HALE SmartFOAM 1.7AHP Description, Installation And Operation Manual Download Page 23

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Page

SmartFOAM

CONTROLLER AND BASE PUMP

SmartFOAM controller

610-00039

SmartFOAM Base Unit, Foam
Pump/Motor Assembly

2.1A

– 12V: 115498

2.1A

– 24V: 115499

1.7AHP

– 12V: 119276

1.7AHP

– 24V: 119277

SmartFOAM Base Unit, Foam
Pump/Motor Assembly

3.3

– 12V: 501-3120-05-0

3.3

– 24V: 501-3120-06-0

5.0

– 12V: 501-3130-05-0

5.0

– 24V: 501-3130-06-0

6.5

– 24V: 501-4480-04-0

Summary of Contents for SmartFOAM 1.7AHP

Page 1: ...7AHP 2 1A Class A B 3 3 5 0 6 5 Description Installation and Operation Manual FSG MNL 00158 HALE PRODUCTS INC CLASS 1 607 NW 27th Avenue Ocala FL 34475 U S A Telephone 352 629 5020 FAX 800 533 3569 GO...

Page 2: ...omponents ruggedly designed accurately machined precision inspected carefully assembled and thoroughly tested In order to maintain the high quality of your unit and to keep it in a ready condition it...

Page 3: ...Page 2 SmartFOAM NOTES...

Page 4: ...26 CHECK VALVE MANIFOLDS FLANGES AND GASKETS 27 ELBOWS AND MANIFOLDS 28 REMOTE START OPTION 29 INSTALLATION 30 FOAM PUMP AND MOTOR ASSEMBLY 30 FOAM CONCENTRATE STRAINER 30 CONTROL UNIT AND INSTRUCTIO...

Page 5: ...PTION 61 START UP CHECKLIST 62 ELECTRICAL 62 LIQUID 62 FOAM PUMP 62 SYSTEM INSTALLER START UP 63 INITIALSYSTEM POWER CHECK 63 INITIALSYSTEM CHECK 63 INSTALLATION AND DELIVERY CHECKLIST 66 INSTALLATION...

Page 6: ...REEZEPROTECTION 81 TROUBLESHOOTING 82 USER DIAGNOSTICS 82 PROBLEM ISOLATION 85 ILLUSTRATED PARTS BREAKDOWN 86 GENERAL 86 ABBREVIATIONS 86 FOAM PUMP ASSEMBLY 1 7AHP AND 2 1A 87 FLOW METER ASSEMBLY 1 7A...

Page 7: ...wledge experience and the proper tools before attempting any installation Make sure proper personal protective equipment is used when operating or servicing apparatus A foam tank low level sensor must...

Page 8: ...re clean before making final connection to foam pump If necessary flush tank and hoses prior to making connection Check all hoses for weak or worn conditions after each use Ensure that all connections...

Page 9: ...f power and ground connections by sealing these connections with silicone sealant provided Prevent possible short circuit by using the rubber boot provided to insulate the primary power connection at...

Page 10: ...NTROL UNIT The control unit mounted on the operator panel is the single control point for the SmartFOAM system Press one of the preset buttons to enable foam concentrate injection once water flow has...

Page 11: ...s A and low viscosity Class B foam concentrates The FS25 strainer uses 1 25mm NPT connection ports and a 2 1 2 NST cap It is suitable for use with both Class A and Class B foam concentrates TANK SELEC...

Page 12: ...VDC Operating Ampere Draw 30 AMPS 12 VDC 25 AMPS 12 VDC Maximum Ampere Draw 40 AMPS 12 VDC 40 AMPS 12 VDC Table 2 Specifications 1 7 and 2 1 3 3 5 0 6 5 Foam Pump Type Rotary Gear Positive Displaceme...

Page 13: ...Page 12 SmartFOAM HALE FOAM PUMP DIMENSIONS Figure 1 1 7 and 2 1 Foam Pump Installation Envelope Dimensions...

Page 14: ...Page 13 SmartFOAM Figure 2 3 3 and 5 0 Foam Pump Installation Envelope Dimensions...

Page 15: ...Page 14 SmartFOAM SYSTEM DIAGRAM Figure 3 Typical Hale SmartFOAM 2 1A and 1 7AHP System...

Page 16: ...Page 15 SmartFOAM Figure 4 SmartFOAM 3 3 5 0 6 5 Single Tank System with In line Strainer...

Page 17: ...Page 16 SmartFOAM Figure 5 SmartFOAM 3 3 5 0 6 5 Single Tank withMSTandIn lineStrainer...

Page 18: ...Page 17 SmartFOAM Figure 6 SmartFOAM 3 3 5 0 6 5 Single Tank withMSTandFSSeriesStrainer...

Page 19: ...Page 18 SmartFOAM Figure 7 SmartFOAM 3 3 5 0 6 5 Dual Tank withMDTIIandIn lineStrainer...

Page 20: ...Page 19 SmartFOAM Figure 8 SmartFOAM 3 3 5 0 6 5 Dual Tank withMDTIIandFSSeriesStrainer...

Page 21: ...Page 20 SmartFOAM Figure 9 SmartFOAM 3 3 5 0 6 5 Dual Tank with ADTandIn lineStrainer...

Page 22: ...Page 21 SmartFOAM Figure 10 SmartFOAM 3 3 5 0 6 5 Dual Tank with ADTandFSSeriesStrainer...

Page 23: ...39 SmartFOAM Base Unit Foam Pump Motor Assembly 2 1A 12V 115498 2 1A 24V 115499 1 7AHP 12V 119276 1 7AHP 24V 119277 SmartFOAM Base Unit Foam Pump Motor Assembly 3 3 12V 501 3120 05 0 3 3 24V 501 3120...

Page 24: ...3 00101 200 Single pump 15 x19 513 00101 201 Dual pump 513 00074 200 Water Flow sensor input module 610 00033 NOT REQUIRED WITH 610 00044 1 7 2 1 Foam system placard 101 1630 70 0 3 3 5 0 6 5 Foam sys...

Page 25: ...PTIONS MDTII Manual Dual Tank 538 1490 14 0 ADT Air Dual Tank 12V 538 1640 05 0 24V 538 1640 06 0 MDTII harness extension 6 feet 513 0320 02 0 ADT color coded air tubing extension 507 0380 00 0 MST ha...

Page 26: ...artFOAM STRAINER OPTIONS In line strainer valve assembly 510 0190 01 0 Do not use if subject to flushing water pressure FS panel mount strainers FS 15 510 0150 00 0 NPT threads FS 25 510 0180 00 0 1 N...

Page 27: ...LPM 1 5 10 350 38 1 219 2 0 20 550 76 2 082 2 5 30 800 114 3 028 3 0 50 1 250 189 4 731 4 0 75 1 800 284 6 813 3 Single Check Valve SCV 30 750 114 2 839 3 Dual Check Valve DCV 30 750 114 2 839 Side mo...

Page 28: ...3 inch Victaulic Single Check Valve SCV 3 0 538 1850 00 0 Dual Check Valve DCV 3 0 538 1840 00 0 Wafer Check Valve 3 0 038 1570 06 0 4 0 038 1570 08 0 Type 115 Flange 3 0 NPT 115 0080 00 0 2 5 NPT 11...

Page 29: ...ictaulic output Close Fit Flanged Elbow 098 0190 00 0 2433D flange inlet with 3 NPT female and 4 Victaulic output Close Fit Flanged Elbow 098 0050 00 0 115 flange inlet with 2 5 NPT female output Clos...

Page 30: ...Page 29 SmartFOAM REMOTE START OPTION Switch with indicator 513 0330 01 0 Harness 513 0680 00 0...

Page 31: ...tor IMPORTANT WHEN DETERMINING THE LOCATIONS OF HALE SMARTFOAM COMPONENTS BEING INSTALLED KEEP IN MIND PIPING RUNS CABLE ROUTING AND OTHER INTERFERENCES THAT COULD HINDER OR INTERFERE WITH PROPER SYST...

Page 32: ...1A and 1 7 AHP Foam systems These systems are provided with 15 4 6 meters of 1 2 13mm ID reinforced PVC foam concentrate suction hose The system installer may need to supply additional fittings and h...

Page 33: ...atus with foam systems to prevent contamination of the foam concentrate with water and contamination of the fresh water tank with foam When a Hale SmartFOAM foam Injection system and related component...

Page 34: ...the best choice for their specific installation Note that there must be ventilation available to cool the area around the unit also to prevent electric motor overheating when the unit is operating in...

Page 35: ...must be a minimum 5 amp dedicated and fused circuit The ground must be connected to the chassis ground stud and protected from corrosion Make sure the ground is attached directly to the chassis frame...

Page 36: ...mounting location must to be drilled accordingly The base plate may be used as a template to mark mounting hole locations Figure 14 Base Plate Mounting Hole Locations 1 7 and 2 1 provides the mountin...

Page 37: ...Page 36 SmartFOAM Figure 14 Base Plate Mounting Hole Locations 1 7 and 2 1 Figure 15 Base Plate Mounting Hole Locations 3 3 5 0 and 6 5...

Page 38: ...AND FOAM SOLUTION PLUMBING Use best industry practices when installing the water and foam solution piping runs Use a suitable pipe sealing compound at all joints CHECK VALVE MANIFOLD Hale pre made sta...

Page 39: ...discharge piping The arrangement shown in Figure 17 Typical Midship Pump Installation provides accurate proportioning across a wide range for up to four discharges from the mini manifold The Hale min...

Page 40: ...Page 39 SmartFOAM Figure 18 Typical 4 Inch Check Valve Installation Midship Pump...

Page 41: ...381 mm 3 in 76 2 mm 18 in 457 2 mm 4 in 101 6 mm 24 in 609 6 mm Table 6 Pipe Size versus Minimum Straight Run Pipe size for flow sensor mounting must be selected to provide accuracy at the lowest flow...

Page 42: ...mm bored hole in the pipe A minimum of six times the pipe diameter of straight run pipe without any fittings is necessary prior to the position of this hole Figure 22 Flow Sensor Saddle Clamp Install...

Page 43: ...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 CONCENRATE PLUMBING CAUTION MAKE SURE THE FOAM TANK AN...

Page 44: ...5mm inside diameter hose for Class B foams For high viscosity Class B foam concentrates use 1 1 4 32mm or 1 1 2 38mm inside diameter hose See Figure 23 In Line Strainer Valve Installation A bracket is...

Page 45: ...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 Ins...

Page 46: ...strainer cap 9 Install the clear plastic hose from the foam tank outlet to the inlet of the strainer Wet the ends of the hose and fittings to make the installation easier CAUTION MAKE SURE THE FOAM TA...

Page 47: ...Valve Injector Fitting Installation This avoids sediment deposits or the formation of an ice plug The check valve injector fitting MUST be mounted in a location that is common to all discharges which...

Page 48: ...the foam pump inject port to the inlet of the check valve injector fitting See Figure 28 Injection and Bypass Hose Connections or Figure 29 Injection and Bypass Hose Connections 3 3 5 0 and 6 5 The ho...

Page 49: ...the foam pump when the ADT option is not installed See Figure 30 Bypass Valve Assembly The bypass handle must be accessible by the pump operator during normal operations See Figure 29 Injection and By...

Page 50: ...nection Part 1 A color coded decal attached to the ADT valve assembly along with an optional color coded air hose harness simplifies air hose connections If the optional air hose harness is not used 1...

Page 51: ...Page 50 SmartFOAM Figure 33 ADT Option Air Hose Connections Part 2...

Page 52: ...h Hale SmartFOAM are tested at the factory with that unit Improper handling and forcing connections can damage these cables which could result in other system damage The system can only perform when t...

Page 53: ...remote start stop and CAN communication respectively C6 C7 C8 C15 and C16 of the pump harness are pre connected by Hale Products at the factory Dual tank models refer to Figure 36 SmartFOAM Harness Co...

Page 54: ...wire length is required use minimum 16 AWG type SXL or GXL SAE J1128 wire Connect the black B wire to a chassis ground stud Protect the ground connection from corrosion Connect the red A wire to the p...

Page 55: ...Page 54 SmartFOAM Figure 36 SmartFOAM Harness Connections Dual Tank Figure 37 SmartFOAM Power and Ground Connections 1 7 2 1...

Page 56: ...E 40 AMP MINIMUM CURRENT PRIMARY POWER SUPPLY CONNECTION Make sure adequate switched electrical power from the battery positive terminal to the IN connection stud on the motor controller is provided S...

Page 57: ...itting with 1 25mm FNPT threads 2 The center of the switch must be located at least 1 to 2 inches 38 to 51 mm from the bottom of the foam tank with the float positioned on top of the switch to allow u...

Page 58: ...hout draining the foam tank The sensor assembly is flange mounted in an access hole at the top of the foam tank The two section telescoping assembly permits adjustment of the low tank level sensor pos...

Page 59: ...nd gasket with the holes on the tank Secure the assembly in place using four 1 4 20 UNC x 1 25mm long cap screws 1 4 7mm washers and lock washers Resizing the Top Mount Low Level Sensor Certain applic...

Page 60: ...lescoping 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 Tig...

Page 61: ...d WeatherPack 2 contact shroud half two 2 14 16 gauge male terminals and two 2 14 16 gauge cable seals Assemble these components to the end of the low tank sensor wires Snap the two halves of the Weat...

Page 62: ...the operator without interfering with other controls on the apparatus Install the remote activation switch as follows 1 Cutout the panel and drill the four 0 203 inch 5mm diameter through holes see F...

Page 63: ...tected from corrosion with silicone sealant Splices in wires sealed from moisture using adhesive filled heat shrink tubing LIQUID Flow sensor mounted with flow arrow in the correct direction for water...

Page 64: ...er Unit Initialization If a default display does not appear refer to the TROUBLESHOOTING section for possible WARM UP SYSTEM CHECKING causes and solutions INITIAL SYSTEM CHECK After initial system pow...

Page 65: ...o the BYPASS position to check the foam pump operation Place a calibrated five gallon container at the discharge end of the bypass hose 3 Place the system in simulated flow mode a Press the MENU butto...

Page 66: ...AM display reads approximately 1 00 7 Exit simulated water flow Use the steps described in step 3 and Figure 46 Setting Simulated Water Flow 8 Drain water from the foam tank and concentrate lines and...

Page 67: ...tem Foam tank filled with user specified foam concentrate Complies with Hale approved concentrate compatibility list Foam pump priming checked Water flow sensor calibration verified with Pitot and smo...

Page 68: ...Page 67 SmartFOAM NOTES...

Page 69: ...tioning by the system Recalibration of the system may be required ONLY after major repairs or component changes are made to the Hale SmartFOAM foam system Different viscosity foam concentrates may als...

Page 70: ...sor s paddlewheel pulse rate with the low flow value 7 Press the SAVE button to save the flow values into non volatile memory Record the calibrated values in the section below These values can be ente...

Page 71: ...martFOAM system can be remotely activated deactivated with an external switch When the system is remotely activated it will use the foam concentrate percentage of the preset which has set the remote a...

Page 72: ...SI 28 BAR see Figure 52 Relief Valve 3 3 5 0 and 6 5 Model 5 0 and 6 5 The pressure relief valve is factory tested and set to 300 PSI 21 BAR see Figure 52 Relief Valve 3 3 5 0 and 6 5 During normal in...

Page 73: ...operator action PRESET SCREEN The SmartFOAM system initializes to the preset screen The preset screen allows the operator to choose any one of the six presets to start the system and show the operatio...

Page 74: ...e may be reset in the main menu It is also reset any time the SmartFOAM controller power is disrupted Total Foam Flow The total foam flow display shows the total amount of foam concentrate pumped for...

Page 75: ...shutting down due to loss of foam prime If the system operates for a period of 35 seconds configurable in the Factory menu without a feedback signal the system turns itself OFF and shows the loss of...

Page 76: ...ater Flow for image steps of how to start simulated water flow 1 Uncoil and place the end of the bypass hose into a suitable container to collect the foam concentrate 2 Place the BYPASS valve in the B...

Page 77: ...topping With the fire pump discharging water and the Hale SmartFOAM operating a small volume of water is provided to separate the two foam types helping to prevent possible adverse reactions 3 After c...

Page 78: ...Operation 3 Place the Hale ADT MDT II or MST to the FLUSH position see Figure 58 Hale MST Selector Operation 4 Observe the discharge hose and allow Hale SmartFOAM and discharge to run for several sec...

Page 79: ...ntroller See Figure 43 Remote Activation Switch Installation Dimensions To operate 1 Press the switch down and release to activate The LED turns ON SOLID indicating the Hale SmartFOAM is in the STANDB...

Page 80: ...79 Page 79 SmartFOAM NOTES...

Page 81: ...can be viewed by going to the main menu and then selecting the Maintenance Minder button Figure 60 Navigate To Maintenance Minder Screen The Maintenance Minder screen contains three intervals one mont...

Page 82: ...empty close all drain valves 2 Pour in five gallons 18 93L of an appropriate antifreeze solution in the foam concentrate reservoir Consider using an environmentally friendly biodegradable formulation...

Page 83: ...ed as a unit Opening of Hale SmartFOAM electronic components voids the manufacturer warranty System Overview The SmartFOAM proportioner is a closed loop system The brain behind the system is the compu...

Page 84: ...d are recognized within the unit DPWR is illuminated when the IN power stud is energized with system voltage This power is required to drive the motor attached to the pump COM is illuminated when the...

Page 85: ...2 201 1631 Recommended wire gage 16 20 AWG Wedge lock W12S PIN CIRCUIT DESCRIPTION 1 SYS POWER INPUT Battery voltage 9VDC 32VDC 2 CAN HIGH DATA SAE J1939 CAN 2 0B 250Kbits s 3 CAN SHIELD DATA SAE J193...

Page 86: ...in The Total Foam flow display is useful in this scenario to determine if the foam sensor is detecting any foam flow PROBLEM ISOLATION SmartFOAM replacement parts are plug and play type devices that d...

Page 87: ...Grd Gr Grade when hardware lists a grade rating it is imperative to maintain that rating when replacing parts HS Hardened Steel Hex Hexagonal Id ID Inner diameter IPB Illustrated Parts Breakdown JIC J...

Page 88: ...1 2 HP 2 1A 1 7AHP 24 Volt B 110522 1 Pump Assembly without motor 2 1A 119345 1 Pump Assembly without motor 1 7AHP C 538 1750 01 0 1 Relief Valve 2 1A 250 PSI 119346 1 Relief Valve 1 7AHP 400 PSI D 51...

Page 89: ...l Pin 0 13 x 0 38 SST 9 200 2483 00 0 1 Speed Sensor 10 097 1971 00 0 1 Sealing Washer 10 11 082 0364 02 0 2 Hex Adapter 2X 3 8 MNPT 12 018 1220 12 0 4 Hex Head Bolt 1 4 20 x 2 00 SST 13 110 1206 02 0...

Page 90: ...Page 89 SmartFOAM PUMP REPAIR KIT 1 7AHP AND 2 1A Item Part number Qty Description Kit A 117495 1 Plunger and Seals Kit B 117496 1 Valve and Seals Kit C 117497 1 Cam Bearing...

Page 91: ...5 0 24 Volt 501 4480 04 0 1 Motor Pump Assembly 6 5 24 Volt A 045 0770 00 0 1 Motor 3 4 HP 3 3 5 0 12 Volt 045 0770 01 0 1 Motor 3 4 HP 3 3 5 0 24 Volt 045 0770 02 0 1 Motor 1 1 4 HP 6 5 24 Volt B 610...

Page 92: ...01 0 2 Rotor assembly 6 5 5 064 5380 00 0 1 Drive pin 3 3 5 0 064 5380 01 0 1 Drive pin 6 5 6 031 1270 00 0 1 Drive gear 3 3 031 1270 02 0 1 Drive gear 5 0 6 5 7 037 1980 00 0 1 Idler gear shaft 3 3 0...

Page 93: ...TRADE OR PATENT INFRINGEMENT FOR A PRODUCT MANUFACTURED TO ORIGINAL BUYER S DESIGN AND SPECIFICATIONS EXCLUSIVE REMEDIES If the Buyer promptly notifies HALE upon discovery of any such defect within t...

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