Chubb QSII - Design, Installation & Commisioning Manual

Design, Installation and Commissioning Manual
Design, Installation & Commissioning Manual 2

General Information
GENERAL INFORMATION
Contents
GENERAL INFORMATION .......................................................................................................................................2
Contents .........................................................................................................................................................2
CYLINDER ASSEMBLIES ........................................................................................................................................6
DISCHARGE SYSTEMS ........................................................................................................................................12
AFFF Distribution Systems...........................................................................................................................12
Foam Concentrate........................................................................................................................................17
DETECTION & ACTIVATION SYSTEMS ..................................................................................................................18
Rise Of Pressure Detection & Actuation ......................................................................................................18
Loss Of Pressure Detection & Actuation......................................................................................................25
Dual Optical Detection & Actuation ..............................................................................................................28
MONITORING SYSTEMS .......................................................................................................................................30
SYSTEM DESIGN ................................................................................................................................................32
Risk Assessment..........................................................................................................................................32
Foam Spray Systems ...................................................................................................................................33
Design Process ............................................................................................................................................34
Final Discharge Time and Application Rate .................................................................................................38
INSTALLATION ....................................................................................................................................................39
Cylinder and Discharge Systems .................................................................................................................39
Detection and Actuation Systems ................................................................................................................39
Typical 10 Nozzle, Fixed Tube Discharge System ......................................................................................42
Typical ROP Detection & Activation System................................................................................................43
Typical LOP Detection & Activation System ................................................................................................44
Shutdown Panel Wiring Schematic ..............................................................................................................45
Dual Optical Detection & Actuation Wiring Schematic.................................................................................46
COMMISSIONING.................................................................................................................................................47
Job Information.............................................................................................................................................48
Design Specifications ...................................................................................................................................50
Installation Details ........................................................................................................................................51
Commissioning Checklist .............................................................................................................................52
Commissioning Complete ............................................................................................................................53
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. Comments should be directed to the address below.
Chubb Fire Safety

(A Division of Chubb Australia Ltd)
Technical Services Department
314 Boundary
Dingley, VIC. 3172
Phone: (03) 9264-9700
Fax: (03) 9264-9751
Prepared by: Adrian Zwaller QS II Copyright Chubb Fire Safety 18-Mar-04

General Information
Background
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, and is a mandatory requirement in many of the states of Australia.
With many modern vehicle or equipment designs, the operators are often positioned well away from the
location of the fire risk. Modern cabs are well insulated from noise and temperature, and operators may not
be aware of the presence of fire in their equipment until it is beyond the control of normal portable fire
extinguishers. Faced with these dangers operators can panic and may abandon the equipment rather than
undertake first aid fire protection.
Field experience has shown the need for improvement over earlier Dry Chemical Powder suppression
systems. These systems generally suffered from compaction of the powder, and often resulted in less than
efficient operation. The advantage of Fire Fighting Foam Systems over gaseous, dry chemical powder and
vaporising liquid systems is there ability to control fire after the discharge is complete, to cool hot spots
preventing re-ignition and to flow with the fuel spills underneath the vehicle.
Australia is leading the world with the development of foam protection systems, and Chubb Fire Safety is at
the forefront of this development. Modern systems now utilise Aqueous Film Forming Foam (AFFF) in
stored pressure stainless steel cylinders as a preferred extinguishant.
Chubb Fire Safety has pioneered the most successful detection and suppression systems in Australia under
the Chubb Fire and Quell Fire & Safety brands.
These systems have been installed on hundreds of vehicles and other equipment over the past 10 years
and have proved themselves as successful fire detection and suppression systems.
Following on with Chubb's commitment to continual improvement, we have now adopted and further refined
this system based on years of field experience. Originally launched as Quell Series II which superseded the
previous Chubb Powermaster I & II and Quell Fire Suppression System, we are therefore extremely proud to
introduce the QS II Pre-Engineered Foam System.
Chubb Fire Safety have taken the basics from the codes NFPA 11 Low Expansion Foam and NFPA 121 Self
propelled and Mobile Surface Mining Equipment along with local regulations from Australian State
Authorities and added in the comments and suggestions from actual users in the field. The Pre-Engineered
Foam System has been designed to add benefits like:
• Flexible Syphon Tubes

• Reinforced extra strong brackets
• Designed for rugged conditions
• Loss of Pressure Detection and Actuation system or a
• Rise of Pressure Detection and Actuation system.
• Ease of installation
• Ease of Maintenance
All of these features put the QS II Pre-Engineered Foam System ahead of its rivals when it comes to a
system which is fit for the purpose at hand while maintaining a degree of flexibility to suit the individual
requirements of our customers.
The Pre-Engineered Foam System has been designed to allow various levels of protection from fully
automatic detection and suppression systems with full engine shut down and cab monitoring to simple
suppression only systems with manual actuation. Customers can decide for themselves what level of
protection they wish to install on their equipment to meet local regulations.

General Information
A flexible package system allows you to simply and easily order all of the equipment required to install a Pre-
Engineered Foam System.
The QS II Pre-Engineered Foam System is a state-of-the-art system especially designed for modern
equipment.
Typical Applications
The Pre-Engineered Foam System has been designed to allow configurations to suit most applications
including the following:
SURFACE MINING EQUIPMENT UNDERGROUND MINING EQUIPMENT

Crawler Tractors Haulage Units
Trucks Haul Trucks (rear Dump 0-60T)
Haul Trucks (rear Dump 0-60T) Haul Trucks (rear Dump 100-200T)
Haul Trucks (rear Dump 100-200T) Haul Trucks (rear Dump 200-300T+)
Haul Trucks (rear Dump 200-300T+) Haul Trucks (bottom Dump articulated)
Haul Trucks (bottom Dump articulated) Loaders
Draglines Shuttle Cars
Shovels (single Diesel) Cutters
Shovels (twin Diesel) Service Units
Shovels (electric) Wheel Loaders
Graders
Wheel Loaders
FORESTRY EQUIPMENT CONSTRUCTION EQUIPMENT

Loggers Bulldozers
Skidders Graders
Graders Shovels (single Diesel)
Trucks Shovels (twin Diesel)
Traxcavators Shovels (electric)
Loaders Tool-carriers
Trackloaders Draglines
Excavators Wheel Loaders
Bulldozers Generator sets
Cable Operation
Yarders
AGRICULTURE ROAD TRANSPORT

Tractors Prime Movers
Headers Garbage Compactor’s
Pump Stations
Harvesters
AIRCRAFT GROUND SUPPORT RAILWAY EQUIPMENT

VEHICLES
Aircraft Tugs Locomotives
Catering Vehicles
Baggage Vehicles
INDUSTRIAL
Fuel Stores
Transformers
Machines
Forklift Trucks

General Information
About This Manual
This manual is written for those who install and maintain Pre-Engineered Foam Systems. It contains design,
installation and commissioning information for the system.
Chubb Fire Safety assumes no responsibility for application of any systems other than those addressed in
this manual. The technical data contained herein is limited strictly for informational purposes only. Chubb
Fire Safety believes this data to be accurate, but it is published and presented without any guarantee or
warranty whatsoever. Chubb Fire Safety disclaims any liability for any use that may be made by the data
and information contained herein by any and all other parties.
QS II Pre-Engineered Foam Systems are to be designed, installed, commissioned, inspected, maintained,

and tested only by qualified, trained personnel.
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.
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.

Cylinder Assemblies
CYLINDER ASSEMBLIES
Rise Of Pressure Cylinder Assemblies
PART DESCRIPTION TOTAL WATER AFFF 6% PRESSURE HEIGHT

NO. CHARGE CONTENT CONTENT MM
6011/12 CYL ASSY C23 ROP QS2 18 lt. 16.9 lt. 1.1 lt. 1350kPa 960
Loss Of Pressure Cylinder Assemblies
PART DESCRIPTION TOTAL WATER AFFF 6% PRESSURE HEIGHT

NO. CHARGE CONTENT CONTENT
6016/12 CYL ASSY C23 LOP QS2 18 lt. 16.9 lt. 1.1 lt. 1350kPa 910
CYLINDER VALVE
CYLINDER VALVE 118554
110269
O’RING
107656
FILLER PLUG
ASSY
23100
ANTI OVERFILL
TUBE ASSY
SIPHON TUBE
ASSY
CYLINDER
BURST DISC
112255
Rise of Pressure Loss of Pressure

Cylinder Assembly Cylinder Assembly

Cylinder Assemblies
Cylinder Specifications
All cylinders are manufactured from 304 stainless steel to AS3509 with an internally re-enforced neck ring
for extra strength. Each cylinder is marked with its design code, design pressure and test pressure. The
water capacity, date of manufacture and design approval number is marked together with the manufacturers
name. Each cylinder is designed to have a maximum fill ratio of 80% that must not be exceeded.
The following specification table covers the range of cylinders used in the Pre-Engineered Foam Systems:
Part No. Description Water Design Test Approval No.

Capacity Pressure MPa Pressure VIC DOL
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
Cylinder C23 C30 C45 C65 C106

Diameter 216 318 360 360 360
Height 726 512 572 772 1188
H
H
H
H
Anti-Overfill Tube Assembly
Cylinder assemblies are fitted with an anti-overfill tube to allow the filling of cylinders to be easy and to
prevent over filling the cylinder with AFFF solution. Each size of cylinder requires a different anti-overfill tube
length. Refer below for details:
Anti-Overfill Tube Cylinder

Assembly Size
30247 C23
30215 & 90127 C30 O’RING
30248 C45 90127
30249 C65
30250 C106

Cylinder Assemblies
Cylinder Valve ROP 110269
The cylinder valve is of robust construction. It comprises a chrome plated brass body containing a piston
assembly. The valve assembly is held together by four stainless steel screws. It is o’ring sealed, single
action and does not require any adjustment.
SOCKET HEAD
SCREW
110265
GRUB SCREW
110264 SPRING
WASHER
103194
CAM
110249 LEVER
110251
CAP
40503
KNOB
107555
SCHRADER VALVE
94001
MANUAL ACTUATOR BODY

110245
PULL PIN PNEUMATIC ACTUATOR BODY

104657 110247
O’RING
107238
CHECK VALVE
PNEUMATIC PISTON 103222
110253
O’RING
110254
SPRING
110255 CAP
40503
PLUG
103514
SCHRADER VALVE
94001
PRESURE VALVE BODY

INDICATOR 110243
103850
PLUG
103604
VALVE STEM
ASSEMBLY SPRING
110263 110273

Cylinder Assemblies
Cylinder Valve LOP 118554
The cylinder valve is of robust construction. It comprises a machined Stainless Steel body containing a
piston assembly. The valve assembly is held together by four stainless steel screws. It is o’ring sealed,
single action and does not require any adjustment.
ADAPTOR ¼”
O’RING SEAL
118540
SOCKET HEAD
SCREW
118537
SPRING
WASHER
118538
CAP
118533
O’RING
90022
PISTON
118534
O’RING BS211
118548
O’RING BS005
103856
CHECK VALVE
118536
O’RING BS208
118549
RETAINER
118535
BODY
118532
PRESURE
INDICATOR
103850

Cylinder Assemblies
Siphon Tube Assembly
Cylinder assemblies are fitted with flexible siphon tubes to allow the cylinders to be mounted either vertically
or horizontally. Siphon tubes are constructed from a composite of brass, nitrile rubber and stainless steel.
Each size of cylinder requires a different siphon tube length. Refer below for details:
Siphon Tube Cylinder

Assembly Size
109298 C23
110281 C30
110282 C45
110283 C65
112040 C106
Cylinder Brackets
The AFFF cylinder brackets are manufactured from welded carbon steel and painted black.
If bracket, part number 103138 or 118094, is installed on a vehicle which is subject to extreme vibration, it
should be attached using four vibration dampers, part number 112182 and M12 bolts.
103466 C23 Cylinder Bracket 103467 C30 Cylinder Bracket

Cylinder Assemblies
103138 C45 & C65 Cylinder Bracket
M12 BOLT
WASHER
RUBBER SPACER
BRACKET
VIBRATION DAMPER
MACHINERY
SPRING WASHER
M12 NUT
DETAIL A
118094 C106 Cylinder Bracket

Discharge Systems
DISCHARGE SYSTEMS
AFFF Distribution Systems

Chubb Fire Safety recommends the use of the following flexible hose, tube and fittings.
Hose
Part No. Size Min Bend Radius Max Working Pressure

mm inch mm psi Bar
118097 12.7 1/2” 180 2320 160
118098 19 3/4” 240 1530 105
The hose is red branded ‘FIRE SUPPRESSION’ made from oil resistant synthetic rubber with one high
tensile steel wire braid reinforcement. The hose can withstand temperatures from -40ºC to +125ºC. The
hose meets the requirements of SAE 100R1AT and Flame Resistance Designation U.S.MSHA 1C-152/1
and LOBA.
Alternative single wire braided hoses may be used with approval from Chubb Fire Safety’s Engineering
Department.
Stainless Steel Tube
Stainless Steel tube should be used where rigid piping with increased fire resistance is required, such as for
the ring main containing the AFFF 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 a 2m length).
The tube must be cut to the required length with a tube cutter, its ends must be flared with an SAE 37° (JIC)
flaring tool and it may be bent with a tube bender, to a minimum radius of 50mm.

Discharge Systems
Fittings – Hose and Tube
Listed below are fittings required to assemble most configurations of hose and tube assemblies.
Type Part No. Size

118099 1/2” Hose x 3/4" JIC (f) swivel
Coupling 118100 3/4" Hose x 1 1/16” JIC (f) swivel
(Field 118101 90° Elbow 1/2” Hose x 3/4" JIC (f) swivel
Attachable)
118102 90° Elbow 3/4" Hose x 1 1/16” JIC (f) swivel
115963 90° Bend 1/2” Hose x 3/4" JIC (f) swivel
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)
Tee 112183 3/8” BSP (f)
117381 3/4" JIC (m) bulkhead
115371 3/4” JIC (m) x ¾” JIC (m) x 1/4” BSP (f)

115815 3/4” JIC (m) x ¾” JIC (m) x 1/2” BSP (f)
112136 3/4” JIC (m & f) swivel
112137 1 1/16" JIC (m & f) swivel
112138 3/8” BSP (m) x 3/4” JIC (m)
112134 3/4” JIC (m)

Elbow
112135 1 1/16” JIC (m)
117322 ¼” BSP (f) x ¾” JIC (m)
112140 3/8” BSP (m) x 3/8” BSP (f)
112139 3/8” BSP (f) x 3/8” BSP (f)
Cap / Nut 112145 3/4” JIC Nut & Sleeve
Adaptor / 112146 3/4” JIC (m) x 1 1/16" JIC (f)

Reducing
Bush 112144 3/8” BSP (m) x 1/4” BSP (f)
112962 3/4” JIC x 1/2” BSP
Nipple 112128 3/4” JIC x 3/4” BSP
112129 1 1/16” JIC x 3/4” BSP
Socket 112143 3/8” BSP (f) x 1/4” BSP (f)

Discharge Systems
Hose Protector 40136
Lightweight protection of hoses from abrasion and impact. Constructed of polyethylene plastic spiral with
rounded edges to protect hose cover. Plastic material is not effected by exposure to air, water, hydraulic oil
and many other fluids and can withstand temperatures from -40ºC to +120ºC. This one size will fit hose
sizes from 3/8” to 3/4”.
Hose and Tube Clamps
The AFFF discharge pipe work must be supported by the appropriate AFFF discharge pipe work supports.
The supports must be attached to the machinery, at intervals not exceeding the specified maximum spacing,
by the specified fastener or weld. The bolts or welds used must be in accordance with the customers or
manufactures specifications. The UV resistant black nylon cable tie may be used for additional intermediate
support of hose.
Support Type Part No. Tube Size Hose Size Maximum

Spacing (m)
103161 8mm (1 x M8) 3/16” 0.5
103197 12.7mm (1 x M8) 1/4" 0.5
Insulated P-Clip
103198 19mm (1 x M8) 1/2” 0.7
103199 29mm (1 x M8) 3/4” 0.7
Used with 103198 P-Clip for:

• Pyrotube Tube
Grommet 103248
• LOP Detection Tube
• ¼” Copper / Stainless Steel Tube
112269 6.4mm (2 x M6) 0.5

112266 8.0mm (2 x M6) 3/16” 0.5
Bolted Clamp Block 112111 12.7mm (2 x M6) 1/4" 0.5
112110 19.0mm (2 x M6) 1/2” 0.7
112264 25.0mm (2 x M6) 3/4” 0.7
112270 6.4mm 0.5
Welded Clamp
Block 112114 12.7mm 1/4" 0.5
112113 19.0mm 1/2” 0.7
Cable Tie 103331 Nylon Black Cable Tie
Nozzle Bracket 104592 Size: 76x51x5 angle, 50mm width, Zinc plated

Discharge Systems
Nozzle Kits
Each nozzle kit comes with a BM17N 60° High Flow Nozzle. All nozzle kits are supplied with protective Hi-
Temp Vinyl blow off caps to prevent blockage of nozzles whilst in service. Nozzle Kits can be altered to suit
specific applications.
TEE
115150 Nozzle Kit Single Straight 115371
NOZZLE
109476
NOZZLE CAP
112116
ELBOW
112138
115151 Nozzle Kit Single 90° End
SOCKET
112143
NOZZLE
109476
NOZZLE CAP
112116
115152 Nozzle Kit Single Angle

ELBOW
112139
TEE
112132
REDUCING
BUSH
112144 NOZZLE
109476
NOZZLE CAP
112116
115153 Nozzle Kit Double Straight 90°/90° TEE

ELBOW
119336 112132
SOCKET
112143
TEE
112183
NOZZLE
109476
NOZZLE CAP
112116
125316 Nozzle Kit Double Straight 90°/45°

ELBOW
SOCKET 119336
112143
TEE
TEE 112132
112183
ELBOW
114632
NOZZLE
109476
NOZZLE CAP
112116

Discharge Systems
125317 Nozzle Kit Triple Straight 45°/90°/45°
TEE TEE
119334 112132
SOCKET ELBOW
112143 114632
NOZZLE
109476
NOZZLE CAP
112116
Nozzles
The nozzles are non-aspirated solid cone spray nozzles with a 1/4” BSP thread. Refer following table for
details:
Part Ref No. Discharge Discharge Range Nozzle Nozzle Use

No. Angle Coverage Flow Value
Ø1100mm 1000mm 2 General Purpose Nozzle.
109476 BM17N 60°
Ø550mm 500mm (high flow) For covering large area risks
Ø460mm 500mm 1
117350 BM8N 50° For covering small area risks
Ø230mm 250mm (med flow)
Ø1100mm 320mm 2 For covering large area risks
119338 BM16W 120°
Ø550mm 160mm (high flow) from a smaller range.
Do not vary nozzles without prior written approval from Chubb Fire Safety.
Nozzle Caps
Standard Nozzle Cap 112116 is a red Hi-Temp Vinyl blow off cap with a maximum operating temperature of
245°C. This blow off cap is supplied as standard with each nozzle kit.
Brass Nozzle Cap 114620 is available as an option and comes with a stainless steel retainer. Brass Nozzle
Caps must only be used with specially machined nozzles. If brass caps are required part number 114620
must be ordered in conjunction with either the nozzles or the nozzle kits. Machined nozzles will then be
supplied complete with brass caps in place.

Discharge Systems
Foam Concentrate
Two types of foam concentrates are available for use in QS2 Pre-Engineered Foam Systems. These are 3M
FC3034 6% AFFF and 3M FC600 6% ATC AFFF. These foams are formulated from fluorocarbon
surfactants which have excellent foaming properties and which produce a vapour suppressing aqueous film
on flammable hydrocarbon liquids whilst 3M FC600 Foam has the added benefit of been suitable for use on
Alcohol based hydrocarbon liquids. Both of these foams are also suitable for extinguishing Class A fires.
3M FC3034 6% AFFF Foam Concentrate
Concentration: 6%
20L Drum 118239 Specific Gravity at 20°C: 1.01 g/ml
Min. useable Temp.: 1.7°C
Freezing Point: -4°C
Max. Storage Temp.: 49°C
pH: 8.5
3M FC600 6% ATC AFFF Foam Concentrate
Concentration: 6%
20L Drum 113540/CFA Specific Gravity at 20°C: 1.03 g/ml
200L Drum 9431211060 Min. useable Temp.: 1.7°C
Freezing Point: -4°C
Max. Storage Temp.: 49°C
pH: 8.5
NOTE: 3M FC600 foam concentrate does not mix readily when added to water. In order to use this foam
concentrate it is required that the foam concentrate is pre-mixed with water at a ratio of 4 parts water to 1
part foam concentrate prior to adding it to the cylinder assemblies. The use of warm water is preferred and
will greatly help with the mixing process.

Detection & Activation Systems
DETECTION & ACTIVATION SYSTEMS
Rise Of Pressure Detection & Actuation

The Rise of Pressure AFFF system may be activated by any of the following methods singly or in
combination:
• Manual actuation from Cylinder Valve.

• Automatic actuation from Pyrotube Line Detectors
• Manual actuation from Manual CO2 Actuators
• Actuation from an Electrical Solenoid Valve
Pyrotube Detection
The detector comprises a length of Pyrocord (a plastic pyrotechnic compound with 2 supporting wires
sheathed in polythene and a woven metal braid) enclosed by a 6mm diameter 304 stainless steel tube.
Threaded male and female connectors are crimped onto the ends of each length of Pyrocord.
Pyrotube is a linear heat detector used for automatic system actuation. The design of detection systems
utilising Pyrotube is simplified as this is a line type heat detector. As it is active along its entire length, heat
in excess of 175°C, applied at any point will cause the Pyrotube to activate and produce a terminal pressure
within the tube of 11MPa regardless of the detector length. The Pyrocord does not require additional
oxygen to sustain burning and it is unaffected by moisture. The Pyrocord has an installed life of 1 year.
In addition to system activation, the pressure generated by the Pyrotube detector may be used to operate
switches, relays and other devices.
Locate the detector above and/or around the hazard. The distance away from the surfaces of the hazard
must be sufficient to ensure that the normal operating ambient temperature felt by the detector is below
100°C. The minimum distance from the surface of the hazard should be at least 200mm and the maximum
distance should not exceed 1000mm.
Pyrotube must be securely mounted using pipe clips with a synthetic sheathed surface to reduce the risk of
chafing. The distance between support clips should be 400mm or less. The minimum bend radius that will
allow the Pyrowick element to be replaced is 200mm. If the confines of the hazard are such that the bends
must be tighter, the complete Pyrotube may have to be replaced after use and at specified service intervals.
The Pyrotube detection circuits may be connected to the manual CO2 actuation circuits to provide complete
manual and automatic operation. At junction points check valves must be fitted to both circuits to ensure
that the pressure from either circuit is directed to the cylinder valve and not to the other circuit.
The extension of the Pyrotube detection circuit from the hazard area to the cylinder valve shall be by 1/4"
copper or stainless steel tube with a minimum wall thickness of 20 gauge (or a material of similar or greater
strength). Flexible 3/16” hose may be used as required by the installation and must be constructed to that
specified in SAE100R1 and have a minimum working pressure of 11MPa. Chubb Fire Safety, Engineering
Department, must approve any flexible hose used that is not specified in this manual. The maximum
allowable length of the extension pipe work is 3 times the length of the Pyrotube.
The maximum number of cylinders that a single length of Pyrotube can be connected to is 5. If multiple
cylinders are required, the length of the Pyrotube needs to be increased by 0.5m for each additional cylinder
while maintaining the original extension pipe work length.
i.e. An installation with x1 C65 litre cylinder needs to run a 10m extension hose from the
cylinder valve to the Pyrotube. Based on the extension ratio of 3:1, the minimum required
length of Pyrotube is 3.5m.
If the number of cylinders needs to be increased to x3 cylinders, 0.5m of Pyrotube needs to

be added for each additional cylinder making the required length of Pyrotube 4.5m. The
maximum allowable length of the extension pipe work still remains the same for a 3.5m
length of Pyrotube being 10.5m.
A Pyrotube filter must be fitted in each Pyrotube detection circuit to prevent debris from the burnt Pyrocord
element fouling other actuation system components.
Pyrotube assemblies are supplied with Swagelok fittings or flared fittings.
Pyrotube Detectors
Length (m) Complete Assemblies. Complete Assemblies. Replacement Wick
Flare Fittings Swagelok Fittings Includes Male & Female Ends
1.0 ES9008-A ES9107-A 93522
1.5 ES9008-B ES9107-B 93523
2.0 ES9008-C ES9107-C 93524
2.5 ES9008-D ES9107-D 93525
3.0 ES9008-E ES9107-E 93526
3.5 ES9008-F ES9107-F 93527
4.0 ES9008-G ES9107-G 93528
4.5 ES9008-H ES9107-H 93529
5.0 ES9008-I ES9107-I 93530
5.5 ES9008-J ES9107-J 93531
6.0 ES9008-K ES9107-K 93532
Pyrotube Filters 94077
Fitted at the junction of the Pyrotube detector and the tube or hose directing pressure to the Pneumatic
Actuator. The Pyrotube Filters have a 230µm mesh element that may be removed for cleaning or
replacement.
94077 Pyrotube Filter with Swagelok fittings 112119 Pyrotube Filter with Flared fittings
Adaptor 93663 is available separately if a 1/4” NPT

connection is required.

Manual CO2 Actuator
Remote manual operation of the system is achieved using a Manual CO2 Actuator.
A manual CO2 actuator must be fitted at the driver/operators station. Further stations are to be located at
suitable external locations. Typical locations are at the bottom of the cabin access step ways and on
structural framework surrounding the hazard. They should be installed at an accessible operating height.
Operating instruction placards must be fitted at each station.
All connecting pipe work shall be ¼” tubing or 3/16” flexible hose. Rigid tubing may be copper or stainless
steel with a min wall thickness of 20 gauge. Any flexible hose used in the actuation circuit must be
constructed to that specified in SAE100R1 and have a minimum working pressure of 11MPa. Chubb Fire
Safety, Engineering Department, must approve any flexible hose used that is not specified in this manual.
IMPORTANT: The allowable length of connecting pipe work between the Manual CO2 Actuator and the
Cylinder Valve must not exceed 20m. The maximum number of cylinders that a single manual CO2 actuator
can be connected to is 5.
The layout of the pipe work should be designed to ensure that the line from each remote actuator is run
separately to reduce the risk of all lines being damaged together.
Check Valves or Non-return Valves must be fitted at the junction points between separate pipe runs from
multiple manual CO2 actuators and Pyrotube.
Specifications:
CO2 Cylinder: 95 cc. Capacity

CO2 Cylinder Life: 5 Years
CO2 Charge: 60g +/- 3 g
Cylinder Material: Cold Rolled Carbon Steel.
Cylinder Approval No: 6865P87
Actuator Body and parts: Stainless Steel.
Manual CO2 Actuators are available in two different mounting configurations:
ES9106-A Flush Mounted

BUTTON
NUT 26172
ORING 92327
90011 O’RING
90222
ORING
CO2 CARTRIDGE 94814
16004
BODY
26171
SLEEVE
26170
PISTON PULL PIN ASSY

WASHER 41010
36404 26173
LABEL
(NOT SHOWN)
66517

ES9106-B Surface Mounted
SPRING WASHER
94234
BOLT
91314
LABEL
(NOT SHOWN)
66517
BRACKET
76818
ES9017-A PVC Enclosure
BUTTON
NUT 26157
92335
ENCLOSURE
86201
ELBOW
93607 PULL PIN
76714
NUT
93604
NUT
92317
ORING
94710
BODY
WASHER
26160
36404
PISTON
26159
CO2 CARTRIDGE
16004

Location Signs
66133
A self-adhesive red location sign with reflective white

text is available for Manual Actuators. The location
sign is to be placed next to the manual actuator,
preferably above, for easy visual location of the
actuator.
Size: 150mm x 70mm
66509
A robust red PVC placard with white text is also

available for Manual Actuators. The location sign is
to be placed next to the manual actuator, preferably
above, for easy visual location of the actuator.
Size: 75mm x 200mm

Fittings
Listed below are fittings required to assemble most configurations of Activation and Pyrotube Detection
Systems
Type Part No. Thread Size

Hose 114563 3/16” Actuation Hose
Hose Fittings 117811 3/16” Hose x 7/16” JIC (f) sw Field Attachable
Tube 36603 6.35mm OD Stainless Steel 304
Nut 93604 7/16” SAE (f)
103518 1/8” BSP (f)
Tee
112149 1/4” NPT (f)
114608 7/16” JIC (m)
114544 7/16” JIC (m & f)
Elbow
114568 45° 7/16” JIC (m & f)
93607 1/8” BSP (m) x 7/16” SAE (m)
93606 7/16” SAE
30313
1/8” NPT
118551
Plug 94107
1/8” BSP
103514
119568 1/4” NPT
103604 1/4” BSP
103520 7/16” SAE
112150 7/16” JIC Bulkhead
93603 1/8” BSP x 7/16” SAE
Nipple
103513 1/4” BSP x 7/16” SAE
86350 3/8” BSP x 7/16” SAE
112148 1/4” NPT x 7/16” SAE
Adaptor 103519 7/16” SAE (m) x 1/4” BSP (f)
x6 1/4” NPT (f) &

112147
x2 1/8” NPT (f)
Manifold
x5 1/4" NPT (f) &
115370
x1 1/8” NPT (f)
NOTE: Thread Differences between standard SAE and JIC Fittings.
Both types of fittings use the same UNF thread form. Standard SAE fittings have a 45° chamfer on
the end for use with standard flaring of tubing. JIC fittings have a 37° chamfer on the end and are
mainly used for hose connections. SAE and JIC fittings may be interchanged but it is not
recommended, as you may not always achieve a perfect seal.

Check Valve 103222
Check valves should be located at the junction of all Manual CO2 Actuators and Pyrotube Detection lines.
The installation of check valves ensures the minimum length of tube or hose is pressurised to ensure fastest
response to pneumatic signal. The check valve comes with 1/4" tube flare fitting and 1/4” NPT male thread
designed to fit into the Manifold block listed below.
Electric Detection
Electronic thermal or flame detectors may be used to activate the Pre-Engineered Foam System. The
number of detectors employed and their location depends upon the type of detectors used and the type and
geometry of the potential hazard (refer to manufacturer’s guidelines).
Detectors should be placed clear of the engines, Turbo-Chargers and Exhaust Systems, preferably
above and on each side of the hazard.
Note: Refer to Regulatory Authorities recommendations and customer requirements regarding location of
electrical circuit cables and time delays for extinguishant release.
If using electronic detection, the Electric Solenoid Valve is used to activate the Pre-Engineered Foam
System. The solenoid valve is connected to the cylinder valve. When an electronic detector goes into alarm
a signal is sent to the Solenoid Valve. The Solenoid Valve will operate and allow the cylinder valve to open
and the cylinder to discharge.
Available in:
RISE OF PRESSURE
24VDC ES9014-A
12VDC ES9014-B
LOSS OF PRESSURE
24VDC ES9014-C

Loss Of Pressure Detection & Actuation

The Loss of Pressure AFFF system may be activated by any of the following methods singly or in
combination:
• Automatic actuation by Loss of Pressure Fire Detection Tubing

• Manual actuation from remote Manual Actuators.
• Actuation from an Electrical Solenoid Valve.
Special Note: Care must be taken when fitting any manual actuator to a LOP Detection System. It is most
important that these actuators are fitted before pressurising the cylinder.
Loss of Pressure Detection Tubing 118837
This detection system uses a special Fire Detection Plastic Tube that is connected to the cylinder valve and
remains pressurised at the same pressure as the cylinder. The LOP Detection Tubing is active along its
entire length. When the tubing’s integrity is broken by fire it losses pressure and this loss of pressure allows
the cylinder valve to open.
The LOP Detection Tubing is located above and/or around the hazard. The distance away from the
surfaces of the hazard must be sufficient to ensure that the normal operating ambient temperature felt by the
Detection Tubing is below 90°C.
The LOP Detection Tubing must be securely mounted using pipe clips with a synthetic sheathed surface to
reduce the risk of chafing. The distance between support clips should be 500mm or less. The LOP
Detection Tubing has a minimum internal bend radius of 50mm.
Multiple lengths of LOP Detection Tubing may be used to cover more than one fire hazard area.
The LOP Detection Tubing can be directly connected to the cylinder Valve or extension pipework maybe
used.
This is a special 1/4” Nylon 12 plastic tubing that is designed to melt at a temperature of 160° - 180°. The
detection tubing should be located above or around the hazard such that it will not be exposed to
temperatures above 90°C. The detection tubing must not be installed in close proximately to high heat
sources such as turbochargers and exhaust systems. LOP Detection Tubing has an installed life of 1 year.
Fittings for LOP Detection Tubing
Normal 1/4” Compression or Swagelok fittings are to be used to connect the LOP Detection Tubing to the
detection and actuation pipe work. Support spigots (Part Number 119226) are to be inserted into the ends
of the LOP Detection Tubing when using the compression fittings. The support spigots prevent the tube
from collapsing and ensure a complete seal is achieved.
119237 119235 118837 119234 119236
¼" O-RING FACE

SEAL MALE
119226
A connector assembly kit 119225 is available that comes with all the above fittings for the LOP Detection
Tubing.

Remote Manual Actuators
The LOP Remote Manual Actuators are available in two models:
• An internal model, part number 118552, for mounting in a vehicle cabin and interfacing with a monitoring
panel, or a monitoring and engine shutdown panel.
• An external model, part number 118553, for mounting elsewhere.
The remote manual actuators include:

• A robust stainless steel housing, powder coated red, for mounting on a vertical surface, using 4 x M6
fasteners.
• A 1350kPa pressure indicator, to indicate the pressure in the AFFF cylinder assembly and the detection
and actuation system.
• A housing label with coloured OPERATIONAL, RECHARGE and ACTUATED sectors corresponding to
the dial of the pressure indicator.
• A ball valve with a red handle, to vent the detection and actuation system and manually actuate the fire
suppression system.
• A 1/4” compression fitting, for connecting to the detection and actuation piping.
The external remote manual actuator also includes:

• A 1/4” SAE 45º flare male connector, for pressurising the AFFF cylinder assembly and the detection and
actuation system, through the vent valve.
MANIFOLD BLOCK PLUG
118531 118551 BALL VALVE
118541
HOUSING
118530
LABEL
118529
SPACER
SCREW 118568
118539
ELBOW
118546
NIPPLE
PRESSURE 118542
INDICATOR
103850
ADAPTOR
118540 CONNECTOR
119409

The internal remote manual actuator also includes:

• A silencer fitted to the outlet of the vent valve to safely diffuse the gas that is vented.
Silencer
118545
Loss of Pressure Inter-Connecting Hose Assemblies
Listed below are fittings required to assemble most configurations of hose assemblies.
Type Part No. Thread Size

Hose 9344220356 ¼” Hose
Hose Fittings 118839 1/4” Hose x 1/4” ORFS(f) Field Attachable
118840 ¼” ORFS(m)
Tee
118841 ¼” ORFS(m)x¼” ORFS(m)x¼” ORFS(f)
Nipple 118836 ¼” ORFS(m)
The hose is red branded ‘FIRE SUPPRESSION’ made from oil resistant synthetic rubber with one high
tensile steel wire braid reinforcement. The hose can withstand temperatures from -40ºC to +125ºC. The
hose meets the requirements of SAE 100R1AT and Flame Resistance Designation U.S.MSHA 1C-152/1
and LOBA.
Alternative single wire braided hoses may be used with approval from Chubb Fire Safety’s Engineering
Department.

Dual Optical Detection & Actuation

The Dual Optical Detection & Actuation system is an additional detection and actuation system designed to
work in conjunction with a Rise of Pressure or Loss of Pressure Detection and Actuation System. It has
been incorporated into the QSII AFFF System to add an additional level of fire detection. It covers a broader
area and provides detection for fires that can often occur outside of the engine bay, where standard fire
protection systems are unable to detect a fire. The key focus of the Dual Optical Detection is to provide fast
responsive detection of fire and shut down of the vehicle engine to eliminate the continued supply of fuel
feeding the fire.
In addition to the standard ROP or LOP Detection & Actuation System, Dual Optical Detection (DOD)
provides the following functions:
• Automatic detection from the Multispectrum IR Flame Detector

• Automatic actuation from an Electrical Solenoid Valve
• Integration with existing Shutdown Fire Alarm Panel and pressure switches
X3300 Multispectrum IR Flame Detector 86989
The X3300 is a Multispectrum infrared (IR) flame detector. It provides unsurpassed detection of fires from
light to heavy hydrocarbon fuels combined with the highest degree of false alarm rejection. It contains three
IR sensors, signal processing circuitry, and fire and fault relays.
Features:
• Long detection range to carbonaceous fires

• Unequalled false alarm rejection
• Responds to a fire in the presence of modulated blackbody radiation (i.e. heaters, ovens, turbines)
without false alarm.
• Heated optics for increased resistance to moisture and ice
• Factory sealed device, explosion/flame proof detector housing.
• Automatic optical integrity testing – a calibrated performance test that is automatically performed once
per minute to verify complete detector operation capabilities.
• Operates under adverse weather conditions and in dirty environments.
• Detector Status Indicator: Normal (Green), Fault (Yellow) and Fire Alarm (Red)

Specifications:
Operating Voltage: 24vDC nominal

(min 18vDC, max 32vDC)
Power Consumption: 7.5watts
Temperature Range: -40°C to +75°C
Humidity Range: 0 to 95%
Cone of Vision: 90° field of vision
Range: ~18m
(will vary with different fuels)
Response Time: <10s
Size: Dia 82mm x 93mm
Weight: 1.1kg X3300 shown with Q9001L Mount
Q9001L Swivel Mount 86990
The Q9001L Swivel Mount provides a

simple and sturdy method to mount the
X3300 Multispectrum IR Flame Detector.
Optical Detection Control Unit 56701
The Optical Detection Control Unit is the heart of the Dual Optical Detection and Actuation System. It
controls the interfacing between all the different components that make the DOD System function. The
Optical Detection Control Unit includes an Electric Actuation & Engine Shutdown isolation switch for testing
and maintenance purposes. The isolation switch does not isolate the detection circuitry, and the unit will still
operate the visual and audible alarms in the Shutdown Fire Alarm Panel. The isolation switch will not isolate
the ROP or LOP automatic detection and actuation systems. The isolation switch will not isolate any of the
manual actuators.
The Control Unit is made from a fully welded, IP66 rated enclosure: H 300mm x W 200mm x D 120mm.

Monitoring Systems
MONITORING SYSTEMS
A Pre-Engineered Foam System may be fitted with a Fire Alarm Panel to allow the status of the Pre-
Engineered Foam System to be monitored. The Fire Alarm Panel monitors the status of the pressure
switches connected to either one of the spare ports on top of the cylinder or to one of the Remote Manual
Actuators. The Fire Alarm Panel should be installed at a safe but accessible distance from the operator to
prevent injury to the operator in the effect of a vehicle rollover. All wiring and electrical connections must be
installed in accordance with the customers or the equipment manufactures specifications.
Pressure Switches
There are several Pressure Switches available for use in monitored systems.
127361 NO / NC 900kPa 1/8”NPT c/w weather proof connectors

127379 NO / NC 200kPa 1/8”NPT c/w weather proof connectors
Standard Fire Panel 125275
The Standard Fire Control Panel is a robust and compact unit and will operate on an external power supply
of 12V DC or 24V DC. The panel will monitor the status of the pressure switches fitted in the system and
provide audible and visual alarm functions (cylinder low pressure and fire alarm).
The control Panel exhibits the following features:

• High quality die-cast aluminium box. The lid features an integral synthetic
rubber sealing gasket and captive stainless steel fixing screws, mounting
holes and lid fixing screws are outside. the seal, giving the box protection to
1P65 (with rubber stops fitted to unused cable glands).
• Three cable gland entries provided to accept cable diameters from 3mm to
6.5mm.
• High Intensity L.E.D. front panel indicators,
o FIRE ALARM RED
o ON GREEN
o LOW CYLINDER PRESSURE YELLOW
• Audible alarm condition beeper.
• Front panel Reset/Test switch RED BUTTON
• Panel input supply protected by automatic reset fuses. When submitted to
an electrical overload, or short circuit, these devices will rapidly switch from
very low resistance to very high resistance. Once the fault condition has
been corrected and the power removed, the devices are quick to
automatically reset themselves to their low resistance state. Input Voltage
reverse polarity protection and transient surge suppression.
Terminal Connections
1 + Positive
12 to 24 V DC
2 - Negative
3 Pressure Switch (127379)
Input 1
4 Fire Alarm
Input 2
6 Cylinder Low Pressure

Monitoring Systems
Shutdown Fire Panel 125276
The Shutdown Fire Control Panel is a robust and compact unit and will operate on an external power supply
of 12V DC or 24V DC. The panel will monitor the status of the pressure switches fitted in the system and
provide audible and visual alarm functions (cylinder low pressure and fire alarm). Upon detection of a fire
alarm condition, the panel will commence the automatic engine shutdown sequence. An adjustable timer is
provided in the panel and can be set at either 15 or 30 seconds. A ‘Delay Shutdown’ button is also provided
on the panel to allow engine shutdown to be manually delayed by the operator.
Chubb Fire Safety recommends that the connection to an engine shutdown device should only be carried
out after consultation with both the operators and manufactures of the equipment being protected.
The control Panel exhibits the following features:
• High quality die-cast aluminium box. The lid features an integral synthetic
rubber sealing gasket and captive stainless steel fixing screws, mounting
holes and lid fixing screws are outside. the seal, giving the box protection to
1P65 (with rubber stops fitted to unused cable glands).
• Four cable gland entries provided to accept cable diameters from 3mm to
6.5mm.
• High Intensity L.E.D. front panel indicators,
o FIRE ALARM RED
o ON GREEN
o ENGINE SHUTDOWN YELLOW
o LOW CYLINDER PRESSURE YELLOW
• Audible alarm condition beeper.
• Front panel Reset/Test switch RED BUTTON
• Front panel Engine Shutdown Delay switch BLUE BUTTON
• Shutdown relay contacts and Panel input supply protected by automatic
reset fuses. When submitted to an electrical overload, or short circuit, these
devices will rapidly switch from very low resistance to very high resistance.
Once the fault condition has been corrected and the power removed, the
devices are quick to automatically reset themselves to their low resistance
state. Input Voltage reverse polarity protection and transient surge
suppression.
Terminal Connections
1 + Positive
12 to 24 V DC
2 - Negative
Input 1
4 Fire Alarm
Input 2
6 Cylinder Low Pressure
7 Normally Closed
8 Normally Open Engine Shutdown Relay
9 Common

System Design
SYSTEM DESIGN
Risk Assessment
One of the key elements in designing and installing a fire protection system is conducting an accurate fire
risk assessment on the equipment to be protected. The following chart shows the procedure for conducting
a typical Fire Risk Assessment.
Fire Risk Assessment
1. Identify the Start

potential for
fire and
2. Assess the
consequences Economic Life
of fire and
explosion
3. Determine the
need for fire Risks are acceptable Risks are unacceptable
protection
No
Action
Action
Required
Required
4. Select
appropriate Fire Risk Reduction: Fire Protection:
options 1. Machine Modification 1. Portable
2. Procedures 2. Fixed System
Stop
Evaluate the
effectiveness of
actions taken
Some key points to consider when identifying the potential for fire are:
Ignition Sources.
• High Temperature: High temperatures are usually found in the vicinity of a vehicle engine, exhaust
system, pumps, turbochargers, batteries, wiring, switches, electrical motors, generators, and friction
sources such as bearings, brakes, and gears.
• Electrical: Electrical ignition sources include switchgear, motor control centers, circuit breakers, motors
and generators, transformers, battery boxes, substations, cable reels, trays, and splices and collector
rings.
• Other: Smoking materials, chemical reactions, and spontaneous ignition sources are examples of other
sources.
Proximity of Fuel to Ignition Sources.
• An assessment should be made of existing areas where lubrication, hydraulic oil, or fuel lines are in
proximity to an engine surface or other heat-emitting equipment component. Other areas include
equipment articulation points, parking brakes, engine pan area, and battery compartments. Areas not to
be overlooked on larger equipment include roller path/collector ring areas, electrical switchgear, and
transformer compartments. Existing thermal shields, hose routing, electrical harnesses, and their
support can influence the potential for fire.
• In identifying risk areas note that a combustible liquid can spray or drip onto a hot surface remote from
the rupture or leak point. Likewise, spatter from a battery or an electrical switch short can carry heat to
another area of the machine.

System Design
• Many similarities of equipment design and operation exist among the manufacturers. However, within
each of the equipment categories there are variations in configurations that could directly influence the
fire potential.
Fire Incident Experience.
Previous fire experience on similar machines should be considered in the fire risk assessment. Past
experience can indicate that special hazards exist, such as hydraulic hose that frequently comes loose at a
specific connection on the equipment; equipment that has an adverse fire history; or other component
failures that increase fire potential. Input from the vehicle manufacturer or operator is essential for
completing a full risk assessment.
Foam Spray Systems

The features and limitations listed below shall be considered when designing systems of this type.
Design Considerations
The foam discharge may be disturbed by fan draught etc if discharged when the engine is operating.
Allowances may need to be made when positioning nozzles to ensure that sufficient extinguishant impinges
on to the target area. Narrow discharge angle nozzles may assist in some installations that are subject to
high airflow.
Foam nozzles have small orifices and may be susceptible to blockage unless protected. Nozzle caps must
be fitted to all nozzles.
The system when activated shall cover all electrical (especially the Starter Motor), hydraulic and hot areas
within the engine compartment, including the turbocharger (and catalytic converter if fitted in that area).
Foam Application Rate
The minimum rate of application of foam solution shall be 4.1 Litres/minute/m2 based on the surface area
of hazard or hazards within the designated protected area.
For example:
If an engine bay is to be protected the surface area to be included is, the engine block including ancillary
equipment plus, any hazardous equipment attached to the sides of the engine bay.

System Design
Minimum Effective Discharge Time
The minimum effective discharge time shall be 50 seconds. Check local authorities and approving bodies
as in some areas a minimum of 90 seconds is required.
Note:
The 50 seconds quoted is based on the recommendations of the Western Australia Department of Minerals
and Energy. Be aware that State Authority requirements may vary.
Discharge times significantly below 50 seconds are not advisable. Although the fire may be extinguished
within 10 to 15 seconds, the extended discharge is required to cool the hazard to reduce the risk of re-
ignition
Foam Quantity
The quantity of AFFF solution required shall be based on the calculated surface area of the hazard and the
time that the discharge must be maintained.
The following procedure is recommended:
1. Survey the equipment that is to be protected and identify the major hazard(s).
2. Calculate the surface area of the hazard to be protected.
3. Multiply the area in m2 by 4.1 to obtain the minimum quantity of AFFF solution
required per minute in litres.
4. Multiply AFFF quantity by the discharge time in minutes to obtain the total AFFF
quantity required.
Having determined the minimum quantity of foam does not determine how this foam can be applied to the
hazard in the optimum manner with the optimum application rate. This is reliant on the correct selection of
nozzles, cylinders and distribution hose or tube.
Design Process
The following simple calculation process can be used to establish which PEFS Cylinder and Discharge
System components should be employed for protecting a particular hazard.
All the design calculations should be completed in the PEFS Design and Commissioning Database on Lotus
Notes. If a manual calculation is required, it can be completed following the steps below.
Step A Calculate Area of Hazard

Step B Cylinder Assembly Selection
Step C Nozzle Selection
Step D Hose Selection
Step A – Calculate Area of Hazard
The area of the hazard is the total surface area of the hazard that has to be protected. For convenience it is
easier to base the hazard area as a rectangular block and calculate the following surface areas:
Top: Length x Width
Front: Width x Height
Back: Width x Height
Left Side: Length x Height
Right Side: Length x Height
The bottom or underneath side of the hazard area is not normally included in the total surface area unless
there is a specific hazard that needs to be covered under the equipment to be protected.

System Design
Step B – Cylinder Assembly Selection
Calculate the minimum quantity of AFFF Solution required for an Application Rate of 4.1 lt/min/m2 with a
minimum Discharge Time of 50 seconds.
AFFF Quantity = Total Area of Hazard x 4.1 * Discharge Time (sec) / 60
This quantity will help determine the minimum size cylinder that can be selected from the following table:
50sec Discharge Time 90sec Discharge Time

Cylinder Maximum Total AFFF Max. Area of Max. Nozzle Max. Area of Max. Nozzle
Charge (litres) Hazard m2 Flow Value Hazard m2 Flow Value
C23 18 5.0 5 - -
C30 24 7.0 7 - -
C45 35 9.9 12 4.9 5
C65 50 13.5 24 8.2 11
C106 85 19.2 44 13.8 25
Multiple cylinders of the same size may be used in combination. Do not mix different size cylinders
together. When using multiple cylinders the Maximum Area of Hazard in the above table needs to be
multiplied by the number of cylinders to be used.
For Example: 3x C45 cylinders: Maximum Area of Hazard is 29.7 m2
The final selection of the Cylinder Assembly to be used can depend on various factors:
• The size and placement of the area in which to install the cylinder.
• The combination and quantity of nozzles to be used.
• The size and length of hose to be used
• The final Application Rate.
Step C – Nozzle Selection
Three types of nozzles can be used, a 60° angle ‘High Flow’ nozzle, a 50° ‘Medium Flow’ nozzle and a 120°
angle nozzle. For most applications High Flow nozzles will cover the hazard area. Medium Flow nozzles
should be used for covering small area risks and 120° Angle nozzles should be used for congested areas
with intricate profiles or where limited space demands nozzles to be located close to the hazard.
Nozzles should be allocated to cover the High Risk items:
• Fuel Injector pump.

• Fuel Injector lines and Injectors.
• Fuel and Oil Filters.
• Oil Pumps.
• Hydraulic Pumps and lines.
• Turbocharger.
• Starter Motor
• Exhaust components.
• Alternators.
Direct remaining nozzles to cover the lower risk areas.
To select the best nozzle for the application, consideration should be given to the nozzle location, spray
angle and the area each nozzle will cover. The all important application rate must be achieved but flows
must not be so high as to produce too short a discharge time.
The number of nozzles that may be used with any cylinder is limited by the capacity to achieve a minimum
initial pressure. A minimum pressure is required to blow off nozzle caps and more importantly produce
effective fast flame knock down.

System Design
In order to cater for systems employing different combinations of nozzles a Nozzle Flow Value has been
assigned to each of the nozzles.
The Nozzle Flow Value (NFV) is an empirical value that has been derived from testing. It enables a
comparison of the different nozzles to be made.
Part No Description Nozzle Flow Value

109476 60° angle High flow nozzle 2
117350 50° angle Medium flow nozzle 1
119338 120° angle High flow nozzle 2
For example:
8x 60° Angle High flow nozzles: Nozzle Flow Value = 16
8x 50° Angle Med flow nozzles: Nozzle Flow Value = 8
Total Nozzle Flow Value = 24

This allows the use of a C65 Cylinder or x2 C45 Cylinders.
Any combination of nozzles can be selected for the system being designed such that they will adequately
cover all fire hazards providing that the Discharge Time and Application Rate are met.
Minimum Discharge Time = 50 seconds

Minimum Application Rate = 4.1 lt/min/m2.
The Effective Discharge Time for the system can be calculated as follows:
Approximate Discharge Time = Volume of AFFF Solution / Discharge Flow Rate (sec)
These calculations should be used as a guide only. A full system discharge test during commissioning
should always be carried out to ensure mandatory minimum times and application rates are achieved.
The Discharge Flow Rate is dependant on the size cylinder and the number and type of nozzles used in the
Discharge System and can be calculated from either the following equation or graph.
Cylinder Size Approximate Discharge Flow Rate

C23 0.1596 * Ln(NFV) + 0.0802
C30 0.471 * Ln(NFV) – 0.4872
C45 0.3905 * Ln(NFV) – 0.2963
C65 0.4656 * Ln(NFV) – 0.5591
C106 0.6598 * Ln(NFV) – 0.1.1899
1.40
1.35
1.30
1.25
1.20
1.15
1.10
Discharge Flow Rate (ltrs/s)
1.05
1.00
0.95
0.90
0.85
0.80
0.75
0.70
0.65 C23
0.60
0.55
0.50 C30
0.45
0.40 C45
0.35
0.30
0.25 C65
0.20
0.15 C106
0.10
0.05
0.00
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50
Total Nozzle Flow Value

System Design
Step D – Hose Selection
When designing the Discharge System, it is important to keep in mind what type of hose and nozzle
arrangement or layout that is to be used to cover the hazard area. Typical arrangements are as follows:
Single Line
Dual Line or Ring
Although equivalent the Ring Configuration is preferred over Duel Line
Whether rigid tubing or flexible hose is used, the flow rate of AFFF foam solution and the length of hose will
govern the diameter. If too small a hose is selected, pressure loss from the foam cylinder to the nozzle will
result in low nozzle pressure which will effect the spray characteristics of the nozzle. Conversely if too large
a hose is selected the drop in pressure due to the initial filling of the distribution hose could also result in
poor nozzle pressure during the critical first few seconds of discharge.
The table below details the maximum Nozzle Flow Value that can be used for each hose diameter size.
Hose Diameter Maximum Nozzle Flow Value

1/2” 14
3/4” 48
A combination of hose sizes can be used when designing a Discharge System.
For example:
1/2" Stainless Steel Tube
8x 60° angle High Flow nozzles:

Nozzle Flow Value = 16
3/4" Hose
4x 50° angle Med Flow nozzles: 2 2 2 2
10
Nozzle Flow Value = 4 1 1
20
Total Nozzle Flow Value = 20
Individual Nozzle Flow Value
Total Nozzle Flow Value
1 1
10 2 2 2 2
The length of the hose to be used is also critical. The Maximum Hose Volume is 5% of the Total AFFF
Solution. The hose volumes in the table below should not be exceeded as this may affect discharge time,
application rate and initial nozzle pressure.
Cylinder Maximum Hose Volume

(ltrs)
C23 0.9
C30 1.2
C45 1.75
C65 2.5
C106 4.25
Where multiple cylinders are used the Maximum Hose Volume is 5% of the Total AFFF Solution of all
cylinder.

System Design
The total volume of hose can be calculated from the following table:
Hose Size Volume

(ltrs / m)
1/2” 0.12
3/4” 0.28
Multiple Cylinder Systems
For applications where space, size and location restrict the use of a single large cylinder, multiple smaller
cylinders may be used to connect to a single discharge system. The number of cylinders that can be
connected to a single discharge system must not exceed 5 cylinders.
To calculate the Discharge Time and Discharge Flow Rate when using multiple cylinders, the discharge
system needs to be treated as if you were calculating separate discharge systems for each individual
cylinder. The following diagram shows 2 cylinders feeding a single ring main discharge system, this is the
same as having 2 cylinders feeding each half of the ring main discharge system separately.
Example:
A system has x2 C65 cylinders feeding a single ring main discharge system using x24 High Flow
Nozzles. The Total Nozzle Flow Value = 48
This is the same as having two separate discharge systems using a single C65 cylinder and x12
High Flow Nozzles with a Total Nozzle Flow Value = 24
Based on this, the Discharge Flow Rate = 0.92 ltrs/sec and the Discharge Time = 50.6 sec.
Final Discharge Time and Application Rate

The final step in the Design Process is to verify the Effective Discharge time and Application Rate to ensure
that they meet the required specifications.
A full system discharge test must be carried out during commissioning to determine the exact Effective
Discharge Time and Application Rate of the system.
The Effective Discharge Time is the time from actuating the system to the time when the discharge from the
nozzles fail to be a cone pattern. When using AFFF Solution the cone pattern will change to a single stream
and when using water the discharge will begin to splutter.
The approximate Discharge Time calculated above and in the Design Database is only an approximate time
and may vary to the actual discharge time determined during commissioning.
Application Rate (ltrs/min/m2) = Total AFFF Solution (ltrs) x 60

Total Hazard Area (m2) Discharge Time (sec)
If the Application Rate is below 4.1 ltrs/min/m2 the choice of cylinder and nozzle selection needs to be re-
evaluated.

Installation
INSTALLATION
The following guidelines are intended to assist you. They are not a complete set of "how to install"
instructions as each installation is different and the requirements of each customer vary. This section is
limited to an overview of the major considerations and parameters that effect the location and fitting of Pre-
Engineered Foam System equipment.
Cylinder and Discharge Systems

Distribution systems are a combination of flexible hose and rigid stainless steel tube. Flexible hose is
utilised for its ease of installation and resistance to vibration. Conversely rigid tube is fitted in areas prone to
mechanical damage and exposure to extreme temperatures.
Nozzles, Flexible Hoses, Stainless Steel Tubing
• The nozzles are to be mounted in a manner to prevent the nozzle from being deflected from the desired
position. Chubb Fire Safety recommends that nozzle kits be used.
• Nozzles are to be placed in a position that allows the application of the foam solution to target high risk
areas such as Fuel Injector Pumps, Oil Pumps, Fuel and Oil Filters, and Turbochargers.
• Stainless steel tubing is to be installed in fire risk areas. Do not use flexible hoses in these areas.
• Support the distribution of hoses or tubing securely with the mounted hose and tube clamps. Clamps
are to be positioned at the recommended spacing intervals as detailed in section ‘Discharge Systems’
and at each side of any radius section and between each nozzle kit location. Any bolts and welding
used to secure the clamps to the equipment must be in accordance with the customers or manufactures
specifications.
• In areas where abrasion is considered a significant risk hose protection spiral guards may be used in
critical abrasive areas.
Cylinder
Securely fix the cylinder bracket to the equipment, insert and clamp cylinder with pressure gauge to front. If
horizontal mounting is required on a vehicle, ensure that the extinguisher is positioned along the length of
the vehicle so that its valve is positioned towards the front or rear of the vehicle. Note: For Loss of Pressure
system cylinders it is recommend that they be mounted in an upright position or at an angle such that the
LOP valve is above the fill level in the cylinder. When LOP cylinders are mounted horizontally, the actuation
pipe work must rise immediately above the cylinder.
• Ensure there is sufficient space available for the connection of hoses without kinking and that the
connections do not place undue stress on either the valve or the pipe work.
• Ensure instruction label on cylinder is easily visible. If not, an extra cylinder label can be located next to
the cylinder in a position where it can be easily read in the event of fire.
• Ensure that the panel or fixture that the cylinder bracket is secured to is capable of carrying the load of
the cylinder and can handle the additional vibration load that will be applied. Refer to the customer or
manufacture of the equipment on the best suitable location for mounting the cylinder. Special supports
for holding the cylinder bracket or reinforcement supports may be required for the installation of the
cylinder.
• Any bolts and welding used to secure the cylinder to the equipment must be in accordance with the
customers or the equipment manufactures specifications.
Detection and Actuation Systems

LOP Manual Actuators and Detection Tubing
• Attach the remote manual actuators to the machinery. Ensure that at least one manual actuator is
located close to the cylinder. It is recommended and also mandatory in some states that one manual
actuator be located in the operator cab and at least one at ground level at a point of egress.
• When selecting the location of manual actuators, consideration should be given to the fact that they
must be accessible yet not prone to possible mechanical damage and a build up of dirt which could
hinder the operation of the manual station.
Installation
• Locate the LOP Detection Tubing above and around the hazard. The distance away from the surfaces
of the hazard must be sufficient to reduce the ambient temperature felt by the Detection Tubing to 90°C
or less.
• Support the LOP Detection Tubing every 0.5m with securely mounted sheathed pipe clips ensuring
internal bend radii are not less than 50mm.
• Connect the LOP Detection Tubing and the remote manual actuators to the cylinder valve using the LOP
Hose Assemblies and fittings.
• Support the LOP Hose Assemblies every 0.5m with securely mounted sheathed pipe clips ensuring
internal bend radii are not less than 100mm.
• After installation and prior to pressurising the system, perform the “Actuation Pipework (LOP) – Test” as
detailed in the Maintenance and Parts List Manual (p/n: 61416).
ROP Manual CO2 Actuator and Pyrotube Detection
Notice: Where multiple cylinders are fitted, no cylinder may be actuated from the discharge pressure of
another cylinder.
• The Pyrotube element is able to withstand a temperature of 100°C for a minimum period of 1 year, but
care must be taken not to locate Pyrotube in close proximity to Turbo Chargers and Exhaust systems.
• Locate the Pyrotube detector above and or around the hazard. The distance away from the surfaces of
the hazard must be sufficient to reduce the ambient temperature felt by the detector to 100°C or less.
• Support the Pyrotube every 400mm with securely mounted sheathed pipe clips.
• The minimum bend radius that allows removal and replacement of the Pyrocord element is 200mm. If
the confines of the hazard require a tighter radius, the complete Pyrotube section may have to be
replaced after use or at specified service intervals.
• The maximum allowable extension of the Pyrotube pressure circuit from the hazard area to any
pressure-operated device is 3 times the length of the Pyrotube.
• Attach the remote manual actuators to the machinery. Ensure that at least one manual actuator is
located close to the cylinder. It is recommended and also mandatory in some states that one manual
actuator be located in the operator cab and at least one at ground level at a point of egress.
• When selecting the location of manual actuators, consideration should be given to the fact that they
must be accessible yet not prone to possible mechanical damage and a build up of dirt which could
hinder the operation of the manual station. Suitable manual station signs are available from Chubb Fire
Safety.
• Actuation lines from each Pyrotube and each Manual CO2 Actuator are to be connected to the manifold
block fitted with check valves. The Manifold block is to be mounted outside any fire risk area.
• Actuation lines that are located in a fire risk area must be run in copper or stainless steel tubing. Wire
braided flexible hose rated with a minimum working pressure of 11MPa may be used outside any fire
risk areas, i.e. from the manifold block to the cylinder valve.
• It is important to clean out check valves and actuation lines with compressed air before installation to
ensure no debris is left inside the lines that could later cause contamination of the check valve seats.
• After installation and prior to pressurising the system, perform the “Actuation Pipework (ROP) – Test” as
detailed in the Maintenance and Parts List Manual (p/n: 61416).
Fire Alarm Panels
In vehicles, the Fire Alarm Panel should be installed at a safe but accessible distance from the operator to
prevent injury to the operator in the effect of a vehicle rollover. All wiring and electrical connections must be
installed in accordance with the customers or the equipment manufactures specifications.
Dual Optical Detection and Actuation System
Reference should be made to X3300 Instruction Manual 95-8480-02
• The detector should be mounted to provide the best unobstructed view of the area to be protected and
are within the field of view and detection range of the device. The detector is designed to cover large
areas, it is recommended that the detector be mounted on top of the operators cabin. Do not mount the
detector within the engine bay compartment.
• The detector should be aimed downward at least 10 to 20 degrees.
• To minimise the possibility of false alarms, the detectors field of view should not cover areas that are
outside the fire hazard area. Avoid placing the vehicle exhaust system or other similar hydrocarbon
exhausts within the field of view of the detector.

Installation
• The Optical Detection Control Unit should be securely mounted in a central position between the
cylinder assemblies, the Shutdown Fire Alarm Panel in the vehicle cabin and the X3300 detector.
• All wiring and electrical connections must be installed in accordance with the customers or the
equipment manufactures specifications. However it is recommended that shielded Radox electrical
cable is used.

Installation
Typical 10 Nozzle, Fixed Tube Discharge System

Single, Elbow End (ROP Cylinder Valve shown)
Nozzle Assy.
115151
Stainless Steel Tube

Double, Tee End
112108
Nozzle Assy.
115153
Nut & Sleeve

112145
Single, Tee End
Nozzle Assy.
Coupling
115150
118100
114609
118098
Tee
Hose
112129
Nipple

Manual CO2 Actuator
ES9106-A
Filter
94077
Pyrotube
Prepared by: Adrian Zwaller

ES9008
Coupling
117811
Hose
114563 Flare Nut
93604
Nipple
112148 Manual CO2 Actuator
ES9106-B
QS II
Check Valve
Installation
103222
Plug
118551
Design, Installation & Commissioning Manual
Typical ROP Detection & Activation System
Manifold Block
112147
Plug
11956
Copyright Chubb Fire Safety 18-Mar-04

43
Installation
Typical LOP Detection & Activation System
Manual Internal LOP Actuator

118552
LOP Detection Tubing

118837
Adaptor
119237 Tee
118840
Nut 119234
Spigot 119226
Olive 119235
Manual External LOP Actuator
Plug 119236
118553
LOP Hose Assembly

Installation
Shutdown Panel Wiring Schematic

Installation
Dual Optical Detection & Actuation Wiring Schematic
0V INPUT 5 AMP FUSED FROM MACHINE
24 V DC INPUT 5 AMP FUSED

FROM MACHINE
24 V DC - 24 V DC POWER SUPPLY
24 V DC +
CAPACITOR
0V DC - T1
125276 SHUTDOWN FIRE PANEL
GROUND
BROWN
24 V DC + 24V SUPPLY T2 1 24V +
86989 X3300 DETECTOR
GREEN BLUE
EARTH 0 V DC - 0V SUPPLY T3 2 0V -
GROUND
RED YELLOW
24V + OPT. DET 1 + T4 3 INPUT 1
BLACK YELLOW
0V - OPT. DET 2 - T5 4 INPUT 1
BLUE GREY
ALARM RELAY COM OPT. DET 3 ALM T6 5 INPUT 2
BROWN GREY
ALARM RELAY OPT. DET 4 ALM T7 6 INPUT 2
PURPLE GREY
FAULT RELAY COM OPT. DET 5 FLT T8 7 NC ENG S/D
GREY BROWN
FAULT RELAY OPT. DET 6 FLT T9 8 NO ENG S/D
WHITE WHITE
MANUAL TEST TERMINATE T10 9 COM ENG S/D
ORANGE
NOT IN USE TERMINATE T11
YELLOW
NOT IN USE TERMINATE + SOLENOID T12
ES9014-A OR ES9014-C
ELECTRIC SOLENOID VALVE
- SOLENOID T13
ISOLATE SWITCH NORMALLY CLOSED
FOAM ACT. P/S T14

127379 NO 200kPa PRESSURE SWITCH
SYSTEM ACTUATION FIRE ALARM
FOAM ACT. P/S T15
LP P/S T16
CYLINDER LOW PRESSURE
LP P/S T17
+ SOLENOID T18
ES9014-A OR ES9014-C
ELECTRIC SOLENOID VALVE
- SOLENOID T19
FOAM ACT. P/S T20

SYSTEM ACTUATION FIRE ALARM
(LOOP TERMINALS IF NOT BEING USED) FOAM ACT. P/S T21
LP P/S T22
CYLINDER LOW PRESSURE
GREY
(LOOP TERMINALS IF NOT BEING USED) LP P/S T23
N/O ENG S/D T24
ENGINE SHUTDOWN
N/C ENG S/D T25
NO CONTACTS & NC CONTACTS
COM ENG S/D T26
T27
T28
T29
YELLOW
T30
NO
+ WHITE
COM
NC
NO
R1
-
COM
NC
NO
COM
NC
R2

Commissioning
COMMISSIONING
The section describes the tests and checks that must be carried out during commissioning of a Pre-
Engineered Foam System to ensure that the system is installed correctly, meets design specifications and is
fully functional. Design Verification and Commissioning Sheets, which can be found at the end of this
section, are designed to fulfil several purposes:
1. As check list to ensure all design criteria have been identified and tested.
2. Confirmation that design parameters have been met.
3. A uniform method of recording each installation.
As part of the commissioning procedure a system discharge test is to be performed. This can be performed
by using either AFFF solution or water only. When using water only, please note that the discharge time
maybe slightly shorter than if the correct AFFF solution is used.
Where multiple detection and actuation systems are employed (i.e. Manual CO2 Release Station, Pyrotube
System etc.), each method must be tested to ensure correct actuation and discharge of Pre-Engineered
Foam System.
The commissioning report must be entered into the Design and Commissioning Database on Lotus Notes.

Commissioning
Job Information
Originator: Date:
Client Information
Customer Name: Contact Name:

Customer Address:
Telephone: Mobile: Fax:
Quotation No.: Project No.: Purchase Order:
Equipment Information
Equipment Type: Equipment Make:

Equipment Model: Equipment Serial No.:
Engine Size: Engine Type: No. of Turbo Chargers:
Other:
AFFF System
Operating Mode: LOP ❑ ROP ❑

Monitoring Panel: Required ❑ Not Required ❑
Engine Shutdown: Required ❑ Not Required ❑
Installation: Required ❑ Not Required ❑
Service Agreement: Required ❑ Not Required ❑
Training: Required ❑ Not Required ❑
Statutory Authority:
Special Requirements:
Risk Assessment
Step 1. Identify Possible Fire Sources
What is the likelihood of a fire in any of the following areas?
Risk Probability
High Medium Low Nil
1. Fuel transfer pump ❑ ❑ ❑ ❑
2. Fuel transfer hoses ❑ ❑ ❑ ❑
3. Fuel injection pump ❑ ❑ ❑ ❑
4. Fuel injection lines ❑ ❑ ❑ ❑
5. Oil Cooler & hoses ❑ ❑ ❑ ❑
6. Turbochargers ❑ ❑ ❑ ❑
7. Transmission ❑ ❑ ❑ ❑
8. Transmission cooler & hoses ❑ ❑ ❑ ❑
9. Electrics ❑ ❑ ❑ ❑
10. Brakes ❑ ❑ ❑ ❑
11. Tires ❑ ❑ ❑ ❑
12. Load ❑ ❑ ❑ ❑
13. External ❑ ❑ ❑ ❑
14. Other ( list below) ❑ ❑ ❑ ❑

Commissioning
Step 2. Consequences of Fire
What are the likely consequences of fire risks identified above?
Risk Consequences
Life Injury Vehicle Loss Downtime
1. Fuel transfer pump ❑ ❑ ❑ ❑
2. Fuel transfer hoses ❑ ❑ ❑ ❑
3. Fuel injection pump ❑ ❑ ❑ ❑
4. Fuel injection lines ❑ ❑ ❑ ❑
5. Oil Cooler & hoses ❑ ❑ ❑ ❑
6. Turbochargers ❑ ❑ ❑ ❑
7. Transmission ❑ ❑ ❑ ❑
8. Transmission cooler & hoses ❑ ❑ ❑ ❑
9. Electrics ❑ ❑ ❑ ❑
10. Brakes ❑ ❑ ❑ ❑
11. Tires ❑ ❑ ❑ ❑
12. Load ❑ ❑ ❑ ❑
13. External ❑ ❑ ❑ ❑
14. Other ( list below) ❑ ❑ ❑ ❑
Step 3. Can the risk be protected?
Risk Protection
Complete Partial None Comments
1. Fuel transfer pump ❑ ❑ ❑
2. Fuel transfer hoses ❑ ❑ ❑
3. Fuel injection pump ❑ ❑ ❑
4. Fuel injection lines ❑ ❑ ❑
5. Oil Cooler & hoses ❑ ❑ ❑
6. Turbochargers ❑ ❑ ❑
7. Transmission ❑ ❑ ❑
8. Transmission cooler & hoses ❑ ❑ ❑
9. Electrics ❑ ❑ ❑
10. Brakes ❑ ❑ ❑
11. Tires ❑ ❑ ❑
12. Load ❑ ❑ ❑
13. External ❑ ❑ ❑
14. Other ( list below) ❑ ❑ ❑
Step 4. List items covered by the installation.
Risk Covered
Complete Partial None Comments
1. Fuel transfer pump ❑ ❑ ❑
2. Fuel transfer hoses ❑ ❑ ❑
3. Fuel injection pump ❑ ❑ ❑
4. Fuel injection lines ❑ ❑ ❑
5. Oil Cooler & hoses ❑ ❑ ❑
6. Turbochargers ❑ ❑ ❑
7. Transmission ❑ ❑ ❑
8. Transmission cooler & hoses ❑ ❑ ❑
9. Electrics ❑ ❑ ❑
10. Brakes ❑ ❑ ❑
11. Tires ❑ ❑ ❑
12. Load ❑ ❑ ❑
13. External ❑ ❑ ❑
14. Other ( list below) ❑ ❑ ❑
Customers Agreement: ______________________ Date: __________

Commissioning
Design Specifications
Step A Calculate Area Of Hazard
Description Length (m) Width (m) Height (m) Area (m2)

1 Engine
2 Transmission
3
4
5
6
7
8
Total Hazard Area = ____________ m2
Step B Cylinder Assembly Selection
Cylinder Assembly: Qty:
Total Volume of AFFF Solution:____________ Litres

Total Maximum Hazard Area:______________ m2
Step C Nozzle Selection
Nozzle NFV Qty

109476 60° Angle High Flow BIM17 2
117350 50° Angle Med. Flow BIM8 1
119338 120° Angle BIM16 2
Total Nozzle Flow Value:____________ (Note: Check against the maximum allowable Nozzle Flow
Value for the cylinder size selected)
Approximate Discharge Time:________ seconds
Approximate Application Rate:_______ lts/m2/s
Step D Discharge Hose Selection
Maximum Hose Volume:_________ Litres
Hose Type and Size Length (m) Volume (ltrs)
Total Hose Volume:___________ Litres
Step E Detection and Activation System
Manual Actuators
Type Qty Location
LOP Detection Tubing / Pyrotube

Type Length (m) Connection Length to Cylinder Valve (m)

Commissioning
Installation Details
Cylinder Serial Numbers:
Drawing, Schematic or Photos of Discharge System (add attachments if required)
Drawing, Schematic or Photos of Detection and Actuation System (add attachments if required)
Final Discharge Test and Application Rate
Actual Discharge Time:___________ seconds
Actual Application Rate:___________ Lts/m2/s

Commissioning
Commissioning Checklist
Prior to Pressurising the Pre-Engineered Foam System
Cylinder Assemblies
• The cylinder type, size and fill are correct as per Design Specifications ❑
• Valve piston moves freely in valve ❑
Distribution System
• Pipework is free of any foreign matter. The pipework must be clear passage tested using air ❑
or nitrogen regulated to 1000kPa prior to connection
LOP Detection and Activation System

• Manual Actuator ball valves turn freely ❑
• Manual Actuator vent diffuser is clean ❑
• Pipework is leak tight. The pipework must be leak tested prior to connection to cylinder ❑
assembly. (Refer to Maintenance and Parts List Manual)
ROP Detection and Activation System

• Ensure Manual Actuator CO2 cartridges are undamaged ❑
• Ensure CO2 cartridges are the correct mass and in service life ❑
• Ensure Manual CO2 actuator mechanisms move freely ❑
• Pipework is leak tight. The pipework must be leak tested prior to connection to cylinder ❑
assembly. (Refer to Maintenance and Parts List Manual)
After Pressurising the Pre-Engineered Foam System

Cylinder Assemblies
• Cylinder brackets are securely located and mounted ❑
• Cylinder bracket vibration dampers are in good condition ❑
• Cylinder pressures are at correct charge (1350kPa) ❑
• Cylinders are firmly held by cylinder brackets ❑
• Cylinder Labels are clearly visible and in good condition ❑
• Cylinder is leak tight. The cylinder assembly must be leak tested. ❑
Distribution System
• Size and length of pipework is to Design Specifications ❑
• Pipework connectors are secure ❑
• Pipework and nozzles are securely mounted to equipment ❑
• Nozzle locations and directions are correctly positioned to cover hazards ❑
LOP Detection and Activation System

• Manual Actuators are easily accessible ❑
• Manual Actuator pressure indicators are at correct pressure (1350kPa) ❑
• Security Ties are fitted to Manual Actuators ❑
• Pipework is securely mounted to equipment ❑
Monitoring System
• Fire Alarm Panels are tested and reset ❑
ROP Detection and Activation System

• Manual CO2 Actuators are easily accessible ❑
• Pull Pins are fitted to Manual CO2 Actuators ❑
• Pipework and Pyrotube is securely mounted to equipment ❑
• Check Valves are fitted correctly ❑
• Pyrotube Filter fitted between Pyrotube and connecting pipework ❑

Commissioning
Commissioning Complete
Discharge Test Complete? Yes No
Are all Design Specifications met? Yes No
System Designed By:

Name Signature Date
System Installed By:

Name Signature Date
System Commissioned By:

Name Signature Date
Customer:
Name Signature Date

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Design, Installation and Commissioning Manual

Design, Installation & Commissioning Manual 2

Chubb Fire Safety

Prepared by: Adrian Zwaller QS II Copyright Chubb Fire Safety 18-Mar-04

• Flexible Syphon Tubes

Prepared by: Adrian Zwaller QS II Copyright Chubb Fire Safety 18-Mar-04

SURFACE MINING EQUIPMENT UNDERGROUND MINING EQUIPMENT

FORESTRY EQUIPMENT CONSTRUCTION EQUIPMENT

AGRICULTURE ROAD TRANSPORT

AIRCRAFT GROUND SUPPORT RAILWAY EQUIPMENT

Prepared by: Adrian Zwaller QS II Copyright Chubb Fire Safety 18-Mar-04

About This Manual

QS II Pre-Engineered Foam Systems are to be designed, installed, commissioned, inspected, maintained,

Prepared by: Adrian Zwaller QS II Copyright Chubb Fire Safety 18-Mar-04

PART DESCRIPTION TOTAL WATER AFFF 6% PRESSURE HEIGHT

Loss Of Pressure Cylinder Assemblies

PART DESCRIPTION TOTAL WATER AFFF 6% PRESSURE HEIGHT

Rise of Pressure Loss of Pressure

Prepared by: Adrian Zwaller QS II Copyright Chubb Fire Safety 18-Mar-04

Part No. Description Water Design Test Approval No.

Cylinder C23 C30 C45 C65 C106

Anti-Overfill Tube Assembly

Anti-Overfill Tube Cylinder

Prepared by: Adrian Zwaller QS II Copyright Chubb Fire Safety 18-Mar-04

Cylinder Valve ROP 110269

MANUAL ACTUATOR BODY

PULL PIN PNEUMATIC ACTUATOR BODY

PRESURE VALVE BODY

Prepared by: Adrian Zwaller QS II Copyright Chubb Fire Safety 18-Mar-04

Cylinder Valve LOP 118554

Prepared by: Adrian Zwaller QS II Copyright Chubb Fire Safety 18-Mar-04

Siphon Tube Assembly

Siphon Tube Cylinder

103466 C23 Cylinder Bracket 103467 C30 Cylinder Bracket

Prepared by: Adrian Zwaller QS II Copyright Chubb Fire Safety 18-Mar-04

103138 C45 & C65 Cylinder Bracket

118094 C106 Cylinder Bracket

Prepared by: Adrian Zwaller QS II Copyright Chubb Fire Safety 18-Mar-04

AFFF Distribution Systems

Part No. Size Min Bend Radius Max Working Pressure

Stainless Steel Tube

Prepared by: Adrian Zwaller QS II Copyright Chubb Fire Safety 18-Mar-04

Fittings – Hose and Tube

Type Part No. Size

Tee 112183 3/8” BSP (f)

117381 3/4" JIC (m) bulkhead

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

112138 3/8” BSP (m) x 3/4” JIC (m)

112134 3/4” JIC (m)

112140 3/8” BSP (m) x 3/8” BSP (f)

112139 3/8” BSP (f) x 3/8” BSP (f)

Cap / Nut 112145 3/4” JIC Nut & Sleeve

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

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

Prepared by: Adrian Zwaller QS II Copyright Chubb Fire Safety 18-Mar-04

Hose Protector 40136

Hose and Tube Clamps

Support Type Part No. Tube Size Hose Size Maximum

103199 29mm (1 x M8) 3/4” 0.7

Used with 103198 P-Clip for:

112269 6.4mm (2 x M6) 0.5

112270 6.4mm 0.5

112113 19.0mm 1/2” 0.7

Cable Tie 103331 Nylon Black Cable Tie

Chubb QSII - Design, Installation & Commisioning Manual

Chubb QSII - Design, Installation & Commisioning Manual