FoamLogix tm Models 3.3 / 5.0 / 6.5 Electronic Foam Proportioning System Installation and Operations Manual Hale Products Inc. ◆ A Unit of IDEX Corporation 700 Spring Mill Avenue ◆ Conshohocken, PA 19428 U.S.A. Telephone: 610-825-6300 ◆ FAX: 610-825-6440 Web: www.haleproducts.
APPARATUS INFORMATION ENGINE ______________________________________________ TRANSMISSION _______________________________________ MAXIMUM CAFS ENGINE RPM ___________________________ CAFS ENGINE SPEED RANGE ___________________________ NOTICE ! Class1 cannot assume responsibility for product failure resulting from improper maintenance or operation. Class1 is responsible only to the limits stated in the product warranty. Product specifications contained in this manual are subject to change without notice.
Table of Contents ❑ Contents Page FoamLogix 3.3 / 5.0 / 6.5 Installation and Operations How to use this manual ........................................................................................ 11 1 Safety Precautions................................................................................................. 13 1.1 Definitions......................................................................................................................... 13 1.2 Guidelines .............................
❑ Table of Contents Contents - continued Page 2.12 Dual Foam Concentrate Tank Options........................................................................... 30 2.13 Single Foam Concentrate Tank Options ....................................................................... 31 2.14 Strainer Options .............................................................................................................. 32 2.15 Low Tank Level Sensor Options .........................................................
Table of Contents ❑ Contents - continued Page 3.4 Installer Supplied Components - continued Flushing Water Hose ........................................................................................................................53 Foam Discharge Drains .................................................................................................................... 54 Electrical Requirements.............................................................................................................
❑ Table of Contents Contents - continued Page 3.4 Installer Supplied Components - continued Check Valve / Injector Fitting .................................................................................................... 71 Figure 3-18: Check Valve/Injector Fitting Orientation .......................................................... 71 Figure 3-19: Check Valve / Injector Fitting Installation ........................................................ 71 Foam Concentrate Injection Hose .................
Table of Contents ❑ Contents - continued Page 3.6 Electrical - continued Low Level Sensor Wiring .................................................................................................................. 97 Remote Activation Switch Option ..................................................................................................... 99 Figure 3-41: Remote Activation Switch Installation Dimensions........................................ 100 3.7 Start Up Check List ..........................
❑ Table of Contents Contents - continued Page 4.2 User Calibration - continued Foam Pump Feedback Calibration ................................................................................................. 116 Figure 4-9: Foam Pump Feedback Calibration, Tank “A” Shown ...................................... 117 Figure 4-10: Foam Concentrate Collection........................................................................ 117 Figure 4-11: Feedback Calibration Factor, Tank “A” Shown .....................
Table of Contents ❑ Contents - continued Page 5.8 Normal Operation Summary - continued Read Total Water or Foam Solution....................................................................... Read Total Foam Concentrate .................................................................................. Reset Totalized Values ............................................................................................. End Foam Injection ......................................................................
❑ Table of Contents Contents - continued Page Appendix A: Foam Concentrate Compatibility ............................................... 149 Chart A-1: Hale Class “A” Foam Concentrate Compatibility.............................................. 149 Chart A-2: Hale Class “B” Foam Concentrate Compatibility.............................................. 150 Reference .......................................................................................................................................
H ow To Use This Manual ❑ How to use this manual This manual is divided into eight (8) sections for clarity and ease of use. Each of the following sections can be stand alone or used in conjunction with each other. 1 SAFETY This section must be carefully read, understood and adhered to strictly by all installer/builders, operators and service personnel using the Hale FoamLogix, Models 3.3, 5.0 and 6.5, Electronic Foam Proportioning System.
❑ How To Use This Manual 5 OPERATION The Operation section primarily used by the apparatus user for proper operation and maintenance of the Hale FoamLogix Proportioning System. It is a guide to the operation of the system and includes operating procedures for the most commonly used options. 6 GENERAL MAINTENANCE This section describes the routine inspection and maintenance requirements for the Hale FoamLogix System.
Safety Precautions ❑ 1 Safety Precautions IMPORTANT ! THE HALE “FOAMLOGIX™” MODELS 3.3, 5.0 and 6.5 ELECTRONIC FOAM PROPORTIONING SYSTEMS ARE DESIGNED FOR OPTIMUM SAFETY OF ITS OPERATORS AND TO PROVIDE RELIABLE AND SAFE FOAM CONCENTRATE INJECTION. FOR ADDED PROTECTION AND BEFORE ATTEMPTING INSTALLATION OR OPERATION PLEASE FOLLOW THE SAFETY GUIDELINES LISTED IN THIS SECTION. ADHERE TO ALL WARNING, DANGER, CAUTION AND IMPORTANT NOTES FOUND WITHIN THIS GUIDE.
❑ Saf et y Precautions NOTICE ! NOTICE – Practices which could result in damage to the apparatus or other property. 1.2 GUIDELINES READ ALL INSTRUCTIONS THOROUGHLY BEFORE BEGINNING ANY INSTALLATION OR OPERATION PROCESS. ❑ Installation should be performed by a trained and qualified installer, or your authorized Hale Products Service Representative. ❑ Be sure the installer has sufficient knowledge, experience and the proper tools before attempting any installation.
Safety Precautions ❑ Conshohocken, PA 19428 Telephone: .........610-825-6300 Fax: ....................610-825-6440 ❑ To prevent electrical shock always disconnect the primary power source before attempting to service any part of the Hale FoamLogix System. ❑ All electrical systems have the potential to cause sparks during service. Take care to eliminate explosive or hazardous environments during service and/or repair.
❑ Saf et y Precautions ❑ Unless engaged in Class “B” foam operations, the air dual tank (ADT) toggle switch, or the manual dual tank (MDT) II selector handle must be in the TANK “A” or FLUSH position. If either is in the FLUSH position when the foam system is started, the foam pump runs for approximately twenty (20) seconds, then SHUTS DOWN. ❑ Make sure the foam tank and foam concentrate suction hoses are clean before making final connections to the foam pump.
Safety Precautions ❑ ❑ There are no user serviceable parts inside Hale Foam system electrical/ electronic components. Opening the distribution box, control unit, foam multiplexing display unit, etc., voids the warranty. ❑ Use mounting hardware that is compatible with all foam concentrates to be used in the system. Use washers, lock washers and cap screws made of brass or 300 series stainless steel.
❑ Saf et y Precautions Notes ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ _________________________________________
❑ Intr oduction 1 System Overview The Hale FoamLogix Models 3.3, 5.0 and 6.5 Foam Proportioning Systems are completely engineered, factory matched foam proportioning systems that provide reliable, consistent foam concentrate injection for Class “A” and Class “B” foam operations. Hale FoamLogix Foam Systems accurately deliver from 0.1% to 10.0% foam concentrate through a check valve/injector fitting, directly into the water discharge stream.
❑ Introduction The control unit display also warns the operator if errors or abnormal operations occur in the system, such as low foam level. 2.3 WATER FLOW SENSOR The foam concentrate injection rate is controlled by a computer chip in the control unit for accurate, repeatable, reliable foam concentrate injection. A water flow sensor constantly monitors water flow through the discharge piping. The information from the flow sensor is provided to the control unit by a shielded cable.
Intr oduction ❑ There are three models of Hale Foam systems covered by this manual. The Hale FoamLogix Model 3.3 (3.3GPM / 12.5LPM), Model 5.0 (5.0GPM / 19LPM) and Model 6.5 (6.5GPM / 24.6LPM). The maximum rated foam concentrate flow in gallons per minute is denoted by the model number. Table 2-1: “Maximum Foam Solution Flows” on page 20 shows the system capacities at various foam concentrate injection rates for each Hale FoamLogix Model. The Hale FoamLogix 3.3, 5.0 and 6.
❑ Introduction The MDT II also provides an electrical interlock for the low tank level sensors and concentrate injection rate. The MDT II is not suitable for top mount operator panel installations and some side operator panels due to gravity feed requirements of foam concentrate to the foam pump. Manual Single Tank (MST) Single tank foam systems can be configured with a Manual Single Tank (MST) selector, which provides a flush function connection to the foam system electronic controls. 2.
❑ Intr oduction 2.7 ORDERING INFORMATION Use the current Hale FoamLogix Foam System Price List and Order Form to help ensure a complete matched system is provided to the end user. Use the following procedure when ordering a Hale FoamLogix Foam System. Follow all steps to ensure that a complete system is ordered: 1. Check Hale Foam system product information update (Bulletin #961) for the latest information and advice for foam system selection.
❑ Introduction 6. Determine the low tank level sensors needed. ❑ Side Mount ❑ Bottom Mount ❑ Top Mount Assembly 7. Select the flow sensor, then the mounting weld fitting or saddle clamp based on discharge pipe size. 8. Select harness length. ❑ 10 feet flow sensor x 15 feet controller ❑ 15 feet flow sensor x 20 feet controller 9. 2.
❑ Intr oduction Rated Foam Concentrate Output - continued Model 6.5 ...................................................................... 6.5 GPM (25 LPM) Maximum System Operating Pressure Model 3.3 ....................................................................... 350 PSI (24 BAR) Model 5.0 ....................................................................... 200 PSI (14 BAR) Model 6.5 .......................................................................
❑ Introduction Figure 2-3: Foam Pump Installation Envelope Dimensions, ADT Option Only 26 FoamLogix 3.3 / 5.0 / 6.
Intr oduction 2.9 ❑ SYSTEM CONFIGURATION Hale Foam Proportioner System, Models 3.3, 5.0 or 6.5 All Hale Foam systems include a: Foam Pump/Motor Assembly, Control Unit, Main Harness and Check Valve/Injector Fitting. Also see Section 8 “Illustrated Parts Breakdown” on page 157. Control Unit p/n: 111530 Foam Pump/Motor Assembly (Shown with Bypass Valve when configured for MDT II, MST or No Tank Selector Option) FoamLogix Model Check Valve/Injector Fitting p/n: 038-1790-00-0 Part Number Model 6.
❑ Introduction 2.10 CABLE HARNESS For cable harness overviews, see Section “ 9 Plate Drawings,” beginning on page 170. Also see Figure 2-6: “Power Connection Wire Harness” on page 28. p/n: 113436 ...Control Head Harness, 10’ x 4’ (3.1 x 1.2 m) 10’ - Flow Sensor x 4’ - Motor Control p/n: 113438 ...Control Head Harness, 10’ x 14’ (3.1 x 4.3 m) 10’ - Flow Sensor x 14’ - Motor Control p/n: 113439 ...Control Head Harness, 15’ x 19’ (4.6 x 5.8 m) 15’ - Flow Sensor x 19’ - Motor Control p/n: 113437 ...
Intr oduction 2.11 ❑ DUAL FOAM CONCENTRATE TANK SYSTEM OPTIONS Figure 2-7: Dual Tank Foam Concentrate Tank System Options FoamLogix 3.3 / 5.0 / 6.
❑ Introduction 2.12 30 DUAL FOAM CONCENTRATE TANK OPTIONS FoamLogix 3.3 / 5.0 / 6.
Intr oduction 2.13 ❑ SINGLE FOAM CONCENTRATE TANK OPTIONS FoamLogix 3.3 / 5.0 / 6.
❑ Introduction 2.14 STRAINER OPTIONS Also see Figure 3-14: “In-Line Strainer/Valve Installation” on page 67. Note: For Hale FS Series Strainers, use when Strainer is subjected to flushing water pressure. 32 FoamLogix 3.3 / 5.0 / 6.
Intr oduction 2.15 ❑ LOW TANK LEVEL SENSOR OPTIONS FoamLogix 3.3 / 5.0 / 6.
❑ Introduction 2.16 FLOW SENSORS Each Hale foam system requires a flow sensor to operate. Pipe size must be selected based on the minimum and maximum water flow in the foam capable discharge. Following is a list of pipe size and rated flow ranges along with flow sensor saddle clamp part numbers. In all instances a weld fitting may be substituted for the saddle clamp.
Intr oduction 2.17 ❑ CHECK VALVE MANIFOLDS The check valve manifolds include flow sensors, check valve/injector fittings and single or dual waterway check valve flappers. End connections for the manifolds are 3” (76mm) Vitaulic. FoamLogix 3.3 / 5.0 / 6.
❑ Introduction 2.18 36 REMOTE ACTIVATION SWITCH OPTION FoamLogix 3.3 / 5.0 / 6.
Intr oduction 2.19 ❑ CHECK VALVES, FLANGES, GASKETS FoamLogix 3.3 / 5.0 / 6.
❑ Introduction 2.20 38 ELBOWS AND MINI MANIFOLDS FoamLogix 3.3 / 5.0 / 6.
System Layout ❑ 2.21 HALE FOAM SYSTEM LAYOUT DRAWINGS Figure 2-10: Typical Single Foam Concentrate Tank FoamLogix 3.3 / 5.0 / 6.
❑ System Layout Figure 2-11: Single Foam Tank with MST and In-Line Strainer/Valve Assembly 40 FoamLogix 3.3 / 5.0 / 6.
System Layout ❑ Figure 2-12: Single Foam Tank with MST and FS Series Strainers FoamLogix 3.3 / 5.0 / 6.
❑ System Layout Figure 2-13: Dual Foam Concentrate Tanks, with MDT II and In-Line Strainer/Valve Assembly 42 FoamLogix 3.3 / 5.0 / 6.
System Layout ❑ Figure 2-14: Dual Foam Concentrate with MDT II and FS Series Strainer Assembly FoamLogix 3.3 / 5.0 / 6.
❑ System Layout Figure 2-15: Dual Foam Concentrate Tanks, with ADT and In-Line Strainer/Valve Assemblies 44 FoamLogix 3.3 / 5.0 / 6.
System Layout ❑ Figure 2-16: Dual Foam Concentrate Tanks with ADT and FS Series Strainer Assemblies FoamLogix 3.3 / 5.0 / 6.
❑ System Layout Notes ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ________________________________________________
❑ Installer Installation 3 Installation Carefully review the procedures that follow to ensure the system is properly designed. This section lists components that have been tested with Hale FoamLogix and provide the best system performance. Using the recommended materials and specified parts ensures a virtually maintenance free installation. Differences in apparatus plumbing and foam system configuration make it impractical to show exactly how the Hale FoamLogix 3.3, 5.0 or 6.
❑ Instal ler Installation IMPORTANT ! WHEN DETERMINING THE LOCATION OF THE HALE FOAMLOGIX COMPONENTS BEING INSTALLED KEEP IN MIND PIPING RUNS, CABLE ROUTING AND OTHER INTERFERENCES THAT COULD HINDER OR INTERFERE WITH PROPER SYSTEM PERFORMANCE. 3.1 FOAM PUMP AND MOTOR ASSEMBLY Ideally, the foam pump and motor assembly should be located in an area that is protected from road debris and excessive heat buildup. The back of a compartment or a compartment shelf is often an ideal location.
Installer Installation ❑ CAUTION ! - continued IF THE STRAINER IS SUBJECT TO FLUSHING WATER PRESSURE, USE HALE “FS” SERIES STRAINERS. Mount the in-line foam strainer/valve assembly in the foam concentrate hose from the foam tank to the foam pump suction connection, ADT, MDT II or MST. If panel mounted FS series strainers are installed, mount the strainer in the foam concentrate hose that supplies concentrate to the ADT, MDT II or MST.
❑ Instal ler Installation 3.4 INSTALLER SUPPLIED COMPONENTS Due to the many differences in apparatus configurations and design requirements, the Hale FoamLogix system installer must supply components, such as, ❑ Mounting brackets ❑ Piping ❑ Hoses ❑ Fittings ❑ Electrical wiring The following guidelines are recommendations for selection of additional components for a complete system installation.
❑ Installer Installation Foam concentrate suction hose subjected to flushing water pressure must be rated for 23 in (584.2mm) Hg vacuum and the maximum discharge pressure of the fire pump (500 PSI [34 BAR] minimum). These hoses include the hose from the outlet of the MDT II or MST to the foam pump inlet.
❑ Instal ler Installation Foam Concentrate Bypass Hose The foam concentrate bypass hose connection is 1/2” (13mm) NPT threads. Hoses and fittings of nominal 1/2” (13mm) inside diameter must be used as bypass hose. Since the bypass hose is used for calibration and draining the system it does not see high operating pressures; therefore, a hose with a lower pressure rating than the inject hose may be used. Fittings and hoses used must be compatible with all foam agents expected to be used.
❑ Installer Installation Individual drain lines should be used on each check valve. The waterway check valves must be rated for 500 PSIG (34.5 BAR) test pressure. Hale 3” (76mm) “115” flange-type check valves (p/n: 038-1570-00-0) can be used for most installations on pumps with “115” style flanges. The Hale “115” flange type check valve has a 4-3/8” (111mm) bolt circle that fits standard Hale “115” flanges, as well as 4-3/8” (111mm) bolt circle discharge flanges on other pumps.
❑ Instal ler Installation ❑ Reducer/regulator ❑ Connections for flushing water for the system Additionally, when the Hale FoamLogix is installed without a Hale provided selector some operating and system protection features are not available. Foam Discharge Drains Drains must be provided from foam capable discharge piping components to prevent freezing in cold weather.
❑ Installer Installation The primary power connection must be made so that power is supplied to the Hale FoamLogix when the main apparatus electrical system is energized and the pump is in gear. Use of a solenoid with a 150 AMP peak, 85 AMP continuous rating is recommended. (See Figure 3-1: “Recommended Relay Wiring Schematic,” on page 55.
❑ Instal ler Installation The ground strap should be a minimum of 1-1/4” (32mm) wide and no longer than 18” (457mm). It must have soldered flat lug ends with 3/8” (10mm) diameter holes. If the ground strap length exceeds 18” (457mm), a wider ground strap should be used or use a double thickness of 1-1/4” (32mm) wide ground strap. The ground strap must be connected to the chassis. Use minimum 5/16” (8 mm) diameter bolt or mounting to secure the strap.
❑ Installer Installation ❑ Baffling ❑ Drain facilities FoamLogix Foam tank capacities for the Hale FoamLogix 3.0, 5.0 or 6.5 are based on NFPA requirements for flammable liquid (Class “B”) fire suppression. (See Table 3-3: “Recommended Foam Tank Capacity.”) Recommended Tank Capacity Model 6.5 100 Gallons (379 Liters) Model 5.0 100 Gallons (379 Liters) Model 3.
❑ Instal ler Installation Position the foam pump so the bypass valve is easily accessible. When the Hale FoamLogix system is ordered without the ADT option, a separate bypass valve is included that may be removed from the foam pump and mounted on a truck panel for easier access. When ordered with the ADT option, the operating knob may be removed from the bypass valve actuator and an extension rod installed to permit remote operation.
❑ Installer Installation Plumbing Installation Hale FoamLogix System plumbing diagrams are located in this section. The diagrams provide recommended guidelines for the installation of system components that handle water, foam concentrate and foam solution. The sequence in which the plumbing installation is performed depends on your individual installation requirements. IMPORTANT ! AFTER INSTALLATION, MAKE SURE ALL PIPES, HOSES AND TUBES ARE PROPERLY SUPPORTED USING THE BEST INDUSTRY PRACTICES.
❑ Instal ler Installation The Hale pre-made stainless steel foam manifolds are recommended. The manifolds are available in kits and eliminate the extra labor and leaks from large pipe thread connections. The manifolds use 3” (76mm) Victaulic connections and are available in single or dual check valve configurations. (See Figure 3-6: “Typical Check Valve Manifold Installation,” on page 59.
Installer Installation ❑ Figure 3-7: Typical Midship Pump Installation Figure 3-8: 4” (102mm) Check Valve Installation FoamLogix 3.3 / 5.0 / 6.
❑ Instal ler Installation “Waterway” Check Valves Check valves in the waterway, rated at 500 PSI (34.5 BAR), are required to keep foam solution out of the main pump and allow pump priming without drawing foam into the piping. Using double check valves, separated by at least 6” to 8” (152 to 203mm) of pipe before the foam injection point ensures that the pump and tank water remain uncontaminated.
❑ Installer Installation Refer to Table 3-10: “Pipe Size vs. Minimum Straight Run” for pipe size. Selecting the next smaller pipe permits reducing the straight pipe run the required distance prior to the flow sensor paddle wheel. In the short length of reduced pipe pressure loss is minimal and there is minimal pressure loss through elbows and fittings. (See Figure 311: “Typical Reduced Size Sensor Piping Arrangement.
❑ Instal ler Installation The downstream piping length is not as critical, but there must be a short length of straight pipe with no fittings or valves immediately after the flow sensor paddle wheel. Two to three times the pipe diameter is recommended. Do not mount a flow sensor directly after an elbow or valve. Valves create severe turbulence when they are “gated.” Figure 3-12: Flow Sensor Placement Saddle Clamp Installation (See Figure 3-13: “Flow Sensor/Saddle Clamp Installation,” on page 65.
❑ Installer Installation Align the indexing pin of the saddle clamp to the indexing hole of the spacer to align the saddle clamp mount. Secure with four 1/2” (13mm) machine screws, without lock washers. Torque to 8.5 in.lbs. (1.0 N-m). Align the paddle wheel indexing pin to the indexing hole in the spacer and secure using four 3/4” screws and lock washers. Torque to 7.5 in.-lbs. (0.9 N-m).
❑ Instal ler Installation It is recommended that a check valve be installed at the pressure tap to prevent contamination. Flush water thread connections are: ❑ ADT - 1/2” (13mm) NPT ❑ MDT II and MST - 1/4” (6.4mm) NPT The system installer must provide proper fittings for these connections. Foam Concentrate Plumbing CAUTION ! MAKE SURE THE FOAM TANK AND FOAM CONCENTRATE SUCTION HOSES ARE CLEAN BEFORE MAKING FINAL CONNECTIONS TO FOAM PUMP. FLUSH TANK AND HOSES PRIOR TO MAKING CONNECTIONS.
Installer Installation ❑ The strainer/valve assembly has 1-1/4” (32mm) NPT female threaded ports. Fittings are supplied for connection to the following inside diameter hose, depending on the viscosity of foam concentrates used. (See Figure 3-14: “In-Line Strainer/Valve Installation,” on page 67.) ❑ 3/4” (19mm) ❑ 1.00” (25mm) ❑ 1-1/4” (32mm) Use 3/4” (19mm) inside diameter hose for Class “A” foam and a 1.00” (25mm) inside diameter hose for Class “B” foams.
❑ Instal ler Installation 2. Mark 4 holes to mount the foam strainer bracket. Drill tapped holes for 1/4”-20 UNC screws (#7 drill for ¼-20 UNC tap)...or...drill clearance holes for 9/32” (7 mm) for 1/4”-20 UNC screws. (See Figure 3-15: “InLine Strainer Mounting Bracket Layout.”) 3. Secure the bracket and strainer/valve assembly to the apparatus. 4. Select the appropriate fittings from the bag attached to the strainer assembly. Two of each fitting are included with the strainer assembly.
Installer Installation ❑ FS Series Strainer When a pressurized water flush is provided to the strainer from one of the discharges, Hale FS series strainers are required. The plumbing exposed to the flush water pressure must be rated at or above the operating pressure of all other discharge plumbing components (500 PSI/34 BAR minimum). To Install FS Series Strainers 1.
❑ Instal ler Installation Figure 3-17: FS Strainer Mounting Dimensions 8. Make sure the strainer is properly oriented. (See Figure 3-16: “FS Strainer Orientation.”) Apply Loctite #242 Threadlock Compound (or equal) to the screws, then secure the strainer body and nameplate to the apparatus. Install the strainer cap. 9. Install the clear plastic hose from the foam tank outlet to the inlet of the strainer. (See Figure 3-14: “In-Line Strainer/Valve Installation,” on page 67.
❑ Installer Installation Check Valve / Injector Fitting The Hale check valve/ injector fitting, supplied with the Hale FoamLogix system, meets NFPA requirements for a nonreturn device in the foam injection system. It prevents back flow of water into the foam concentrate tank.
❑ Instal ler Installation Foam Concentrate Injection Hose Connect a hose from the foam pump inject port to the inlet of the check valve injector fitting. (See Figure 3-20: “Injection and Bypass Hose Connections.”) Figure 3-20: Injection and Bypass Hose Connections The hose and fittings from the INJECT port to the check valve injector fitting should have a minimum 1/2” (13 mm) inside diameter and be rated at 500 PSI (34 BAR) working pressure (Aeroquip 2580-10 or equal).
❑ Installer Installation This hose is used for calibrating the foam pump, pumping the concentrate into a container to empty the foam tank or to assist in priming of the foam pump. The hose from the BYPASS port, must be long enough to reach a container outside the truck. Note: If the handle or placard is removed from the bypass valve for repairs or to facilitate remote mounting make sure they are installed on the valve correctly. Make sure the tang on the handle engages the cast stops.
❑ Instal ler Installation Figure 3-22: ADT Option Panel Placard Layout Dimensions Figure 3-23: ADT Air Hose Connections, Part 1 74 FoamLogix 3.3 / 5.0 / 6.
Installer Installation ❑ Figure 3-24: ADT Option Air Hose Connections, Part 2 FoamLogix 3.3 / 5.0 / 6.
❑ Instal ler Installation Notes ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________
Plum bi ng Installation 3.5 ❑ SYSTEM PLUMBING DIAGRAMS The following pages contain sample Hale FoamLogix system plumbing diagrams for various system configurations. Due to variations in apparatus configuration and individual component locations, the lengths of hoses and piping is not provided. The material described and component sizes shown provide optimum performance for a Hale FoamLogix system.
❑ Plumbing Installation (For barb fitting sizes, see Figure 3-14: “In-Line Strainer/Valve Installation” on page 67.) Figure 3-25: Typical Single Foam Concentrate Tank 78 FoamLogix 3.3 / 5.0 / 6.
Plum bi ng Installation ❑ (For barb fitting sizes, see Figure 3-14: “In-Line Strainer/Valve Installation” on page 67.) Figure 3-26: Typical Single Foam Tank with MST and In-Line Strainer/Valve Assembly FoamLogix 3.3 / 5.0 / 6.
❑ Plumbing Installation Figure 3-27: Typical Single Foam Tank, with MST and FS Series Strainers 80 FoamLogix 3.3 / 5.0 / 6.
Plum bi ng Installation ❑ (For barb fitting sizes, see Figure 3-14: “In-Line Strainer/Valve Installation” on page 67.) Figure 3-28: Single Foam Tank with MST II and In-Line Strainer/Valve Assembly FoamLogix 3.3 / 5.0 / 6.
❑ Plumbing Installation Figure 3-29: Typical Single Foam Tank with MST II and FS Series Strainers 82 FoamLogix 3.3 / 5.0 / 6.
❑ Plum bi ng Installation (For barb fitting sizes, see Figure 3-14: “In-Line Strainer/Valve Installation” on page 67.) (For barb fitting sizes, see Figure 3-14: “In-Line Strainer/Valve Installation” on page 67.) Figure 3-30: Typical Single Foam Tank with ADT and In-Line Strainer/Valve Assemblies FoamLogix 3.3 / 5.0 / 6.
❑ Plumbing Installation Figure 3-31: Typical Dual Foam Tanks, with ADT and FS Series Strainer Assemblies 84 FoamLogix 3.3 / 5.0 / 6.
❑ Electri cal Installation 3.6 ELECTRICAL See Figure 3-32: “Single Tank Electrical Harness Overview,” on page 87. Also see Figure 3-33: “Dual Tank Electrical Harness Overview” on page 88. Complete system electrical diagrams are provided at the end of this manual. Refer to these diagrams for proper installation of each of the electrical components. The Hale FoamLogix 3.3, 5.0 or 6.5 system is designed to be installed with a minimum of electrical connections.
❑ Elect rical Installation CAUTION ! - continued ❑ Before connecting the cables, inspect the O-ring seal in the female connector. If the seal washer is missing or damaged, water can enter the connector causing corrosio, resulting in possible system failure. ❑ The ground strap must be a minimum of 1-1/4” (32mm) wide and no longer than 18” (457mm). A longer ground strap must be wider or a double thickness strap must be used. Make sure the ground strap is attached to the chassis frame.
Electri cal Installation ❑ Single and Dual Tank Electrical Harness Overview Figure 3-32: Single Tank Electrical Harness Overview FoamLogix 3.3 / 5.0 / 6.
❑ Elect rical Installation Figure 3-33: Dual Tank Electrical Harness Overview Control / Display Unit The control/display unit mounts in the operator panel of the apparatus. The display is secured with four #10 socket head screws. (See Figure 3-34: “Control/Display Unit Mounting Dimensions” on page 89.) The display requires a 7.00” (178mm) minimum clearance from the back of the operator panel to allow proper cable connection.
❑ Electri cal Installation Figure 3-34: Control/Display Unit Mounting Dimensions Notes: Ensure that the panel where the control unit is mounted has an adequate ground. For stainless steel and vinyl coated panels a ground strap, 1/2” (13mm) wide, must be attached from one of the four screws securing the control unit in place to the frame of the fire truck to ensure adequate grounding. Add a service loop to avoid strain on the wires or connectors during body and frame flex.
❑ Elect rical Installation Figure 3-35: Distribution Box Connections Distribution Box Ground / Primary Power CAUTION ! CONNECT THE PRIMARY POSITIVE LEAD FROM THE TERMINAL BLOCK TO THE MASTER SWITCH TERMINAL OR RELAY TERMINAL USING MINIMUM 4 AWG TYPE SGX (SAE J1127), CHEMICAL RESISTANT, BATTERY CABLE AND PROTECT WITH WIRE LOOM. PREVENT CORROSION OF POWER AND GROUND CONNECTIONS BY SEALING THESE CONNECTIONS WITH THE SILICONE SEALANT PROVIDED.
❑ Electri cal Installation When making the ground strap connections make sure lugs are soldered to the strap ends for trouble free connections. Seal all connection against corrosion. When the length of the ground strap exceeds 18” (457mm) use a wider strap or a double thick strap. CAUTION ! DO NOT CONNECT THE MAIN POWER LEAD TO SMALL LEADS THAT ARE SUPPLYING SOME OTHER DEVICE, SUCH AS A LIGHT BAR OR SIREN. THE HALE FOAMLOGIX MODELS 3.3, 5.0 AND 6.5 REQUIRE 60 AMP MINIMUM CURRENT.
❑ Elect rical Installation Proper installation of system components and cables, along with proper grounding, limits radio interference caused by the Hale FoamLogix system. Additionally, make sure radio cables and hardware are not located in the immediate area where the FoamLogix system is mounted. Making round coils of extra control and flow sensor cables in the pump compartment can act as an antenna.
❑ Electri cal Installation CAUTION ! FOAM TANK LOW LEVEL SENSORS MUST BE USED TO PROTECT THE HALE FOAMLOGIX FROM DRY RUNNING. FAILURE TO USE LOW LEVEL SENSORS WITH THE HALE FOAMLOGIX SYSTEM VOIDS THE WARRANTY. Side Mount Installation A side mount low tank level sensor is used if the bottom of the foam tank is not accessible. 1. The sensor has 1/2” (13mm) NPT threads. If tank design and construction allows, the side mount sensor is threaded directly into the side of the tank at the proper height.
❑ Elect rical Installation Note: When the side mount low level sensor senses a low concentrate condition the system operates for an additional one minute unless the foam concentrate level is restored. If the foam concentrate level is not restored the system SHUTS DOWN. When locating the side mount low tank level sensor on the tank sufficient foam concentrate should be present for one minute of operation at the rated flow. 3.
❑ Electri cal Installation Flange cutout dimensions are shown in Figure 3-39: “Top Mount Sensor Dimensions.” The flange gasket can also be used as a template to mark hole location. 1. Layout and drill holes in the top of the foam tank. (See Figure 3-39: “Top Mount Sensor Dimensions.”) 2. The center of the sensor should be located at least 11/2” to 2” (38 to 51mm) from the sides of the foam tank.
❑ Elect rical Installation CAUTION ! USE MOUNTING HARDWARE THAT IS COMPATIBLE WITH ALL FOAM CONCENTRATES BEING USED IN THE SYSTEM. USE WASHERS, LOCK WASHERS AND CAP SCREWS MADE OF BRASS OR 300 SERIES STAINLESS STEEL. Resizing the Top Mount Low Level Sensor Certain applications may require the top mounted sensor to be shorter than factory length. (See Figure 3-40: “Top Mount Low Level Sensor Assembly” on page 97.) To resize (See Figure 3-40: “Top Mount Low Level Sensor Assembly” on page 97.) 96 1.
Electri cal Installation 10. Install and tighten the 5/ 8” (16mm) tube compression nut. 11. Slide the 1/2” diameter tube in the 5/8” (16mm) diameter tube and adjust the telescoping section until the desired length is achieved, as measured from the bottom of the flange to the bottom of the sensor. Tighten the compression fittings on the union to lock length setting. 12. Tighten the strain relief gland nut and strain relief.
❑ Elect rical Installation Single Foam Tank System For cable harness overviews, see Section 9 “ 9 Plate Drawings,” on page 170. Also see Figure 3-32: “Single Tank Electrical Harness Overview” on page 87. Use a minimum 16 AWG type SXL or GXL (SAE J1128) wire to extend the low tank sensor wire to the 2-pin Packard WeatherPack connector C10 of the main cable harness. Low tank level sensors are not polarity sensitive therefore terminal connections are not specific.
❑ Electri cal Installation Use a minimum 16 AWG type SXL or GXL (SAE J1128) wire to extend the low tank sensor wires to the 2-pin Packard WeatherPack the following connectors of the main cable harness: ❑ Tank “A” - C10 ❑ Tank “B” - C11 Low tank level sensors are not polarity sensitive therefore terminal connections are not specific. When splicing wires make sure the splices are sealed using an adhesive filled heat shrink tubing.
❑ Elect rical Installation Figure 3-41: Remote Activation Switch Installation Dimensions 1. Insert switch assembly through the panel cutout and secure to using the #10-24 UNC x 1/2” (13mm) screws and nuts provided. Note: When making cable connections, make sure the cable is routed by the shortest most direct route. A maximum of 40 feet (12 meters) of remote cable may be used. 2. 100 Connect the remote activation switch cable from the main cable harness connector C2.
❑ Start -Up Check List 3.7 START UP CHECK LIST Before energizing the apparatus and the Hale FoamLogix system for the first time make sure the following items are checked: Electrical Refer to the following for an overview of electrical connections: ● Figure 3-33: “Dual Tank Electrical Harness Overview” on page 88 ● Figure 3-34: “Control/Display Unit Mounting Dimensions” on page 89 ● For cable harness overviews, see Section “ 9 Plate Drawings,” beginning on page 170.
❑ Start- up Check Li st ❑ If ADT, MST or MDT II are used, check electrical cable connects. ❑ If the Remote Activation Switch is used, check electrical cable connections from the On/OFF switch. Liquid Refer to the following heading for overview drawings of typical plumbing arrangements: ● See Section 3.5 “System Plumbing Diagrams” on page 77. ● See Section “Plumbing Installation” on page 59. ❑ Flow sensor mounted with flow arrow in the correct direction for water flow.
Start -Up Check List ❑ Foam Pump Refer to the following heading for overview drawings of typical plumbing arrangements: ● See Section 3.5 “System Plumbing Diagrams” on page 77. ● See Section 3.1 “Foam Pump and Motor Assembly” on page 48. ❑ Foam pump and motor assembly mounted in horizontal position with base plate down. ❑ Foam pump and motor assembly properly secured using proper mounting hardware. ❑ Foam pump suction and discharge hoses connected to proper ports.
❑ Start- up Check Li st 3.8 INSTALLATION AND DELIVERY CHECK LIST After the Hale FoamLogix system is installed, use the following check list to verify installation and ensure proper system setup when the apparatus is delivered to the end user. Installation Date _______ Initials _______ ❑ _______ _______ ❑ _______ _______ ❑ _______ _______ ❑ _______ _______ ❑ System properly installed. See Section 3.7 “Start Up Check List” on page 101. Tank level sensor function verified. See Section 3.
Start -Up Check List 3.9 ❑ SYSTEM INSTALLER START-UP When energizing the Hale FoamLogix system at the system installer facility for the first time the following procedures shall be used. Initial System Power Check Observe the display on the control unit while energizing the apparatus electrical system. On initial power up of the apparatus, the Hale FoamLogix system begins a brief self-diagnostic routine. When completed, the system enters the STANDBY or System Ready mode.
❑ Start- up Check Li st System Operation Check After initial system power-up, low tank level sensor operation, foam pump operation and flow sensor calibration must be checked. CAUTION ! WATER IS USED AT THE SYSTEM INSTALLER FACILITY TO VERIFY LOW TANK LEVEL SENSOR OPERATION AND FOAM PUMP OPERATION AS THE END USER SPECIFIED FOAM CONCENTRATES MAY NOT BE READILY AVAILABLE. DO NOT PUMP WATER WITH THE HALE FOAMLOGIX FOAM PUMP FOR MORE THAN ONE MINUTE PER FOAM TANK.
❑ Start -Up Check List 5. Place the BYPASS valve in the BYPASS position to check foam pump operation. Place a calibrated five gallon container at the discharge of the bypass hose. 6. Place the system in simulated flow mode by selecting the FLOW display and buttons simultaneously. Set simulated and pressing both flow value to 100 GPM by pressing the or buttons. (See Figure 344: “Simulated Flow Mode Display.”) Figure 3-44: Simulated Flow Mode Display 7.
❑ Start- up Check Li st Note: If the system is equipped with an ADT or MDT II, move the selector to TANK B position and repeat steps 8 through 10 for Tank B. 12. After foam pump operation has been checked with both foam tanks exit simulated flow mode by selecting the FLOW display and depressing both up Ï and down Ð buttons simultaneously. 13. Drain water from foam tanks and concentrate lines and return the bypass valve to the INJECT position. 14.
Setup and Cal ibration ❑ 4 User Setup and Calibration 4.1 INITIAL END USER SETUP When the apparatus is delivered to the end user facility the foam tank(s) must be filled with the specified foam concentrate(s). Make sure the proper foam concentrate is put into the correct tank. The system must then be adjusted to operate with the end user foam concentrate(s) for best accuracy. Also see heading “Appendix A: Foam Concentrate Compatibility” on page 149.
❑ Setup and Calibrati on Note: Pressing the DISPLAY button ( i ) cycles through the four functions as indicated by the red LED illuminating under each function (FLOW, %, TOTAL FLOW and TOTAL FOAM). Priming the Foam Pump After the foam tank(s) are filled with the proper foam concentrate and the system is powered up, foam concentrate flow must be checked to verify the foam pump is primed.
Setup and Cal ibration ❑ Increase the simulated flow value by pressing button to allow easier priming (above factory default value of 150 GPM). The display shows S at the left most position to indicate the simulated flow. 3. Engage the Hale FoamLogix system by pressing the ON button. The left LED on the horizontal bar graph illuminates to indicate the system is on. 4. As the foam pump begins to run the bar graph LEDs to the right illuminate, indicating foam concentrate is being pumped.
❑ Setup and Calibrati on The system allows easy checking of component calibration to assure accurate operation. The calibration process verifies the calibration process and allows adjustments to the flow sensor and feedback sensor display readings, to allow for variations in apparatus piping configurations and end user selected foam concentrate. Default values for simulated flow and the foam concentrate injection rate may be set to end user specifications while in the calibration mode.
Setup and Cal ibration ❑ Restoring Factory Defaults To return to the factory default values, enter the restore factory values password ( ). (See Figure 43: “Password Sequence.”) Once the password is entered correctly the control unit displays FAC and returns to normal operation. Factory default values: ❑ Simulated Flow -150 GPM (568 LPM) ❑ % FOAM 0.5% Class “A” (See Figure 4-4: “Password and Calibration Modes - Display.”) Calibration 1.
❑ Setup and Calibrati on 3. The display shows CAL for several seconds, followed by CO (or LO when display is set to metric). (See Figure 4-4: “Password and Calibration Modes - Display” on page 113.) 4. The FLOW LED (Water Flow Sensor Calibration) also illuminates. Flow Sensor Calibration Verify flow sensor calibration during NFPA/UL testing of the apparatus and delivery to end user. (See Figure 4-5: “Flow Sensor Calibration - Display.
Setup and Cal ibration ❑ Verify that the reading on the control unit is within 5% of the actual value. 5. STOP the water flow when adjustments are completed. Record Calibration Factors 1. Press and release the i button. The display shows F xx.x, which is the water flow sensor calibration factor. (See Figure 4-6: “Flow Sensor Calibration Factor.”) 2. Record this value for future reference.
❑ Setup and Calibrati on 2. Adjust the setting to the required rate by pressing the S 150). or buttons (e.g., Foam Concentrate Injection Rate When the Hale FoamLogix system is powered ON, the foam concentrate injection rate stored in memory is the default setting. The user specific default concentrate injection rate is adjusted in the calibration mode. 1. Press the i button. The display shows the current default concentrate injection rate stored in memory for the selected foam concentrate tank.
Setup and Cal ibration ❑ 1. Press the i button. 2. The display shows A x.xx for Tank “A”, or B x.xx for Tank “B” for the total volume of foam concentrate pumped during the last calibration run. (See Figure 4-9: “Foam Pump Feedback Calibration, Tank “A” Shown.”) 3. Set the bypass valve to the BYPASS position. 4. Place a graduated measure container at the outlet of the bypass hose, capable of containing the expected volume of foam concentrate, 5 gallons (19 liters) minimum.
❑ Setup and Calibrati on 7. Adjust the reading on the display to match the volume actually pumped using or button. the 8. Repeat the procedure as necessary to verify the setting is correct. 9. Set the bypass valve handle back to the INJECT position. Record Foam Feed Back Factor 1. Press and release the i button. 2. The display shows FA xxx for Tank “A”, or FB xxx for Tank “B” for the foam pump feedback calibration factor. (See Figure 4-11: “Feedback Calibration Factor, Tank “A” Shown.
Setup and Cal ibration ❑ 4. The display shows SCAL for several seconds then cycles through the start-up sequence followed by the flow display O. (See Figure 4-12: “Exit and Save Calibration.”) 5. This completes verification and adjustment of the system. The Hale FoamLogix system is now ready to be placed in service. Figure 4-12: Exit and Save Calibration Relief Valve The pressure relief valve is factory tested and set to ❑ Model 3.3 - 350 PSI (24 BAR) ❑ Model 5.0 - 200 PSI (14 BAR) ❑ Model 6.
❑ Setup and Calibrati on English to Metric Units The FoamLogix Display offers both English and Metric readouts. The Hale FoamLogix system is calibrated at the factory for ENGLISH - U.S. measurement units (GPM, PSI, GALLONS, etc.). To switch from English to Metric and back again, 1. Press and hold the i button. The display show PASS, then clears. 2. While continuing to hold the display button, enter the password ( ). 3. The display shows IN to indicate Metric units are selected.
Operation 5 ❑ Operation 5.1 DESCRIPTION Operation of Hale FoamLogix system is controlled by the Digital Display Control Unit, provided with four push buttons (pads). (See Figure 5-1: “Control Unit Identification.”) Figure 5-1: Control Unit Identification The Hale FoamLogix system constantly monitors the water and foam concentrate flow values, maintaining foam injection at the specified concentrate injection rate.
❑ Operation Note: TOTAL FLOW and TOTAL FOAM values may be reset any time while they are displayed. When the % FOAM LED is ON, or in any other function mode, the foam concentrate injection rate may be set to the desired value, if different from the default value. This may be adjusted prior to or during foam operations by pressing the or arrow buttons. Also see heading “Control Unit Functions” on page 122. When the ON button is pressed, the FLOW LED illuminates indicating that the system is ready.
Operation ❑ % Foam Selecting % FOAM shows the foam concentrate injection rate setting. For example, with a single tank system or when the dual tank system selector is in the TANK “A” position the display shows A 0.5. When the dual tank system selector is in the TANK “B” position the display shows B 1.0. (See Figure 5-2: “Function Modes.”) When the system includes an MST, MDT II or ADT and the selector is in the FLUSH position the display reads FLUSH. (See Figure 5-3: “Flush,” on page 125.
❑ Operation Bar Graph (See Figure 5-1: “Control Unit Identification,” on page 121.) The bar graph consists of a ten (10) LED array. When the ON button is pressed the left-most LED illuminates to indicate the system is ON and ready to inject foam concentrate. When water is flowing, the LEDs to the right on the bar graph illuminate indicating foam concentrate is being injected. The number of LEDs illuminated indicates the approximate pump capacity being used (percentage of foam being pumped).
Operation ❑ While operating in any function, with the exception of FLOW during simuor buttons are momentarily lated flow operation, whenever the pressed, the display switches to the % FOAM display and shows the current injection rate for two (2) seconds. or button is held down for a period In any display mode, if either the of two (2) seconds or more, the injection rate value increases or decreases accordingly. Once released, the display returns to the last selected display after two (2) seconds.
❑ Operation Messages appearing on the display alert the operator to adverse conditions that could cause damage to Hale FoamLogix system components, the apparatus and cause personnel injury. Low Foam Tank Level Message The Hale FoamLogix foam pump is interlocked with the foam concentrate tank LOW level switch. If the tank is empty, the pump runs for one (1) minute. A low foam concentrate tank level message is shown (Lo A or Lo B) alternating with the normal selected function on the display.
❑ Operation If the system operates for a period of thirty (30) seconds without a feedback signal the system switches to the STANDBY mode and the display flashes no Pr (no prime), indicating there is no foam concentrate flow. High Ambient Temperature Message (See Figure 5-5: “Priming, HIGH Temperature and LOW Battery Messages.”) If the Hale FoamLogix system is operating in an environment of excessive ambient temperatures, the display shows HIGH.
❑ Operation 5.7 PRIMING THE FOAM PUMP When the Foam Tank Runs Dry In some instances, the foam tank could run dry while operating the Hale FoamLogix system. When the fire pump is running the foam pump may not pump efficiently against 100 to 150 PSI (7 to 10 BAR) back pressure. To re-establish foam concentrate flow quickly: 1. Turn the bypass valve to the BYPASS position. 2. With the fire pump flowing water from foam discharge and the Hale FoamLogix ON, observe the hose from the bypass valve. 3.
Operation 5.8 ❑ NORMAL OPERATION SUMMARY Operation Action Energize System. Energize the apparatus. The Hale FoamLogix enters initial start up and a brief self-diagnostic mode. Select Foam Tank. If system is equipped with dual foam tanks, place selector to proper tank. Display Figure 5-6: Normal Operation Summary Chart FoamLogix 3.3 / 5.0 / 6.
❑ Operation Operation Action Begin Foam Injection. Establish water flow and press ON button. Change Injection Rate. Press and HOLD Read Injection Rate. Press and release Read Total Water or Foam Solution. Press i until LED below TOTAL FLOW illuminates. Display and for two (2) seconds. Release once desired rate is set. or . The display shows the injection rate and returns to the selected function after two (2) seconds. Figure 5-6: Normal Operation Summary Chart 130 FoamLogix 3.3 / 5.0 / 6.
Operation Operation Action Display Read Total Foam Concentrate Press i until LED below TOTAL FOAM illuminates. Reset Totalized Values While in TOTAL FLOW or TOTAL or FOAM, press and release End Foam Injection ❑ . Press ON. Figure 5-6: Normal Operation Summary Chart 5.9 SIMULATED FLOW MODE OPERATION The Simulated Flow mode of the Hale FoamLogix system allows operation of the foam pump without discharging water through a foam capable discharge or when the flow sensor is not functioning.
❑ Operation ❑ Verifying foam pump operation ❑ Manually controlling foam injection if the flow sensor malfunctions. The factory default simulated flow rate is 150 GPM (568 LPM). The simulated flow rate and the concentrate injection percentage rate are set by the rate adjustment buttons on the control unit display, while in SIMULATED FLOW mode. The simulated flow function provides manual operation of the foam injection system required by NFPA standards.
❑ Operation 3. Energize the apparatus electrical system and press Hale FoamLogix DISPLAY button to turn ON the system. 4. The Hale FoamLogix enters the STANDBY mode. (See Chapter 4, Figure 47: “Simulated Flow Calibration,” on page 115.) 5. When the FLOW LED illuminates, press and release the simultaneously. and buttons 6. The display shows S 150 (or other preset default value) and the FLOW LED illuminates. (See Figure 5-7: “Simulated Flow Display Sequence,” on page 132.) 7. Press the ON button.
❑ Operation CAUTION ! UNLESS ENGAGED IN CLASS “B” FOAM OPERATIONS, THE HALE FOAMLOGIX ADT TOGGLE SWITCH OR HALE FOAMLOGIX MDT II SELECTOR HANDLE MUST BE IN THE TANK “A” POSITION. IF THE TOGGLE SWITCH OR SELECTOR HANDLE IS IN THE FLUSH POSITION WHEN THE FOAM PUMP IS STARTED, THE FOAM PUMP RUNS FOR ONLY TWENTY (20) SECONDS, THEN SHUTS DOWN. Figure 5-8: Dual Tank Selector Operating Positions Make sure the Hale FoamLogix is operating and foam solution is being discharged.
❑ Operation 2. When changing toggle switch or selector handle position, move smoothly from the TANK “A” position through the FLUSH position to TANK “B” position in one motion without stopping. With the fire pump discharging water and the Hale FoamLogix operating, a small volume of water is provided to separate the two foam types helping to prevent possible adverse reactions. 3.
❑ Operation 3. Place the Hale ADT, MDT II or MST to the FLUSH position. (See Figure 5-9: “Hale MST Selector Operation.”) 4. Observe the discharge hose and allow Hale FoamLogix and discharge to run for several seconds. 5. Figure 5-9: Hale MST Selector Operation After several seconds place the Hale ADT or MDT II to the TANK “A” position and allow the system to run until all foam solution is discharged through the foam capable hose line.
Operation 5.12 ❑ REMOTE ON/OFF SWITCH OPTION The remote ON/OFF switch is used to activate the Hale FoamLogix system from the driver compartment or a location other than the control unit. The switch activates and deactivates the Hale FoamLogix system. It does not permit adjustment of the injection rate. (See Section 3, Figure 3-41: “Remote Activation Switch Installation Dimensions,” on page 100.) To operate: 1. Press the switch down and release to activate.
❑ Operation Notes ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ____________________________________________________
General Maintenance ❑ 6 Maintenance 6.1 MAINTENANCE PROCEDURES After each use 1. Inspect wiring, hoses, flow sensors and connections for tightness, corrosion, leaks and/or damage. See heading “System Plumbing Diagrams” on page 77. Also see heading “Electrical” on page 85. 2. Flush the foam pump if a non-approved foam concentrate is used. Also see heading “Appendix A: Foam Concentrate Compatibility” on page 149. Monthly Verify water flow calibration.
❑ Gener la Maintenance Notes ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ________________________________________
Troubleshooting ❑ 7 Troubleshooting 7.1 USER DIAGNOSTICS Power indicator LEDs are provided on the distribution box and on the feedback sensor and illuminate when power is supplied to the FoamLogix system. (See Figure 7-1: “Distribution Box Overview.”) The LED on the feedback sensor FLASHES when the feedback sensor is receiving pulses from the flow sensor. These LEDs help to ease tracing of power supply faults and eliminates some of the guesswork in troubleshooting.
❑ Troubleshooting ❑ Hale FoamLogix is activated by pressing the power push button ( i ) on the control display unit. (See Figure 5-1: “Control Unit Identification,” on page 121.) Once all the above conditions are met proceed to the system troubleshooting section to determine cause of malfunction. NOTE: Hale FoamLogix system electronic components have no user serviceable components inside and are replaced as a unit. Opening of Hale FoamLogix electronic components voids the manufacturer’s warranty. 7.
Troubleshooting ❑ Note: The FoamLogix system has a SIMULATYED FLOW function. (See Section 5.9, “Simulated Flow Mode Operation,” on page 131 for more information.) This allows troubleshooting without flowing water. Distribution Box The Distribution Box, part of the pump/motor assembly, sends data to the control unit for LOW tank warnings, TANK A or B selection status, as well as foam concentrate flow feedback.
❑ Troubleshooting If the control unit does not receive data that foam concentrate is flowing, it displays the “No Pri” error message, indicating no prime, and turns the system OFF. Pressing ON starts the cycle again. There must be water flow or the unit must be in the simulated flow mode. (See Section 5, “Operation,” on page 121 for more information.) Summary FoamLogix replacement parts are “plug-and-play” type devices that do not require specialized equipment to service.
Troubleshooting ❑ 4. If there is no indication of water flow on the control unit display troubleshoot the flow sensor. 5. If water flow is established, turn the Hale FoamLogix system ON to flow foam. 6. Observe foam pump discharge. If foam is NOT flowing troubleshoot the foam pump. 7. Check accuracy of system using the calibration procedures and making adjustments as required. (See Section 4.2, “User Calibration,” on page 111 for more information.
❑ Troubleshooting 7.4 FLOW CHARTS Chart 7-3: Hale FoamLogix System Troubleshooting Flow Chart 146 FoamLogix 3.3 / 5.0 / 6.
Troubleshooting ❑ Chart 7-4: Power System Troubleshooting FoamLogix 3.3 / 5.0 / 6.
❑ Troubleshooting Notes ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ _____________________________________________
Hale Foam Concent rate Compatibilit y C hart ❑ Appendix A: Foam Concentrate Compatibility The following foam concentrates are approved for use in Hale Foam Proportioning Systems. The Class “A” foam concentrates are approved for use in all Hale Foam Proportioning Systems (i.e., Hale FoamLogix 5.0, 3.3, 2.1 and Hale V Series).
❑ Hale Foam Concent rate Com pat ibility Chart Type of Foam Concentrate Manufacturer Brand Name CLASS “B” FOAM * The Class “B” Foam, Specialty foam and Fire Fighting Additive Concentrates are approved for use in FoamLogix Models 5.o and 3.3 Foam Proportioning System only. AFFF Alcohol Resistant Concentrate Reference * Note: This list of compactible foam concentrate is updated regularly. For latest information see www.haleproducts.com.
Hale Foam Concent rate Compatibilit y C hart ❑ Reference The preceding foam concentrates have been tested by Hale Products to ensure compatibility with Hale FoamLogix models 5.0 and 3.3 Foam Proportioning Systems. These chemicals were run for several hundred hours over several months to make sure they do not harm the Foam System. This list is solely intended to assist the end user in selection of foam concentrate(s) compatible with a Hale FoamLogix Model 5.0 and 3.
❑ Hale Foam Concentrate Compatibility Chart Hale Products Inc. A Unit of IDEX Corporation 700 Spring Mill Avenue Conshohocken, PA 19428 U.S.A. Telephone..............1-610-825-6300 Fax ........................1-610-825-6440 Web........... www.haleproducts.
Limited Warranty Express Warranty EXPRESS WARRANTY: Hale Products, Inc. (HALE) hereby warrants to the original Buyer that products manufactured by Hale are free of defects in material and workmanship for one (1) year. The “Warranty Period” commences on the date the original Buyer takes delivery of the product from the manufacturer. LIMITATIONS: Hale’s obligation is expressly conditioned on the Product being: ● Subjected to normal use and service.
Hale Products, Inc. A Unit of IDEX Corporation 700 Spring Mill Avenue Conshohocken, PA 19428 U.S.A. Telephone ...................610-825-6300 Fax .. ...........................610-825-6440 Web...........www.haleproducts.
FoamLogix tm Models 3.3, 5.0 and 6.5 Electronic Foam Proportioning System Parts Identification and Drawing Package Hale Products Inc. ◆ A Unit of IDEX Corporation 700 Spring Mill Avenue ◆ Conshohocken, PA 19428 U.S.A. Telephone: 610-825-6300 ◆ FAX: 610-825-6440 Web..........www.haleproducts.
APPARATUS INFORMATION ENGINE ______________________________________________ TRANSMISSION _______________________________________ MAXIMUM CAFS ENGINE RPM ___________________________ CAFS ENGINE SPEED RANGE ___________________________ NOTICE ! Class1 cannot assume responsibility for product failure resulting from improper maintenance or operation. Class1 is responsible only to the limits stated in the product warranty. Product specifications contained in this manual are subject to change without notice.
Illustr at ed Parts Br eakdown 8 ❑ Illustrated Parts Breakdown GENERAL This section contains the parts breakdown for the serviceable assemblies, components and most commonly used options for the FoamLogix 3.3 / 5.0 and 6.5 Electronic Foam Proportioning System. ABBREVIATIONS The following abbreviations may be used in this IPB: A/R...........As required Max.......... Maximum Cm ...........Centimeters Min........... Minimum Cont. ........Continued MM .......... Millimeters Dia. ..........
❑ Illustrated Parts Br eakdow n 8.1 AIR DUAL TANK VALVE (ADT) OPTION Item Part No. Qty. Description ..............538-1610-00-0......................1 .............ADT Selector Panel Assembly, Includes items below marked with an asterisk ( * ) ..............538-1640-00-0......................1 .............ADT Valve Assembly, Includes items below marked with a plus ( + ) *1 ..............101-1630-00-0......................1 .............ADT Nameplate) *2 ..............200-0540-00-0...................
Illustr at ed Parts Br eakdown ❑ Figure 8-1: Air Dual Tank Valve Option FoamLogix 3.3 / 5.0 / 6.
❑ Illustrated Parts Br eakdow n 8.2 HARNESS COMPONENTS Item Part No. Qty. Description 1 ..............513-0320-23-0......................1 .............Tank Select Plug 2 ..............513-0270-04-0......................1 .............Display Power Connection, 12” (305mm) Long, Wiring Harness) Figure 8-2: Harness Components 160 FoamLogix 3.3 / 5.0 / 6.
Illustr at ed Parts Br eakdown 8.3 ❑ DUAL FOAM CONCENTRATE TANK OPTIONS FoamLogix 3.3 / 5.0 / 6.
❑ Illustrated Parts Br eakdow n 8.4 SINGLE FOAM CONCENTRATE TANK OPTIONS Note: For Hale FS Series Strainers, use when Strainer is subjected to flushing water pressure. 162 FoamLogix 3.3 / 5.0 / 6.
Illustr at ed Parts Br eakdown 8.5 ❑ LOW TANK LEVEL SENSOR OPTIONS FoamLogix 3.3 / 5.0 / 6.
❑ Illustrated Parts Br eakdow n 8.6 FLOW SENSORS Each Hale foam system requires a flow sensor to operate. Pipe size must be selected based on the minimum and maximum water flow in the foam capable discharge. Following is a list of pipe size and rated flow ranges along with flow sensor saddle clamp part numbers. In all instances a weld fitting may be substituted for the saddle clamp.
❑ Illustr at ed Parts Br eakdown 8.7 MAIN CABLE HARNESS, SINGLE AND DUAL TANK Item Part No. Qty. Description ..............113436 ................................. 1 .............Control Head Harness, 10’ x 4’ (3.1 x 1.2 m) 10’ - Flow Sensor x 4’ - Motor Control ..............113438 ................................. 1 .............Control Head Harness, 10’ x 14’ (3.1 x 4.3 m) 10’ - Flow Sensor x 14’ - Motor Control ..............113439 ................................. 1 .............
❑ Illustrated Parts Br eakdow n 8.8 CHECK VALVE MANIFOLDS The check valve manifolds include flow sensors, check valve/injector fittings and single or dual waterway check valve flappers. End connections for the manifolds are 3” (76mm) Vitaulic. 166 FoamLogix 3.3 / 5.0 / 6.
Illustr at ed Parts Br eakdown 8.9 ❑ REMOTE ACTIVATION SWITCH OPTION FoamLogix 3.3 / 5.0 / 6.
❑ Illustrated Parts Br eakdow n 8.10 168 CHECK VALVES, FLANGES, GASKETS Threads Part Number 3” (76mm) 115-0080-00-0 2-1/2” (64mm) 115-0070-00-0 2” (51mm) 115-0060-00-0 Blank 115-0050-00-0 Threads Part Number 4” (102mm) 115-0040-00-0 3” (76mm) 115-0030-00-0 2-1/2” (64mm) 115-0020-00-0 Blank 115-0010-00-0 FoamLogix 3.3 / 5.0 / 6.
Illustr at ed Parts Br eakdown 8.11 ❑ ELBOWS AND MINI MANIFOLDS FoamLogix 3.3 / 5.0 / 6.
❑ Illustrated Parts Br eakdow n 9 Plate Drawings Description Plate Number FoamLogix System Packaging ................................................................................... 850B Pump Motor Sub-Assembly........................................................................................ 844B Foam Pump Sub-Assembly........................................................................................ 849A FoamLogix with NO Tank Selector Option ..............................................
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Hale Products, Inc. A Unit of IDEX Corporation 700 Spring Mill Avenue Conshohocken, PA 19428 U.S.A. Telephone ...................610-825-6300 Fax .. ...........................610-825-6440 Web. ............www.haleproducts.
