ESFR "PRE-PRIMED SINGLE INTERLOCKED PREACTION" COLD STORAGE SYSTEM MANUAL The Viking Corporation 210 N Industrial Park Road Hastings MI 49058 Telephone: 269-945-9501 Technical Services: 877-384-5464 Fax: 269-945-9599 F_120805 1 December 6, 2005
Table of Contents 1.0 System Description ............................................................................................... 7 2.0 ESFR Sprinkler Description .................................................................................. 9 3.0 2.1 Storage Arrangements ................................................................................. 9 2.2 Commodity Classification ............................................................................. 9 2.
6.5 7.0 Pressure Switch Set-up.............................................................................. 28 CS-1 Antifreeze Pump System ........................................................................... 29 7.1 Description ................................................................................................. 29 7.2 Operating Principle..................................................................................... 30 7.3 CS-1 Control Scheme .................................
13.2 Typical Properties....................................................................................... 45 13.3 Features ..................................................................................................... 46 14.0 Heat Trace System & Insulation.......................................................................... 46 14.1 Insulation of Riser Main............................................................................... 46 14.2 Insulation of Isolation Check Valve ............
Figure 1: Straight Through Configuration 5
Figure 2: Angle Style Configuration 6
1.0 SYSTEM DESCRIPTION The Viking ESFR “Pre-Primed Single Interlocked Preaction” Cold Storage System is a fixed fire protection system designed for installation in refrigerated or cold warehouse storage applications. This system is also appropriate for unheated storage applications in areas subject to freezing. This is a pre-primed preaction system with electric release that utilizes a deluge valve with conventional and electric release trims.
In the event of a fire, the system pressure supervisory switch that controls the pump unit is wired through the alarm switch located on the deluge valve and to the CS-1 pump unit. In this case, the CS-1 pump solenoid valve is restricted from opening for the riser that is flowing to the fire area and stops the flow of antifreeze to the discharging system. In order to effectively apply 100% water as rapidly as possible, the system size must be limited in volume.
2.0 ESFR SPRINKLER DESCRIPTION Viking ESFR Pendent K 25.2 Sprinkler VK510 is UL Listed for use with a maximum 50% by volume factory premix propylene glycol and water antifreeze solution. This listing is based on full-scale fire testing at Underwriter’s Laboratories. The following limitations of system design and application shall apply: 2.
3.2 Hydraulic Calculation Procedure: 1. A calculation with a design of twelve ESFR K25.2 VK510 Sprinklers and water, using four sprinklers on three most remote lines, discharging at the minimum design pressure for the hazard, with piping friction loss determined by HazenWilliams method of determining friction loss in piping. 2. A second hydraulic calculation with a design of six K25.
remote sprinklers as calculated. The operation of the control valve is caused by the operation of the detection system after sensing a fire condition. The installation position must be directly adjacent and at the bottom of the supply riser to the area of protection and must be in a heated room that maintains a minimum temperature of 40 °F (4 °C). 5.
or lines should not be looped together as done in some dry pipe and preaction systems. Tree Sprinkler System: A system of dead-end branch lines centrally fed by a cross main. The discharge pressure for all sprinklers flowing must maintain at a minimum of the required design. The 1,100 gallon (4,163 liter) system volume is established by adding the piping volume from the remote area to the top of the Easy RiserTM Check Valve at the base of the riser.
• • • • • • • Where the minimum temperature in the area being protected is between 8 °F (-13.3 °C) and -21 °F (-29.4 °C), the percentage by volume of propylene glycol must be 50%, factory premixed with water for antifreeze solution. Viking requires Firefighter Eliminator F type 50% propylene glycol/water mixture, with a freeze temperature rating (freeze point) of -26 °F (-32.2 °C). Minimum ambient temperature is -21 °F (-29.4 °C).
solution above freezing for air below the primary check valve.
imperfections. Also, pipes should be capped to prevent contaminant during shipping, storage, etc. 5.1.2 • Antifreeze solution is very lubrise and difficult to seal compared to plain water and initial care in pipe connections will minimize leaks at start-up. Also, antifreeze solution will prevent microbiological attack to piping material 5 times greater than water. Cleanliness is required to improve longevity of solution.
Propylene glycol/water solutions are designed to be installed on systems supplied by potable water supplies. Local authorities should be consulted prior to draining system to storm sewers or to natural drainage areas. In the main drain line between the valve and Easy RiserTM Check Valves inlet, a tee is provided on the check valve trim with a 1” NPT connection for supply and maintenance of the antifreeze solution to the system above the primary Easy RiserTM Check Valve. 5.1.
piping due to expansion of the propylene glycol when the temperature rises in the storage area. In order to prevent the pressure relief valve (PRV) on the Easy RiserTM valve trim from operating, the pressure control system is set to maintain pressure below the set point of the PRV and above the system maintenance pressure. The alarm pressure switch will prevent the APCS from operating when the deluge valve has operated.
5.1.6 Re-Charging System Piping with 35% or 50% Premix Propylene Glycol/Water Solution A suitable portable pump can be utilized to fill the system. The CS-1 pump can be used for filling the system initially at 15 GPM (56 l/min) to 100 ft. head pressure or system static pressure, however, it is a less efficient pump for filling the system because of the duration of time required to do so.
For freezers or coolers that fluctuate in temperature, an automatic pressure control system is required that utilizes a special DIGITAL pressure switch and solenoid valve that allows antifreeze to be relieved back into the CS-1 or reclaim tank. Calculation of volume fluctuation of the largest system where multiple systems are installed must be made in order to make sure the tank volume of antifreeze supply is large enough to contain the volume differential.
The purpose the antifreeze pressure pump is to lock in a supervisory pressure in the system and eliminate air for proper performance of the system. The CS-1 pump utilized on the ESFR Cold Storage System provides a static pressure on the propylene glycol/water solution in the system by taking suction from an atmospheric storage tank with premix propylene glycol and water solution and discharging to the downstream or system side of the primary Easy RiserTM check valve clapper.
Where multiple riser systems exist, the antifreeze solution system can be supplied to multiple risers from a single pump system and the pressure switch for each system must be controlled through the pump system control panel. When the pressure drops below set point, a solenoid valve supplied from the CS-1 pump shall open to allow flow of antifreeze solution into the system(s) that are low on pressure. When pressure is established, the solenoid valve will shut off.
The system must include a supervised system control valve upstream of the deluge valve and a supervised system isolation valve downstream of the isolation check valve. The downstream system isolation valve is required to facilitate maintenance of the system and isolation of antifreeze solution during maintenance and testing. A pressure relief valve on the antifreeze side of the primary check valve shall be pre-set to protect the sprinklers at 175 PSI (1 207 kPa) and piped to drain.
antifreeze inlet ball valve. The deluge valve must be operated (opened) to perform the flow test. Close the prime line valve and open the emergency manual release valve. Make sure the diversion drain valve is open to flow water to a drain area or the recovery tank as desired. Note: if antifreeze is stored in the recovery tank, do not allow water to enter, or contamination of solution will occur. Record the water supply pressure on the water supply pressure gauge upstream of the deluge valve.
5.3 Taking the System Out of Service If the system has to be taken out of service for maintenance on the system piping, follow these instructions: 1. Close the water supply control valve to the riser being serviced. 2. Close the antifreeze supply valve to the riser being serviced. 3. If the system is being serviced, then the solution in the system can be drained into clean containers or reclaim tank and reused as long as water has not entered the systems.
maintains the desired solution pressure. The ESFR Pre-Primed Single Interlocked Preaction Cold Storage System utilizes the Viking Deluge Valve and Easy RiserTM Check Valve with special trim to isolate the antifreeze in the system from the water supply. (NOTE: For previous Viking ESFR Cold Storage Systems, which utilized a wet system with the Model J-1 Alarm Check Valve, please contact the Viking Technical Services Department for details.
the PRV that protects the sprinklers at the ceiling at 175 PSI (1206kpa) maximum. The APCS is required in order to eliminate operation of the PRV. For warehouses with 40 ft (12,2 m) and 45 ft (13,7 m) ceiling heights, the head pressure increase could require more precise pressure control. The APCS allows for precise system control and prevents unwanted operation of the PRV. Normal operation of PRV is 90-105% of the set point. The closing pressure is only designed to 80% or greater of the set point.
6.4 Wiring Diagram 6.5 Pressure Switch Set-Up for Automatic Pressure Control System: 1. Connect to power supply. Turn on power supply. The pressure switch needs to be set-up without any pressure against it. 2. The pressure switch should have a digital reading displaying 0.0. 3. Depress the Mode/Enter button several times. The first variable to be defined is EF. 4. Depress the Set button. The value that will appear is HI. 5. Depress the Mode/Enter button several times until the value that appears is dS1.
20. Depress the Set button. The value that appears is the factory or previously set value. Depress the Set button and hold until the value changes (5 seconds). Set the value to minimum system pressure that is desired. 21. Depress the Mode/Enter button to return to rP1. 22. Depress the Mode/Enter button to change the display value to OU1. 23. Depress the Set button. The value that appears is the factory or previously set value. Depress the Set button and hold until the value changes (5 seconds).
supply. The tank and pump system automatically maintains the supervisory solution pressure in the piping above the check valves, until the detection system is activated. When the detection system is activated, the deluge valve is operated from the system releasing control panel. In the event of a fire condition, the detection system operates the deluge valve and pressurizes the system with the design discharge water pressure.
includes a low-pressure alarm switch that indicates a loss of supervisory pressure and requires a manual shutoff of the antifreeze supply valve. Up to six individual risers are connected to the CS-1 Tank and Pump System through normally closed solenoid valves. The supervisory pressure switch and flow alarm switch for each system are connected on site to the CS-1 system control. As system supervisory pressure drops, the corresponding solenoid valve opens, allowing flow from the CS-1 system to that system.
7.3 CS-1 Control Scheme 7.3.1 General The CS-1 Tank and Pump System maintains pressure for up to six risers with individual control to each riser. A two-way normally closed solenoid valve is connected to each riser. The pressure maintenance switch on each riser controls the corresponding solenoid valve. At a low riser pressure condition, the solenoid opens, allowing flow from the CS-1 to that riser.
In Automatic mode, each system solenoid valve opens if its system pressure drops to a low-pressure condition and there is no alarm pressure signal. In Manual mode, each system valve is selected by means of two selector switches and the solenoid valve opens as long as system pressure is below the set-point value and there is no system alarm. 7.3.4 Level Switch Relay Coil Operation The level switch relay coil is energized when tank level is above the level switch height. This is when tank level is satisfied.
Output 3: SYSTEM 1 SOLENOID VALVE Output 3 on when: (Manual Mode) Input 1 on and Input 5 on and Input 12 on and Input 13 off and Input 14 off. OR (Automatic Mode) Input 2 on and Input 5 on. Output 4: SYSTEM 2 SOLENOID VALVE Output 4 on when: (Manual Mode) Input 1 on and Input 6 on and Input 11 on and Input 13 off and Input 14 off. OR (Automatic Mode) Input 2 on and Input 6 on.
7.4 Installation 7.4.1 Receiving And Inspection When the equipment is received, immediately inspect it for shortages and visible and concealed damage. If the equipment has been damaged in shipment or shortages are noticed, immediately notify the carrier and file a claim. 7.4.2 Handling Move the CS-1 on the shipping pallet as close to the final location as possible. Always lift the unit from underneath. Never lift the unit when it is full of liquid. Personal injury and/or equipment damage could result.
Size piping between the CS-1 and the system to minimize pressure drop. Too small of a line size restricts pump flow, lowering capacity when filling the system. Lower capacity while filling the system requires longer fill times. The sprinkler system must contain air vent/bleed valves at all local high points. These are used to let air out of the system while filling with antifreeze. Consult the system instructions for specifics. Individual check valves and isolation valves are required for each system.
An arrow on the pump indicates the correct direction of rotation. If the pump rotates in the opposite direction, reverse the rotation of the motor. Interchanging any two incoming 3-phase supply wires reverses rotation of three phase motors. WARNING: Operating the pump in the wrong direction may damage the pump. Verify pump rotation is correct before placing the unit in service. Make sure there is liquid on the suction side of the pump before checking rotation.
Display mode: (Indication of parameters and the set parameter values) When the “Mode/Enter” button is pressed for a short time, the unit passes to the Display mode. Internally it remains in the operating mode. • The parameter names are scrolled with each pressing of the “Mode/Enter” button • When the “Set” button is pressed for a short time, the corresponding parameter value is displayed for approximately 15 seconds, then the unit returns to the Run mode.
3. Depress the Mode/Enter button several times. The first variable to be defined is EF. 4. Depress the Set button. The value that will appear is HI. 5. Depress the Mode/Enter button several times until the value that appears is dS1. 6. Depress the Set button. The value that appears is the factory or previously set value. Depress the Set button and hold until the value changes (5 seconds). Set the value to 0. 7. Depress the Mode/Enter button to return to dS1. 8.
9.0 ALARM SWITCH 9.1 INSTALLATION WARNING: The Alarm Pressure Switches are general service switches, not designed for use in explosive atmospheres. Refer to the technical data page for the Explosion-Proof/Watertight Alarm Pressure Switch intended for use in those environments. 1. Refer to the current Viking Trim Chart for the valve used to determine the appropriate location for installing the Viking Alarm Pressure Switch on Viking Trim. Viking Trim Sets provide: a.
The relief valve should be installed where it is easily accessible for maintenance. Care should be taken that the relief valve CANNOT be isolated from the system when the system is operational. A relief valve should never have a shutoff valve or a plug downstream of its outlet. The PRV MUST be piped to an adequate drain. Operation will discharge antifreeze or water from its outlet. See Section 19.0 System Parts List for listing of part numbers and pressures available. 11.
base, it can be used with EPDM, Nitrile and Fluoroelastomer gasket materials. It is not to be used with silicone gaskets. • In low temperature applications the gasket will shrink, thereby lowering the sealing force on the gasket sealing lips. The temperature change will also force the gasket to slightly re-position itself. This will cause pipe end sealing surfaces, with small cuts or damage, to become more susceptible to leakage.
12.0 ANTIFREEZE SOLUTION 50% 12.1 Description Viking Firefighter Eliminator F is a certified premixed 50% propylene glycol/water antifreeze solution required for use with the Viking ESFR Cold Storage System. The system provides fixed fire protection for refrigerated or cold warehouse storage and is also appropriate for unheated storage applications in areas subject to freezing, to a minimum temperature of -21 °F (-29.4 °C).
12.3 Features • • • • 13.0 Has a freeze temperature rating (freeze point) of -26 °F (-32.2 °C). (Note: Freeze temperature is where ice crystals begin to form.) Is a ready-to-use solution pre-mixed in the proper 50% propylene glycol concentration for the Viking ESFR Cold Storage System, in areas subject to freezing, to a minimum temperature of -21 °F (-29.4 °C). Was utilized in the full-scale research fire tests for the Viking ESFR Cold Storage System.
Appearance: Fluorescent green color For further details, see the Viking Firefighter Eliminator C Material Safety Data Sheet (page 50 e-h). 13.3 Features • • • • 14.0 Has a freeze temperature rating (freeze point) of 2.4 °F (-16.4 °C). (Note: Freeze temperature is where ice crystals begin to form.) Is a ready-to-use solution pre-mixed in the proper 35% concentration of propylene glycol for the Viking ESFR Cold Storage System for use in areas subject to a minimum temperature as low as 8 °F (-13.3 °C).
15.0 SYSTEM FILL PROCEDURE 15.1 Filling The Reservoir Tank The CS-1 has been designed to fill the reservoir tank using either of two methods: gravity fill or pumped fill. NOTE: This is not a self-priming pump. Manual prime or fill the reservoir for prime. NOTE: Never leave the unit unattended when filling the system or tank. Running the pump dry, without liquid, will damage pump seals and possibly damage pump impeller. Follow the steps below: 15.1.1 Gravity Fill: 1.
15.2 Filling Systems A suitable portable pump can be utilized to fill the system. (The CS-1 pump can be used for filling the system initially at 15 GPM (56 l/min) to 100 ft. head pressure or supervisory pressure, however, it is a less efficient pump for filling the system because of the duration of time required to do so. To fill the system, the CS-1 is connected to the antifreeze supply. The system to be filled is selected using two toggle switches on the CS-1 control enclosure.
7. 8. 9. 10. 11. 12. 13. 14. With the CS-1’s switch in the “OFF” position turn on the power supply to the unit. Turn the “Off-On” switch to “ON”. Switch the “Man-O-AUTO” switch on the unit control panel to “Man”. Liquid will begin to fill the selected system. As the system fills, monitor the system vent/bleed valves. Close each valve when liquid leaks from it. When the liquid leaks from the uppermost vent/bleed valve, close the vent valve.
valves are to be installed in several areas on the system piping for testing with a refractometer (refer to data page 45 a-j for testing requirements and procedures). If the propylene glycol/water solution becomes diluted or does not pass the refractometer test, the entire system is to be drained. All sections of trapped piping are to be drained. Five percent (5%) of the pendent ESFR sprinklers in all locations throughout the system are to be removed and inspected for frozen solution.
17.1 18.0 Pressure Setting Example SYSTEM TROUBLESHOOTING TROUBLESHOOTING PROBLEM POSSIBLE CAUSE REMEDY 1) Power disconnected. 2) Blown fuse. 1) No power to unit. Pump does not operate in 2) Liquid level in tank low. Automatic mode when CS- 3) Magnetic starter overload tripped. 1 pressure drops. 4) Time delay active. 5) Pump motor defective. 1) Pump operates on manifold pressure, not Pump does not operate in system pressure.
19.0 SYSTEM PARTS LIST 19.1 Major Components of System COMPONENTS OF PRE-PRIMED PREACTION ESFR COLD STORAGE SYSTEM A.1 Deluge Valve (1 Required) Flange/Flange Flange/Groove Groove/Groove 4" ANSI 05909C 05839C N/A Model E-1 Valve 6" ANSI 8" ANSI 05906C N/A 05456C N/A N/A N/A 4" ANSI 11953 11952 11513 DN100 08629 09540 N/A Model E-1 Valve DN150 DN200 08631 N/A 05456C N/A N/A N/A DN100 11965 11958 11513 4" 10205 --- Model E-1 Valve 6" 10206 --- 4" -11938-1 11712-1 A.
19.
