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FoamPRO AccuMax 3040, Installation And Operation Manual

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FoamPRO AccuMax 3040 Installation And Operation Manual Download Page 50

50

Installation and Operation Manual

Connection

Model Minimum Hose ID

Pump Port Fitting

Motor Port Fitting

& Pressure Rating

& Type

3020/3040

1” Suction

#16 SAE O-Ring

N/A

Hydraulic Reservoir to

3060

1” Suction

#16 SAE O-Ring

N/A

Hydraulic Charge

3090

1” Suction

#16 SAE O-Ring

N/A

Pump Inlet

3150

1” Suction

#16 SAE O-Ring

N/A

3300

1-1/4” Suction

#20 SAE O-Ring

N/A

Hydraulic Pump Port B to

3020/3040 3/4” - 3000 PSI

#16 SAE O-Ring

#10 SAE O-Ring

Motor Port A

3060

1” - 3600 PSI

1” SAE Split Flange

#12 SAE O-Ring

Hydraulic Pump Port B to

3090

1” - 4500 PSI

1” SAE Split Flange

1” SAE Split Flange

Motor Port B

3150

1”- 4500 PSI

1” SAE Split Flange

1” SAE Split Flange

3300

1” - 6000 PSI

1-1/4” SAE Split Flange 1” SAE Split Flange

Hydraulic Pump Port A to

3020/3040 3/4” - 3000 PSI

#16 SAE O-Ring

#10 SAE O-Ring

Motor Port B

3060

1” - 3600 PSI

1” SAE Split Flange

#12 SAE O-Ring

Hydraulic Pump Port A to

3090

1” - 4500 PSI

1” SAE Split Flange

1” SAE Split Flange

Motor Port A

3150

1” - 4500 PSI

1” SAE Split Flange

1” SAE Split Flange

3300

1” - 6000 PSI

1-1/4” SAE Split Flange 1” SAE Split Flange

3020/3040 3/4” - 1500 PSI

#12 SAE O-Ring

#8 SAE O-Ring

Hydraulic Motor Case Drain

3060

3/4” - 1500 PSI

#12 SAE O-Ring

#10 SAE O-Ring

to Hydraulic Pump Case Drain 3090

3/4” - 1500 PSI

#12 SAE O-Ring

#10 SAE O-Ring

3150

3/4” - 1500 PSI

#12 SAE O-Ring

#10 SAE O-Ring

3300

3/4” - 1500 PSI

#12 SAE O-Ring

#10 SAE O-Ring

3020/3040 3/4” - 1500 PSI

#12 SAE O-Ring

N/A

Hydraulic Pump Case Drain

3060

3/4” - 1500 PSI

#12 SAE O-Ring

N/A

to Hydraulic Cooler

3090

3/4” - 1500 PSI

#12 SAE O-Ring

N/A

3150

3/4” - 1500 PSI

#12 SAE O-Ring

N/A

3300

3/4” - 1500 PSI

#12 SAE O-Ring

N/A

Notes:

SAE O-Ring Ports are per SAE J514
SAE Split Flange Ports are to SAE J518 code 62
Hydraulic pump inlet hose to conform to SAE 100R4

Hydraulic Fittings and Hose Specifications

Summary of Contents for AccuMax 3040

Page 1: ...roughly inspected and tested In order to maintain the high quality of your unit and to keep it in a ready condition it is important to follow the instructions on care and operation Proper use and good...

Page 2: ...ION 18 9 ELECTRICAL EQUIPMENT INSTALLATION 23 10 MAKE SURE EVERYTHING IS WORKING RIGHT 30 11 CALIBRATION AND SETUP 33 12 OPERATION INSTRUCTIONS 36 13 MAINTENANCE 43 14 TROUBLESHOOTING 44 15 SPECIFICAT...

Page 3: ...only pipe hose and fittings from the foam pump outlet to the injection point which are rated at or above 400 PSI 28 BAR minimum rating at which the water pump system operates Use only pipe hose and f...

Page 4: ...tions CAUTION The cables shipped with each FoamPro system are tested at the factory with that unit Improper handling and forcing connections can damage these cables which could result in other system...

Page 5: ...e of the desired proportion of foam concentrate at all times based on water flow rate independent of any variations in fire pump intake or discharge pressures As water flow increases or decreases the...

Page 6: ...6 Hydraulic Pump and ground Hydraulic Control Driver Figure 2 1 FoamPro 3000 System Layout Installation and Operation Manual...

Page 7: ...NFPA 1906 draft required check valve prevents water back flowing into foam system 10 RFI EMI Suppression Beads 11 FoamPro Paddelwheel Flowmeter The flowmeter is a required component The size is speci...

Page 8: ...the discharge piping The FoamPro MultiFlo Interface allows a total of four flowmeters to be used The display will show the discharge flow on the selected flowmeter Part Number 2527 0140 System Placar...

Page 9: ...ange size and shaft configuration Other shaft configurations are available The shaft rotation of the pump is clockwise when looking at the pump shaft or counterclockwise when facing the rear of the pu...

Page 10: ...te Suction Lines Fittings and hoses from the foam tank to the inlet of the foam pump must be supplied Use the minimum inside diameter or larger clear suction hose shown below for the corresponding sys...

Page 11: ...hat may be available Drain lines must be provided from all water and foam solution piping components to prevent freezing in cold weather Multiple drain systems that allow individual drain lines to con...

Page 12: ...gral foam tank s make sure provisions are made for installation of the low tank level sensor as well as foam suction connections and tank drainage Determine a location on the operator panel of the app...

Page 13: ...nts and the main water system Do not hard plumb the system Be sure the hydraulic hoses and the foam concentrate hoses can be properly routed to the inlets and outlets on the foam pump Foam concentrate...

Page 14: ...Code 62 Port A 1 Split Flange Boss SAE J518 Code 62 Port A 12 SAE O ring Port 2 NPT Suction Port 2 NPT Discharge Port 531 20 9 226 8 9 51 2 0 200 7 9 251 9 9 169 6 6 789 31 1 308 12 1 142 5 6 203 8 0...

Page 15: ...r Thd Case Outlet Port B 1 Split Flange Boss SAE J518 Code 62 Port A 1 Split Flange Boss SAE J518 Code 62 1 SAE Split Flange Port A 1 SAE Split Flange Port B 3 NPT Inlet 3 NPT Outlet 476 18 7 601 23 7...

Page 16: ...ngs with SAE JIC 37 flare swivel and SAE Split Flange port connections CAUTION To ensure the integrity of fitting connections in the hydraulic system use only SAE JIC 37 flare SAE O Ring Boss or SAE S...

Page 17: ...is supplied with these systems CAUTION Ensure all hydraulic hoses and components are clean and free of debris CAUTION Ensure hydraulic fluid is clean and free from contamination when filling and chan...

Page 18: ...lation The following diagram Figure 8 1 provides recommended guidelines for the installation of the system components that handle water foam concentrate and foam solution Note that additional options...

Page 19: ...stem are sized properly for most applications See Section 4 for further information The appropriate strainer is to be installed on the inlet side of the foam pump The hose from the foam tank should ha...

Page 20: ...is common to all discharges which require foam capability This position may be before or after the main water flowmeter but not within the straight run distance required for the flowmeter as previous...

Page 21: ...s or other means of isolation are not to be used as a substitute for proper flushing of apparatus lines after usage Figure 8 6 Recommended Midship Pump Installation Flushing System Depending on the co...

Page 22: ...oam pump inlet The pickup should be positioned between the foam tank shut off valve and the foam inlet line strainer A tee the same size as the tank to pump line may be placed in the suction line with...

Page 23: ...ook up the main power cables until all connections are made to each of the electrical components The last connection should be the power cable to foam pump motor base assemblies Warning The electric m...

Page 24: ...ds on the back of the front plate see Section 15 for a mounting template The display requires 5 inches 127 mm minimum clearance from the back of the operator panel to clear wires and connectors Make s...

Page 25: ...ctions must be made inside the pipe nipple a 3 8 NPT pipe nipple with a 3 8 by 1 8 NPT reducer at the lower end is the minimum size recommended When the foam tank low level sensor is suspended for the...

Page 26: ...ire protected with a wire loom Install a 5 amp fuse to the power line to the valve driver Always connect the ground lead from the valve driver to the chassis or to a good solid ground location Never c...

Page 27: ...h the AMP connector attaches to the flowmeter This foam flowmeter will also need a separate power and ground line that will connect with the 2 pin Weatherpak connector as shown in Fig 9 10 The wiring...

Page 28: ...pressure in the manifold is maintained at 218 PSI 15 BAR If foam is drained from the manifold the foam pump will run to ensure the pressure is maintained The foam pump will maintain the set pressure i...

Page 29: ...out 1 4 of the way open 4 Turn the Override switch from OFF to MANUAL 5 The foam pump will deliver foam to the override manifold and injection line The foam pump will deliver enough foam to maintain a...

Page 30: ...ured radio antennas power lines and equipment are away from control cables and flowmeter cables All components Digital Display Control Module Flowmeter Tee and Pump Base are properly grounded using fl...

Page 31: ...on The hydraulic motor driven foam pump should begin to operate and foam concentrate should begin flowing into the container If concentrate is not being pumped first check to make sure the hydraulic m...

Page 32: ...ll the pump with concentrate 3 Replace the pipe plug CAUTION When pouring foam concentrate directly into the foam pump the inlet strainer is bypassed Make sure contaminates are not poured into the pum...

Page 33: ...enter the setup and diagnostic modes See Figure 11 1 Enter the setup mode by pressing the internal button on the left side of the controller Enter the diagnostics mode by pressing the internal button...

Page 34: ...th an accurate flow measuring device Determine the water flow normally expected from that flowmeter discharge outlet For example actually establish a flow of 150 gpm 568 L min of water through a nozzl...

Page 35: ...tem Reset During calibration procedures it may be necessary to return the system to the original factory default settings if errors are made and the system locks up To return to the factory default va...

Page 36: ...foam injection at the specified concentrate injection rate The system responds to variations in water flow by increasing or decreasing the speed of the foam pump When the FOAM button is again pressed...

Page 37: ...ed to keep a record of how many units of water and or foam is used per incident Foam Percentage When the concentrate percentage is selected the up and down buttons will respectively increase or decrea...

Page 38: ...OW labels will illuminate and the lamp below the ON label will flash The rate of water flow will be displayed in units per minute 3 Press the SELECT button white upper right button until the LED lamp...

Page 39: ...on press the FOAM button the foam injection will stop Press the SELECT button white upper right button until the LED lamp below FLOW is illuminated The water flow rate through the foam discharge s wil...

Page 40: ...UP or DOWN to select the desired simulated water flow rate The FoamPro will respond and immediately begin operating at the new flow rate CAUTION Be certain that an outlet is provided for the foam conc...

Page 41: ...utlet tube NOTE FoamPro must be in Simulated Flow Mode 5 Press both rate adjustment buttons at the same time The symbol will leave the display and the FoamPro will operate automatically from the flow...

Page 42: ...discharge and shut down apparatus 6 Open foam concentrate tank shut off valve 7 Perform required maintenance checks on the FoamPro AccuMax SP Priming the Foam Pump When Foam Tank Has Run Dry In some...

Page 43: ...ydraulic oil reservoir with proper hydraulic oil as noted in Section 4 NOTE Other types of hydraulic fluids are too viscous for proper load sense compensator operation Do not mix hydraulic fluid types...

Page 44: ...lue shown reflects the level of the liquid foam concentrate in the tank Lo Con indicates that the tank is empty Hi Con indicates a satisfactory level for operation This is a test of the low tank level...

Page 45: ...ctuates fittings for leaks by pressurizing hose with water Make sure thread sealant has been used on all fittings Suction line is blocked collapsed Remove suction line and inspect it for a loose liner...

Page 46: ...Replace control cable Digital display has been damaged Replace the digital display Poor ground on system or controller Make sure screws are tight and a good ground is maintained System is powered up...

Page 47: ...precise proportioning Check flowmeter calibration Foam pump capacity below rating Inlet strainer obstructed Remove and clean inlet strainer Inlet plumbing obstructed Check all piping valves and hoses...

Page 48: ...values selected are out Perform system reset as of range of system or setup memory described in Calibration Section is full and recalibrate Cannot enter Calibration Mode Truck hydraulics and hydraulic...

Page 49: ...7 29 5 111 7 47 4 179 4 PTO Pump RPM for Max Performance RPM 1381 1336 1579 1200 1485 1387 PTO HP HP kW at Max Performance 20 5 21 0 29 5 22 0 53 3 39 8 70 5 52 8 85 3 63 6 185 1 138 1 PTO Torque at M...

Page 50: ...g Motor Port B 3060 1 3600 PSI 1 SAE Split Flange 12 SAE O Ring Hydraulic Pump Port A to 3090 1 4500 PSI 1 SAE Split Flange 1 SAE Split Flange Motor Port A 3150 1 4500 PSI 1 SAE Split Flange 1 SAE Spl...

Page 51: ...51 RFI Kit for Controller 3430 0353 RFI Kit for Flowmeter 8 6032 0012 Instruction Placard Ref Part No Description 9 3320 0046 Check Valve 3020 3040 3320 0041 Check Valve 3060 3320 0047 Check Valve 309...

Page 52: ...2740 0014 Coupling Pump 3020 3040 1 2740 0008 Coupling Pump 3060 1 2740 0012 Coupling Pump 3090 3150 3300 1 3 2729 0007 Insert Coupling 1 4 2740 0013 Coupling Motor 3020 3040 1 2740 0009 Coupling Moto...

Page 53: ...s for Display Control Module Cutout Dimensions for Instruction System System Spec Placards Display Requires 3 7 8 98 mm Diameter Hole 68 7 88 9 88 9 108 4 25 108 4 25 4 25 4 25 2 81 20 DIA THRU 3 50 1...

Page 54: ...16 mm 20 750 8 900 2660 0034 3 8 NPT 4 Pipe 5 1 2 140 mm 4 7 8 124 mm 30 1150 12 1380 2660 0034B 3 11 BSP 4 Pipe 5 1 2 140 mm 4 7 8 124 mm 30 1150 12 1380 2660 0035 4 8 NPT 5 Pipe 5 1 2 140 mm 5 3 8 1...

Page 55: ...et Root Side Fit 4 00 Dia 38 1 59 Port A Pressure Port 6 SAE ORP 10 26 Port B Pressure Port 6 SAE ORP 1 32 5 66 8 34 Case Drain Port 12 SAE ORP Charge Inlet Port 16 SAE ORP 56 Dia 5 75 6 87 6 85 4 73...

Page 56: ...1 1 16 12 SAE O ring Port Port B Outlet 1 SAE Split Flange Port Charge Pump Inlet 1 5 16 12 SAE O ring Port Port A Return 1 SAE Split Flange Port Flat Root Side Fit 12 24 Pitch 14 Tooth SAE Splined Sh...

Page 57: ...m Gauge Port M2 9 16 18 SAE Ring Port 1 SAE Split Flange Port Outlet SAE O ring Port 1 5 16 12 Charge Pump Inlet 1 SAE Split Flange Port Return Electric Control Valve SAE C Mounting Flange Rotation CW...

Page 58: ...9 16 18 SAE O Ring Port Port B 1 1 4 6000 PSI Split Flange Port Code 62 Port A 1 1 4 6000 PSI Split Flange Port Code 62 Charge Port 1 5 8 12 SAE O Ring Port Case Drain 1 5 16 12 SAE O Ring Port Note...

Page 59: ...59 Installation and Operation Manual AccuMax SP Notes...

Page 60: ...ated THERE ARE NO OTHER EXPRESS WARRANTIES ANY IMPLIED WARRANTIES INCLUDING IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO ONE YEAR FROM THE DATE...

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