Janus 3M Novec 1230 Refill Manual

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Refill Manual for
3M™ Novec™ 1230 Fire Protection Fluid
Sv Series, Mv Series, Lv Series
Issued May 31, 2011
DOC181 REV E
(June 23, 2020)

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  • Page 1 Refill Manual for 3M™ Novec™ 1230 Fire Protection Fluid Sv Series, Mv Series, Lv Series Issued May 31, 2011 DOC181 REV E (June 23, 2020)
  • Page 3: Table Of Contents

    Page: iii Contents GENERAL INFORMATION Listings and Approvals Extinguishing Agent Safety Considerations CYLINDER ASSEMBLY Cylinder 2.1.1 Rupture Disc 2.1.2 Liquid Level Indicator Dip Tube (Siphon Tube) Cylinder Valve 2.3.1 Sv Series Valve Features 2.3.2 Mv Series Valve Features 2.3.3 Lv Series Valve Features FILL COMPONENTS Fill Adapter 3.1.1...
  • Page 4 Page: iv SYSTEM RECHARGE AND RESET Piping and Nozzles Recharging 5.2.1 Removing The Cylinder 5.2.2 Cleaning and Servicing The Valve Assembly 5.2.3 Recharge Procedure APPENDIX A - MATERIAL SAFETY DATASHEET APPENDIX B - ASSORTED CHARTS APPENDIX C - LIQUID LEVEL INDICATOR REPLACEMENT Document # DOC181 REFILL MANUAL FOR 3M™...
  • Page 5 Page: v Diagram Index Figure 2.3.1 Sv Cylinder Valve Assembly Figure 2.3.2 Mv Cylinder Valve Assembly Figure 2.3.3 Lv Cylinder Valve Assembly Figure 3.1.1 Sv Series Fill Adapter Figure 3.1.2 Mv Series Fill Adapter Figure 3.1.3 Lv Series Fill Adapter Figure 3.2 Cylinder Fill Assembly Figure 3.3 Nitrogen Regulator/Hose Assembly Figure 3.4 Valve Closing Adapter...
  • Page 6 Page: vi Revision History Revision Description of Change Date Initial Printing 31-May-2011 All references to "Dow Corning No. 4" replaced with "Molykote 55 by Dow Corning 02-Mar-2012 (P/N 19056)". Appendix C added. 02-Apr-2012 Figure 3.6 revised. 31-May-2013 Section 4.3.2 added. Sentence beginning "For a fill station to be UL Listed," and 25-Nov-2013 Table 1.1 added to Section 1.1.
  • Page 7 Page: vii Preface This manual is intended for use with the Janus Fire Systems® Sv Series, Mv Series, and Lv Series Clean Agent Engineered Fire Extinguishing Systems utilizing 3M™ Novec™ 1230 Fire Protection Fluid. Those responsible for the agent fill or agent refill of these systems should read this entire manual.
  • Page 8 Page: viii Document # DOC181 REFILL MANUAL FOR 3M™ NOVEC™ 1230 FIRE PROTECTION FLUID Issued: May 31, 2011 Revision E Revised: June 23, 2020...
  • Page 9: General Information

    (21.1°C). When discharged, Novec 1230 fluid is atomized at the discharge nozzles and becomes thoroughly mixed with the air throughout the protected area reaching a predetermined design concentration. NOTE: Bulk Novec 1230 fluid must be purchased from Janus Fire Systems and must bear the UL and FM marks on the container.
  • Page 10 Page: 2 Section 1 General Information At a minimum, Janus Fire Systems recommends the following safety equipment be worn at all times during the fill procedure: • Work boots with protective toe guards • Safety glasses or goggles • Gloves to prevent injury of the hands or fingers.
  • Page 11: Cylinder Assembly

    Page: 3 Section 2 Cylinder Assembly CYLINDER ASSEMBLY The cylinder assembly consists of the cylinder, dip tube, and cylinder valve. Cylinder The Novec 1230 fluid is stored as a liquid inside a welded steel cylinder. The cylinders are superpressurized with dry nitrogen to a pressure of 360 psig (24.8 bar) at 70°F (21°C). Every cylinder has a minimum fill density of 35 lb/ft (561 kg/m ) and a maximum fill density of 70 lb/ft...
  • Page 12: Dip Tube (Siphon Tube)

    Page: 4 Section 2 Cylinder Assembly Dip Tube (Siphon Tube) A rigid dip tube is threaded into the cylinder valve and extends down the entire length of the cylinder. Cylinder Valve A differential pressure operated cylinder valve controls the release of Novec 1230 fluid from the cylinder. It is made of forged brass and is threaded onto the cylinder neck.
  • Page 13: Sv Series Valve Features

    Page: 5 Section 2 Cylinder Assembly 2.3.1 Sv Series Valve Features (See Figure 2.3.1) The Sv Series valve has six key features: 1. Valve Actuation Connection: A threaded connection located on top of the cylinder valve serves as the attachment point for the electric (primary) or pneumatic (slave) valve actuator. 2.
  • Page 14: Mv Series Valve Features

    Page: 6 Section 2 Cylinder Assembly 2.3.2 Mv Series Valve Features (See Figure 2.3.2) The Mv Series cylinder valve has six key features: 1. Valve Actuation Connection: A threaded connection located on top of the cylinder valve serves as the attachment point for the electric (primary) or pneumatic (slave) valve actuator.
  • Page 15: Lv Series Valve Features

    Page: 7 Section 2 Cylinder Assembly 2.3.3 Lv Series Valve Features (See Figure 2.3.3) The Lv Series cylinder valve has five key features: 1. Valve Actuation Connection: A threaded connection located on top of the cylinder valve serves as the attachment point for the electric (primary) or pneumatic (slave) valve actuator.
  • Page 16 Page: 8 Section 2 Cylinder Assembly Document # DOC181 REFILL MANUAL FOR 3M™ NOVEC™ 1230 FIRE PROTECTION FLUID Issued: May 31, 2011 Revision E Revised: June 23, 2020...
  • Page 17: Fill Components

    Page: 9 Section 3 Fill Components FILL COMPONENTS The following components are necessary to fill a Janus Fire Systems® cylinder assembly with Novec 1230 fluid. Fill Adapter A fill adapter is installed into the discharge outlet of the cylinder valve during the fill procedure to accommodate the attachment of the cylinder fill assembly.
  • Page 18: Cylinder Fill Assembly

    Page: 10 Section 3 Fill Components Cylinder Fill Assembly P/N 99517 (See Figure 3.2) The cylinder fill assembly is formed from a series of interconnected fittings and valves to serve as a connection point between the agent fill station and the cylinder assembly. 1/4"...
  • Page 19: Nitrogen Pressurization Port

    Page: 11 Section 3 Fill Components 3.2.4 Nitrogen Pressurization Port The nitrogen pressurization port is located opposite of the gauge connection port and is a 1/4 in (8 mm) male quick-connect fitting that serves as the connection point for the nitrogen supply used to superpressurize the cylinder assembly.
  • Page 20: Valve Closing Adapter

    Page: 12 Section 3 Fill Components 1/4" (8 mm) Male Quick-Connect Fitting (P/N 99499) Valve Closing Adapter P/N 17292 (See Figure 3.4) The valve closing adapter is threaded onto the valve actuation connection of the cylinder valve and receives pressure from the nitrogen supply at the end of the filling procedure to close the cylinder valve.
  • Page 21: Supply Drum

    Page: 13 Section 3 Fill Components 3.5.2 Supply Drum Because Novec 1230 fluid is a liquid at typical ambient temperatures and pressure, pumping agent from a supply drum in a closed system can create a vacuum detrimental to the structural integrity of the IBC container.
  • Page 22: Fill Station Displays

    Page: 14 Section 3 Fill Components The agent fill station has an inlet hose (agent supply tank hose) designed to connect to the agent supply tank and an outlet hose (cylinder fill hose) designed to connect to the cylinder fill assembly. The face of the agent fill station contains three displays (liquid/moisture indicator, inlet pressure gauge, discharge pressure gauge) and three controls (selector control knob, pump control knob, agent/nitrogen selection knob).
  • Page 23: Fill Procedure

    Page: 15 Section 4 Fill Procedure FILL PROCEDURE This section contains a step-by-step procedure for weighing, filling, pressurizing, and closing the cylinder assembly. Refer to Figure 4 for a P&ID diagram that illustrates how each cylinder fill component connects to the agent fill station, nitrogen supply, and cylinder assembly. Each component should be only installed when indicated in the sections that follow.
  • Page 24 Page: 16 Section 4 Fill Procedure • Restrain the cylinder assembly securely. It is recommended the cylinder assembly remain placed on the calibrated scale during the fill procedure. Do not attempt to fill a cylinder assembly unless the cylinder has been properly restrained. Accidental discharge of an unsecured cylinder may result in property damage, injury, or death from violent cylinder movement.
  • Page 25: Seating Cylinder Valve

    Page: 17 Section 4 Fill Procedure 4.2.1 Seating Cylinder Valve The piston inside the cylinder valve must be seated using nitrogen before proceeding to ensure agent does not escape from the open cylinder valve. • After ensuring that the valve set line ball valve and cylinder pressurization line ball valve of the nitrogen regulator/hose assembly are closed, connect the regulator CGA fitting to the nitrogen supply valve.
  • Page 26: Overfill Retrieval Procedure

    Page: 18 Section 4 Fill Procedure • Remove the valve closing adapter from the cylinder valve. • Remove the cylinder fill hose from the pump connection port. If the cylinder fill hose quick-connect fitting is difficult to remove, this indicates the cylinder fill hose is still under pressure. Repeat the above steps to depressurize the cylinder fill hose.
  • Page 27: Pressurization Procedure

    Page: 19 Section 4 Fill Procedure Attaching the electric valve actuator to the cylinder valve when the actuation pin is not fully locked into the “up” position may cause the cylinder valve to actuate, resulting in potential injury and/or property damage. •...
  • Page 28 Page: 20 Section 4 Fill Procedure • Ensure that the fill pressure gauge is connected to the gauge connection port of the cylinder fill assembly. • Connect the cylinder connection port of the cylinder fill assembly to the male quick-connect fitting of the fill adapter.
  • Page 29 Page: 21 Section 4 Fill Procedure • Open the the supply tank liquid valve. • Set the direction of flow for the fill station towards the agent supply tank. Do this by setting the pump selector knob to "recovery cylinder". •...
  • Page 30: Finalization Procedure

    All cylinder assemblies must be tested for leakage and shall have a leak rate of no greater than 0.139 percent of the total amount of the agent fill in a cylinder, per year. Janus Fire Systems specifies the use of Bacharach Industrial Refrigerant Leak Detector Model H-10 PRO, H25-IR PRO, or equivalent in conjunction with Novec 1230 calibrated leak standard with a leak rate of 0.48 oz/yr maximum to verify that the refrigerant...
  • Page 31 Page: 23 4. Turn the H-10 PRO switch to the ON position (the leak detector should warm-up for a minimum 2 minutes, after which the flashing probe light and sound indicator will idle at approximately one click per second). Set the leak size switch to MEDIUM and the manual/automatic switch to AUTOMATIC. 5.
  • Page 32 Page: 24 CHECK FOR LEAK: Actuation Connection Port CHECK FOR LEAK: Cylinder Cap Connection CHECK FOR LEAK: CHECK FOR Pressure Switch LEAK: Connection Discharge Outlet Connection CHECK FOR LEAK: Rupture Disk Connection CHECK FOR LEAK: LLI Connection Note: Lv Valve is shown. All comparable lo- cations must be leak checked on Mv and Sv Valves.
  • Page 33: System Recharge And Reset

    Those individuals responsible for maintenance of a Janus Fire Systems® fire extinguishing system utilizing Novec 1230 fluid must be trained. To maintain FM Approval cylinder recharge must be done at a Janus Fire Systems® recognized facility. This chapter does not include instructions on resetting the automatic control system. Refer to the appropriate technical manual for this information.
  • Page 34: Cleaning And Servicing The Valve Assembly

    5.2.2 Cleaning and Servicing The Valve Assembly Janus Fire Systems recommends that the following steps be followed prior to refilling the cylinder(s): Check the pressure gauge and cylinder weight to verify the cylinder is empty and at atmospheric pressure before attempting to remove the valve.
  • Page 35: Recharge Procedure

    Page: 27 Section 5 System Recharge and Reset Table 5.2.2 Clean Agent Valve Replacement Components Part Description Sv P/N Mv P/N Lv P/N Collar O-ring 17551 18400 18400 Upper Piston O-ring 17552 18475 18398 Lower Piston O-ring 17553 18476 18399 Valve Cap O-ring 17551 18399...
  • Page 36 Page: 28 Document # DOC181 REFILL MANUAL FOR 3M™ NOVEC™ 1230 FIRE PROTECTION FLUID Issued: May 31, 2011 Revision E Revised: June 23, 2020...
  • Page 37: Appendix A - Material Safety Datasheet

    Page: 29 Appendix A Material Safety Datasheet Document # DOC181 REFILL MANUAL FOR 3M™ NOVEC™ 1230 FIRE PROTECTION FLUID Issued: May 31, 2011 Revision E Revised: June 23, 2020...
  • Page 38 Page: 30 Appendix A MATERIAL SAFETY DATA SHEET 3M™ Novec ™ 1230 Fire Protection Fluid [FK-5-1-12] 08/28/13 Material Safety Data Sheet Copyright, 2013, 3M Company All rights reserved. Copying and/or downloading of this information for the purpose of properly utilizing 3M products is allowed provided that: (1) the information is copied in full with no changes unless prior written agreement is obtained from 3M, and (2) neither the copy nor the original is resold or otherwise distributed with the intention of earning a profit thereon.
  • Page 39 Page: 31 Appendix A MATERIAL SAFETY DATA SHEET 3M™ Novec ™ 1230 Fire Protection Fluid [FK-5-1-12] 08/28/13 Inhalation: If thermal decomposition occurs: May be harmful if inhaled. Ingestion: No health effects are expected. 3.3 POTENTIAL ENVIRONMENTAL EFFECTS This substance has a high Henry's Law constant and therefore will be primarily found in the atmosphere where photolysis will be the dominant reaction pathway.
  • Page 40 Page: 32 Appendix A MATERIAL SAFETY DATA SHEET 3M™ Novec ™ 1230 Fire Protection Fluid [FK-5-1-12] 08/28/13 SECTION 6: ACCIDENTAL RELEASE MEASURES 6.1. Personal precautions, protective equipment and emergency procedures Ventilate the area with fresh air. 6.2. Environmental precautions For larger spills, cover drains and build dikes to prevent entry into sewer systems or bodies of water. Collect the resulting residue containing solution.
  • Page 41 Page: 33 Appendix A MATERIAL SAFETY DATA SHEET 3M™ Novec ™ 1230 Fire Protection Fluid [FK-5-1-12] 08/28/13 8.2.3 Respiratory Protection As a good industrial hygiene practice: Avoid breathing of vapors, mists or spray. Under normal use conditions, airborne exposures are not expected to be significant enough to require respiratory protection. If thermal decomposition occurs: Do not breathe vapors.
  • Page 42 Page: 34 Appendix A MATERIAL SAFETY DATA SHEET 3M™ Novec ™ 1230 Fire Protection Fluid [FK-5-1-12] 08/28/13 Stability: Stable. Materials and Conditions to Avoid: 10.1 Conditions to avoid Light 10.2 Materials to avoid Strong bases Amines Alcohols Additional Information: Listed materials to avoid should not be mixed with liquid Novec 1230 fluid. Avoid direct sunlight and ultraviolet light.
  • Page 43 Page: 35 Appendix A MATERIAL SAFETY DATA SHEET 3M™ Novec ™ 1230 Fire Protection Fluid [FK-5-1-12] 08/28/13 SECTION 13: DISPOSAL CONSIDERATIONS Waste Disposal Method: Reclaim if feasible. To reclaim or return, contact your 3M sales representative. Incinerate in an industrial or commercial facility in the presence of a combustible material. As a disposal alternative, dispose of waste product in a facility permitted to accept chemical waste.
  • Page 44 Page: 36 Appendix A MATERIAL SAFETY DATA SHEET 3M™ Novec ™ 1230 Fire Protection Fluid [FK-5-1-12] 08/28/13 application. This MSDS has been prepared to meet the U.S. OSHA Hazard Communication Standard, 29 CFR 1910.1200. SECTION 16: OTHER INFORMATION NFPA Hazard Classification Health: 3 Flammability: 0 Reactivity: 1 Special Hazards: None National Fire Protection Association (NFPA) hazard ratings are designed for use by emergency response personnel to address the hazards that are...
  • Page 45: Appendix B - Assorted Charts

    Page: 37 Appendix B Assorted Charts Document # DOC181 REFILL MANUAL FOR 3M™ NOVEC™ 1230 FIRE PROTECTION FLUID Issued: May 31, 2011 Revision E Revised: June 23, 2020...
  • Page 46 Page: 38 Appendix B Table B.1 - Approximate Container Pressure vs. Temperature Temperature Pressure 90% Pressure °F °C psig psig 288 (284) 19.86 (19.56) 259 (256) 17.87 (17.62) 20.89 18.80 22.13 19.92 15.6 23.44 21.10 21.1 24.82 22.34 26.7 26.27 23.64 32.2 27.72...
  • Page 47 Page: 39 Appendix B Table B.2a U.S. Standard to Metric Conversion Factors (Approximate) Measure U.S. Standard Multiply By Metric inches (in) 25.4 millimeters (mm) Length feet (ft) 304.8 millimeters (mm) feet (ft) 0.3048 meters (m) square inches (in²) 645.16 square millimeters (mm²) Area square feet (ft²) 0.0929...
  • Page 48 Page: 40 Appendix B Janus Fire Systems® 250 lb Cylinder (US Standard) 32 F 40 F 50 F 60 F 70 F 80 F 90 F 100 F 110 F 120 F 130 F WEIGHT OF NOVEC 1230 FLUID (LBS Table B.3a Liquid Level Chart – 250 lb Cylinder (U.S. Standard) Document # DOC181 REFILL MANUAL FOR 3M™ NOVEC™ 1230 FIRE PROTECTION FLUID...
  • Page 49 Page: 41 Appendix B Janus Fire Systems® 250 lb Cylinder (Metric) 0.0 C 4.4 C 10.0 C 15.6 C 21.1 26.7 32.2 37.8 C 43.3 C 48.9 C 54.4 C 54.4 WEIGHT OF NOVEC 1230 FLUID (KGS) Table B.3b Liquid Level Chart – 250 lb Cylinder (Metric) Document # DOC181 REFILL MANUAL FOR 3M™ NOVEC™ 1230 FIRE PROTECTION FLUID...
  • Page 50 Page: 42 Appendix B Janus Fire Systems® 420 lb Cylinder (US Standard) 32 F 40 F 50 F 60 F 70 F 80 F 90 F 100 F 110 F 120 F 130 F WEIGHT OF NOVEC 1230 LIQUID (LBS Table B.4a Liquid Level Chart – 420 lb Cylinder (U.S. Standard) Document # DOC181 REFILL MANUAL FOR 3M™ NOVEC™ 1230 FIRE PROTECTION FLUID...
  • Page 51 Page: 43 Appendix B Janus Fire Systems® 420 lb Cylinder (Metric) 0.0 C 4.4 C 10.0 C 15.6 C 21.1 26.7 32.2 37.8 C 43.3 C 48.9 C 54.4 C 54.4 WEIGHT OF NOVEC 1230 FLUID (KGS) Table B.4b Liquid Level Chart – 420 lb Cylinder (Metric) Document # DOC181 REFILL MANUAL FOR 3M™ NOVEC™ 1230 FIRE PROTECTION FLUID...
  • Page 52 Page: 44 Appendix B Janus Fire Systems® 600 lb Cylinder (US Standard) 32 F 40 F 50 F 60 F 70 F 80 F 90 F 100 F 110 F 120 F 130 F WEIGHT OF NOVEC 1230 LIQUID (LBS Table B.5a Liquid Level Chart – 600 lb Cylinder (U.S. Standard) Document # DOC181 REFILL MANUAL FOR 3M™ NOVEC™ 1230 FIRE PROTECTION FLUID...
  • Page 53 Page: 45 Appendix B Janus Fire Systems® 600 lb Cylinder (Metric) 0.0 C 4.4 C 10.0 C 15.6 C 21.1 26.7 32.2 37.8 C 43.3 C 48.9 C 54.4 C 54.4 WEIGHT OF NOVEC 1230 LIQUID (KGS) Table B.5b Liquid Level Chart – 600 lb Cylinder (Metric) Document # DOC181 REFILL MANUAL FOR 3M™ NOVEC™ 1230 FIRE PROTECTION FLUID...
  • Page 54 Page: 46 Appendix B Janus Fire Systems® 900 lb Cylinder (US Standard) 32 F 40 F 50 F 60 F 70 F 80 F 90 F 100 F 110 F 120 F 130 F WEIGHT OF NOVEC 1230 LIQUID (LBS Table B.6a Liquid Level Chart – 900 lb Cylinder (U.S. Standard) Document # DOC181 REFILL MANUAL FOR 3M™ NOVEC™ 1230 FIRE PROTECTION FLUID...
  • Page 55 Page: 47 Appendix B Janus Fire Systems® 900 lb Cylinder (Metric) 0.0 C 4.4 C 10.0 C 15.6 C 21.1 26.7 32.2 37.8 C 43.3 C 48.9 C 54.4 C 54.4 WEIGHT OF NOVEC 1230 LIQUID (KGS) Table B.6b Liquid Level Chart – 900 lb Cylinder (Metric) Document # DOC181 REFILL MANUAL FOR 3M™ NOVEC™ 1230 FIRE PROTECTION FLUID...
  • Page 56 Page: 48 Appendix B Janus Fire Systems® 1000 lb Cylinder (US Standard) 32 F 40 F 50 F 60 F 70 F 80 F 90 F 100 F 110 F 120 F 130 F WEIGHT OF NOVEC 1230 FLUID (LBS Table B.7a Liquid Level Chart – 1000 lb Cylinder (U.S. Standard) Document # DOC181 REFILL MANUAL FOR 3M™ NOVEC™ 1230 FIRE PROTECTION FLUID...
  • Page 57 Page: 49 Appendix B Janus Fire Systems® 1000 lb Cylinder (Metric) 0.0 C 4.4 C 10.0 C 15.6 C 21.1 26.7 32.2 37.8 C 43.3 C 48.9 C 54.4 C 54.4 WEIGHT NOVEC 1230 LIQUID (KGS) Table B.7b Liquid Level Chart – 1000 lb Cylinder (Metric) Document # DOC181 REFILL MANUAL FOR 3M™ NOVEC™ 1230 FIRE PROTECTION FLUID...
  • Page 58 Page: 50 Document # DOC181 REFILL MANUAL FOR 3M™ NOVEC™ 1230 FIRE PROTECTION FLUID Issued: May 31, 2011 Revision E Revised: June 23, 2020...
  • Page 59: Appendix C - Liquid Level Indicator Replacement

    Page: 51 Appendix C Liquid Level Indicator Replacement Document # DOC181 REFILL MANUAL FOR 3M™ NOVEC™ 1230 FIRE PROTECTION FLUID Issued: May 31, 2011 Revision E Revised: June 23, 2020...
  • Page 60 Page: 52 Appendix C LIQUID LEVEL INDICATOR REPLACEMENT The following steps detail the procedure for removing and replacing the liquid level indicator. 1. Pump down the cylinder. ENSURE THAT THE CYLINDER IS COMPLETELY EMPTY AND DEPRESSURIZED BEFORE CONTINUING. 1. Remove the cylinder valve and dip tube by lifting straight up and out.
  • Page 61 Page: 53 Appendix C 9. Once the o-ring is in place, reinsert the LLI rod through the LLI boss just enough so that the ball float can be reinstalled. Before replacing the ball float, locate the directional arrow that indicates proper positioning on the ball surface and ensure that the arrow is pointed up.

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