FRC Turbofoam TFC100 User Manual Download Page 4

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TFC100 Rev180215

List of Figures

Figure 1. General System Layout ...................................................................................................................................11

Figure 2. Controls and Indicators ....................................................................................................................................14

Figure L1. TFC Control Module Mounting Dimensions ................................................................................................41

Figure L2. Foam Pump Assembly Mounting Dimensions..............................................................................................43

Figure L3. Foam Pump Assembly Dimensions ..............................................................................................................44

Figure L4. Manual ABF Selector Mounting Dimensions ...............................................................................................45

Figure L5. Electric ABF Selector Mounting Dimensions ...............................................................................................46

Figure L6. TFC100/200 Plumbing Single Tank System .................................................................................................49

Figure L7. TFC100/200/300 Plumbing Single Tank System w/Electric Flush Valve ....................................................50

Figure L8. TFC200 Plumbing Two Tank System w/Manual ABF Selector ...................................................................51

Figure L9. TFC400 Plumbing Two Tank System w/Electric ABF Selector ...................................................................52

Figure L10. Discharge Check Valve Assembly Dimensions ..........................................................................................53

Figure L11. Flow Sensor Location Guidelines ...............................................................................................................54

Figure L12. Saddle Clamp Installation ...........................................................................................................................55

Figure L13. Weldment Installation .................................................................................................................................56

Figure L14. Summing Box Mounting Dimensions.........................................................................................................57

Figure W1. System Cables ..............................................................................................................................................59

Figure W2. Control Module Wiring ................................................................................................................................61

Figure W3. Foam Pump Control Wiring .........................................................................................................................62

Figure W4. Electric Flush Valve Wiring ........................................................................................................................63

Figure W5. Manual ABF Selector Wiring .....................................................................................................................63

Figure W6. Electric ABF Selector Wiring .....................................................................................................................64

Figure W7. Flow Sensor Wiring ....................................................................................................................................65

Figure W8. Summing Box Wiring .................................................................................................................................65

Figure W9. Remote Switch Wiring ................................................................................................................................66

Figure W10. Optional Remote Control Module Wiring ................................................................................................67

Figure P1. TurboFoam Control Modules ........................................................................................................................69

Figure P2. TurboFoam Single Tank System Cables .......................................................................................................71

Figure P3. TurboFoam Two Tank System Cables ...........................................................................................................73

Figure P4. 1.6, 2.1 and 2.6 GPM Foam Pump Assembly ...............................................................................................75

Figure P5. 3.5, 5.0, 6.2, and 6.5 GPM Foam Pump Assembly .......................................................................................77

Figure P6. Electric ABF Selector and Electric Flush Valve ............................................................................................79

Figure P7. Manual ABF Selector ....................................................................................................................................81

Figure P8. Miscellaneous Plumbing Components ..........................................................................................................83

List of Tables

Table 1. TurboFoam Standard Components and Options .................................................................................................6

Table 2. Foam Pump Assembly Dimensions ....................................................................................................................7

Table 3. Direct Injection Foam Proportioning System Specifications

..............................................................................8

Table 4. Detailed Information .........................................................................................................................................16

Table 5. Error Codes .......................................................................................................................................................19

Table 6. Fault Warning Codes .........................................................................................................................................20

Table 7. Program Functions P100 Codes Quick Reference ............................................................................................24

Table 8. Calibration Failure Messages ............................................................................................................................30

Table 9. Error Codes and Fault Warnings Troubleshooting ............................................................................................39

Table 10. Foam Pump DC Supply Power Input Wire Size .............................................................................................62

Summary of Contents for Turbofoam TFC100

Page 1: ... 26 Southern Blvd Nesconset NY 11767 TEL 631 724 8888 FAX 631 360 9727 TOLL FREE 1 800 645 0074 Document Number XE TFC1PM R0A TFC400 TFC300 TFC200 TFC100 DIRECT INJECTION FOAM PROPORTIONING SYSTEM WITH ELECTRIC FOAM CONCENTRATE PUMP MODELS TFC100 TFC200 TFC300 TFC400 ...

Page 2: ...100 Codes 23 Set Date and Time 25 Set Discharge Flow Sensor ID Names TFC200 300 400 26 Set Increment Value 27 Restore Programmed Functions 28 CALIBRATION MAINTENANCE AND TROUBLESHOOTING 29 CALIBRATION 30 Calibrate Discharge Flow Sensor Password Code 1111 31 Calibrate Foam Concentrate Pump Password Code 1112 32 MAINTENANCE RECOMMENDATIONS 34 After Operations 34 Routine Checks 34 Required Periodic M...

Page 3: ...Install Flow Sensor s 54 Install Summing Box Multiple Flow Sensors Only 57 WIRING 58 WIRING 59 Cables 59 Control Module 61 Foam Pump Control 62 Electric Flush Valve TFC300 TFC100 200 Option 63 Manual ABF Selector TFC200 Only 63 Electric ABF Selector TFC400 Only 64 Flow Sensor 65 Summing Box Multiple Flow Sensors Only 65 Remote ON OFF Switch or Flush Switch Option 66 Optional Remote Control Module ...

Page 4: ...trol Wiring 62 Figure W4 Electric Flush Valve Wiring 63 Figure W5 Manual ABF Selector Wiring 63 Figure W6 Electric ABF Selector Wiring 64 Figure W7 Flow Sensor Wiring 65 Figure W8 Summing Box Wiring 65 Figure W9 Remote Switch Wiring 66 Figure W10 Optional Remote Control Module Wiring 67 Figure P1 TurboFoam Control Modules 69 Figure P2 TurboFoam Single Tank System Cables 71 Figure P3 TurboFoam Two ...

Page 5: ...s The maximum injection rate ranges from the smallest pump at 1 6 GPM to the largest pump at 6 5 GPM The pumps are triplex plunger types that have die cast bodies forged brass heads solid ceramic plungers and use Viton seals Each pump is powered by an electric motor that is designed for use in wet environments The motors range in size from 1 3 to 1 horsepower The foam pump and motor along with a p...

Page 6: ... S S S S S S S S Electric Flush Valve O O O O O O O O O O O O O O S S S S S S S Summing Box O O O O O O O O O O O O O O O O O O O O Discharge Check ValveAssy O O O O O O O O O O O O O O O O O O O O O O O O O O O Discharge Check Valve Assy with Flow Sensor Mount O O O O O O O O O O O O O O O O O O O O O O O O O O O Remote ON OFF Switch O O O O O O O O O O O O O O O O O O O O O O O O O O O Tank Floa...

Page 7: ... oz for 1 6 2 1 and 2 6 GPM pump 15 oz for 3 5 5 0 6 2 6 5 GPM pump Electric Flush Valve TFC100 200 300 Only Supply Power 12 24 VDC from Foam Pump Control Box Supply Current 3 5 Amps at 12 VDC Maximum 1 75 at 24 Volts Electric ABF Selector Valve TFC400 Only Supply Power 12 24 VDC Supply Current 3 5 Amps at 12 VDC Maximum 1 75 at 24 Volts Flow Sensors Type Paddlewheel Sensor Material Acetal Delrin ...

Page 8: ... TFC165 TFC265 TFC365 TFC465 SPECIFICATION PUMP SIZE GPM LPM 1 6 6 06 2 1 7 95 2 6 9 84 3 5 13 25 5 0 18 93 6 2 23 47 6 5 24 61 MOTOR SIZE HORSE POWER 1 3 1 1 2 3 4 1 1 1 DC VOLTAGE 12 or 24 12 or 24 12 or 24 12 or 24 12 or 24 12 24 MAX CURRENT AMPS 36 or 18 90 or 45 50 or 25 68 or 34 78 or 39 90 45 CLASS A FOAM RANGE 0 1 to 1 0 0 1 1600 6057 2100 7950 2600 9842 3500 13249 5000 18927 6200 23470 65...

Page 9: ...ting base include an electric motor and pump a pump control a relief valve and a calibration bypass valve Manual ABF Selector Option The manualABF selector is an option with the TFC200 models It allows the operator to select Class A foam Class B foam or Flushing operations by rotating the ABF selector handle The selector is connected between the foam tanks and the foam pump assembly intake and has...

Page 10: ...le sensors are installed they are mounted in each discharge Systems with multiple discharge flow sensors require a summing box Each discharge flow sensor is connected to the summing box which in turn is connected with the FRC datalink to the control module Multiple mounting options are available for the flow sensor s Summing Box Note The summing box is required when there is two or more foam disch...

Page 11: ...or Waterway Check Valve Shutoff Valve Check Valve Strainer Calibration Bypass Valve Foam Pump Control Pump Motor Pump Discharge Check Valve Assembly with Sensor Mount Strainer B Foam Concentrate Tank A Foam Concentrate Tank Check Valve TFC100 or TFC200 Single Tank System TFC100 or TFC200 Single Tank System w Electric Flush Option TFC200 Two Tank System w Manual ABF Selector Option Control Module F...

Page 12: ...tor Pump Discharge Check Valve Assembly with Sensor Mount Strainer B Foam Concentrate Tank A Foam Concentrate Tank Check Valve TFC300 Single Tank System w Electric Flush Valve TFC400 Two Tank System w Electric ABF Selector Notes The water flush line may not be necessary for all single tank systems The water flush line can be used for priming the foam concentrate pump if needed It is important that...

Page 13: ... 4 segment display FOAM TOTAL FOAM FLOW and TOTAL WATER FOAM EMPTY LED TFC100 Only The input from a TankVision Pro or foam tank level indicator drives this LED FOAM Display The display shows the selected percent of foam concentrate in the discharge foam solution A B Button TFC400 Only Used to select the A foam or B foam tank The FOAM A or FOAM B LED goes on for tank selected When this button is pr...

Page 14: ...ttons MODE Button Message Display FOAM Display FLOW Display ON OFF Button and LED PRESET Button Buttons MENU Button A B Button FLUSH Button and LED FOAM B LED FOAM A LED FOAM EMPTY LED Mode LEDs TFC200 300 400 TFC200 does not include the FLUSH button or the A B button TFC300 does not include the A B button ...

Page 15: ... Password for Program Access 1 Press the and buttons and scroll to code P109 2 Press the PRESET button Result The message display shows the time with the hours flashing 3 Press the and buttons to change hours 4 Press the PRESET button Result The message display shows time with the minutes flashing 5 Press the and buttons to change the minutes 6 Press the PRESET button Result The message display sh...

Page 16: ...flush valve Detailed Information TFC100 The TFC100 does not have a message display Information is shown in a 4 digit display and on four LEDs Operations are the same as TFC200 300 400 substitute MODE button for MENU button in procedure steps The TFC100 control module four LEDs indicate the display mode for the 4 digit display FOAM TOTAL FOAM FLOW and TOTAL WATER Press and release the MODE button t...

Page 17: ...s The system will hold a maximum of 20 recorded incidents Once the maximum number of 20 is reached the system will drop the oldest incident in order to make room for a new incident Flow Display will show r and current record number The following lines will cycle about 3 seconds for each screen per incident Line 1 Displays foam type Line 2 Line 1 Line 2 Press PRESET Display will change to Line 1 Di...

Page 18: ...rmation is not received by the control module It allows the operator to manually enter a discharge flow rate for system operations In the manual mode the foam percent value can be changed by pressing the MENU button and using the and buttons Ensure water continuously flows through the discharge during Manual Mode operation The manual mode is activated when discharge water is flowing but no flow is...

Page 19: ...Motor not turning control module to off mode E09 DRIVER LIMIT Hardware power limit over current protection E10 POWER LIMITED Motor does not come up to requested speed RPM low E11 NO RPM DETECTED No RPM detected from the pump motor E12 NO ABF DETECTED Auto flush communications failed no auto flush mode E13 FOAM A VALVE Foam A valve failed to open E14 FOAM B VALVE Foam B valve failed to open E15 FLU...

Page 20: ...switched off when the tank empty goes active Preset Settings The preset button allows the operator to go to a pre programmed percent setting during operations The preset value shows in the display Note The preset setting selected when the PRESET button is pressed can only be set to a program enabled value Refer to Programming Section for information on Set Increment Value codes P118 and P119 To ac...

Page 21: ...igit Press the and buttons to change the digit 4 Repeat step 3 and enter the password code Result When a correct password code is entered the FLOW display flashes the program P code and the message display shows the name of the program or a description of the program code 5 Press the and buttons to scroll through the codes 6 Use the PRESET button to enter the programming mode and select specific v...

Page 22: ...OEM Dealer Password Restricted Contact FRC Provides access to system programming P300 codes Password Restricted OEM Dealer Programs Formoreinformation refertotheOEM DealerP300Codeslistedinthe separate OEMprogramming manual ...

Page 23: ...n switching between A and B foam tanks TFC200 400 It can be programed to PRESET the programmed preset value or LAST VAL the last used value set by the operator 5 Code P117 With this code is set to AUTO when power is applied the system the control module is active and the system is in auto mode operational 6 Codes P118 and P119 These codes are used to set the increment steps when the and buttons ar...

Page 24: ...es for Discharge Flow Sensors w Summing Box N A SET FLOW Refer to Set Discharge Flow Sensor ID Names P111 3 Pump Device Data PUMP INFO P112 3 Summing Box 1 Device Data N A SUMBOX 1 INFO P113 3 Summing Box 2 Device Data N A SUMBOX 2 INFO P114 3 Summing Box 3 Device Data N A SUMBOX 3 INFO P115 3 Auto Flush Device Data N A AUTOFLSH INFO P116 4 Proportioning Rate at Power Up or when Switching Between ...

Page 25: ...ear flashes 7 Press the and buttons to change the year 8 Press and hold the MENU button for five 5 seconds to save Result The message display shows DONE Set Time Code P109 Enter password code 1221 Refer to Enter Password for Program Access 1 Press the and buttons and scroll to code P109 2 Press the PRESET button Result The message display shows the time with the hours flashing 3 Press the and butt...

Page 26: ...d scroll to code P110 2 Press the PRESET button Result The display shows Sb 1 1 1 1 flashes indicating summing box 1 input 1 message display shows the ID name 3 Press the PRESET button or press the INC or DEC button to scroll inputs Result The message display flashes the ID name 4 Press the and buttons to scroll the ID names 5 Press the PRESET button to choose a name Result The message display fla...

Page 27: ...crements that can be used to control foam percentage concentration The software requires that at least one value is set to YES The preset and last used value can only be one of the set values The software checks that the current preset and the last used value matches a set value If not the software changes it to the lowest value set at yes The TFC100 does not have a message display Information is ...

Page 28: ...not have a message display Information is only shown in the 4 digit display procedures are the same Substitute MODE for MENU Programming Restore The system restore function is used when the control module or foam pump control module is replaced Each contains a copy of all program settings and system calibration in memory When one of these components are replaced the program settings and the system...

Page 29: ...ATION MAINTENANCE AND TROUBLESHOOTING Refer to the Error Codes and Fault Warnings Troubleshooting Table Check dc voltage to the control module 12 pin connector pins 1 and 2 Remove and replace the control module Does the control module enter the manual mode Is an error code or fault warning shown in the display Supply system with power Does OFF show in the FLOW display Does the system pass the Oper...

Page 30: ... control module foam pump control module have memory that contains a copy of the system calibration This redundancy allows for either component to be replaced without re programming or re calibrating the system If one is replaced the system calibration can be restored from the memory of the other Refer to Programming Restore Programmed Functions Section TankVision Pro Indicator TankVision Pro indi...

Page 31: ...display to match the flow rate shown on the reference meter Press the and buttons to change the digit Press the PRESET button to move the curser to the next digit 5 Press and hold the MENU button for five 5 seconds to save and exit Result The message display shows UPDATING SYSTEM then CAL DONE Multi Sensor System w Summing Box 1 Enter password code 1111 Refer to Password Protected Programs Section...

Page 32: ...mps foam concentrate The concentrate is routed through the calibration bypass valve where it is collected to be measured The control module message display shows the calculated foam concentrate the system has pumped The amount collected is measured and compared with amount shown in the display Adjustments to the values shown are made if necessary Note Dual foam systems have two calibration program...

Page 33: ...bration This along with the water flow setting determines the amount of concentrate to be pumped Press the and buttons to change the digit Press the PRESET button to move the curser to the next digit 6 Press the MENU button Result The foam pump start to pump concentrate The message display shows SECS and elapsed pumping time 7 Press the MENU button to stop pumping Result The foam pump stops The me...

Page 34: ...connections Look for looseness wear or deterioration of materials corrosion and damage Clean the Paddlewheel Flow Sensor Use plain water to clean the paddlewheel sensor Do not use solvents Clean the Strainers Clean the foam concentrate and flush water strainers Required Periodic Maintenance Change Foam Pump Oil Change the foam pump oil after first 50 hours of use then every 500 hours The program s...

Page 35: ...em re starts auto mode 8 Close the manual flush valve if installed 9 Close discharge 10 Reset all valves as required Clean Paddlewheel Flow Sensors The paddlewheel type flow sensors need to spin freely to generate flow rate data Should the sensor get clogged and stuck it can be removed for cleaning Remove the retainer cap which holds the paddlewheel sensor in the housing and slide the sensor out U...

Page 36: ... from rubbing pinching or damage from heat and other equipment Plumbing Checks Foam tank check valves are secure and installed for correct direction of flow Electric ABF selector hose and fittings are tight input and output hoses are correct If installed Manual ABF selector hose and fittings are tight input and output hoses are correct If installed Flush valve hose connections and fittings are tig...

Page 37: ...e message display changes to show USE FOR FLOW the FLOW display flashes TFC100 flashes the ON OFF LED the FLOW LED is on TFC400 only Press the A B button to select the tank with fluid 2 Press the and buttons to set the flow rate Results The FLOW display shows the operator entered flow rate the message display shows moving arrows to indicate the foam concentrate pump RPM and the foam pump pumps flu...

Page 38: ...ion in the manual to verify that all Operator P100 Codes and the OEM Dealer P300 Codes are set as required Perform a flush operation to prime the pump Re check plumbing and manual flush valve For low flow re check plumbing Ensure that power to pump motor meets requirements For low flow re check plumbing Ensure that power to pump motor meets requirements Does the control module enter the manual mod...

Page 39: ...Foam Pump Foam Pump Motor Foam Pump Control E11 No RPM detected from the pump motor RPM Sensor Foam Pump Motor Foam Pump Control E12 Auto flush communications failed no auto flush mode Datalink cable between Control Module and Electric ABF Selector Control Control Module Electric ABF Selector Control E13 A valve failed to open Electric ABF Selector Control A Foam Valve E14 B valve failed to open E...

Page 40: ...eresearch com 26 Southern Blvd Nesconset NY 11767 TEL 631 724 8888 FAX 631 360 9727 TOLL FREE 1 800 645 0074 DIRECT INJECTION FOAM PROPORTIONING SYSTEM WITH ELECTRIC FOAM CONCENTRATE PUMP MODELS TFC100 TFC200 TFC300 TFC400 INSTALLATION A C B INSTALLATION ...

Page 41: ... module panel cutout and mounting screw holes Make sure there is clearance behind the panel before cutting holes Refer to figure for layout and dimensions 2 Cut a hole in the panel check model and dimension and drill four holes for 10 32 mounting screws 3 Place the control module in position and secure with four screws 4 Connect the cable s to the module Refer to Wiring Section Note The standard s...

Page 42: ...o ground when the tank is empty Refer to Wiring Section Install Remote ON OFF Switch or Flush Switch The remote on off switch and flush switch are wired to the control module Two connections are available one for each switch and one for each indicator light The switch mounting hole diameter is 1 3 8 and it uses two 10 32 screws to secure the 2 1 2 by 2 1 2 label plate to the panel Refer to Wiring ...

Page 43: ...nnections and to open the calibration valve before drilling holes The larger electric motors require 1 2 clearance at the rear for fan intake Refer to figure for dimensions 2 Mount with 3 8 hardware 3 Connect the cables to the pump control module Rout the wiring under the motor to provide a drip loop to help prevent water from getting to the terminals Refer to Wiring Section Figure L2 Foam Pump As...

Page 44: ...am Pump Assembly must be mounted in an upright position Not all mounting holes are easily accessible on every foam pump assembly Remove and replace the pump oil reservoir red shipping plug with the yellow vented cap dip stick Check the oil level use the sight glass or dip stick A strainer must be installed along the pump input line refer to Plumbing The calibration bypass valve needs to be accessi...

Page 45: ...r layout and dimensions 2 Drill one 1 3 8 center hole and four through holes for the 3 8 bolts 3 Place the front plate in position run bolts through front plate panel spacers and valve plate Secure with nuts 4 Connect the handle assembly 5 Connect the foam tanks flush water and foam pump plumbing Refer to Plumbing Connections 6 Connect the cable to the module Refer to Wiring Section The front plat...

Page 46: ... and mark location for four 4 mounting holes Make sure there is clearance for plumbing connections before drilling holes Refer to figure for layout and dimensions 2 Mount with 5 16 hardware 3 Connect the foam tanks flush water and foam pump plumbing Refer to Plumbing Connections 4 Connect the valve cables and system cable Refer to Wiring Section Note The assembly must be mounted so the manifold di...

Page 47: ... may vary TFC100 200 Single Tank TFC100 200 300 Single Tank with Electric Flush Valve TFC200 Two Tank with Manual ABF Selector Valve TFC400 Two Tank with Electric ABF Selector Valve Refer to the plumbing diagrams for detailed information Foam Tank and Concentrate Pump Intake Low Pressure Lines Clear Suction Hose 23 584mm Hg Vacuum 50 PSI 3 bar Connect the tanks to the selector valves and or the co...

Page 48: ...hould be as short as possible All lines and fittings down stream of the flush valve are required to be for high pressure This would include the hose between the tank check valve and the tank line tee fitting Pay attention to flow direction of check valves and strainers The tank to valve to foam pump lines should be plumbed as if they were gravity feed lines ie The tank needs to be higher then the ...

Page 49: ...eds 10 minimum of hose for vibration absorption Standard All Pumps 1 2 Female Standard All Pumps 3 4 Male Pressure Hose 500 PSI 34 bar Standard All Pumps 1 2 13mm ID Clear Suction Hose 23 584mm Hg Vacuum 50 PSI 3 bar 1 6 2 1 and 2 6 GPM Pumps 3 4 19mm ID 3 5 5 0 6 2 6 5 GPM Pumps 1 25 4mm ID 1 6 2 1 and 2 6 GPM Pumps 3 4 Female 3 5 5 0 6 2 6 5 GPM Pumps 1 Female 1 6 2 1 and 2 6 GPM Pumps 3 4 Male ...

Page 50: ...84mm Hg Vacuum 50 PSI 3 bar 1 6 2 1 2 6 GPM Pumps 3 4 19mm ID 3 5 5 0 6 2 6 5 GPM Pumps 1 25 4mm ID Pressure Hose 500 PSI 34 bar Standard All Pumps 1 2 13mm ID Pressure Hose 500 PSI 34 bar Standard All Pumps 1 2 13mm ID Tee and fittings provided by installer Clear Suction Pressure Hose 23 584mm Hg Vacuum 500 PSI 34 bar 1 6 2 1 2 6 GPM Pumps 3 4 19mm ID 3 5 5 0 6 2 6 5 GPM Pumps 1 25 4mm ID Standar...

Page 51: ...umps 3 4 Male Clear Suction Hose 23 584mm Hg Vacuum 50 PSI 3 bar 1 6 2 6 GPM Pumps 3 4 19mm ID 3 5 5 0 6 2 6 5 GPM Pumps 1 25 4mm ID Pressure Hose 500 PSI 34 bar Standard All Pumps 1 2 13mm ID Pressure Hose 500 PSI 34 bar Standard All Pumps 1 2 13mm ID Clear Suction Pressure Hose 23 584mm Hg Vacuum 500 PSI 34 bar 1 6 2 6 GPM Pumps 3 4 19mm ID 3 5 5 0 6 2 6 5 GPM Pumps 1 25 4mm ID Fitting Sizes Fit...

Page 52: ...dard All Pumps 1 2 Male Standard All Pumps 3 4 Male Clear Suction Hose 23 584mm Hg Vacuum 50 PSI 3 bar Standard All Pumps 1 25 4mm ID Pressure Hose 500 PSI 34 bar Standard All Pumps 1 2 13mm ID Pressure Hose 500 PSI 34 bar Standard All Pumps 1 2 13mm ID Clear Suction Pressure Hose 23 584mm Hg Vacuum 500 PSI 34 bar Standard All Pumps 1 25 4mm ID Standard All Pumps 1 2 Female Hose Sizes Hoses Provid...

Page 53: ...pring Loaded Check Valve 1 5 2 0 2 5 3 0 4 0 Victaulic Coupling 1 5 2 0 2 5 3 0 4 0 Height A 4 13 16 5 5 16 5 13 16 6 7 16 7 7 16 Height B 5 1 16 5 9 16 6 1 16 6 11 16 7 11 16 Discharge Check Valve Assembly Discharge Check Valve Assembly w Flow Sensor Note Allow a minimum of 3 inches clearance above the flow sensor for removal installation A B 6 9 1 2 Spring Loaded Check Valve Spring Loaded Check ...

Page 54: ...area in the plumbing that tends to increase water stream turbulence a valve increase in pipe diameter etc it is critical that steps are taken to stabilize the flow When a pipe is reduced in diameter the water stream tends to be squeezed into a more uniform flow This can help stabilize flow when there is not sufficient straight pipe up stream Figure L11 Flow Sensor Location Guidelines The preferred...

Page 55: ... Note The retainer cap is hand tightened There is an inside lip that stops the cap from turning when it makes contact with the alignment tab This provides the correct pressure to make the seal at the O ring Make sure the flow sensor engages the alignment tab and does not rotate 6 Install retainer cap and hand tighten 7 Connect flow sensor cable Refer to Wiring Section Figure L12 Saddle Clamp Insta...

Page 56: ... the sensor housing does not rotate causing dimension A to change 6 Insert flow sensor into sensor housing Align flat spot on sensor rim with alignment tab and make sure O ring is in groove Note The retainer cap is hand tightened There is an inside lip that stops the cap from turning when it makes contact with the alignment tab This provides the correct pressure to make the seal at the O ring Make...

Page 57: ...ut and dimensions 2 Drill four holes clearance or tapped for 8 mounting screws 3 Place box in position and secure with four screws 4 Connect the cable s to the module Refer to Wiring Section LED Indicators Green LED Flashing when there is no flow input Steady on when flow input is detected Red LED Flashing indicates that there is a datalink problem Steady on when there is a conflict with the box a...

Page 58: ...N www fireresearch com 26 Southern Blvd Nesconset NY 11767 TEL 631 724 8888 FAX 631 360 9727 TOLL FREE 1 800 645 0074 DIRECT INJECTION FOAM PROPORTIONING SYSTEM WITH ELECTRIC FOAM CONCENTRATE PUMP MODELS TFC100 TFC200 TFC300 TFC400 WIRING WIRING ...

Page 59: ...ded wire sizes DC Volts TFC100 200 300 Single Tank with Electric Flush Valve FRC Datalink Y Cable FRC Datalink Y Cable RPM Sensor Cable Foam Pump Control Cable Foam Pump Control Cable Control Module Control Module TankVision Pro Display TankVision Pro Display Pump Motor Cables Motor DC Supply Power Input Wires are supplied by the installer Refer to Foam Pump Control Wiring for recommended wire siz...

Page 60: ... by the installer Refer to Foam Pump Control Wiring for recommended wire sizes Flow Sensor Cable Flow Sensor Cable DC Volts DC Volts DC Volts DC Volts DC Volts TFC200 Two Tank with Manual ABF Selector TFC400 Two Tank with Electric ABF Selector Electric ABF Selector Cable Manual ABF Selector Cable Tank Float Switch If tank float switches are used the FRC datalink y cables for the TankVision Pro are...

Page 61: ...Spare Control Module The control module communicates with other components of the system via the 2 wire FRC datalink The datalink is also used to communicate with other FRC products such as the TankVision Pro Pin 10 is Tank Empty Sensor active low for TFC100 Only 6 Pin Connector Notes The Tank Empty inputs are used with tank float switches The Select A B Sensor input is used when the TFC200 is ins...

Page 62: ...e motor Pump Size in GPM LPM 1 6 6 06 2 1 7 95 2 6 9 84 3 5 13 25 5 0 18 93 6 2 23 47 6 5 24 61 Motor Horse Power 1 3 1 1 2 3 4 1 1 1 DC Voltage 12 24 12 24 12 24 12 24 12 24 12 24 Maximum Current AMPS 36 18 90 45 50 25 68 34 78 39 90 45 Wire Size AWG Recommended for up to a 10 foot run 6 6 2 4 4 6 2 4 2 4 2 4 Table 10 Foam Pump DC Supply Power Input Wire Size 12 Pin Connector Cable Pin Wire Descr...

Page 63: ... 3 Yellow Close Limit Switch 4 Blue Open Limit Switch 5 Brown Limit Switch Return 6 Green Open Valve Pins 2 and 5 are jumped together in the cable harness Connect the cable to the foam pump control 12 Pin Connector pins 5 9 Closed for Flush Manual ABF Selector Micro Switches GND Closed for B Foam Both Opened for A Foam Control Module 12 Pin Connector Pin 6 Flush Switch Control Module 6 Pin Connect...

Page 64: ...t Switch Return 6 Green Open Valve Water Flush Valve There is a position indicator and manual adjustor located on the side of each valve A Tank Valve B Tank Valve Status LEDs Note The assembly must be mounted so the manifold discharge is not above the foam input connections Pin 1 A Tank Pin 1 Water Flush Pin 1 Pin 1 B Tank Electric ABF Selector TFC400 Only TFC400 system requires that the electric ...

Page 65: ...le boxes are interconnected using the FRC datalink Power is provided by the control model CONNECTOR J1 CONNECTOR J2 Summing Box Top View Pin 1 Four conductor cable from control module Note When more than one box is installed the address of each box must be set Refer to Installation Section Flow Sensor Systems with a single discharge flow sensor The sensor cable is connected directly to the control...

Page 66: ...FF Switch and Indicator Option The remote switch and indicator mirrors the control module ON OFF button and LED on the control module Flush Switch and Indicator Option The flush switch is provided with the electric flush valve option for TFC100 200 models The flush switch also provides prime capabilities if needed for the concentrate pump Code P313 set to yes Red Green White Black 2 Butt Crimps Co...

Page 67: ...Remote Control Module Wiring NOTE For either the TFC100 or TFC200 300 400 Connect pin 7 and pin 8 to the primary control module Remote Control Module TFC200 300 400 Rear View DC Power FRC Datalink Cable FRC Datalink Cable Remote Control Module TFC100 DC Power USB Access Port USB Access Port NOTE If opened USB access port plug must be tightened to a torque of 8 10 in lbs Exceeding this torque value...

Page 68: ...m 26 Southern Blvd Nesconset NY 11767 TEL 631 724 8888 FAX 631 360 9727 TOLL FREE 1 800 645 0074 DIRECT INJECTION FOAM PROPORTIONING SYSTEM WITH ELECTRIC FOAM CONCENTRATE PUMP MODELS TFC100 TFC200 TFC300 TFC400 ILLUSTRATED PARTS BREAKDOWN ILLUSTRATED PARTS BREAKDOWN ...

Page 69: ...TFC100 Rev180215 69 CONTROL MODULES Figure P1 TurboFoam Control Modules 6 7 5 4 3 2 1 ...

Page 70: ...ACARD PLUMB 2 FOAM 1 XE TFC2PLSPC A16A XE TFC2PLSPC A21A XE TFC2PLSPC A26A XE TFC2PLSPC A35A XE TFC2PLSPC A50A XE TFC2PLSPC A62A XE TFC2PLSPC A65A ACCY TFC PLACARD SPECS 1 6 GPM ACCY TFC PLACARD SPECS 2 1 GPM ACCY TFC PLACARD SPECS 2 6 GPM ACCY TFC PLACARD SPECS 3 5 GPM ACCY TFC PLACARD SPECS 5 0 GPM ACCY TFC PLACARD SPECS 6 2 GPM ACCY TFC PLACARD SPECS 6 5 GPM 1 6 XE TF100RSW A0A XE TF100RSW A1A ...

Page 71: ...100 200 300 Single Tank with Electric Flush Valve Control Module Control Module TankVision Pro Display TankVision Pro Display TFC100 200 Single Tank 5 4 3 3 2 2 1 1 6 6 Motor DC Supply Power Wires are Supplied by the Installer Motor DC Supply Power Wires are Supplied by the Installer DC Aux Out 3 A DC Aux Out 3 A ...

Page 72: ...Crimp 1 5 XE TF10EEXTF C30A CABLE TFC PUMP PWR DATA FLSH 30 FT 12 Pin Deutsch Plug 4 Pin Deutsch Receptacle 2 Pin Deutsch Receptacle 6 Pin Deutsch Receptacle w 10 ft cable 1 Wire wButt Crimp 1 6 6A XE XX6PDP A0A XE TF2TNKEXT C0A ACCY 6 PIN DEUTSCH SEALING PLUG CABLE TURBOFOAM TANK EMP SENS 8 IN 6 Pin Deutsch Plug 3 Wires wButt Crimps 1 TurboFoam Single Tank System Cables Notes Cables 2 and 3 are o...

Page 73: ...d by the Installer Figure P3 TurboFoam Two Tank System Cables TurboFoam Two Tank System Cables Control Module Control Module TankVision Pro Displays TankVision Pro Displays TFC200 Two Tank with Manual ABF Selector TFC400 Two Tank with Electric ABF Selector 6 7 4 4 3 3 2 2 2 2 1 1 2 3 3 6A DC Aux Out 3 A DC Aux Out 3 A ...

Page 74: ... CABLE TURBOFOAM PWR SENSOR DATA 15 FT CABLE TURBOFOAM PWR SENSOR DATA 20 FT CABLE TURBOFOAM PWR SENSOR DATA 30 FT 12 Pin Deutsch Plug 3 Pin Flow Sensor Plug 4 Pin Deutsch Plug 2 Wires wButt Crimps 1 2 XE XXDLY4 C1A CABLE DATALINK WYE 4P CONN 4 Pin Deutsch Receptacle 4 Pin Deutsch Plug 4 Pin Deutsch Plug 3 XE XXDLWLEXT C10A CABLE DLINK TankVision Pro 4PDR BLK PIN 10FT 4 Pin Deutsch Receptacle 2 So...

Page 75: ...TFC100 Rev180215 75 FOAM PUMP ASSEMBLY 1 6 2 1 and 2 6 GPM Foam Pump Assembly Figure P4 1 6 2 1 and 2 6 GPM Foam Pump Assembly 9 7 8 6 5 3 4 2 1 15 18 24 22 19 10 12 21 14 13 17 27 20 11 16 28 25 26 23 ...

Page 76: ...ESSION BRASS 90 DEG ELBOW 1 13 ZH3816HC114SS ZHW38LSS SCREW HEX CAP 3 8 16 X 1 1 4 S S WASHER LOCK 3 8 S S 4 4 14 XE TF10ERPM S0A SENSOR RPM FOR ELECTRIC FOAM PUMP 1 15 XM TFA800 ZH832SS38CSS ZH832AT38SS HALL MOTOR MOUNT SCREW SOCKET SET CUP 8 32 X 3 8 S S SCREW SOCKET CAP 8 32 X 3 8 S S 18 8 1 1 2 16 XM TFA805 BELL HOUSING 1 17 ZHM8AT25SS SCREW METRIC SOCKET CAP M8 X 25MM S S 4 18 XE TF10EMAG A0A...

Page 77: ...TFC100 Rev180215 77 Figure P5 3 5 5 0 6 2 and 6 5 GPM Foam Pump Assembly 3 5 5 0 6 2 and 6 5 GPM Foam Pump Assembly 28 29 31 30 32 9 7 8 6 5 3 4 2 1 15 18 19 25 23 20 10 12 22 14 13 17 21 11 16 26 27 24 ...

Page 78: ... COUPLING HUB SERIES L090 24MM 1 14 XM TFA804 PUMP STANDOFF 1 15 ZH3816HC114SS ZHW38LSS SCREW HEX CAP 3 8 16 X 1 1 4 S S WASHER LOCK 3 8 S S 4 4 16 XE TF10ERPM S0A SENSOR RPM FOR ELECTRIC FOAM PUMP 1 17 XM TFA800 ZH832SS38CSS ZH832AT38SS HALL MOTOR MOUNT SCREW SOCKET SET CUP 8 32 X 3 8 S S SCREW SOCKET CAP 8 32 X 3 8 S S 18 8 1 1 2 18 XM TFA805 BELL HOUSING 1 19 ZHM8AT90SS SCREW METRIC SOCKET CAP ...

Page 79: ...TFC100 Rev180215 79 ELECTRIC ABF SELECTOR AND ELECTRIC FLUSH VALVE Figure P6 Electric ABF Selector and Electric Flush Valve 4 3 2 1 A ...

Page 80: ...0 D1A ASSY TURBOFOAM ELEC VALVE 1 0 IN 12V ASSY TURBOFOAM ELEC VALVE 1 0 IN 24V 2 2 XE TF101EV05 D0A XE TF101EV05 D1A ASSY TURBOFOAM ELEC VALVE 0 5 IN 12V ASSY TURBOFOAM ELEC VALVE 0 5 IN 24V 1 3 XM TF600 S12 MANIFOLD FOR A B ELEC 1 4 XE TF101VDRV A3A XE TF101VDRV3 A3A ASSY ABF VALVE CNTL BOX ASSY ABF VALVE CNTL BOX CHINESE 1 A XE TF101 D1A XE TF101 D11A ACCY TF ELEC FLUSH VALVE 12V ACCY TF ELEC F...

Page 81: ...TFC100 Rev180215 81 MANUAL ABF SELECTOR Figure P7 Manual ABF Selector 9 8 6 5 4 3 2 1 7 ...

Page 82: ... 3 4 S S 1 1 3 XM TF502 HUB 1 4 ZH3816HPB112SS TFA 0600 TFA 1120 SCREW SOCKET HEX BUTTON 3 8 16 X 1 1 2 WASHER LOCK 3 8 S S NUT HEX 3 8 16 S S 4 4 4 5 XM TF510 02 C4 Z TF510 MACHPRT PLATE AB MANUAL YELLOW TURBO FOAM A B NAME PLATE 5 X 5 1 1 6 XM TF503 L STANDOFF 4 7 XM TF505 MAG MOUNT 1 8 ZSN 59135 010 ZH440PP14SS SENSOR MAGNETIC SPST NO FLANGE SCREW PHIL PAN 4 40 X 1 4 S S 2 4 9 XM TF 78 125 ZPG ...

Page 83: ...TFC100 Rev180215 83 MISCELLANEOUS PLUMBING COMPONENTS Figure P8 Miscellaneous Plumbing Components 9 7 8 6 5 4 3 2 1 12 11 10 11 2 2 8 A 12 B ...

Page 84: ... 4 0IN 9 XM TF155 S01 XM TF205 S01 XM TF255 S01 XM TF305 S01 XM TF405 S01 1 1 2 INJECTOR NO PADDLE 2 INJECTOR NO PADDLE 2 1 2 INJECTOR NO PADDLE 3 INJECTOR NO PADDLE 4 INJECTOR NO PADDLE 1 B XE TF2FMANFL M15A XE TF2FMANFL M20A XE TF2FMANFL M25A XE TF2FMANFL M30A XE TF2FMANFL M40A ASSY TF FOAM MANIFOLD W FLOW 1 5 IN ASSY TF FOAM MANIFOLD W FLOW 2 0 IN ASSY TF FOAM MANIFOLD W FLOW 2 5 IN ASSY TF FOA...

Page 85: ...TFC100 Rev180215 85 NOTES ...

Page 86: ...TFC100 Rev180215 86 NOTES ...

Page 87: ...TFC100 Rev180215 87 NOTES ...

Page 88: ...TFC100 Rev180215 88 ...

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