Attachment 38 - Section J.38 MHU Fire Sprinkler System Installation Test Maintenance Repair and Deactivation Guide Rev 1.0 July 15 2017.pdf

Attachment 38 Section J.38

MHU Fire Sprinkler System Installation, Test, Maintenance, Repair, and Deactivation Guide, Rev 1.0, July 15, 2017

MHU Fire Sprinkler System Installation, Test, Maintenance, Repair, and Deactivation Guide

Revision 1.0

July 15, 2017

MHU Fire Sprinkler System Installation, Test, Maintenance, Repair, and Deactivation Guide

Rev. 1.0 July 15, 2017 ii

This Guide supplements, but does not replace, the operation and maintenance manuals

(O&M) that are packaged with each Tank Pump System (TPS). The O&M Manuals contain the manufacturer’s instructions for proper operation of the TPS, and they should be consulted for all questions.

This Guide supersedes the TPS placement instructions found in the O&M Manual shipped with the TPS.

Where a conflict exists between the manufacturers’ O&M Manual and this Guide, contact the Logistics team at FEMA Headquarters.

The team at Logistics will very much appreciate receiving your suggestions about how we can improve and simplify the installation process and this document. Please forward your comments to the Logistics team.

Rev. 1.0 July 15, 2017 iii

Contents

1. Overview

1.1. Life Safety

1.2. Fire Protection Consultant

1.3. General Requirements

2. TPS Acceptance Testing and Inspection

3. Receiving or Dispatching a TPS

4. Where to Place the TPS

5. Preparing the Base

5.1. Grass Reinforcement mesh base for the TPS:

5.2. Gravel pad base for the TPS:

5.3. ABS pads base for the TPS:

5.4. Existing hard surface base for the TPS:

6. Placing the TPS on the Prepared Base

7. Anchor the TPS

8. Pressure Test the MHU Sprinkler System

9. Connect the TPS to the MHU

9.1. Route the TPS power cable and water hose

Above‐Ground Installations:

TPS Hose Too Short:

TPS Wire Too Short:

9.2. Connect the TPS power cable and water hose

9.2.1. Power Cable Connection:

9.2.2. Water Hose Connection:

Threaded Pipe Couplings:

Cam‐Locking Couplings:

9.2.3. Heat Trace Cable Installation

10. Commission the TPS and Sprinkler System

10.1. Cold Weather Installation:

10.2. Filling the Water Tank:

10.3. Water Leaks:

10.4. MHU Sprinkler Drain Line:

10.5. MHU Floor Penetrations:

10.6. Pressure Test TPS to MHU Connection:

11. Final Steps before RFO

11.1. Insulate the Water Hose Connection

11.2. Install Sprinkler Cover Plates

11.3. Final Setup

11.4. Locks and Keys

11.5. Documentation

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12. Monthly Maintenance

13. Repairs

13.1. Definitions

13.2. Qualifications Required

13.3. Approvals

13.4. Post Repair Testing

14. Deactivation

14.1. When a MHU is to be sold in place:

14.2. Purchaser refuses to accept a TPS:

14.3. Changing the Locks:

14.4. Decommissioning the TPS:

14.5. Prepare the TPS for Shipping:

14.6. Decommissioning the MHU sprinkler system

Appendix A. Sprinkler Water Supply for Group Sites or Multiple MHUs

A‐1. Alternatives:

A‐2. TPS Supplies Multiple MHUs:

A‐3. Local Water Utility Supplies MHU Fire Sprinklers as Dual‐Use:

A‐4. Dual‐Use, Dual‐Feed Water System:

A‐5. FEMA Provided Dual‐Use Water System:

A‐6. Dual Water Systems:

A‐7. Booster Pump for Fire Sprinkler Supply:

Appendix B. Hard Pipe Connection between TPS and MHU

B‐1. Pipe:

B‐2. Electrical Work:

Appendix C. MHU Sprinkler Pressure Test

C‐1. Requirements:

C‐2. Equipment Required:

C‐3. Procedure:

C‐4. Pass/Fail Criteria:

C‐5. Troubleshooting:

Appendix D. Information to be left for the Occupant

Appendix E. Information to be given to the local Fire Department

Appendix F. Commissioning Checklist Form

Appendix G. Monthly Maintenance Checklist

Appendix H. Deactivation Checklist

Appendix I. Visual Inspection Checklist

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Photos

Photo 1. GrassGuard® grass reinforcement mesh

Photo 2. Sod staples

Photo 3. Darley Gen 1 TPS placed on properly prepared base of ¾ inch crusher run mix inside pressure‐ treated 4x4 wood frame. Gravel outside the wood frame is not required but is acceptable.

Tie‐downs remain to be installed

Photo 4. ABS pad that has drain holes in every pocket from the factory

Photo 5. Example of spreader bar made of 4x4 and 2x4 lumber. The 4x4 bar is 12 inches longer thah the width of the TPS

Photo 6. Properly installed TPS showing tie‐down straps with protective covers

Photo 7. Moisture resistant, UV resistant, closed cell foam pipe insulation

Photo 8. Properly installed TPS with piers

Photo 9. Properly installed TPS

Photo 10. Properly installed TPS. Photo shows PVC pipe shroud entering the trench, and the point of exit under the MHU. Trench and PVC pipe shroud can be run at any angle required for efficient installation based on site conditions

Photo 11. Mechanical interlock devices by Hubbell and ABB as installed on FEMA MHUs. Similar devices from other manufacturers may be present

Photo 12. Cam‐locking coupling

Photo 13. An end seal must be installed on the cut end of the heat trace cable

Photo 14. Sprinkler riser pipe as shipped from the MHU factory with protective cap and insulation in place and two nylon pull tapes

Photo 15. Pipe wrench with backup wrench

Photo 16. Typical pipe caps on sprinkler inlet and sprinkler drain

Photo 17. This floor penetration needs to have the sealant repaired

Photo 18. Water connection insulated and completed

Photo 19. Protective cap on sprinkler

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Figures

Figure 1. Acceptable locations for TPS unit

Figure 2. Pressure‐treated wood frame for gravel base under TPS, showing minimum required dimensions

Figure 3. Wood frame placed on level ground to provide a base for TPS

Figure 5. Wood frame / retaining wall on high‐slope lot to provide a level base for TPS. Excavate as needed to provide a level base for the TPS. Additional support may be required for walls greater than 12 inches in height. Rebar secures each layer, and extends not less than 2 ft. into the ground

Figure 6. TPS Installation Schematic – Type A

Figure 7. TPS Installation Schematic – Type B

Figure 8. TPS Installation Schematic – Type C

Figure 9. TPS hose and cable installation beneath MHU – Type A

Figure 10. TPS hose and cable installation beneath MHU – Type B

Figure 11. TPS hose and cable installation beneath MHU ‐ Type C

Figure 12. Schematic of heat trace cable connection beneath MHU

Figure 13. Water filter to be attached to the TPS end of the garden hose when filling the TPS tank

Tables

Table 1. Required TPS Inspections

Table 2. TPS Base Fill Estimates

Table 3. Disposition of TPS Unit and Component Parts at Decommissioning

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Document Revision History:

It is intended that this document change over time as we learn how to do this job better.

This table tracks revisions and changes made to this document since the initial issue.

Date Sections Revised Revision Explanation

07/15/2017 All Initial Issue

Rev. 1.0 July 15, 2017 1

1. Overview

1.1. Life Safety

The Fire Sprinkler System is a life safety system, and as such, careful attention must be paid to the details and procedures described in this document. As a life safety system, the sprinkler system and the

Tank and Pump System (TPS) are subjected to more oversight and scrutiny during installation and maintenance than any other portion of the MHU. This is normal practice in the construction and code enforcement communities throughout the United States.

1.2. Fire Protection Consultant

At FEMA’s sole discretion, FEMA may require that the installation, testing, and/or maintenance be overseen by an independent third‐party fire protection consultant (FPC). The FPC may be responsible for witnessing and reporting on any or all of the setup, testing, and repackaging of the TPS unit. The FPC will not conduct any tests or perform any other work, their role is limited to quality assurance inspection and reporting the results of their observations to FEMA.

1.3. General Requirements

Usually, each MHU is provided with its own TPS unit. Where multiple MHUs are to be installed on adjoining lots or for group sites, water for the sprinkler systems may be provided by an engineered system. A single TPS can supply up to four MHUs in some situations. See Appendix A for a more complete discussion of sprinkler water supply requirements and alternative approaches.

The steps to install and activate the residential sprinkler system in FEMA’s Manufactured Housing Unit

(MHU) are described in detail in this document. In general, the steps include the following:

1. Set the MHU on the selected site. Block and tie down the MHU.

2. Decide where on the site the TPS should go.

3. Prepare the base to install the TPS on.

4. Place the TPS on the prepared base.

5. Pressure test the MHU sprinkler system.

6. Connect the TPS to the MHU.

7. Commission and test the TPS unit and sprinkler system.

8. Install tie‐down straps.

9. Provide Living with Fire Sprinklers information sheet for the occupants.

10. Deliver Fire Department Information Sheet to the local fire department.

A separate Operation and Maintenance (O&M) manual is provided for each brand of TPS in inventory that covers the installation process once the TPS has been placed on the prepared base. That manual is a mandatory part of this Guide.

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Detailed descriptions of each of the steps are given below or in the installation document for each TPS.

Unless specifically stated, the instructions below are requirements for the proper installation of the TPS and the MHU sprinkler systems. Where more than one installation or operation practice is acceptable, this is clearly noted in the instructions below.

In every instance, deviations from this document require advance approval from FEMA’s Contracting

Officer’s Representative (COR).

2. TPS Acceptance Testing and Inspection

Experience has shown that TPS units can be damaged during shipping. When a TPS is delivered to

Cumberland, Selma, or any FEMA staging yard, the TPS must be tested and inspected. This testing is required to ensure that the TPS delivered is functional, to identify any damage that may have occurred during transport, and to fairly document the chain of custody of the unit. All TPS units must be tested before being dispatched to an installation site. Acceptance testing must be performed when:

A TPS is delivered from the factory to FEMA Manufactured Housing Storage Site (MHSS) Cumberland or Selma.

A TPS is delivered from the factory to a staging yard near a disaster area.

A TPS is delivered from FEMA MHSS to a staging yard near a disaster area.

A TPS is delivered from one staging yard or disaster to another.

A TPS unit is refurbished.

A TPS unit is repaired.

This testing may be performed at Cumberland, Selma, any staging yard, or any other location as directed by FEMA.

Every TPS is to be installed on a properly prepared base.

Every TPS must have the heat trace protection for the hose and sprinkler riser installed and activated.

Every TPS must have the connection between the MHU sprinkler riser and the insulated hose assembly wrapped in insulation.

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Detailed instructions for performing this acceptance test are contained in a separate document: “Tank and Pump System (TPS) Acceptance Test Procedure”. The most recent edition of this procedure should be used in every instance.

Every acceptance test must be documented and reported as described in the procedure.

3. Receiving or Dispatching a TPS

The TPS is government property. Custody and condition of the TPS must be properly documented at every step of its life. On initial receipt of a TPS unit from the factory, it should be barcoded and entered into the property tracking system.

The TPS unit must be visually inspected, and the inspection must be documented on the form provided in Appendix I. Table 1 shows when a visual inspection and transfer of custody using the TPS Inspection

Form is required. The TPS Inspection form is available as a separate PDF file on request.

Contractors are required to sign the form to acknowledge receipt of the TPS unit and to verify the condition of the unit before a TPS will be released. Failure to sign the form will result in a contractor being escorted off the property and may result in other consequences under the contract. If there is disagreement over the condition of the TPS as described on the form, contact FEMA’s Contracting

Officer’s Representative (COR).

No TPS unit will be released to a contractor until the contractor has completed training on the TPS system and the installation protocols.

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Table 1. Required TPS Inspections

EVENT REQUIRING TPS INSPECTION

INSPECT TO IDENTIFY

CHECK FOR

CONTRACT

COMPLIANCE

DAMAGE

DURING

SHIPPING

DAMAGE

DURING

STORAGE

DAMAGE

DURING

USE

Receipt of a new TPS (received from factory or Selma/Cumberland)

Dispatch of TPS unit from Selma or Cumberland to a staging yard (dispatch to staging yard)

Dispatch of TPS unit from the staging yard to the final installation site (dispatch to staging yard)

At start of TPS unit commissioning (received from staging yard)

Prior to handoff of TPS unit to contractor for return the staging yard from final installation site (dispatch to staging yard)

Receipt of the TPS at the staging yard from installation site (received from installation site)

Dispatch of TPS unit from staging yard to:

Selma, Cumberland, TPS factory, or other destination (dispatch to other than installation site)

Receipt of TPS at Selma or Cumberland from staging yard. (received from staging yard)

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4. Where to Place the TPS

TPS position is to be determined by the specific conditions at each site. The TPS hose is 30 ft. long; and the wire is 45 ft. long. Be sure that both the TPS hose and wire can reach the connection points on the

MHU. Preferred locations of the TPS relative to the MHU are illustrated in Figure 1.

No guide or instruction can provide absolute clarity for every possible situation. On a perfect site, all of the requirements and dimensions in this Guide could be accomplished. In practice, there are many sites where perfection cannot be achieved, and some latitude in interpreting the placement instructions in this Guide is in order.

It is permissible to deviate from the requirements and dimensions shown in Figure 1. It is important to understand that the required dimensions shown are not equally important. Potential deviations from the dimensions should consider the following 6 factors, which are listed in order of priority. Factors listed earlier in the list are more important than factors listed later.

1. The TPS must be fully functional.

2. The TPS and the tie‐down straps must not present a hazard to the MHU occupants, to persons walking or running around the yard, or to neighbors.

3. Position the TPS to discourage climbing onto the TPS from the porch, deck, or ramp structure.

4 ft. or more separation between the TPS wall and a porch, deck, or ramp is the standard requirement.

4. Position the TPS to permit maintenance access to the air handling equipment. 4 ft. clearance from the TPS wall to exterior HVAC units or Bard units is the standard requirement.

5. Position the TPS to allow access to beneath the MHU for maintenance. 2 ft. space between the

TPS wall and the MHU skirting is the standard requirement. When access to utility connections beneath the MHU will not be obstructed, the TPS may be placed closer to, but never in contact with, the home.

6. The TPS unit should be positioned so that the alarms on the outside of the TPS are visible from the street. Alarms are not required in most jurisdictions, and are loud and bright enough to attract attention even when there is not a direct line of sight between the alarm and the street.

A direct line of sight is the standard requirement, but it is not mandatory.

The TPS units may be installed farther away from the MHU than the minimum values shown in Figure 1 without the need for approval from FEMA, as long as the TPS is placed within the boundaries of the lot.

If the distance between the TPS and the MHU is greater than the values shown in Figure 1, the TPS hose and wire must be installed below grade.

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Figure 1. Acceptable locations for TPS unit.

5. Preparing the Base

The TPS must be installed on a prepared level base. The base must be level within one inch (1”) across both length and width dimensions. A prepared base is required to facilitate installation, decommissioning, and removal of the TPS, by ensuring adequate space is present for the forks of a fork lift.

Four acceptable options for the TPS base include:

A grass reinforcement mesh, A prepared gravel pad, ABS pads, or

A pre‐existing concrete or asphalt surface.

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Requirements applicable to each of these options are presented below. Where the installation site is very nearly level, grass reinforcement mesh is the preferred installation method since it is fastest and least expensive.

Unless required by local code, do not install a new concrete, asphalt or other hard surface pad for the

TPS. Installation of a new hard surface to be used as a base for the TPS must be pre‐approved by

FEMA’s COR.

5.1. Grass Reinforcement mesh base for the TPS:

In those instances where the TPS site is very nearly level, grass reinforcement mesh such as GrassGuard®

(www.grassguard.biz) may be used as a TPS base. If grass reinforcement mesh is used, no other base preparation is required (i.e., gravel base, ABS pads, or pavement are not to be used); the mesh is to be used alone.

Use the Heavy Duty (HD) or Heavy Duty Xtra (HDX) grade of reinforcement mesh. When used, the grass reinforcement mesh should be installed directly on the lawn surface.

Landscape fabric is not needed underneath the mesh and should not be used.

Since no natural surface is completely level, the area beneath the mesh should be levelled by adding sand to fill low spots to level the pad to within one inch (1”) across both length and width dimensions.

The mesh must cover the entire surface of the lawn or ground beneath the TPS unit, and must protrude beyond the edges of the

TPS pallet/base at least two inches (2”) on each of the four sides.

The exposed portions of the mesh must be secured to the ground using sod staples so that the mesh does not curl up and cause a tripping hazard or get caught in lawn maintenance equipment.

Photo 1. GrassGuard® grass reinforcement mesh

Photo 2. Sod staples.

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5.2. Gravel pad base for the TPS:

Where the site is not level, or when directed by FEMA’s COR, a prepared gravel base is an acceptable method for installation of the TPS. Gravel must be retained inside a wood frame, fabricated on site to provide a level base for the TPS. Three‐quarter inch (¾”) crusher run mix is the preferred gravel product.

Geotextile fabric is required. Place the fabric over the ground before installation of the gravel pad base and frame. This will help make deactivation and restoration of the site easier.

Fabricate the wood frame from pressure‐treated 4”x__ or 6”x__ lumber (see Figure 2). Landscape timbers are also acceptable. Pressure treated lumber shall be rated for exterior use, in contact with ground. Use American Wood Preservers’ Association (AWPA) Use Category (UC) UC4A or better.

The dimensions of the wood frame shall be not less than 3½ inches high (nominal 4” lumber or timber), 10 ft. long and 8 ft. wide (to leave room for the tie‐down anchors to be installed inside the frame).

Install blocking in each corner to reinforce the corner connections; minimum size of blocking is 4”x4”.

Pin all layers of timber used to fabricate the frame to the ground using rebar. Rebar pins shall be driven at least 24 inches into the ground. Pin locations shown in Figure 2 are the minimum number of pins that are required.

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Rebar pin through each layer of wood extends not less than 2 ft. into soil.

Stagger joints in wood frame to improve stability.

10'‐0"

Figure 2. Pressure‐treated wood frame for gravel base under TPS, showing minimum required dimensions.

Where the slope of the site exceeds the thickness of the bottom timber or lumber used to fabricate the wood frame, build up a retaining wall on the high areas as needed to keep the soil out of the TPS base.

Where a retaining wall is built, only the lowest layer of wood framing is to be filled with gravel. Figures

3, 4, and 5 show the desired installation on site elevations that may be encountered. Photo 3 shows a properly prepared gravel base with a Darley TPS placed correctly.

Be careful to layout the frame and retaining wall so that the fork lift truck can place the TPS on the prepared base safely and without damage to the TPS or base.

Table 2. TPS Base Fill Estimates

Minimum dimensions of wood frame 10 ft. long x 8 ft. wide

Volume of 4” (nominal) high frame 0.9 cubic yards

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Figure 3. Wood frame placed on level ground to provide a base for TPS.

Figure 4. Wood frame placed on sloped ground to provide a level base for TPS. Ground is partially excavated at high end so that the frame can be placed level.

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TPS

Geotextile fabric

Vegetation removed under frame

Rebar extends at least 2 ft.

into ground (typical)

Pressure Treated Wood

Frame w/Gravel to top

Layers of wood timber to hold soils out of pad as required by site conditions.

Figure 5. Wood frame / retaining wall on high‐slope lot to provide a level base for TPS.

Excavate as needed to provide a level base for the TPS. Additional support may be required for walls greater than 12 inches in height. Rebar secures each layer, and extends not less than 2 ft. into the ground.

Photo 3. Darley Gen 1 TPS placed on properly prepared base of ¾ inch crusher run mix inside pressure‐treated 4x4 wood frame. Gravel outside the wood frame is not required but is acceptable. Tie‐downs remain to be installed.

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5.3. ABS pads base for the TPS:

ABS pads may be used only where the slope of the ground across the length of the installation site is equal to or less than two inches. Where site slope exceeds 2 inches across both length and width dimensions of the TPS base, a gravel pad/base is required. ABS pads should not be used where leveling of the site results in removal of more than 2 inches of soil from one end of the site. (i.e., the soil surface should not extend above the top of the ABS pad anywhere.) ABS pads shall never be leveled by placing shims under one side; excavate the high areas to create a level base for the pads.

1. Level the pad site. Slope of the soil shall not exceed 1 inch across both length and width dimensions of the TPS base.

2. Place one layer of geo‐textile fabric on the prepared soil so that the fabric extends beyond the outer edges of the pads to be placed.

3. If the ABS pads do not have a drain hole in every pocket (see Photo 4), drain holes must be drilled. Drill a ¼ inch drain hole in every pocket in the ABS pads before placing the pads on the base. The pockets in the ABS pads can hold rain water that will form a pool where mosquitos can breed, so it is necessary to ensure that water can drain out of the pad. One manufacturer of

ABS pads with pre‐drilled drain holes is Sedco Pier, Inc.

4. Place the ABS pads to cover an area not less than 7.5 ft. long x 6 ft. wide. It is intended that the ABS pads extend beyond the edges of the TPS to create an area without vegetation, protecting the TPS from lawnmower and/or weed‐eater damage.

ABS pads should be placed directly on the geo‐textile fabric on level soil to keep soil from infiltrating into the pads and to make for easier decommissioning.

ABS pads must be installed with the correct side facing up (normally the flat side is to face down). Do not put gravel under the ABS pads.

Photo 4. ABS pad that has drain holes in every pocket from the factory

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5.4. Existing hard surface base for the TPS:

Where a hard surface is already available to use as a base for the TPS, check to ensure that the water hose and electrical cord can reach the connections points on the MHU. Clear away any debris from the hard surface, and place the TPS on the hard surface. The hard surface should be level; slope shall not exceed 1 inch across both length and width dimensions.

6. Placing the TPS on the Prepared Base

TPS units are designed to be moved using a fork lift or a hoisting device. If the unit is to be hoisted, safe lifting procedures must be observed. Safe lifting procedures include, but are not limited to, using proper equipment, attaching the lifting slings to the lift points on the TPS, using spreader bars at the top of the

TPS to prevent the slings from damaging the TPS, avoiding overhead wires and obstructions, and ensuring slings are strong enough to safely lift the TPS without a danger of breaking. Since the hoisting requirements for each brand of TPS are different, detailed instructions about hoisting the TPS are in the

Operation and Maintenance manual inside the TPS door.

Ensure that the device used to move the TPS can safely lift and move the unit. The heaviest TPS in

FEMA’s inventory weighs 2,100 pounds empty.

Photo 5. Example of spreader bar made of 4x4 and 2x4 lumber. The 4x4 bar is 12 inches longer thah the width of the TPS.

Carefully place the TPS on the prepared base using a proper lifting device. See Figures 6, 7, and 8 for clarification of the installation requirements.

Check that the TPS is level in both directions. If the TPS is not level, remove it from the prepared base, adjust the base to ensure that the base is level, and place the TPS back onto the level base. Never shim the TPS to bring it into level.

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7. Anchor the TPS

TPS units must be anchored to the ground using manufactured home anchors and anchor straps. Two straps (and 4 anchors) are required over each TPS unit. Install the ground anchors within 4 inches of the outside wall of the TPS. Where a gravel pad is used, install the ground anchors inside the wood frame whenever possible.

Anchor strap roof brackets are shipped in the parts kit in the Darley and General Air TPS units; the Talco TPS unit has points for the anchor straps molded into the top edge of the enclosure. Anchors and straps must be provided by the installation contractor.

Anchor straps must be wrapped to protect persons from injury if they trip into the straps. Pre‐formed pipe insulation is shipped with the newer TPS units as part of the parts kit. Where this is not provided, locally purchase pipe insulation that meets the following technical requirements:

UV resistant for full‐sun exposure for several years outdoors.

Moisture resistant, closed cell foam to resist mold growth.

Pre‐slit insulation for easy installation, with factory‐ installed tape to seal the insulation over the strap.

There are a number of products on the market that meet these requirements.

8. Pressure Test the MHU Sprinkler System

The sprinkler systems are pressure tested when the systems are installed in the home at the MHU factory. Experience has shown that some systems are inadequately tested at the factory, and that other systems are damaged during transportation or storage. In order to prevent system failure and water damage, it is imperative that the sprinkler system in the MHU be pressure tested to not less than 200 psi before the TPS is connected to the MHU.

Photo 6. Properly installed TPS showing tie‐down straps with protective covers.

Photo 7. Moisture resistant, UV resistant, closed cell foam pipe insulation

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This 200 psi pressure test is required for every MHU installation. The pressure test shall be performed as described in Appendix C, MHU Sprinkler Pressure Test. All safety procedures described in Appendix C must be complied with.

The proper procedure for performing the pressure test is provided in Appendix C, MHU Sprinkler

Pressure Test. The Appendix includes the complete procedure, specifies the required tools and equipment to conduct the testing, and includes a flow chart.

9. Connect the TPS to the MHU

Only after the MHU sprinkler system has passed the pressure test should the TPS be connected to the

MHU. Two connections are required: the power cable and the water hose. The water hose connection must be pressure tested after the TPS is connected. In addition to the connections, the heat trace cable must be routed into the MHU, and the water hose connection must be insulated.

9.1. Route the TPS power cable and water hose.

Figures 6, 7, and 8 show the three acceptable installations of the hose and cable between the TPS and the MHU. Key requirements are described below.

All portions of the hose assembly and electric cable between the TPS and the underside of the MHU must be fully encased in 6” schedule 40 PVC pipe. No part of the TPS hose and wire may be exposed to view or tampering. PVC pipe and fittings are shipped with the TPS to be used for this purpose.

Those portions of the hose assembly and electric cable that are beneath the home and concealed within the skirting of the home do not need to be installed in PVC pipe; the hose assembly may be laid directly on the ground; the electric cable should be secured to the underside of the MHU as high as possible to discourage rodent damage.

Where foot traffic can be reasonably anticipated across/over the TPS connections, the hose/cord should be buried beneath the surface of the soil. Where a trench is not possible, the pipe should be laid on the ground (i.e., Figure 7) and a crossover ramp or steps must be constructed over the pipe to facilitate safe

NOTE: The fire sprinkler system is a life‐safety system. FEMA may decide to employ an independent, third‐party fire protection consultant to oversee sprinkler system work. This fire protection consultant will oversee and provide technical advice and guidance to the individuals conducting the test. The fire protection consultant will not perform the test, nor will they train persons how to perform the work; their role is limited to oversight, reporting, and guidance.

Rev. 1.0 July 15, 2017 16 traffic flow across the pipe. If the ramp or steps is part of a normal accessible compliant means of access to the home, it must be constructed to comply with the UFAS requirements.

Above‐Ground Installations:

The following safety requirements must be provided for all above‐ground installations:

All exposed portions of the hose/wire assemblies between the TPS and the MHU must be fully encased in 6 inch diameter schedule 40 PVC pipe and fittings. A supply of pipe and fittings is supplied with the TPS that should be sufficient for the majority of installations. If necessary, additional pipe and/or fittings must be procured locally. Only the portion of the hose/wire assemblies that are visible to the public need to be enclosed in PVC pipe; inside the skirting, beneath the MHU, the hose and wire do not need to be enclosed in PVC pipe. The short length of cable that is exposed between the top of the skirt and the electrical connection on the rear of the MHU shall not be encased in pipe or conduit.

When the pipe is installed above grade, the PVC pipe must be supported with piers or stands that will support a 200 lb. load imposed at the top of the pier or stand. Refer to Figure 6 and Photo 8.

o Vertical supports or piers must be provided so that there is not more than 36 inches between the supports.

o The pipe must be secured so that it cannot move vertically or horizontally if lawn maintenance equipment or an individual runs into it or climbs on it.

o Photo 8 shows an above ground installation that is acceptable. As shown in the photo, dry‐ stacked concrete block (on ABS pad) with wood shims and band clamps that secure the PVC pipe are acceptable as piers.

The pipe may be installed directly on the ground as shown in Figure 7 and Photo 9.

o When laid on the ground, the pipe must be securely staked down at 36 inch intervals to prevent lateral movement or lifting if lawn maintenance equipment or an individual runs into it or attempts to lift it.

The opening in the skirting must be made in a good and workmanlike manner. There shall not be more than ¼ inch gap between the outside wall of the pipe and the skirt, all the way around the pipe.

The PVC pipe does not need to be plumb or level for the TPS to function properly. It is, however, desirable that the pipe be level for aesthetic reasons.

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Below Ground Installation:

When the electric cable and hose assembly is to be buried (i.e., Figure 8, Photo 10), the cable must be buried not less than 24 inches below grade to comply with the National Electric Code. The TPS power cable is rated for direct burial, and does not need to be encased in conduit. It must, however, be routed on the inside of the provided 6” PVC pipe where it enters or exits from the ground for protection from rodent damage.

TPS Hose Too Short:

The TPS unit comes equipped with a 30 ft. long hose assembly to provide for a great deal of flexibility in

TPS location on the installation site. In rare instances, the water hose may not be long enough to reach the MHU connections due to site conditions.

Under no circumstances is the TPS hose assembly to be altered in the field. This hose assembly is assembled and tested in the factory, using materials and techniques that require special training and experience. The length of the hose impacts the performance of the sprinkler system and simply adding more hose at the end of the factory‐provided 30 ft. is not acceptable. Furthermore, the heat trace cable and the hose temperature sensor that are part of the hose assembly require special installation techniques that are difficult to perform properly in the field.

If a longer hose is necessary, order one directly from the manufacturer of the TPS. The replacement hose assembly must include factory installed heat trace and a hose temperature sensor. Specify the required length of the replacement hose. The manufacturer will provide installation instructions with the replacement hose assembly.

Instead of procuring a special‐order hose assembly, the water supply may be hard‐piped between the

TPS and the MHU water connection. Appendix B. outlines the required materials and procedures to hard‐pipe a TPS to the MHU. Deviations from the requirements listed in Appendix B. must be approved in advance by FEMA’s COR or the work will be rejected.

TPS Wire Too Short:

The TPS unit comes equipped with a 45 ft. long electric cord assembly. (The first generation TPS had 30

ft. long electric cords, which have been upgraded to 45 ft. in the Gen 2 TPS units.) If the TPS wire is too short, it is acceptable to have a licensed electrician replace the provided electric wire connecting the TPS to the MHU with a longer cable. The replacement cable must be minimum 10 AWG Type VNTC cable suitable for direct bury. Electrical Wiring Assembly shall be suitable for 240 volts, 30 amps. The length of the new cable shall not exceed 100 ft.

Rev. 1.0 July 15, 2017 18

During the replacement, the existing IEC 60‐309‐2 International Pin and Sleeve connector should be removed from the provided cable and re‐installed on the new cable in accordance with factory instructions for the connector and the National Electrical Code. It is not necessary to install a new IEC

60‐309‐2 International Pin and Sleeve connector, the existing connector can be re‐used since it has never been used.

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Tank and Pump System

(TPS)

Grass Reinforcement Mesh, Wood Frame w/Gravel, ABS Pads or Hard Surface Base

Grade

Pier 1

AC Power (red line)

TPS Skid / Base

Heat Trace Cable (black line)

MHU

Pier 2

Pier 1 not more than 7 inches from outside surface of TPS enclosure.

Pier 2 not more than 3 inches from skirting. Pier 2 may be located inside the skirting if it is visible for inspection.

Install additional piers as needed to provide supporting piers 36 inches on center or less.

Piers must be able to support 200 lbs.

Gap between pipe and skirt shall be neatly made and shall not exceed 1/4 inch.

Securely attach pipe to piers with UV and weather resistant material.

Skirt

Figure 6. TPS Installation Schematic – Type A

Photo 8. Properly installed TPS with piers.

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Tank and Pump System

(TPS)

Grass Reinforcement Mesh, Wood Frame w/Gravel, ABS Pads, or Hard Surface Base

Grade

AC Power (red line)

TPS Skid / Base

Heat Trace Cable (black line)

MHU

Secure pipe to ground at 36 inches on center. Secure at the skirt, at TPS end, and every 36 inches between. Attachment must prevent lateral movement if pipe is kicked hard, as well as prevent lifting. Stake may be located inside the skirt if visible for inspection.

Gap between pipe and skirt shall be neatly made and shall not exceed 1/4 inch.

Skirt

Figure 7. TPS Installation Schematic – Type B

Photo 9. Properly installed TPS.

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Grade

MHU

NOT TO SCALE

Tank and Pump System

(TPS)

Skirting

Belly Board

Pipe union

Close Nipple

Floor Pipe insulation installed at factory

Pipe insulation field installed after heat trace cable is installed.

TPS Installation Schematic

PVC Pipe extends to bottom of trench

Coil excess cable and tie it to the underside of the MHU, out of reach of rodents.

Run heat trace cable into MHU and install end seal kit from TPS, firmly mounting heat trace to pipe.

Trench not less than 24 inches deep.

Cable exits at top of skirt, directly below electrical connection.

Straight drop, 45º, or 90º pipe elbow as required by site conditions

ABS Pads, Wood Frame w/Gravel, or Hard Surface Base

Position TPS on base so that PVC pipe runs as close to prepared base as possible

Straight PVC pipe to protect cable from rodents where it exits trench. Pipe to extend at least 8" above grade.

Bury electric wire minimum 24" below grade for NEC compliance.

Inside the skirting, burial is not required, but is acceptable.

Bury hose assembly at bottom of trench wherever it would otherwise be exposed to view. Inside the skirting, burial is not required, but is acceptable.

Heat trace cable (black line)

IEC 60-309-2 Mechanical Interlock on home

IEC 60-309-2 connector on cord

Electric power cord (red line)

Figure 8. TPS Installation Schematic – Type C

Photo 10. Properly installed TPS. Photo shows PVC pipe shroud entering the trench, and the point of exit under the MHU. Trench and PVC pipe shroud can be run at any angle required for efficient installation based on site conditions.

Rev. 1.0 July 15, 2017 22

9.2. Connect the TPS power cable and water hose.

Once the power cable and water hose assembly have been properly installed between the TPS and

MHU, the next step is to connect the power, water, and heat trace to the MHU.

9.2.1. Power Cable Connection:

The power cable is connected to the MHU by a mechanical interlock. The mechanical interlock is installed on the rear of the MHU, and is shipped from the factory set up to be locked in the OFF position.

We need the interlock to be locked in the ON position to prevent tampering with the TPS power supply, so there is a minor modification that must be made to the switch handle on some brands of mechanical interlock. The handle is designed so that this modification can be easily done. See Photo 11.

1. Ensure that the main power switch inside the TPS is turned OFF. Ensure that the 30A 240V circuit breaker that powers the sprinkler system TPS inside the MHU is turned OFF.

2. Route the cable assembly to the mechanical interlock as described earlier in this Guide.

3. Cut a small hole in the top of the MHU skirt directly beneath the mechanical interlock for the electric cable. Work the connector and cable over and through the skirt. Extend the electric cable to the point of connection.

4. Loosen and remove the protective cover on the bottom of the mechanical interlock assembly. The cover is attached to the interlock, and simply swings back and away once it has been unscrewed.

CAUTION!

THE MECHANICAL INTERLOCK IS DESIGNED SO THAT IT CANNOT BE SWITCHED TO THE ON POSITION UNLESS THERE IS A

CABLE PLUGGED INTO THE INTERLOCK. DO NOT ATTEMPT TO ROTATE THE SWITCH HANDLE UNTIL THE CABLE IS

PLUGGED IN AND THE LOCKING RING ATTACHED TO THE PLUG IS SECURELY ATTACHED (HAND TIGHT) TO THE

MECHANICAL INTERLOCK RECEPTACLE.

CAUTION

DO NOT PROCEED UNLESS YOU ARE SURE THAT THE SWITCH INSIDE THE TPS

AND THE BREAKER IN THE MHU ARE TURNED OFF.

Rev. 1.0 July 15, 2017 23

5. Insert the plug from the TPS cable into the receptacle on the bottom of the mechanical interlock.

The plug can only be inserted one way; look at the tabs on the plug and the receptacle and align them. Once properly aligned, the plug can be easily inserted.

Note: The mechanical interlock is designed so that the connection can only be put together when the switch is in the OFF position. This is an important safety feature.

6. Tighten the locking ring on the plug assembly, securing the plug and cord to the interlock.

7. Leave the switch on the mechanical interlock in the OFF position for now.

8. Switch the 240V / 30A circuit breaker inside the MHU main electric panel that supplies power to the mechanical interlock / TPS to the ON position.

Rev. 1.0 July 15, 2017 24

Photo 11. Mechanical interlock devices by Hubbell and ABB as installed on FEMA MHUs. Similar devices from other manufacturers may be present.

Tabs inside the handle that must be punched out to insert the lock.

Tabs removed, locking handle ready to receive the lock.

Interlock with cable connected, and switch in the ON position.

Cable connected, switch in OFF position.

Mechanical interlock on

MHU as delivered.

Switch in OFF position, no cable connected.

Interlock with cable connected, and switch in the ON position.

Tab removed, and lock being installed to lock the handle in the ON position.

Proper final installation, with switch locked in the

ON position.

Rev. 1.0 July 15, 2017 25

9.2.2. Water Hose Connection:

Figures 9, 10, and 11 illustrate the details of the water hose and power connection cable beneath the

MHU. These sketches correspond to the hose installation methods shown in Figures 6, 7, and 8, respectively.

Extend the hose assembly to the point of connection under the MHU. Lay the excess hose neatly on ground inside the skirting underneath the MHU.

When ready to make the connection, remove the protective pipe caps from both the sprinkler drain pipe and from the sprinkler riser pipe on the underside of the MHU. Remove the protective cap from the end of the TPS hose. Place the caps into the TPS enclosure for safe keeping so that they can be re‐ used during deactivation.

Threaded Pipe Couplings:

Connect the water hose assembly to the sprinkler riser using the fittings and pipe thread tape provided in the TPS parts box. The parts box includes a pipe union, close nipples, a 45° elbow, a 90° elbow, and pipe thread tape. The hose may be connected to the riser in any of the arrangements shown in Figures

9, 10, and 11, depending on site conditions. You will not need to use all of the pipe fittings provided in the parts box.

Cam‐Locking Couplings:

FEMA will be converting to the use of Cam‐Locking devices to connect the TPS hose to the sprinkler riser. Once conversion is complete, the sprinkler riser will be equipped with the male cam‐ lock fitting, and the TPS hose will have the female cam‐lock fitting.

A positive seal requires that the surfaces on the gasket seat, the adapter face, and the gasket are smooth and uncontaminated.

Be sure that the couplings and gasket are clean and free of debris before attempting to make the connection.

NOTE!

DO NOT REMOVE THE PROTECTIVE CAPS ON THE END OF THE HOSE AND SPRINKLER

PIPE UNTIL YOU ARE READY TO MAKE THE CONNECTIONS. THE CAPS PREVENT DEBRIS

THAT MIGHT PLUG UP THE SPRINKLERS FROM GETTING INTO THE HOSE.

Photo 12. Cam‐locking coupling.

Rev. 1.0 July 15, 2017 26

To connect the cam‐locking couplings, remove the protective covers, store the covers in the TPS enclosure for safe keeping. Carefully slip the female coupler on the hose over the male coupler on the sprinkler riser until contact is made with the gasket. Both cam arms on the coupler are then closed simultaneously to produce a uniform gasket compression between the seal surfaces.

Cam arms must be in the full closed position for proper locking of coupling. Gasket deterioration and excessive wear on cam, groove, and seal surfaces can reduce the performance of the coupler. Spare gaskets for the cam‐lock coupling are shipped with the TPS parts kit.

Secure the cam arms in the open position using a cable tie to prevent accidental release.

Rev. 1.0 July 15, 2017 27

MHU

Skirting

Belly Board

Pipe union

Close Nipple

FloorPipe insulation installed at factory

Pipe insulation field installed after heat trace cable is installed and pressure test is passed.

Coil excess cable and tie it to the underside of the MHU, out of reach of rodents.

Cable exits at top of skirt, directly below electrical connection.

Straight drop, 45º, or 90º pipe elbow as required by site conditions

Run heat trace cable into MHU and install end seal kit from TPS, firmly securing heat trace to pipe.

NOT TO SCALE

TPS Installation Schematic

Heat trace cable (black line) under insulation

Pier 2

Figure 9. TPS hose and cable installation beneath MHU – Type A.

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MHU

Skirting

Belly Board

Pipe union

Close Nipple

FloorPipe insulation installed at factory

Pipe insulation field installed after heat trace cable is installed and pressure test is passed.

Coil excess cable and tie it to the underside of the MHU, out of reach of rodents.

Cable exits at top of skirt, directly below electrical connection.

Straight drop, 45º, or 90º pipe elbow as required by site conditions

Run heat trace cable into MHU and install end seal kit from TPS, firmly securing heat trace to pipe.

NOT TO SCALE

TPS Installation Schematic

Heat trace cable (black line) under insulation

Figure 10. TPS hose and cable installation beneath MHU – Type B.

Rev. 1.0 July 15, 2017 29

MHU

Skirting

Belly Board

Pipe union

Close Nipple

Floor

Pipe insulation installed at factory

Pipe insulation field installed after heat trace cable is installed and pressure test.

Coil excess cable and tie it to the underside of the MHU, out of reach of rodents.

Trench not less than 24 inches deep.

Cable exits at top of skirt, directly below electrical connection.

Straight drop, 45º, or 90º pipe elbow as required by site conditions

Run heat trace cable into MHU and install end seal kit from TPS, firmly mounting heat trace to pipe.

NOT TO SCALE

TPS Installation Schematic

PVC pipe to protect cable from rodents where it exits trench. Pipe to extend at least 8" above grade.

Electric Cable (red line) runs inside PVC pipe.

Heat trace cable (Black line) under insulation

Figure 11. TPS hose and cable installation beneath MHU ‐ Type C.

Rev. 1.0 July 15, 2017 30

9.2.3. Heat Trace Cable Installation

Heat trace cable is provided in the TPS hose assembly, between the hose and the insulation to protect the hose from freezing. The assembly has been tested and shown to prevent freezing in the hose and pipe to ̶ 50°F when installed correctly.

The excess heat trace cable at the MHU end of the TPS hose assembly is to be used to protect the connection and the MHU sprinkler riser. Run the end of the heat trace cable into the MHU.

Fish the heat trace cable from the end of the insulated hose assembly into the MHU. Use the pull tapes provided or an electrician’s fish tape to fish the new heat trace cable into position. The heat trace cable must be located directly against the pipe under the pipe insulation. See Photo 14 and Figure 12.

Cleanly cut the end of the heat trace cable 12 – 16 inches above the floor of the water heater closet. Install a new

End Seal from the TPS parts kit onto the cut end of the heat trace cable. See Photo 13. Secure the heat trace cable to the sprinkler pipe using duct tape or wire ties.

Do not insulate the connection at this time. The pipe couplings must be covered with insulation after the pressure test has been passed.

NOTE:

EVERY END OF THE HEAT TRACE CABLE MUST BE COVERED BY AN END SEAL PROVIDED IN THE TPS PARTS KIT. THE CABLE IS VERY SENSITIVE TO MOISTURE IN THE AIR; FAILURE TO INSTALL THE END SEAL ON THE END OF THE CABLE

WILL RESULT IN SHORT CIRCUIT OF THE HEAT TRACE CABLE.

Photo 14. Sprinkler riser pipe as shipped from the MHU factory with protective cap and insulation in place and two nylon pull tapes.

Photo 13. An end seal must be installed on the cut end of the heat trace cable.

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Insulation on riser pipe

Insulation on hose

Insulation over coupling and joint is applied after heat trace and pressure tests are complete.

Tape all joints.

Heat trace cable as shipped from factory (dashed line).

Use pull tape to pull heat trace cable from end of hose assembly into the MHU to be 6" above floor.

Tie to sprinkler riser pipe with plastic cable tie.

Position of heat trace cable under insulation after being pulled into home (red line).

End seal required on end of heat tape cable.

Figure 12. Schematic of heat trace cable connection beneath MHU.

Rev. 1.0 July 15, 2017 32

10. Commission the TPS and Sprinkler System

Commissioning is the process of ensuring that all parts of the sprinkler system will properly perform their job in the event of a fire. It is vitally important that the commissioning process described below be followed. Any and all deficiencies should be reported to FEMA’s COR for prompt correction.

A MHU shall not be considered Ready for Occupancy (RFO) until the sprinkler system has been fully commissioned and the commissioning forms have been signed, certifying that the system has passed the commissioning tests.

The commissioning process is described in a flow chart shown in Error! Reference source not found..

The sprinkler system pressure test can be started any time after the MHU has been set. In no case is the

TPS to be connected to the MHU until the sprinkler system pressure test has been passed.

FEMA presently has three manufacturers that supply TPS units. Each of the three TPS models is different; each model requires different (yet similar) startup and commissioning procedures. Each TPS ships with an Operation and Maintenance (O&M) manual that is stored on the inside of the TPS door.

The instructions in the TPS O&M manuals are not repeated here; the manuals are incorporated into the contract by reference, and are mandatory parts of this Guide. The manufacturer’s manuals must be followed for successful completion of the work described in this Guide.

The paragraphs below provide additional information and directions that supplement the instructions provided in the manufacturer’s manuals.

NOTE: The fire sprinkler system is a life‐safety system.