Spark Extinguishment System

Project: Garbuio
Order No.: 12002123 / 12003185
Installation Instructions




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P.O. Box 1243
31042 Alfeld / Hannover

Telephone: 0049 5181 / 79-0
Telefax: 0049 5181 / 79-229

Telephone Service department:
Heinz Eberlie 0049 5181 / 79-327


Impressum

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Project: Garbuio
Order No.: 12002123 / 12003185
Software: from version 1.7

Technical documentation
Consisting of page 1 18
All rights reserved

Erected: 13.07.2009 S. Heine
Checked: 13.07.2009 H. Schrader
Revision A: 28.09.2009 S. Heine
Revision B:
Revision C:

Subject to technical modifications.

Installation Instructions
Project: Garbuio
Order No.: 12002123 / 12003185


3

Table of contents


List of devices 4
Connection diagram 6
Cable list 7
Overview Control Console CC7004 8
Overview master module 9
Overview line module 10
Electric mains of control console 11
Connecting the alarm means 12
Connection of pressure switch (pneumatic system) 13
Connection of two spark sensors FM 1/8 or FM 3/8 14
Disconnecting the control console (system disconnection) 15
Interface overview master module 16
Interface overview line-referred contacts (line module) 17
Purging air 18

Installation Instructions List of devices
Project: Garbuio
Order No.: 12002123 / 12003185


4

List of devices




Pos. 0.1 1 Control console CC 7004
Pos. 0.2 1 Alarm horn / Flash light
Pos. 0.3 1 Pressure switch (pneumatic system)



Line: 1
Pos. 1.2.0 1 Terminal box KELEX
Pos. 1.2.1 1 Spark detector FM 1/8-PM incl. air purge unit (weld-on)
Pos. 1.2.2 1 Spark detector FM 1/8-PM incl. air purge unit (weld-on)
K11 1 Voltage-free relay contact alarm
K12 1 Voltage-free relay contact alarm 2


Line: 12
Pos. 2.2.0 1 Terminal box KELEX
Pos. 2.2.1 1 Spark detector FM 1/8-PM incl. air purge unit (weld-on)
Pos. 2.2.2 1 Spark detector FM 1/8-PM incl. air purge unit (weld-on)
K13 1 Voltage-free relay contact alarm
K14 1 Voltage-free relay contact alarm 2


Installation Instructions



5
Installation Instructions Connection diagram
Project: Garbuio
Order No.: 12002123 / 12003185


6

Connection diagram






Installation Instructions Cable list
Project: Garbuio
Order No.: 12002123 / 12003185


7

Cable list


Cable No. from Pos. to Pos. Cable type
W 1.0 Locally earth
curcuit connector
0.1 NYM-J 1G10
W 1.1 Mains 0.1 H05VV5-F 3G1,5
W 2.1, W 2.2 0.1 Spark detectors H05VV5-F 3X0,75
W 4.1 0.1 0.2 H05VV5-F 3X0,75
W 5.1 0.1 0.3 H05VV5-F 2X0,75
W 7.1 0.1 Steering by customer H05VV5-F *

G = with protective earth conductor
X = without protective earth conductor
* = Specify as required!





















H05VV5-F
Control cable, applicable by middle mechanical strain in dry, damp and wet areas. Oil- and
chemical resistant. Not UV-proof, may not be used in free areas!
e.g. LAPPKABEL LFLEX

CLASSIC 100 (with colored wires)

e.g. LAPPKABEL LFLEX

CLASSIC 110 (with numbered wires)

e.g. LAPPKABEL LFLEX

CLASSIC 140 (with (HAR)-approval for Europe)

Control cable, applicable by high mechanical- and chemical strain. UV-proof, may be used in free
areas!
e.g. LAPPKABEL LFLEX

CLASSIC 400 P (UV-proof)

The local lay-regulations are to be considered!

Installation Instructions Overview Control Console


Project: Garbuio
Order No.: 12002123 / 12003185



8

Overview Control Console CC7004









1
2
3
4
5
6
7
8
9
10

Power supply
Battery
Fuses master and line modules F5, F6
Bridge
Master module
Line module
Cable duct
Relays (project-specific)
Mains connection
Mains switch Q1

11
12
13
14
15
16
17
18
19

Fuse mains connection F1, F3
Overvoltage protection F7, F8
FI Protective switch F2
Service socket X1.1
Fuse external 24V F4
Connection external 24V
Connection Notebook X3

Connection terminals KKSI 9/3
(project-specific)

Installation Instructions Overview master module


Project: Garbuio
Order No.: 12002123 / 12003185



9

Overview master module

Connection terminals: max. 2,5mm



24V GND
Lines I/O 2 Lines I/O 1
51 Feed in 33 Feed in
52 not assigned 34 not assigned 17 GND 1 GND CAN
53 not assigned 35 not assigned 18 24V (max. 1 A) 2 24V (max. 1A)
54 not assigned 36 not assigned 19 RS232 TxD (Display) 3
CAN TxD
Communication bus
55 not assigned 37 not assigned 20 RS232 RxD (Display) 4
CAN RxD
Communication bus
56 not assigned 38 not assigned 21
KKSI 9/3 Mains adapter
monitoring 1
5
KKSI 9/3 Mains adapter
monitoring 2
57 not assigned 39 not assigned 22
KKSI 9/3 Cut-off /
Horn reset
6
KKSI 9/3 Mains adapter
monitoring 3
58 not assigned 40 not assigned 23
KKSI 9/3
Pressure increase 1
7
KKSI 9/3
Pressure increase 2
59 not assigned 41 not assigned 24
KKSI 9/3
Heating tape 1
8
KKSI 9/3
Heating tape 2
60 not assigned 42 not assigned 25
Relay 10
System cut-off 2
9
Relay 9
Leakage - Line
61 not assigned 43 not assigned 26
Relay 8
Sum cut-off
10
Relay 4
Leakage - Master
62 not assigned 44 not assigned 27
Relay 7
Sum Trouble
11
Relay 3
Sum Maintenance
63 not assigned 45 not assigned 28
Relay 6
Sum Alarm 1
12
Relay 2
Sum Alarm 2
64 not assigned 46 not assigned 29
Relay 5
System cut-off 1
13
Relay 1
Operational
65 not assigned 47 not assigned 30 Signal output reserve 14
Signal output
Mains adapter cut-off
66 not assigned 48 not assigned 31 Horn 1 (+) 15 Horn 2 (+)
67 not assigned 49 Flash lamp / Horn 2 (-) 32 Flash lamp 1 (+) 16 Flash lamp 2 (+)
68 Transmission 50 Flash lamp / Horn 1 (-) 24V

Installation Instructions Overview line module


Project: Garbuio
Order No.: 12002123 / 12003185



10

Overview line module

Connection terminals: max. 2,5mm



24V GND I/O 2
Lines I/O 2 Lines I/O 1
65 Feed in 47 Feed in 33 GND 2
66 not assigned 48 not assigned 34 Detector 3 17
GND
Detector circuit
1
GND
Detector circuit
67 not assigned 49 not assigned 35 Detector 4 18 Test line 2 2 Test line 1
68 not assigned 50 not assigned I/O 2 T
19 Detector 3 3 Detector 1
69 not assigned 51 not assigned 36 Test 2 20 Detector 4 4 Detector 2
70 not assigned 52 not assigned 37 Detector 3 21 KKLE 9/1 Valve 4 5 KKLE 9/1 Valve 1
71 not assigned 53 not assigned 38 Detector 4 22 KKLE 9/1 Valve 5 6 KKLE 9/1 Valve 2
72 not assigned 54 not assigned
I/O 1
23 KKLE 9/1 Valve 6 7 KKLE 9/1 Valve 3
73 not assigned 55 not assigned 39 GND 1 24 KKSI 9/3 MG cut-off 8 KKSI 9/3 MG cut-off
74 not assigned 56 not assigned 40 Detector 1 25 Relay 10 9 Relay 9
75 not assigned 57 not assigned 41 Detector 2 26 Relay 8 10 Relay 4
76 not assigned 58 not assigned I/O 1 T
27 Relay 7 11 Relay 3
77 not assigned 59 not assigned 42 Test 1 28 Relay 6 12 Relay 2
78 not assigned 60 not assigned 43 Detector 1 29 Relay 5 13 Relay 1
79 not assigned 61 not assigned 44 Detector 2 30 Valve 6 Output 14 Valve 3 Output
80 not assigned 62 not assigned Res
31 Valve 5 Output 15 Valve 2 Output
81 not assigned 63 not assigned 45 not assigned 32 Valve 4 Output 16 Valve 1 Output
82 Transmission 64 not assigned 46 not assigned


24V


Installation Instructions Electric wiring


Project: Garbuio
Order No.: 12002123 / 12003185



11

Electric mains of control console

Attention !
It must not be possible to switch of the console by the main switch of a distribution.























Installation Instructions Electric wiring


Project: Garbuio
Order No.: 12002123 / 12003185



12

Connecting the alarm means

Flash light: active in case of alarm or trouble in one zone
Horn: active only in case of alarm in one zone

Optionally the horn can be reset also over an external contact. The contact must be closed to the
reset. The Jumper J1 on the KKSI -B12 may not be set.










MM 32
GND
31
24V
22
Terminal

MM = Master module




Installation Instructions Electric wiring


Project: Garbuio
Order No.: 12002123 / 12003185



13

Connection of pressure switch (pneumatic system)

Caution !
The Jumper J1 on the KKSI B13 may not be set.

The control console of the spark extinguishment system scans a switch contact of the pressure
switch in order to check the correct functioning of the pressure booster.
(contact open = trouble)









MM
24V
23

Terminal

MM = Master module




Installation Instructions Electric wiring


Project: Garbuio
Order No.: 12002123 / 12003185



14

Connection of two spark sensors FM 1/8 or FM 3/8

Caution !
Switch S1 in terminal box has to be OFF during operation.












Line 1 LM 1
IO1T IO1
3
Line 2 LM 1
IO1T IO1
4
Terminal

LM = Line module





Installation Instructions Electric wiring


Project: Garbuio
Order No.: 12002123 / 12003185



15

Disconnecting the control console (system disconnection)

During production downtimes, e.g. necessary for carrying out maintenance and cleaning work or at
night, on weekends and public holidays, the spark detectors may be activated due to external
influences. The spark detectors could then activate the extinguishment devices and water could
flow into the system and thus cause a lot of damage.
In order to avoid damage caused by water, it is necessary to activate the function for automatically
disconnecting the system (stand-by mode).

We recommend you to use a signaling lamp in order to clearly indicate the control consoles cut-off
state. Mount the signaling lamp directly next to the control console or the switching cabinet for
fans. Please use a signaling lamp that has an adequate size so that operators standing some
meters away can still see the systems cut-off state easily.

There are two different types of system disconnection:
System disconnection 1:
In general, the system only deactivates spark detectors. The heat sensors remain active. The
different lines can be configured at will!
System disconnection 2:
The entire system is cut off. All detectors and sensors!

During system disconnection the contact must be closed!
The Jumper J1, J2 and J3 on the KKSI -B12 may not be set.



For safety reasons, it can be required that the control console does not stop immediately after
the contacts closing but after a certain time delay. In general, this time delay is 15 minutes.
However the configurator can be used to set it to values from 0 to 127 minutes.

After the adjusted time delay, the relay System disconnection 1 (K5) or System disconnection 2
(K10) actuates. The relays can activate the signaling lamp and/ or stop the production process.
The production can only begin after the control consoles reactivation.

Installation Instructions Interface overview
Project: Garbuio
Order No.: 12002123 / 12003185


16

Interface overview master module

Maximum load of the voltage-free relay contacts: ~250V / 6A



Ready: System ready. All modules and configuration checked.
Sum of alarm 2: Relay switches when the adjusted threshold of one line is exceeded
Sum of maintenance: At least one sensor channel or extinguishment group are in maintenance
mode.
Leakage Master: Uncontrolled water flow at one of the main flow switches.
System disabled 1: Contact switches during system disconnection 1 (System disabled).
Sum of alarms: Switches upon alarm in one of the lines.
Sum of troubles: Switches upon trouble in the system. (for example: at one of the lines or
extinguishing groups
* This Relays is picked up in normal operational state!
Sum of disabled: Switches when one of the lines or extinguishing groups are disabled.
Leakage Line: Uncontrolled water flow at one of the line flow switches.
System disabled 2: Contact switches during system disconnection 2 (System disabled).

All contacts on the master module can be operated also inverted, like that they are picked up in
normal operational state. No standard!

Installation Instructions Interface overview
Project: Garbuio
Order No.: 12002123 / 12003185


17

Interface overview line-referred contacts (line module)

Maximum load of the voltage-free relay contacts: ~250V / 6A

The relays of the line modules can be configured as follows:

Alarm: Contact switches upon recognition of the first spark.
Alarm threshold: Relay switches when the adjusted threshold is exceeded.
Trouble: Relay switches with a trouble on the pertinent detection
group.
This Relays is picked up in normal operational state!
Disconnection: Relay switches during disconnection of the pertinent detection
group.
Trouble Extinguishing Group: Relay switches with a trouble of the extinguishing group.
Disconnection Extinguishing Group: Relay switches during disconnection of the extinguishing
group.

According to standard 2 relays (alarm and alarm 2) are intended for each line.



The exact allocation of the relays to the lines you infer please from the list of devices.

All contacts on the line module can be operated also inverted, like that they are picked up in
normal operational state. No standard!

Installation Instructions Purging air
Project: Garbuio
Order No.: 12002123 / 12003185


18

Purging air