 Handle Assembly Micrometer 1 in. to 2 in.
4483 Lead Screw Filler block thread gauges:
4487 Handle, Finished Thread Plug, 1 1/16-20-NSRH Go P.D. 1.0300
4488 Jaw (2) Thread Plug, 1 1/16-20-NSRH No Go P.D. 1.0374
4489 Spacer (2) Thread Plug, 1 1/16-20-NSLH Go P.D. 1.0300
4624 Pin Thread Plug, 1 1/16-20-NSLH No Go P.D. 1.0374
Note: Cylinder vises for cartridges larger than 2 in. Cylinder Plug Gauge, 1 1/16-20 No Go P.D. 1.0138
(5.1 cm) in diameter may be purchased from the follow-
ing companies: Cartridge Test Tank
www.getzmfg.com Drawing 819 in the Reference Section details a typical cartridge
www.galiso.com test tank (capacity 31 cartridges). Although ANSUL does not
www.hydro-test.com manufacture the tank, the enclosed drawing will provide the
6380 Strap Wrench necessary information (gauge of wall steel, immersion heater,
etc.) for making the cartridge test tank locally. Dimensions will vary
59371 Filler Block Assembly (RH) (Required to fill right hand depending on the diameter and quantity of cartridges being tested.
cartridges) Consisting of:
55723 Filler Block, RH Thread To control rust in the cartridge test tank, add 1 Gal (3.79 L) of
53675 Neck Ring Spacer Hydrotone (anti-rust) or equal to 50 gallons (189.27 L) of water.
53676 Neck Ring Spacer This is available (in small cans) at filling stations or at automotive
supply dealers. Sodium Nitrite (NaSO2) should be added to the
All additional components same as Part No. 2157 with tank to maintain a 0.75% (by vol.) solution. Clear cartridge bubble
the exception of Filler Block Assembly covers, of a type impervious to heat, are recommended.
 SECTION 3 – EQUIPMENT
4-15-11        Page 3-2
REV. 2

Cartridge Weighing Scale

An accurate scale graduated in easily read 1/8 ounce (3.54 g)
increments is also required. Scale must be capable of handling
cartridge weights of up to 10 lb (4.5 kg). Any scale selected must
be checked twice per shift with weights for accuracy. The scale
should be properly mounted to eliminate vibration from the work
bench and to avoid scale damage. To keep the cartridge from
rolling while being weighed, mount a cradle to the plate and rebal-
ance the scale. The scale shall be calibrated a minimum of once
every six months by a certified company.

Carbon Dioxide Supply

The carbon dioxide supply shall comply with NFPA-10 require-
ments and conform to Grade B of Federal Specification BB-C-
101B – April 15, 1971.

Nitrogen Supply
The nitrogen supply shall be Type-1, Grade B, Class 1 in accor-
dance with Federal Specification BB-N-411C – January 3, 1973.
 SECTION 4 – SAFETY AND MAINTENANCE RECOMMENDATIONS
4-15-11        Page 4-1
REV. 2

SAFETY AND MAINTENANCE RECOMMENDATIONS Maintenance

1. Use Neatsfoot oil on packing in filler block and adjust packing
! WARNING gland nut, as required, to prevent loss of gas.
2. Use gauge cleaner and preservative to prolong the life of
Failure to follow the safety instructions set forth below could gauges.
lead to serious personal injury or property damage.
3. Store gauges and tools carefully to prevent damage, rust
and/or corrosion.
Safety
4. Replace or repair damaged tools or equipment immediately.
1. A hard hat fitted with a full face shield is required.
5. Inspection gauges and filler block shall be calibrated and
2. Use a safety guard at the filling block. checked regularly.* In addition, should a ring gauge be
3. When working with filled cartridges, keep bottom end pointed dropped, it must be recalibrated with the proper set plug
away from operator (and others working in the area) at all before using.
times. * This service can be provided by ANSUL Marinette for a nominal charge, but a purchase
order must accompany the material. Direct all correspondence to the attention of the
4. Never work on a cartridge (or any pressure vessel) with your Quality Control Department.

head or body positioned over, or in line with, the normal thrust (For ease of shipment, return filler block without mounting stand and handwheel.)
of the cartridge should the seal disc rupture (or should a valve
or fill cap fail).
5. Keep the cover on the cartridge test tank closed, except while
inserting, inspecting or removing cartridges.
6. Plastic cartridge bubble covers must be of the heat resistant
type.
7. Safety shipping caps must be in place on charged cartridges
before storing or shipping.
8. Never remove the safety shipping cap from a gas supply cylin-
der until it has been securely mounted. Local codes will also
dictate safe methods for storage of spare cylinders; chaining
them to a wall will normally be satisfactory.
9. Each cartridge must be weighed immediately after filling to
assure that it has not been overfilled. If the cartridge has been
overfilled, as it warms up in the bath, the internal pressure will
rise and could cause the cartridge seal disc to rupture. Since
the cartridge lacks a safety shipping cap at this stage, the
cartridge could become a projectile.
10. Cartridges should always be stored with the bottom of the
cartridge pointed away from the operator or other personnel.
11. Wear gloves when handling cold cartridges.

NOTICE
These are but the most obvious precautions
and they must be supplemented by your own
safety procedures as well as strict observance
of all state, local and federal safety codes and
standards.

PRE-FILLING INSPECTION PROCEDURES
Purpose
The proper inspection of cartridges before filling is mandatory; not
only to ensure the integrity of the filled cartridge assembly, but also
to avoid possible personal injury to persons filling or using a worn
or damaged cartridge. For example, the external cartridge thread
is not as strong as the filling block or the cartridge receiver insert.
If the threads become undersized, for whatever reason, the
cartridge may break loose from the assembly it is mated with due
to the high end thrust caused by gas pressure. Likewise, the shear
strength of the seal assembly is directly dependent on the internal
cartridge threads staying within specification.
Consider that there may be ANSUL cartridges in service which are
over fifty years old. While age alone does not determine the fitness
of cartridges, it is a factor, along with usage and exposure to corro-
sive atmospheres.
The seat machined in the cartridge and the external gasket
surface must also be clean and free of nicks. Remove any foreign
material such as dirt or dry chemical which may have accumulated
in the cartridge. Cartridges which have been burned or damaged
must be scrapped.
General Inspection
1. Non-ANSUL cartridges shall not be refilled using these proce-
dures. The manufacturer of those cartridges should be
consulted for their own procedures and recommendations.
2. Before filling, ensure cartridge complies with the appropriate
NFPA and DOT hydrostatic test requirements.
3. Make certain cartridge is empty. If cartridge is charged or
partially charged, place cartridge in cartridge receiver of bleed
off assembly and bleed off pressure.
4. Fire burned, damaged, badly corroded or pitted cartridges
must not be refilled. Refer to CGA pamphlet C-6 for additional
recommendations.
5. Cartridges with damaged threads must not be refilled. If avail-
able, use a thread chaser to repair external threads and tap to
repair internal threads. After repair, check threads with gauges
as detailed on Pages 3-1 and 3-2. If cartridge cannot be
repaired properly, it must be discarded.
6. ICC or DOT stamping must be legible. If not, the cartridge
shall be discarded. (Wire brush if necessary.) (Cartridges
1 1/2 in. (38.1 mm) diameter or less are not stamped.)
7. Stamped weight of cartridge must be legible. Wire brush if
necessary. If stamped weight can not be determined,
cartridge must be discarded.
8. Remove seal assembly and check internal threads and seal
seat for damage. Reject cartridge and properly discard if
damaged.
9. Remove any dry chemical or foreign material from inside of
cartridge. Blow cartridge out with air jet.
10. Prepare cartridge for subsequent painting. Remove rust, dirt,
scale, etc.
11. Inspect cartridge threads for indication of wear or damage. If
in doubt, use appropriate thread gauges.
SECTION 5 – PRE-FILLING INSPECTION PROCEDURES
4-15-11        Page 5-1
REV. 2
Using Cartridge Gauges
If the threads on the inside and outside of the cartridge are within
specifications and are not damaged in any way, the gauges will
work with ease as specified in the following paragraphs. At no
time should the gauges be forced on the cartridges. If this is done,
the life of the gauges will be shortened considerably and
cartridges will be checked with gauges that are not within specifi-
cations.
Cartridge gauges must never be used as thread chasers. Wire
brush dirty or rusty cartridge threads before checking with gauge.
A thin dressing of light machine oil will extend the life of a gauge.
All gauges shall be calibrated a minimum of once per year.
1. Cylindrical plug gauge 3/4-16N-1, No Go 0.6930. This gauge
is used for checking the minor diameter of the internal threads
in the cartridge and is marked: “Cart. Wear No Go Minor D
0.6930 in.” This gauge should not enter into the threaded hole
more than 1/8 in. (3.2 mm).
If this gauge enters the cartridge more than 1/8 in. (3.2 mm),
the cartridge is not to be used and must be condemned and
discarded.
The reason for this is that if the minor diameter is too large, a
seal could relieve when the cartridge is being filled or tested
in the water bath.
2. Double end thread plug gauge 3/4-16-N-1 marked: “Go P.D.
0.7094 in.” on one end and “No Go P.D. 0.7139 in.” on the
other end.
The “Go” thread plug member is applied to the cartridge by
threading it into the 3/4 in. threaded hole and should turn in all
the way until the end strikes against the seat of the cartridge.
If the “Go” member does not enter all the way into the seat of
the cartridge, the hole must be tapped out with the correct size
tap which can be furnished by ANSUL. (After tapping the
threads, the cartridge must be checked again with both
gauges as specified, and any metal filings from retapping
should be cleared out of cartridge interior.)
The “No Go” thread plug member is applied to the cartridge
in the same manner as the “Go” member. However, this “No
Go” member must not turn into the cartridge more than 1 1/2
turns. If the “No Go” member enters the cartridge more than
1 1/2 turns, the cartridge must be condemned and discarded.
The application of the minor diameter gauge (cylindrical plug)
must not be confused with that of the thread plug gauge. The
minor diameter gauge checks only the minor diameter of the
3/4 in. threads; the thread plug gauge checks the pitch diam-
eter of the 3/4 in. threads. For example, a cartridge may be a
reject in the application of the minor diameter gauge and be
acceptable in application of the thread gauge or vice versa. In
either case, the cartridge should not be used.
 SECTION 5 – PRE-FILLING INSPECTION PROCEDURES
4-15-11        Page 5-2
REV. 2

PRE-FILLING INSPECTION PROCEDURES (Continued)

Using Cartridge Gauges (Continued)
3. Thread ring gauge 1.0610-20-NS-LEFT HAND “Go” marked:
“Cart. Wear Go. P.D. 1.0285 in.” This “Go” thread ring gauge
is applied to the cartridge by threading it onto the outside
threads of the cartridge. It should go down all the way until the
side of the gauge comes in contact with the shoulder below
the threads. If the “Go” gauge does not thread all the way
down, the threads must be chased with a die which can be
furnished by Tyco Fire Protection Products. (After chasing
with a die, the threads must again be checked with the thread
ring gauges as specified.)
4. Thread ring gauge 1.0610-20-NS LEFT HAND “No Go”
marked: ʻʻSpecial Cart. Wear No Go P.D. 1.0180 in.ʼʼ The “No
Go” thread ring gauge is to be applied in the same manner as
the “Go” thread ring gauge, however, this “No Go” gauge
must not turn on the cartridge threads more than 1 1/2 turns.
If it goes on more than specified, the cartridge must be
condemned and discarded.
5. The major diameter of the external cartridge thread should be
checked with a micrometer to 1.0538 minimum.
 SECTION 6 – FILLING CARBON DIOXIDE CARTRIDGES
4-15-11        Page 6-1
REV. 2

FILLING CARBON DIOXIDE CARTRIDGES

! WARNING

See safety instructions in Section 2 before proceeding. To

lessen the risk of personal injury or property damage, follow all
instructions in the proper sequence.

Equipment Setup
1. Attach filling unit to bench and connect to either the gravity
flow or siphon tube type supply of carbon dioxide (CO2). (See
Figures 1 and 2.) The 50 lb (22.7 kg) CO2 gravity flow cylin-
der should be inclined at an angle of about 45 degrees. It must
also be fastened securely in this position. The siphon tube
type of CO2 cylinder would be more convenient, if available.
This type of cylinder should be fastened securely to the bench
or wall in an upright position.
2. Attach cartridge vise to bench near filling unit.
3. A scale of balance or digital type construction (properly
mounted) with 1/8 ounce (3.54 g) graduations and capable of
10 lb (4.5 kg) capacity, shall be used.

GAS CONTROL GRAVITY

VALVE FLOW
CYLINDER

GAS RELEASE
VALVE
CO2 CYLINDER
VALVE
45°

VENT TO
UNOCCUPIED AREA
FIGURE 1
007305

GAS CONTROL
VALVE
CO2
CYLINDER
VALVE

GAS RELEASE
VALVE

SIPHON
VENT TO TUBE TYPE
UNOCCUPIED CO2
AREA CYLINDER

FIGURE 2
007306
 SECTION 6 – FILLING CARBON DIOXIDE CARTRIDGES
4-15-11        Page 6-2

FILLING CARBON DIOXIDE CARTRIDGES (Continued) 5. Before inserting new seal, all cartridges must be inspected as
Cartridge Refill Procedure detailed in Section 3.
6. Thread new seal into the cartridge snugly, but do not tighten.
NOTICE
Procedures apply to left-handed CO2 cartridge 7. Check the weight of the empty cartridge. This is a double
threads. For right-handed cartridges, simply check against the possibility of some foreign material being
reverse thread direction instructions. lodged in the cartridge. The check is made by subtracting the
minimum fill weight indicated in the Cartridge Specification
1. Remove shipping cap. Table in the Reference Section for the cartridge being filled,
2. If seal is not punctured, place cartridge in cartridge receiver of from the weight stamped on the cartridge. If weight of
bleed off assembly and bleed off pressure. (See Figure 3.) If cartridge varies more than 1/8 ounce (3.54 g) from stamped
seal is already punctured, proceed to Step 3. weight, recheck for foreign material in cartridge. Reweigh and
reject all cartridges which exceed 1/8 ounce (3.54 g) tolerance
VENT TO (actual or stamped weight).
UNOCCUPIED AREA CARTRIDGE
BLEED OFF
ASSEMBLY 8. It is advisable to pre-cool the cartridges in a freezer before
attempting to fill them with CO2. They will fill faster than when
they are at room temperature.
CHECK
VALVES 9. With completion of the previous steps, proceed to fill the CO2
cartridge by completing the following procedures and referring
CARTRIDGE
RECEIVERS
to Figures 1 and 2:
(RIGHT AND
LEFT HAND)
a. Make sure gas release, gas control and CO2 cylinder
SCHEDULE 40
valves are closed.
PIPING
b. Insert the cartridge into the filling unit by inserting the
spline shaft down as far as the handle or handwheel will
allow it to go, turning the handle clockwise and pushing
down at the same time. This will allow the spline end of the
shaft to project about 1 in. (25 mm) from the filling unit. Fit
the cartridge into the unit by guiding it with one hand, while
at the same time turning the handle clockwise with the
FIGURE 3 other hand (left-hand threads on cartridge and filling unit).
007307
(See Figure 5.) Take extreme care not to get the threads
3. Place and secure cartridge to be recharged in a of the cartridge crossed into the filling unit. Tighten
cartridge/cylinder vise of appropriate size for cartridge to be cartridge snugly into place with the aid of the strapwrench.
recharged. Refer to CO2 Cartridge Specification Table located DO NOT FORCE A TIGHT FIT.
in reference material. (See Figure 4.)
4. Remove punctured seal from the cartridge using spline
wrench. (See Figure 4.) FILLER
BLOCK

SPLINE
WRENCH SPLINE
SHAFT

FIGURE 5
CARTRIDGE 007309
VISE
c. Back the seal from the cartridge seat by turning the handle
counterclockwise one half to one full turn.
d. Slowly open CO2 cylinder valve wide open. Open gas
control valve at least one full turn for approximately five
seconds when filling ANSUL 20 lb cartridges, ten seconds
SHOWN: PART NO. 4476, for the ANSUL 30 lb cartridges, and three to five seconds
CARTRIDGE VISE ASSEMBLY, for the 5 lb and 10 lb cartridges. This time will vary depend-
MAX. 2 IN. (5.1 cm) DIAMETER
ing on the temperature of the cartridges and the 50 lb (22.7
kg) CO2 cylinder.
FIGURE 4
007308

FILLING CARBON DIOXIDE CARTRIDGES (Continued)
Cartridge Refill Procedure (Continued)
e. When the cartridge is filled with a sufficient quantity of
CO2, thread the seal down into the cartridge by turning the
handwheel clockwise until the seal fits snugly on the
cartridge seat. (See Figure 6.)
SEAL
SEAT
FIGURE 6
007310
f. Close the gas control valve.
g. Open the gas release valve until all gas has escaped
between the filling unit and control valve.
NOTICE
Very often when charging the cartridge, there
will be leakage around the cartridge threads.
Usually this is slight. Donʼt try to tighten the
cartridge more than just snug. If a leak
should occur around the spline shaft packing
nut, tighten packing nut. Each filler block is
packed around the spline shaft with a leather
lacing treated with Neatsfoot Oil. Periodically,
the packing nut should be removed and the
spline shaft lubricated with this oil to ease
turning of the handle.
10.
WARNING
!
Since the cartridge lacks a safety shipping cap at this
time, the cartridge could become a projectile.
Remove cartridge from filling unit by first loosening the
cartridge with a strap wrench by turning counterclockwise
approximately 1/8 of a turn and then backing it out completely
by turning the handwheel counterclockwise. (See Figure 7.)
Always keep one hand on the cartridge while backing it out so
that it does not fall.
FIGURE 7
007311
SECTION 6 – FILLING CARBON DIOXIDE CARTRIDGES
4-15-11        Page 6-3
11.
! WARNING
Each cartridge must be weighed immediately after filling
to assure that it has not been overfilled. If the cartridge
has been overfilled, as it warms up, the internal pressure
will rise and could cause the cartridge seal disc to rupture.
Lacking a safety shipping cap, the cartridge will ʻʻrocketʼʼ
and severe personal injury or property damage could
result.
Weigh cartridge immediately after it has been removed from
filling unit. It should weigh within ± 1/8 ounce (3.54 g) of its
stamped weight. If it weighs less, replace the cartridge in the
filling unit and add the necessary amount of CO2 to bring it up
to the stamped weight. (It may be necessary to re-cool
cartridge to take additional gas.) If the cartridge is overweight,
place the cartridge in the vise and retract the seal with the
spline wrench just enough to allow the gas to escape slowly
and then resnug. Reweigh the cartridge. Repeat this proce-
dure until proper weight has been reached. (Although a toler-
ance of ± 1/8 ounce (3.54 g) is allowed from the weight
stamped on the cartridge, it is good practice to try to hold the
weight to the plus tolerance only. This is advisable because in
the final weighing prior to using, any cartridge which reads
under the minus 1/8 ounce (3.54 g) weight may be a possible
leaker. If weight loss is below stamped weight, but is not
below minus 1/8 ounce (3.54 g), it is possible to retighten the
seal and put the cartridge back into the hot water bath for
further examination.)
12.
! WARNING
Care must be taken not to tighten the seal excessively.
Otherwise the seal will break or the threads will strip.
Replace the cartridge in the vise and tighten the seal firmly in
place. A tightening torque of 40 to 50 ft lb (54.2 to 67.8 Nm) is
required for optimum sealing.
13. Immediately ensure filled cartridges have safety shipping
caps installed. (See Figure 8.) All refilled cartridges shall
utilize only the following safety shipping caps: the left-hand
threaded safety shipping caps are Part No. 77250 while the
right-hand threaded safety shipping caps are Part No. 77251.
If an older style shipping cap is found, it should be replaced
with the appropriate shipping cap described above.
SAFETY
SHIPPING
CAP
FIGURE 8
007312
 SECTION 6 – FILLING CARBON DIOXIDE CARTRIDGES
4-15-11        Page 6-4

FILLING CARBON DIOXIDE CARTRIDGES (Continued)

Cartridge Refill Procedure (Continued)
14. When the CO2 supply cylinder becomes nearly empty, it will
become quite difficult to charge the cartridge regardless of
how cold it may be. Even though there will be a high gas pres-
sure, a cylinder is considered empty when all the liquid CO2
has been used. One way to determine that a cylinder is empty
is to check for an absence of ʻʻsnowʼʼ when the valve is
opened. To get a better picture of this, as soon as a new cylin-
der is hooked up, open the cylinder valve and the gas control
valve allowing a small amount of gas to escape through the
filling unit (minus cartridge) into space. You will notice
snowflakes form about 4–12 in. (10–30 cm) away from filling
unit. When the 50 lb (22.7 kg) cylinder is empty, try the same
thing. You will notice gas escaping, but no snow. Another way
of checking a CO2 cylinder is to weigh it before and after use.
The filled weight is stamped on each cylinder.

NOTICE
If any cartridge continues to leak after filling
instructions mentioned in this procedure are
correctly followed, the empty cartridge should
be taken out of service and destroyed.
 SECTION 7 – FILLING NITROGEN CARTRIDGES SMALLER THAN 23 FT3 (0.7 m3)
4-15-11        Page 7-1
REV. 2

FILLING NITROGEN CARTRIDGES SMALLER THAN 23 FT3

(0.7 m3)

! CAUTION

See safety instructions in Section 2 before proceeding. To

lessen the risk of personal injury or property damage, follow all
instructions in the proper sequence.

Equipment Setup
1. Attach filling unit to bench and connect nitrogen supply. (See
Figure 9.) If using cylinders, they must be fastened securely to
the bench or wall.
2. Attach cartridge vise to bench near filling unit.
3. A scale of balance or digital type construction (properly
mounted) with 1/8 ounce (3.54 g) graduations capable of 10 lb
(4.5 kg) capacity, shall be used.
GAS CONTROL
VALVE NITROGEN
CYLINDER
VALVE

NITROGEN
CYLINDER

GAS RELEASE
VALVE

VENT TO
UNOCCUPIED
AREA

FIGURE 9
007313
 SECTION 7 – FILLING NITROGEN CARTRIDGES SMALLER THAN 23 FT3 (0.7 m3)
4-15-11        Page 7-2

FILLING NITROGEN CARTRIDGES SMALLER THAN 23 FT3 5. Before inserting new seal, all cartridges must be inspected as
(0.7 m3) (Continued) detailed in Section 3.
Cartridge Refill Procedure 6. Thread new seal into the cartridge snugly, but do not tighten.
1. Remove shipping cap. 7. Check the weight of the empty cartridge. This is a double
2. If seal is not punctured, place cartridge in cartridge receiver of check against the possibility of some foreign material being
bleed off assembly and bleed off pressure. (See Figure 10.) If lodged in the cartridge. The check is made by subtracting the
seal is already punctured, proceed to Step 3. minimum fill weight indicated in the Cartridge Specification
Table in Reference Section for the cartridge being filled from
VENT TO the weight stamped on the cartridge. If weight of cartridge
UNOCCUPIED CARTRIDGE
AREA BLEED OFF varies more than 1/8 ounce (3.54 g) from stamped weight,
ASSEMBLY recheck for foreign material in cartridge. Reweigh and reject
all cartridges which exceed 1/8 ounce (3.54 g) tolerance
CHECK VALVES (actual or stamped weight).
8. In order for the cartridge to readily accept the nitrogen charge
CARTRIDGE required, it is recommended that the cartridge be placed in a
RECEIVERS
(RIGHT AND freezer and cooled to approximately 0 °F (–18 °C). This will
LEFT HAND) allow the cartridge to be filled faster and will result in fewer
SCHEDULE 40 underfilled cartridges.
PIPING
9. With completion of the previous steps, proceed to fill the nitro-
gen cartridge by completing the following procedures and
refer to Figure 9:
a. Make sure gas control, gas release and nitrogen cylinder
valves are closed.
b. If neck ring spacers are needed, choose the appropriate
size as shown in Figure 12. Place the spacer over the
FIGURE 10 cartridge threads and let it rest on the cartridge shoulder.
007314

3. Place and secure cartridge to be recharged in a NECK LENGTH

_____________ SPACER SIZE
____________
cartridge/cylinder vise of appropriate size for cartridge to be LESS THAN 1/8 IN. (3.2 mm) NO SPACER REQUIRED
recharged. Refer to Nitrogen Cartridge Specification Table APPROX. 1/4 IN. (6.4 mm) 1/8 IN. (3.2 mm)
GREATER THAN 1/4 IN. (6.4 mm) 1/4 IN. (6.4 mm)
located in reference material. (See Figure 11.)
4. Remove punctured seal from the cartridge using spline
wrench. (See Figure 11.)
NECK LENGTH
SPLINE
(SEE TABLE)
WRENCH

CARTRIDGE SPACER
VISE

SHOWN: PART NO. 4476,

CARTRIDGE VISE ASSEMBLY,
MAX. 2 IN. (5.1 cm) DIAMETER

FIGURE 11
007315

FIGURE 12
007316
 SECTION 7 – FILLING NITROGEN CARTRIDGES SMALLER THAN 23 FT3 (0.7 m3)
4-15-11        Page 7-3

FILLING NITROGEN CARTRIDGES SMALLER THAN 23 FT3
(0.7 m3) (Continued)
Cartridge Refill Procedure (Continued)
c. Insert the cartridge into filling unit by inserting the spline
shaft down as far as the handwheel will allow it to go,
turning the handle clockwise and pushing down at the
same time. This will allow the spline end of the shaft to
engage the seal body. Thread the cartridge into the unit by
guiding it with one hand, while at the same time turning the
handle counterclockwise with the other hand (Right-hand
threads on cartridge and filling unit). (See Figure 13.)
Take extreme care not to get the threads of the cartridge
crossed in the filling unit. Tighten cartridge snugly into the
place with the aid of a strap wrench. DO NOT FORCE A
TIGHT FIT.
10.
FILLER
BLOCK
SPLINE
SHAFT
g. Close the gas control valve.
h. Open the gas release valve until all gas has escaped
between filling unit and control valve.
NOTICE
Very often when charging the cartridge, there
will be leakage around the cartridge threads.
Usually this is slight. Donʼt try to tighten the
cartridge more than just snug. If a leak
should occur around the spline shaft packing
nut, tighten packing nut. Each filler block is
packed around the spline shaft with a leather
lacing which is treated with Neatsfoot Oil.
Periodically, the packing nut should be
removed and the spline shaft lubricated with
this oil to ease turning of the handle.
! CAUTION
Since the cartridge lacks a safety shipping cap at this
time, the cartridge could become a projectile.
Remove cartridge from filling unit by first loosening the
cartridge with a strapwrench, turning clockwise approximately
1/8 of a turn and then backing it out completely by turning the
handwheel clockwise. Always keep one hand on the cartridge
while backing it out so that it does not fall. (See Figure 15.)

FIGURE 13
007317

d. Back the seal from the cartridge seat by turning the handle
counterclockwise one-half to one full turn.
e. Slowly open nitrogen cylinder valve wide open. Note pres-
sure on gauge. Open gas control valve. A noticeable drop
in pressure will be indicated when gas control valve is
opened. The gauge will almost immediately (3-5 seconds)
return to a steady pressure reading. The equalization of
pressure between gauge and cartridge means the FIGURE 15
cartridge is filled. The time will vary due to the temperature 007319

of cartridges and nitrogen cylinder.

f. When the cartridge is filled with a sufficient quantity of
nitrogen, thread the seal down into the cartridge by turning
the handle clockwise until the seal fits snugly on the
cartridge seat. (See Figure 14.)

SEAL
SEAT

FIGURE 14
007318
 SECTION 7 – FILLING NITROGEN CARTRIDGES SMALLER THAN 23 FT3 (0.7 m3)
4-15-11        Page 7-4

FILLING NITROGEN CARTRIDGES SMALLER THAN 23 FT3 Nitrogen Supply Cylinder

(0.7 m3) (Continued)
Cartridge Refill Procedure (Continued)
11.
! WARNING
Each cartridge must be weighed immediately after filling
to assure that it has not been overfilled. If the cartridge
has been overfilled, as it warms up, the internal pressure
will rise and could cause the cartridge seal disc to rupture.
Lacking a safety shipping cap, the cartridge will ʻʻrocketʼʼ
and severe personal injury or property damage could
result.
The number of cartridges that can be charged from a nitrogen
supply cylinder depends on methods used, if the cartridges are
being cooled, how warm the cylinder is, and the amount of
leakage from the filling unit. For example, approximately 25 LT-20
cartridges can be filled from a 400 ft3 (11.3 m3) cylinder. When the
supply cylinder pressure drops below 1800 psi (124.1 bar), it will
become quite difficult to charge the cartridge regardless of its
temperature. The nitrogen supply can be determined by the pres-
sure reading indicated on the cylinder valve gauge or by weighing
the cylinder before and after use. Immediately ensure filled
cartridges have safety shipping caps installed. Proceed to Section
7, Leak Testing and Painting.

Weigh cartridge immediately after it has been removed from

filling unit. It should weigh within ± 1/8 ounce (3.54 g) of its
stamped weight. If it weighs less, replace the cartridge in the
filling unit and add the necessary amount of N2 to bring it up
to the stamped weight. (It may be necessary to re-cool
cartridge to take additional gas.) If the cartridge is overweight,
place the cartridge in the vise and retract the seal with the
spline wrench just enough to allow the gas to escape slowly
and then resnug. Reweigh the cartridge. Repeat this proce-
dure until proper weight has been reached. (Although we
allow a tolerance of ± 1/8 ounce (3.54 g) from the weight
stamped on the cartridge, it is good practice to try to hold the
weight to the plus tolerance only. This is advisable because in
the final weighing prior to using, any cartridge which reads
under the minus 1/8 ounce (3.54 g) weight may be a possible
leaker. If weight loss is below stamped weight, but is not
below minus 1/8 ounce (3.54 g), it is possible to retighten the
seal and put the cartridge back into the hot water bath for
further examination.)
12.
! WARNING

Care must be taken not to tighten the seal excessively.

Otherwise the seal will break or the threads will strip.

Replace the cartridge in the vise and tighten the seal firmly in
place. A tightening torque of 40 to 50 ft lb (54.2 to 67.8 Nm) is
required for optimum sealing.
13. Immediately ensure filled cartridges have safety shipping
caps installed. (See Figure 8.) All refilled cartridges shall
utilize only the following safety shipping caps: the left-hand
threaded safety shipping caps are Part No. 77250 while the
right-hand threaded safety shipping caps are Part No. 77251.
If an older style shipping cap is found, it should be replaced
with the appropriate shipping cap described above.

NOTICE
If any cartridge continues to leak after filling
instructions mentioned in this procedure are
correctly followed, the empty cartridge should
be taken out of service and destroyed.
 SECTION 8 – FILLING 23/55 FT3 (0.7/1.6 m3) NITROGEN CARTRIDGES
4-15-11        Page 8-1
REV. 2

FILLING 23/55 FT3 (0.7/1.6 m3) NITROGEN CARTRIDGES Booster Pump Specifications
Note: Pump not supplied by ANSUL. Other manufacturerʼs pumps
! CAUTION may be used as long as the following technical specifications are
met.
See safety instructions in Section 2 before proceeding. To Sprague Air-Operated Gas Booster –
lessen the risk of personal injury or property damage, follow all
instructions in the proper sequence. Model No.: S-86-JN-15
Ref. No: 90081-1
Equipment Setup Ratio: 15:1
Driving Air Supply (See Note): 25-200 psi (1.7-13.8 bar)
1. Place and secure cartridge to be recharged in a cylinder vise
capable of handling cylinders up to a diameter of 7 in. Precharge Inlet Air Range: 100-3100 psi (7.0-213.7 bar)
(17.8 cm). Cartridge must be inserted into vise in the vertical Outlet Air Range: 375-3100 psi (25.9-213.7 bar)
position. (See Figure 16.) Port Thread Size: Driving Air – 1/2 NPT
Note: Cylinder vises for cartridges larger than 2 in. (5.1 cm) in Inlet-Outlet Air – 1/4 NPT
diameter may be purchased from the following companies: Size:  Length – 17.5 in. (44.5 cm)
www.getzmfg.com Width – 7.75 in. (19.7 cm)
www.galiso.com Weight: Actual – 18 lb (8.2 kg)
Shipping – 21 lb (9.5 kg)
www.hydro-test.com
Note: Maximum driving air consumption of the boosters is approx-
imately 80 SCFM at 100 psi (7.0 bar). Boosters will operate with
less than 80 SCFM and with less than 100 psi (7.0 bar).

Cartridge Refill Procedure

1. Remove shipping cap, and gauge guard from cartridge.
2. If seal is not punctured, place cartridge in cylinder vise capable
of handling cylinders up to 7 in. (17.8 cm) in diameter.
3. Insert spline wrench and slowly loosen seal until gas audibly
begins to vent. Allow all pressure to vent until gauge indicates
zero and gas is completely vented. If seal is punctured,
proceed to Step 4. This may take up to 30 minutes.

! CAUTION

Do not attempt to remove seal completely while gas is

venting. Failure to observe this precaution may result in
personal injury.

4. Remove punctured seal from the cartridge using spline

FIGURE 16 wrench. (See Figure 17.)
008685

2. Due to fill volumes (approximately 23 ft3 and 55 ft3 (0.7 m3

and 1.6 m3) and fill pressures of 2015 psi (138.9 bar) at 70 °F SPLINE
(21 °C), a nitrogen booster pump is recommended. WRENCH

REMOVE
GAUGE
GUARD

SECURE IN
CYLINDER VISE

FIGURE 17
008679

5. Before inserting new seal, all cartridges must be inspected as

detailed in Section 3.
6. Thread new seal into the cartridge snugly, but do not tighten.
 SECTION 8 – FILLING 23/55 FT3 (0.7/1.6 m3) NITROGEN CARTRIDGES
4-15-11        Page 8-2

FILLING 23/55 FT3 (0.7/1.6 m3) NITROGEN CARTRIDGES e. Attach the hose from the booster pump to the filler block
(Continued) inlet.
Cartridge Refill Procedure (Continued)
7. In order for the cartridge to readily accept the nitrogen charge
required, it is recommended that the cartridge be placed in a
freezer and cooled to approximately 0 °F (–18 °C). This will GAS CONTROL
allow the cartridge to be filled faster and will result in fewer VALVE
underfilled cartridges.
8. With completion of the previous steps, proceed to fill the nitro- FILLER
BLOCK
gen cartridge by completing the following procedures:
a. Make sure gas control, gas release and nitrogen pump
valves are closed.
b. If neck ring spacers are needed, choose the appropriate
size as shown in Figure 18. Place the spacer over the
GAS
cartridge threads and let it rest on the cartridge shoulder. RELEASE
VALVE
NECK LENGTH
_____________ SPACER SIZE
____________
LESS THAN 1/8 IN. (3 mm) NO SPACER REQUIRED
APPROX. 1/4 IN. (6 mm) 1/8 IN. (3 mm) VENT TO
GREATER THAN 1/4 IN. (6 mm) 1/4 IN. (6 mm) UNOCCUPIED AREA

NECK LENGTH FIGURE 19

(SEE TABLE) 008680

f. Back the seal from the cartridge seat by turning the handle
counterclockwise one-half to one full turn.
g. Follow booster pump manufacturerʼs documentation for
hookup and filling procedures.
h. When the cartridge is filled with a sufficient quantity of
nitrogen, thread the seal down into the cartridge by turning
the handle clockwise until the seal fits snugly on the
cartridge seat. (See Figure 20.)

SPACER
SEAL
SEAT

FIGURE 20
007318

i.
FIGURE 18 ! WARNING
007316

c. Thread the filler block onto the valve, approximately two Care must be taken not to tighten the seal excessively.
threads down, ensuring that the spline wrench is seated Otherwise the seal will break or the threads will strip.
inside the cartridge seal. Hand tighten.
Note: Take extreme caution not to cross the threads of the Replace the cartridge in the vise and tighten the seal firmly
filler block. in place. A tightening torque of 45 ft lb (61.0 Nm) is
required for optimum sealing.
d. Make sure vent valve on filler block is closed.
j. Close the gas control valve.
 SECTION 8 – FILLING 23/55 FT3 (0.7/1.6 m3) NITROGEN CARTRIDGES
4-15-11        Page 8-3

FILLING 23/55 FT3 (0.7/1.6 m3) NITROGEN CARTRIDGES

(Continued)
Cartridge Refill Procedure (Continued)
k. Open the gas release valve until all gas escapes between
filling unit and control valve.

NOTICE
Very often when charging the cartridge, there
will be leakage around the cartridge threads.
Usually this is slight. Donʼt try to tighten the
cartridge more than just snug. If a leak
should occur around the spline shaft packing
nut, tighten packing nut. Each filler block is
packed around the spline shaft with a leather
lacing which is treated with Neatsfoot Oil.
Periodically, the packing nut should be
removed and the spline shaft lubricated with
this oil to ease turning of the handle.
9.
! CAUTION

Since the cartridge lacks a safety shipping cap at this

time, the cartridge could become a projectile.

Remove fill hose from filler block inlet. Remove filler block
from cylinder valve.
10. Immediately ensure filled cartridges have gauge guards and
safety shipping caps installed. (See Figure 21.) All refilled FIGURE 21
008683
cartridges shall utilize only the following safety shipping caps:
the threaded Cartridge Safety Shipping Cap (Left-hand, Part
No. 77250; Right-hand, Part No. 77251) and the Cylinder
Shipping Cap (Part No. 73066). If an older style shipping cap
is found, it should be replaced with the appropriate shipping
cap described above.

NOTICE
If any cartridge continues to leak after filling
instructions mentioned in this procedure are
correctly followed, the empty cartridge should
be taken out of service and destroyed.
 SECTION 9 – LEAK TESTING AND PAINTING
4-15-11        Page 9-1

LEAK TESTING AND PAINTING
! WARNING
Never work in a position above cartridges placed in the test
bath. If a cartridge seal ruptures due to overfilling, it is usually
during the initial warm up period. If seal ruptures, cartridge
could become a projectile and cause serious personal injury
or damage.
Painting Cartridges Smaller Than 23 ft3 (0.7 m3)
Paint the cartridges with a good quality nongloss paint 1.5 – 2.0
mils thick. Color is CCA-GE BEIGE CAMEL. Do not paint external
threads. (Stamped information on cartridge must be legible after
painting.) Hang the cartridges up to dry using the cartridge caps.
Insert wire under cap or into the gas escape holes and bend in the
form of a hook. When the paint has dried, apply a thin coating of
liquid wax to the external threads. This will help guard against
rusting.

Painting 23/55 ft3 (0.7/1.6 m3) Cartridges

Leak Testing
Paint the cartridges using a primer coat of epoxy primer (Part No.
1. The cartridge should be placed in a hot water bath for a period 21944), dry film thickness of a minimum of 1.0 mil. Let cartridges
of at least four hours under bubble covers. dry for 30 minutes at 200 °F (93 °C). After drying, top the primer
Note: When leak testing 23/55 ft3 (0.7/1.6 m3) cartridges, coat with epoxy polyester (Part No. 21917), dry film thickness of a
make sure that the hot water bath can accommodate a height minimum of 2.0 mils. Dry for 30 minutes at 225 °F (107 °C).
of 28 in. (71.1 cm) for the 23 ft3 (0.7 m3) cartridge, and 27.9 in. Stamped information on cartridge must be legible after painting.
(70.8 cm) for the 55 ft3 (1.6 m3) cartridge. Note: If a cartridge needs to be re-painted, this should be done
Make sure that the water temperature never drops below prior to refilling.
110 °F (43 °C) or goes over 120 °F (49 °C). If the seal has not
been tightened enough, bubbles will form immediately and will Final Inspection and Marking
rise to the surface. If this happens, remove the cartridge from Before shipping, recheck weight of cartridge. If cartridge weighs to
the bath, tighten the seal and re-weigh cartridge to ensure stamped weight, identify cartridge size by marking on side with
proper weight. Replace cartridge in water bath. After cartridge ANSUL ink stamp. Stamp artwork can be obtained by contacting
has warmed up, cover cartridge with bubble cover for the leak the ANSUL Marketing Communications Department. If weight of
test. Submerge bubble cover in water. Do this in such a cartridge is below weight allowed by filling tolerance, the cartridge
manner as to allow the air bubbles to escape from the cover. must be refilled. The weight stamped on a cartridge DOES NOT
After the bubble cover has been filled with water, and while include shipping cap. Federal regulations prohibit shipment of
still submerged, invert it. Check the bottom of the bubble charged cartridges without a safety shipping cap.
cover for air bubbles. If there are no air bubbles visible, raise
bubble cover up and place it over the cartridge, always
keeping the bubble cover full of water as it is being moved into
position. When the bubble cover is over the cartridge, again
check to make sure that there are no bubbles in the cover. If
a bubble does show up, remove the bubble cover and repeat
procedure. If the bubble appears in the bubble cover a second
time, remove cartridge, tighten seal and repeat procedure. If a
bubble appears again, release the gas from the cartridge and
check the condition of the cartridge seat. If the seat is in satis-
factory condition, insert a new seal and recharge the
cartridge.
2. Clean and dry the tested cartridges that did not show bubbles
after the four hour leakage test. Only cartridges with NO
bubbles have passed the test. If small bubbles appeared
during the four hour leak test, it does not necessarily indicate
CO2 or N2 leakage. Along with air becoming trapped around
the cartridge seal and threads, the hot water can be contami-
nated by the following:
a. Free air dissolved in the water driven out by heat.
b. Hydrolysis of water into hydrogen and oxygen.
c. Gas created by corrosion.
3. If any small bubbles are found, the cartridge must be retested.
 SECTION 10 – OUT-OF-SPEC CARTRIDGES
4-15-11        Page 10-1

OUT-OF-SPEC CARTRIDGES

! WARNING

Be sure cartridges are empty before destroying.

Problem
_______ Corrective-Action
______________
Small 1-1/16 in. Condemn and discard per CGA P-2
threads recommendation.
Large 1-1/16 in. Repair with thread chase or condemn
threads and discard per CGA P-2
recommendation.
Large 3/4 in. Condemn and discard per CGA P-2
threads recommendation.
Small 3/4 in. Repair with tap or condemn and discard
threads per CGA P-2 recommendation.
Bad seat for Condemn and discard per CGA P-2
cartridge seal recommendation.
Corrosion Condemn and discard per CGA P-2
recommendation.
Loose hex nut Condemn and discard per CGA P-2
recommendation.
Short threads Condemn and discard per CGA P-2
(less than 4 full recommendation.
threads)
Large minor Condemn and discard per CGA P-2
diameter on recommendation.
3/4 in. threads
Fire burned Condemn and discard per CGA P-2
cartridges recommendation.
CARTRIDGE SPECIFICATION TABLE – CO2 EXPELLANT

REFILL O.D. DIMENSION DIMENSION

SHIP. SEAL THREAD I.D. VOL. H2O WEIGHT OF CHARGE D.O.T. A B
ASSY. ASSY. MODEL 1 1/16-20 THREAD GMS.70 °F OZ.                              (g) SPEC. IN.          (cm) IN.          (cm) STAMP

4523 24654 4 and 5 L.H. 3/4-16 63 to 67 1 1/4 – 1 1/2 (35.5 – 42.5) — 1 1/2 (3.8) 3 29/32 (9.9) 4445

4616 24654 10 L.H. 3/4-16 109 to 113 2 7/16 – 2 11/16 (69.2 – 76.1) — 1 1/2 (3.8) 5 15/16 (15.1) 3634

4614 24654 20 L.H. 3/4-16 230 to 245 5 – 5 1/2 (142 – 156.2) 3E-1800 2 (5.1) 6 13/16 (17.3) 1054

30660 24654 MILITARY 20 L.H. 3/4-16 230 to 245 5 – 5 1/2 (142 – 156.2) 3E-1800 2 (5.1) 6 13/16 (17.3) 1054

4615 24654 30 L.H. 3/4-16 355 to 370 8 – 8 1/2 (227.2 – 241.4) 3E-1800 2 (5.1) 9 13/16 (24.9) 1055

30661 24654 MILITARY 30 L.H. 3/4-16 355 to 370 8 – 8 1/2 (227.2 – 241.4) 3E-1800 2 (5.1) 9 13/16 (24.9) 1055

15850 53803 101-10 R.H. 3/4-20 308 to 328 7 – 7 3/8 (198.8 – 209.5) 3E-1800 2 (5.1) 9 (22.9) 15324

17490 53803 K-101-10 R.H. 3/4-20 308 to 328 5 1/4 – 5 5/8 (149.1 – 159.8) 3E-1800 2 (5.1) 9 (22.9) 25771

17492 53803 101-20 R.H. 3/4-20 427 to 443 10 – 10 1/4 (284 – 291.1) 3A-2100 2 1/2 (6.4) 7 7/8 (20.0) 17356

15851 53803 101-30/PS-30 R.H. 3/4-20 682 to 700 15 3/4 – 16 1/4 (447.3 – 461.5) 3A-2100 2 1/2 (6.4) 11 5/8 (29.5) 15601

15920 24654 NM-20 L.H. 3/4-16 230 to 245 5 — 5 1/2 (142 – 156.2) 3E-1800 2 (5.1) 7 7/16 (18.8) 15924

15041 24654 NM-30 L.H. 3/4-16 355 to 395 8 – 8 1/2 (227.2 – 241.4) 3E-1800 2 (5.1) 10 7/16 (26.4) 15051
4-15-11        Page 11-1
SECTION 11 – APPENDIX
CARTRIDGE SPECIFICATION TABLE – NITROGEN EXPELLANT

REFILL O.D. DIMENSION DIMENSION

SHIP. SEAL THREAD I.D. VOL. H2O WEIGHT OF CHARGE D.O.T. A B
ASSY. ASSY. MODEL 1 1/16-20 THREAD GMS.70 °F OZ.                              (g) SPEC. IN.          (cm) IN.          (cm) STAMP

7013 53819 LT-5-L L.H. 3/4-16 179 to 200 23/32 – 31/32 (20.4 – 27.5) 3E-1800 2 (5.1) 6 (15.2) 6957

6979 53819 LT-5-R R.H. 3/4-16 179 to 200 23/32 – 31/32 (20.4 – 27.5) 3E-1800 2 (5.1) 6 (15.2) 6915

13193 53803 LT-10-R R.H. 3/4-20 230 to 245 1 1/8 – 1 3/8 (31.9 – 39.1) 3E-1800 2 (5.1) 6 13/16 (17.3) 13008

13177 53819 LT-10-L L.H. 3/4-16 230 to 245 1 1/8 – 1 3/8 (31.9 – 39.1) 3E-1800 2 (5.1) 6 13/16 (17.3) 13162

7032 53803 LT-20-R R.H. 3/4-20 427 to 443 2 3/16 – 2 7/16 (62.1 – 69.3) 3A-2100 2 1/2 (6.4) 7 7/8 (20.0) 7072

7012 53803 LT-20-L L.H. 3/4-20 427 to 443 2 3/16 – 2 7/16 (62.1 – 69.3) 3A-2100 2 1/2 (6.4) 7 7/8 (20.0) 7028

5373 53803 LT-30-R R.H. 3/4-20 682 to 700 3 7/16 – 3 13/16 (97.7 – 108.5) 3A-2100 2 1/2 (6.4) 11 5/8 (29.5) 4894

6641 53803 LT-30-L L.H. 3/4-20 682 to 700 3 7/16 – 3 13/16 (97.7 – 108.5) 3A-2100 2 1/2 (6.4) 11 5/8 (29.5) 6698

29187 53821 LT-A-101-30 R.H. 3/4-20 1802 to 1835 15 3/4 – 16 1/4 (447.3 – 461.5) 3AA-1800 3 9/16 (9.1) 14 5/8 (37.1) 29250

73022 53803 R-102 DOUBLE R.H. 3/4-20 1513 – 1690 9 1/4 – 9 3/4 (262.7 – 276.9) 3AA-2100 4 3/16 (10.6) 10 1/4 (26.0) 57392

428060 53803 LT-A-101-125 — 3/4-20 4632-5047 See gauge on valve and reference 3AA-2015 28 (71.2) 4 1/4 (10.8) —
Temperature Correction Chart

428061 53803 LT-A-101-250 — 3/4-20 10897 See gauge on valve and reference 3AA-2015 27 7/8 (70.8) 6 3/4 (17.1) —
Temperature Correction Chart
4-15-11        Page 11-2
SECTION 11 – APPENDIX
 SECTION 11 – APPENDIX
4-15-11        Page 11-3

TEMPERATURE CORRECTION CHARTS
CYLINDER FILL CHART – NITROGEN – 23 FT3 (MEDICAL E) CYLINDER
CYLINDER
PRESSURE
psi (bar)
2000 (137.9)

E
1900 (131.0) SUR
ES
L PR
FIL
1800 (124.1) R
NDE
LI
CY
1700 (117.2)

1600 (110.3)

1500 (103.4)

1400 (96.5)

1300 (89.6)
–65 –40 –20 0 20 40 60 80 100 120 °F
(–54) (–40) (–29) (–18) (–7) (4) (16) (27) (38) (49) (°C)
NITROGEN CYLINDER TEMPERATURE

CYLINDER FILL CHART – NITROGEN – 55 FT3 (MEDICAL E) CYLINDER

CYLINDER
PRESSURE
psi (bar)
2300 (158.6)

2200 (151.7)

RE
SSU
2100 (144.8) E
L PR
FIL
R
2000 (137.9) NDE
LI
CY

1900 (131.0)

1800 (124.1)

1700 (117.2)

1600 (110.3)
–65 –40 –20 0 20 40 60 80 100 120 °F
(–54) (–40) (–29) (–18) (–7) (4) (16) (27) (38) (49) (°C)
NITROGEN CYLINDER TEMPERATURE
SECTION 11 – APPENDIX
4-15-11        Page 11-4

008693

OUNCES-TO-GRAMS CONVERSION TABLE
1/16 oz  =  1.77 grams
1/8 oz  =  3.54 grams
1/4 oz  =  7.09 grams
5/16 oz  =  8.86 grams
3/8 oz  =  10.63 grams
7/16 oz  =  12.40 grams
1/2 oz  =  14.17 grams
9/16 oz  =  15.95 grams
5/8 oz  =  17.72 grams
3/4 oz  =  21.26 grams
7/8 oz  =  24.81 grams
1 oz  =  28.35 grams
2 oz  =  56.70 grams
3 oz  =  85.05 grams
4 oz  =  113.40 grams
5 oz  =  141.75 grams
6 oz  =  170.10 grams
7 oz  =  198.35 grams
8 oz  =  226.80 grams
9 oz  =  255.15 grams
10 oz  =  283.50 grams
11 oz  =  311.85 grams
12 oz  =  340.19 grams
SECTION 11 – APPENDIX
4-15-11        Page 11-5
13 oz  =  368.55 grams
14 oz  =  396.89 grams
15 oz  =  425.25 grams
16 oz  =  453.59 grams
17 oz  =  481.95 grams
18 oz  =  510.29 grams
19 oz  =  538.65 grams
20 oz  =  566.99 grams
21 oz  =  595.35 grams
22 oz  =  623.69 grams
23 oz  =  652.05 grams
24 oz  =  680.39 grams
25 oz  =  708.75 grams
26 oz  =  737.09 grams
27 oz  =  765.45 grams
28 oz  =  793.79 grams
29 oz  =  822.15 grams
30 oz  =  850.49 grams
31 oz  =  878.85 grams
32 oz  =  907.18 grams
33 oz  =  935.55 grams
34 oz  =  963.88 grams
35 oz  =  992.25 grams
 SECTION 12 – REFERENCES
4-15-11        Page 12-1

REFERENCES
1. ANSUL Technical Bulletin No. 31, Form No. F-80261, ʻʻCarbon
Dioxide Cartridgesʼʼ
2. ANSUL Technical Bulletin No. 34, Form No. F-80195, ʻʻUse
and Refilling of ANSUL Gas Cartridgesʼʼ
3. ANSUL Technical Bulletin No. 50, Form No. F-81301,
ʻʻHydrostatic Retest Requirements for ANSUL Hand Portable
and Wheeled Fire Extinguishersʼʼ
Technical Bulletin ANSUL ®

Number 31

Carbon Dioxide Cartridges For ANSUL INCORPORATED

Hand Portable Fire Extinguishers MARINETTE, WI 54143-2542

Each Ansul hand portable cartridge-operated fire extinguisher is provided with a small cartridge of compressed
gas which furnishes the pressure to expel the dry chemical agent. Most of these cartridges are charged with liq-
uid carbon dioxide, but some nitrogen cartridges are used in extreme temperature environments.
All Ansul cartridges are manufactured, tested and assembled according to U.S. Department of Transportation
regulations. The smaller carbon dioxide cartridges which are exempted from certain D.O.T. regulations (car-
tridges installed in 4, 5 and 10 lb. extinguishers) are designed, manufactured and tested in accordance with the
requirements of Underwriters Laboratories, Inc.
Rupture Pressure
Every DOT-3E-1800 cylinder is designed to withstand rupture up to a minimum of 6000 psi (41370 kPa) (see
chart). One cartridge of every 500 manufactured must be hydrostatically tested to determine rupture pressure.
Reports of these tests must be given to the Department of Transportation. Every Ansul cartridge is also subject-
ed to hydrostatic test at 4500 psi (31028 kPa) and pneumatic leakage at 1800 psi (12411 kPa). Because all
Ansul cartridges are designed to meet and exceed minimum rupture pressure, a large safety factor between
charged pressure (850 psi at 70 °F) (5861 kPa at 21 °C) and minimum rupture pressure (6000 psi) (41370 kPa)
is created (see chart).

PRESSURE
(POUNDS PER SQ. IN.)
(850 psi AT 70 °F) CARTRIDGE CYLINDER
(5861 kPa AT 21 °C) RUPTURE PRESSURE
(MINIMUM 6000 psi
(41370 kPa))
6000

CYLINDER SAFETY MARGIN

(MINIMUM 1500 psi
(10343 kPa))
5000
MAXIMUM RUPTURE PRESSURE OF
FRANGIBLE DISC
(4500 psi (31028 kPa)) FRANGIBLE DISC RUPTURE
RANGE (450 psi (3103 kPa))
4000 MINIMUM RUPTURE
PRESSURE OF
FRANGIBLE DISC (4050 psi
(27925 kPa))

3000 DISC AND CYLINDER

SAFETY MARGIN
(MINIMUM 3200 psi
(22064 kPa))

2000

1000
CHARGED PRESSURE
(850 psi AT 70 °F
(5861 kPa AT 21 °C))

–50 0 50 100 150 200 250 300

TEMPERATURE – °F

Temperature – Pressure Relationships in Carbon Dioxide Cartridges

For 4, 5, 10, 20, and 30 lb. Capacity Ansul Fire Extinguishers
002221
Each cartridge is closed and sealed by a threaded plug containing a frangible disc with carefully controlled mate-
rial integrity, thickness, and diameter so that it will rupture at pressures between 4050 and 4500 psi (27925 and
31028 kPa) according to D.O.T. requirements. This creates an additional safety factor of at least 1500 psi (10343
kPa) between disc rupture pressure (4050 to 4500 psi) (27925 to 31028 kPa) and minimum cylinder rupture
pressure (6000 psi) (41370 kPa) (see chart).
Specially designed safety shipping caps should always be utilized on the cartridges whenever they are not
installed onto a system or extinguisher. These safety shipping caps protect the threads and seal surfaces while
ensuring safe pressure venting of the cartridge should it be exposed to excessive temperatures.
Filling and Pressures
The weight of carbon dioxide placed in the cartridge is not allowed to exceed 68% of the weight of water the car-
tridge would hold (68% density). At this density the carbon dioxide is under a pressure of approximately 850 psi
at 70 °F (5861 kPa at 21 °C) and about 4200 psi at 200 °F (28959 kPa at 93 °C) (see chart).
The cartridge filling process is closely controlled to reduce the possibility of the cartridge being filled over 68%
density. Each cartridge is also tested for leakage by immersion in a hot water bath for several hours. This test will
detect a leak rate of 1/4 oz. in 127 years. The temperature in the water bath is also high enough to rupture the
safety disc in an over-filled cartridge. A final weighing ensures against shipping of overfilled or empty cartridges.
Ansulʼs Quality
By insisting on the highest manufacturing standards and quality testing procedures, Ansul assures that all its
extinguisher cartridges are accurately filled, safe and reliable. Non-Ansul cartridges should never be used in
Ansul extinguishers. Refer to Technical Bulletin No. 58, Replacement Components and Service, Form No.
F-8922.

ANSUL INCORPORATED, MARINETTE, WI 54143-2542 715-735-7411 Form No. F-80261-1          ©1998 Ansul Incorporated          Litho in U.S.A.
Technical Bulletin ANSUL ®

Number 34

ANSUL INCORPORATED
Use And Refilling Of Ansul Gas Cartridges MARINETTE, WI 54143-2542

Published standards from the National Fire Protection Association, Occupational Health and Safety Act,
Underwriters Laboratories and Factory Mutual Laboratories, state that materials other than those furnished by
the manufacturer shall not be used in dry chemical extinguishers. This, of course, means that a manufacturerʼs
cartridge refilled by anyone not authorized to do so by the manufacturer of the original equipment would not be
acceptable.
In this bulletin we will discuss certain pitfalls which could occur from not adhering to these standards.
1. Use of non-Ansul cartridges in Ansul extinguishers
A. External threads do not fit cartridge receiver
1. Galls threads do not fit cartridge receiver
2. Cartridge strips threads and blows out upon being punctured
3. Does not seat tightly against gasket…
a. Impossible to puncture cartridge seal
b. After puncturing some gas leaks past threads
B. Different design of cartridge seal and its assembly into cartridge body could result in the inability to punc-
ture the cartridge seal when used in an Ansul extinguisher
C. These non-Ansul cartridges will not be refilled by Ansul or authorized Ansul agents
2. Refilling of Ansul cartridge by other than authorized agents may result in…
A. Threads not checked with “Go” and “No Go” thread gauges with cartridges having dangerously worn
threads not being junked
B. Damaged threads not being repaired
C. Depth and condition of cartridge seal seat not checked
D. Dangerously rusted or damaged cartridges being refilled
E. Cartridges weakened by being involved in a fire being refilled
F. Weight of empty cartridge not checked before refilling
G. Use of cartridge seal not manufactured by Ansul
1. Disc may rupture as low as 110° F
2. Disc may rupture at temperatures and pressure too high for built-in safety factor
3. May require pipe dope or some other sealing compound to effect temporary sealing of gas. This proce-
dure is not recommended.
H. Reuse of Ansul seal body with a new rupture disc not to specification. Used seal body is also more subject
to leaking gas.
I. Cartridge being underfilled with consequent poor performance
J. Cartridge being overfilled
1. A 3/8 ounce overfill in a carbon dioxide filled Model 5 cartridge can cause rupture of seal disc at 130° F
(standard filling will result in seal disc rupture at 194° F or more).
2. A 1 ounce overfill in a nitrogen filled Model LT-20-R cartridge can cause rupture at 130° F (standard fill-
ing will result in seal disc rupture at 360° F or more).
3. A 4 ounce overfill in a carbon dioxide filled PS-30 cartridge can cause rupture at 115° F (standard filling
will result in seal disc rupture at 170° F or more).
K. Failure to subject cartridge to 12 hour 115° F water bath test to cull out leakers
 L. Poor paint finish because of…
1. Failure to wire brush thoroughly

2. Paint allowed to get on threads

3. Instructions partially obliterated
M. Rubber stamped instructions not reproduced after painting
N. Threads not treated with proper lubricant to prevent rusting. Rusted external threads make proper seating
of cartridge difficult and can cause freezing to threads of cartridge receiver.
O. Failure to reweigh before shipping
P. May result in failure to rehydrostatic test PS-30, 101-30 and LT-30-R cartridges every five years as
required by D.O.T.
Ansul Incorporated has had over 40 yearsʼ experience in the manufacture, refilling and testing of gas pressure
cartridges for dry chemical extinguishers. The large volume of extinguishers produced by Ansul permits us to
manufacture all gas cartridges used in Ansul fire extinguishers. This volume also justifies elaborate equipment
for testing every critical feature of Ansul gas cartridges. This is important since the gas pressure cartridge is the
heart of a cartridge operated dry chemical fire extinguisher.
Over the years rigid standards for refilling Ansul cartridges have been developed. As new inspection procedures
have been added, labor saving tools for automation have kept pace allowing us to absorb the costs of the added
inspection steps in Ansulʼs cartridge filling department.
The tools, fixtures, gauges and other test equipment required to fill and test gas cartridges to the standards of
Ansul Incorporated, represent a sizeable capital expenditure. Only the factory and authorized agents for refilling
Ansul cartridges realize the volume necessary to justify this expenditure. Cartridge refill volume is also important
in keeping material and labor costs at a level so that the extensive quality control in this operation does not
become uneconomical.
A few Ansul gas cartridges are being refilled by those not authorized to do so. We, like the N.F.P.A. and
other agencies, wish to discourage this practice. Those not authorized to fill Ansul cartridges cannot possibly
afford to install proper tools, fixtures, gauges and other equipment when their volume of Ansul cartridges refilled
totals a few hundred cartridges a year or less. Likewise, when volume is small, certain obvious short cuts in test-
ing procedures must be taken so that the operation shows a profit.
In summary, Ansul Incorporated heartily concurs with the N.F.P.A., OSHA and other agencies concerning the fact
that spare and refill cartridges other than those furnished by the manufacturer shall not be used in dry chemical
fire extinguishers. Again, the gas cartridge is the heart of an Ansul dry chemical fire extinguisher. To assure prop-
er functioning of the extinguisher, the cartridge must be serviced by those qualified to do so.

ANSUL INCORPORATED, MARINETTE, WI 54143-2542 715-735-7411 Form No. F-80195-1          ©1998 Ansul Incorporated          Litho in U.S.A.
Technical Bulletin
Number 50

Hydrostatic Retest Requirements for ANSUL

Portables, Wheeled Units, and Pre-engineered Vessels

Federal laws (and in some cases state and municipal statutes) require that most of the pressure vessels associ-
ated with ANSUL hand portable and wheeled extinguishers must be periodically hydrostatically retested to ensure
their safety. In addition, the laws require hydrostatic retesting of vessels which show evidence of corrosion or
mechanical injury.
The purpose of this bulletin is to 1) indicate what Tyco Fire Suppression & Building Products understands to be
the legal requirements, and 2) provide guidance for the user in determining recommended retest practices and
procedures for such vessels.
We have prepared a chart, designed to show what we understand to be the current legal requirements for
periodic retest, indicating both test intervals and pressures. These requirements are shown for the two principal
authorities having jurisdiction over this type of product, the National Fire Protection Association (NFPA); and the
Codes of Federal Regulations, (D.O.T., M.S.H.A., and O.S.H.A.). It is important to understand the jurisdiction of
these two authorities and how it may effect the product in question. You may wish to refer directly to these
principal authorities to make your own interpretation of the current legal requirements.
NFPA standards have no force of law in and of themselves unless adopted by a regulatory entity that is
empowered by statute to enforce regulations. However, as consensus standards developed by teams of
recognized experts, they represent sound fire safety principles, practices and procedures, and we recommend
that they be observed in the case of hydrostatic retesting. Moreover, some states and municipalities have
adopted NFPA standards as a part of their fire protection codes, including those parts dealing with the
maintenance and hydrostatic retesting of extinguishers.
OSHA has safety jurisdiction over most workplaces in the U.S., and as such its regulations have the force of
federal law. OSHA has not adopted NFPA standards for hydrotesting per se, but its requirements follow NFPA
standards closely.
D.O.T.ʼs hydrostatic retest requirements apply only to charged pressure vessels which are transported in
commerce in the U.S. or to foreign countries. Once the product reaches its original destination, D.O.T. rules apply
only when the container is reshipped in a charged condition or being re-filled.
M.S.H.A. has safety jurisdiction over mines and generally references the appropriate NFPA and D.O.T.
regulations for additional guidelines on extinguisher hydrostatic testing.
It will be noted that there are some gaps and overlapping in the legal requirements for periodic hydrostatic
retesting of some vessels, which may be due to an oversight or other reason. However, appropriate retest
intervals and test pressures have been determined for such vessels through the NFPA Committee process and/or
Tyco Fire Suppression & Building Productsʼ own research and experience. In many cases, compliance to the
NFPA standards may put you in compliance with OSHA (refer to the National Consensus Standards, Appendix B,
Subpart L). A Tyco Fire Suppression & Building Products recommendation is indicated for each of the pressure
vessels addressed by this Bulletin.
Hydrostatic testing should only be performed by trained, qualified persons with suitable testing equipment and
facilities. For additional guidance you are referred to CFR-49, CFR-29, NFPA-10, the current ANSUL manual
“Hydrostatic Test Instructions for Portables, Wheeled Units, and Pre-engineered Systems,” Form No. F-7602 and
the Compressed Gas Association phamplets “C-6,” “C-6.1” and “C-1” which cover the visual inspection and hydro-
static test methods. To secure a copy of CGA Pamphlet “C-6,” “C-6.1,” or “C-1,” contact the:
Compressed Gas Association Inc.
1235 Jefferson Davis Highway
Arlington, VA 22202
 PERIODIC HYDROSTATIC RETEST REQUIREMENTS FOR PRESSURE VESSELS IN ANSUL

N.F.P.A. CODE OF
STD. RETEST TEST REF. RETEST
PRESSURE VESSEL NO. PERIOD PRESSURE NO.* PERIOD

ANSUL Stored Pressure Dry Chemical, 10 12 years Factory test pressure (not to exceed 1 12 years
FE-36, and Halon 1211 Extinguishers 3X the normal operating pressure)
(Agent Tanks)

ANSUL Stored Pressure Water and Wet 10 5 years Factory test pressure (not to exceed 1 5 years
Chemical Hand Portable Extinguishers 3X the normal operating pressure)
(Agent Tanks) (See note)

ANSUL CO2 Hand Portable 10 5 years 5/3 service pressure as 1 5 years

Extinguishers (aluminum and steel (See note) stamped into the cylinder
Agent Tanks) D.O.T. 3A-1800, 3AA-1800,
3AL-1800 and 3AA-2015

ANSUL Dry Chemical, Cartridge- 10 12 years Original factory test N/A N/A
Operated and Wheeled Extinguishers and pressure as shown on
Spill Control Application (Agent Tanks) the nameplate or shell

ANSUL Model 33-D AFFF 10 5 years Unspecified N/A N/A

Wheeled Extinguishers
(Agent Tank)

ANSUL Halon 1211 Wheeled 10 Per D.O.T. Factory test pressure (not to exceed 3, 6 7 or 12 years
Extinguishers marking 3X the normal operating pressure) (See Ref. No. 6)
(D.O.T. 4BW-240 Agent Tanks) (See notes)

CO2 Cartridges for 5, 10, 20 10

and 30 Models None Required 1, 4 None Required
N2 Cartridges for 5 and 10 Low
Temperature Extinguisher Models

N2 Cartridges for 20 and 30 10 Per D.O.T. or C.T.C. markings 2, 5 Per stamped markings
Low Temperature Extinguisher Models 5 or 10 years

Nitrogen Cylinders for all 10 5 or 10 years 5/3 service pressure as 2, 5 5 or 10 years

ANSUL Wheeled Extinguishers stamped into the cylinder

Pre-Engineered 101 Agent Tanks 17 12 years Original factory test pressure N/A N/A
as shown on nameplate or shell

ANSUL Model SPA-50 and IND-X 17 12 years Factory test pressure (not to exceed 1, 3, 6 7 or 12 years
(D.O.T. 4BW-500 Agent Tanks) 2X the normal operating pressure)

ANSUL R-102 Wet Chemical Agent 17A 12 years Factory test pressure (not to exceed 1 12 years
Tanks (carbon steel and stainless tanks) 3X the normal operating pressure)

ANSUL Model H-1000 and H-101 12A 12 years Factory test pressure (not to exceed 3, 6 7 or 12 years
(D.O.T. 4BW-500 Agent Tanks) 2X the normal operating pressure)

ANSUL Model H-1000 with 3A or 3AA 12/ 5 years 5/3 service pressure as 1 5 years
D.O.T. Stamp (Agent Tanks) 12A stamped into the cylinder

Pre-engineered System Cartridges 17/ 12 years Factory test pressure 2, 5 5 or 10 years

—Except LT-5, LT-10 and 101-10 17A

Pre-engineered System Cartridges 17/ None Required 1 None Required

—LT-5, LT-10 and 101-10 17A Per D.O.T. 3E Stamp D.O.T. 3E Tank
—  As used in this chart, service pressure and operating pressure are the same.
—  Dry Powder Extinguishers should be tested at the same intervals and pressures as Dry Chemical Extinguishers.
PORTABLES, WHEELED UNITS, AND PRE-ENGINEERED VESSELS

FEDERAL REGULATIONS TYCO RECOMMENDS
TEST RETEST TEST
PRESSURE PERIOD PRESSURE NOTES

Factory test pressure (not to exceed 12 years 600 PSI (41.4 bar) • Agent hose assemblies with a shut-off nozzle
2X the service pressure) must be tested @ 300 psi (20.7 bar).

Factory test pressure (not to exceed
2X the service pressure)
5 years 200 PSI (13.8 bar) • Exception: Does not apply to ANSUL ENSIGN
Model WF-2 1/2 fiberglass extinguishers which
were recalled in 1973. Under no circumstances
are these units to be hydrostatically tested or
recharged.

5/3 service pressure 5 years 5/3 service pressure • Aluminum tanks suspected of being exposed
(See note) to temperatures in excess of 350 °F (177 °C)
shall be removed from service and subjected to
a hydrostatic retest.

N/A 12 years 600 PSI (41.4 bar) • Agent hose assemblies must be tested at
same intervals @ 300 PSI (20.7 bar), or at
service pressure, whichever is higher.

N/A 5 years 600 PSI (41.4 bar) • Agent hose assemblies must be tested at
same intervals @ 300 PSI (20.7 bar), or at
service pressure, whichever is higher.

2X service pressure 7 or 12 years 480 PSI (33.1 bar) • Agent hose assemblies must be tested at same
intervals @ 300 PSI (20.7 bar).

None Required None Required • Exempt because of size and stamp.

Per stamped markings 5 or 10 years 5/3 service pressure

5/3 service pressure

5/3 service pressure 5 or 10 years 5/3 service pressure

N/A 12 years 600 PSI (41.4 bar) • Agent hose assemblies must be tested at same
intervals @ 300 PSI (20.7 bar), or at service
pressure, whichever is higher.

Factory test pressure (not to exceed 7 or 12 years 1000 PSI (68.9 bar) • Test 1 inch discharge hose and 1/4 inch
2X the normal operating pressure) actuation hose @ 1000 PSI (68.9 bar).

Factory test pressure (not to exceed 12 years 300 PSI (20.7 bar) • Test 1/4 inch gas hose assembly @ 300 PSI
2X the normal operating pressure) (20.7 bar).

Factory test pressure (not to exceed 7 or 12 years 1000 PSI (68.9 bar) • Test 1 inch discharge hose and 1/4 inch
2X the normal operating pressure) actuation hose @ 1000 PSI (68.9 bar).

5/3 service pressure 5 years 5/3 service pressure

Factory test pressure 12 years Factory test pressure

None Required • LT-5-L, LT-5-R, LT-10-L, LT-10-R, 101-10 and

K-101-10 exempt because of size and stamp.
—  Factory test pressures are indicated on the extinguisher nameplates. * See next page for references to Code of Federal Regulations.
—  Recording of hydrostatic testing shall be in accordance with NFPA-10 recommendations.
REFERENCE NUMBERS FOR CODE OF FEDERAL REGULATIONS CFR-49
1. Part 173.34 (e) Periodic retesting, reinspection and marking of cylinders. Reference the table in this paragraph that
specifies cylinder retest pressure and retest period.
2. Part 173.34 (e) (1) The periodic retest must be performed by an authorized retester and a test by interior hydrostatic
pressure in a water jacket or other apparatus suitable for determination of the expansion of the cylinder. [Proposed 1996:
173.34 (e) (1), (2), (3), and (4)]
3. Part 173.34 (e) (9) Note 2 The 10 year retest period may be extended to a 12-year period, and the 5 year retest period
may be extended to a 7-year period after expiration of the first 12-year period. [Proposed 1996: 173.34 (e) (12) Note 2]
4. Part 173.34 (e) (12) All cylinders not exceeding 2 inches outside diameter and length less than 2 feet are exempted from
hydrostatic retest. [Proposed 1996: 173.34 (e) (15)]
5. Part 173.34 (e) (15) For DOT-3A or 3AA cylinders manufactured after Dec. 31, 1945 and stamped with a five pointed
star after the most recent test date the retest interval may be extended to 10 years. [Proposed 1996: 173.34 (e) (18)]
6. Part 173.34 (e) (18) Cylinders tested without determination of expansion (modified hydrostatic test method) will have the
first retest performed 12 years after the original test date, and at 7-year intervals thereafter. If the water jacket method
is used, retest must be performed every 12 years. [Proposed 1996: 173.34 (e) (21)]

Additional References:
CFR-29 Part 1910.157 (OSHA)
CFR-30 (MSHA)
Part 56 Surface Metal/Non metal
Part 57 Underground Metal/Non Metal
Part 75 Underground Coal
Part 77 Surface Coal
CFR-49 Part 173.309 Fire Extinguishers

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