FireFlex TOTALPAC2 User manual

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TOTALPAC2 Integrated Fire Protection System
Cycling Wet Pipe Systems
FM-072G-0-143 E
General
1. Applicable Standards
The TOTALPAC2complies with the following standards:
- NFPA-13 Sprinkler Systems;
- NFPA-15 Water Spray Fixed Systems;
- NFPA-16 Foam-Water Deluge and Foam-Water Spray
Systems;
- NFPA-72 Fire Alarm Systems.
Before the installation, the contractor installing the unit shall
be familiar with the following documents and standards:
- Applicable Local & State Building Codes
- Any additional requirements of the Local Authority
Having Jurisdiction.
2. Listings and Approvals
In addition to being fabricated under tight ISO-9001
manufacturing and quality control procedures, your
TOTALPAC2Unit has also been tested and approved by
recognized laboratories. Here is the list of Listings &
Approvals it meets:
- Underwriters Laboratories Inc. (UL): Cycling Wet Pipe
TotalPac2 systems are UL Listed under "Special System
Water Control Valves - Assembled Units, category
# VKYL.EX4641".
- Factory Mutual Research <FM>: Cycling Wet Pipe
TOTALPAC2systems are FM Approved under the
heading: "Automatic Water Control Valves" when
installed with specific components.
- NYC-MEA: Cycling Wet Pipe TOTALPAC2systems are
MEA Approved under New-York City's Fire Dept.
Information Bulletin # 1-92 under section MEA 89-92-E,
Vol. XXVI.
Note: Although most TOTALPAC2units are Listed, custom
built units are sometimes supplied on request. Components
in these special units maintain their individual
Listings/Approvals but the units are not Listed as an
assembled unit.
CAUTION ! Any unauthorized modification or addition
made on-site to a factory built Listed Unit will void this
Listing. Such modifications or additions may void the
unit's warranty as well. Consult your nearest FireFlex
Systems Authorized Distributor before proceeding with
such modifications or additions.
3. Environment
TOTALPAC2units shall be installed in a dry and clean
location. Verify that all equipment is properly heated and
protected to prevent freezing and physical damage.
The unit and it's components must be kept free of foreign
matter, freezing conditions, corrosive atmospheres,
contaminated water supplies, and any condition that could
impair its operation or damage the components.
The frequency of the inspections and maintenance will vary
depending on these environmental conditions. The owner is
responsible for maintaining the fire protection system and
devices in proper operating condition.
Refer to CONFIGURATION DESCRIPTION for
maintenance instructions.
4. General Description
There are various types of wet pipe systems, all of them
using closed automatic sprinklers in the sprinkler piping.
This TOTALPAC2integrated fire protection system by
FireFlex Systems Inc. consists of a cycling wet pipe
system trim totally pre-assembled, pre-wired and factory
tested. All electrical and mechanical components of the
system are contained in one single unit.
The only connections required for installation are the
water supply inlet, water discharge outlet, main drain, and
the electrical detection and alarm connections. The
discharge outlet is connected to a fixed piping system of
automatic sprinklers. Water is the extinguishing agent.
Wet pipe systems are usually supervised. The
TOTALPAC2system is completely supervised in order to
monitor its integrity. The sprinkler piping is supervised by
the water. If there is a leak on the system or if a sprinkler
head is accidentally broken, an audible signal will sound.
Electrical detectors and associated wiring are also
supervised.
The most common applications are any structure not
subject to freezing, to automatically protect the structure,
contents and/or personnel from loss due to fire. The
structure must be substantial enough to support the
piping system filled with water.
Using water as the extinguishing agent, one wet pipe
system can cover as much as 52,000 square feet in a
single fire area. Small unheated areas of a building may
be protected by a wet system if an antifreeze-loop or
auxiliary dry system is installed. For rules and limitations,
see appropriate codes and standards.
Systems should be designed by qualified fire-protection
engineers in conjunction with the appropriate Authority
Having Jurisdiction.
Note: Each TOTALPAC2Unit is identified with it's unique
Serial Number. This number is located on a sticker
inside the main door panel and is used to maintain a
record in our computerized data base. Have this Serial
Number handy when calling for information on your unit
(format is TOT#####).
5. Features
The TOTALPAC2unit is superior than many other products
available on the market now and has been manufactured by
the company that has introduced and developed the concept
of integrated fire protection systems in the market.
Main features are:
- Trouble free design for safe and easy application
- Cycling trim available in 5 sizes from 1½" to 6" diameter
- Uses the Viking Flow Control Valves
- Integrated Control Panel

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TOTALPAC2 Integrated Fire Protection System
Cycling Wet Pipe Systems
FM-072G-0-143 E
- Compact, aesthetic and easy to move
- User-friendly standardized owner's manual with every unit
- Unique serial number on every unit
- Uses only UL, ULC Listed and FM Approved components
- Designed in accordance with NFPA Standards
- Trim is fully assembled and tested at the factory
- Water supply and drain connections on both sides,
available both with grooved end or flanged fittings
- Sturdy 14 Gauge steel cabinet painted fire red with oven
baked polyester powder on phosphate base
- Textured rust proof finish
- Neoprene gasket on all doors to eliminate vibrations
- Easily removable doors for ease of access
- Key-alike locks on all cabinet doors
- Manufactured under ISO-9001 quality control procedures.
Configurations Description
A wet pipe system is a fixed fire-protection system using
piping filled with pressurized water, supplied from a
dependable source. Closed heat sensitive automatic
sprinklers spaced and located in accordance with recognized
installation standards are used to detect a fire. Upon
operation the sprinklers discharge water over a specific area
to control or extinguish the fire. As the water flows through
the system an alarm is activated to indicate the system is
operating. Only those sprinklers immediately over or
adjacent to the fire operate, minimizing water damage.
TOTALPAC2Cycling Wet Pipe systems are built around the
Viking trim using Flow Control Valves Model H-3 for 1½" (40
mm) diameter (Model H-4 is the Halar®Coated version for
use in corrosive environments) and Model H-1 for 2" (50 mm)
diameter and up (Model H-2 is the Halar®Coated version for
use in corrosive environments). The valves are rated up to a
maximum of 250 psi WWP (1724 kPa) and are available in
the following diameters:
1½" (40 mm) 2" (50 mm)
3" (80 mm) 4" (100 mm) 6" (150 mm)
Cycling TOTALPAC2Wet Pipe systems are supplied with a
flange–groove Flow Control Valve. Units with a flange–
flange Valve are also available on request.
Release System
The Viking FirecycleIII cycling wet pipe system utilizes a
Viking Flow Control Valve (A2) in lieu of the Alarm Check
Valve and a FirecycleIII Model E-2 Control Panel, together
with additional valves, devices and trim to form a unique
operating system.
In addition to automatically detecting a fire and turning the
system on, FirecycleIII has the added ability to sense when
the fire has been controlled, and automatically turn off the
water flow once a preprogrammed "Soak Timer" has been
satisfied. Should the fire rekindle, the FirecycleIII will
initiate the sequence again. This unique cycling feature will
repeat as long as power is available to the panel, helping to
minimize water usage, water damage, and the danger of
pollution to surrounding areas. FirecycleIII systems are
also "Fail-Safe".
Note: TOTALPAC2FirecycleIII Systems are available with
electrical type release and the integrated FirecycleIII Model
E-2 Control panel.
The FirecycleIII Cycling System has several "Fail-Safe"
features, some of which are not available on other wet pipe
systems. Refer to SYSTEM OPERATION for more details.
Installation
TOTALPAC2Units must be installed in an area not subject to
freezing temperatures or physical damage.
1. Install the TOTALPAC2unit and connect the system
according to instruction manual and technical data
supplied.
Note: The drain collector shall be connected to an open
drain. Do not restrict or reduce drain piping.
2. Install the automatic sprinkler piping, detection and
signaling circuits in accordance with applicable NFPA
standards.
3. Conform to local municipal or other codes regarding
installations of fire protection systems.
4. Perform preliminary inspection outlined below prior to
putting system in service.
5. Put the system into operation as outlined below.
Perform the annual inspection sequence and test each
detector and alarm unit (if applicable).
6. If the system does not operate as it should, make the
necessary corrections according to manuals issued or
consult your distributor or FireFlex Systems Inc.
7. Make sure that building owner or a delegated
representative has received instructions regarding the
operation of the system.
Preliminary inspection before placing the
system in service
1. Open door to mechanical section. Main Water Supply
Control Valve (D1) should be CLOSED. Alarm test
valve (B5) must be CLOSED. All gauges (B11 and
B12) should show 0 psi pressure.
2. OPEN Emergency Release Valve (B10), then Main
Water Supply Control Valve (D1).
3. Using the built-in contractor's hydrostatic test port (see
TRIM SCHEMATIC for location) once the sprinkler
system is filled with water, maintain a pressure of
200 psi for 2 hours. Correct leaks if any before
completing test.
4. Connect all detection and alarm audible devices
according to electrical schematics (see TBA field wiring
diagram in PROGRAMMING SECTION).
Note: For proper operation of the wet system and to
minimize unwanted (false) alarms, it is important to remove
trapped air from the system when filling it with water. Air
trapped in the system may also cause intermittent operation
of the water motor alarm during sustained flow of water (such
as the flow required by an open sprinkler or the system test

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TOTALPAC2 Integrated Fire Protection System
Cycling Wet Pipe Systems
FM-072G-0-143 E
valve). Consider installation of auxiliary vents to facilitate
venting.
Placing the system in service
(Refer to mechanical trim description and TRIM
SCHEMATIC)
All initiating devices (detectors), indicating appliances and
releasing devices must be compatible and approved for use
with the FirecycleIII System. Refer to CONTROLS
SECTION for the list of compatible devices.
1. Verify that the system has been properly tested.
Emergency Release Valve (B10) should be OPEN.
2. SLOWLY OPEN and secure the system Main Water
Supply Control Valve (D1). Consider venting any
trapped air in the system.
3. CLOSE the Emergency Release Valve (B10).
4. Verify that the Alarm Test Valve (B5) is CLOSED and
that all other valves are in their "normal" operating
position (Refer to TRIM SCHEMATIC for details).
5. Open FirecycleIII control Panel and press "RESET".
Release solenoid valve (F1) should open.
6. On new installations, systems that have been placed
out of service, or where new equipment has been
installed, trip test system to verify that all equipment
functions properly. Refer to MAINTENANCE –
ANNUALLY for instructions.
7. After completing the trip test, perform MAINTENANCE
– SEMI-ANNUALLY.
Note: When a valve has been removed from service and is
subject to freezing or will be out of service for an extended
period of time, all water must be removed from the priming
chamber, trim piping, water supply piping and any other
trapped areas.
Mechanical Trim Section
1. System Operation
In the SET condition:
System water supply pressure enters the priming chamber
of the Flow Control Valve (A2) through the ¼" (8mm)
priming line which includes a strainer (B2), a restricted
orifice (B3) and a spring check valve (B4). Normally open
solenoid valve (F1) allows priming water to escape so that
the Flow Control Valve (A2) will not set, but remain open,
filling the system with water.
In a fire condition:
In a fire condition, when the detection system operates,
system Control Panel activates an alarm and energizes
normally closed Solenoid valve (F2) open and normally
open Solenoid valve (F1) closed.
Pressure is released from the priming chamber to open
drain manifold faster than it is supplied through the
restricted orifice (B3). The Flow Control Valve (A2) clapper
remains fully open to allow water to flow into the system
piping and activate alarm devices, including a water flow
Alarm Pressure Switch (C1).
Water will immediately flow from any sprinklers which may
have operated. Water Flow Alarm Switch (C1) activates,
latching normally open solenoid valve (F1) closed. Water
discharges until all Firecycle Detectors have reset (cooled
below their set point). After all detectors have reset, the
control panel activates the "Soak Timer" allowing the
system to continue discharging water for a preset time
period.
When the Soaking Timer has expired, the control panel de-
energizes normally closed Release Solenoid Valve (F2),
allowing it to close. (The normally open Release Solenoid
Valve (F1) remains energized closed until the control panel
is manually reset, or both the AC power and battery
backup have failed).
The Flow Control Valve (A2) re-primes and closes,
stopping the flow of water through the system piping.
Should a Firecycledetector go into alarm at this time, the
control panel re-energizes normally closed release
Solenoid valve (F2) open, and the entire cycle repeats.
Trouble conditions:
- False alarms – If water pressure surges produce false
alarms check if air is trapped in the sprinkler piping.
Trapped air can cause false alarms, the alarms to cycle on
and off during testing and other nuisance problems. To
correct bleed as much air as possible from the trapped
high points of system piping. This condition can be
minimized by opening the remote inspectors test valve and
slowly filling the system with water when placing the
system in service.
If the detection system is damaged or malfunctions, the
FirecycleIII Control panel will go into alarm and the flow
control valve will open. Water will not flow from any
sprinklers until a sprinkler has operated, as in a fire. The
cycling function of the Firecycle III®will not operate in this
condition and the system must be manually shutoff. All
alarms will operate normally.
If the piping system is damaged sufficiently to activate the
Water Flow Alarm Switch (C1), the control Panel will
energize normally open Release Solenoid Valve (F1)
closed. Because a detector has not gone into alarm mode,
release Solenoid Valve (F2) will remain non-energized
closed. The Flow Control valve (A2) will re-prime and
close after a short delay. This feature ensures that should
a sprinkler or the system piping become damaged, the
amount of water which will discharge is limited by the
system pressure and the location of the system damage.
Should a Firecycledetector detect a fire during this
condition, normally closed Release Solenoid valve (F2) will
be energized open, allowing the Flow Control valve (A2) to
open, and water will be discharged from any sprinklers
which may have operated as a result of the fire, as well as
from the damaged portion of the system and all alarms will
operate normally in this condition.
If the AC power fails, the FirecycleIII System continues
to operate on the standby batteries. Should both AC and

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TOTALPAC2 Integrated Fire Protection System
Cycling Wet Pipe Systems
FM-072G-0-143 E
batteries fail prior to the operation of the system, all alarms
will be lost but the system will fail-safe and operate like a
standard wet pipe system.
The cycling function of the system will not operate in this
condition, and the system must be manually shut-off.
If power fails while the system is flowing water, the system
will not cycle off and must also be manually shut-off.
2. Emergency Instructions (refer to piping diagram
provided)
To take system Out of Service:
WARNING ! Placing a control valve or detection system
out of service may eliminate the Fire Protection
capabilities of the system. Prior to proceeding, notify all
Authorities Having Jurisdiction. Consideration should be
given to employ a fire patrol in the affected areas.
After a fire, verify that the fire is OUT and that placing the
system out of service has been authorized by the
appropriate Authority Having Jurisdiction.
.1 Close Water Supply Control Valve (D1).
.2 Open system Main Drain Valve (D3) and inspectors test
valve. Drain the system piping.
.3 Silence alarms (refer to CONTROL PANEL SECTION
for additional details).
Note: Electric alarms controlled by a pressure switch (C2)
installed in the ½" (15mm) NPT connection for a Non-
interruptible Alarm Pressure Switch cannot be shut-off until
the Flow Control Valve is reset or taken out of service.
Sprinkler systems that have been subjected to a fire must
be returned to service as soon as possible. The entire
system must be inspected for damage, and repaired or
replaced as necessary.
.4 Replace any detectors or sprinkler heads that have
been damaged, or have been exposed to fire
conditions.
.5 Perform all maintenance procedures recommended in
MAINTENANCE, describing individual components of
the system that has operated.
.6 Return the system to service as soon as possible.
Refer to PLACING THE SYSTEM BACK IN SERVICE.
3. Placing the system back in service
(refer to TRIM SCHEMATIC)
Note: For additional details, refer to instructions provided in
the Viking Data Book describing the Flow Control Valve,
and other system components.
When the wet pipe system is ready to be placed in service,
verify that all the equipment is adequately heated and
protected to prevent freezing and physical damage.
Note: For proper operation of the wet system and to
minimize unwanted (false) alarms, it is important to remove
trapped air from the system when filling it with water. Air
trapped in the system may also cause intermittent operation
of the water motor gong during a sustained flow of water
(such as the flow required by an open sprinkler or the
system test valve). Consider installation of auxiliary vents to
facilitate venting.
CAUTION: Opening of the water supply main control
valve (A2) will result in water flow from any openings in
the system.
1. Slowly open the Emergency Release (B10) to allow the
system pressure to return to normal.
2. Once the pressure has stabilized, close the Emergency
Release (B10) and press the "System Reset" button on
the Firecycle® III Control Panel.
Trouble conditions:
Inspections & Tests
It is imperative that the system be inspected on a regular
basis. Refer to INSPECTIONS and TESTS recommended
in current Viking technical Data describing individual
components of the Viking Wet pipe System used.
The frequency of the inspections may vary due to
contaminated water supplies, corrosive or humid
atmospheres as well as the condition of the air supply to the
system. In addition to the instructions herewith, local
Authority Having Jurisdiction may have additional
maintenance, testing and inspection requirements which
must be followed.
WARNING ! Any system maintenance which involves
placing a control valve or detection system out of service
may eliminate the fire protection capabilities of that system.
Prior to proceeding, notify all Authorities Having
Jurisdiction. Consideration should be given to employment
of a fire patrol in the affected areas.
Maintenance
Note: The owner is responsible for maintaining the fire
protection system and devices in proper operating condition.
For additional information, refer to MAINTENANCE
INSTRUCTIONS provided in current Viking Technical Data
describing individual components of the Viking Preaction
System used.
Where difficulty in performance is experienced, the valve
manufacturer or his authorized representative shall be
contacted if any field adjustment is to be made.
The following requirements are based upon NFPA-25:
Records.
Records of inspections, tests, and maintenance of the
system and its components shall be made available to the
authority having jurisdiction upon request. Typical records
include, but are not limited to, valve inspections; flow, drain,
and pump tests; and trip tests of Flow Control valves.
Acceptance test records should be retained for the life of the
system or its special components. Subsequent test records
should be retained for a period of 1 year after the next test.

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TOTALPAC2 Integrated Fire Protection System
Cycling Wet Pipe Systems
FM-072G-0-143 E
The comparison determines deterioration of system
performance or condition and the need for further testing or
maintenance.
Monthly:
.1 Inspection of gauges (water supply and system
pressure) to ensure good condition and normal water
supply pressure.
.2 Flow Control valve shall be externally inspected. The
valve inspection shall verify the following:
a. The gauges indicate normal supply water pressure is
being maintained.
b. The valve is free of physical damage.
c. All valves are in the appropriate open or closed position.
d. There is no leakage from the alarm drains.
Quarterly:
- Alarm Device (pressure or flow switch).
(Testing by opening the inspector's test connection)
- Main Drain Test (Riser Flow Test) to determine if change
in water supply or control valve position.
Test procedure:
- Record the pressure indicated by the supply water
gauge.
- Fully open the main drain valve.
- Record residual pressure.
- Close the main drain valve slowly.
- Record the time taken for supply water pressure to
return to the original pressure.
- Open the alarm control valve
Semi-Annually:
- Valve supervisory switch shall be tested to verify the
operation of the switch upon movement of the hand
wheel.
Annually:
- Manual Pull station test.
- Record indicating the date of the last trip, tripping time
and name of organization conducting the test shall be
maintained at a location available for review by the
Authority Having Jurisdiction.
Every 5 years:
- Alarm valve and associated strainers, restriction orifice,
gaskets, moving parts shall be inspected internally.
- Test on gauge (gauge precision required: less than 3%
of the full scale)
- Test on control valves operation

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TOTALPAC2 Integrated Fire Protection System
Cycling Wet Pipe Systems
FM-072G-0-143 E