High-Expansion Foam Generators: Installation, Operation, and Maintenance Manual

HIGH-EXPANSION
FOAM GENERATORS
INSTALLATION, OPERATION, AND MAINTENANCE MANUAL
010040
One Stanton Street | Marinette, WI 54143-2542, USA | +1-715-735-7411 | www.ansul.com

© 2018 Johnson Controls. All rights reserved. All specifications and other information shown were
current as of document revision date and are subject to change without notice. | Part No. 442855-01
ANSUL High-Expansion Foam Generators FOREWORD
Installation, Operation, and Maintenance Manual 2018-MAR-22 REV. 01
(Part No. 442855)
This manual is intended for use with the ANSUL®

High-Expansion Foam Generator System.
Those who install, operate, recharge, or maintain these fire
suppression systems should read this entire manual. Specific
sections will be of particular interest depending on one’s
responsibilities.
Design, installation, recharge, and maintenance of the system
must conform to the limitations detailed in this manual and
performed by an individual who attended an ANSUL training
program and became trained to design, install, recharge, and
maintain the ANSUL system(s).
Fire suppression systems are mechanical devices. The
devices need periodic care to provide maximum assurance
the system will operate effectively and safely. Inspection
frequency shall be performed monthly, or sooner, depending
on operating and/or environmental conditions. Maintenance
shall be performed semi-annually or sooner, depending on
operating and/or environmental conditions.
This ANSUL systems manual is limited to the uses herein
described. For other applications, contact your local
Authorized ANSUL Distributor, Domestic District Manager,
International Area Manager, or Johnson Controls Technical
Services Department.
Note: The converted metric values in this manual are provided

for dimensional reference only and do not reflect an actual
measurement.
Part Number: 442855-01

Date: 2018-MAR-22
ANSUL and the product names listed in this material are marks and/or registered
marks. Unauthorized use is strictly prohibited.
* TEFLON and LIFE SAFETY CODE are trademarks of their respective owners.
EXPLANATION OF SAFETY ALERTS ANSUL High-Expansion Foam Generators
REV. 0 2018-MAR-22 Installation, Operation, and Maintenance Manual
(Part No. 442855)
!
p DANGER
Indicates a hazardous situation in which a person will experi-
ence serious personal injury or death if the situation is not
avoided.
! WARNING
Indicates a hazardous situation in which a person could expe-
rience serious personal injury or death if the situation is not
avoided.
! CAUTION
Indicates a hazardous situation in which a person could expe-
rience minor or moderate personal injury if the situation is
not avoided.
CAUTION
Addresses practices not related to personal injury, such as
a system part malfunctioning, property damage, or system
failure.
NOTICE
Addresses general practices or observations
related to system function that are not related
to personal injury.
ANSUL High-Expansion Foam Generators REVISION RECORD
Installation, Operation, and Maintenance Manual 2018-MAR-22 REV. 0 PAGE 1
(Part No. 442855)
DATE PAGE REV. NO. DATE PAGE REV. NO.
2018-MAR-22 1-1 01 2018-MAR-22 15-5 01
2018-MAR-22 4-1 01 2018-MAR-22 15-6 01
2018-MAR-22 4-3 01 2018-MAR-22 15-7 01
2018-MAR-22 4-4 01 2018-MAR-22 15-8 01
2018-MAR-22 5-1 01 2018-MAR-22 15-9 01
2018-MAR-22 9-1 01 2018-MAR-22 15-10 01
2018-MAR-22 10-1 01
2018-MAR-22 11-1 01
2018-MAR-22 11-2 01
2018-MAR-22 12-1 01
2018-MAR-22 12-3 New
2018-MAR-22 12-4 New
2018-MAR-22 12-5 01
2018-MAR-22 12-6 01
2018-MAR-22 12-7 01
2018-MAR-22 12-8 01
2018-MAR-22 12-9 01
2018-MAR-22 12-10 01
2018-MAR-22 12-11 01
2018-MAR-22 12-12 01
2018-MAR-22 13-1 01
2018-MAR-22 14-1 01
2018-MAR-22 15-2 New
2018-MAR-22 15-3 01
2018-MAR-22 15-4 01
LEGEND FOR PAGES WITH Indicates revised technical information.

REVISION INDICATORS: Indicates change in page sequence (located at top of page, left of header).
REVISION RECORD ANSUL High-Expansion Foam Generators
PAGE 2 REV. 0 2018-MAR-22 Installation, Operation, and Maintenance Manual
(Part No. 442855)
NOTES:
ANSUL High-Expansion Foam Generators TABLE OF CONTENTS
Installation, Operation, and Maintenance Manual 2018-MAR-22 REV. 01 PAGE TOC-1
(Part No. 442855)
SECTION PAGE SECTION PAGE

1 GENERAL INFORMATION 1-1 – 1-2 7 OPERATION 7-1 – 7-2
Introduction 1-1 Operation Procedures 7-1
2 SYSTEM DESCRIPTION 2-1 – 2-2 8 RESTORATION 8-1 – 8-2

System Description 2-1 System Restoration 8-1
Restoration Recommendations 8-1
3 SYSTEM SCHEMATICS 3-1 – 3-2
System Schematics 3-1 9 INSPECTION AND MAINTENANCE 9-1 – 9-2
Inspection and Maintenance 9-1
4 SYSTEM DESIGN 4-1 – 4-8
High-Expansion Foam Systems Design 4-1 10 TROUBLESHOOTING 10-1 – 10-2
Introduction 4-1 Troubleshooting 10-1
Installation 4-1
11 TESTING PROCEDURES AND TRAINING 11-1 – 11-4
Piping Materials 4-1
Testing Procedures and Training 11-1
Design Information 4-1
Recommendation and Best Practices for 11-1
Typical Requirements for HEF Generators 4-3
Managing High-Expansion Foam
System Discharges
Local Application System 4-5 Chemical Exposure Consideration 11-1
Aircraft Hangars – Design 4-5 Discharge Test Recommendation 11-1
Aircraft Hangars Classifications 4-5 Disposal and Environmental Consideration 11-2
Fire Protection Options 4-6 Recommendations for Containment, Overhaul 11-2
Hangar Fire Protection Design Requirements 4-6 Cleanup, and Disposal
Foam System Application 4-7
Supplementary Protection Systems 4-7 12 COMPONENTS LIST 12-1 – 12-12
Detection and Actuation Requirements 4-8 Components List 12-1
Alarms and Signaling Requirements 4-8
13 REFERENCE 13-1 – 13-2
Interconnection Considerations 4-8
Reference 13-1
5 INSTALLATION 5-1 – 5-2 Product Warranty 13-1
Installation 5-1
14 APPENDIX A – FM REQUIREMENTS 14-1 – 14-4
6 INSTALLATION DRAWINGS 6-1 – 6-4
Installation Drawings 6-1 15 APPENDIX B – UL PERFORMANCE DATA 15-1 – 15-10
TABLE OF CONTENTS ANSUL High-Expansion Foam Generators
PAGE TOC-2 REV. 0 2017-JUL-25 Installation, Operation, and Maintenance Manual
(Part No. 442855)
NOTES:
ANSUL High-Expansion Foam Generators SECTION 1 – GENERAL INFORMATION
Installation, Operation, and Maintenance Manual 2018-MAR-22 REV. 01 PAGE 1-1
(Part No. 442855)
INTRODUCTION
This manual provides operating and maintenance information
for ANSUL equipment only. It is the responsibility of the
! WARNING
designer of record to meet applicable codes, National Fire Pump, piping, and other high-expansion foam system compo-
Protection Agency (NFPA) recommendations, and insurance nents containing water should be protected from freezing,
underwriter requirements. which could damage the system, resulting in injury or flooding.
This manual provides general descriptions and typical Permitting a pump, piping, or other high-expansion foam
characteristics of high-expansion foam (HEF) generators system component to freeze will void its warranty.
and systems. For information on related equipment such
as bladder tanks, pumps, piping and valves, refer to their
respective manuals. Carefully review all relevant manuals and ! WARNING
information before operating a HEF system.
High-expansion foam systems rapidly create large volumes of
For warranty information about ANSUL HEF generators foam. In the event of an unplanned discharge of a high-expan-
systems, refer to the general terms and conditions for sion foam system, whether due to a fire or accidental release,
Johnson Controls available on the website: it is imperative that all personnel immediately evacuate the
www.ansul.com. discharge area.
! WARNING
Like any piece of complex equipment, the high-expansion
! WARNING
foam generators systems perform as designed only if used Foam can create slippery surfaces. High-expansion foam
and serviced in accordance with the manufacturer’s instruc- concentrates and high-expansion foam solutions can make
tions. All individuals operating or servicing the apparatus must floors and other surfaces slippery. Use caution when evacuat-
carefully read this manual. ing areas during a foam discharge or during emergency
response, overhaul, and cleanup operations where foam has
!
been present.
p DANGER
Rotating parts can catch hands, feet, and/or clothing. To
reduce the risk of injury, read the manuals before operating ! WARNING
the high-expansion foam generator equipment, keep shields
Exits should be kept clear at all times. Exits and evacuation
in place while equipment is operating and stay clear of moving
routes out of areas protected by a high-expansion foam system
parts, and shut off equipment before servicing.
should be kept clear and free of obstruction at all times. Per
NFPA 409, Standard on Aircraft Hangars, exits and evacuation
!
p DANGER routes from an aircraft hangar should comply with the NFPA
101, LIFE SAFETY CODE*.
Under no circumstances should personnel enter an area
during a high-expansion foam discharge to retrieve equip-
ment, tools, or other items. Personnel should not enter a foam
filled area or become immersed in foam because the foam
can make hearing difficult, obstruct visibility, inhibit normal
breathing, and possibly lead to disorientation.
SECTION 1 – GENERAL INFORMATION ANSUL High-Expansion Foam Generators
PAGE 1-2 REV. 0 2017-JUL-25 Installation, Operation, and Maintenance Manual
(Part No. 442855)
NOTES:
ANSUL High-Expansion Foam Generators SECTION 2 – SYSTEM DESCRIPTION
Installation, Operation, and Maintenance Manual 2017-JUL-25 REV. 0 PAGE 2-1
(Part No. 442855)
SYSTEM DESCRIPTION Foam Concentrate

High-Expansion foam generators use ANSUL JET-X high-ex-
HEF Generators
pansion foam concentrate.
The ANSUL HEF generators system consists of the following
Refer to the product data sheet JET-X 2% High-Expansion
components:
Foam Concentrate (Form No. F-2009121, latest revision) and
• Foam proportioning system JET-X 2 3/4% High-Expansion Foam Concentrate (Form No.
• HEF concentrate F-93139, latest revision) for further details.
• HEF generator Automatic Roof Door Vent

• Detection and control system The automatic roof door vents are actuated by a minimum of
• Intake and exhaust ventilation (optional) 40 psi (2.76 bar) water or foam solution pressure. The vent
can also be actuated by a fusible link or manually opened.
The HEF generator is powered by a foam solution (a mixture
of foam concentrate and water) driving a hydraulic (water) Refer to the product data sheet ANSUL Automatic Roof Door
motor, and requires no outside source of power. Vents (Form No. F-2017128, latest revision) for further details.
Refer to the product data sheet JET-X High-Expansion Foam
Generators (Form No. F-93137, latest revision) for more
information.
SECTION 2 – SYSTEM DESCRIPTION ANSUL High-Expansion Foam Generators
(Part No. 442855)
NOTES:
ANSUL High-Expansion Foam Generators SECTION 3 – SYSTEM SCHEMATICS
(Part No. 442855)
SYSTEM SCHEMATICS
Figure 3-1 represents the system piping and valving arrange-
ments for the ANSUL High-Expansion Foam Generator
system.
FOAM SOLUTION
BLADDER VENT VALVE
TANK SHELL FOAM CONCENTRATE

VENT VALVE
SIGHT
GLASS
WATER INTO
BLADDER TANK
FOAM SOLUTION
HIGH-EXPANSION FOAM
BLADDER TANK WITH GENERATORS (TYPICALLY
HIGH-EXPANSION FOAM LOCATED IN 2 PLACES)
CONCENTRATE
TANK SHELL
DRAIN/FILL
VALVE
SIGHT
GLASS HYDRAULIC ACTUATED
VALVE DOOR INTAKE (TYPICALLY
LOCATED IN 2 PLACES)
WATER SUPPLY
BLADDER
DRAIN/FILL
VALVE
MASTER HYDRAULIC ACTUATED PRESSURE GAUGE

SHUTOFF BALL VALVE, N.C.
VALVE OS&Y VALVE
MANUAL BALL VALVE, N.O.
PROPORTIONER
MANUAL BALL VALVE, N.C.
SWING CHECK VALVE SENSING LINES
DELUGE VALVE GROOVE COUPLING
PROCESS SYMBOLS
FIGURE 3-1
SYSTEM SCHEMATIC
010217
SECTION 3 – SYSTEM SCHEMATICS ANSUL High-Expansion Foam Generators
(Part No. 442855)
NOTES:
ANSUL High-Expansion Foam Generators SECTION 4 – SYSTEM DESIGN
(Part No. 442855)
HIGH-EXPANSION FOAM SYSTEMS - DESIGN When mounting a generator in a fixed location, care should be
taken so as not to distort the cylinder section of the generator
Introduction housing as this could interfere with the rotation of the fan/
High-expansion foam (HEF) concentrate and water are mixed motor assembly. It is imperative that the generator be firmly
in the correct proportion by various methods to form a foam braced to ensure there is no flex or movement when the
solution. This solution flows to the HEF generator with a water system is in operation.
powered motor. It is then discharged through a nozzle onto
a fine mesh stainless steel screen. A rotating fan (powered Piping Materials
by the water motor) in the generator forces large volumes of Stainless steel 304, 316, brass, galvanized and black steel
air through the stainless steel screen as the foam solution is pipe are suitable for use with foam solutions. The black steel
sprayed onto it. The air mixes with the foam solution to form pipe is only recommended for use with foam concentrates
a large discharging mass of foam solution. This clean highly when the pipe is kept flooded at all times. Stainless steel
expanded foam mass quickly fills large areas flowing around pipe is suitable for use with foam concentrates at all times.
obstacles and flooding every void smothering the fire quickly Galvanized pipe cannot be used with foam concentrate.
and effectively. It is recommended that where threaded pipe joints are in
The output of an ANSUL HEF generator in a fixed installation contact with the foam concentrate or the foam solution, use a
depends on which generator is selected. These generators TEFLON* based pipe-joining compound or a TEFLON tape to
are available in a wide output range (specified in cubic feet help ensure leak tight screw fittings.
per minute) at various foam solution inlet pressures. When
multiple units are used an almost limitless output can be Design Information
achieved. The HEF system is used for fire suppression Note: For aircraft hangars please see the section titled Fire Protection Options.
of solid fuel or flammable liquid fires in areas where the
expanded foam can be contained. Flooding System is a fixed foam fire protection system
consisting of HEF generators, a proportioning system, foam
Examples of applications include: concentrate, water supply, and the necessary intercon-
• Ship holds necting piping. This type of system is designed to discharge
the expanded foam into an enclosed space, or around the
• Aircraft hangars
hazard. The total flood system is suitable for use where there
• Hazardous material/waste storage areas is a permanent enclosure around the hazard that is capable
• Flammable liquid packaging areas of holding the required amount of foam for the designed
duration.
• Flammable liquid drum storage
For adequate protection, there should be sufficient foam
• Warehouse areas such as rolled paper, tire storage, in rack
concentrate to allow the system a discharge rate suffi-
storage of combustible materials, and boat storage
cient to cover the hazard to an effective depth before any
HEF systems have been installed as added protection for unacceptable damage occurs.
Liquid Natural Gas (LNG) facilities for fire suppression and
The minimum total depth of foam is to be not less than
for controlling vapors released from an accidental LNG spill.
1.1 times the height of the highest hazard being protected
Blanketing spills with HEF is an effective method for reducing
but in no case can it be less than 2 ft (0.61 m) above that
and controlling fire intensity and decreasing LNG vapor
hazard. Submergence time varies with the type of building
generation.
construction and if the building has a sprinkler system.
Installation Table 4-1 provides the maximum submergence times in
minutes for high-expansion foam measured from the start of
The HEF system must be designed and installed in strict
foam discharge. The chart does not include submergence
accordance with NFPA 11 (2002 or later) standard for low-,
times when used on water miscible/polar solvent type fuels or
medium-, and high-expansion foam and any guidelines estab-
flammable liquids having a boiling point less than
lished by the “Authority Having Jurisdiction” or insurance
100 ºF (38 ºC). These products may require higher application
provider.
rates. Please check with Technical Services at Johnson
Johnson Controls recommends a contractor having previous Controls for application guidelines. When used in tire storage
experience in installing fixed fire protection foam systems areas, the submergence time shown reflects the area also
install the HEF system. Upon installation, the HEF system having sprinkler protection. When certain combustible
components should be located and arranged so that any products are stored 15 ft (4.57 m) or higher, fire spread may
recharging, inspection, testing or general maintenance will still be rapid and the discharge times in the submergence
cause a minimum disruption to the fire protection system. chart may not be suitable. A faster submergence time may be
The HEF Generator may be installed in either a vertical or a more appropriate.
horizontal position.
Note: Always refer to the UL Certification Directory and the FM Approval Guide
for Approved operating parameters and orientations.
SECTION 4 – SYSTEM DESIGN ANSUL High-Expansion Foam Generators
(Part No. 442855)
HIGH EXPANSION FOAM SYSTEMS - DESIGN (Continued)
Design Information (Continued)

The foam discharge rate is to be sufficient to satisfy the
foam depth requirements and submergence times allowing
compensation for normal foam shrinkage, foam leakage and
breakdown effects of any sprinkler discharge.
The factor for compensation for normal foam shrinkage is
1.15.
TABLE 4-1: M
AXIMUM SUBMERGENCE TIME (MINUTES) FOR HIGH-EXPANSION FOAM MEASURED FROM START OF
ACTUAL FOAM DISCHARGE
Light or Unprotected Steel Heavy or Protected or Fire-Resistive
Construction Construction
Hazard Sprinklered Non-Sprinklered Sprinklered Non-Sprinklered
Flammable liquids (flash points below 3 2 5 3
100 ºF (38 ºC) having a vapor pressure not
exceeding 276 kPa (40 psia)
Combustible liquids (flash points of 4 3 5 3
100 ºF (38 ºC) and above)1
Low-density combustibles (i.e., foam rubber, 4 32 6 42
foam plastics, rolled tissue, or crepe paper)
High-density combustibles (i.e., rolled paper 7 52 8 62
kraft or coated banded)
High-density combustibles (i.e., rolled paper 5 42 6 52
kraft or coated unbanded)
Rubber tires 7 52 8 62
Combustibles in cartons, bags, fiber drums 7 52 8 62
1 Polar
solvents are not included in this table. Flammable liquids having boiling points less than 100 ºF (38 ºC) might require
higher application rates (see NFPA 30).
2 These
submergence times might not be directly applicable to storage piled above 15 ft (4.6 m) or where fire spread through
combustible contents.
(Part No. 442855)
HIGH EXPANSION FOAM SYSTEMS - DESIGN (Continued) TYPICAL REQUIREMENTS FOR A HEF GENERATOR SYSTEM
The typical requirements for a HEF system for a building
Design Information (Continued)
without a sprinkler system are:
The compensation factor for loss of foam due to leakage
• Building: Light steel, no sprinklers
around doors, windows and through unclosable openings is
determined by the design engineer after proper evaluation of • Size: 100 ft x 30 ft x 10 ft (30.48 m x 9.14 m x 3.05 m)
the structure. This factor cannot be less than 1.0. Depending • Products stored: Low density combustibles, 7 ft (2.13 m) in
on foam expansion ratio, sprinkler operation and foam height
depth, this factor may be as high as 1.2 for a building with all
• Cubic area to be protected: 100 ft x 30 ft x 9 ft (30.48 m x
openings normally closed.
9.14 m x 2.74 m) above height of combustibles, or 27,000
Calculating Factor for Compensation of Breakdown by ft3 (764.6 m3)
Sprinkler Discharge • Fill time: Per NFPA 11, 3 minutes
The factor for compensation of breakdown by sprinkler
Formula for system without sprinklers:
discharge (Rs) is determined by the following formula, or by
test: R = (V/T) x Cn x CL
Rs = S x Q Where:
Where: • V = 27,000 ft3 (764.6 m3)
•R
s = Factor for compensation of breakdown by sprinkler • T = 3 minutes
discharge • Cn = 1.15
• S = Foam breakdown in cfm per gpm of sprinkler discharge. • CL = 1.1 (slight leakage)
S is to be 10 cfm/gpm (0.748 cmm/Lpm)
• Q = Estimated total discharge from maximum number of R = (9,000) x 1.15 x 1.1 = 11,385 cfm (322.4 cmm)
sprinklers expected to operate gpm (Lpm) 11,385 cfm (322.4 cmm) is required for this set of building
requirements.
Calculating Minimum Rate of Foam Discharge
The formula for calculating the minimum rate of foam Equipment List
discharge or total generator capacity allowing for compen- • 1 x HEF generator 12,000 cfm (339.8 cmm) / 59 psi
sation of normal foam shrinkage, foam leakage and (4.07 bar) / 170 gpm (643.5 Lpm)
breakdown effects of sprinkler discharge is:
• 1 x 3 in. between flange style, ratio controller, flow range
R = (V/T + Rs) x Cn x CL 70 gpm to 750 gpm (265 Lpm to 2,839 Lpm)
Where: • 1 x 50 gallon vertical bladder tank (170 gpm x 0.02 =
• R = Rate of discharge in cfm (cmm) 3.4 gpm of 2% JET-X Foam x 15 minutes = 51 gallons of
• V = Submergence volume in ft3 (m3) foam concentrate)
• T = Submergence time in minutes • 55 x gallons JET-X foam concentrate (51 gallons system fill,
4 gallons system test)
• Rs = Rate of foam breakdown by sprinklers in cfm (cmm)
• Selection of swing checks and ball valves
• Cn = Compensation for normal foam shrinkage
• CL = Compensation for leakage Ventilation
All openings such as doorways, windows, etc. below the When outside air is used for the generation of high-expansion
design filling depth shall close automatically before or during foam, air intake and exhaust vents shall be used to allow the
foam discharge when the system is activated. system to function correctly.
Discharge Duration: There shall be sufficient high-expansion Air Intake Requirements
foam concentrate and water to allow continuous operation of
the system at the design density for 25 minutes or to generate Air intakes for the use of outside air shall have an area
4 times the submergence volume, whichever is less, but in no greater than or equal to the flow area of the high expansion
case less than enough for a 15 minute discharge. generators used. Ducting shall be designed by a qualified
HVAC (Heating, Ventilation, and Air Conditioning) engineer
to minimize any pressure loss. A single air intake per high
expansion foam generator is typical but use of ducting to feed
multiple generators from a single air intake vent is acceptable
providing the flow area requirement is met.
PAGE 4-4 REV. 01 2018-MAR-22 Installation, Operation, and Maintenance Manual
(Part No. 442855)
TYPICAL REQUIREMENTS FOR A HEF GENERATOR SYSTEM Example Calculation 1:

(Continued) Generator Model: JET-X 5A
Ventilation (Continued) Quantity: 8 units at 70 psi (4.8 bar)
Output: 7,632 cfm per unit (216 cmm per unit)
Generator Flow
Area Exhaust Vent Model: 48 in. Automatic Roof Vent1
Model ft2 (m2)
NFPA Air Velocity Requirement Calculation
High-Expansion JET-X 2A 1.5 (0.14)
Qty. of Generators x Output Qty. of Exhaust
Generator JET-X 5A 9.6 (0.90) = Vents Required
Vent Area x Maximum Allowable Air Velocity
JET-X 15A 13.4 (1.24)
JET-X 20 13.4 (1.24)
8 Generators x 7,632 cfm
JET-X 27 13.0 (1.21) = 3.8*
16 ft2 x 1000 ft/min
Vent Flow Area * Round up quantity to four 48 in. Exhaust Roof Vents.
Automatic Roof Vent 48 in. 16.0 (1.50)
(FM Approved)* FM Flow Area Requirement Calculation
60 in. 25.0 (2.32)
Qty. of Generators x Generator Area
= Qty. of Exhaust Vents
Vent Area
Wall Intake Damper JET-X 5A 15.8 (1.47)
(Not FM Approved) JET-X 15/20/27 25.2 (2.34) 8 Generators x 9.6 ft2
= 4.8**
16 ft2
Wall Relief Louver JET-X 5A 6.8 (0.63) ** Round up quantity to five 48 in. Exhaust Roof Vents.
(Not FM Approved) JET-X 15/20/27 23.8 (2.21) Example Calculation 2:
Note: Free Flow Area is the same for standard models and LNG models. Generator Model: JET-X 15A
* Can be utilized as intake and/or relief vents in FM Approved systems. Quantity: 8 units at 70 psi (4.8 bar)
Exhaust Vent Requirements Output: 19,141 cfm per unit (542 cmm per unit)
NFPA Requirement (NFPA 11 2016 Edition, Section Exhaust Vent Model: 48 in. Automatic Roof Vent1
6.12.4.1.2.2): Venting velocity shall not exceed 305 m/min
(1000 ft/min) in free air. NFPA Air Velocity Requirement Calculation
Qty. of Generators x Output Qty. of Exhaust
FM Requirement (FM 5130): Per FM 5130, no backpressure =
shall be placed on the high expansion foam generator. To Vent Area x Maximum Allowable Air Velocity Vents Required
achieve this, the exhaust vent area must be greater than
or equal to the generator flow area. In addition, FM Global 8 Generators x 19,141 cfm
requires compliance with NFPA 11. When specifying venti- = 9.6*
16 ft2 x 1000 ft/min
lation for a project requiring compliance with FM Global
standards, calculations for both requirements must be * Round up quantity to ten 48 in. Exhaust Roof Vents.
completed and the more conservative of the two should be
used. FM Flow Area Requirement Calculation
Qty. of Generators x Generator Area
= Qty. of Exhaust Vents
Vent Area
8 Generators x 13.4 ft2

= 6.7**
16 ft2
** Round up quantity to ten 48 in. Exhaust Roof Vents.
1 Exhaust vent model selected for example purposes. Other

sizes and styles of exhaust vents are available to fit a variety
of roof or sidewall intake or exhaust venting applications.
(Part No. 442855)
LOCAL APPLICATION SYSTEM GROUP II AIRCRAFT HANGAR

This type of system consists of a fixed foam-generating device A hangar having an aircraft access door height of 28 ft (8.5 m)
complete with the necessary piping and foam concentrate or less can be classified as a Group II aircraft hangar.
proportioning equipment. The system is designed to protect The fire area and type of hangar are defined as follows:
a specific piece of equipment or discharge directly onto a
potential hazard area. Local application systems can be
Single Fire Area (Inclusive)
used to protect hazards located indoors, outdoors or in partly
sheltered areas. When used outdoors or in partly sheltered Type of Construction ft2 (m2)
areas, provisions should be made to compensate for the Type I 443 and 332 30,000 - 40,000 (2,787 - 3,716)
effects of wind or other climatic conditions.
Type II (222) 20,001 - 40,000 (1,858 - 3,716)
Discharge Duration: Foam shall be discharged at a rate to
Type II (111), III 15,001 - 40,000 (1,394 - 3,716)
cover the spill hazard to a depth of 2 ft (0.61 m) within 2
(211), and IV (2HH)
minutes. System must be sized for no less than 12 minutes of
continuous operation. Type II (000) 12,001 - 40,000 (1,115 - 3,716)
Note: For aircraft hangar design there may be additional requirement per Type III (200) 12,001 - 40,000 (1,115 - 3,716)
NFPA 409, Standard on Aircraft Hangars and the Department of Defense Fire
Protection Engineering Design Criteria. Type V (111) 8,001 - 40,000 (743 - 3,716)
Type V (000) 5,001 - 40,000 (465 - 3,716)
Aircraft Hangers - Design
GROUP III AIRCRAFT HANGAR
AIRCRAFT HANGAR CLASSIFICATIONS
The classification criteria for a Group III aircraft hangar
Considering the value of commercial and military aircraft, it include:
has become extremely important to have a reliable fixed fire
• An aircraft access door height of 28 ft. (8.5 m) or less
protection system in aircraft storage, servicing, maintenance
and paint facilities. The HEF generator fire protection system • A single fire area that measures up to the maximum square
is designed to provide a reasonable degree of protection for footage permitted for specific types of construction per
any Class A or B type fire. NFPA 409 Table 4.1.3
Most fire protection systems for aircraft handling facilities are The fire area and type of hangar are defined as follows:
designed in accordance with NFPA 409, Standard on Aircraft
Hangars, or the Department of Defense Unified Facilities Maximum Single Fire Area
Criteria - Aircraft Maintenance Hangars (UFC 4-211-01). Per Type of Construction ft2 (m2)
NFPA 409 there are four basic aircraft hangar designs that
are classified: Type I 443 and 332 2,787 (30,000)
• Group I Aircraft Hangar Type II (222) 1,858 (20,000)
• Group II Aircraft Hangar Type II (111), III 1,394 (15,001)

(211), and IV (2HH)
• Group III Aircraft Hangar
Type II (000) 1,115 (12,001)
• Group IV Aircraft Hangar
Type III (200) 1,115 (12,001)
GROUP I AIRCRAFT HANGAR
Type V (111) 743 (8,000)
A hangar having at least one of the following features and
operating conditions: Type V (000) 465 (5,001)
• An aircraft access door height over 28 ft (8.5 m)

Note: Building construction types are defined in NFPA 220,
• A single fire area in excess of 40,000 ft2 (3,716 m2) Standard on Types of Building Construction.
• Provision for housing an aircraft with a tail height over 28 ft GROUP IV AIRCRAFT HANGAR
(8.5 m)
A Group IV aircraft hangar may be a member-covered, ridge,
• Provision for housing strategically important military aircraft steel or frame structure.
as determined by the Department of Defense
(Part No. 442855)
LOCAL APPLICATION SYSTEM (Continued) Hangar Fire Protection Design Requirements

Aircraft Hangers - Design (Continued) GROUP I HANGAR FIRE PROTECTION DESIGN
FIRE PROTECTION OPTIONS REQUIREMENTS
Once the aircraft hangar classification has been determined, Other than those housing unfueled aircraft, there are three
a suitable fire protection system can be established. There recommended options for protecting Group I hangars:
are four types of foam fire protection systems suitable for the • A foam-water overhead deluge system. If the hangar
protection of an aircraft hangar bay. houses single aircraft having wing areas greater than
• Overhead Foam/Water Sprinkler System 3000 ft2 (278.7 m2) a supplementary system consisting of
• Foam Monitor System a either a low-level low-expansion system or a low-level
• Foam Hand Hose Line System high-expansion foam system shall be provided covering
the floor area beneath the aircraft being protected. Both
• High-Expansion Foam System
AFFF systems shall be designed for 10 minute operation.
These systems may be used separately or they may be combined. The system shall achieve control of the fire within the
OVERHEAD FOAM/WATER SPRINKLER SYSTEM protected area in 30 seconds of the system actuation, and
An overhead foam water sprinkler system can be one of the suppression of the fire within 60 seconds.
following types: • A combination of a closed-head water sprinkler system and
• Closed Head Preaction an automatic low-level low-expansion foam system.
• Standard Wet Pipe • A combination of a closed-head water sprinkler system and
• Deluge System an automatic low-level high-expansion foam system.
If used with any protein based type foam concentrate, the If the foam-water sprinkler system is also used for column fire
foam water sprinkler heads must be air-aspirating. When protection within the hangar in lieu of the column having a fire
used with an aqueous film-forming foam (AFFF), the sprinkler resistive rating of not less than 2 hours, allowances must be
heads can be standard non-air aspirating. When using protein made for the required additional foam concentrate. A reserve
based foam concentrates, use the appropriate application rate supply of foam concentrate must be directly connected into
as noted in NFPA 409 for each hangar type. AFFF systems the system and be readily available if required.
shall use an application rate of 0.16 gpm per square foot of Foam-water hand hose systems shall be installed if the
floor area. aircraft DOES NOT have drained and purged fuel tanks.
MONITOR SYSTEMS GROUP II HANGAR FIRE PROTECTION REQUIREMENTS
Monitor systems may be one of two types:
Other than those housing unfueled aircraft, there are four
• Oscillating recommended options for protecting Group II hangars:
• Fixed nozzle type
• In accordance with the requirements for a Group I Hangar.
OSCILLATING MONITOR SYSTEMS
• A combination of a closed-head water sprinkler system and
Oscillating monitor systems consist of monitors that automat- an automatic low-level low-expansion foam system.
ically oscillate from side to side when discharging foam onto
the hangar floor. They are normally preset to oscillate over a • A combination of a closed-head water sprinkler system and
given arc to provide required flow rate over a specific area. an automatic low-level high-expansion foam system.
• A closed-head foam-water sprinkler system.
FIXED MONITOR SYSTEMS
Fixed monitor systems have nozzles that are typically GROUP III HANGAR FIRE PROTECTION REQUIREMENTS
mounted on a manifold or as single units approximately • Fixed fire protection systems are not normally required.
3 ft (0.91 m) above the hangar floor. They are preset for
• If any hazardous operations such as fuel transfer, welding,
angle of elevation and discharge pattern to achieve the best
painting, torch cutting, etc. are performed in a Group III
possible stream pattern and range while keeping the stream
Hangar, the hangar should be protected as per a Group II
low enough to flow under the wing of any aircraft. This type
Aircraft Hangar.
of monitor system is often used where aircraft or mainte-
nance equipment in the hangar could interfere in the normal GROUP IV HANGAR FIRE PROTECTION REQUIREMENTS
operation of the oscillating type monitor. Where the hangar fire area is greater than 12,000 ft2
FOAM HAND HOSE LINE SYSTEMS (1114.8 m2) and housing fueled aircraft, the design require-
Foam hand hose line systems are required as supplementary ments shall be in accordance with any of the following options:
protection in Group I and II Aircraft Hangars. • A low-expansion foam system
HIGH-EXPANSION FOAM SYSTEMS • A high-expansion foam system
High-expansion foam systems use a high-expansion generator • An automatic sprinkler protection system
to mix foam concentrate with air and water creating large
ADDITIONAL REQUIREMENTS FOR HANGARS
volumes of foam for an effective foam blanket.
Fire extinguishers must be distributed throughout the aircraft
hangar per NFPA 10 Standard for Portable Fire Extinguishers.
(Part No. 442855)
AIRCRAFT HANGERS - DESIGN (Continued) SUPPLEMENTARY PROTECTION SYSTEMS
Foam System Application High-Expansion Foam System

OVERHEAD PRIMARY PROTECTION SYSTEMS The generators should only be mounted at the ceiling or
• Discharge duration of 10 minutes on exterior walls of the hangar where outside air is used to
generate the foam. It is recommended that the high-expansion
• Application rate: generators be installed so that the flow of foam on the floor is
- 0
.16 gpm per sq. ft for non-aspirating discharge devices directed to areas immediately adjacent to, but not directly onto
using AFFF solution the aircraft. Please refer to the section on High-Expansion
Foam Systems, page 4-1, for further information.
- 0
.20 gpm per sq. ft for air-aspirating discharge devices
using protein foam, fluoroprotein foam or AFFF solution If more than one aircraft is located within any drainage
system, it is recommended that the supplementary foam
• A reserve supply of foam concentrate should be directly
monitor system be capable of effectively covering the
connected to the system and be readily available.
complete floor beneath all aircraft.
• If the foam concentrate is injected into the water supply by Note: FM Approved systems must meet the requirements as listed in FM Global
a foam pump, two pumps are required - one main, and one Property Loss Prevention Data Sheet 7-93N.
reserve, either of which can provide the necessary supply of
foam concentrate at the design rate.
CALCULATING PRIMARY FOAM QUANTITY
1. U
se the following formula to determine the foam solution
discharge rate:
Foam Solution Discharge Rate = Floor Area x
Application Rate
Note: The foam solution discharge rate is required to
determine the proportioner size:
2. C
alculate the foam concentrate quantity using the following
formula:
Quantity = Foam Solution Discharge Rate x 10 Minutes x
Concentrate % * x 1.15 (15% Overage)
*Concentrate % is expressed as: 0.01 for 1% concentrates,
0.03 for 3% concentrates, 0.06 for 6% concentrates, etc.
Note: The foam concentrate supply must be based upon two
separate calculations (demand calculation and supply calcu-
lations). The supply calculation is not normally available at
the preliminary system design stage. It is recommended that
a 15% overage be included to compensate for this unknown
factor. The 15% overage is based upon the maximum
variance allowed between the lowest density and highest
density sprinkler within an individual sprinkler zone.
(Part No. 442855)
DETECTION AND ACTUATION REQUIREMENTS

Foam fire suppression systems may require listing or
approved automatic detection devices capable of sensing and
indicating, heat, smoke, and/or flames, as required by local
code and installed to NFPA standards. Automatic detection
devices must use a reliable source of power that meets
NFPA 72. All automatic devices for fire suppression systems
must include a means of immediately signaling an alert in the
event of a detection device failure.
ALARMS AND SIGNALING REQUIREMENTS

HEF systems must include audible alarms that will alert
personnel when the HEF system is operating, as well as when
any supervised component of the system has failed. The
appropriate type and number of alarms must be installed and
must be located where they will be effective.
Alarms must be sounded both before discharge and after HEF
system operation. Alarms that indicate system failure must be
immediate, as well as distinctive from hazard and operational
alarms.
Refer to detection sections of NFPA 11, NFPA 72 and
NFPA 409 for detection systems and actuation devices.
Follow the regulations of the Authority Having Jurisdiction
(AHJ) and relevant insurance underwriters.
FM requires the submission of the alarm detection system for
review and approval on FM-insured locations.
INTERCONNECTION CONSIDERATIONS
Interconnections can be made through the alarm detection
system. Considerations should be given to the requirements
of NFPA 72 and insurance underwriters, based on specific job
requirements and the Authority Having Jurisdiction (AHJ).
ANSUL High-Expansion Foam Generators SECTION 5 – INSTALLATION
(Part No. 442855)
INSTALLATION There are more corrosion-resistant materials that may be

To prepare the HEF foam generators for placement in service: used - reference Tyco Technical Bulletin Foam Systems
- Acceptable Materials of Construction Technical Bulletin
1. Verify all units and support items ordered are shipped (Form No. T-2016111, latest revision) or contact Johnson
and received. Move each unit to the desired installation Controls Technical Services Department for other recom-
location prior to removing the packaging restraints. mended piping materials.
! WARNING NOTICE
Moving the units on the shipping pallet with the packaging Galvanized carbon steel should not be
restraints removed could lead to possible shift loading, used with any foam concentrate piping.
which in turn could lead to damage to the unit and/or All piping, fittings and valves should be
injury to personnel. appropriately rated to handle the required
system pressure.
2. Remove all cord, wrapping, and banding ties. Examine
entire system and component parts for concealed Johnson Controls recommends using a TEFLON based
shipping damage before placement or securing in place pipe-joining compound and/or a TEFLON tape where
on site. threaded pipe joints are in contact with the foam concen-
3. Lift the units into place using appropriate load rated trate or solution to help ensure leak-tight threaded
shackles, straps, and/or chains and appropriate machines fittings. Grooved fittings with EPDM gasket material are
to lift the units. Take care to handle the units in a manner acceptable alternatives to threaded pipe joints.
that prevents the painted surfaces from being scratched. The relevant piping schedule information is described
in the NFPA 11, NFPA 13, NFPA 16, and NFPA 409
NOTICE standards.
Units must never be lifted by the discharge 7. Various techniques can be employed to install HEF
screen, inlet guard or piping. generators and hydraulic air/intake/exhaust vents.
Best practices, as described in NFPA 12 and NFPA 16
standards, should be employed and verified by a qualified
4. To install the HEF generators system, Tyco recommends
engineering firm.
the use of a licensed fire protection contractor with
previous experience of designing and installing fixed For seismic bracing guidelines, see the latest version of
high-expansion fire protection foam systems. NFPA 13.
The unit must be installed in accordance with the latest
version of NFPA 11 or NFPA 409, and/or any guidelines
established by the authority having jurisdiction where
applicable.
The system should be supported from the bottom (not
the top) when in a horizontal position, and from the front
and the rear when in a vertical position. The system must
be firmly braced to ensure there is no flex or movement
during operation.
5. To install the hydraulic actuated air intake and exhaust
vent refer to the manufacturer’s instructions or to the
datasheet ANSUL Automatic Roof Door Vents (Form No.
F-2017128, latest revision). The ducting necessary to
connect HEF generators must provide adequate air flow,
as required for each generator, and must be designed by
a qualified HVAC engineer.
6. Piping for the HEF generators must comply with the
current versions of NFPA 11, NFPA 13, NFPA 16 and
NFPA 409.
The acceptable piping materials are:
• Carbon steel
• Galvanized carbon steel (foam solution only)
• 304 and 316 grade stainless steel
• Brass
SECTION 5 – INSTALLATION ANSUL High-Expansion Foam Generators
(Part No. 442855)
NOTES:
ANSUL High-Expansion Foam Generators SECTION 6 – INSTALLATION DRAWINGS
(Part No. 442855)
INSTALLATION EXAMPLES
For installation details, review Figure 6-1 to Figure 6-9.
FIGURE 6-1
SIDE VIEW OF FOAM GENERATOR WITH
ANGLE IRON BRACKETING JET-X 15A
010214
FIGURE 6-2
TYPICAL WALL MOUNT
010216
SECTION 6 – INSTALLATION DRAWINGS ANSUL High-Expansion Foam Generators
(Part No. 442855)
INSTALLATION EXAMPLES (Continued)
FIGURE 6-3
TYPICAL ROOF MOUNT
010215
HYDRAULIC ACTUATED ROOF TOP

DOOR INTAKE
AIR INTAKE DUCT

FIGURE 6-4
FRONT VIEW OF FOAM GENERATOR WITH AIR
INTAKE IN HORIZONTAL MOUNT POSITION
009635
ANSUL High-Expansion Foam Generators SECTION 6 – INSTALLATION DRAWINGS
(Part No. 442855)
INSTALLATION EXAMPLES (Continued)
HYDRAULIC ACTUATED ROOF TOP

DOOR INTAKE
GENERATOR HOUSING
STRUCTURAL SUPPORT
FOAM SCREEN
FOAM SOLUTION INLET
AIR INTAKE DUCT
FIGURE 6-5
ROOFTOP VIEW OF FOAM GENERATOR WITH AIR
INTAKE IN HORIZONTAL MOUNT POSITION
009636
RETAINING STRAP
(2 PLCS)
TOP BEAM CLAMP
W/ LOCKNUT (2 PLCS)
STEEL BAR 2 1/2 IN. DIA X 5 FT - 6 IN. SCHEDULE 40 2 1/2 IN. PIPE
JOISTS TRAPEZE BAR RINGS
(2) TRAPEZE BAR PER GENERATOR (2 PLCS) AFCON “FIG. 077“
AFCON “FIG. 077“
QUICK END THREADLESS QUICK END THREADLESS
BRACE FITTING BRACE FITTING
2-1/2 IN. PIPE RING
1IN. SCH. 40 PIPE 1 IN. SCH. 40 PIPE

1 IN. DIA SCH.
40 PIPE (TYP)
1/2 IN. DIA ALL 1 IN. PIPE CLAMP

THREAD 1/2 IN. DIA ALL
ROD (TYP.) THREAD
ROD (TYP.)
1/2 IN. ANGLE 1/2 IN. ANGLE

BRACKET BRACKET
3/8 IN. X 1IN. HEX 3/8 IN. X 1IN. HEX

BOLT (TYP.) BOLT (TYP.)
FOAM GENERATOR
FIGURE 6-6Z
FOAM GENERATOR MOUNTING DETAILS
010255
SECTION 6 – INSTALLATION DRAWINGS ANSUL High-Expansion Foam Generators
(Part No. 442855)
NOTES:
ANSUL High-Expansion Foam Generators SECTION 7 – OPERATION
(Part No. 442855)
OPERATING PROCEDURES
Reference relevant portions of NFPA 11, NFPA 409 and other
applicable codes and standards for operation and control of
the HEF generators system. Refer to NFPA 11, NFPA 25,
NFPA 409 and other applicable codes and standards for
maintenance and inspection activities.
To produce the rated capacity for the HEF generators system:
1. Connect the foam solution supply to the HEF generators
system inlet. Foam solution supply must be free of scale,
mud, dirt, etc. Use a strainer if necessary.
2. Turn on the foam solution supply. Ensure each generator
is operating within the approved pressure range. Refer
to data sheet JET-X High-Expansion Foam Generators
(Form No. F-93137, latest revision) for performance
parameters.
SECTION 7 – OPERATION ANSUL High-Expansion Foam Generators
(Part No. 442855)
NOTES:
ANSUL High-Expansion Foam Generators SECTION 8 – RESTORATION
(Part No. 442855)
SYSTEM RESTORATION Restoration Recommendations
System Restoration After Discharge CONTAINMENT

After foam generation, the HEF generator system inlet strainer An unplanned discharge, by definition, means that compre-
should be cleaned and the HEF generators should be flushed, hensive containment measures are likely not to be in place.
if applicable, with clean water. To flush the HEF generators, While the effectiveness of a HEF system is dependent upon
first turn off the foam concentrate isolation valve and then keeping the foam in the area being protected, design calcu-
operate the system until clean water exits the generator. lations generally assume significant loss. For example, NFPA
After flushing, reset the HEF generators system by following 409, Standard on Aircraft Hangars system calculations include
these steps: a safety factor of 20% to account for “leakage”, so foam lost
through openings does not degrade system performance.
1. Shut down the system. However, keeping as much of the foam as possible in the
2. Drain all interconnecting piping. protected area is desirable to prevent unintentional release to
the environment.
3. Re-setup the system for use.
It is recommended that any site with a HEF system has
Note: If automatic roof vents are installed in the system, they
an emergency containment plan in place. This plan should
need to be reset.
include measures to contain expanded foam to the protected
Clean Up After Discharge space and prevent discharge of foam solution to waterways
and sewers. Containment of high-expansion foam is readily
Fresh high-expansion foam is very resilient and difficult accomplished by closing doors and windows. Openings that
to break down by spraying with water. However, the foam cannot be closed can be blocked with commonly available
solution will drain out of the foam blanket over time, making materials such as plywood, plastic sheet, or fine screen like
it much easier to break down as time passes. It is recom- that used for windows. NFPA 11, Standard for Low-, Medium-,
mended that discharged foam be left to drain for 3 - 6 hours, and High-Expansion Foam, Annex E provides excellent infor-
or overnight, before beginning cleanup efforts. mation on containment scenarios and options.
! WARNING OVERHAUL FOLLOWING A FIRE EVENT

The recommendations of the latest version of NFPA 11,
High-expansion foam concentrates and high-expansion foam Annex A, A.6.12.10 – A.6.13.3.2, should be followed during
solutions can make floors and other surfaces slippery. All overhaul of the protected area following a fire event. Failure
personnel should be warned of this risk and use caution to to follow these recommendations could lead to re-ignition or
avoid slips and falls. resurgence of the original fire, in addition to increasing the
potential for environmental release of foam and/or unnec-
Disposal and Environmental Considerations essary property damage. As noted in Annex A of NFPA 11,
HEF systems are typically designed with the intent of rapidly
The owner or operator of a facility is ultimately responsible for controlling a fire in order to minimize total property damage
the proper disposal of all effluent produced. Every facility is from the fire, and not necessarily to extinguish it. Unless it
different and it is the owner/operator’s responsibility to ensure is known with certainty that there is no fire and there are no
proper containment and disposal of waste water in accor- personnel in the protected space, special care should be
dance with local, state, and federal regulations. Refer to the taken to ensure that overhaul operations do not compromise
latest version of NFPA 11, Standard for Low-, Medium-, and the fire suppression being provided by the foam blanket.
High-Expansion Foam, Annex E for options and best practices
on containment and disposal. CLEAN UP AND DISPOSAL FOLLOWING A FIRE EVENT
In general, firefighting foam waste waters are treatable in The cleanup and disposal recommendations in the event
sewage treatment works. The bacteria in most wastewater of an accidental discharge, described above, also apply to
treatment facilities will readily break down the components in discharges following a fire event, with additional attention
firefighting foams as they are very similar to components in given to fuel contamination. A discharge in a fire situation
many soaps and shampoos. However, these bacteria may not may produce wastewater contaminated with fuel that must
be accustomed to large quantities of these components and be disposed of properly. Care should be taken to ensure that
may need to be acclimated to prevent a treatment plant upset. wastewater is free of fuel contamination prior to discharge.
It is strongly recommended that the EHS department for the NFPA 11, Annex E, E.6 provides information and guidance on
site, the local wastewater treatment plant, and the Authority fuel separation from foam-water solutions.
Having Jurisdiction (AHJ) for disposal be consulted before
discharging any foam solution.
SECTION 8 – RESTORATION ANSUL High-Expansion Foam Generators
(Part No. 442855)
NOTES:
ANSUL High-Expansion Foam Generators SECTION 9 – INSPECTION AND MAINTENANCE
(Part No. 442855)
INSPECTION AND MAINTENANCE
CAUTION
Prior to any inspection and maintenance activities, de-energize
and lock-out the system according to site procedures.
HEF generator system should be inspected semi-annually

and should be maintained on a regular schedule by trained or
certified technicians. The HEF generators system water motor
should be checked for free rotation annually and the nozzle
inspected for visible clogging. Fan rotation can be checked by
reaching through the fan guard with a slim screwdriver with a
6-inch or longer blade and rotating the fan. Johnson Controls
recommends the HEF generators system be operated with
water annually to verify full rotation and flow.
The generator motor should be greased as needed (applicable
to JET-X 27 model only) by removing the rear guard screen
and lubricating each of the four grease fittings with approxi-
mately 2 ounces of lithium-based NLGI No. 2 Grease, such as
one of the following suggested grease products:
• Amoco Amolith EP2
• Atlantic Richfield Litholine EP2
• Exxon Ronex MP
• Mobil Oil Mobilith AW2
• Shell Alvania EP2
• Chevron SRI NLGI 2
After greasing, wipe off any grease that has leaked out and
rotate the fan to work in the new grease. Reinstall the guard
screen upon completion.
Refer to the inspection checklist in NFPA 25 for inspection
and maintenance activities (see Section 13, “Reference”).
SECTION 9 – INSPECTION AND MAINTENANCE ANSUL High-Expansion Foam Generators
(Part No. 442855)
NOTES:
ANSUL High-Expansion Foam Generators SECTION 10 – TROUBLESHOOTING
(Part No. 442855)
TROUBLESHOOTING
Table 10-1 displays troubleshooting guidelines.
Be sure the temperature of the concentrate is within 35 °F to
120 °F (2 °C to 49 °C).
For assistance, consult Johnson Controls Technical Services
Department.
Component Disorder Corrective Action

Foam Insufficient Check the following operational aspects of the foam generation process:
foam generation 1. Ensure the water pressure is within the operating range at the water turbine inlet (see data
sheet for specific pressure and volume needed for each unit).
2. Check for a clogged nozzle or turbine by performing the following steps:
a. De-energize and lock out the system.
b. R
emove the intake screen.
c. T
urn the fan by hand to dislodge any potential obstructions. If necessary, remove the
front screen, nozzle, and motor to locate potential obstructions.
d. R
eassemble the system.
3. Confirm the foam proportioning system is operating properly (see NFPA 11, Appendix D).
4. E
nsure the temperature of the concentrate is within the specified range of the foam concen-
trate (see specific data sheet for operating temperature range).
Wet (low Check the following operational aspects of the foam generation process:
expansion) 1. Verify the pressure at the riser meets the design criteria.
foam generation
2. Verify the inlet pressure at the unit meets the design calculations.
3. If all pressures are correct, check for obstructions (see Insufficient foam generation disorder).
SECTION 10 – TROUBLESHOOTING ANSUL High-Expansion Foam Generators
(Part No. 442855)
NOTES:
ANSUL High-Expansion Foam Generators SECTION 11 – TESTING PROCEDURES AND TRAINING
(Part No. 442855)
TESTING PROCEDURES AND TRAINING Recommendations and Best Practices for Managing
Johnson Controls recommends that testing of HEF systems is High-Expansion Foam Discharges
performed in accordance with NFPA or jurisdiction procedures HEF systems provide superior fire protection for aircraft
and by trained personnel. hangars, while helping to minimize potential impacts to the
environment. High-expansion foams rapidly isolate a fire
! WARNING from additional sources of fuel, helping to reduce property
damage, while using less than half the water and less than
High-expansion foam systems rapidly create large volumes of one-third the foam concentrate of a traditional low-expansion
foam. In the event of an unplanned discharge of a high-expan- foam system. Highly expanded foam is easier to contain and
sion foam system, whether due to a fire or accidental release, creates less wastewater to be disposed of after a discharge,
it is imperative that all personnel immediately evacuate the helping to minimize potential environmental impact. However,
discharge area. Personnel should use caution and avoid like any fire suppression system, HEF systems can create
walking through foam or foam solution while evacuating, and potentially hazardous situations if some basic precautions are
be aware that high-expansion foam solutions and concen- not observed.
trates can make surfaces slippery.
The following recommendations on methods for safe testing,
handling and use of HEF systems are based on applicable
! WARNING codes and Johnson Controls’ extensive experience. These
recommendations are not exhaustive, and installers and
Under no circumstances should personnel enter an area facility operators should take care to evaluate the specific
during a high-expansion foam discharge to retrieve equip- needs of their sites. Any questions regarding these guidelines
ment, tools, or other items. Personnel should not enter a foam should be directed to Johnson Controls Technical Services.
filled area or become immersed in foam because the foam can
make hearing difficult, obstruct visibility, inhibit normal breath- Chemical Exposure Considerations
ing, and possibly lead to disorientation. High-expansion foam is similar in composition to many
household soaps and shampoos, and poses similar chemical
! WARNING exposure hazards. The primary potential health hazard from

these foams is eye or skin irritation. When handling foam
High-expansion foam concentrates and high-expansion foam concentrate, foam solution or expanded foam, personnel
solutions can make floors and other surfaces slippery. Use should wear chemical resistant gloves and safety glasses.
caution when evacuating areas during a foam discharge or To the extent possible, direct contact with the skin should
during emergency response, overhaul, and cleanup opera- be avoided as frequent or prolonged exposure may cause
tions where foam has been present. dry skin or irritation. Avoid contact of foam concentrate or
expanded foam with the eyes. If eye contact occurs, flush with
clean water for at least 15 minutes. Seek medical attention
! WARNING if irritation persists after flushing. See the foam concentrate
material safety data sheet (SDS) for additional information and
Exits and evacuation routes out of areas protected by a first aid procedures.
high-expansion foam system should be kept clear and free of
In general, respiratory protection is not required when
obstruction at all times. Per NFPA 409, Standard on Aircraft
handling or working around HEF concentrate, solution, or
Hangars, exits and evacuation routes from an aircraft hangar
expanded foam (e.g., when filling a bladder tank or conducting
should comply with the NFPA 101, LIFE SAFETY CODE.
a discharge test).
Discharge Test Recommendations
SYSTEM INSPECTION
Prior to any planned HEF system discharge, it is recom-
mended that the system be inspected for proper installation
and piping continuity. Prior to operating the system, a facility
survey should be conducted to verify that all equipment is
properly installed. A water-only discharge can be conducted
to verify piping continuity and pressures at the risers and
the most remote generator to ensure that the system is
functioning as designed. These system checks will minimize
the risk of erroneous foam test results and help prevent
unintended foam discharge.
SECTION 11 – TESTING PROCEDURES AND TRAINING ANSUL High-Expansion Foam Generators
(Part No. 442855)
TESTING PROCEDURES AND TRAINING (Continued) DISPOSAL AND ENVIRONMENTAL CONSIDERATIONS

The owner or operator of a facility will ultimately be respon-
Discharge Test Recommendations (Continued)
sible for the proper disposal of all effluent produced. Every
facility is different and it is the owner/operator’s responsibility
SYSTEM INSPECTION (Continued)
to ensure proper containment and disposal of waste water in
Prior to conducting a foam discharge test, it is common accordance with local, state, and federal regulations. Refer to
practice to hang plastic sheeting to a height of 4 – 8 feet on NFPA 11, Standard for Low-, Medium-, and High-Expansion
all surrounding walls in the discharge area to protect building Foam, Annex F for options and best practices on containment
surfaces and equipment and make post-test cleanup easier. and disposal.
All doors should be closed and secured prior to the test to
In general, firefighting foam wastewaters are treatable in
prevent unwanted foam release. It is recommended that all
sewage treatment works. The bacteria in most wastewater
entrances to the test area be marked with signs indicating
treatment facilities will readily break down the components in
“High-Expansion Foam Test in Progress – Do Not Open”
firefighting foams as they are very similar to components in
to prevent unwanted foam release or unauthorized access
many soaps and shampoos. However, these bacteria may not
to the area. Different design protocols (NFPA 409 Group I,
be accustomed to large quantities of these components and
NFPA 409 Group II, Department of Defense Fire Protection
may need to be acclimated to prevent a treatment plant upset.
Engineering Design Criteria), as well as local code and
It is strongly recommended that the EHS department for the
individual AHJ preferences, may affect the test criteria for
site, the local wastewater treatment plant, and the Authority
system acceptance. It is important to verify applicable require-
Having Jurisdiction (AHJ) for disposal be consulted before
ments and put appropriate measurement devices in place
discharging any foam solution.
prior to the test.
TECHNICAL SUPPORT
SAFETY CONSIDERATIONS
Proper installation, commissioning, and testing of a HEF
Prior to conducting a foam discharge test, a sign in/out sheet
system is critical to its reliability as a fire protection system.
should be utilized to control access to the test area. A final
Johnson Controls has extensive experience with the design
walk-through should be conducted prior to discharge to be
and testing of HEF systems in accordance with applicable
sure the area is clear of non-essential personnel. Maintaining
codes and standards, including NFPA 409, Standard on
open communication lines among and between all test
Aircraft Hangars and United States Air Force. For assis-
participants is highly recommended; this can be facilitated
tance with design or onsite testing, contact Johnson Controls
by using appropriate radios or other open communication
Technical Services.
devices. Should any personnel be required to stay in the foam
discharge area, a rope or lifeline leading to the nearest exit
Recommendations for Containment, Overhaul, Cleanup
should be put in place and appropriate personal protective
and Disposal
equipment provided. It is critical to have a trained person
ready to operate the foam shutoff valve and an exit plan for CONTAINMENT
all personnel participating in or witnessing a HEF discharge
test in case the foam discharge exceeds expected volume, An unplanned discharge, by definition, means that compre-
duration or foam height. This exit plan should include a hensive containment measures will likely not be in place.
meeting point outside of the test area, and the sign in/out While the effectiveness of a HEF system is dependent upon
sheet should be available to verify that all participants are keeping the foam in the area being protected, design calcu-
accounted for. lations generally assume significant loss. For example, NFPA
409, Standard on Aircraft Hangars system calculations include
CLEAN UP a safety factor of 20% to account for “leakage,” so that foam
lost through openings will not degrade system performance.
Fresh high-expansion foam is very resilient and difficult
However, keeping as much of the foam as possible in the
to break down by spraying with water. However, the foam
protected area is desirable to prevent unintentional release to
solution will drain out of the foam blanket over time, making
the environment.
it much easier to break down as time passes. It is recom-
mended that discharged foam be left to drain for 3-6 hours, It is recommended that any site with a HEF system have
or overnight, before beginning cleanup efforts. The discharge an emergency containment plan in place. This plan should
area should remain secured during this period. After this include measures to contain expanded foam to the protected
waiting period, breakdown and cleanup of high-expansion space and prevent discharge of foam solution to waterways
foam can be accomplished with water spray. Firefighting hose and sewers. Containment of high-expansion foam is readily
hand lines are available in most aircraft hangar and generally accomplished by closing doors and windows. Openings that
work well for this purpose. Care should be taken to contain cannot be closed can be blocked with commonly available
water used for cleanup to facilitate proper disposal. materials such as plywood, plastic sheet, or fine screen like
that used for windows. NFPA 11, Standard for Low-, Medium-,
HEF concentrates and HEF solutions can make floors and
and High-Expansion Foam, Annex F provides excellent infor-
other surfaces slippery. All personnel should be warned of this
mation on containment scenarios and options.
risk and use caution to avoid slips and falls.
ANSUL High-Expansion Foam Generators SECTION 11 – TESTING PROCEDURES AND TRAINING
(Part No. 442855)
TESTING PROCEDURES AND TRAINING (Continued)
Recommendations for Containment, Overhaul, Cleanup

and Disposal (Continued)
OVERHAUL FOLLOWING A FIRE EVENT

The recommendations of NFPA 11 Annex A, A.6.12.10
– A.6.13.3.2, should be followed during overhaul of the
protected area following a fire event.
Failure to follow these recommendations could lead to
re-ignition or resurgence of the original fire, in addition to
increasing the potential for environmental release of foam
and/or unnecessary property damage. As noted in Annex A of
NFPA 11, HEF systems are typically designed with the intent
of rapidly controlling a fire in order to minimize total property
damage from the fire, and not necessarily to extinguish it.
Unless it is known with certainty that there is no fire and
there are no personnel in the protected space, special care
should be taken to ensure that overhaul operations do not
compromise the fire suppression being provided by the foam
blanket.
CLEAN UP AND DISPOSAL FOLLOWING A FIRE EVENT

The cleanup and disposal recommendations in the event
of an accidental discharge, described above, also apply to
discharges following a fire event, with additional attention
given to fuel contamination. A discharge in a fire situation
may produce wastewater contaminated with fuel that must
be disposed of properly. Care should be taken to ensure that
wastewater is free of fuel contamination prior to discharge.
NFPA 11 Annex E, E.6 provides information and guidance on
fuel separation from foam-water solutions.
SECTION 11 – TESTING PROCEDURES AND TRAINING ANSUL High-Expansion Foam Generators
(Part No. 442855)
NOTES:
ANSUL High-Expansion Foam Generators SECTION 12 – COMPONENTS LIST
(Part No. 442855)
COMPONENTS LIST For more information contact your local Authorized ANSUL
For spare components, see the expanded view drawing in Distributor, Territory Manager, or Technical Services
Figures 12-1 to 12-6 and their components lists below. Only Department.
spare and replacement components available from Johnson
Controls should be used, otherwise the performance cannot
be guaranteed and the factory warranty may be voided.
5, 6
14
26
19 15
17 22
20
21
4
24, 25
5, 7, 8 9, 10, 11
1
2
27, 28
16
18
5, 7, 8
23
12 13
FIGURE 12-1
JET-X 2A FOAM GENERATOR COMPONENTS LIST EXPANDED VIEW
010256
SECTION 12 – COMPONENTS LIST ANSUL High-Expansion Foam Generators
(Part No. 442855)
COMPONENTS LIST (Continued)
TABLE 12-1: BILL OF MATERIAL FOR JET-X 2A GENERATOR ASSEMBLY (See Figure 12-1)
Drawing No. Drawing No.

BOM Level Item Stainless Steel Standard QTY. Description
2 28 2 #10 LOCK WASHER
2 27 2 HSHCS #10-24X 1/2 LG
2 26 1 1 IN. PIPE PLUG (BRASS)
2 25 3 #6 LOCK WASHER
2 24 3 6-32 X 0.5 CAP SCREW
2 23 420158 420158 1 NOZZLE
2 22 420157 420157 4 NOZZLE (6.9)
2 21 420164 420164 2 NOZZLE (8.4)
2 20 6 1/2 IN. X 90° ELBOW
2 19 428653 428653 1 FAN, PAINTED, 2A
2 18 1 RETAINING WASHER, 2A
2 17 6 NIPPLE, 1/2 IN. STD, 1-1/2 IN. LG
2 16 1 ROTOR 2A
2 15 1 STATOR, MACHINING, 2A
1 14 1 MOTOR ASSEMBLY (JET-X 2A)
1 13 1 1 IN. “Y” STRAINER, FINISHED
1 12 1 1 IN. PIPE
1 11 3 #10-32 LOCKNUT
1 10 3 FLATWASHER #10
1 9 3 HEX HEAD SCREW, 0.190-32 X 0.63
1 8 10 1/4 IN. - 20 STOP NUT (SS)
1 7 10 WASHER, FLAT, 1/4, SS
1 6 4 WSHR, 1/4 SPLT LK VM11
1 5 14 HEX HEAD MACHINE SCREW 0.250-20 X 0.75 LONG
1 4 437263 420175 1 FAN GUARD, FINISHED, 2A
1 3 439882 420167 1 FOAM SCREEN, 2A
1 2 2 MOTOR BRACKET, FINISHED
1 1 1 HOUSING, FINISHED
(Part No. 442855)
10
7 5 25
9
16
17
21
22
13
14
12
2
1
11
4 6
15 20
8
19
18
3 24 23
FIGURE 12-2
JET-X 3 FOAM GENERATOR COMPONENTS EXPANDED VIEW
009641a
(Part No. 442855)
TABLE 12-2: JET-X 3 FOAM GENERATOR COMPONENTS LIST (See Figure 12-2)
Item Part
No. No. Description
1 HOUSING, FOAMAKER 3000WP
2 703508 MOTOR, WATER TURBINE
3 703509 NOZZLE, FULLJET, 2 IN. NPT(F ), 0.828 IN. ORIFICE
4 703510 PROPELLER 3000WP
5 ADAPTER SWIVEL 1 1/2 IN. NST X 1 1/2 IN. NPT
6 703513 GUARD, INLET 3000WP
7 GAUGE 0 psi TO 160 psi (0 bar TO 11 bar)
8 703516 SCREEN ASSEMBLY FOAMAKER, 3000WP
9 PRESSURE SNUBBER 1/4 IN. NPT
10 703524 EDUCTOR ASSEMBLY 95 gpm (360 Lpm)
11 0.31 LOCKNUT
12 PIPE NIPPLE, TBE 1 IN. NPT X 1 1/2 IN. LGE, SCH. 40
13 REDUCER, BELL 1 1/2 IN. X 1 IN.
14 BOLT, SS 5/16-18 X 1 IN.
15 SHIM, MOTOR SUPPORT FOAMAKER 1500WP & 3000WP
16 1 1/2 IN. X 1/4 IN. REDUCING BUSHING
17 TEE, 1 1/2 IN., CL125
18 HEX NUT 3/8-16
19 WASHER, LOCK 3/8 IN.
20 BOLT, 3/8 IN. X 1 1/2 IN.
21 ELBOW, STREET 90° 1 1/2 IN.
22 PIPE NIPPLE, TBE 1 1/2 IN. NPT X 5 IN. LGE, SCH. 40
23 BUSHING, PIPE 2 IN X 1 1/4 IN.
24 PIPE NIPPLE, TBE 1 1/4 IN. NPT X 1-5/8 IN. LGE, SCH. 40
25 5/16 IN. FLAT WASHER
(Part No. 442855)
20
31 30
21
28 22 23
29
11, 13, 14
7, 8, 9 27 26
1 5
19
3
14, 15
24
25, 33
32, 32
10
16, 17, 18
FIGURE 12-3
010257
(Part No. 442855)

2 34 3 HEX HEAD MACHINE SCREW 0.250 - 20 x 0.75 LONG
2 33 3 WASHER, LOCK INTERNAL TOOTH NO. 8
2 32 3 WSHR, 1/4 SPLT LK VMI 1/4 IN.
2 31 6 1/2 IN. x 90° ELBOW
2 30 6 PIPE NIPPLE, 1/2 IN. NPT x 6 IN. LG, SCH 40
2 29 2 O-RING (142)
2 28 420184 420184 6 NOZZLE (13.4)
2 27 420181 420181 1 NOZZLE-SPRAY
2 26 1 3/4 X 1/2 REDUCING COUPLING
2 25 3 CAPSCREW #8-32 X 1/2 LG
2 24 1 RETAINING WASHER
2 23 1 STATOR
2 22 1 ROTOR ASS’Y
2 21 423922 423922 1 FAN (36 IN.) PAINTED
1 20 1 MOTOR ASS’Y, 5A
1 19 1 PIPE PLUG, 1 - 1/2 IN.
1 18 8 1/4 IN. - 20 STOP NUT (SS)
1 16 8 HEX HEAD MACHINE SCREW 0.250 - 20 X 0.75 LONG
1 15 4 WASHER, FL 1/4 IN. WASHER, LOCK 3/8 IN.
1 14 4 HEX HEAD BOLT, 3/8 - 16 X 3/4 IN. LG
1 13 8 3/8 - 16 LOCK NUT, S.S.
1 12 8 3/8 IN. FLAT WASHER
1 11 8 BOLT, 3/8 - 16 X 7/8 IN. LG
1 10 1 1 1/2 IN. “Y”- STRAINER, FINISHED
1 9 4 #10-32 LOCKNUT
1 7 4 HEX HEAD SCREW, 0.190 - 32 X 0.63
1 6 1 1 1/2 IN. PIPE
1 5 4 RETAINER
1 4 437264 420173 1 GUARD SCREEN, FINISHED
1 3 439883 420172 1 FOAM SCREEN
(Part No. 442855)
19
34 24
30
23
25
31 21 5
33 28
1 32
7, 8, 9
20 10, 11
22
35
26, 27
29, 36
6
17
10, 12, 13
14, 15, 16
FIGURE 12-4
010258
(Part No. 442855)
Drawing No.
BOM Level Item Standard QTY. Description
2 36 3 HEX HEAD MACHINE SCREW 0.250 - 20 X 0.75 LONG
2 35 2 O-RING (142)
2 34 3 3/4 X 3/8 REDUCED BRUSHING
2 33 1 PIPE, COUP, RED 1 - 1/4 IN. X 3/4 IN. NPT, 125#
STEAM
2 32 420127 1 SPRAY NOZZLE
2 31 420126 3 NOZZLE
2 30 420124 3 NOZZLE-FLAT PATTERN
2 28 1 2 x 1/4 REDUCING BUSHING
2 27 3 WASHER, LOCK INTERNAL TOOTH NO. 8
2 26 3 CAPSCREW #8-32 X 1/2 LG
2 25 1 1/4 IN. PIPE PLUG
2 24 6 3/4 IN. X 90° ELBOW
2 23 6 PIPE NIPPLE, TBE 3/4 IN. NPT X 13.5 IN. LG, SCH 40
2 22 1 RETAINING
2 21 1 ROTOR
2 20 1 STATOR
1 19 1 MOTOR ASSEMBLY
1 18 422677 1 FAN (48 IN.) PAINTED

1 17 1 2 IN. “Y”-STRAINER FINISHED
1 16 16 1/4 IN. - 20 STOP NUT (SS)
1 14 16 HEX HEAD MACHINE SCREW 0.250 -20 X 0.75 LONG
1 13 8 3/8 - 16 LOCK NUT, S.S.
1 11 8 WASHER, FL 1/4 IN. WASHER, LOCK 3/8 IN.
1 10 16 BOLT, 3/8 - 16 X 7/8 IN. LG
1 9 4 #10-32 LOCKNUT
1 7 4 HEX HEAD SCREW, 0.190-32 X 0.63
1 6 1 PIPE 2 IN., SCH 40 X 26 IN. LG
1 5 4 RETAINER
1 4 420505 1 GUARD SCREEN, FINISHED
1 3 420103 1 FOAM SCREEN - 64 IN.
(Part No. 442855)
7, 8
17
29 23
18
5
22
32
4
25, 12, 11 20
1 31 33 24 2
30
21
25, 26
27, 28
14, 13 15, 16
6
10, 9, 7
FIGURE 12-5
JET-X 20 FOAM GENERATOR COMPONENTS LIST EXPANDED VIEW
010260
(Part No. 442855)
TABLE 12-5: BILL OF MATERIAL FOR JET-X 20 GENERATOR ASSEMBLY (See Figure 12-5)

2 33 1 2 X 1/4 REDUCING BUSHING
2 32 2 O-RING (142)
2 31 1 1-1/4 IN. PIPE CAP
2 30 421593 421593 3 0.425 NOZZLE
2 29 421594 421594 3 0.324 NOZZLE
2 28 3 WASHER, LOCK INTERNAL TOOTH
2 27 3 CAPSCREW #8-32 X 1/2 LG
2 25 19 HEX HEAD MACHINE SCREW 0.250-20 x 0.75 LONG
2 24 1 1/4 IN. PIPE PLUG
2 23 6 3/4 IN. X 90° ELBOW
2 22 6 PIPE NIPPLE, TBE 3/4 IN. NPT X 13.5 IN. LG, SCH 40
2 21 421591 421592 1 FAN, PAINTED
2 20 1 RETAINING WASHER
2 19 1 ROTOR
2 18 1 STATOR
1 17 1 JET-X 20 MOTOR ASSEMBLY
1 16 4 #10-32 LOCKNUT
1 15 4 SCREW, SELF TAPPING #8-32 X 3/8 IN. LG
1 13 4 HEX HEAD SCREW, .190-32 X 0.63
1 12 16 WASHER, FLAT, 1/4
1 11 16 1/4 IN. -20 STOP NUT
1 10 8 3/8-16 LOCK NUT
1 8 8 LOCK WASHER 3/8 IN.
1 7 16 BOLT, 3/8-16 X 7/8 IN. LG
1 6 1 COVER
1 5 4 RETAINER
1 4 437265 420505 1 GUARD SCREEN
1 3 439884 420103 1 FOAM SCREEN, FINISHED
1 2 2 MOTOR BRACE, FINISHED
(Part No. 442855)
18
23
20 29
9 22
8, 26, 14
2
1
3
21
10
19
11, 25, 6
30
13, 24, 5, 16
28
17 7
12, 27, 4, 15
FIGURE 12-6
JET-X 27 FOAM GENERATOR COMPONENTS LIST EXPANDED VIEW
010261
(Part No. 442855)
TABLE 12-6: BILL OF MATERIAL FOR JET-X 27 GENERATOR ASSEMBLY (See Figure 12-6)
Item Drawing No. QTY. Description

30 447082 1 SCREEN SUB-ASSEMBLY
29 1 THREAD ON FLANGE, FINISHED, 2 IN. NPS 150# RAISED FACE
28 1 PUMP BRIDGE, PAINTED
27 10 WSHR, 1/4 SPLT LK VMI 1/4 IN.
26 4 #10-32 LOCKNUT
25 12 0.50 LOCKWASHER
24 8 WASHER, LOCK 3/8 IN.
23 436490 1 GENERATOR FAN (FIN)
22 1 GENERATOR PUMP (FIN)
21 436478 1 GENERATOR NOZZLE
20 1 JET-X-27 HOUSING, PAINTED
19 437842 1 INLET SCREEN/FAN GUARD, PAINTED
18 1 HUB ASSEMBLY, PLATED, 1.625

17 12 HEX NUT, 1/2- 13 UNC - 2B
16 8 HEX NUT, 3/8 - 16
15 10 0.25-20 HEX NUT (SS)
14 4 HEX HEAD SCREW, 0.190-32 X 0.63
13 8 BOLT, 3/8 - 16 X 1 IN. LG
12 10 HEX HEAD MACHINE SCREW 0.250-20 X 0.75 LONG
11 4 0.50 DIA HEX HEAD BOLT
10 1 GASKET, SPIRAL WOUND, 2.50 INCH
9 1 GASKET, SPIRAL WOUND, 2.50 INCH
8 4 FLATWASHER #10
7 4 FLAT, SQUARE WASHER, 0.50 I.D. ”
6 20 WASHER, FLAT 1/2 IN.
5 16 3/8 IN. FLAT WASHER, 0.25
4 20 FLAT WASHER, 0.25
3 1 FLANGE (FINISHED) 3 IN. CLASS 150
2 8 CAP SCREW, 0.50-13 UNC X 2.75 LG, SS
1 1 2 IN. NPT INLET PIPE
ANSUL High-Expansion Foam Generators SECTION 13 – REFERENCE
(Part No. 442855)
REFERENCE
Johnson Controls recommends using the latest editions and
versions of all reference material.
Documents
• Data sheet: ANSUL Water Powered High-Expansion Foam
Generators (F-93137, latest revision)
• Data sheet: ANSUL Automatic Roof Door Vents (F-2017128,
latest revision)
• Tyco Technical Bulletin Foam Systems - Acceptable
Materials of Construction Technical Bulletin (Form No.
T-2016111, latest revision)
National Fire Protection Association Documents

• NFPA 4: Standard for Integrated Testing of Fire Protection
and Life Safety Systems
• NFPA 11: Standard for Low-, Medium, and High-Expansion
Foam, 2010 Edition
• NFPA 12: Standard on Carbon Dioxide Extinguishing
Systems
• NFPA 13: Standard for the Installation of Sprinkler Systems
• NFPA 16: Standard for the Installation of Foam-Water
Sprinkler and Foam-Water Spray Systems
• NFPA 25: Standard for the Inspection, Testing, and
Maintenance of Water-Based Fire Protection Systems
• NFPA 72: National fire Alarm and Signaling Code
• NFPA 101: LIFE SAFETY CODE, 2012 Edition
• NFPA 409: Standard on Aircraft Hangars
National Institute of Building Sciences

• Unified Facilities Criteria - Aircraft Maintenance Hangars
(UFC 4-211-01)
• FM Documents - FM Global Property Loss Data Sheet
7-93N
PRODUCT WARRANTY
Product warranty information may be found in the terms and
conditions at www.ansul.com.
SECTION 13 – REFERENCE ANSUL High-Expansion Foam Generators
(Part No. 442855)
NONE:
ANSUL High-Expansion Foam Generators SECTION 14 – APPENDIX A – FM APPROVAL REQUIREMENTS
(Part No. 442855)
APPENDIX – FM APPROVAL REQUIREMENTS FM Approved Concentrates

• FM approved concentrates all have operating temperatures
FM Approved Systems
between 35 °F and 120 °F (2 °C and 49 °C).
• A high-expansion generator on its own is not an FM
• A system must utilize FM approved foam concentrates
Approved system unless it is paired with an Approved
per the FM Approval Guide (www.ApprovalGuide.com) to
proportioning system.
maintain FM approval.
– Consult FM Approval Guide (www.ApprovalGuide.com)
– ANSUL JET-X 2% High-Expansion Foam Concentrate
for most up to date approval status of foam concentrates
and hardware.
NOTICE
Pressure Operated Release Always consult FM Approval Guide
A pressure operated release shall be provided on all doors, (www.ApprovalGuide.com) for most up to
windows, and other openings below the intended flooding date approval status of foam concentrates
level in the protected hazard area. The release shall operate and hardware.
at a maximum pressure of 50 psi (3.5 bar) system water
pressure. The release shall not permit the escape of water
from the system. It shall automatically reset and may have a Installation / Service Condition
control for manual operation. • System piping should be mounted in accordance with
good engineering practices and subject to Authority Having
Time Delays Jurisdiction (AHJ) approval.
A delay device shall be installed on systems when safety – Please refer to specific data sheets (latest revision) for:
dictates the evacuation of personnel from the hazard area.
This device may either delay the operation of the system,
n
Vertical Bladder Tanks (F-2016280)
or delay the discharge of foam after the system has been
n Horizontal Bladder Tanks (F-2016321)
actuated. In the first arrangement, the actual discharge shall

n
Vertical Pre-Piped Bladder Tank with Proportioner
be manually controlled. A manual override shall be provided in (F-2016281)
the second arrangement to allow instant discharge.

n
Horizontal Pre-Piped Bladder Tank with Proportioner
Automatic Venting (F-2016322)
High-expansion foam systems shall use air from outside the
n JET-X High-Expansion Foam Generators (F-93137)
protected space for foam generation. Air must be vented from

n
ANSUL Flanged Proportioners (3 in., 4 in., 6 in., and
the protected space at the same rate of flow to allow the foam 8 in.) (F-85143)
generators to operate at their specified capacities. Air intake

n ANSUL Between Flange Proportioner (F-8452)
and venting devices for air movement into the foam gener-
ators and out of the protected volume shall be automatically
n
ANSUL Threaded Proportioners (2 in. and 2.5 in.)
operated at system actuation and protected from mechanical (F-85144)
damage, corrosion, and freezing.
n ANSUL Automatic Roof Door Vents (F-2017128)
Watertight Electrical Equipment – Contact Johnson Controls Technical Services for specific
questions.
Electrical equipment below the design level of flooding shall
be designed for submerged operation to eliminate the risks of • Valve Condition
short circuiting of controls and shocking to personnel. – To achieve and maintain an FM approved system all
• A concentrate control valve is required per FM Global valves (tank valves, special operational valves, etc.) must
Property Loss Prevention Data Sheet (Standard 5130) have the ability to be locked into the “service position.”
section 4-12.
n
Reference NFPA 11 section 4.7.6.5 for further definition
– Supervisory option must be available on concentrate of the “service position.”
control valve per FM Global Property Loss Prevention
n
When choosing tank or system valves every effort
Data Sheet (Standard 5130) Section 4-12. should be made to choose an FM Approved valve.
– See ANSUL data sheet/specification sheet Hydraulic Contact Johnson Controls Technical Services for
Concentrate Control Valve (F-9197, latest revision) or assistance.
contact Johnson Controls Technical Services
(www.ansul.com).
SECTION 14 – APPENDIX A – FM APPROVAL REQUIREMENTS ANSUL High-Expansion Foam Generators
(Part No. 442855)
APPENDIX - FM APPROVAL REQUIREMENTS (Continued)
JET-X 5A FM Performance
JET-X 5A FM Approved Capacity and Expansion JET-X 5A FM Approved Flow Performance
FIGURE 14-1 FIGURE 14-2

010301
010302
TABLE 14-1: ANSUL JET-X 5A PERFORMANCE
JET-X 5A FM Approved Performance Data (JET-X 2%)
FM Approved Inlet Pressure Flow Rate Foam Output Expansion

Generator Model Part No. Orientation psi (bar) gpm (Lpm) cfm (cmm) Ratio
JET-X 5A Standard 420003 Horizontal 40 (2.8) 55 (208) 4020 (114) 547
50 (3.4) 62 (235) 5184 (147) 625
LNG 436936 75 (5.2) 76 (288) 7632 (216) 751
100 (6.9) 88 (333) 7794 (221) 662
ANSUL High-Expansion Foam Generators SECTION 14 – APPENDIX A – FM APPROVAL REQUIREMENTS
(Part No. 442855)
JET-X 15A FM Performance
JET-X 15A FM Approved Capacity and Expansion JET-X 15A FM Approved Flow Performance

010303
010304
TABLE 14-2: ANSUL JET-X 15A Performance
JET-X 15A FM Approved Performance Data (JET-X 2%)

JET-X 15A Standard 420005 Horizontal 40 (2.8) 107 (405) 9540 (270) 667
50 (3.4) 119 (450) 12150 (344) 764
75 (5.2) 149 (562) 17100 (484) 861
100 (6.9) 174 (659) 19296 (546) 829
SECTION 14 – APPENDIX A – FM APPROVAL REQUIREMENTS ANSUL High-Expansion Foam Generators
(Part No. 442855)
JET-X 27 FM Performance
JET-X 27 FM Approved Capacity and Expansion JET-X 27 FM Approved Flow Performance

010325 010326
TABLE 14-3: ANSUL JET-X 27 Performance
JET-X 27 FM Approved Performance Data (JET-X 2%)

JET-X 27 Standard 436899 Horizontal or 40 (2.8) 184 (697) 19548 (554) 795
Vertical 50 (3.4) 202 (765) 21600 (612) 800
75 (5.2) 244 (924) 27036 (766) 829
100 (6.9) 280 (1060) 29916 (847) 799
ANSUL High-Expansion Foam Generators SECTION 15 – APPENDIX B – UL PERFORMANCE DATA
(Part No. 442855)
APPENDIX – UL PERFORMANCE DATA
2% Performance Data
JET-X 2A UL Performance
JET-X 2A UL Listed Capacity and Expansion

010225
010306
TABLE 15-1: ANSUL JET-X 2A UL PERFORMANCE
JET-X 2A UL Listed Performance Data (JET-X 2%)

JET-X 2A Standard 420001 Horizontal or 50 (3.4) 35 (132) 2188 (62) 468
vertical 75 (5.2) 42 (159) 2727 (77) 486
LNG 471066 100 (6.9) 50 (189) 3010 (85) 450
SECTION 15 – APPENDIX B – UL PERFORMANCE DATA ANSUL High-Expansion Foam Generators
(Part No. 442855)
APPENDIX – UL PERFORMANCE DATA
2% Performance Data
JET-X 3 UL Performance
JET-X 3 UL Listed Capacity and Expansion JET-X 3 UL Listed Flow Performance

4000 450 90
80
3500 400
Foam Output (cfm)
Expansion Rao
Flow (gpm)
70
3000 350
60
2500 300 50
40 60 80 100 120 40 60 80 100 120
Pressure (psi) Pressure (psi)
Foam Output Expansion Rao FIGURE 15-3 Flow

FIGURE 15-4
010373 010374
TABLE 15-1: ANSUL JET-X 3 UL PERFORMANCE
JET-X 3 UL Listed Performance Data (JET-X 2%)

Generator
Model Material Part No. Inlet Pressure Flow Rate Foam Output Expansion
JET-X 3 Carbon 448163 psi (bar) gpm (Lpm) cfm (cmm) Ratio
Steel 50 (3.4) 60 (227) 2834 (80) 356
60 (4.1) 66 (250) 3088 (87) 353
70 (4.8) 70 (265) 3336 (94) 356
80 (5.5) 77 (291) 3616 (102) 354
90 (6.2) 80 (303) 3808 (108) 358
100 (6.9) 84 (318) 3753 (106) 336
(Part No. 442855)
APPENDIX – UL PERFORMANCE DATA (Continued)
2% Performance Data (Continued)

010307 010227
TABLE 15-2: ANSUL JET-X 5A UL Performance

vertical 75 (5.2) 75 (284) 9383 (266) 939
LNG 436936 100 (6.9) 87 (329) 10655 (302) 916
(Part No. 442855)

010308 010229

vertical 50 (3.4) 119 (450) 14491 (410) 911
75 (5.2) 145 (549) 19141 (542) 987
100 (6.9) 169 (640) 21796 (617) 965
(Part No. 442855)
JET-X 20 UL Listed Capacity and Expansion

010309 010233
JET-X 20 UL Listed Performance Data (JET-X 2%)

vertical
50 (3.4) 238 (901) 14746 (418) 463
75 (5.2) 294 (1113) 19007 (538) 484
LNG 471871 100 (6.9) 338 (1279) 22598 (640) 500
(Part No. 442855)
JET-X 27 UL Approved Capacity and Expansion

010305 010223
TABLE 15-6: ANSUL JET-X 27 PERFORMANCE
JET-X 27 UL Approved Performance Data

vertical 50 (3.4) 203 (768) 23965 (679) 883
75 (5.2) 243 (920) 27303 (773) 840
100 (6.9) 276 (1045) 28802 (816) 781
(Part No. 442855)
2.75% Performance Data

010265 010266
JET-X 2A UL Listed Performance Data (JET-X 2.75%)

vertical 75 (5.2) 42 (159) 2785 (79) 496
LNG 471066 100 (6.9) 50 (189) 3162 (90) 473
(Part No. 442855)
2.75% Performance Data (Continued)
JET-X 5A LNG UL Performance

010267 010268

vertical 75 (5.2) 75 (284) 6628 (188) 661
LNG 436936 100 (6.9) 87 (329) 7182 (203) 617
(Part No. 442855)

010269 010270

vertical 75 (5.2) 145 (549) 15479 (438) 799
100 (6.9) 169 (640) 18447 (522) 816
(Part No. 442855)
JET-X 20 UL Listed Capacity and Expansion

010273 010274
JET-X 20 UL Listed Performance Data (JET-X 2.75%)

vertical 50 (3.4) 238 (901) 16034 (454) 504
LNG 471871 75 (5.2) 294 (1113) 21145 (599) 538
100 (6.9) 338 (1279) 24301 (688) 538
(Part No. 442855)
NOTES:

High-Expansion Foam Generators: Installation, Operation, and Maintenance Manual

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HIGH-EXPANSION

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

One Stanton Street | Marinette, WI 54143-2542, USA | +1-715-735-7411 | www.ansul.com

This manual is intended for use with the ANSUL®

Note: The converted metric values in this manual are provided

Part Number: 442855-01

DATE PAGE REV. NO. DATE PAGE REV. NO.

2018-MAR-22 1-1 01 2018-MAR-22 15-5 01

2018-MAR-22 4-1 01 2018-MAR-22 15-6 01

2018-MAR-22 4-3 01 2018-MAR-22 15-7 01

2018-MAR-22 4-4 01 2018-MAR-22 15-8 01

2018-MAR-22 5-1 01 2018-MAR-22 15-9 01

2018-MAR-22 9-1 01 2018-MAR-22 15-10 01

2018-MAR-22 12-3 New

2018-MAR-22 12-4 New

2018-MAR-22 15-2 New

LEGEND FOR PAGES WITH Indicates revised technical information.

SECTION PAGE SECTION PAGE

2 SYSTEM DESCRIPTION 2-1 – 2-2 8 RESTORATION 8-1 – 8-2

SYSTEM DESCRIPTION Foam Concentrate

• HEF generator Automatic Roof Door Vent

BLADDER VENT VALVE

TANK SHELL FOAM CONCENTRATE

MASTER HYDRAULIC ACTUATED PRESSURE GAUGE

SWING CHECK VALVE SENSING LINES

DELUGE VALVE GROOVE COUPLING

HIGH EXPANSION FOAM SYSTEMS - DESIGN (Continued)

Design Information (Continued)

TYPICAL REQUIREMENTS FOR A HEF GENERATOR SYSTEM Example Calculation 1:

8 Generators x 13.4 ft2

1 Exhaust vent model selected for example purposes. Other

LOCAL APPLICATION SYSTEM GROUP II AIRCRAFT HANGAR

• Group II Aircraft Hangar Type II (111), III 1,394 (15,001)

• An aircraft access door height over 28 ft (8.5 m)

LOCAL APPLICATION SYSTEM (Continued) Hangar Fire Protection Design Requirements

AIRCRAFT HANGERS - DESIGN (Continued) SUPPLEMENTARY PROTECTION SYSTEMS

Foam System Application High-Expansion Foam System

DETECTION AND ACTUATION REQUIREMENTS

ALARMS AND SIGNALING REQUIREMENTS

INSTALLATION There are more corrosion-resistant materials that may be

INSTALLATION EXAMPLES (Continued)

HYDRAULIC ACTUATED ROOF TOP

AIR INTAKE DUCT

INSTALLATION EXAMPLES (Continued)

HYDRAULIC ACTUATED ROOF TOP

FOAM SOLUTION INLET

AIR INTAKE DUCT

2-1/2 IN. PIPE RING

1IN. SCH. 40 PIPE 1 IN. SCH. 40 PIPE

1/2 IN. DIA ALL 1 IN. PIPE CLAMP

1/2 IN. ANGLE 1/2 IN. ANGLE

3/8 IN. X 1IN. HEX 3/8 IN. X 1IN. HEX

SYSTEM RESTORATION Restoration Recommendations

System Restoration After Discharge CONTAINMENT

! WARNING OVERHAUL FOLLOWING A FIRE EVENT

INSPECTION AND MAINTENANCE

HEF generator system should be inspected semi-annually

Component Disorder Corrective Action

! WARNING exposure hazards. The primary potential health hazard from

Discharge Test Recommendations

TESTING PROCEDURES AND TRAINING (Continued) DISPOSAL AND ENVIRONMENTAL CONSIDERATIONS

TESTING PROCEDURES AND TRAINING (Continued)

Recommendations for Containment, Overhaul, Cleanup

1 Exhaust vent model selected for example purposes. Other

Foam Output Expansion Rao FIGURE 15-3 Flow