SPILL-X CARTRIDGE-OPERATED SPILL
CONTROL APPLICATOR MODEL 30
®
Operation, Recharge, Inspection and Maintenance Manual
This manual is intended for use with the ANSUL® SPILL-GUN®
Model SC-30 hand portable spill control applicator.
Those who operate, recharge, inspect or maintain the spill
control applicator should read this entire manual. Specific
sections will be of particular interest depending upon one’s
responsibilities.
The spill control applicator is a mechanical device. It requires
periodic care. Maintenance should be conducted at six-month
intervals to provide maximum assurance that the applicator will
operate effectively and safely. Inspection should be conducted
at more frequent intervals to provide reasonable assurance
that the spill control applicator is charged and operable.
!
CAUTION
The spill control applicator is not a fire extinguisher and must not
be used for that purpose. To avoid the risk of personal injury, the
applicator must be used only for the purpose of controlling spills
and with the spill control agent indicated on the applicator label.
ANSUL, SPILL-X, SPILL-GUN, SPILL-X-A, SPILL-X-C, and SPILL-X-S are trademarks of
Tyco International Ltd. or its affiliates.
TABLE OF CONTENTS
PAGE
Introduction
Operation
1
Recharge
2–4
Inspection
5–6
Maintenance
Vehicle Bracket
7–11
12
Heavy Duty/Vehicle Bracket
Introduction
Capabilities and Limitations
Installation
Mounting Location
Inspection
Maintenance
Adjustment
12 – 15
12
13
14
14
14
14
15
Service and Repair
16 – 17
INTRODUCTION
FOREWORD
The ANSUL Model 30 spill control applicator is similar in construction to a portable fire extinguisher; therefore, for further details for
conducting required inspections, proper maintenance operations
and required tests, see NFPA Pamphlet No. 10 – Chapter 4,
‘‘Portable Fire Extinguishers.’’ This pamphlet is available from
National Fire Protection Association, One Batterymarch Park,
Quincy, Massachusetts, U.S.A. 02169-7471.
RESPONSIBILITY
The owner or occupant of a property in which spill control applicators are located has an obligation for the care and use of these
applicators at all times. By doing so, they are contributing to the
protection of life and property. The nameplates and instruction
manual should be read and thoroughly understood by all persons
who may be expected to use spill control applicators.
RECHARGE
All spill control applicators shall be recharged immediately after
any use. They shall also be recharged when dictated by an
inspection or when performing maintenance. Recharge is the
replacement or replenishment of the spill control agent; it also
includes the replenishment of the expellant.
!
CAUTION
When performing recharge, use only those materials specified
on the nameplate. The use of other recharging materials may
cause a chemical reaction that could impair the efficiency,
cause malfunction or result in rupture of the applicator causing
possible personal injury.
• Repairs MAY NOT BE MADE TO THE SHELL ITSELF. Thus, if
the mild steel shell is damaged as by tearing of the parent metal
from the shell, the applicator must be discarded.
• After completion of repairs, the applicator shall be hydrostatically tested in accordance with the ANSUL Hydrostatic Test
Instruction Manual (Form No. F-7602).
HYDROTEST
Spill control applicators shall be hydrostatically tested at regular
intervals of at least 12 years as required in the NFPA Pamphlet 10
– ‘‘Portable Fire Extinguishers,’’ or more frequently when inspection or maintenance indicates a specific need. Such tests are
usually required on applicator shells, cylinders, some cartridges,
and certain hose assemblies.
IF AT ANY TIME, AN APPLICATOR SHOWS EVIDENCE OF
CORROSION OR MECHANICAL DAMAGE, IT SHALL BE
SUBJECTED TO A HYDROSTATIC PRESSURE TEST, OR
REPLACED.
!
WARNING
AIR OR GAS SHOULD NOT BE USED FOR PRESSURE
TESTING AS FAILURE OF THE SHELL COULD BE VIOLENT
AND DANGEROUS RESULTING IN POSSIBLE PERSONAL
INJURY.
THE APPLICATOR SHALL BE EMPTIED AND HYDROSTATICALLY TESTED AT TWELVE-YEAR INTERVALS. The first
retest may be conducted within twelve months of the specified
interval.
RECORD KEEPING
INSPECTION
Inspection is a ‘‘quick check’’ that a spill control applicator is available and will operate. It is intended to give reasonable assurance
that the applicator is fully charged and operable. This is done by
seeing that the applicator is in its designated place, that it has not
been actuated or tampered with, and that there is no obvious
physical damage or condition to prevent operation. The value of
an inspection lies in the frequency, regularity and thoroughness
with which it is conducted. Applicators shall be inspected at
regular monthly intervals, or at more frequent intervals when
circumstances require.
MAINTENANCE
Spill control applicators shall be maintained at regular intervals,
not more than one year apart, or when specifically indicated by an
inspection. Maintenance is a ‘‘thorough check’’ of the applicator. It
is intended to give maximum assurance that an applicator will
operate effectively and safely. It includes a thorough examination
and any necessary repair, recharging, or replacement. It will
normally reveal the need for hydrostatic testing of an applicator.
WELDING/BRAZING
Field repair of ANSUL spill control applicators is allowed only if the
repairs are made in accordance with good brazing practices and
the following restrictions:
• Repairs shall be made by means of silver brazing only.
• Silver brazing is restricted to the carrying handle lug, nozzle
holster nuts, hanger attachment, and the visual seal attachment.
Each applicator shall have a tag or label securely attached that
indicates the month and year the maintenance was performed and
shall identify the person performing the service. The same record
or tag shall indicate if recharging was also performed. At least
monthly, the date the inspection was performed and initials of the
person performing the inspection shall be recorded.
A separate label shall also be affixed to the applicator following a
successful hydrostatic test. This label shall include the month and
year the test was performed, the test pressure used, and the
name or initials of the person performing the test. This label shall
be self-destructive when removal from the applicator is attempted.
In addition to the required tags or labels, a permanent file record
should be kept for each applicator. This file record should include
the maintenance date and the name of the person performing the
maintenance, the date when last recharged and the name of the
person or agency performing the hydrostatic test, and a description of the applicator’s physical condition after passing a hydrostatic test.
Parts of above were taken from NFPA Pamphlet 10.
PARTS LISTS
To order parts lists, contact Marketing Services, Ansul Fire
Protection, Marinette, WI 54143-2542.
OPERATION
To Operate
1. Remove the applicator from its station.
2. Use the handle to carry the applicator to the spill. Walk at a
rapid pace. DO NOT RUN.
3. Proceed to the upwind side of the spill to lessen exposure to
vapors of material spilled. Stay well clear of any vapors and/or
aerosols from the spill. When you are approximately 10 ft (3 m)
upwind of the near edge, stop, remove the nozzle from its
holder and pull the hose free from behind the puncture lever.
Then take a firm grip on the nozzle and ‘‘push’’ the puncture
lever down firmly. The puncture lever must be depressed to
become almost flush with the top of the cartridge guard to
assure full penetration of the cartridge disc by the puncture pin.
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4. Position yourself within 6 ft (1.8 m) of the near edge upwind of
the spill. From this position, the air currents help carry the agent
onto the spill, assure maximum visibility and provide protection
from the vapors and/or aerosols.
5. Then, squeeze the nozzle handle to achieve the desired range,
aim your stream just short of the near edge and direct the
stream around the perimeter to dike the liquid. Then apply
inward to completely adsorb the spill. Take care to avoid
splashing.
6. Advance cautiously and blanket the spill area.
!
CAUTION
Avoid all direct physical contact with chemicals treated with
SPILL-X-A® agent since chemical or thermal burns may
result. If adequate ventilation does not exist, wear breathing apparatus to avoid inhalation of fumes from the chemical treated. Follow each of the treatment procedures listed
below in sequential order. Failure to comply with these
warnings may result in personal injury.
7. Stop short of the already adsorbed spill area. DO NOT STEP
INTO SPILL. Cease discharge of unit. Standby for five minutes
and examine the spill area for any remaining pools of liquid.
8. Direct the nozzle at the liquid pools; using short bursts, assure
that these pools are covered. Discharge additional agent as
required.
9. For spills involving acids or caustics, after steaming and foamings of the chemical and SPILL-X agent has subsided, mix
thoroughly with a shovel or other implement in order to assure
there are no pockets of untreated chemical; then allow 15
minutes for the treated chemical to cool. Check pH value for
neutralization by an appropriate method or ANSUL pH test kit
(Part No. 76393).
Spills involving organic solvents or fuels that are treated
with SPILL-X-S® agent may be flammable. To avoid risk
of personal injury or property damage from fire, take care
that the treated chemical is not exposed to flame or materials that may generate sparks. Do not use metal equipment. Use only spark resistant plastic or wooden
equipment when handling the treated chemical.
!
CAUTION
Improper handling of treated material could result in burns
or other personal injury. See Spill Treatment Guide (Part
No. 78908) for further information.
1
RECHARGE
To return the applicator to service after use:
1. Invert the applicator and open the nozzle to clear spill
control agent from the hose and to relieve all pressure
remaining in the shell.
2. Return the applicator to the upright position, place the
hose in its normal position and insert the nozzle in the
holder.
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8
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3. Remove the fill cap slowly and deliberately. If there is any
residual pressure in the shell, it will be relieved through the
pressure relief vent hole in the top collar while 3 1/2
threads are still engaged.
4. Place the funnel (Part No. 699) in the fill opening and
charge the applicator to the rated capacity with only the
type of spill control agent specified on the nameplate.
!
CAUTION
Placing a spill control agent, other than the one specified, into the applicator could cause a chemical reaction resulting in possible personal injury due to rupture,
malfunction or impaired efficiency of the applicator.
5. Clean the fill opening threads and the gasket seating
surface of the shell. If pressure vents are cut in the
threads, be sure they are clean and unobstructed.
DO NOT REPLACE FILL CAP AT THIS TIME.
6. Instead, remove the gaskets (one is a quad ring) from the
fill cap, stretch to examine them for elasticity – do not rely
on a visual determination of condition.
7. Remove all surface deposits from the gaskets using a
clean, dry rag and lubricate them with a good grade of
grease capable of withstanding both low and high temperature without a change in consistency. Spread the grease
by hand to effect a light coating of all surfaces.
8. Clean the threads and gasket seating surface on the cap
with a stiff bristle brush before returning the gaskets to the
cap. If pressure vents are cut in the threads, be sure they
are clean and unobstructed.
2
RECHARGE
9. Reset the visual indicator by pulling down the red stem;
then return the fill cap to the shell and hand tighten.
10. Remove the cartridge guard and spent cartridge (cartridge
has a right-hand thread).
!
CAUTION
Do not install cartridge at this time. Failure to comply
will result in applicator pressurization which could
result in personal injury.
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11.Operate the puncture lever to make sure the lever works
freely – a bent or dull puncture pin may hang up and not
puncture the cartridge seal disc cleanly.
12. Inspect the cartridge receiver to verify that the pressure
relief vent (indicated in the figure) is clear.
13. Remove the safety shipping cap from the replacement
cartridge assembly and weigh the cartridge using scale
(Part No. 3923). If weight is 1/2 oz. (14.2 g) less than
weight stamped on the cartridge, replace with a fully
charged nitrogen cartridge (Part No. 4893).
14. Make certain puncture pin is fully retracted to assure safe
cartridge installation. Screw the full cartridge into the
receiver, hand tighten.
15. Replace the cartridge guard, making sure the guide fork
inside the guard fits into the recessed groove in the
cartridge receiver body.
16. Attach visual inspection seal (Part No. 15999), through the
puncture lever, over the hose, under the hose confiner
attachment and back around to the lock device.
3
RECHARGE
17. Remove all spill control agent and foreign deposits from
the shell and other components – a clean applicator is a
visual indication of a properly serviced applicator even to
the eye of a casual observer.
18. Record the date of recharge on the tag affixed or attached
to the applicator and in your permanent file record in
accordance with company, local, state or federal codes,
regulations or standards.
17
4
003187
18
003188
INSPECTION
To provide reasonable assurance that spill control applicator is charged and operable:
NOTICE
Inspection is a ‘‘quick check’’ that an applicator is available and will operate. It is intended
to give reasonable assurance that the applicator is fully charged and operable. Where an
inspection reveals that tampering has
occurred or that the applicator is damaged,
impaired, leaking or has obvious corrosion,
complete maintenance as described on Pages
7 through 11 must be performed.
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1. Make certain the applicator is in its designated place, is
clearly visible and is accessible for immediate use in the
event of a spill. Any obstructions that obscure it, or that
would otherwise impair its being readily accessible, should
be removed or the unit moved to a visible and accessible
location.
2. Check the visual inspection seal on the cartridge receiver.
The absence of a seal or a broken seal may indicate either
unreported use or tampering. In either case, a complete
maintenance check is required.
3. Check the red indicator stem in the fill cap. If up, a
complete maintenance check is in order as the applicator
may have been pressurized.
4. Remove the applicator from its mounting bracket and heft
(lift up and down slightly) to determine if it is filled. If in
doubt after hefting, remove the fill cap to make absolutely
certain the shell is filled to rated capacity.
5. Examine the applicator shell, cartridge guard, cartridge
receiver and all other external parts for evidence of physical damage, corrosion or other impairments.
6. Check the nameplate for readability – especially the operating instructions. If they are not legible, an instructed, but
not necessarily trained person may not understand the
method of operation in the excitement created by a spill.
5
INSPECTION
7. Examine the hose for cuts, severe weather checking,
abrasion, or deformed exterior. Depending upon the severity of the disorder, the hose could rupture upon pressurization of the applicator.
8. Check the hose couplings for tightness, corrosion or
cracks. A loose connection of coupling to shell outlet or
nozzle could contribute to a significant change in
discharge characteristics upon use. A corroded or cracked
coupling could separate under pressure.
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008272
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003200
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003199
9. Check the nozzle tip for obstructions. Insects are common
causes of nozzle obstruction – particularly in the warmer
climates.
10. Operate the nozzle handle to check for free movement. If
the handle is binding or immovable, replace the nozzle or
clean deposits from the internal passages and parts with a
small, stiff bristle brush.
11.Secure the nozzle in its holder.
12. Personnel making inspections are usually required to keep
records by way of marking a tag attached or affixed to the
applicator and/or in a permanent file. Your precise guide to
record keeping requirements should be the applicable
company, local, state or federal authority having jurisdiction.
13. If the applicator is wall hung, verify that the support is able
to hold the applicator safely. If a vehicle bracket or a heavy
duty vehicle bracket is used, refer to Pages 12 – 15.
6
MAINTENANCE
To provide maximum assurance that applicator will
operate effectively and safely:
NOTICE
Always be alert for any indications of damage or
inoperability in the unit. No manual can anticipate
everything that could happen to a unit. In the
event that something not covered in the manual is
found, ascertain whether any potential for damage
or effect on the operation of the applicator exists
and repair or replace, as necessary. For any
component disorders found during maintenance,
refer to Service and Repair section of this manual
for corrective action.
1. Make certain the applicator is in its designated place, is
clearly visible and is accessible for immediate use in the
event of a spill. If valuable time is wasted hunting for an
applicator or moving around obstructions in its normal path
of travel, move unit to a visible and accessible location.
2. Remove the applicator from its wall hanger or bracket and
check the securement of the hanger or bracket. See Page
14 for maintenance of the ANSUL heavy duty bracket. A
loose hanger or bracket could lead to loss of the applicator with resultant harm to the applicator and/or people in
the vicinity.
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3. Check the date of manufacture stamped on the shell or the
date of last hydrostatic test stamped on the tag attached or
label affixed to the applicator to make certain it does not
exceed the test interval (twelve years) specified. If it does,
reference Hydrostatic Test Instructions (Form No. F-7602).
4. Examine the agent shell and all other external components
for evidence of corrosion, mechanical damage, or the
presence of welding, soldering or brazing repairs other
than as allowed by ANSUL. (See Introduction Page of this
manual for welding/brazing restrictions.) Depending on the
degree of corrosion, extent of mechanical damage, or type
of repair, your applicator may constitute a potential hazard
to persons in its vicinity, to operators, or service personnel;
and may require replacement or hydrostatic test.
5. Check the nameplates for legibility or looseness. If the
wording is illegible, the nameplate must be cleaned or
replaced. A loose nameplate must be removed for examination of the area under the plate. If corroded, take appropriate corrective action as the surface condition would
indicate, meaning clean and repaint, hydrostatic test and
then re-affix the nameplate using a good grade of heatless
adhesive or replace applicator if necessary.
6. Remove the cartridge guard to effect examination of the
gas pressure cartridge. Then, before setting the guard off
to one side, check the integral inside components for
mechanical damage or evidence of corrosion.
7
MAINTENANCE
7. Unscrew the cartridge (cartridge has right-hand thread)
and examine seal to see that it has not been punctured. A
spent or used cartridge is readily identifiable from a full
cartridge by the large hole made by the puncture pin upon
operation of the applicator.
!
CAUTION
The cartridge is under high pressure. Take care to
avoid puncturing seal or cartridge may become a
projectile resulting in personal injury or property
damage. For safety, install shipping cap on cartridge
when not on applicator.
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8
.
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003203/003204
8. Weigh the cartridge with scale (Part No. 3923). If weight is
1/2 oz (14.2 g) less than weight stamped on cartridge,
replace with full nitrogen cartridge (Part No. 4893). Install
safety shipping cap (Part No. 77251) onto cartridge at this
time.
!
CAUTION
Cartridge safety shipping caps must always be
installed whenever cartridge is removed from receiver
(except while weighing). If shipping cap is not installed,
and seal ruptures due to damage or high temperature,
the cartridge could become a projectile causing possible personal injury or property damage.
9. Remove nozzle from its holder and lift hose out from
behind and under puncture lever.
10. Operate the puncture lever to make sure the lever works
freely – a bent or dull puncture pin may hang up and not
puncture the cartridge seal disc cleanly.
11. Check the pressure relief vent in the cartridge receiver for
obstruction. This relief vent may be a small hole in the
receiver collar, or a set of grooves in the threads. The pressure relief vent provides an audible signal and vent if a
cartridge is unscrewed while there is still pressure inside
the applicator. A stiff wire or a bristle brush may be used
for cleaning.
12. Remove and examine gasket in the cartridge receiver.
Replace if brittle, compression set, cracked, cut or
missing.
13. Carefully examine the hose assembly. A cut, cracked,
abraded or deformed exterior may constitute a potential
rupture upon pressurization and require replacement.
14. Check the hose couplings. Corroded or cracked couplings,
cross-threaded or worn threads dictate replacement
8
MAINTENANCE
15. Operate the nozzle handle to check for free movement. If
handle is binding or immovable, refer to ‘‘Nozzle(s)’’ in the
Service and Repair Section of this manual for corrective
action.
16. Unscrew the nozzle tip while squeezing the nozzle handle.
Remove any obstructions from nozzle tip and discharge
outlet.
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17. Inspect plunger tip inside nozzle body. If tip shows
evidence of cuts, abrasions, degraded rubber, brittleness,
or separation from plunger, refer to ‘‘Nozzle(s)’’ in the
Service and Repair section of this manual for corrective
action.
18. Squeeze nozzle handle and screw nozzle tip into nozzle
body.
19. To check the hose for internal blockage by blowing through
the hose by mouth…first invert the applicator and rest it on
the fill cap for several seconds.
20. Next, place the applicator horizontally on a solid surface
with the agent discharge outlet up and loosen the fill cap
approximately 3 1/2 turns.
21. Now wipe the nozzle tip clean to avoid undue exposure to
any contaminants generic to the area in which the applicator is located. Then, place your mouth on end of nozzle
in much the same manner as a musician would a trumpet,
squeeze the handle open and blow through nozzle, hose,
elbow and shell. Rap the applicator bottom lightly on
surface to free spill control agent from the elbow if an
audible escape of air or observable puff of agent is not
immediately evident at the fill cap.
22. If unable to clear passage, remove the hose and blow
through the nozzle. If the hose is obstructed, manipulate
(flex) hose manually until free of agent. Then make certain
the elbow is free of agent and return the hose to the elbow.
9
MAINTENANCE
23. Return the applicator to the upright position, remove the fill
cap, examine the top collar fill opening threads for nicks,
cross-threading, corrosion or wear and check the gasket
seating surface for nicks, gouges, corrosion or dirt
deposits. Then, check the pressure relief vent (a set of
grooves in the collar) for obstruction.
3 IN. – 6 IN.
(7.6 cm-15.2 cm)
24. Once the agent has settled, make certain the tank is filled
to rated capacity with free-flowing ANSUL spill control
agent of the type specified on the applicator nameplate.
!
CAUTION
Placing a spill control agent, other than the one specified, into the applicator could cause a chemical reaction resulting in possible personal injury due to rupture,
malfunction or impaired efficiency of the applicator.
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003179a/0003181
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003219
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003263
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003180
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003220
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003178
Check the spill control agent for caking. If caking is
present, refer to corrective action as outlined in the
Service and Repair section of this manual.
25. Do not replace the fill cap without benefit of thorough
examination. First, remove the flat gasket and quad ring
from the fill cap. Then thoroughly clean the fill cap threads
and gasket seating surface with a stiff, non-wire bristle
brush. Use of a wire brush could abraid the crown of the
threads which could result in leakage.
NOTICE
Since the fill cap has pressure relief vent grooves,
be sure they are unobstructed.
26. Next, examine the fill cap for abrasions, cracks or corrosion and the fill cap threads for nicks, burrs, cross-threading, rough or feathered edges. Grasp the indicator stem
and gently move the stem up and down to check for free
movement. If the stem will not move, the mechanism may
be damaged and the cap must be replaced.
27. Examine the fill cap gasket and quad ring for cuts, checks,
deformities and wear; then stretch them to determine elasticity. Do not rely on a visual determination of condition.
28. Clean the gasket and quad ring thoroughly with a clean,
dry rag. Do not return the gasket and quad ring to the fill
cap in a completely dry state. Instead, apply a coat of good
grade grease capable of withstanding low and high
temperature without a significant change in consistency.
Spread the grease lightly and evenly on the gasket
surfaces. A thin coating is all that is required to eliminate
seizing and stretching which could conceivably be experienced with a dry gasket.
29. Return the gasket and quad ring to fill cap, taking care not
to twist the quad ring as you return it to its recess in the
cap.
30. Do not return the fill cap to the applicator shell at this time.
Instead, use a stiff, non-wire bristle brush to clean spill
control agent from the threads or top collar gasket seating
surface of the shell.
10
MAINTENANCE
31. Secure the fill cap to the agent shell opening by hand tightening only. Over-tightening using a bar or similar leverage
may result in mechanical injury to the fill cap; especially to
the threads.
32. Lift the puncture lever, place the hose behind the lever and
secure the nozzle in the holder. With the puncture lever
fully retracted and the hose in place to prevent the lever
from being depressed, safe installation of the cartridge is
assured.
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33. Return the cartridge to the receiver (hand tight to assure
proper use of the cartridge receiver gasket) and carefully
engage the cartridge guard to align the guide fork with the
recess in the cartridge receiver body.
34. After cleaning the applicator to remove all agent traces
and foreign deposits, insert and secure visual inspection
seal (Part No. 15999) through puncture lever (over hose)
and hose confiner attachment on the shell.
35. The date (month and year) of the maintenance check and
the initials or special mark of the examiner should be
recorded on a tag which is tied or clipped to the applicator,
on a pressure-sensitive label affixed to the applicator, or
on a space provided on the permanent nameplate. The
date, year and initials should not be metal-stamped on the
shell. A permanent record should also be maintained for
each applicator. The maintenance check date and examiner’s name or initials should be recorded along with any
maintenance work or hydrostatic testing. This is especially
true where maintenance checking has revealed a need for
hydrostatic test.
11
VEHICLE BRACKET
If the applicator is secured by any type of bracket or hung by a
support, that bracket or support and the applicator hanging ring
must be maintained. Bracket inspection and maintenance
should be performed whenever the applicator is inspected
(monthly, or more often if conditions indicate the need).
1. Examine each vehicle unit for any looseness between
applicator and bracket.
2. The band clamp should shut tightly, compressing the band
grommet.
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3. Inspect the applicator and the bracket for wear caused by
movement of the applicator within the bracket.
4. Examine entire bracket closely for loose or worn hinges or
hinge-pins, bent or cracked bands, and worn or missing
grommets.
Avoid future damage by replacing or repairing all components
that are missing, worn or damaged.
For wall hung applicators, be certain that the hanging ring on
the applicator is still secure (free from rust or other damage).
HEAVY DUTY/VEHICLE BRACKET
Introduction
Vibration and Shock Loading Limits in G’s
The illustration at the right shows an ANSUL heavy
duty/vehicle bracket. The heavy duty construction of this
bracket makes it desirable wherever vibration or other abuse
might ruin other brackets. Typical applications include on and
off-road vehicles.
5 G’s
1G
1G
0032222
12
HEAVY DUTY/VEHICLE BRACKET
Capabilities and Limitations
Acceptable Mounting Positions
The ANSUL applicator brackets are designed to withstand
specified vibration and shock loads which correspond to those
indicated by transportation industries (vehicle manufacturers,
etc.) as the maximum that the vehicles are designed to withstand. These loads are the acceptable loads for a bracket with
applicator and are indicated in the illustration on Page 12.
The load ratings shown on Page 12 apply only to properly
mounted brackets. The illustrations to the right show acceptable and unacceptable mounting of the brackets. When mounting a bracket, refer to them and use only the approved
mounting positions.
003223
003223
003224
003265
Unacceptable Mounting Positions
003225
003226
003266
13
HEAVY DUTY/VEHICLE BRACKET
Installation
Inspection
Make certain that the mounting location and position meet the
requirements of Mounting Location and Capabilities and
Limitations located within this section.
Inspection should be performed often, between the times of maintenance.
The brackets are provided with four mounting holes in the back
plate (frame) and four mounting holes in the base. The mounting surface will usually dictate that either the back or the base
holes be used, but in some instances both sets may be used
to improve the stress distribution. Use good quality 3/8 inch
fasteners, one in each mounting hole. Fasteners should be
tightened as is recommended for the specific type and grade
of fastener being used.
Even though welding is an effective method of securing the
bracket in place, it is NOT recommended. This is because
ANSUL has no control over the placement and quality of the
welds.
After the bracket is properly installed, refer to the Adjustment
sub-section within this section. Proper adjustment is vital if the
applicator is to be held firmly and not damaged.
Mounting Location
Two basic areas of consideration will affect the choice of
bracket mounting location.
The first consideration is accidental spill control needs.
1. The applicator must be visible, not hidden in an out-of-theway spot.
2. The applicator must be easily reached, even from the
ground.
3. It should not be placed where a spill is likely to make it
inaccessible.
The second set of considerations deal with keeping the applicator safe and secure.
1. Choose a place that is relatively safe from falling rocks and
tools, and where the brushing of tree limbs, or minor collisions are not likely to cause damage. For vehicles, the
best place is at the rear, a few feet from the ground
(mounting on the side of any vehicle is not recommended).
2. Avoid locations where grease or oil could build up on the
applicator and bracket.
3. For vehicles, select a mounting surface which is strong
enough to support the weight of the applicator and bracket
during vehicle operation, and is relatively flat to avoid
stress on the bracket.
4. Avoid surfaces which may flex enough to cause metal
fatigue in the member supporting the bracket.
5. Be sure there is enough space to allow proper mounting of
the bracket and easy access to the applicator.
6. Avoid locations that may expose the applicator to high
temperatures which are detrimental to its operation such
as near a motor or manifold.
14
Before replacing the applicator in the bracket, perform the following
steps:
1. Be certain that all pads are present in the bracket and clean any
pads that are oily or greasy.
2. Check the pads for resiliency. Replace any that seem hard or
have no ‘‘give’’ to them.
3. Be sure the bracket is still firmly mounted. Tighten or replace
fasteners if necessary.
4. Inspect the bracket for bends or breaks that might impair its operation.
5. Return the applicator to its bracket, and check to see that the
bracket is properly adjusted.
Maintenance
Maintenance is a very important factor in the lifespan and reliability of
a bracket. Maintenance of the bracket should be performed whenever applicator maintenance is performed.
1. Clean any dirt, ice, or other foreign material from the applicator
and bracket using a bristle brush, cleaning cloths, or soap and
water.
2. Remove the applicator from the bracket and clean the applicator
surface where the bracket pads contact it. Spill control applicator
maintenance procedures are found on Pages 7 – 11.
3. Examine the bracket pads which hold the applicator in place.
Clean the pad surfaces to maintain their gripping power on the
applicator. Check the pads for resiliency, and replace if necessary.
4. Inspect the bracket. If it has been bent, replace it. If it has been
cracked, repair or replace it.
NOTICE
If any welding is done, take steps to protect the bracket
pads from excessive heat.
5. Grease each moving part of the bracket arm and test its action.
The bracket must be able to hold the applicator firmly, but release
easily when necessary.
6. Check to see that the bracket is firmly mounted. Tighten or
replace mounting fasteners, or reweld connections as needed.
7. Avoid possible rust damage by cleaning and painting wherever
bare steel is exposed.
8. Following applicator maintenance, secure the applicator in its
bracket.
9. If the bracket does not hold the applicator securely or the bracket
is difficult to close, refer to the Adjustment procedure which
follows.
HEAVY DUTY/VEHICLE BRACKET
Adjustment
If a bracket is not properly adjusted, the bracket may be
damaged, and the applicator may be damaged or lost.
Readjustment of a bracket may be required periodically due to
physical abuse of the bracket and/or the aging of the neoprene
pads. This procedure covers both initial adjustment and later
readjustment.
1. Place the applicator in the bracket as shown, making sure
that it is firmly in the bracket base.
2. Hold the clamp arm level as you place it around the applicator. Arrange the arm, the applicator and the hose for the
best fit.
1
003227
2
003228
3
003229
4
003230
5
003231
6
003232
7
003233
3. Swing the handle open as shown. (The handle on the
bracket has mechanical stops which prevent the handle
from being opened too far.)
4. Adjust the length of the T-bolt so that it just fits into the
notches on the bracket handle when the handle is properly
opened. Be certain that the T-bolt retaining nut is properly
positioned as indicated in the figure. (The T-bolt length is
adjusted by turning it.)
5. Place the T-bolt in the notches in the handle. Check carefully to see the T-bolt is properly seated in the handle and
is square to the bracket back. If necessary, reposition the
bracket arm to obtain a good square fit.
6. With the T-bolt properly seated in the handle notches,
carefully close the handle, clamping the applicator into the
bracket. Take care to avoid being pinched as the handle
snaps closed.
7. Check the adjustment. If the applicator or the bracket arm
have any play in them, or if the bracket handle opens and
closes too easily, the bracket needs tightening. If the
tension makes it difficult to open or close the the bracket
handle, the bracket is too tight and should be loosened.
Remember that either too tight or loose a bracket may
cause damage. Maintain a snug, but not overtight, bracket.
15
SERVICE AND REPAIR
The best protection against spill control applicator malfunction is proper operation, recharge, inspection and maintenance. The
following table lists some of the possible irregularities that may be detected through periodic inspection or maintenance examinations and gives suggestions for corrective action.
COMPONENT
DISORDER
CORRECTIVE ACTION
Spill Control
Applicator Shell
Dents* or abrasions
Hydrostatically test (see Form No. F-7602, Hydrostatic Test
Instructions) and refinish (clean damaged area and repaint, using
a primer and finish coat); or replace applicator.
Rust spots, pits and corrosion deposits
Clean corroded areas with a wire brush, replacing tank if there is
any corrosion penetration; or repaint, using a primer and finish
coat.
Paint peeling
Remove loose paint with a wire brush and repaint, using a primer
and finish coat.
Fill opening threads nicked, cross-threaded,
corroded or worn
Clean threads with a stiff, non-wire bristle brush. Small nicks,
burrs, rough or feathered edges may be eliminated by careful
retapping or filing. If damaged or worn extensively, the applicator
should be replaced.
Fill opening gasket seating surface nicked,
gouged, corroded or bearing dirt deposits
Clean seating surface with a mild abrasive and lubricate the
surface lightly with a good grade of high heat resistant grease. If
surface is sharply nicked or deeply gouged, replace applicator.
Obstructed pressure vent hole in
fill opening threads
Clear vent hole with a stiff, unbreakable wire probe of
lesser diameter than vent hole.
Seam welds evidencing discoloration
or pin holes
Replace shell or consult Ansul Incorporated,
Marinette, Wisconsin 54143-2542.
Abraded, cracked, corroded or otherwise
damaged fill cap
Replace, destroying affected cap to prevent reuse.
Threads corroded, nicked, cross-threaded or worn
Replace, destroying affected cap to prevent reuse.
Cut, checked, deformed, stiff, brittle or
worn gasket or quad ring
Replace, coating new gasket lightly with a good grade
of high heat resistant grease.
Plastic indicator housing cap cracked or missing
Replace plastic cap.
Indicator stem immovable or stiff operating
Disassemble and clean, replacing parts as required.
Improper fill level
Fill shell to rated capacity with spill control agent specified on
nameplate only.
Caked agent**
Discard agent and refill tank to rated capacity with spill control
agent specified on nameplate only.
Fill Cap
Spill Control Agents
Gas Tube
Nameplate
Expellant Gas
Cartridge
Bent, cracked, broken or obstructed
Replace, using factory built and pressure tested assembly only.
Loose, leaking, damaged, or missing check valve
Replace, using factory built and pressure tested assembly only.
Unreadable wording
Use a mild abrasive (scouring powder) to clean plate. If readability cannot be improved, replace nameplate.
Loose
Remove nameplate and inspect area under plate. If corroded,
see ’’Spill Control Applicator Shell(s) – Rust spots, pits and corrosion deposits’’ and take appropriate corrective action as surface
condition would indicate or clean areas (repaint, using a prime
and finish coat if necessary) and reaffix nameplate using a good
grade of heatless adhesive.
Missing
Replace with correct nameplate (see applicable parts list).
Rust spots, pits and corrosion deposits
Clean corroded areas with wire brush, replacing cartridge if
there is any corrosion penetration; or repaint.
Dents or abrasions
Depressurize, remove seal and destroy both internal and external
threads on the cartridge to render the vessel unusable.
Paint peeling
Remove loose paint with a wire brush and repaint.
Threads on cartridge nicked, cross-threaded,
corroded or worn
Clean threads with a stiff, non-wire bristle brush, small
nicks, burrs, rough or feathered edges may be eliminated by
careful filing. If damaged, worn or corroded severely, the
cartridge should be replaced with a new nitrogen cartridge (Part
* Record dents for reference in future servicing, replacing shell if dents are other than shallow.
** The term caked, as applied to the agent describes a condition. It is best identified as agent containing hard lumps. These lumps will render a spill control applicator inoperative. The condition
usually follows the absorption and later the evaporation of an unusual amount of moisture. It is often confused with packing – a condition produced by normal settling, by vibration or by impact. A
simple procedure to determine which condition exists is the Underwriters Laboratories four inch drop to a clean hard surface test. If the lumps do not break up into individual particles, caking is
16
SERVICE AND REPAIR
No. 4893).
COMPONENT
DISORDER
CORRECTIVE ACTION
Bracket
Rubber pads loose
Clean area (repaint, using a prime and a finish coat if necessary)
and reaffix, using a strong adhesive such as cyanoacrylate
(Eastman 910, Locktite 404, etc.).
Cartridge Guard
Rust spots, pits or corrosion deposits
Clean corroded areas with a wire brush, replacing guard if there
is any corrosion penetration; or repaint, using a primer and finish
coat.
Dents or abrasions
Repair and refinish (clean damaged area and repaint, using a
primer and finish coat); or replace guard.
Paint peeling
Remove loose paint with a wire brush and repaint using a primer
and finish coat.
Bent, binding, corroded or dull puncture pin
Replace puncture pin.
Obstructed pressure vent hole
Clear vent hole with a stiff, unbreakable wire probe of lesser
diameter than vent hole.
Threads corroded, nicked, cross-threaded
or worn
Replace, destroying affected receiver to prevent reuse.
Cut, cracked, abraded or deformed exterior
Replace entire hose assembly.
Corroded or cracked coupling, swivel joint
or ferrule
Replace entire hose assembly.
Corroded, cross-threaded or worn
coupling threads
Replace entire hose assembly.
Internal blockage
Clear by blowing dry air or nitrogen at 250 psi (17.2 bar) through
hose.
CAUTION
!
Cartridge Receiver
Hose
To avoid risk of personal injury from violent movement of hose,
restrain the hose before blowing high pressure gas through it.
Nozzle(s)
Coupling gasket(s), brittle, compression set,
cracked, cut or missing
Replace, lubricating new gasket(s) lightly with a good grade
of high heat resistant grease before insertion.
Wrong nozzle
Replace with type nozzle recommended by the manufacturer
(ANSUL).
Nozzle body corroded, cracked or dented
Replace nozzle or replace body and pressure test at 250 psi
(17.2 bar).
Operating handle broken or deformed
Replace handle.
Operating handle binding or immovable
See ‘‘Leaking Nozzle’’ below.
Leaking nozzle, plugged tip and/or
discharge passage
Disassemble and clean deposits from internal passages
and parts with a small, stiff bristle brush; examine internal parts
and replace if cut, checked, or deformed, stiff, brittle or worn.
Reassemble nozzle and pressure test at 250 psi (17.2 bar).
Threads nicked, worn or cross-threaded
Replace thread bearing component and pressure test at 250 psi
(17.2 bar).
Gaskets or O-rings brittle, compression set,
cracked, cut or missing
Replace, lubricating gasket(s) or O-rings lightly with a good
grade of high heat resistant grease before insertion.
Plunger tip evidencing cuts, abrasions,
degrading rubber, brittleness, or separation
from plunger
Squeeze nozzle handle and unscrew nozzle tip. Remove
rivet from handle. Remove handle and spring from body.
Remove and discard plunger assembly. Install new plunger
assembly (Part No. 56117). Install spring and handle making
certain plunger engages slotted portion of handle. Align holes in
nozzle body and handle, insert and peen new rivet (Part No.
3621).
17
Form No. F-8645-2
Copyright © 2009 Tyco International Ltd.
TYCO FIRE SUPPRESSION & BUILDING PRODUCTS
MARINETTE, WI 54143