Minot AFB_T500 OM Manual_5-29-2026.pdf

STRUCTURAL FIRETRAINER T-500

MINOT AFB, ND

OPERATION & MAINTENANCE MANUAL

KFT Fire Trainer, LLC (Formerly known as Kidde Fire Trainers, Inc.)

5 Pearl Court, Unit D Allendale, NJ 07401 USA Tel: 1-800-899-1701 EXT. 502

Subject to design or specification changes. Please consult Kidde Fire Trainers/KFT Fire Trainer for current configuration

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RESERVED. REPRODUCTION OF THIS MANUAL IN ANY MEDIUM WITHOUT THE EXPRESS

PERMISSION OF KIDDE FIRE TRAINERS/KFT FIRE TRAINER. IS PROHIBITED.

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This technical manual shall not, without the written permission of Kidde Fire Trainers/KFT Fire Trainer be either (a) used, released, disclosed, or reproduced in whole or in part or (b) used in whole or in part for manufacture except that (i) such release, disclosure or use is necessary for emergency repair or overhaul; (ii) such release, disclosure, or use is made subject to a prohibition that the person to whom the data is released or disclosed may not further release, disclose, or use such data; (iii) Kidde Fire Trainers/KFT Fire Trainer is notified of such release, disclosure or use.

DOCUMENT NO.: 4B1-007-653

DATE: 05-13-10 / 05-24-2016 / 05-29-2026

Revision: New existing manual, Revision B cover page update

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this manual.

Table of Contents 1

Structural FireTrainer® T-500

Operation and Maintenance Manual

TABLE OF CONTENTS

Table of Contents

1.0 Introduction ........................................................ 1-1

1.1 General ................................................................................................................ 1-1

1.2 How To Use This Manual ................................................................................... 1-2

1.3 Safety .................................................................................................................. 1-3

1.3.1 Safety Symbols .........................................................................................................1-3

1.3.2 Trainer Personnel Safety Responsibilities ............................................................1-3

1.3.3 Student Safety Guidelines .......................................................................................1-4

1.3.4 System Safety Warning ...........................................................................................1-5

1.3.5 Cold Weather Operation Guidelines .......................................................................1-6

1.3.4 Peripheral Equipment ..............................................................................................1-6

2.0 System Description ............................................. 2-1

2.1 Introduction ........................................................................................................ 2-1

2.2 Fire Trainer Components ................................................................................... 2-4

2.2.1 Ventilation/Exhaust System ....................................................................................2-4

2.2.2 Smoke Generation ....................................................................................................2-6

2.2.3 Manual Emergency E-Stop Button .........................................................................2-7

2.2.4 Combustible Gas Detection ....................................................................................2-7

2.2.5 Temperature Monitoring ........................................................................................2-10

2.2.6 Control Panel ..........................................................................................................2-11

2.2.7 Control Pendant .....................................................................................................2-14

2.2.8 Wireless Control System .......................................................................................2-17

2.2.9 Combustible Gas Sensor Transmitter ..................................................................2-21

2.2.10 Electrical Control Cabinet Assy. (Vent Fan) ........................................................2-23

3.0 Operation ........................................................... 3-1

3.1 Introduction ........................................................................................................ 3-1

3.2 Pre-Operational Checkouts ............................................................................... 3-1

3.3 System Operation .............................................................................................. 3-2

3.3.1 Start Up .....................................................................................................................3-2

3.3.2 Fireplace Operation (Wired Control Pendant) .......................................................3-3

3.3.3 Fireplace Operation (Wireless Control System) ....................................................3-5

3.3.4 Sound System Operation ........................................................................................3-6

3.3.5 Ventilation Control Cabinet Operation (2ND Floor) ................................................3-6

3.4 Operator Panel Messages ................................................................................. 3-7

3.3 Emergency Stop Lamp Indications ................................................................ 3-11

3.5 System Shutdown ............................................................................................ 3-12

3.6 Mock-up Assembly Instructions ..................................................................... 3-13

3.6.1 Stove FPLC Mock-UP .............................................................................................3-13

3.6.2 Bed FPLC Mock-UP ................................................................................................3-16

3.6.3 Sofa FPLC Mock-UP ...............................................................................................3-18

3.6.4 Hazmat Rack FPLC Mock-UP ................................................................................3-20

3.6.5 Bottle Rack FPLC Mock-UP ...................................................................................3-21

3.6.6 Motor Generator FPLC Mock-UP...........................................................................3-23

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this manual.

2 Table of Contents

4.0 Maintenance & Servicing ..................................... 4-1

4.1 Maintenance ........................................................................................................ 4-1

4.1.1 Introduction .............................................................................................................. 4-1

4.1.2 Maintenance Schedule ............................................................................................. 4-2

4.2 Servicing ............................................................................................................. 4-8

4.2.1 Consumable Materials ............................................................................................. 4-8

4.2.2 Combustible Gas Detection System Adjustment .................................................. 4-8

4.2.3 Combustible Gas Detection System test ............................................................. 4-12

4.2.4 PLC Battery Removal and Replacement .............................................................. 4-13

4.2.5 Smoke Fluid Reservoir Filling ............................................................................... 4-14

5.0 Parts Lists .......................................................... 5-1

5.1 General ................................................................................................................ 5-1

5.2 Burner Control Assembly .................................................................................. 5-1

5.3 Flashover Valve Cabinet Assembly RF ............................................................ 5-2

5.4 Electrical Control Cabinet (Panel) ..................................................................... 5-4

5.5 Electrical Control Cabinet (Enclosure) ............................................................. 5-6

5.6 Control Pendant Assembly ................................................................................ 5-8

5.7 Wireless Control System ................................................................................. 5-10

5.8 E-Stop Assembly .............................................................................................. 5-12

5.9 Gas Detection System Assy. (Burn Rooms) .................................................. 5-13

5.10 Temperature Sensor Assembly ....................................................................... 5-14

5.11 HVC Exhaust Fan Assembly ............................................................................ 5-15

5.12 Electrical Control Cabinet (2ND Floor) ............................................................. 5-16

5.13 Bed FPLC Mock-UP .......................................................................................... 5-19

5.14 Stove FPLC Mock-UP ....................................................................................... 5-20

5.15 Electric Motor Generator ................................................................................. 5-22

5.16 Gas Bottles........................................................................................................ 5-23

5.17 Hazmat ............................................................................................................... 5-25

5.18 Sofa .................................................................................................................... 5-26

5.19 Pan Assembly ................................................................................................... 5-27

5.20 Second Stage Regulating Station ................................................................... 5-28

5.21 Sound System ................................................................................................... 5-29

6.0 Drawings & Reference Material ........................... 6-1

6.1 Introduction ......................................................................................................... 6-1

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this manual.

Introduction 1-1

Structural FireTrainer® T-500

Operation and Maintenance Manual

1.0 INTRODUCTION

1.1 GENERAL

This manual provides all of the necessary information to operate the:

Structural FireTrainer® T-500

LOCATED AT:

Minot AFB, ND

MANUFACTURED BY:

Kidde Fire Trainers Inc.

If you have any questions regarding the operation or maintenance of this trainer that are not answered in this manual contact the Kidde Fire Trainers Customer Support Group at:

KIDDE FIRE TRAINERS INC.

17 PHILIPS PARKWAY

MONTVALE, NJ 07645-1810 USA

TEL: (201)300-8100

WEB SITE: WWW.KIDDEFT.COM

E-MAIL: INFO@KIDDE.COM

Utilization of the Structural FireTrainer® T-500 for live-fire training exercises brings a level of versatility and realism that cannot be duplicated using conventional fire fighting training methods. The operator of the trainer will be able to vary the difficulty, complexity or scale of the fires to challenge the skills of the trainees.

To maximize training effectiveness and use the full potential of the system, a thorough understanding of the trainer system and controls is necessary. This section describes the layout of the manual and the Safety Guidelines for the Trainer. Read and understand the Safety Guidelines and system controls before operating the Trainer.

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this manual.

1-2 Introduction

1.2 HOW TO USE THIS MANUAL

The Operation Manual for the Structural FireTrainer® T-500 is presented in the following order:

Section 1 Introduction This section provides a brief functional description how to use the manual and relevant safety guidelines and instructions.

Section 2 System Description This section provides an equipment overview and a functional description of the major equipment components that are part of the site.

Section 3 Operation Detailed operating instructions including Theory of Operation are given in this section.

Section 4 Maintenance & Servicing This section provides information on maintaining the various systems, assemblies and components of the trainer.

Section 5 Parts Lists This section provides figures and parts list tables for each of the Structural FireTrainer® T-500 major assemblies.

Section 6 Drawings & Reference Material

This section contains interconnection drawings and reference material for the trainer.

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this manual.

Introduction 1-3

Structural FireTrainer® T-500

Operation and Maintenance Manual

1.3 SAFETY

Normal operation of the training system presents potentially hazardous situations to student firefighting personnel. It is of the utmost importance that operators read, understand, and follow the safety precautions and guidelines detailed in the following chapters. Failure to follow these safety guidelines could place training area personnel at undue risk of personal injury or death.

1.3.1 SAFETY SYMBOLS

Various symbols are used throughout the manual to alert the reader to a potentially dangerous situation.

WARNING

THE WARNING SYMBOL IS USED WHENEVER A CONDITION EXISTS THAT COULD POTENTIALLY CAUSE

DEATH OR SERIOUS INJURY.

CAUTION

THE CAUTION SYMBOL IS USED WHENEVER A CONDITION EXISTS THAT MAY CAUSE INJURY OR DAMAGE

TO ASSOCIATED EQUIPMENT.

1.3.2 TRAINER PERSONNEL SAFETY RESPONSIBILITIES

Trainer Personnel (instructors, safety officers, system operators and maintenance personnel) are ultimately responsible for the safety of all personnel entering the training area and compliance to all applicable NFPA, OSHA, national, state and local codes and standards. The safety responsibilities of Trainer Personnel are summarized below:

The safety responsibilities of Trainer Personnel are summarized below:

1. Read and fully understand all provided trainer manuals and this safety handbook.

2. Ensure that the trainer is operated and maintained in accordance with all trainer manuals.

3. Discontinue trainer use if potentially hazardous conditions or anomalies occur.

4. Be familiar with each fireplace's behavior in all modes of operation under all conditions, and insure the safety of personnel with respect to potentially hazardous behaviors.

5. Ensure that personnel are properly trained in the use of self contained breathing apparatus (SCBA).

6. All personnel entering the training area shall wear full firefighting gear. This gear shall include: full-face mask, self-contained breathing apparatus (SCBA) and appropriate protective clothing. As in any fire situation, the exposure of personnel to smoke (real or synthetic), fumes, or other combustion products should be avoided.

7. Ensure that personnel are in a safe position prior to, and during, flame initiation.

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this manual.

1-4 Introduction

Structural FireTrainer® T-500

Operation and Maintenance Manual

8. Ensure that the operator and instructors have a full knowledge and understanding of the training scenario prior to initiation. This should include all fireplace parameter settings as well as reflash capabilities or simulated flame effects.

9. At no time during live-fire operation should the trainer be left unmanned.

10. Ensure that only water is used as the extinguishing agent. Use of extinguishing agents other than water can result in diminished trainer life and performance and adversely impact safe trainer operation.

11. Ensure that at the completion of a training exercise, personnel without adequate protective clothing and SCBA do not enter a training structure until the ventilation system has been operated at maximum capacity for a minimum of 3 minutes to remove combustion by-products and smoke.

12. Ensure that proper communication is established and in operation between instructors and safety officers before and throughout each training exercise.

1.3.3 STUDENT SAFETY GUIDELINES

Prior to conducting training, Trainer Personnel must inform students of the dangers involved in live fire training. The following is a list of safety guidelines that must be presented to instructors and students before use of the trainer.

Normal operation of the training system presents potentially hazardous situations to student firefighting personnel. It is of the utmost importance that operators read, understand, and follow the safety precautions and guidelines detailed on this page.

Failure to follow these safety guidelines could place training area personnel at undue risk of personal injury or death.

1. Do not enter the training area until authorized to do so by Trainer Personnel.

2. Do not enter the training area without proper protective clothing and self-contained breathing apparatus (SCBA). Keep this equipment on during the entire live fire training exercise.

3. While within the training area, be alert at all times. Treat the live fire-training situation the same as an actual fire emergency. Be prepared for any aspect of flame behavior that is possible with an uncontrolled, fully involved fire.

4. Avoid contact with hot surfaces within the training area before, during, and after the live fire training exercise.

5. Avoid breathing smoke and products of combustion while outside the training area.

6. Minimize or avoid contact with clothing and equipment exposed to smoke, soot, and any other fire training residue. If contact cannot be avoided, clean exposed skin surfaces with soap and water as soon as practical.

7. In addition to the guidelines listed above, listen to and carefully follow all rules and directions provided by Trainer Personnel.

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this manual.

Introduction 1-5

Structural FireTrainer® T-500

Operation and Maintenance Manual

1.3.4 SYSTEM SAFETY WARNING

HIGH VOLTAGES capable of causing serious injury or death are used in the training system equipment. Unless required for voltage measurement, all power should be turned off when servicing is being performed. When power must be on, use extreme care when working near exposed conductors.

FUEL GAS used in the trainer is capable of forming explosive mixtures with air that can be triggered by open flames or sparks. Even residual gas from piping sections can create a hazardous condition. Work only in well ventilated areas, with no exposed flames or possible ignition source.

OPEN FLAMES generated in the fireplace area during operation of this equipment can cause serious injury or death. Use extreme care when working in this area whenever training fires are in operation.

EXPOSURE to extremes in the environmental conditions such as high or low temperatures, high winds, etc. may occur during a training scenario. Extreme care should be used when training under adverse environmental conditions. Failure to exercise extreme care could result in serious injury or death.

WARNING

SAFE OPERATION OF THE TRAINING SYSTEM MANDATES THAT THE FOLLOWING SAFETY

PRECAUTIONS BE TAKEN PRIOR TO ANY OPERATION OR ACTIVITY. FAILURE TO FOLLOW THESE

PROCEDURES MAY RESULT IN SERIOUS INJURY OR DEATH.

1. All personnel entering the training area shall wear full firefighting gear. This gear shall include: full-face mask, self-contained breathing apparatus (SCBA) and appropriate protective clothing. As in any fire situation, the exposure of personnel to smoke (real or synthetic), fumes or other combustion products should be avoided.

2. All live fire training evolutions shall be conducted in accordance with all applicable NFPA Codes (such as 1402 1403, 1404, and 1500); OSHA; national; state; and local codes and standards.

3. If fuel leaks are detected, they must be repaired. Under no circumstance is trainer operation to be performed when a leak is present.

4. Keep flames and ignition sources away from fuel handling components. When ignited, the fuel may cause serious injury or death.

5. Ensure the upstream fuel supply valve is fully closed prior to the purging of any lines to atmosphere. Tag all valves closed to alert other personnel that service is being performed. Failure to comply may result in serious injury or death.

6. Only smoke generators approved by Kidde Fire Trainers for use in flame areas shall be used.

7. Only smoke fluid recommended by Kidde Fire Trainers shall be used in the smoke generator(s).

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this manual.

1-6 Introduction

Structural FireTrainer® T-500

Operation and Maintenance Manual

1.3.5 COLD WEATHER OPERATION GUIDELINES

Kidde Fire Trainers strongly recommends that all FIRETRAINER systems not be operated for training purposes when the ambient temperature is below 32F. Operation below this temperature may impact the effectiveness of student training.

As water is used as the primary extinguishing agent in most training scenarios, it should be apparent that freezing water and ice may become hazardous to trainees and other site personnel. It is with this safety consideration in mind that Kidde Fire Trainers issues this cold weather operation recommendation.

NOTE

THIS RECOMMENDATION DOES NOT AND SHOULD NOT BE CONSTRUED TO IMPLY THAT THE TRAINER

WILL NOT OPERATE BELOW THE KIDDE FIRE TRAINERS RECOMMENDED OPERATING TEMPERATURE.

CAUTIONS

Each fireplace has a water bath fabricated from steel. The burner elements are located at the bottom of the bath. For this reason refer to the CAUTION located below.

CAUTION

WHEN NOT IN USE ALL FIREPLACE WATER BATHS SHOULD BE DRAINED OF WATER DURING COLD

WEATHER PERIODS, WHEN THE ANTICIPATED AMBIENT TEMPERATURE IS GOING TO BE BELOW 32ºF

WHEN TRAINING DURING THE ABOVE MENTIONED CONDITION, FILL WATER BATHS JUST PRIOR TO

OPERATION AND DRAIN IMMEDIATELY UPON THE COMPLETION OF TRAINING.

FAILURE TO FOLLOW THESE CAUTIONS MAY RESULT IN SERIOUS DAMAGE TO THE ASSOCIATED

EQUIPMENT.

1.3.4 PERIPHERAL EQUIPMENT

Integrated Sound System

Smoke Generator

Hartzell Ventilation Fan

FOR THE ABOVE EQUIPMENT REFER TO SECTION 6 FOR SAFETY INFORMATION.

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this manual.

System Description 2-1

2.0 SYSTEM DESCRIPTION

2.1 INTRODUCTION

The Structural FireTrainer® T-500 is a live-fire-training system used to conduct training of firefighters and emergency rescue personnel in live-fire situations. The trainer is a system that generates propane fueled fires under the control of a PLC and an instructor. The trainer simulates Class A and B type fires. Class A fires involve ordinary dry combustible materials. Class B fires involve flammable liquids.

The T-500 Live FIRE TRAINER consists of one live fire training burn room. The Burn Room contains a fireplace platform with a water pan fabricated from steel sheet. At the bottom of the pan, a sparging system is installed through which the flammable gas is liberated. Gas/ oxygen mixing occurs above the water surface where a standing pilot initiates combustion. The liberation of gas through water greatly enhances the depth of flame and gives the impression of a substantial fire.

Burn room 1 is located on the first floor and is equipped with a fireplace platform for multiple mockup use. Depending upon the type of scenario a mockup is assembled on top of the fireplace platform and fires are created that engulf the mockup. This burn room is also equipped with a flashover and rollover effect. See Figure 2-1 & Table 2-1 for location. When the flashover effect is activated it produces a flame that extends across the ceiling. When the rollover effect is activated it produces a flame that extends up the wall to the ceiling. A Second Stage Gas Regulation Assembly is located on the outside wall of the first floor (Figure 2-1 & Table 2-1). The Second Stage Gas Regulation Assembly filters and regulates the pressure of the supplied gas.

Fire extinguishment is accomplished by applying extinguishing agent to the fire while the operator simulates the appropriate response of the fire.

Since the gas-fueled fires do not create smoke as a normal part of combustion, the burn room is equipped with a fixed smoke generator. See Figure 2-1 & Table 2-1 for locations. Smoke is generated using non-toxic mineral fluid and supplied to the training compartment to create obscuration normally associated with fire scenarios.

A T-500 Class A ventilation system is installed in the second floor Class A burn room.

The system operates automatically and controls the environment to ensure student safety during live fire training drills See Figure 2-2.

The trainer is also equipped with an Integrated Sound Effects System that enhances the realism of the training system. The Integrated Sound Effects System produces audio effects that firefighters and emergency rescue personnel would experience during actual live fire situations. For further information refer to the Integrated Sound Effects Operation and Maintenance manual, located in Section 6 of this manual.

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this manual.

2-2 System Description

Structural FireTrainer® T-500

Operation and Maintenance Manual

FIRST FLOOR

ES1

SC1

EE1

F1

BC1

FRCS1

SG1

CGS2

ES2

FP1

TC1

CGS1

VF1

Figure 2-1. Training Building - First Floor

Table 2-1. Legend (refer to Figure 2-1)

Tag Description Tag Description

FP1 Fireplace Platform FRCS 1 Fuel Regulation & Control Station

BC1

Burner Control Assembly (for FP1)

SG1 Smoke Generator

EE1

Electrical Control Cabinet W/ Control Pendant

TC1 Temp Sensor (for FP1)

ES1 & 2 Emergency Stop (for FP1) VF1 Vent Fan (for FP1)

F1 Flashover Effect Cabinet SC1 Sound System Enclosure

GDS1 & 2

Combustible Gas Sensors (for FP1)

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this manual.

System Description 2-3

SECOND FLOOR

VFC2

TC2

TC3

VF2

Figure 2-2. Training Building - Second Floor

Table 2-2. Legend (refer to Figure 2-2)

Tag Description Tag Description

VF2 Vent Fan (for 2ND Floor) TC2 & 3 Temp Sensors (for 2ND Floor)

VFC2

Vent Fan Electrical Control Enclosure

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this manual.

2-4 System Description

Structural FireTrainer® T-500

Operation and Maintenance Manual

2.2 FIRE TRAINER COMPONENTS

2.2.1 VENTILATION/EXHAUST SYSTEM

The trainer contains four ventilation/exhaust fans. The main function of the ventilation/exhaust fan is to purge the building of all air impurities and to pull clean air into the burn area. The ventilation / exhaust fan accelerates and decelerates based on operation, warning, and alarm conditions.

When the Control Panel STBY/ON/RESET key is placed in the ON position the ventilation / exhaust fan turns on and will run an initial 30 second purge cycle at high speed. The Control Panel PURGE light flashes during the purge cycle.

CAUTION

NOTE! DURING THE PURGE CYCLE DO NOT TOUCH ANY BUTTONS OR SWITCHES. THIS MANY CAUSE

THE PURGE CYCLE TO START OVER AGAIN!

At the end of the purge cycle, the fans go off. The system is now ready for operation.

In addition to the purge cycle the fan will also run at high speed if any of the following conditions occur:

An emergency button is pressed

An unsafe concentration of gas is detected

The Pendant SMOKE switch is turned to VENT.

A temperature of 500oF is exceeded

A temperature of 700oF is exceeded

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this manual.

System Description 2-5

2.2.1.1 EXHAUST FAN OPERATION-EMERGENCY

When an Emergency Stop button is activated, the exhaust fan in the structural trainer accelerates to ‘high’ speed and will continue to run at high speed until the emergency switch system is reset.

2.2.1.2 EXHAUST FAN OPERATION 10% LEL OF PROPANE GAS

When the gas detection system reads over 10% LEL the ventilation/exhaust fan will accelerate from low speed and the system will continue to run and attempt to remove the unburned gas buildup.

2.2.1.3 EXHAUST FAN OPERATION 25% LEL OF PROPANE GAS

When a reading above 25% LEL of propane gas is detected an emergency shutdown is initiated. All main flames and pilot flames are removed and the ventilation fan ramps to high speed. When the gas level drops below a reading of 10% LEL a system purge sequence is initiated. At the end of the 30 second system purge sequence, the trainer is ready for operation.

2.2.1.4 EXHAUST FAN OPERATION-SMOKE CLEAR

The Control Pendant has a three-position switch for the operation of the smoke system.

The positions of this switch are:

SMK = Smoke On

Center Pos. = Smoke/Vent Off

Vent = Exhaust fan runs at high speed (Control Panel PURGE light goes on)

2.2.1.5 EXHAUST FAN OPERATION-500OF IS EXCEEDED

When the temperature in a fire room is detected as exceeding 500oF, the exhaust fan of the module will accelerate and continue to run at this speed until the temperature is detected as being less than 500oF. When the temperature drops below 500oF the fan will revert to low speed. A Message will appear at the Control Panel screen.

2.2.1.6 FAN OPERATION-700OF IS EXCEEDED

When the temperature in a burn room is detected as exceeding 700oF the exhaust fan will accelerate to high speed from the warning operating speed. When the temperature is detected as exceeding 700oF the burner(s) in the burn room turns off.

After a room temperature is detected as being greater than 700oF the fan runs at high speed and will continue to do so until the temperature drops below 700o, STBY-ON- RESET key switch is placed in the RESET position and released and all burner and pilot switches are in the OFF position.

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this manual.

2-6 System Description

Structural FireTrainer® T-500

Operation and Maintenance Manual

2.2.2 SMOKE GENERATION

To increase the realism of the fire training, a non-toxic smoke can be generated from a smoke generator. There is one smoke generator associated with each burn room (See Figure 2-1 & Table 2-1 for locations. The smoke generator is equipped with a nitrogen regulator and a nitrogen/CO2 Bottle (CO2 bottle by others). The smoke fluid is fed to the smoke generator from a tank located inside the smoke generator. An element heats the smoke fluid inside the smoke generator, causing it to vaporize creating a dense smoke effect. Smoke travels from the nozzle through a smoke duct in the wall and into the burn room. The smoke generation system can use nitrogen or CO2 propellant to atomize the smoke fluid.

The smoke system must complete a pre-heat cycle before it is operational. The system must reach a temperature of 340-380°C and be pressurized by CO2 or nitrogen to 95 psi before smoke can be generated. When the correct temperature has been reached, the Pendant SMOKE switch flashes.

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this manual.

System Description 2-7

2.2.3 MANUAL EMERGENCY E-STOP BUTTON

When an E-Stop is pressed it shuts down all operating main and pilot flames. The exhaust fan will ramp up to full speed and remain at that speed until the activated push button is reset and the STBY-ON-RESET key switch is rotated to the RESET and released. The message “System Emergency Stop Pressed” will be displayed on the Control Panel screen.

2.2.4 COMBUSTIBLE GAS DETECTION

The Structural FireTrainer® T-500 training system continuously monitors the gas levels inside the burn room. The burn room is equipped with two combustible gas sensors (See Figure 2-1 for locations and Figure 2-3 for detail). Each sensor is connected to a Transmitter located in the Electrical Control Cabinet. See Figure 2-1 for the Electrical Control Cabinet locations and Figure 2-4 for Transmitter locations. This system is hard-wired and fail-safe.

The gas sensor transmitter has two alarm levels; the first is a warning. The warning will trigger, when the presence of a combustible gas concentration exceeding 10% of the Lower Explosive Limit (LEL), for gas is detected in the burn area. This will accelerate the ventilation/exhaust system fan. The second alarm is triggered when the presence of a combustible gas concentration exceeds 25% of the LEL. When a concentration exceeding this amount is detected the system will automatically fault into an emergency stop condition.

The gas detection transmitter display indicates the percentage of LEL for the corresponding sensor and also displays alarm status.

The combustible gas sensor(s) in the burn area are fitted with protective splashguards that will prevent fire-extinguishing agent from impinging the sensing module readily.

CAUTION

THE GAS DETECTION HEADS ARE SENSING DEVICES. HARSH SOLVENTS AND SILICON BASED

PRODUCTS CAN/WILL POISON THE GAS DETECTION HEADS. IF THE NEED ARISES TO USE THESE

PRODUCTS WITHIN THE AREA OF THE GAS DETECTION HEADS MAKE SURE THAT THE HEADS ARE

COVERED WELL, AND THAT THE AREA IS WELL VENTILATED.

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this manual.

2-8 System Description

GAS

SENSOR

FRONT VIEWSIDE VIEW

SIDE OF COVER REMOVED

FOR CLARITY

Figure 2-3. – Combustible Gas Sensor

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this manual.

System Description 2-9

E-STOPON

RESETSTBY

SYSTEM ON PURGE LAMP TEST

COMBUSTIBLE GAS

TRANSMITTERS

ELECTRICAL CONTROL CABINET

Figure 2-4. Gas Detection Transmitter

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this manual.

2-10 System Description

Structural FireTrainer® T-500

Operation and Maintenance Manual

2.2.5 TEMPERATURE MONITORING

The temperature in the fire training burn room is monitored at all time when the system is in operation. The temperature-sensing device is a thermocouple. The thermocouple is mounted approximately five feet from the floor (See Figure 2-1 & Table 2-1 for locations). This thermocouple is hard wired to two alarms in the corresponding Electrical Control Panel. There is a 500 ° Fahrenheit and 700 °Fahrenheit alarm. With the thermocouple reading of 500°, a warning condition occurs, and the ventilation/exhaust fan accelerates. With the thermocouple reading at or above 700°F an alarm condition occurs, the system will automatically fault into an emergency stop condition. There is a 500 °Fahrenheit and 700 °Fahrenheit alarm. With the thermocouple reading of 500 a warning condition occurs, and the ventilation/exhaust fan accelerates. With the thermocouple reading at or above 700°F an alarm condition occurs, and the system will automatically fault into an emergency stop condition.

The thermocouple will be used to activate two levels. They are:

Warning Level

Alarm taken to PLC and causes associated ventilation/exhaust to ramp up, which will exhaust the excess heat from the burn area. As well a 500° F amber lamp will illuminate until the system drops below 500° F.

Alarm level

Hard wired into emergency stop circuit and monitored by PLC. At PLC the alarm causes the fan to run at high speed until alarm is cleared, shuts down all fireplaces and illuminates the red 700 level alarm light until emergency stop is reset. Set at 700° F.

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this manual.

System Description 2-11

2.2.6 CONTROL PANEL

The Control Panel is located on the front of each Electrical control Cabinet. This panel is used to control and monitor all functions associated with each burn room. See Table 2-3 for Control/Indicator Descriptions and see Figure 2-5 for the Control Panel layout.

Table 2-3. Control Panel-Controls and Indicators Descriptions

No. Control Indicator Description

1 X STBY-ON-RESET – This key switch has three positions:

STBY- In this position power is applied to the combustible gas detection system.

ON- When in this position, power is supplied to all trainer hardware. This is the normal switch position for training.

RESET- This key switch must be rotated to this position and released after any type of emergency stop has occurred on the trainer. The condition that caused the emergency stop must be cleared before the reset is effective.

The possible emergency stop conditions are:

Emergency Stop Pushbutton pressed.

Fire Room temperature exceeded 700°F.

Gas detection level exceeded 25% LEL.

2 X X E-STOP - Pressing this button will immediately shutdown all fires in the trainer. Operation can only be resumed by completing the following:

Clear the condition that caused the emergency stop.

Reset the E-Stop button (Rotate and release)

Turn the STBY-ON-RESET Key switch to the RESET position and release (Item 1).

3 - X SYSTEM ON - This lamp will turn on when the STBY- ON-RESET key switch has been turned to the ON position

4 - X

PURGE - This lamp flashes during the 30 second purge cycle and will turn off when purge cycle is complete.

This lamp will light solid when the Pendant SMOKE switch is placed in the VENT position.

5 X X LAMP TEST - Pressing this button will test all lamps on the Control Panel and Pendant.

6 - X Operator Panel – Used to display messages.

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this manual.

2-12 System Description

Structural FireTrainer® T-500

Operation and Maintenance Manual

Table 2-3. Control Panel-Controls and Indicators Descriptions

No. Control Indicator Description

6A X Message Screen

6B X - Press to clear messages

6C-D X - Scroll Up & down through messages

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this manual.

System Description 2-13

E-STOPON

RESETSTBY

SYSTEM ON PURGE LAMP TEST

ITEM 6 DETAIL

1 2 3 4 5

MENU CLEAR/

ABORT ENTER

A

BC D

NOT

USED

NOT

USED

NOT USED

SEE DETAIL

Figure 2-5. Control Panel

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this manual.

2-14 System Description

Structural FireTrainer® T-500

Operation and Maintenance Manual

2.2.7 CONTROL PENDANT

The pendant is used to give the instructor full control of the training scenario. See Table 2-4 for Control/Indicator Descriptions and see Figure 2-6 for the Control Pendant layout.

Table 2-4. Control Pendant-Controls and Indicators Descriptions

No. Control Indicator Description

1 X X PILOT – Turn switch to ON position and release to initiate the pilot flame.

Flashing switch indicates pilot flame sequence is in progress. When lit bright and steady, indicates fireplace pilot flame sequence is complete and pilot flames are confirmed.

Turn switch to OFF position and release, to turn pilot flame off.

2 X X FLAME – This three-position switch is used to control the fireplace burner main flame i.e. OFF, LOW or HIGH.

The Green ON/OFF button must be held down to operate main flame.

Turn switch to OFF position to turn main flame off.

3 X X EFFECT – This two-position switch is used to control the flashover effect (FLSH) and the rollover effect (ROLL).

FLSH – When switch is held in this position, the flashover effect will be activated. The flashover effect will be active for about 5 sec. or until the switch is released.

ROLL – When switch is held in this position, the rollover effect will be active until the switch is released.

4 X X SMOKE –This two-position switch is used to control the smoke generator (SMK) and the vent/exhaust fan

(VENT).

To generate smoke the Control Panel STBY-ON-RESET key switch must be in the ON position.

SMK – Once indicator is flashing turn switch to this position to produce smoke. Switch indicator lights steady. Turn switch to center position to turn smoke off.

Switch indicator light flashes.

VENT - When the switch is turned to this position the vent/exhaust fan ramps up to high speed to clear the Burn Room. Turn switch to center position to return vent/exhaust fan to normal operation.

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this manual.

System Description 2-15

Table 2-4. Control Pendant-Controls and Indicators Descriptions

No. Control Indicator Description

5 X X ON/OFF – With pilot confirmed, Press and hold ON/OFF button to enable use of the FLAME selection switch.

When ON/OFF button pressed light comes on bright and steady.

When ON/OFF button released, the main flames extinguish and button flashes. Press and hold ON/OFF button again and main flames return to current FLAME switch setting.

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this manual.

2-16 System Description

ELECTRICAL

CONNECTOR

Figure 2-6. Control Pendant

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this manual.

System Description 2-17

2.2.8 WIRELESS CONTROL SYSTEM

The Wireless Control System assembly allows the instructor control of the burn room fireplace operation with the inherent mobility available without a cable connection. The Wireless Control System assembly consists of a hand held wireless transmitter and a wall mounted wireless receiver that connects to the connection on the Electrical Control Panel. Refer to Figure 2-7 for layout.

RECEIVER

HAND HELD

TRANSMITTER

FIBERGLASS

ENCLOSURE

W/ CLEAR FRONT

WINDOW

E-STOP JUNCTION

BOX CONNECTION

Figure 2-7. Wireless Control System

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this manual.

2-18 System Description

Structural FireTrainer® T-500

Operation and Maintenance Manual

2.2.8.1 WIRELESS TRANSMITTER

The switches on the transmitter are used for Burn Room #3 operation. A trigger switch on the handle functions as a “Deadman” switch for the main flame. The trigger switch must be pulled in and held for main flame operation. See Table 2-5 for Control/Indicator Descriptions and see Figure 2-8 for the Wireless Transmitter layout.

Table 2-5. Wireless Transmitter-Controls and Indicators Descriptions

No. Control Indicator Description

1,2 X

1 Slow Flashing Red, 2 Fast Flashing Yellow – Low Battery. Unit will run approximately 10 hours after indication.

1,2 X

1 Slow Flashing Red, 2 Slow Flashing Yellow – Stuck Transmitter Switch Detected. Ensure all switches are in .

1 X

Rapid Flashing Red for 10 Seconds - Transmitter Failure

2 X

Solid Yellow – A transmitter function is ON.

2 X

Fast Flashing Yellow – Normal Operation. This light will flash several times per second, indicating that the transmitter is sending signals to the receiver. The light will remain on momentarily whenever a function changes.

3 X ON/OFF - This two-position switch is used to enable operation of the wireless transmitter.

The transmitter yellow indicator lamp will automatically stop flashing after sixty minutes of transmitter inactivity.

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this manual.

System Description 2-19

Table 2-5. Wireless Transmitter-Controls and Indicators Descriptions

No. Control Indicator Description

4 X FLAME, PILOT/ON/OFF - This two-position switch is used to control the pilot flame. Toggle the switch to the ON position to turn on the pilot flame. Toggle the switch to the OFF position to turn off the pilot flame.

5 X FLAME, HIGH/LOW/OFF - This three-position switch is used to control the fireplace main flame i.e. LOW or HIGH. The pilot flame must be on and the Deadman Trigger (6) pulled in and held to operate the main flames. Releasing the Deadman Trigger (6) will turn the main flame off (pause). Pull the Deadman Trigger (6) in and hold again to turn main flame back on. Toggle the FLAME, HIGH/LOW/OFF switch to the OFF position to turn off main flame operation.

6 X Deadman Trigger - This trigger must be pulled in and held to enable the main, flashover and rollover flames to operate. Releasing the trigger will turn the main flame off (pause). Pull trigger in and hold again to turn main flame back on.

7 X FLAME, FLASHOVER/OFF/ROLLOVER – This three-position switch is used to control the FLASHOVER and ROLLOVER effects.

FLSHOVER – When switch is held in this position, the flashover effect will be activated. The flashover effect will be active for about 5 sec. or until the switch is released.

ROLL – When switch is held in this position, the rollover effect will be active until the switch is released. !

8 X

SMOKE/VENT, SMOKE/OFF/VENT - This three-position switch is used to control the smoke generator and vent fan in the associated burn room.

To generate smoke the Control Panel STBY-ON-RESET key switch must be in the ON position.

SMOKE – Toggle switch to this position to signal the smoke generator to emit smoke. Toggle switch to OFF position to stop emitting smoke.

VENT - Toggle switch to this position to turn on the exhaust fan. Exhaust fan will ramp up to high speed to clear the Burn Room. When switch is toggled to OFF position the exhaust fan returns to current operating mode.

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this manual.

2-20 System Description

SMOKE

OFF

VENT

FLAME SMOKE/VENT

PILOT

ON

OFF

ONOFF

HIGH

LOW

OFF

FLASHOVER

OFF

ROLLOVER

Figure 2-8. Wireless Transmitter

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this manual.

System Description 2-21

2.2.9 COMBUSTIBLE GAS SENSOR TRANSMITTER

There are two Combustible Gas Sensor Transmitters, located in each Electrical Control Cabinet, one for each Burn Room detection sensor and one in each of the Burn Room #2 & #3 equipment areas. When the STBY-ON-REST switch is in the STBY or ON position, the Transmitters continuously monitor the gas levels received from the detection sensors (See figures 2-2 & 2-3 for component locations). See Table 2-6 for Transmitter Indicators Descriptions and see Figure 2-9 for the Transmitter layout.

Table 2-6. Combustible Gas Detection Transmitter Indicators Descriptions

No. Control Indicator Description

1 - X SENSOR INPUT READING – When STBY-ON-REST switch is in the STBY or ON position, this display is on and functions as a power indicator. This display provides a continuous reading of the gas detection sensor input in both the normal and calibration modes.

2 - X ALARM HISTORY INDICATOR – Asterisk indicates an alarm has activated since last reset. Blank indicates no alarm has energized since last reset.

3 - X AUXILIARY ALARM STATUS INDICATOR – Solid black bar indicates that the 25% LEL threshold has been exceeded. Blank indicates no alarm.

4 - X LOW ALARM STATUS INDICATOR – Solid black bar indicates that the 10% LEL threshold has been exceeded. Blank indicates no alarm.

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this manual.

2-22 System Description

Figure 2-9. Combustible Gas Detection Transmitter

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this manual.

System Description 2-23

2.2.10 ELECTRICAL CONTROL CABINET ASSY. (VENT FAN)

A T-500 Class A ventilation system is installed in the second floor Class A burn room.

The system operates automatically and controls the environment to ensure student safety during live fire training drills. See Table 2-7for Control/Indicator Descriptions and see Figure 2-10 for Control Cabinet layout.

Table 2-7. Control Cabinet - Controls and Indicators Descriptions

No. Control Indicator Description

1 X HAND/OFF/AUTO - This three-position switch is used to control the exhaust fan.

HAND – This setting is the manual mode. Turning the switch to this position will run the exhaust fan at full speed.

OFF - Turning the switch to this position will do the following:

Turn the exhaust fan off if it is running.

Not allow it to automatically operate.

AUTO – When in this position the exhaust fan will operate based on the burn room temperature (+500°F & +750°F). See item numbers 2 and 3.

2 X TS1. – This temperature controller will activate the exhaust fan when the temperature in the burn room rises above 500°F. The exhaust fan will run at medium speed from a temp of +500°F to 750°F (See item 3). The Exhaust fan will stop when the temperature lowers to below 500°F.

3 X

TS2 - This temperature controller will increase the exhaust fan speed to full when the temperature in the burn room rises above 750°F. The Exhaust fan will reduce to medium speed when the temperature lowers below 750°F.

4 X ALARM - This alarm will activate when the temperature in the burn room rises above 700°F. The alarm will go off when the temperature lowers to below 700°F.

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2-24 System Description

2 3

Figure 2-10 Electrical Control Cabinet Assy. (VF2)

Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this manual.

Operation 3-1

Structural FireTrainer® T-500

Operation and Maintenance Manual

3.0 OPERATION

3.1 INTRODUCTION

This section describes the necessary procedures to operate the trainer.

3.2 PRE-OPERATIONAL CHECKOUTS

1. Do a visual inspection of burner control cabinets, electrical cabinet and exhaust fan.

2. Visually check main gas regulator.

3. Open tank valve(s) slowly.

4. Check gauge at regulator, it should read 5 psi.

5. Ensure 1/4 turn valve is open at each burner control cabinet.

6. Verify that fire…