Godiva Prima PC1 Installation And Operation Manual Download Page 2

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©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the
right to amend specifications without notice or obligation.

AMENDMENT RECORD

Model: PC1_ or PC2_ with SmartCAFS50/100 Control and FoamLogix 2.1A, 3.3, 5.0 Systems

Mod

Date

Page/s

Amendment

New Issue
No.

September

2011

All

New Issue

Issue 1,

April 2012

11, 25-26 Gearbox oil capacity

– now 1.2 litres

Issue 2.

April 2012

CAFS mixing manifold

– greasing ball valve

Issue 3

September

2012

8, 38

Information on clutch sparking, normal condition

Issue 4

Feb 2014

Items 11,12,13, can be located on top row

Issue 5

Feb 2014

Add details on new Interlock for compressor clutch
control

Issue 6

Feb 2014

9, 34

Insert minimum pump idle speed information

Issue 6

Summary of Contents for Prima PC1

Page 1: ...rtCAFS100 Control with FoamLogix 2 1A 3 3 or 5 0 Systems Installation and Operation Manual Godiva Ltd A Unit of IDEX Corporation Charles St Warwick CV34 5LR England 44 0 1926 623600 44 0 1926 623666 623689 www godiva co uk godiva idexcorp com GP 293 Issue 5 February 2014 ...

Page 2: ...ew Issue No 1 September 2011 All New Issue Issue 1 2 April 2012 11 25 26 Gearbox oil capacity now 1 2 litres Issue 2 3 April 2012 42 CAFS mixing manifold greasing ball valve Issue 3 4 September 2012 8 38 Information on clutch sparking normal condition Issue 4 5 Feb 2014 16 Items 11 12 13 can be located on top row Issue 5 6 Feb 2014 14 Add details on new Interlock for compressor clutch control Issu...

Page 3: ...BLE 10 FOAM PROPORTIONING SYSTEM 3 3 CLASS A AND B FOAM COMPATIBLE 10 FOAM PROPORTIONING SYSTEM 5 0 CLASS A AND B FOAM COMPATIBLE 10 DIRECTION OF ROTATION GEARBOX INPUT FLANGE 10 LUBRICANTS 11 COMPRESSOR TEMPEST 3 11 COMPRESSOR TEMPEST 6 11 PUMP GEARBOX 11 PUMP BEARING HOUSING 11 RECOMMENDED FOAM AGENTS 11 MAJOR COMPONENTS AND CONTROLS PRIMA SMARTCAFS50 SYSTEM USING TEMPEST 3 COMPRESSOR 12 MAJOR C...

Page 4: ... TENSION METER 29 ELECTRICAL CONNECTIONS 29 FOAM TANK LOW LEVEL SENSOR 31 ADDITIONAL INSTALLATION POINTS 31 VEHICLE DESIGN CONSIDERATIONS 32 INSTALLATION AND INITIAL SET UP FOAMLOGIX 2 1A 33 INSTALLATION AND INITIAL SET UP FOAMLOGIX 3 3 5 0 33 OPERATION 34 FOAMLOGIX CONTROL PANEL FUNCTIONS 34 COMMISSIONING START UP PROCEDURE 34 CALIBRATION OF FOAMLOGIX 35 SMART SWITCH OPERATION 35 WET AND DRY BUTT...

Page 5: ...R 45 COMPRESSOR OIL SEPARATOR ELEMENT 45 COMPRESSOR DRIVE BELT 45 MAINTENANCE OPERATIONS FOAMLOGIX 45 STRAINER FOAM 45 CALIBRATION 45 FAULT FINDING 46 PUMP OPERATING FAULTS 1 LOSS OF SUCTION 46 PUMP OPERATING FAULTS 2 EXCESSIVE PUMP NOISE 47 GENERAL OPERATING FAULTS CAFS 48 AIR INJECTION FAULTS 49 PARTS LISTS 51 RECOMMENDED SPARES KIT FOR BI ANNUAL SERVICE 52 INSTALLATION DRAWINGS PC2_ WITH SMARTC...

Page 6: ...lease see the separate manuals supplied IMPORTANT NOTES Please read this manual before operating the pump CRITICAL The pump Bearing Housing Gearbox and Compressor are NOT filled with oil ex works Refer to section Installation and Set up Oil Filling Points before operation Correct lubrication and maintenance is essential if satisfactory performance is to be maintained Do not run the pump without wa...

Page 7: ...nel Maintenance The user must maintain the equipment in an operational condition as per regulation 5 in the Provision and Use of Work Equipment Regulations 1998 Risk Assessment It is the duty of the pump installer to make a method statement and risk assessment of their operations when installing the pump please contact Godiva Ltd if assistance is required Transportation and Storage The pump is sup...

Page 8: ... observe some sparking occurring around the clutch assembly This small amount of sparking is quite normal and nothing to be concerned about The lower the engagement speed the less sparking will occur ENVIRONMENTAL PROTECTION It is prohibited to pour engine oil and other contaminants onto the ground down sewers drains or into water courses Dispose of lubricants through authorised waste disposal con...

Page 9: ...oling water flow rate 10 15 Litres Min at 7 0 Bar Compressor 100scfm rating Model Tempest 6 Maximum Operating Speed 8000 rpm Nominal speed of operation 5350 rpm Nominal power draw 28 kW Direction of rotation Anti clockwise viewed on pulley Volume output 2830 l min Oil Capacity 4 5 litres Oil Capacity with filter change 6 0 litres Operational pressure range 4 10 bar Cooling System Type Oil Water Sh...

Page 10: ...acturer Hale Products Inc Model FoamLogix 3 3 Type Electronic foam proportioning system Operating voltage 12 and 24 volt systems available Fuse rating 12V 24V 60 40 amp Current draw Operating 12V 24V 30 24 amp Current draw Max 12V 24V 60 30amp Wire size 12V 24V Minimum 8 5mm2 Max Foam Agent Flow rate 12 Litres Minute Foam Proportioning System 5 0 Class A and B Foam Compatible Manufacturer Hale Pro...

Page 11: ...Housing Capacity 1 0 litres approximately Recommended 10W 40 or 15W 40 Multi grade engine oil RECOMMENDED FOAM AGENTS Hale FoamLogix Models 2 1A 3 3 or 5 0 can be used with the foam concentrates specified on the Hale Foam Proportioning System Foam Concentrate Compatibility List provided at the rear of this manual Hale Bulletin 650 Rev 32 7 17 07 The foam concentrates in the list have been tested b...

Page 12: ...oling heat exchanger Note Hale FoamLogix 2 1A or 3 3 foam pump is mounted in a separate location to the main pump PTO driven Gearbox with compressor drive via an electromagnetic clutch Integral gearbox oil cooler Rotary twin screw compressor with integral air receiver separator and lubrication system Mounting platform incorporates forklift points anti vibration mountings and fluid drain points See...

Page 13: ...ng heat exchanger Note Hale FoamLogix 3 3 or 5 0 foam pump is mounted in a separate location to the main pump PTO driven Gearbox with compressor drive via an electromagnetic clutch Integral gearbox oil cooler Rotary twin screw compressor with integral air receiver separator and lubrication system Mounting platform incorporates forklift points anti vibration mountings and fluid drain points See pag...

Page 14: ...fitted with a solid state device complete with pressure switch indicating LEDs and compressor hours run meter This unit is primarily of interest to service technicians for CAFS fault diagnosis The device is located on the left side of the pump LEDs for water pressure switch and air pressure switch will be alight when circuit is closed no pressure LED replicates the Air Enabled Indicator on the mai...

Page 15: ...ix 2 1A Foam Pump Component Group Showing parts supplied loose with standard pump FoamLogix 2 1A Pump 24V shown Quickstart guides 3 off with full manual on CD Foam supply tube and fixings Extension lead for low foam level sensor Foam pump Harness fitted to Distribrution box motor controller driver Instruction plate and fixings Covers for power leads ...

Page 16: ...can be MST Manual Single Tank Select one foam tank or flush option not shown MDT Manual Dual Tank Select one of two foam tanks or flush option shown ADT Air Dual Tank Air operated valve select one of two foam tanks or flush option not shown 2 High pressure switches only supplied loose when blue water panel is not fitted Multi pin connector for engine control warning light functions Low foam level ...

Page 17: ... gauge Tank A FoamLogix 2 1A 9 Foam tank level gauge Tank B FoamLogix 3 3 5 0 10 Foam On indicator 11 Air Enabled indicator 12 Solution or CAFS selector switch 13 Top Compressor temperature warning light Bottom Air inject on 14 FoamLogix control unit 15 SmartCAFS control unit 16 Compressor pressure 17 High pressure discharge valve LH open close PC2_ model only 18 Low High pressure hose reel select...

Page 18: ...ced unless water is flowing through the unit Compressed air cannot be introduced unless foam concentrate is flowing 2 Slugging unmixed air and water in the discharge line is prevented Air cannot be injected in the absence of foam and water 3 Air injection when the foam tank is empty is prevented Foam tank low level switches are provided and MUST be fitted Compressor There are two levels of compres...

Page 19: ...ow measurement and injection manifold All three elements combine to provide accurate foam proportioning From the control panel the operator can initiate the system adjust the foam ratio monitor real time water flow rate and record total water and foam concentrate usage The FoamLogix system is powered up when the PTO is engaged Foam concentrate is only injected when the RED ON control button is ope...

Page 20: ...T 3 COMPRESSOR AND FOAMLOGIX 2 1A PRIMASMARTCAFS100 USING TEMPEST 6 COMPRESSOR AND FOAMLOGIX 3 3 OR 5 0 The following connection points should be considered when installing the PC1_ or PC2_ assembly into a vehicle Lifting Points Prima SmartCAFS50 and Prima SmartCAFS100 Secure handling of the unit for installation and maintenance is vital Use only the lifting points provided on the unit Fork Lift p...

Page 21: ...unted CAFS Discharge ports see installation drawing for dimensions Hose reel outlet Low pressure delivery hose outlet for CAFS Electrical interface connector Inlet from foam tank Ø 13mm ID pipe airtight connection required Note foam tank must be located above FoamLogix unit FoamLogix filter By pass valve and connection point To foam injection point on manifold Tubing suitable for 22 5 bar pressure...

Page 22: ...ical interface connector CAFS Discharge ports see installation drawing for dimensions Inlet from foam tank Models 3 3 or 5 0 19mm 3 4inch NPT Note foam tank must be located above FoamLogix unit Also refer to installation notes in FoamLogix manual To foam injection point on manifold 13mm 1 2inch NPT Tubing suitable for 22 5 bar pressure By pass valve and connection point on reverse of valve Low pre...

Page 23: ...de of the pump viewed from the suction tube end Note Oil should only be drained from the gearbox compressor bearing housing when it has cooled to a reasonable temperature to avoid accidental or inadvertent injury through contact with hot oil The oil can be slightly warm to assist in flowing from the unit Gearbox heat exchanger coolant and the CAFS manifold drain points are located at the lower rig...

Page 24: ...for the compressor and pump bearing housing are located at the left side of the pump viewed from suction tube Oil level dipstick gearbox not fitted on later models Oil level dipstick pump bearing housing Compressor oil filling point Note the plug has a grooved thread to allow for a controlled release of internal pressure For oil type and capacity refer to Recommended Lubricants Compressor oil filt...

Page 25: ...g the pump The oil filling points for the compressor and pump bearing housing are located at the left side of the pump viewed from suction tube Oil level dipstick pump bearing housing Compressor oil filling point Note the plug has a grooved thread to allow for a controlled release of internal pressure For oil type and capacity refer to Recommended Lubricants Compressor oil filter Compressor oil le...

Page 26: ...earbox in Down Position Gearbox in Horizontal Position Left or Right of pump The oil filling point is on the side of the casing LH gearbox shown and is symmetrically opposite for RH gearbox The oil level check point is lower on the side Oil capacity and type as Down position detail Oil filling point For oil type and capacity refer to Recommended Lubricants Oil level check Direction of rotation Clo...

Page 27: ... are located at the front of the mounting platform see page 23 Fill the gearbox until the oil flows from the oil level check point This is the only accurate method of checking that the correct amount of oil has been added to the gearbox as it allows for different sizes of gear ratios Approximate capacity is 1 2 litres Foam Injection Point Foam injection point connect tubing suitable for 22 5 bar p...

Page 28: ...ter If an optical belt tension meter is available e g the Clavis Optical Belt Tensioner then the belt can be tightened correctly by measuring the vibration frequency Follow these steps 1 Tighten the belt so it is reasonably taut 2 Operate the optical belt tensioner according to the manufacturer s instructions 3 The device will register a frequency reading when the belt has been tapped It is recomm...

Page 29: ...If an optical belt tension meter is available e g the Clavis Optical Belt Tensioner then the belt can be tightened correctly by measuring the vibration frequency Follow these steps 1 Tighten the belt so it is reasonably taut 2 Operate the optical belt tensioner according to the manufacturer s instructions 3 The device will register a frequency reading when the belt has been tapped It is recommende...

Page 30: ...it part number 60764 The connections used will vary according to the pump specification Power to the system should be such that the minimum required system voltage is maintained continuously throughout operation System voltage dips of any duration may cause the interlocking circuitry to inadvertently disengage the system compressor Having a direct as possible wiring path to the battery supply may ...

Page 31: ...itional Installation Points Foam Tank to Foam Pump The foam feed line must not at any point be lower that the foam pump have a 13mm bore and be fitted with an isolating tap for maintenance purposes The isolating tap should be located as close to the tank as possible A flushing point should be fitted close to the isolating tap to ensure that the maximum length of hose line can be flushed out The fl...

Page 32: ...compatible with those foam concentrates used Brass or 300 series stainless steel are suitable The areas containing the PC2_ or PC1_ components must be adequately shielded from the ingress of road spray debris and chassis and vehicle power train lubricant Exposure to dirt water and grease will have a detrimental effect on the working life of the drive belt and electronics Full access to the bearing...

Page 33: ...gix Model 2 1A Description Installation and Operation manual part number 029 0020 74 0 supplied separately INSTALLATION AND INITIAL SET UP FOAMLOGIX 3 3 5 0 For foam pump installation please refer to the FoamLogix Model 3 3 5 0 Description Installation and Operation manual part number 029 0021 68 0 supplied separately For further information on the MDTII Manual Tank Selector please see the separat...

Page 34: ... prevent unnecessary operation of the pump priming system maintain an idle speed of 900 1000rpm FoamLogix Control Panel Functions Commissioning Start Up Procedure 1 Check that all the necessary connections have been correctly made 2 Ensure that the compressor pump gearbox and bearing housing are filled with the correct oil type and quantity 3 Run the water pump at 2 3 bar with compressor engaged 4...

Page 35: ...B and repeat the priming procedure for that tank 11 When prime is achieved deselect simulated flow by pressing both up down at the same time 12 Return the bypass valve to the inject position The unit is now ready to run Calibration of FoamLogix The FoamLogix package as supplied is factory tested and calibrated and should not require further attention However should any calibration issue arise plea...

Page 36: ...f the Compressor is engaged pressing either the WET or DRY button will start the FoamLogix and send the Air Ratio Control valve to its respective pre set Note the Air Ratio Control Valve can only be controlled when in CAFS mode Configure the WET and DRY presets The operator can set the WET and DRY presets for desired CAFS consistency Run the water pump and select CAFS open the branch nozzles Confi...

Page 37: ...compressor will send the Air Ratio Control valve to the extreme WET position Operating the PC2_ or PC1_ from a Vehicle Water Source 1 Delivery Hose Connect a suitable delivery hose and branch to the CAFS discharge 38 to 45mm diameter lay flat hose is suitable for delivering compressed air foam 2 Nozzles If a single discharge is used For both Prima SmartCAFS50 and 100 a 25 to 38mm smooth bore nozzl...

Page 38: ...ump is drained run the pump at idle until a vacuum of approximately 0 5 bar is achieved and then slowly open the tank to pump valve Tank Selection FoamLogix 3 3 5 0 only For specific detail please refer to the FoamLogix Model 3 3 5 0 Description Installation and Operation manual Connection Harness Dual Tank Selector Three positions Tank A for Class A foam concentrate Tank B for Class B foam concen...

Page 39: ... PRESSURE TO PUMP SUCTION WHEN OPERATING CAFS 1 Set the water pump to idle 2 Select CAFS by pressing the top of the CAFS selector switch marked CAFS If pump speed is 2400rpm or compressor pressure is 1 0 bar the Air Enabled indicator 11 will flash and the compressor will not engage Reduce speed and or allow Compressor pressure to relieve so that Compressor will engage then the light will be on per...

Page 40: ...oil temperature reach 105o C a control panel warning indicator will illuminate The compressor can sustain 105º C for short periods without damage 2 If the compressor oil temperature reaches 110º C the electromagnetic drive clutch will automatically disengage This will stop the compressed air supply and only foam water solution will be discharged The compressor will automatically re engage when the...

Page 41: ... 0 Check that foam pipe connections are tight See FoamLogix manual Operate the system in bypass to move the concentrate and prevent gelling if concentrate is left in the system without use for three months See FoamLogix manual EVERY 12 MONTHS PC1_ PC2_ Change the pump bearing housing oil Maintenance Manual Compressor Change the air filter Maintenance Manual Change the oil and oil filter Maintenanc...

Page 42: ...ove procedures may need to be more frequent The best practise is to flush the system after each use MAINTENANCE OPERATIONS PC2 Strainer High Pressure 1 Remove strainer Cap assembly 2 With care remove debris from the strainer by washing 3 The Dowty seal may be reused if free from damage or cuts 4 Re fit the strainer assembly and secure Gauges Do not clean the glass surfaces of the gauges with abras...

Page 43: ...plied by Tetrosyl Ltd Bury Lancashire BL9 6RE www tetrosyl com Ball Valves without remote grease lines On early models of the CAFS mixing manifold the grease is inserted through one or two grease nipples The first nipple is located on the side of the valve facing the rear of the pump If a second nipple is fitted it will be on the side of the manifold facing the compressor Connect a suitable grease...

Page 44: ... vacuum Apply a water pressure of 3 5 7 0 bar to the pump and check for leaks The area causing the leak should be visible and can be dismantled and rectified Check each primer drain hole for water leakage If leakage is found replace the primer seals and O rings as described in the Maintenance Manual Procedures If the pump will not achieve 0 81 bar vacuum and will not hold what it does achieve ther...

Page 45: ...mpressor Drive Belt Check and adjust belt tension as required in accordance with section Installation and Initial Set Up Change the drive belt at the recommended interval or if damage occurs To remove the belt slacken the tensioner bolt and position the tensioner to allow belt removal Fit the new belt ensuring that belt alignment and position on the pulleys is uniform See section Installation and ...

Page 46: ... shooting please refer to the relevant FoamLogix 2 1A or 3 3 5 0 Description Installation and Operation manual PUMP OPERATING FAULTS 1 LOSS OF SUCTION Do a Pressure Test Do a Vacuum Test No Yes No Yes Loss of Suction All suction connectios air tight Tighten all connections Suction lift too deep Reduce suction lift Trace leaks rectify and retest pump Suction is restored Air leaks in system system ...

Page 47: ...bligation PUMP OPERATING FAULTS 2 EXCESSIVE PUMP NOISE No Pump makes excessive rattling noise during operation Probably due to pump cavitation Decrease pump speed Has noise disappeared Yes Continue using the pump Investigate further possible mechanical problem Reduce suction lift Has noise disappeared No Yes Continue using the pump ...

Page 48: ...G FAULTS CAFS No Foam Solution FoamLogix not operating Switch on FoamLogix No concentrate in foam tank Foam pump not primed Refill the foam tank Prime the foam pump Compressor Overheating No water supply or restricted flow Check oil cooler pipework for obstructions Depleted foam supply Refill foam tank Foam set too low Increase foam setting Chatter Slugflow ...

Page 49: ...ion AIR INJECTION FAULTS No No Air Injection Is FoamLogix turned on Turn on FoamLogix and set the required Is CAFS turned on Turn on CAFS Is compressor running Check drive belt Is Foam Low Level Switch Activated Disconnect Low Level Switch to verify if faulty Fill foam tank Continued on next page No No No Yes Check power supply to clutch ...

Page 50: ...n FoamLogix Manual Replace the solenoid valve Replace interlock control module Yes No No No Continued from previous page Is solenoid seeing 12 24V and common at connection Press test button on solenoid valve Yes Does flow register when discharging liquid No Yes Does air injection occur Check the air valve pipework No Test flow sensor and wiring connections Does flow register when discharging liqui...

Page 51: ...lustrated parts list Please refer to Godiva Ltd Compressor illustrated parts list Please refer to Gardener Denver Tamrotor Tempest manual Foamlogix illustrated parts list Please refer to FoamLogix Model 2 1A Description Installation and Operation manual part number 029 0020 74 0 FoamLogix Model 3 3 5 0 Description Installation and Operation manual part number 029 0020 68 0 ...

Page 52: ...328 4 Filter Oil TAM 89675429 2 Filter Air TAM 81166609 1 Belt Drive 60578 03 AR Tensioner Belt drive 65447 PC2_ PC1_ AR Strainer Hi Pressure 60051 Not PC1_ series 4 Washer Dowty Oil drain UFP 2303 08 2 Washer Dowty High Pressure strainer UFP 2303 15 Common part 2 Washer Dowty NRV Inlet UFP 2303 10 Common part Notes Under normal conditions those items marked AR As Required are not deemed to be dis...

Page 53: ...development We therefore reserve the right to amend specifications without notice or obligation INSTALLATION DRAWINGS PC2_ WITH SMARTCAFS50 FOR OPTIONS OF DRIVE FLANGE VALVES SUCTION TUBE CONTROL PANEL CONTACT GODIVA Sheet 1 of 3 based on PC2_3010 ...

Page 54: ...54 Godiva Ltd Our policy is one of continuous development We therefore reserve the right to amend specifications without notice or obligation Sheet 2 of 3 based on PC2_3010 ...

Page 55: ...55 Godiva Ltd Our policy is one of continuous development We therefore reserve the right to amend specifications without notice or obligation Sheet 3 of 3 based on PC2_3010 ...

Page 56: ...L 458 0 490 0 280 0 125 0 305 0 125 0 305 0 122 0 279 0 572 0 361 0 111 0 837 0 40 0 40 0 TYP 80 0 186 0 FOAM C PANEL 1018 0 130 0 min height for filter removal D C B A F E G H 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 10 9 8 7 D C B A F E G H MATERIAL SPEC FINISH TITLE PART NUMBER ISSUE CHANGE NOTE NO DATE DRAWN CHECKED DATE PATTERN DIE No SCALE UNLESS OTHERWISE SPECIFIED ALL DIMENSIONS IN MILLIMETRES SUR...

Page 57: ...FIXING 515 0 CHASSIS FIXING D C B A F E G H 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 10 9 8 7 D C B A F E G H MATERIAL SPEC FINISH TITLE PART NUMBER ISSUE CHANGE NOTE NO DATE DRAWN CHECKED DATE PATTERN DIE No SCALE UNLESS OTHERWISE SPECIFIED ALL DIMENSIONS IN MILLIMETRES SURFACE TEXTURE IN µM Ra GENERAL TOLERAN CE 0 25 ANGULAR TOLERANCE 0 25 Deg HOLES WITHIN 0 13 OF TRUE POSIT ION FRAISE SHARP CORNERS 0 2...

Page 58: ...0 169 5 HP OUTLETS 186 0 HP OUTLETS DETAIL A DRIVE FLANGE 1 1 D C B A F E G H 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 10 9 8 7 D C B A F E G H MATERIAL SPEC FINISH TITLE PART NUMBER ISSUE CHANGE NOTE NO DATE DRAWN CHECKED DATE PATTERN DIE No SCALE UNLESS OTHERWISE SPECIFIED ALL DIMENSIONS IN MILLIMETRES SURFACE TEXTURE IN µM Ra GENERAL TOLERANCE 0 25 ANGULAR TOLERANCE 0 25 Deg HOLES WITHIN 0 13 OF TRUE P...

Page 59: ...59 Godiva Ltd Our policy is one of continuous development We therefore reserve the right to amend specifications without notice or obligation FOAM CONCENTRATE COMPATIBILITY LIST ...

Page 60: ...60 Godiva Ltd Our policy is one of continuous development We therefore reserve the right to amend specifications without notice or obligation ...

Page 61: ...61 Godiva Ltd Our policy is one of continuous development We therefore reserve the right to amend specifications without notice or obligation ...

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