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Boss RAPTOR SPARK RS-CUSP1L Installation & Operation Manual

Detection and extinguishing system
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Installation & Operation Manual for
The Raptor Spark Detection and
Extinguishing System
2021 - First Edition - Version 0001

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Summary of Contents for Boss RAPTOR SPARK RS-CUSP1L

  • Page 1 Installation & Operation Manual for The Raptor Spark Detection and Extinguishing System 2021 - First Edition - Version 0001...

  • Page 2: Table Of Contents

    Page 2 Table of Contents Manual Information..........................3 Safety................................3 Warranty..............................3 Introduction............................4 NFPA Compliance............................4 Raptor Spark Detection and Extinguishing System Main Components......8 Raptor Spark Control Unit (RS-CUSP1L)..................10 Raptor Spark Batteries Replacement....................17 Spark Detector(s) (RS-SD02) ..18 ........................Test Lamp(s) (RS-TL02) ..23 ..........................Extinguishing Water Unit (RS-EXT02) ............25 ..........

  • Page 3: Manual Information

    • Boss Products further warrants to the buyer that the product will remain free of defect for a period of 12 months of shipment on the condition that product has been maintained, installed and operated according to its intended use.

  • Page 4: Introduction

    This document may not be reproduced, transmitted or stored in any kind of storage system using any means (electronic, photocopying and etc.), unless prior written authorization from Boss Products LLC®; furthermore, the company reserves the right to review this document and make appropriate changes to its content without having to provide prior communication or notice.
  • Page 5 Page 5 NFPA 69 – Standard on Explosion Prevention Systems - 2019 Edition • Chapter 9 - Predeflagration Detection and Control of Ignition Sources ▶ 9.1 - Application. Systems used for the predeflagration detection and control of certain specific ignition sources shall be permitted to be used to reduce the probability of the occurrence of deflagrations in sys- tems that handle combustible particulate solids.
  • Page 6 Page 6 NFPA 654 – Standard for the Prevention of Fire and Dust Ex- plosions from the Manufacturing, Processing, and Handling of Combustible Particulate Solids – 2020 Edition • Chapter 9 - Hazard Management: Mitigation and Prevention ▶ 9.8.3.2.4 - Detection Systems ▷...
  • Page 7 Page 7 NFPA 664 – Standard for the Prevention of Fires and Explosions in Wood Processing and Woodworking Facilities – 2017 Edition ▶ 9.3 - Equipment Design ▷ 9.3.5.4.1 Dust Collector systems of capacity less than or equal 2.4 m3 / sec (5000 cfm), one of the following shall apply: 1.

  • Page 8: Raptor Spark Detection And Extinguishing System Main Components

    Page 8 Raptor Spark Detection and Extinguishing System Main Components The Raptor Spark Detection & Extinguishing Control Unit (RS-CUSP1L) is designed to minimize the risk of fire and explosion in dust filtration and pneumatic conveying systems. This control unit communicates with a variety of components to monitor and protect up to six individual zones.
  • Page 9 Page 9 Raptor Spark Detection and Extinguishing System Main Components The Thermal Probe (RS-TP02) is designed to work either as a thermove- locimetric output (rapid raise in temperature in a short amount of time), or as a thermostatic output (fixed temperature threshold) to alarm the RS-CUSP1L Control Unit of potential fire hazards in the ductwork, dust collector units, hoppers, cyclones and etc.

  • Page 10: Raptor Spark Control Unit (Rs-Cusp1L)

    Page 10 Raptor Spark Control Unit (RS-CUSP1L) Overview Figure 7 - Control Unit (RS-CUSP1L) The Raptor Spark Detection & Extinguishing Control Unit (RS-CUSP1L) is specifically designed to be used with spark detectors, test lamps, water extinguishing unit, and other devices such as thermal probes, dust probes, firebreak shutters, and high speed abort gates.
  • Page 11 Page 11 Raptor Spark Buttons and LED Lights Description Figure 8 - Front panel of Control Unit (RS-CUSP1L) Input Power Supply Battery Check Solenoid Valve Status Pressure Switch, Water Temperature, and Ball Valve Status Enable/Disable Extinguishing Unit Fault on power supply and/or Water Extinguishing Unit Alarm on L1, L2, and/or L3 Alarm on L4, L5, and/or L6 Fault(s) on any line (L1 through L6)
  • Page 12 Page 12 Raptor Spark Buttons and LED Lights Description Power Supply is OK. OFF: Fault on Power Supply/Power Supply is not connected. Blinking: Memory event about fault(s) on power supply. Figure 10 - Input power LED light Batteries are connected and OK. OFF: Fault on Batteries/Not connected or low charge.
  • Page 13 Page 13 Raptor Spark Buttons and LED Lights Description Alarm from L1, L2, and/or L3. OFF: No alarm from L1, L2, and/or L3. Figure 16 - Detect LED light Alarm from L4, L5, and/or L6. OFF: No alarm from L4, L5, and/or L6. Figure 17 - Extinguishing check LED light Fault on any line (L1 through L6).
  • Page 14 Page 14 Raptor Spark Terminals Layout P5 P6 -B +B L1 +24 L2 +24 L3 T1 +24 L4 +24 L5 +24 L6 GU EV PS SR SI C NO NO C NC NO C NC ENABLE BATTERY ABORT FIREBREAK L1/L2/L3 DETECTION L4/L5/L6 EXTINGUISHING CHECK EXTINGUISHING GROUP STOP FAN...
  • Page 15 Page 15 Raptor Spark Inputs/Outputs Terminals Description L1 +24 L2 +24 L3 T1 +24 L4 +24 L5 +24 L6 GU EV PS SR SI C NO NO C NC NO C NC ENABLE BATTERY ABORT FIREBREAK L1/L2/L3 DETECTION L4/L5/L6 EXTINGUISHING CHECK EXTINGUISHING GROUP STOP FAN 24V1...
  • Page 16 Page 16 Raptor Spark Dip Switches Settings Figure 33 - Detailed view of dip switches Dip 1 (Pulses): Defines how many pulses must be received from an input to generate alarm. Refers to all inputs. OFF: 1 input pulse to generate alarm. ON: 3 input pulses to generate alarm.

  • Page 17: Raptor Spark Batteries Replacement

    Page 17 Raptor Spark Batteries Replacement During an event of power loss, the batteries guarantee 4 hours in standby mode. After a power loss of about 1 hour, batteries can take up to 8 hours to recharge. Step 1: To check or replace batteries, first turn off power supply.

  • Page 18: Spark Detector(S) (Rs-Sd02)

    Page 18 Spark Detector(s) (RS-SD02) With Mounting Kit (RS-MK02) Overview Figure 39 - Spark detector (RS-SD02) The Spark Detector (RS-SD02) is FM Approved and ATEX Certified, it is designed for installation on spark detection and extinguishing systems for the detection of sparks on dust extraction applications. The detector employs advanced infrared light-sensitive technology and circuitry to detect sparks, flames and incandescent material that pass by the detector’s optical element.
  • Page 19 Page 19 Spark Detector(s) (RS-SD02) Specifications Positioning and Number of Spark Detectors Required in Relation to Duct Diameter Inside Duct View Duct Diameter Duct Diameter between Duct Diameter smaller than 20” (500mm) 20”- 40” (500mm - 1000mm) bigger than 40” (1000mm) Figure 40 - 1 Spark detector required if duct Figure 41 - 2 Spark detectors required Figure 42 - 3 Spark detector required if duct...
  • Page 20 Page 20 Spark Detector(s) (RS-SD02) Dip Switches Settings Spark Detector (RS-SD02) 1 2 3 4 5 6 7 8 Figure 46 - Spark detector (RS-SD02) dip switches 1 2 3 4 Figure 47 - Spark detector (RS-SD02) LED lights Figure 45 - Spark detector (RS-SD02) open face Green LED 1 ON = Power ON Red LED 2 ON = Alarm ON Green LED 3 ON = Test ON...
  • Page 21 Page 21 Spark Detector(s) and Test Lamp(s) Installation On Duct NOTE: Do not install in places with strong light. Avoid direct light. Always ground components to properly grounded duct. Step 1: Drill 1-1/2” hole on duct using a hole saw. Figure 48 - 1-1/2”...
  • Page 22 Page 22 Spark Detector(s) and Test Lamp(s) Installation On Duct Step 6: Insert O-ring provided around the bushing. Figure 53 - O-ring installation Step 7: Insert coupling into the bushing. Figure 54 - Coupling insertion Step 8: Tighten coupling into the bushing using tool provided.

  • Page 23: Test Lamp(S) (Rs-Tl02)

    Page 23 Test Lamp(s) (RS-TL02) With Mounting Kit (RS-MK02) Overview Figure 58 - Test lamp (RS-TL02) The Test Lamp (RS-TL02) is FM Approved and ATEX Certified, it is designed for external monitoring of the Spark Detectors (RS-SD02) to ensure that detector performance is not compromised by an excessive amount of dust/material on the optical window that could render them ineffective.
  • Page 24 Page 24 Test Lamp(s) (RS-TL02) Specifications Positioning and Number of Test Lamps Required in Relation to Duct Diameter Inside Duct View Duct Diameter Duct Diameter between smaller than 20” (500mm) 20” - 40” (500mm - 1000mm) Spark Detector Spark Detector Test Lamp Test Lamp Figure 59 - 1 Test lamp if duct diameter is...

  • Page 25: Extinguishing Water Unit (Rs-Ext02)

    Page 25 Extinguishing Water Unit (RS-EXT02) Overview Water Temperature Probe Electrical Connection Pressure Switch Microswitch Ball Valve Solenoid Valve Water Filter Figure 62 - Extinguishing water unit (RS-EXT02) components • The extinguishing water unit is FM Approved and ATEX Certified. •...
  • Page 26 Page 26 Extinguishing Water Unit (RS-EXT02) Specifications Positioning of Extinguishing Water Unit and Flexible Hoses on Duct NOTE: If using extinguishing water unit, it is recommended to install additional detectors downstream to ensure sparks have been eliminated. Duct Diameter between 6”...
  • Page 27 Page 27 Extinguishing Water Unit (RS-EXT02) Specifications Positioning of Extinguishing Water Unit and Minimum Distances From Spark Detector(s) NOTE: Minimum distance between spark detection 1 and extinguishing system 1, and spark detection 2 and extinguishing system 2 is the same. Allow 5ft -10ft between extin- guishing 1 and spark detection 2.
  • Page 28 Page 28 Flexible Hoses Specifications Figure 66 - (2) Flexible hoses (RS-FH) • The flexible hoses are FM Approved and ATEX Certified. • Flexible hoses with crimped fittings are ideal for a simple and safe installation between the extin- guishing water unit’s T fitting and the spray nozzles located inside the duct. •...
  • Page 29 Page 29 Extinguishing Water Unit (RS-EXT02) Installation Figure 67 - Installation details of flexible hoses and extinguishing water unit Step 1: Drill (2) 1-1/2” holes on the top side of duct using a hole saw. Figure 68 - (2) 1-1/2” holes on duct Step 2: Insert bushing and washer in both drilled holes on duct using provided tool and turn until washer is completely...
  • Page 30 Page 30 Step 4: Tighten the locking nut using wrench provided. NOTE: Do not exceed 4 Nm in torque. Figure 71 - Locking nut tightening Step 5: Insert O-ring provided around the bushing. Figure 72 - O-ring installation Step 6: Insert mounting support into the bushing.
  • Page 31 Page 31 Flexible Hoses Installation Step 1: Follow steps 1-5 from installation of the extin- guishing unit. Insert spray nozzle into coupling. Figure 76 - Spray nozzles installation Step 2: Screw one end of flexible hoses into nozzles couplings. Repeat for the other hose, on opposite side. Figure 77 - Flexible hose to nozzle installation Step 3: Screw provided 1”-3/4”...

  • Page 32: Thermal Probe (Rs-Tp02)

    Page 32 Thermal Probe (RS-TP02) Overview Front View Side View Top View Figure 81 - Thermal probe (RS-TP02) Figure 82 Thermal probe (RS-TP02) dimensions The thermal probe (RS-TP02) is specifically designed for fire protection in dust collecting and process ventilation. Alarm functions signal and operate on a rapid temperature rise and/or on a fixed tempera- ture threshold.
  • Page 33 Page 33 Thermal Probe LEDs, Jumpers, and P1 Button Descriptions U1 U2 U3 2 3 4 TEST Figure 83 Thermal probe (RS-TP02) open face details LEDs Description: Green LED 1 ON: Power supply is OK. Red LED 2 Flashing: Probe in operation. Red LED 3 ON: Thermovelocimetric Alarm (Output setting to alarm at a rapid raise in temperature, see J1 and J2 jumpers below for details).
  • Page 34 Page 34 Thermal Probe (RS-TP02) Specifications Positioning and Number of Thermal Probes on Pipes and Ducts: Regardless of diameter, it is recommended to install a thermal probe every 23ft – 26 ft (7m-8 m). When dust collecting systems are operational, quick detection is critical and achieved through thermal measurements at several points due to air movement.
  • Page 35 Page 35 Thermal Probe (RS-TP02) Installation Figure 84 - 2 thermal probes (RS-TP02) installation. 1 on dust col- Figure 85 - Detailed view of thermal probes lector and 1 on the hopper (RS-TP02) installation Step 1: Use 1/2” female threaded coupling (not provided). Step 2: Drill Ø1/3”...

  • Page 36: Dust Probe (Rs-Dp03)

    Page 36 Dust Probe (RS-DP03) Overview Front View Side View Top View Figure 86 - Dust probe (RS-DP03) Figure 87 Dust probe (RS-DP03) dimensions The dust probe (RS-DP03) is FM Approved and ATEX Certified, it uses the principle of the displace- ment of the electric charge in the electrode, induced by the electrical charges, carried by dust im- mersed in a gaseous fluid.
  • Page 37 Page 37 Dust Probe LEDs, Jumpers, and P1 Button Descriptions U1 U2 U3 2 3 4 TEST Figure 88 Dust probe (RS-DP03) open face details LEDs Description: Green LED 1 ON: Power supply is OK. Red LED 2 ON: Warm up (3 mins after power on) or self-acquisition or serial switching. Red LED 3 ON: Output U1 ON.
  • Page 38 Page 38 Dust Probe (RS-DP03) Specifications 5x Duct Ø 5x Duct Ø Figure 89 Dust probe (RS-DP03) installation specifications The dust probe must be installed on a metallic duct electrically connected to the ground to ensure shielding from electromagnetic noise. The distance from obstacles that may disturb the laminar flow of air (valves, bottlenecks, elbows, bends etc.) that could possibly change the uniform concentration of dust, both upstream and down- stream of the probe, must be at least 5 times the diameter of the pipe.
  • Page 39 Page 39 Dust Probe (RS-DP03) Installation Horizontal Duct Installation Mount dust probe on top of duct. Electrode must be at least 3/4 long but not touch the bottom side of duct. Direction of Dust Figure 92 Dust probe (RS-DP03) installation on horizontal duct Vertical Duct Installation Mount dust probe on either side of duct.

  • Page 40: Raptor Spark Operation

    Page 40 Raptor Spark Operation Overview Direction of Spark Firebreak shutter Figure 94 - Overview of the raptor spark detection and extinguishing system The Raptor Spark Detection and Extinguishing System is an FM approved safety system designed to reduce the risk of ignition of fire or explosion in dust collection systems. The spark detector(s) use in- frared light-sensing technology to detect the presence of sparks or glowing embers traveling through ducting.
  • Page 41 Page 41 Spark Detectors and High Speed Abort Gates (Em-HSAG02) High Speed Abort Gate (EM-HSAG02, Product Code: 56702) Min. Distance (ft) 25.00 22.50 21.75 20.25 18.75 20.00 17.25 15.75 14.25 15.00 12.75 11.25 10.00 5.00 0.00 1500 1700 1900 2100 2300 2500 2700...
  • Page 42 Page 42 Spark Detectors and FireBreak Shutters (EM-FBS) Distance dependent on air speed and firebreak shutter type and size. Refer to charts below. Magnetic FireBreak Shutter sizes Ø8” to Ø18” (EM-FBS00 M/MA, Product Code: 50301) Min. Distance (ft) 14.0 11.6 11.9 10.8 11.2 12.0 10.1 10.5...
  • Page 43 Page 43 Pneumatic FireBreak Shutter sizes Ø20” to Ø30” (EM-FBS00 PA/PHA, Product Code: 50304) Min. Distance (ft) 162.5 157.5 152.5 147.5 142.5 137.5 132.5 127.5 122.5 117.5 112.5 107.5 102.5 97.5 92.5 87.5 82.5 77.5 72.5 67.5 62.5 57.5 52.5 47.5 42.5 37.5...

  • Page 44: Raptor Spark Wiring

    Page 44 Raptor Spark Wiring Components Wiring Spark Detector (RS-SD02) 1 2 3 4 5 6 7 8 Figure 97 - Spark detector (RS-SD02) dip switches BIL OUT Figure 98 - Spark detector (RS-SD02) terminals Figure 96 - Spark detector (RS-SD02) open face Test Lamp (RS-TL02) Figure 100 - Test lamp (RS-TL02) LED lights Green LED 1 ON = Power ON...
  • Page 45 Page 45 Raptor Spark Wiring Components Wiring Thermal Probe (RS-TP02) Thermovelocimetric U1 U2 U3 Figure 106 - U1, U2, and U3 terminals TEST Figure 105 - Thermal probe (RS-TP02) open face Figure 107 - Thermal probe (RS-TP02) terminals Thermal Probe (RS-TP02) Thermostatic U1 U2 U3 Figure 109 - U1, U2, and U3 terminals...

  • Page 46: Alarm Bell

    Page 46 Raptor Spark Wiring Components Wiring Dust Probe (RS-DP03) Threshold 1 (5mg/m³) U1 U2 U3 Figure 115 - U1, U2, and U3 terminals TEST Figure 114 - Dust probe (RS-DP03) open face Figure 116 - Thermal probe (RS-DP03) terminals Dust Probe (RS-DP03) Threshold 1 (10mg/m³) U1 U2 U3...
  • Page 47 Page 47 Raptor Spark Wiring Raptor Spark Control Unit Wiring Turn off power supply then unscrew both screws to remove access door to terminal blocks. Figure 122 - Raptor Spark Control Unit Figure 123 - Raptor Spark Control Unit power board L1 +24 L2 +24 L3 T1 +24...
  • Page 48 Page 48 Raptor Spark Control Unit Mounting For properly mounting, use (2) pre-drilled holes on each lower corner of the control unit enclosure after removing access door. Additionally, use mount located on the top center on the back side of the unit.

  • Page 49: Raptor Spark Wiring Schematic

    Page 49 Raptor Spark Wiring General Wiring Schematic for Common Components Raptor Spark Manual 2021 - First Edition - Version 0001 Print date: 03/18/2021...

  • Page 50: Maintenance Schedule

    Page 50 Maintenance Schedule General Maintenance for All Components To be performed at least once every six months. 1: Check supply voltage. 2: Check grounding. 3: Physical inspection of all enclosures. 4: Tighten terminals (where wires are connected). 5: Check the control units’ displays (buttons, displays, LEDs, buzzers, etc.). 6: Perform trial operation of inputs and outputs (standby, alarm, fault, block).

  • Page 51: Raptor Spark Spare/Replacement Parts

    Page 51 Raptor Spark Spare/Replacement parts Control Unit (RS-CUSP1L) Protective Cover Terminal Blocks (2-6 terminals) P/N: P/N: P/N: Alarm Bell Batteries Siren P/N: P/N: P/N: Mounting Kit (RS-MK02) Spark Detector (RS-SD02) Test Lamp (RS-TL02) P/N: P/N: P/N: Thermal Probe (RS-TP02) Dust Probe (RS-DP03) Dust Probe (RS-DP03) Electrode Extensions...
  • Page 52 Page 52 Raptor Spark Spare/Replacement parts Extinguishing Unit (RS-EXT02) T-Fitting Couplings Flexible Hoses (RS-FH) P/N: P/N: P/N: Microswitch Nozzles Ball Valve P/N: P/N: P/N: Water Filter Solenoid Valve Pressure Switch P/N: P/N: P/N: Raptor Spark Manual 2021 - First Edition - Version 0001 Print date: 03/18/2021...

  • Page 53: Raptor Spark Kits

    Page 53 Raptor Spark Kits Duct Diameter smaller than Duct Diameter between Duct Diameter bigger than 20” (500mm) 20” and 40” (500mm - 1000mm) 40” (1000mm) KIT 1 (with extinguishing group) KIT 2 (with extinguishing group) KIT 3 (with extinguishing group) *(2) Spark Detectors (RS-SD02) *(2) Spark Detectors (RS-SD02) *(3) Spark Detectors (RS-SD02)

  • Page 54: Installation And Testing Form

    Page 54 Installation and Testing Form Raptor Spark Manual 2021 - First Edition - Version 0001 Print date: 03/18/2021...

  • Page 55: Notes

    Page 55 Notes Raptor Spark Manual 2021 - First Edition - Version 0001 Print date: 03/18/2021...

  • Page 56: Contact Information

    Page 56 Contact Information 6729 GUADA COMA DR, SUITE 100 SCHERTZ, TX 78154 Phone: 210-664-4200 FAX: 913-620-6280 Email: INFO@BOSSPRODUCTSAMERICA.COM WWW.BOSSPRODUCTSAMERICA.COM © Boss Products, LLC 2021 Raptor Spark Manual 2021 - First Edition - Version 0001 Print date: 03/18/2021...

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