Johnson Controls ANSUL CD05A-1 User manual

APPROVED ANSUL®ASSEMBLY MANUAL
FOR ALTERNATE MANUFACTURING
LOCATION - FHC
ASSEMBLY MANUAL
One Stanton Street |Marinette, WI 54143-2542, USA |[phone] |www.ansul.com
© 2019 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. |Form No. F-2018124-01
000769

Approved ANSUL®Assembly Manual for
Alternate Manufacturing Location - FHC
(Form No. F-2018124)
2019-MAY-29 REV. 01
FOREWORD
This manual is intended for use in the assembly of SENTRY
Carbon Dioxide Hand Portable Extinguishers and RED LINE
Cartridge-Operated Hand Portable Extinguishers.
Those who assemble these fire extinguishers should read this
entire manual. Specific sections will be of particular interest
depending upon one’s responsibilities.
Fire extinguishers are mechanical devices. They require
periodic care. If the extinguishers are not assembled properly,
they may not perform reliably.
These extinguishers are pressure vessels that must be treated
with respect and handled with care.
Only Authorized SENTRY and RED LINE Distributors shall
be allowed to service and maintain SENTRY and RED LINE
products with genuine SENTRY and RED LINE components.
This manual is limited to uses herein described.
Note: The converted values in this manual are provided
for dimensional reference only and do not reflect an actual
measurement.
DISCLAIMER:
Johnson Controls does not make any representations,
warranties or guarantees, expressed or implied, as to the
accuracy or completeness of the manual. Users must be aware
that updates and amendments will be made from time to time to
the manual. It is the user’s responsibility to determine whether
there have been any such updates or amendments. Neither
Johnson Controls nor any of its directors, officers, employees,
or agents shall be liable in contract, tort, or in any other manner
to any person for any loss, damage, injury, liability, cost, or
expense of any nature, including without limitation incidental,
special, direct, or consequential damages arising out of or in
connection with the use of the manual.
All instructions contained herein relate to a typical installation.
Form Number: F-2018124-01
Date: 2019-MAY-29
ANSUL®, SENTRY, and the product names listed in this material are marks
and/or registered marks. Unauthorized use is strictly prohibited.

Approved ANSUL®Assembly Manual for
Alternate Manufacturing Location - FHC
(Form No. F-2018124)
REV. 01 2019-MAY-29
EXPLANATION OF SAFETY ALERTS
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.

Approved ANSUL®Assembly Manual for
Alternate Manufacturing Location - FHC
(Form No. F-2018124)
TABLE OF CONTENTS
2019-MAY-29 REV. 01 PAGE TOC-1
SECTION PAGE
1 SENTRY CARBON DIOXIDE 1-1 – 1-8
HAND PORTABLE EXTINGUISHER
About this Section 1-1
Introduction 1-1
Technical Information 1-2
Table 1-1: SENTRY Carbon Dioxide 1-2
Hand Portable Extinguishers
Cross References 1-3
Bill of Materials 1-3
Table 1-2: Unassembled Kits to Final Shipping 1-3
Assembly Part Numbers for Carbon Dioxide
Extinguishers
Goods In and Inspection 1-3
Approved Agency Manufacturer’s 1-4
Test and Batch Inspection Program
SENTRY Carbon Dioxide Extinguisher 1-5 –1-8
Assembly Work Instructions
2 RED LINE CARTRIDGE-OPERATED 2-1 – 2-14
PORTABLE EXTINGUISHER
About this Section 2-1
Introduction 2-1
Technical Information 2-2
Table 2-1: Technical Data for RED LINE 2-2
Cartridge-Operated Extinguishers
Containing Purple-K Dry Chemical Agent
Table 2-2: Technical Data for RED LINE 2-3
Cartridge-Operated Extinguishers
Containing FORAY Dry Chemical Agent
Cross References 2-4
Bill of Materials 2-4
Table 2-3: Unassembled Kits for Final 2-4
Shipping Assembly Part Numbers for
RED LINE Dry Chemical Cartridge-
Operated Extinguishers
Goods In and Inspection 2-4
Approved Agency Manufacturer’s Test 2-5
and Batch Inspection Program
RED LINE Extinguisher 2-6 –2-12
Assembly Work Instructions
SECTION PAGE
3 APPENDIX 1 – CARBON DIOXIDE 3-1 – 3-4
EXTINGUISHER
ENGINEERING CONSIDERATIONS
Carbon Dioxide Extinguisher 3-1
Engineering Considerations
(Not for Agency Field Representative’s Use)
Table 3-1: Rate of Flow / Discharge Duration 3-1
for Carbon Dioxide Extinguishers
Table 3-2: Carbon Dioxide Extinguisher 3-2
Inspection Form
4 APPENDIX 2 – RED LINE CARTRIDGE- 4-1 – 4-2
OPERATED EXTINGUISHER
ENGINEERING CONSIDERATIONS
RED LINE Cartridge-Operated Extinguisher 4-1
Engineering Considerations
(Not for Agency Field Representative’s Use)
Table 4-1: Rate of Flow / Discharge Duration 4-1
for RED LINE Extinguishers
Table 4-2: RED LINE Cartridge-Operated 4-2
Extinguisher Inspection Form
5 APPENDIX 3 – FM CRITICAL DOCUMENT 5-1 – 5-2
LIST (CDL) FOR RED LINE CARTRIDGE-
OPERATED EXTINGUISHERS
Blueprint Report - Condensed Version for 5-1
FHC Only
6 APPENDIX 4 – UL CALIBRATION 1-7
REQUIREMENTS
Note: Ofcial UL document included with this
manual

Approved ANSUL®Assembly Manual for
Alternate Manufacturing Location - FHC
(Form No. F-2018124)
TABLE OF CONTENTS
PAGE TOC-2 REV. 01 2019-MAY-29
NOTES:

Approved ANSUL®Assembly Manual for
Alternate Manufacturing Location - FHC
(Form No. F-2018124) 2019-MAY-29 REV. 01 PAGE 1-1
SECTION 1 – SENTRY CARBON DIOXIDE
HAND PORTABLE EXTINGUISHER
ABOUT THIS SECTION
This section is a comprehensive guide containing the
necessary information for filling, assembling, and handling of
Approved Agency manufacturer’s test program for SENTRY
Carbon Dioxide Extinguishers.
The information outlined in this section is to be used as
instruction for properly trained personnel. The outline of
this section has been arranged in a logical way for easy
comprehension.
Each assembly is to receive the Approved Agency’s
Certification mark. This means each manufacturer’s test
program listed in this section must be strictly followed.
INTRODUCTION
SENTRY Carbon Dioxide Extinguishers are designed to
protect areas where Class B (flammable liquids and gases)
or Class C (energized electrical equipment) fires could occur.
They may be used indoors where winds and drafts do not
affect discharge or where a clean suppressing agent is
required.
SENTRY Carbon Dioxide Extinguishers are ideal for labora-
tories, electronic equipment, low voltage electrical equipment,
and municipal fire departments.
Available in agent capacities of 5 lb (2.3 kg), 10 lb (4.5 kg),
15 lb (6.8 kg), and 20 lb (9.1 kg).

Approved ANSUL®Assembly Manual for
Alternate Manufacturing Location - FHC
(Form No. F-2018124)
PAGE 1-2 REV. 01 2019-MAY-29
SECTION 1 – SENTRY CARBON DIOXIDE
HAND PORTABLE EXTINGUISHER
TECHNICAL INFORMATION
The assemblies covered in this section reflect SENTRY Carbon Dioxide Hand Portable Extinguishers. Tables 1-1, 1-2, and 1-3
contain technical data pertaining to the final assembly.
TABLE 1-1: SENTRY CARBON DIOXIDE HAND PORTABLE EXTINGUISHERS
Model CD05A-1 CD10A-1 CD15A-1 CD20A-1
Extinguisher Part No. 431622 431623 431624 431625
Agent Capacity 5 lb (2.3 kg) 10 lb (4.5 kg) 15 lb (6.8 kg) 20 lb (9.1 kg)
UL/ULC Rating 5-B:C 10-B:C 10-B:C 10-B:C
Coast Guard Classification Type B, C,
Size I
Type B, C,
Size I
Type B, C,
Size I
Type B, C,
Size II
Discharge Time (sec) 10 10 11 13
Service Pressure 1,800 psi (124 bar) 1,800 psi (124 bar) 1,800 psi (124 bar) 1,800 psi (124 bar)
Maximum Effective Range 6 ft (1.8 m) 6 ft (1.8 m) 6 ft (1.8 m) 6 ft (1.8 m)
Shell (outside diameter) 5 1/4 in. (133 mm) 6 29/32 in. (175 mm) 6 29/32 in. (175 mm) 8 in. (203 mm)
Hose Length
(5/16 in. Dia.)
(7.9 mm Dia.)
Discharge Tube with
Horn
36 in. (914 mm) 36 in. (914 mm) 36 in. (914 mm)
Charged Weight
(with agent, without hose
and horn)
13.50 lb (6.1 kg) 26.75 lb (12.1 kg) 35.75 lb (16.2 kg) 46.75 lb (21.2 kg)
Dimensions
(without hose and horn)
Height:
Width:
Depth:
19.75 in. (502 mm)
7.25 in. (184 mm)
5.69 in. (136 mm)
22.25 in. (565 mm)
10.94 in. (278 mm)
7 in. (178 mm)
28 in. (711 mm)
10.94 in. (278 mm)
7 in. (178 mm)
28 in. (711 mm)
12 in. (305 mm)
8.098 in. (206 mm)
Fire Suppression
Capability
Novice:
Experienced:
5 ft2(0.47 m2)
12 ft2(1.2 m2)
10 ft2(0.93 m2)
25 ft2(2.3 m2)
10 ft2(0.93 m2)
25 ft2(2.3 m2)
10 ft2(0.93 m2)
25 ft2(2.3 m2)

Approved ANSUL®Assembly Manual for
Alternate Manufacturing Location - FHC
(Form No. F-2018124) 2019-MAY-29 REV. 01 PAGE 1-3
SECTION 1 – SENTRY CARBON DIOXIDE
HAND PORTABLE EXTINGUISHER
CROSS REFERENCES
Fire Hazard Control (FHC) will receive unassembled kits from
Marinette, WI facility. Each unassembled kit part number refer-
ences the final assembly part number listed in Tables 1-1 and
1-2. Once the unassembled kits have been fully assembled
in accordance with this assembly manual, the extinguishers
receive the final shipping assembly part number. Table
1-2 references unassembled kit part numbers to shipping
assembly part numbers.
BILL OF MATERIALS
Each assembled kit consists of various sub-assemblies and
parts. Reference the Final Assembly print that correlates to
the Alternate Manufacturing Location (AML) unassembled
kit in Table 1-2 Unassembled Kits to Final Shipping. Each
component listed in the Kit Bill of Materials (Kit BOM) must be
accounted for in the final shipping assembly.
TABLE 1-2: UNASSEMBLED KITS TO FINAL SHIPPING ASSEMBLY PART NUMBERS
FOR CARBON DIOXIDE EXTINGUISHERS
Description Final Shipping Assembly Part No. FHC Unassembled Kits Part No.
CD05A-1 (Aluminum Shell) 431622 448002
CD10A-1 (Aluminum Shell) 431623 448003
CD15A-1 (Aluminum Shell) 431624 448004
CD20A-1 (Aluminum Shell) 431625 448005
GOODS IN AND INSPECTION
Upon receiving material, the following procedure is to be
performed.
1. When the shipment from the primary manufacturing
location has been received, each component must be
accounted for, component received must be checked to
Kit BOM. Each component to be stored in a designated
area that is marked specifically by part number.
2. Verify that all split inspection identified components, per
final shipping assembly Kit BOM are properly labeled
with the split inspection green dot from the Marinette, WI
facility. Components identified with split inspection green
dot must remain marked and/or in packaging until used
for assembly.
3. All bulk CO2gases must meet the approved criteria:
a. CO2: Shall meet Drawing Specifications.
b. A Certificate of Conformance (COC) to the previously
mentioned requirements must accompany each ship-
ment and maintained in the record.
4. All nameplates must be recorded and COCs maintained
on file from manufacturer. Scrap nameplates must be
recorded and the serial numbers retained for Approved
Agencies.

Approved ANSUL®Assembly Manual for
Alternate Manufacturing Location - FHC
(Form No. F-2018124)
PAGE 1-4 REV. 01 2019-MAY-29
SECTION 1 – SENTRY CARBON DIOXIDE
HAND PORTABLE EXTINGUISHER
APPROVED AGENCY MANUFACTURER’S TEST AND
BATCH INSPECTION PROGRAM
In order for the Approved Agency mark to be applied to
finished assemblies, the manufacturing site must comply
with the listed manufacturer inspection responsibilities. If
requirements are not met, the Approved Agency mark cannot
be placed on the extinguisher. Test equipment used during
inspection must remain in calibration and perform properly.
Calibration must be completed according to the Approved
Agency Calibration requirements, see Section 3, Appendix 1
for details.
Calibration certificate and standards for calibration must
be kept until the next calibration is complete and be readily
available for review by an Approved Agency Representative.
Quality procedures must be in place; if calibration of
equipment is returned out of specification (e.g., a fill gauge
calibration is returned as out of specification), implement the
corrective action procedure for any items that were manufac-
tured while the equipment was out of calibration.
Proper documentation of inspections must be kept for 6 months
and made readily available to Approved Agency Represen-
tative. The documentation must include the model or catalog
designation of the product, the date of production, the tests
performed, and the test results. A system must be in place to
identify and isolate material that has been tested or not tested,
either complies or not complies, scheduled for rework, or the
like.
Manufacturer’s Inspection Responsibilities
The manufacturer is responsible for completing all test require-
ments outlined in the Approved Agency follow-up procedure.
The following inspection responsibilities are for reference:
1. Locking Devices and Seals: Once a week, 2 samples
must be selected from production. The manufacturer will
determine the force required to remove the locking device
(visual seal). The force must comply with the specified
amount in the procedure.
Either a spring scale or an incremental weight test may
be used to determine the force required to remove or
deactivate the locking device. Have the scale or weights
attached to locking device and the device operated in the
intended manner. The tension will increase uniformly until
the locking device pulls (breaks) the seal.
2. The maximum force read on tester to disengage the locking
device must be recorded and within specification in the
Approved Agency's procedure.
3. Discharge Duration, Minimum Carbon Dioxide Discharged,
and Weight of Charge Determinations: One sample per
model for low volumes under 500 pieces. If multiple CO2
models are made during a shift, then test one sample of the
smallest and one sample of the largest capacity models.
The manufacturer will determine the discharge duration
to gas point, the minimum Carbon Dioxide discharge
(complete discharge), and weight of the charge are as
required. The samples selected for the charged weight,
discharge duration, and minimum Carbon Dioxide discharge
does not need to be from the same sample. To determine
the charged weight, take the difference of the full weight
and the empty weight of the extinguisher. It must be verified
that all are within the specification as listed in the Approved
Agency's follow up procedure, reference data in Table 3-1.
Note: Charge weight for CO2is without horn/hose
assembly.
Necessary equipment to perform the test include a
stopwatch and a scale in ounces. The sample unit will be
weighed fully charged and recorded. The sample unit will
then be discharged and timed. The sample unit will be held
vertically 3 ft (9.1 m) off the ground. If a hose is on the unit,
the unit may stay on the ground with the hose extended
horizontally.
The discharge time to gas point and weight of the
extinguisher after discharge are to be recorded. Depress
push-lever and discharge any remaining pressure.
Reassemble the valve and weigh empty unit and record the
weight.
4. Extinguisher Leakage Test: All stored pressure
extinguishers will undergo an extinguisher leakage test.
Extinguishers that show no sign of leaking are acceptable.
Extinguishers showing evidence of leaking will be rejected.
The manufacturer has the option to retest the failed unit by
setting it aside for 24 hours and then retest. If the unit now
passes, the unit will be considered as acceptable.
5. Rate of Flow: Once a week, 2 units will be used for this test.
The extinguishers are to be charged with the appropriate
agent and pressurized according to specifications. The unit
hose will be held horizontally and discharged. The time
taken to discharge the unit will be recorded and compared
to the time specified in the technical data tables.
Additional Approved Agency Testing
For testing that is required off-site by an Approved Agency's
laboratory or representative, samples must be made
readily available upon request of the Approved Agency's
representative.
Calibration Timing
Calibration of all equipment used for manufacturers inspection
and assembly/filling processes must be kept according to the
following schedule:
1. Quarterly: Plug Gauge Scales
2. Monthly: Pressure Gauge
3. Annually: Stop Watches
Spring Scale
Incremental weight test

Approved ANSUL®Assembly Manual for
Alternate Manufacturing Location - FHC
(Form No. F-2018124) 2019-MAY-29 REV. 01 PAGE 1-5
SECTION 1 – SENTRY CARBON DIOXIDE
HAND PORTABLE EXTINGUISHER
SENTRY CARBON DIOXIDE EXTINGUISHER ASSEMBLY
WORK INSTRUCTIONS
Note: For part drawings associated with assembly and
verification, see Approved Agency's file for applicable
drawings.
1. Inspect Cylinder
a. Pick cylinder from pallet.
b. Ensure no paint damage, scratches, or dents.
c. Check for internal debris and moisture/water using
small light. Cylinder must be completely dry without
contamination.
2. Attach Valve Assembly
a. Locate valve assembly.
b. Inspect condition of valve assembly and pick-up tube.
c. Apply Blue Loctite 242 on threads of pick-up tube.
d. Connect the pick-up tube to valve using proper wrench
tool.
e. Screw valve assembly into cylinder until hand tight to 3
to 4 turns.
f. Tighten valve assembly to a maximum of
37 ft-lb to 44 ft-lb (50 N•m to 59.7 N•m) using assem-
bly equipment.
NOTICE
Overtightening can cause cylinder to
crack.
3. Attach Nameplates
a. Clean the exterior of the shell of all Carbon Dioxide
and foreign debris.
b. Position nameplate so that the vertical centerline of the
nameplate is aligned with the centerline of the stamped
side of valve.
c. Position the nameplate so that it is located the proper
distance from the bottom edge of the extinguisher (see
assembly print for proper label location).
d. Remove covering from self-sticking adhesive and care-
fully press label to extinguisher.

Approved ANSUL®Assembly Manual for
Alternate Manufacturing Location - FHC
(Form No. F-2018124)
PAGE 1-6 REV. 01 2019-MAY-29
SECTION 1 – SENTRY CARBON DIOXIDE
HAND PORTABLE EXTINGUISHER
SENTRY CARBON DIOXIDE ASSEMBLY
WORK INSTRUCTIONS (Continued)
4. Record Weight
a. Tare scale.
b. Weigh cylinder with valve assembly only. Do not
include horn or hose assembly.
c. Stamp empty weight on valve.
5. Fill Cylinder with Carbon Dioxide (CD)
a. Connect extinguisher to fill station port using charging
adapter.
b. Place on scale.
c. Tare cylinder weight.
!WARNING
Never leave a regulated high pressure source
connected to an extinguisher for an extended period of
time. Defective regulator could result in a violent failure
of the extinguisher.
d. Open the CD cylinder valve.
e. Open the charging system ball valve.
f. Press extinguisher lever and fill to the proper extin-
guisher weight (see Table 1-3).
NOTICE
Do not relieve charging system pressure
or remove charging adaptor until ring pin
and visual seal are assembled.
g. Release extinguisher lever.
TABLE 1-3
Extinguisher Weight Range
CD05A-1 5 lb ± 0.25 lb
CD10A-1 10 lb ± 0.5 lb
CD15A-1 15 lb ± 0.5 lb
CD20A-1 20 lb ± 0.5 lb
6. Attach Ring Pin and Visual Seal
a. Insert ring pin through the hole in the top push lever
and valve body.
b. Install visual seal through ring pin loop and around
top push lever.
c. 2 x week, pull test to be completed and not exceed
15 lb (6.8 kg) on seal.
7. Remove from Charging System
a. Release pressure from the charging system at the
regulator.
b. Remove the charging adapter.
c. Fill weight of extinguisher to be stamped into valve
body. Does not include horn or hose assembly.

Approved ANSUL®Assembly Manual for
Alternate Manufacturing Location - FHC
(Form No. F-2018124) 2019-MAY-29 REV. 01 PAGE 1-7
SECTION 1 – SENTRY CARBON DIOXIDE
HAND PORTABLE EXTINGUISHER
SENTRY CARBON DIOXIDE ASSEMBLY
WORK INSTRUCTIONS (Continued)
8. Leak Test
a. Maintain water bath at 90 °F to 110 °F
(32 °C to 43 °C)
b. Fully submerge all extinguishers.
c. Cover top push lever/valve with clear cover. Make sure
all air pockets are removed.
d. Hold in water bath for 1 hour.
e. If no bubbles are observed, unit passes test.
f. If bubbles are observed, the following are test require-
ments:
1. Minimum size of bubble to be detected:
1/8 in. (3.175 mm)
2. Smallest allowable leak rate: 1.05x10^-5 cc/sec
9. Attach Hose and Retainer
a. Attach hose retainer around cylinder, pulling snug.
b. Trim off excess retainer band.
10. Assemble Horn and Hose
a. Apply Loctite on nozzle threads before assembly.
b. Assemble hose, horn, and nozzle orifice.
c. Once assembled, perform a pull test to ensure nozzle
is seated into the horn.
NOTICE
No movement allowed.
11. Carton Assembly
a. Assemble carton by stapling.
b. Apply carton label over preprinted artwork on wide side
of carton.
12. Record Serial Number
a. Record and maintain records of serialized nameplates.
1. Serial numbers must be documented per date of
manufacture.
2. Serial numbers must be documented per order.
3. Records must be maintained.
b. Any serialized nameplates that are damaged or unus-
able for any reason must be destroyed and serial
numbers recorded.
13. Final Check
a. Check the following:
1. Operating push-lever and carry handle are assem-
bled correctly.
2. Labels are in correct position.
3. Paint is free of blemishes.
4. Visual Seal is present.
14. Packaging
a. Place completed assembly into carton.
b. Add hose/horn assembly to carton.
c. Add operation manual and necessary documentation.
d. Add hanger bracket.
e. Make sure hose is not crimped.
f. Close carton by stapling.

Approved ANSUL®Assembly Manual for
Alternate Manufacturing Location - FHC
(Form No. F-2018124)
PAGE 1-8 REV. 01 2019-MAY-29
SECTION 1 – SENTRY CARBON DIOXIDE
HAND PORTABLE EXTINGUISHER
NOTES:

Approved ANSUL®Assembly Manual for
Alternate Manufacturing Location - FHC
(Form No. F-2018124) 2019-MAY-29 REV. 01 PAGE 2-1
SECTION 2 – RED LINE CARTRIDGE-OPERATED
PORTABLE EXTINGUISHER
ABOUT THIS SECTION
This section is a comprehensive guide containing the
necessary information for filling, assembling, and handling
of Approved Agency manufacturer’s test program for
RED LINE Cartridge-Operated Extinguishers.
The information outlined in this section is to be used as
instruction for properly trained personnel. The outline of
this section has been arranged in a logical way for easy
comprehension.
Each assembly is to receive the Approved Agency's
Certification mark. This means each Approved Agency
manufacturer’s test program listed in this section must be
strictly followed.
INTRODUCTION
RED LINE Cartridge-Operated extinguishers are the premium
firefighting extinguishers preferred by safety directors
worldwide in high fire risk industries such as chemical,
petro-chemical, oil and gas, mining, aviation, and power
generation. Cartridge-operated means increased reliability,
on-the-spot recharge, ease of service, and superior firefighting
performance.
Typical applications include fuel loading racks, heavy
construction sites, dip tanks, oil pumping stations, mining
equipment, paint lockers, trucks and buses, fuel storage
rooms, production lines and other. Tough, carbon steel shells
resist impact, vibration, and corrosion; quality components
stand up to years of service; and Super Durable polyester
powder paint provides superior protection against cracking and
chipping.
Available in agent capacities of approximately 10 lb (4.5 kg),
20 lb (9.1 kg), and 30 lb (13.6 kg).

Approved ANSUL®Assembly Manual for
Alternate Manufacturing Location - FHC
(Form No. F-2018124)
PAGE 2-2 REV. 01 2019-MAY-29
SECTION 2 – RED LINE CARTRIDGE-OPERATED
PORTABLE EXTINGUISHER
TECHNICAL INFORMATION
The assemblies covered in this section reflect RED LINE Cartridge-Operated Extinguishers. Tables: 2-1, 2-2, and 2-3 contain
technical data pertaining to the final assembly.
TABLE 2-1: TECHNICAL DATA FOR RED LINE CARTRIDGE-OPERATED EXTINGUISHERS CONTAINING PURPLE-K DRY
CHEMICAL AGENT
Model I-K-10-G I-K-20-G I-K-30-G
Extinguisher Part No. 428227 428229 428231
Agent Capacity 9 lb (4.1 kg) 18 lb (8.2 kg) 27 lb (12.3 kg)
UL/ULC Rating 60-B:C 80-B:C 120-B:C
Coast Guard Classification Type B, C Type B, C Type B, C
Size II Size III Size IV
Discharge Time (sec) 19 21 27
Maximum Effective Range 25 ft (7.6 m) 30 ft (9.1 m) 30 ft (9.1 m)
Flow Rate 0.53 lb/sec (0.24 kg/sec) 0.89 lb/sec (0.40 kg/sec) 0.99 lb/sec (0.45 kg/sec)
Shell (outside diameter) 4.9 in. (124.5 mm) 6 in. (152.4 mm) 7 in. (177.8 mm)
Hose Length 26.6 in. (676 mm) 31.6 in. (803 mm) 35.6in. (904 mm)
Charged Weight
(with agent) 21 lb (9.5 kg) 36 lb (16.3 kg) 51.5 lb (23.4 kg)
Dimensions
Height:
Width:
Depth:
16.1 in. (409 mm)
8.3 in. (211 mm)
5.3 in. (135 mm)
20.5 in. (521 mm)
10.4 in. (264 mm)
7.0 in. (178 mm)
16.1 in. (409 mm)
8.3 in. (211 mm)
5.3 in. (135 mm)
Fire Suppression
Capability
Novice:
Experienced:
60 ft2(5.6 m2)
150 ft2(13.9 m2)
80 ft2(7.4 m2)
200 ft2(18.6 m2)
120 ft2(11.1 m2)
300 ft2(27.9 m2)

Approved ANSUL®Assembly Manual for
Alternate Manufacturing Location - FHC
(Form No. F-2018124) 2019-MAY-29 REV. 01 PAGE 2-3
SECTION 2 – RED LINE CARTRIDGE-OPERATED
PORTABLE EXTINGUISHER
TECHNICAL INFORMATION (Continued)
TABLE 2-2: TECHNICAL DATA FOR RED LINE CARTRIDGE-OPERATED EXTINGUISHERS CONTAINING FORAY DRY
CHEMICAL AGENT
Model I-A-10-G-1 I-A-20-G-1 I-A-30-G-1
Extinguisher Part No. 435099 435127 435165
Agent Capacity 8.5 lb (3.9 kg) 17 lb (7.7 kg) 25 lb (11.3 kg)
Charged Weight 20.5 lb (9.3 kg) 35 lb (15.9 kg) 49.5 lb (22.5 kg)
Discharge Time (sec) 15 22 26
Coast Guard Classification Type A, Size II Type A, Size II Type A, Size II
Type B, C, Size I Type B, C, Size II Type B, C, Size III
UL/ULC Rating 4-A:40-B:C 6-A:60-B:C 10-A:80-B:C
Maximum Effective Range 17 ft (5.2 m) 20 ft (6.1 m) 20 ft (6.1 m)
Flow Rate 0.50 lb/sec (0.22 kg/sec) 0.77 lb/sec (0.35 kg/sec) 0.89 lb/sec (0.40 kg/sec)
Shell (outside diameter) 4.9 in. (124 mm) 6 in. (152 mm) 7 in. (178 mm)
Hose Length 26.6 in. (676 mm) 31.6 in. (803 mm) 35.6 in. (904 mm)
Charged Weight
(with agent, without hose and
horn) 21 lb (9.5 kg) 36 lb (16.3 kg) 51.5 lb (23.4 kg)
Dimensions
(without hose and horn)
Height:
Width:
Depth:
16.1 in. (409 mm)
8.3 in. (211 mm)
5.3 in. (135 mm)
20.5 in. (521 mm)
10.4 in. (264 mm)
7.0 in. (178 mm)
22.5 in. (572 mm)
11.1 in. (282 mm)
8.0 in. (203 mm)
Fire Suppression
Capability
Novice:
Experienced:
40 ft2(5.6 m2)
100 ft2(9.3 m2)
60 ft2(7.4 m2)
150 ft2(13.9 m2)
80 ft2(11.1 m2)
200 ft2(18.6 m2)

Approved ANSUL®Assembly Manual for
Alternate Manufacturing Location - FHC
(Form No. F-2018124)
PAGE 2-4 REV. 01 2019-MAY-29
SECTION 2 – RED LINE CARTRIDGE-OPERATED
PORTABLE EXTINGUISHER
CROSS REFERENCES
FHC will receive unassembled kits from Marinette, WI facility.
Each unassembled kit part number references the final
assembly part number listed in Tables 2-1, 2-2, and 2-3. Once
the unassembled kits have been fully assembled in accor-
dance with this assembly manual, the extinguishers receive
the final shipping assembly part number. Table 2-3 references
unassembled kit part numbers to final assembly shipping part
numbers.
BILL OF MATERIALS
Each assembled kit consists of various sub-assemblies and
parts. Reference the Final Assembly print that correlates to
the AML unassembled kit in Table 2-3 Unassembled Kits to
Final Shipping Assembly. Each component listed in the Kit
BOM must be accounted for in the final shipping assembly.
Assembly Part Numbers For RED LINE Dry Chemical Cartridge-Operated Extinguishers
Description Final Shipping
Assembly
Part No.
FHC
Unassembled
Kit Part No.
Bulk Dry Chemical
Part No. from Final
Shipping Assembly
AML Dry Chemical
in Pails
Part No.
Cartridge Part No.
from Final
Shipping Assembly
AML
Cartridge
Part No.
I-K-10-G 428227 448008 9342 447591 8832 447583
I-K-20-G 428229 448009 9342 447591 8833 447584
I-K-30-G 428231 448010 9342 447591 8834 447585
I-A-10-G-1 435099 448011 434905 447593 8832 447583
I-A-20-G-1 435127 448012 434905 447593 8833 447584
I-A-30-G-1 435165 448013 434905 447593 8834 447585
GOODS IN AND INSPECTION
Upon receiving material, the following procedure is to be
performed:
1. When the shipment from the primary manufacturing
location has been received, each component must be
accounted for and checked to Kit BOM. Each component
to be stored in a designated area that is marked
specifically by part number.
2. Verify that all split inspection identified components, per
final shipping assembly Kit BOM are properly labeled
with the split green inspection dot from the Marinette, WI
facility. Components identified with split inspection green
dot must remain marked and/or in packaging until used for
assembly.
3. Bulk agent must be stored in a location not exposed to
more than 55% Relative Humidity, temperature range
65 °F to 80 °F (18 °C to 27 °C) and kept tightly sealed
after opening.
.
TABLE 2-3: UNASSEMBLED KITS TO FINAL SHIPPING ASSEMBLY
4. All bulk CO2gases must meet the approved criteria:
a. CO2: Shall meet Drawing Specifications.
b. A Certificate of Conformance (COC) to the Drawing
Specification must accompany each shipment and
maintained in the record.
5. All nameplates must be recorded, COCs maintained on file
from manufacturer. Scrap Nameplates must be recorded
and the serial numbers retained for Approved Agencies.

Approved ANSUL®Assembly Manual for
Alternate Manufacturing Location - FHC
(Form No. F-2018124) 2019-MAY-29 REV. 01 PAGE 2-5
SECTION 2 – RED LINE CARTRIDGE-OPERATED
PORTABLE EXTINGUISHER
APPROVED AGENCY MANUFACTURER’S TEST AND
BATCH INSPECTION PROGRAM
In order for the Approved Agency mark to be applied to
finished assemblies, the manufacturing site must comply with
the listed manufacturer inspection responsibilities. If require-
ments are not met, the Approved Agency mark cannot be
placed on the extinguisher.
Test equipment used during inspection must remain in
calibration and perform properly. Calibration must be
completed according to the Approved Agency Calibration
requirements, see Section 4, Appendix 2 for details.
Calibration certificate and standards for calibration must
be kept until the next calibration is complete and be readily
available for review by an Approved Agency Representative.
Quality procedures must be in place; if calibration of
equipment is returned as out of specification (e.g. a fill gauge
calibration is returned as out of specification), implement
the corrective action procedure for any items that were
manufactured while the equipment was out of calibration.
Proper documentation of inspections must be kept for
6 months and made readily available to Approved Agency
Representative. The documentation must include the model
or catalog designation of the product, the date of production,
the tests performed, and the test results. A system must be
in place to identify and isolate material that has been tested
or not tested, either complies or not complies, scheduled for
rework, or the like.
Manufacturer’s Inspection Responsibilities
The manufacturer is responsible for completing all test
requirements outlined in the Approved Agency follow-up
procedure. The following inspection responsibilities are for
reference.
1. Locking Devices and Seals: Once a week, 2 samples
must be selected from production. The manufacturer will
determine the force required to remove the locking device
(visual seal). The force must comply with the specified
amount in the procedure.
Either a spring scale or an incremental weight test may
be used to determine the force required to remove or
deactivate the locking device (visual seal). Have the scale
or weights attached to locking device and the device
operated in the intended manner. The tension will increase
uniformly until the locking device pulls (breaks) the seal.
2. The maximum force read on tester to disengage the locking
device must be recorded and within specification in the
Approved Agency's procedure.
3. Discharge Duration, Minimum Dry Chemical Discharged,
and Weight of Charge Determinations: two samples per
model lots 500 and above, one sample per shift for low
volumes under 500 pieces. The manufacturer will determine
the discharge duration to gas point, the minimum dry
chemical agent discharge (complete discharge), and weight
of the charge are as required. The samples selected for
the charged weight, discharge duration, and minimum
dry chemical agent discharge does not need to be from
the same sample. To determine the charged weight, take
the difference of the full weight and the empty weight of
the extinguisher. It must be verified that all are within the
specification as listed in the Approved Agency's follow up
procedure, reference data in Table 4-1.
Necessary equipment to perform the test include a
stopwatch and a scale in ounces. The sample unit will be
weighed fully charged and recorded. The sample unit will
then be discharged and timed. The sample unit will be held
vertically 3 ft (9.1 m) off the ground. If a hose is on the unit,
the unit may stay on the ground with the hose extended
horizontally.
The discharge time to gas point and weight of the extin-
guisher after discharge are to be recorded. Remove the fill
cap and empty the remaining agent. Reassemble the fill
cap and weigh empty unit and record the weight.
4. Rate of Flow: Once a week, 2 units will be used for this
test. The extinguishers are to be charged with the appro-
priate agent and pressurized according to specifications.
The unit hose will be held horizontally and discharged.
The time taken to discharge the unit will be recorded and
compared to the time specified in the technical data tables.
Additional Approved Agency Testing
For testing that is required off-site by an Approved Agency's
laboratory or representative, samples must be made
readily available upon request of the Approved Agency's
representative.
Calibration Timing
Calibration of all equipment used for manufacturers inspection
and assembly/filling processes must be kept according to the
following schedule:
1. Quarterly: Plug Gauge Scales
2. Monthly: Pressure Gauge
3. Annually: Stop Watches
Spring Scale
Incremental Weight Test

Approved ANSUL®Assembly Manual for
Alternate Manufacturing Location - FHC
(Form No. F-2018124)
PAGE 2-6 REV. 01 2019-MAY-29
SECTION 2 – RED LINE CARTRIDGE-OPERATED
PORTABLE EXTINGUISHER
RED LINE EXTINGUISHER ASSEMBLY
WORK INSTRUCTIONS
Note: For part drawings associated with assembly and
verification, see Approved Agency's file for applicable
drawings.
1. Inspect Cylinder (Shell)
a. Pick shell from pallet.
b. Ensure no paint damage, scratches, or dents.
c. Check for debris and moisture/water in shell using
small light.
2. Attach Handle
a. Locate pin, spring, and Rivet Tool.
b. Line up spring with grooves in tool.
c. Place handle over tool, lining up the holes.
d. Place tool/handle on shell lug.
e. Line up holes.
f. Push rivet through handle and spring holes
remove tool.
g. Roll rivet using proper rivetor.