f-8986 ansul cartridge

8/12/2019 F-8986 Ansul Cartridge

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CARBON DIOXIDE AND

NITROGEN CARTRIDGESField Inspection and Refill Manual

007227

Cov

erLabelNo.

F-2011137


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Indicates revised information.

Indicates change in page sequence.

REVISION INDEX

4-15-11 REV. 1

7-23-10Revision Record page

started at manual revision 2

7-23-10 CGA C-6 2001 DeletedSee Introduction pagefor more information

7-23-10 CGA P-22 1995 DeletedSee Introduction pagefor more information

7-23-10 49 CFR See DeletedSee Introduction pagefor more information

7-23-10ANSUL CO2 and N2 Cartridge Deleted

Recharging Equipment List

4-15-11 Table of Contents New

4-15-11 1-1 2

4-15-11 1-2 Deleted

4-15-11 2-1 1

4-15-11 3-1 2

4-15-11 3-2 2

4-15-11 4-1 2

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

4-15-11 7-1 2

4-15-11 7-2 New

4-15-11 7-3 New

4-15-11 7-4 New

4-15-11 8-1 2

4-15-11 8-2 New

4-15-11 8-3 New

4-15-11 9-1 New

4-15-11 10-1 New

4-15-11 11-1 New

4-15-11 11-2 New

4-15-11 11-3 New

4-15-11 11-4 New

4-15-11 11-5 New

4-15-11 12-1 New

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

LEGEND FOR MANUAL PAGE

REVISION INDICATORS:


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INTRODUCTION

This manual is intended to be used by only those companieswhich have been authorized by Tyco Fire Protection Products torefill ANSUL Carbon Dioxide and Nitrogen cartridges. This manualdoes not apply to other manufacturers 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 associatedwith filling pressure vessels. The technical publications are asfollows:

1. Compressed Gas Association Pamphlets

CGA C-6: Standards for Visual Inspection of SteelCompressed Gas Cylinders

CGA P-15: Filling of Industrial and Medical NonflammableCompressed Gas Cylinders

CGA P-2: The Responsible Management and Dispositionof Compressed Gases and their Cylinders

2. Code of Federal Regulations

49 CFR Transportation

Transport Canada

3. National Fire Protection Association Standards

NFPA 10

SECTION 1 INTRODUCTION

4-15-11 Page 1-1

REV. 2

TYCO FIRE PROTECTION PRODUCTS Copyright 2011 Tyco Fire Protection ProductsONE STANTON STREET All rights reserved.MARINETTE, WI 54143-2542 +1-715-735-7411 Form No. F-8986-03


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WARNING!

CARTRIDGE INSPECTION AND REFILL OVERVIEW

The following procedures have been established to provide auniform method for the processing of ANSUL carbon dioxide andnitrogen cartridges returned for refill. Strict adherence to therecommended practices and use of the recommended equipmentwill help to assure the safety of those handling the cartridges andthe sale of only those cartridges which meet specifications.

The procedure has been divided into eight sections and must befollowed 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 CARTRIDGESSMALLER THAN 23 FT3 (0.7 m3)

SECTION 6 FILLING 23/55 FT3 (0.7/1.6 m3) NITROGENCARTRIDGES

SECTION 7 LEAK TESTING AND PAINTING

SECTION 8 OUT-OF-SPEC CARTRIDGES

SECTION 2 CARTRIDGE INSPECTION AND REFILL OVERVIEW

4-15-11 Page 2-1

REV. 1

To lessen the risk of serious personal injury and to betterassure the proper results when filling ANSUL cartridges, theprocedures set forth in this manual must be followed in theproper sequence.


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EQUIPMENT

Cartridge Refilling Equipment

PartNo. Description____ _________

2590 CO2 CARTRIDGE RECHARGE UNIT, COMPLETE

(Inspection Gauges and CO2 source not included)Consisting of:2157 Filler Block Assembly (LH) Consisting of:

793 Filler Block, LH Thread496 Filler Block Stand257 Cap Screw 3/8 in. (2)1459 Packaging2481 Packing Follower2480 Packing Nut4346 Handwheel, Machined906 Lockwasher (2)560 Spline Shaft1870 Washer (2)904 Nut (2)173 Bolt (2)

174 Nipple 1 in. x 2 in. (3)175 Tee 1/4 in. NPT (2)2482 Gas Control Valve (2)

2492 Copper Tubing & Fitting Consisting of:2485 Union2486 Nut, Union2487 Tubing, Copper 24 in.2488 Square2489 Tailpiece2490 Nut2491 Washer

2591 Cartridge (Spline) Wrench Consisting of:148 Handle490 Spline

2658 1/4 in. x 1-1/4 in. Rod Stock (Pin)

4476 Cartridge Vise Assembly (Maximum of 2 in.(5.1 cm) Diameter) Consisting of:545 Nut (2)968 Lockwasher (2)4478 Base4479 Screw (2)4480 Handle Assembly4483 Lead Screw4487 Handle, Finished4488 Jaw (2)4489 Spacer (2)4624 Pin

Note: Cylinder vises for cartridges larger than 2 in.(5.1 cm) in diameter may be purchased from the follow-

ing companies:www.getzmfg.comwww.galiso.comwww.hydro-test.com

6380 Strap Wrench

59371 Filler Block Assembly (RH) (Required to fill right handcartridges) Consisting of:55723 Filler Block, RH Thread53675 Neck Ring Spacer53676 Neck Ring Spacer

All additional components same as Part No. 2157 withthe exception of Filler Block Assembly

Cartridge Refilling Equipment (Continued)

PartNo. Description____ _________

438601 23/55 ft3 (0.7/1.6 m3) Cartridge Filler Block Assembly(RH) (Required to fill 23/55 ft3 (0.7/1.6 m3) cartridges)

Consisting of:55723 Filler Block, RH Thread53675 Neck Ring Spacer53676 Neck Ring Spacer

This assembly does not include filler block stand. Fillerblock is attached to cartridge valve while cartridge issecured in cylinder vise.

77250 LH Shipping Cap77251 RH Shipping Cap24654 CO2 Cartridge Seal53803 CO2 Cartridge Seal53819 Nitrogen Cartridge Seal53821 Nitrogen Cartridge Seal

Inspection Gauges

433695 Complete Set of CO2 Cartridge GaugesConsisting of:

Cylindrical Plug Gauge, 3/4-16 N2 No Go Dia. 0.6930Thread Plug, 3/4-16 N2 Go P.D. 0.7094Thread Plug, 3/4-16 N2 No Go P.D. 0.7139Thread Ring Gauge, 1-1/16-20 NSLH Go P.D. 1.0285Thread Ring Gauge, 1-1/16-20 NSLH No Go

P.D. 1.0180Set Plug, 1-1/16 NSLH P.D. 1.0285Set Plug, 1-1/16 NSLH P.D. 1.0180

433696 Complete Set of Nitrogen Cartridge GaugesConsisting of:

Ring Gauges, 1/2-14-L1 NPTPlug Gauge, 1/2-14-L1 NPTCylinder Plug Gauge, 3/4-20 No Go Dia. 0.7027

Thread Plug, 3/4-20-NEF-2B Go P.D. 0.7175Thread Plug, 3/4-20-NEF-2B No Go P.D. 0.7221Thread Ring, 1 1/16-20-NSRH Go P.D. 1.0285Thread Ring, 1 1/16-20-NSRH No Go P.D. 1.0180Set Plug, 1 1/16-20-NSRH Go P.D. 1.0285Set Plug, 1 1/16-20-NSRH No Go P.D. 1.0180

Other Inspection Equipment includes:

Micrometer 1 in. to 2 in.Filler block thread gauges:

Thread Plug, 1 1/16-20-NSRH Go P.D. 1.0300Thread Plug, 1 1/16-20-NSRH No Go P.D. 1.0374Thread Plug, 1 1/16-20-NSLH Go P.D. 1.0300Thread Plug, 1 1/16-20-NSLH No Go P.D. 1.0374Cylinder Plug Gauge, 1 1/16-20 No Go P.D. 1.0138

Cartridge Test Tank

Drawing 819 in the Reference Section details a typical cartridgetest tank (capacity 31 cartridges). Although ANSUL does nomanufacture the tank, the enclosed drawing will provide thenecessary information (gauge of wall steel, immersion heateretc.) for making the cartridge test tank locally. Dimensions will varydepending on the diameter and quantity of cartridges being tested

To control rust in the cartridge test tank, add 1 Gal (3.79 L) oHydrotone (anti-rust) or equal to 50 gallons (189.27 L) of waterThis is available (in small cans) at filling stations or at automotivesupply dealers. Sodium Nitrite (NaSO2) should be added to thetank to maintain a 0.75% (by vol.) solution. Clear cartridge bubblecovers, of a type impervious to heat, are recommended.

SECTION 3 EQUIPMENT

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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 handlingcartridge weights of up to 10 lb (4.5 kg). Any scale selected mustbe checked twice per shift with weights for accuracy. The scale

should be properly mounted to eliminate vibration from the workbench and to avoid scale damage. To keep the cartridge fromrolling while being weighed, mount a cradle to the plate and rebal-ance the scale. The scale shall be calibrated a minimum of onceevery 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 3 EQUIPMENT

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REV. 2


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SAFETY AND MAINTENANCE RECOMMENDATIONS

Safety

1. A hard hat fitted with a full face shield is required.

2. Use a safety guard at the filling block.

3. When working with filled cartridges, keep bottom end pointedaway from operator (and others working in the area) at alltimes.

4. Never work on a cartridge (or any pressure vessel) with yourhead or body positioned over, or in line with, the normal thrustof the cartridge should the seal disc rupture (or should a valveor 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 cartridgesbefore 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 alsodictate safe methods for storage of spare cylinders; chainingthem to a wall will normally be satisfactory.

9. Each cartridge must be weighed immediately after filling toassure that it has not been overfilled. If the cartridge has beenoverfilled, as it warms up in the bath, the internal pressure willrise and could cause the cartridge seal disc to rupture. Sincethe cartridge lacks a safety shipping cap at this stage, thecartridge could become a projectile.

10. Cartridges should always be stored with the bottom of thecartridge pointed away from the operator or other personnel.

11. Wear gloves when handling cold cartridges.

NOTICEThese are but the most obvious precautionsand they must be supplemented by your ownsafety procedures as well as strict observanceof all state, local and federal safety codes andstandards.

Maintenance

1. Use Neatsfoot oil on packing in filler block and adjust packinggland nut, as required, to prevent loss of gas.

2. Use gauge cleaner and preservative to prolong the life ogauges.

3. Store gauges and tools carefully to prevent damage, rusand/or corrosion.

4. Replace or repair damaged tools or equipment immediately.

5. Inspection gauges and filler block shall be calibrated andchecked regularly.* In addition, should a ring gauge bedropped, it must be recalibrated with the proper set plugbefore using.

* This service can be provided by ANSUL Marinette for a nominal charge, but a purchaseorder must accompany the material. Direct all correspondence to the attention of theQuality Control Department.

(For ease of shipment, return filler block without mounting stand and handwheel.)

SECTION 4 SAFETY AND MAINTENANCE RECOMMENDATIONS

4-15-11 Page 4-1

REV. 2

WARNING!

Failure to follow the safety instructions set forth below could

lead to serious personal injury or property damage.


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PRE-FILLING INSPECTION PROCEDURES

Purpose

The proper inspection of cartridges before filling is mandatory; notonly to ensure the integrity of the filled cartridge assembly, but alsoto avoid possible personal injury to persons filling or using a worn

or damaged cartridge. For example, the external cartridge threadis not as strong as the filling block or the cartridge receiver insert.If the threads become undersized, for whatever reason, thecartridge may break loose from the assembly it is mated with dueto the high end thrust caused by gas pressure. Likewise, the shearstrength of the seal assembly is directly dependent on the internalcartridge threads staying within specification.

Consider that there may be ANSUL cartridges in service which areover fifty years old. While age alone does not determine the fitnessof cartridges, it is a factor, along with usage and exposure to corro-sive atmospheres.

The seat machined in the cartridge and the external gasketsurface must also be clean and free of nicks. Remove any foreignmaterial such as dirt or dry chemical which may have accumulatedin the cartridge. Cartridges which have been burned or damagedmust be scrapped.

General Inspection

1. Non-ANSUL cartridges shall not be refilled using these proce-dures. The manufacturer of those cartridges should beconsulted for their own procedures and recommendations.

2. Before filling, ensure cartridge complies with the appropriateNFPA and DOT hydrostatic test requirements.

3. Make certain cartridge is empty. If cartridge is charged orpartially charged, place cartridge in cartridge receiver of bleedoff assembly and bleed off pressure.

4. Fire burned, damaged, badly corroded or pitted cartridgesmust 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 torepair internal threads. After repair, check threads with gaugesas detailed on Pages 3-1 and 3-2. If cartridge cannot berepaired properly, it must be discarded.

6. ICC or DOT stamping must be legible. If not, the cartridgeshall be discarded. (Wire brush if necessary.) (Cartridges1 1/2 in. (38.1 mm) diameter or less are not stamped.)

7. Stamped weight of cartridge must be legible. Wire brush ifnecessary. If stamped weight can not be determined,cartridge must be discarded.

8. Remove seal assembly and check internal threads and sealseat 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. Ifin doubt, use appropriate thread gauges.

Using Cartridge Gauges

If the threads on the inside and outside of the cartridge are withinspecifications and are not damaged in any way, the gauges wilwork with ease as specified in the following paragraphs. At notime should the gauges be forced on the cartridges. If this is done

the life of the gauges will be shortened considerably andcartridges will be checked with gauges that are not within specifi-cations.

Cartridge gauges must never be used as thread chasers. Wirebrush dirty or rusty cartridge threads before checking with gaugeA thin dressing of light machine oil will extend the life of a gaugeAll gauges shall be calibrated a minimum of once per year.

1. Cylindrical plug gauge 3/4-16N-1, No Go 0.6930. This gaugeis used for checking the minor diameter of the internal threadsin the cartridge and is marked: Cart. Wear No Go Minor D0.6930 in. This gauge should not enter into the threaded holemore 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 anddiscarded.

The reason for this is that if the minor diameter is too large, aseal could relieve when the cartridge is being filled or testedin the water bath.

2. Double end thread plug gauge 3/4-16-N-1 marked: Go P.D0.7094 in. on one end and No Go P.D. 0.7139 in. on theother end.

The Go thread plug member is applied to the cartridge bythreading it into the 3/4 in. threaded hole and should turn in althe way until the end strikes against the seat of the cartridgeIf the Go member does not enter all the way into the seat ofthe cartridge, the hole must be tapped out with the correct sizetap which can be furnished by ANSUL. (After tapping thethreads, the cartridge must be checked again with bothgauges as specified, and any metal filings from retappingshould be cleared out of cartridge interior.)

The No Go thread plug member is applied to the cartridgein the same manner as the Go member. However, this NoGo member must not turn into the cartridge more than 1 1/2turns. If the No Go member enters the cartridge more than1 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. Theminor diameter gauge checks only the minor diameter of the3/4 in. threads; the thread plug gauge checks the pitch diam-eter of the 3/4 in. threads. For example, a cartridge may be areject in the application of the minor diameter gauge and beacceptable in application of the thread gauge or vice versa. Ineither case, the cartridge should not be used.

SECTION 5 PRE-FILLING INSPECTION PROCEDURES

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PRE-FILLING INSPECTION PROCEDURES (Continued)

Using Cartridge Gauges (Continued)

3. Thread ring gauge 1.0610-20-NS-LEFT HANDGo marked:Cart. Wear Go. P.D. 1.0285 in. This Go thread ring gaugeis applied to the cartridge by threading it onto the outside

threads of the cartridge. It should go down all the way until theside of the gauge comes in contact with the shoulder belowthe threads. If the Go gauge does not thread all the waydown, the threads must be chased with a die which can befurnished by Tyco Fire Protection Products. (After chasingwith a die, the threads must again be checked with the threadring gauges as specified.)

4. Thread ring gauge 1.0610-20-NS LEFT HAND No Gomarked: Special Cart. Wear No Go P.D. 1.0180 in. The NoGo thread ring gauge is to be applied in the same manner asthe Go thread ring gauge, however, this No Go gaugemust not turn on the cartridge threads more than 1 1/2 turns.If it goes on more than specified, the cartridge must becondemned and discarded.

5. The major diameter of the external cartridge thread should bechecked with a micrometer to 1.0538 minimum.

SECTION 5 PRE-FILLING INSPECTION PROCEDURES

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FILLING CARBON DIOXIDE CARTRIDGES

Equipment Setup

1. Attach filling unit to bench and connect to either the gravityflow or siphon tube type supply of carbon dioxide (CO2). (SeeFigures 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 mustalso be fastened securely in this position. The siphon tubetype of CO2 cylinder would be more convenient, if available.This type of cylinder should be fastened securely to the benchor 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 of10 lb (4.5 kg) capacity, shall be used.

FIGURE 1007305

FIGURE 2007306


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REV. 2

WARNING!

See safety instructions in Section 2 before proceeding. To

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

45

GRAVITYFLOWCYLINDER

SIPHONTUBE TYPECO2CYLINDER

CO2CYLINDERVALVE

GAS CONTROLVALVE

GAS CONTROLVALVE

GAS RELEASEVALVE

GAS RELEASEVALVE

VENT TOUNOCCUPIED AREA

VENT TOUNOCCUPIEDAREA

CO2 CYLINDERVALVE


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FILLING CARBON DIOXIDE CARTRIDGES (Continued)

Cartridge Refill Procedure

NOTICEProcedures apply to left-handed CO2 cartridgethreads. For right-handed cartridges, simplyreverse thread direction instructions.

1. Remove shipping cap.

2. If seal is not punctured, place cartridge in cartridge receiver ofbleed off assembly and bleed off pressure. (See Figure 3.) Ifseal is already punctured, proceed to Step 3.

FIGURE 3007307

3. Place and secure cartridge to be recharged in acartridge/cylinder vise of appropriate size for cartridge to berecharged. Refer to CO2 Cartridge Specification Table locatedin reference material. (See Figure 4.)

4. Remove punctured seal from the cartridge using splinewrench. (See Figure 4.)

FIGURE 4007308

5. Before inserting new seal, all cartridges must be inspected asdetailed in Section 3.

6. Thread new seal into the cartridge snugly, but do not tighten

7. Check the weight of the empty cartridge. This is a doublecheck against the possibility of some foreign material being

lodged in the cartridge. The check is made by subtracting theminimum fill weight indicated in the Cartridge SpecificationTable in the Reference Section for the cartridge being filledfrom the weight stamped on the cartridge. If weight ofcartridge varies more than 1/8 ounce (3.54 g) from stampedweight, recheck for foreign material in cartridge. Reweigh andreject all cartridges which exceed 1/8 ounce (3.54 g) tolerance(actual or stamped weight).

8. It is advisable to pre-cool the cartridges in a freezer beforeattempting to fill them with CO2. They will fill faster than whenthey are at room temperature.

9. With completion of the previous steps, proceed to fill the CO2cartridge by completing the following procedures and referringto Figures 1 and 2:

a. Make sure gas release, gas control and CO2 cylindevalves are closed.

b. Insert the cartridge into the filling unit by inserting thespline shaft down as far as the handle or handwheel willallow it to go, turning the handle clockwise and pushingdown at the same time. This will allow the spline end of theshaft to project about 1 in. (25 mm) from the filling unit. Fitthe cartridge into the unit by guiding it with one hand, whileat the same time turning the handle clockwise with theother hand (left-hand threads on cartridge and filling unit)(See Figure 5.) Take extreme care not to get the threadsof the cartridge crossed into the filling unit. Tightencartridge snugly into place with the aid of the strapwrenchDO NOT FORCE A TIGHT FIT.

FIGURE 5007309

c. Back the seal from the cartridge seat by turning the handlecounterclockwise one half to one full turn.

d. Slowly open CO2 cylinder valve wide open. Open gascontrol valve at least one full turn for approximately fiveseconds when filling ANSUL 20 lb cartridges, ten secondsfor the ANSUL 30 lb cartridges, and three to five secondsfor the 5 lb and 10 lb cartridges. This time will vary depend-ing on the temperature of the cartridges and the 50 lb (22.7kg) CO2 cylinder.


4-15-11 Page 6-2

CARTRIDGEBLEED OFFASSEMBLY

CHECKVALVES


SCHEDULE 40PIPING

CARTRIDGEVISE

SHOWN: PART NO. 4476,CARTRIDGE VISE ASSEMBLY,MAX. 2 IN. (5.1 cm) DIAMETER

SPLINEWRENCH

FILLERBLOCK

SPLINESHAFT

CARTRIDGERECEIVERS

(RIGHT ANDLEFT HAND)


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Cartridge Refill Procedure (Continued)

e. When the cartridge is filled with a sufficient quantity ofCO2, thread the seal down into the cartridge by turning thehandwheel clockwise until the seal fits snugly on the

cartridge seat. (See Figure 6.)

FIGURE 6007310

f. Close the gas control valve.

g. Open the gas release valve until all gas has escapedbetween the filling unit and control valve.

NOTICEVery often when charging the cartridge, therewill be leakage around the cartridge threads.Usually this is slight. Dont try to tighten thecartridge more than just snug. If a leakshould occur around the spline shaft packingnut, tighten packing nut. Each filler block ispacked around the spline shaft with a leatherlacing treated with Neatsfoot Oil. Periodically,

the packing nut should be removed and thespline shaft lubricated with this oil to easeturning of the handle.

10.

Remove cartridge from filling unit by first loosening thecartridge with a strap wrench by turning counterclockwiseapproximately 1/8 of a turn and then backing it out completelyby turning the handwheel counterclockwise. (See Figure 7.)Always keep one hand on the cartridge while backing it out sothat it does not fall.

FIGURE 7007311

11.

Weigh cartridge immediately after it has been removed fromfilling unit. It should weigh within 1/8 ounce (3.54 g) of itsstamped weight. If it weighs less, replace the cartridge in thefilling unit and add the necessary amount of CO2 to bring it upto the stamped weight. (It may be necessary to re-coocartridge to take additional gas.) If the cartridge is overweightplace the cartridge in the vise and retract the seal with thespline wrench just enough to allow the gas to escape slowlyand 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 weightstamped on the cartridge, it is good practice to try to hold theweight to the plus tolerance only. This is advisable because inthe final weighing prior to using, any cartridge which readsunder the minus 1/8 ounce (3.54 g) weight may be a possibleleaker. If weight loss is below stamped weight, but is notbelow minus 1/8 ounce (3.54 g), it is possible to retighten theseal and put the cartridge back into the hot water bath forfurther examination.)

12.

Replace the cartridge in the vise and tighten the seal firmly inplace. A tightening torque of 40 to 50 ft lb (54.2 to 67.8 Nm) isrequired for optimum sealing.

13. Immediately ensure filled cartridges have safety shippingcaps installed. (See Figure 8.) All refilled cartridges shalutilize only the following safety shipping caps: the left-handthreaded safety shipping caps are Part No. 77250 while theright-hand threaded safety shipping caps are Part No. 77251If an older style shipping cap is found, it should be replacedwith the appropriate shipping cap described above.

FIGURE 8007312


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WARNING!

Since the cartridge lacks a safety shipping cap at thistime, the cartridge could become a projectile.

WARNING!

Care must be taken not to tighten the seal excessively.Otherwise the seal will break or the threads will strip.

WARNING!

Each cartridge must be weighed immediately after fillingto assure that it has not been overfilled. If the cartridgehas 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 rocketand severe personal injury or property damage couldresult.

SEAT

SEAL

SAFETYSHIPPINGCAP


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14. When the CO2 supply cylinder becomes nearly empty, it willbecome quite difficult to charge the cartridge regardless ofhow cold it may be. Even though there will be a high gas pres-

sure, a cylinder is considered empty when all the liquid CO2has been used. One way to determine that a cylinder is emptyis to check for an absence of snow when the valve isopened. To get a better picture of this, as soon as a new cylin-der is hooked up, open the cylinder valve and the gas controlvalve allowing a small amount of gas to escape through thefilling unit (minus cartridge) into space. You will noticesnowflakes form about 412 in. (1030 cm) away from fillingunit. When the 50 lb (22.7 kg) cylinder is empty, try the samething. You will notice gas escaping, but no snow. Another wayof checking a CO2 cylinder is to weigh it before and after use.The filled weight is stamped on each cylinder.

NOTICEIf any cartridge continues to leak after fillinginstructions mentioned in this procedure arecorrectly followed, the empty cartridge shouldbe taken out of service and destroyed.


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FILLING NITROGEN CARTRIDGES SMALLER THAN 23 FT3

(0.7 m3)

Equipment Setup

1. Attach filling unit to bench and connect nitrogen supply. (SeeFigure 9.) If using cylinders, they must be fastened securely tothe bench or wall.

2. Attach cartridge vise to bench near filling unit.

3. A scale of balance or digital type construction (properlymounted) with 1/8 ounce (3.54 g) graduations capable of 10 lb(4.5 kg) capacity, shall be used.

FIGURE 9007313

SECTION 7 FILLING NITROGEN CARTRIDGES SMALLER THAN 23 FT3 (0.7 m3)

4-15-11 Page 7-1

REV. 2

CAUTION!

See safety instructions in Section 2 before proceeding. To

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

NITROGENCYLINDER

NITROGENCYLINDERVALVE

GAS CONTROLVALVE

GAS RELEASEVALVE



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(0.7 m3) (Continued)

Cartridge Refill Procedure

1. Remove shipping cap.

2. If seal is not punctured, place cartridge in cartridge receiver ofbleed off assembly and bleed off pressure. (See Figure 10.) Ifseal is already punctured, proceed to Step 3.

FIGURE 10007314

3. Place and secure cartridge to be recharged in acartridge/cylinder vise of appropriate size for cartridge to berecharged. Refer to Nitrogen Cartridge Specification Tablelocated in reference material. (See Figure 11.)

4. Remove punctured seal from the cartridge using splinewrench. (See Figure 11.)

FIGURE 11007315

5. Before inserting new seal, all cartridges must be inspected asdetailed in Section 3.

6. Thread new seal into the cartridge snugly, but do not tighten

7. Check the weight of the empty cartridge. This is a doublecheck against the possibility of some foreign material being

lodged in the cartridge. The check is made by subtracting theminimum fill weight indicated in the Cartridge SpecificationTable in Reference Section for the cartridge being filled fromthe weight stamped on the cartridge. If weight of cartridgevaries more than 1/8 ounce (3.54 g) from stamped weightrecheck for foreign material in cartridge. Reweigh and rejecall cartridges which exceed 1/8 ounce (3.54 g) tolerance(actual or stamped weight).

8. In order for the cartridge to readily accept the nitrogen chargerequired, it is recommended that the cartridge be placed in afreezer and cooled to approximately 0 F (18 C). This wilallow the cartridge to be filled faster and will result in fewerunderfilled cartridges.

9. With completion of the previous steps, proceed to fill the nitro-gen cartridge by completing the following procedures andrefer to Figure 9:

a. Make sure gas control, gas release and nitrogen cylindevalves are closed.

b. If neck ring spacers are needed, choose the appropriatesize as shown in Figure 12. Place the spacer over thecartridge threads and let it rest on the cartridge shoulder.

NECK LENGTH SPACER SIZE_____________ ____________

LESS THAN 1/8 IN. (3.2 mm) NO SPACER REQUIRED

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)

FIGURE 12007316


4-15-11 Page 7-2

CARTRIDGEBLEED OFFASSEMBLY

CHECK VALVES


SCHEDULE 40PIPING

CARTRIDGERECEIVERS(RIGHT ANDLEFT HAND)

CARTRIDGEVISE

SPLINEWRENCH

NECK LENGTH

(SEE TABLE)

SPACER

SHOWN: PART NO. 4476,CARTRIDGE VISE ASSEMBLY,MAX. 2 IN. (5.1 cm) DIAMETER


32/66


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35/66


(0.7 m3) (Continued)


11.

Weigh cartridge immediately after it has been removed fromfilling unit. It should weigh within 1/8 ounce (3.54 g) of itsstamped weight. If it weighs less, replace the cartridge in thefilling unit and add the necessary amount of N2 to bring it upto the stamped weight. (It may be necessary to re-coolcartridge to take additional gas.) If the cartridge is overweight,

place the cartridge in the vise and retract the seal with thespline wrench just enough to allow the gas to escape slowlyand then resnug. Reweigh the cartridge. Repeat this proce-dure until proper weight has been reached. (Although weallow a tolerance of 1/8 ounce (3.54 g) from the weightstamped on the cartridge, it is good practice to try to hold theweight to the plus tolerance only. This is advisable because inthe final weighing prior to using, any cartridge which readsunder the minus 1/8 ounce (3.54 g) weight may be a possibleleaker. If weight loss is below stamped weight, but is notbelow minus 1/8 ounce (3.54 g), it is possible to retighten theseal and put the cartridge back into the hot water bath forfurther examination.)

12.

Replace the cartridge in the vise and tighten the seal firmly inplace. A tightening torque of 40 to 50 ft lb (54.2 to 67.8 Nm) isrequired for optimum sealing.

13. Immediately ensure filled cartridges have safety shippingcaps installed. (See Figure 8.) All refilled cartridges shallutilize only the following safety shipping caps: the left-handthreaded safety shipping caps are Part No. 77250 while theright-hand threaded safety shipping caps are Part No. 77251.If an older style shipping cap is found, it should be replacedwith the appropriate shipping cap described above.


Nitrogen Supply Cylinder

The number of cartridges that can be charged from a nitrogensupply cylinder depends on methods used, if the cartridges arebeing cooled, how warm the cylinder is, and the amount ofleakage from the filling unit. For example, approximately 25 LT-20

cartridges can be filled from a 400 ft3

(11.3 m3

) cylinder. When thesupply cylinder pressure drops below 1800 psi (124.1 bar), it wilbecome quite difficult to charge the cartridge regardless of itstemperature. The nitrogen supply can be determined by the pressure reading indicated on the cylinder valve gauge or by weighingthe cylinder before and after use. Immediately ensure filledcartridges have safety shipping caps installed. Proceed to Section7, Leak Testing and Painting.


4-15-11 Page 7-4

WARNING!

Each cartridge must be weighed immediately after fillingto assure that it has not been overfilled. If the cartridgehas been overfilled, as it warms up, the internal pressurewill rise and could cause the cartridge seal disc to rupture.Lacking a safety shipping cap, the cartridge will rocketand severe personal injury or property damage couldresult.

WARNING


!


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


7. In order for the cartridge to readily accept the nitrogen chargerequired, it is recommended that the cartridge be placed in a

freezer and cooled to approximately 0 F (18 C). This willallow the cartridge to be filled faster and will result in fewerunderfilled cartridges.

8. With completion of the previous steps, proceed to fill the nitro-gen cartridge by completing the following procedures:

a. Make sure gas control, gas release and nitrogen pumpvalves are closed.

b. If neck ring spacers are needed, choose the appropriatesize as shown in Figure 18. Place the spacer over thecartridge threads and let it rest on the cartridge shoulder.

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)

GREATER THAN 1/4 IN. (6 mm) 1/4 IN. (6 mm)

FIGURE 18007316

c. Thread the filler block onto the valve, approximately twothreads down, ensuring that the spline wrench is seatedinside the cartridge seal. Hand tighten.

Note: Take extreme caution not to cross the threads of thefiller block.

d. Make sure vent valve on filler block is closed.

e. Attach the hose from the booster pump to the filler blockinlet.

FIGURE 19008680

f. Back the seal from the cartridge seat by turning the handlecounterclockwise one-half to one full turn.

g. Follow booster pump manufacturers documentation fohookup and filling procedures.

h. When the cartridge is filled with a sufficient quantity ofnitrogen, thread the seal down into the cartridge by turningthe handle clockwise until the seal fits snugly on thecartridge seat. (See Figure 20.)

FIGURE 20007318

i.

Replace the cartridge in the vise and tighten the seal firmlyin place. A tightening torque of 45 ft lb (61.0 Nm) isrequired for optimum sealing.

j. Close the gas control valve.

SECTION 8 FILLING 23/55 FT3 (0.7/1.6 m3) NITROGEN CARTRIDGES

4-15-11 Page 8-2

FILLERBLOCK

GAS CONTROLVALVE

GASRELEASEVALVE


SEAT

SEAL

NECK LENGTH(SEE TABLE)

SPACER

WARNING


!


40/66


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


k. Open the gas release valve until all gas escapes betweenfilling unit and control valve.

NOTICEVery often when charging the cartridge, therewill be leakage around the cartridge threads.Usually this is slight. Dont try to tighten thecartridge more than just snug. If a leakshould occur around the spline shaft packingnut, tighten packing nut. Each filler block ispacked around the spline shaft with a leatherlacing which is treated with Neatsfoot Oil.Periodically, the packing nut should beremoved and the spline shaft lubricated withthis oil to ease turning of the handle.

9.

Remove fill hose from filler block inlet. Remove filler blockfrom cylinder valve.

10. Immediately ensure filled cartridges have gauge guards andsafety shipping caps installed. (See Figure 21.) All refilledcartridges shall utilize only the following safety shipping caps:the threaded Cartridge Safety Shipping Cap (Left-hand, PartNo. 77250; Right-hand, Part No. 77251) and the CylinderShipping Cap (Part No. 73066). If an older style shipping capis found, it should be replaced with the appropriate shippingcap described above.


FIGURE 21008683

SECTION 8 FILLING 23/55 FT3 (0.7/1.6 m3) NITROGEN CARTRIDGES

4-15-11 Page 8-3

CAUTION!

Since the cartridge lacks a safety shipping cap at thistime, the cartridge could become a projectile.


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LEAK TESTING AND PAINTING

Leak Testing

1. The cartridge should be placed in a hot water bath for a periodof at least four hours under bubble covers.

Note: When leak testing 23/55 ft3 (0.7/1.6 m3) cartridges,make sure that the hot water bath can accommodate a heightof 28 in. (71.1 cm) for the 23 ft3 (0.7 m3) cartridge, and 27.9 in.(70.8 cm) for the 55 ft3 (1.6 m3) cartridge.

Make sure that the water temperature never drops below110 F (43 C) or goes over 120 F (49 C). If the seal has not

been tightened enough, bubbles will form immediately and willrise to the surface. If this happens, remove the cartridge fromthe bath, tighten the seal and re-weigh cartridge to ensureproper weight. Replace cartridge in water bath. After cartridgehas warmed up, cover cartridge with bubble cover for the leaktest. Submerge bubble cover in water. Do this in such amanner as to allow the air bubbles to escape from the cover.After the bubble cover has been filled with water, and whilestill submerged, invert it. Check the bottom of the bubblecover for air bubbles. If there are no air bubbles visible, raisebubble cover up and place it over the cartridge, alwayskeeping the bubble cover full of water as it is being moved intoposition. When the bubble cover is over the cartridge, againcheck to make sure that there are no bubbles in the cover. Ifa bubble does show up, remove the bubble cover and repeat

procedure. If the bubble appears in the bubble cover a secondtime, remove cartridge, tighten seal and repeat procedure. If abubble appears again, release the gas from the cartridge andcheck the condition of the cartridge seat. If the seat is in satis-factory condition, insert a new seal and recharge thecartridge.

2. Clean and dry the tested cartridges that did not show bubblesafter the four hour leakage test. Only cartridges with NObubbles have passed the test. If small bubbles appearedduring the four hour leak test, it does not necessarily indicateCO2 or N2 leakage. Along with air becoming trapped aroundthe 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.

Painting Cartridges Smaller Than 23 ft3 (0.7 m3)

Paint the cartridges with a good quality nongloss paint 1.5 2.0mils thick. Color is CCA-GE BEIGE CAMEL. Do not paint externathreads. (Stamped information on cartridge must be legible aftepainting.) Hang the cartridges up to dry using the cartridge caps

Insert wire under cap or into the gas escape holes and bend in theform of a hook. When the paint has dried, apply a thin coating ofliquid wax to the external threads. This will help guard againstrusting.

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

Paint the cartridges using a primer coat of epoxy primer (Part No21944), dry film thickness of a minimum of 1.0 mil. Let cartridgesdry for 30 minutes at 200 F (93 C). After drying, top the primecoat with epoxy polyester (Part No. 21917), dry film thickness of aminimum of 2.0 mils. Dry for 30 minutes at 225 F (107 C).Stamped information on cartridge must be legible after painting.

Note: If a cartridge needs to be re-painted, this should be doneprior to refilling.

Final Inspection and MarkingBefore shipping, recheck weight of cartridge. If cartridge weighs tostamped weight, identify cartridge size by marking on side withANSUL ink stamp. Stamp artwork can be obtained by contactingthe ANSUL Marketing Communications Department. If weight ocartridge is below weight allowed by filling tolerance, the cartridgemust be refilled. The weight stamped on a cartridge DOES NOTinclude shipping cap. Federal regulations prohibit shipment ocharged cartridges without a safety shipping cap.

SECTION 9 LEAK TESTING AND PAINTING

4-15-11 Page 9-1

WARNING!

Never work in a position above cartridges placed in the testbath. If a cartridge seal ruptures due to overfilling, it is usuallyduring the initial warm up period. If seal ruptures, cartridgecould become a projectile and cause serious personal injuryor damage.


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OUT-OF-SPEC CARTRIDGES

Problem Corrective-Action_______ ______________

Small 1-1/16 in. Condemn and discard per CGA P-2threads recommendation.

Large 1-1/16 in. Repair with thread chase or condemnthreads and discard per CGA P-2

recommendation.

Large 3/4 in. Condemn and discard per CGA P-2threads recommendation.

Small 3/4 in. Repair with tap or condemn and discardthreads 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-2recommendation.

Loose hex nut Condemn and discard per CGA P-2recommendation.

Short threads Condemn and discard per CGA P-2(less than 4 full recommendation.threads)

Large minor Condemn and discard per CGA P-2diameter on recommendation.3/4 in. threads

Fire burned Condemn and discard per CGA P-2

cartridges recommendation.

SECTION 10 OUT-OF-SPEC CARTRIDGES

4-15-11 Page 10-1

WARNING!

Be sure cartridges are empty before destroying.


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SECTION 11 APPENDIX

4-15-11 Page 11-2

CARTRIDGESPECIFICATION

TABLE

NITROGEN

EXPELLANT

REFILL

O.D.

DIMENSION

DIMENSION

SHIP.

SEAL

THREAD

I.D.

VOL.H2O

WEIGHTOFCHARGE

D

.O.T.

A

B

ASSY.

ASSY.

MODEL

11/16-20

THREAD

GMS.70F

O

Z.

(g)

S

PEC.

IN.

(cm)

IN.

(cm

)

STAMP

7013

53819

LT-5-L

L.H.

3/4-16

179to200

2

3/3231/32

(20.427.5)

3E

-1800

2

(5.1)

6

(15

.2)

6957

6979

53819

LT-5-R

R.H.

3/4-16

179to200

2

3/3231/32

(20.427.5)

3E

-1800

2

(5.1)

6

(15

.2)

6915

13193

53803

LT-10-R

R.H.

3/4-20

230to245

1

1/813/8

(31.939.1)

3E

-1800

2

(5.1)

613/16

(17

.3)

13008

13177

53819

LT-10-L

L.H.

3/4-16

230to245

1

1/813/8

(31.939.1)

3E

-1800

2

(5.1)

613/16

(17

.3)

13162

7032

53803

LT-20-R

R.H.

3/4-20

427to443

2

3/1627/16

(62.169.3)

3A

-2100

21/2

(6.4)

77/8

(20

.0)

7072

7012

53803

LT-20-L

L.H.

3/4-20

427to443

2

3/1627/16

(62.169.3)

3A

-2100

21/2

(6.4)

77/8

(20

.0)

7028

5373

53803

LT-30-R

R.H.

3/4-20

682to700

3

7/16313/16

(97.7108.5)

3A

-2100

21/2

(6.4)

115/8

(29

.5)

4894

6641

53803

LT-30-L

L.H.

3/4-20

682to700

3

7/16313/16

(97.7108.5)

3A

-2100

21/2

(6.4)

115/8

(29

.5)

6698

29187

53821

LT-A-101-30

R.H.

3/4-20

1802to1835

1

53/4161/4

(447.3461.5)

3AA-1800

39/16

(9.1)

145/8

(37

.1)

29250

73022

53803

R-102DOUBLE

R.H.

3/4-20

15131690

9

1/493/4

(262.7276.9)

3AA-2100

43/16

(10.6)

101/4

(26

.0)

57392

428060

53803

LT-A-101-125

3/4-20

4632-5047

S

eegaugeonvalveandreference

3AA-2015

28

(71.2)

41/4

(10

.8)

T

emperatureCorrectionChart

428061

53803

LT-A-101-250

3/4-20

10897

S

eegaugeonvalveandreference

3AA-2015

277/8

(70.8)

63/4

(17

.1)

T

emperatureCorrectionChart


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SECTION 11 APPENDIX

4-15-11 Page 11-3

CYLINDER FILL CHART NITROGEN 23 FT3 (MEDICAL E) CYLINDER

CYLINDERPRESSURE

psi (bar)2000 (137.9)

1900 (131.0)

1800 (124.1)

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

CYLIN

DERFIL

LPRE

SSUR

E

CYLINDER FILL CHART NITROGEN 55 FT3 (MEDICAL E) CYLINDER

CYLINDERPRESSURE

psi (bar)

2300 (158.6)

2200 (151.7)

2100 (144.8)

2000 (137.9)

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

CYLIN

DERFIL

LPRE

SSUR

E

TEMPERATURE CORRECTION CHARTS


52/66


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SECTION 11 APPENDIX

4-15-11 Page 11-4

008693


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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 grams3/8 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 grams5 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

13 oz = 368.55 grams

14 oz = 396.89 grams

15 oz = 425.25 grams

16 oz = 453.59 grams17 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 grams28 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 11 APPENDIX

4-15-11 Page 11-5


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REFERENCES

1. ANSUL Technical Bulletin No. 31, Form No. F-80261, CarbonDioxide Cartridges

2. ANSUL Technical Bulletin No. 34, Form No. F-80195, Useand Refilling of ANSUL Gas Cartridges

3. ANSUL Technical Bulletin No. 50, Form No. F-81301,Hydrostatic Retest Requirements for ANSUL Hand Portableand Wheeled Fire Extinguishers

SECTION 12 REFERENCES

4-15-11 Page 12-1


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Technical BulletinNumber 31

Carbon Dioxide Cartridges ForHand Portable Fire Extinguishers

Each Ansul hand portable cartridge-operated fire extinguisher is provided with a small cartridge of compressedgas 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 Transportationregulations. 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 therequirements 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) (seechart). 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 betweencharged pressure (850 psi at 70 F) (5861 kPa at 21 C) and minimum rupture pressure (6000 psi) (41370 kPa)is created (see chart).

ANSUL

ANSUL INCORPORATEDMARINETTE, WI 54143-2542

DISC AND CYLINDERSAFETY MARGIN(MINIMUM 3200 psi(22064 kPa))

002221

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

MAXIMUM RUPTURE PRESSURE OFFRANGIBLE DISC(4500 psi (31028 kPa))

MINIMUM RUPTUREPRESSURE OFFRANGIBLE DISC (4050 psi(27925 kPa))

FRANGIBLE DISC RUPTURERANGE (450 psi (3103 kPa))

CYLINDER SAFETY MARGIN(MINIMUM 1500 psi(10343 kPa))

CARTRIDGE CYLINDERRUPTURE PRESSURE(MINIMUM 6000 psi(41370 kPa))

PRESSURE(POUNDS PER SQ. IN.)

(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 CartridgesFor 4, 5, 10, 20, and 30 lb. Capacity Ansul Fire Extinguishers

6000

5000

4000

3000

2000

1000


60/66

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 and31028 kPa) according to D.O.T. requirements. This creates an additional safety factor of at least 1500 psi (10343kPa) between disc rupture pressure (4050 to 4500 psi) (27925 to 31028 kPa) and minimum cylinder rupturepressure (6000 psi) (41370 kPa) (see chart).

Specially designed safety shipping caps should always be utilized on the cartridges whenever they are notinstalled onto a system or extinguisher. These safety shipping caps protect the threads and seal surfaces whileensuring safe pressure venting of the cartridge should it be exposed to excessive temperatures.

Filling and PressuresThe 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 psiat 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 willdetect a leak rate of 1/4 oz. in 127 years. The temperature in the water bath is also high enough to rupture thesafety disc in an over-filled cartridge. A final weighing ensures against shipping of overfilled or empty cartridges.

Ansuls Quality

By insisting on the highest manufacturing standards and quality testing procedures, Ansul assures that all itsextinguisher cartridges are accurately filled, safe and reliable. Non-Ansul cartridges should never be used inAnsul 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.


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Use And Refilling Of Ansul Gas Cartridges

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 bythe manufacturer shall not be used in dry chemical extinguishers. This, of course, means that a manufacturerscartridge refilled by anyone not authorized to do so by the manufacturer of the original equipment would not beacceptable.

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 wornthreads not being junked

B. Damaged threads not being repaired

C. Depth and condition of cartridge seal seat not checkedD. 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 subjectto 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 fillingwill 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

ANSUL

ANSUL INCORPORATEDMARINETTE, WI 54143-2542


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Hydrostatic Retest Requirements for ANSULPortables, 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 ensuretheir safety. In addition, the laws require hydrostatic retesting of vessels which show evidence of corrosion ormechanical injury.

The purpose of this bulletin is to 1) indicate what Tyco Fire Suppression & Building Products understands to bethe legal requirements, and 2) provide guidance for the user in determining recommended retest practices andprocedures for such vessels.

We have prepared a chart, designed to show what we understand to be the current legal requirements forperiodic retest, indicating both test intervals and pressures. These requirements are shown for the two principalauthorities having jurisdiction over this type of product, the National Fire Protection Association (NFPA); and theCodes of Federal Regulations, (D.O.T., M.S.H.A., and O.S.H.A.). It is important to understand the jurisdiction ofthese two authorities and how it may effect the product in question. You may wish to refer directly to theseprincipal 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 isempowered by statute to enforce regulations. However, as consensus standards developed by teams ofrecognized experts, they represent sound fire safety principles, practices and procedures, and we recommendthat they be observed in the case of hydrostatic retesting. Moreover, some states and municipalities haveadopted NFPA standards as a part of their fire protection codes, including those parts dealing with themaintenance and hydrostatic retesting of extinguishers.

OSHA has safety jurisdiction over most workplaces in the U.S., and as such its regulations have the force offederal law. OSHA has not adopted NFPA standards for hydrotesting per se, but its requirements follow NFPAstandards closely.

D.O.T.s hydrostatic retest requirements apply only to charged pressure vessels which are transported incommerce 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 hydrostaticretesting of some vessels, which may be due to an oversight or other reason. However, appropriate retestintervals and test pressures have been determined for such vessels through the NFPA Committee process and/orTyco Fire Suppression & Building Products own research and experience. In many cases, compliance to theNFPA 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 pressurevessels addressed by this Bulletin.

Hydrostatic testing should only be performed by trained, qualified persons with suitable testing equipment andfacilities. For additional guidance you are referred to CFR-49, CFR-29, NFPA-10, the current ANSUL manualHydrostatic 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 HighwayArlington, VA 22202


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N.F.P.A. CODE OF

STD. RETEST TEST REF. RETESTPRESSURE VESSEL NO. PERIOD PRESSURE NO.* PERIOD

ANSUL Stored Pressure Dry Chemical, 10 12 years Factory test pressure (not to exceed 1 12 yearsFE-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 yearsChemical 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 yearsExtinguishers (aluminum and steel (See note) stamped into the cylinderAgent 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/AOperated and Wheeled Extinguishers and pressure as shown onSpill Control Application (Agent Tanks) the nameplate or shell

ANSUL Model 33-D AFFF 10 5 years Unspecified N/A N/AWheeled Extinguishers(Agent Tank)

ANSUL Halon 1211 Wheeled 10 Per D.O.T. Factory test pressure (not to exceed 3, 6 7 or 12 yearsExtinguishers 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 10and 30 Models None Required 1, 4 None RequiredN2 Cartridges for 5 and 10 LowTemperature Extinguisher Models

N2 Cartridges for 20 and 30 10 Per D.O.T. or C.T.C. markings 2, 5 Per stamped mar

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 yearsANSUL Wheeled Extinguishers stamped into the cylinder

Pre-Engineered 101 Agent Tanks 17 12 years Original factory test pressure N/A N/Aas 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 yearsTanks (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 yearsD.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 yearsExcept LT-5, LT-10 and 101-10 17A

Pre-engineered System Cartridges 17/ None Required 1 None RequiredLT-5, LT-10 and 101-10 17A Per D.O.T. 3E Stamp D.O.T. 3E Tank

PERIODIC HYDROSTATIC RETEST REQUIREMENTS FOR PRESSURE VESSELS IN AN

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.


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FEDERAL REGULATIONS TYCO RECOMMENDS

TEST RETEST TESTPRESSURE PERIOD PRESSURE NOTES

Factory test pressure (not to exceed 12 years 600 PSI (41.4 bar) Agent hose assemblies with a shut-off nozzle2X the service pressure) must be tested @ 300 psi (20.7 bar).

Factory test pressure (not to exceed 5 years 200 PSI (13.8 bar) Exception: Does not apply to ANSUL ENSIGN2X the service pressure) Model WF-2 1/2 fiberglass extinguishers which

were recalled in 1973. Under no circumstancesare these units to be hydrostatically tested orrecharged.

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 toa hydrostatic retest.

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

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

2X service pressure 7 or 12 years 480 PSI (33.1 bar) Agent hose assemblies must be tested at sameintervals @ 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 sameintervals @ 300 PSI (20.7 bar), or at servicepressure, 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 inch2X 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 PSI2X 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 inch2X 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 andK-101-10 exempt because of size and stamp.

ORTABLES, WHEELED UNITS, AND PRE-ENGINEERED VESSELS

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.


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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 thatspecifies 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 hydrostaticpressure 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 periodmay 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 fromhydrostatic 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 pointedstar 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 thefirst retest performed 12 years after the original test date, and at 7-year intervals thereafter. If the water jacket methodis 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 metalPart 57 Underground Metal/Non MetalPart 75 Underground CoalPart 77 Surface Coal

CFR-49 Part 173.309 Fire Extinguishers

f-8986 ansul cartridge

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