HALE SmartFOAM Page 1 Description, Installation And Operation Manual Download

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SmartFOAM

Electronic Foam Proportioning Systems

Models:

Class A only – 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: (800) 533.3569

FAX: 800-533-3569

GODIVA LTD

Charles Street

●

Warwick, England CV34 5LR

Telephone: 44-1-926-623600

Summary of Contents for SmartFOAM

Page 1: ...cription Installation and Operation Manual FSG MNL 00158 HALE PRODUCTS INC CLASS 1 607 NW 27th Avenue Ocala FL 34475 U S A Telephone 800 533 3569 FAX 800 533 3569 GODIVA LTD Charles Street Warwick Eng...

Page 2: ...Proper use and good preventive maintenance will lengthen the life of your unit REVISION RECORD Revi sion Date Page Description A DEC 2015 All New Issue B FEB 2018 6 12 13 22 34 35 47 23 53 54 36 82 8...

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

Page 4: ...S FLANGES AND GASKETS 34 ELBOWS AND MANIFOLDS 35 REMOTE START OPTION 36 SAM OPTION 36 INSTALLATION 37 FOAM PUMP AND MOTOR ASSEMBLY 37 FOAM CONCENTRATE STRAINER 37 CONTROL UNIT AND INSTRUCTION SYSTEM D...

Page 5: ...AL 71 LIQUID 71 FOAM PUMP 71 SYSTEM INSTALLER START UP 72 INITIALSYSTEM POWER CHECK 72 INITIALSYSTEM CHECK 72 INSTALLATION AND DELIVERY CHECKLIST 75 INSTALLATION 75 DELIVERY 75 NOTES 76 USER CALIBRATI...

Page 6: ...CEDURES 90 ON SCREEN MAINTENANCE MINDER 90 FREEZEPROTECTION 91 TROUBLESHOOTING 92 USER DIAGNOSTICS 92 PROBLEM ISOLATION 95 ILLUSTRATED PARTS BREAKDOWN 96 GENERAL 96 ABBREVIATIONS 96 FOAM PUMP ASSEMBLY...

Page 7: ...ure to use a low level sensor with the Hale Foam system voids warranty DO NOT permanently remove or alter any guard or insulating devices or attempt to op erate the system when these guards are re mov...

Page 8: ...system The in line strainer valve assembly is a low pressure device and WILL NOT withstand flush ing water pressure in excess of 45 PSI 3 BAR When determining the location of Hale Foam system componen...

Page 9: ...enance Manual For Hale SAM Genera tion 2 FSG MNL 00210 When integrated with SAM the SmartFOAM CAN bus connector B must be bridged with the SAM Green CAN bus Use SmartFOAM control unit display connecto...

Page 10: ...nection ports and a 1 1 2 in NST cap It is suitable for use with Class A and low viscosity Class B foam concentrates The FS25 strainer uses 1 25 mm NPT connection ports and a 2 1 2 in NST cap It is su...

Page 11: ...AMP 12 VDC 40AMP 12 VDC Maximum Ampere Draw 24VDC 20 AMP 24 VDC 20AMP 24 VDC Table 3 Specifications 3 3 and 5 0 3 3 5 0 Foam Pump Type Rotary Gear Positive Displacement Rotary Gear Positive Displaceme...

Page 12: ...Page 11 SmartFOAM HALE FOAM PUMP DIMENSIONS Figure 1 1 7 and 2 1 Foam Pump Installation Envelope Dimensions...

Page 13: ...Page 12 SmartFOAM Figure 2 Installation Envelope Dimensions for 3 3 and 5 0 Foam Pumps Figure 3 Installation Envelope Dimensions for 6 5 12VDC Foam Pump Converter Installed...

Page 14: ...Page 13 SmartFOAM Figure 4 Installation Envelope Dimensions for 6 5 24VDC Foam Pump or 12VDC Foam Pump with Converter Located Remote...

Page 15: ...Page 14 SmartFOAM Figure 5 Converter Installation Envelope Dimensions Located Remote for 6 5 12VDC Systems...

Page 16: ...Page 15 SmartFOAM SYSTEM DIAGRAM Figure 6 Typical Hale SmartFOAM 2 1A and 1 7AHP System...

Page 17: ...Page 16 SmartFOAM Figure 7 SmartFOAM 3 3 5 0 6 5 Single Tank System with In line Strainer...

Page 18: ...Page 17 SmartFOAM Figure 8 SmartFOAM 3 3 5 0 6 5 Single Tank withMSTandIn lineStrainer...

Page 19: ...Page 18 SmartFOAM Figure 9 SmartFOAM 3 3 5 0 6 5 Single Tank withMSTandFSSeriesStrainer...

Page 20: ...Page 19 SmartFOAM Figure 10 SmartFOAM 3 3 5 0 6 5 Dual Tank withMDTIIandIn lineStrainers...

Page 21: ...Page 20 SmartFOAM Figure 11 SmartFOAM 3 3 5 0 6 5 Dual Tank withMDTIIandFSSeriesStrainer...

Page 22: ...Page 21 SmartFOAM Figure 12 SmartFOAM 3 3 5 0 6 5 Dual Tank withADTandIn lineStrainers...

Page 23: ...Page 22 SmartFOAM Figure 13 SmartFOAM 3 3 5 0 6 5 Dual Tank withADTandFSSeries Strainers...

Page 24: ...Page 23 SmartFOAM Figure 14 SmartFOAM Dual Pump 1 Single Tank with Valve Options and In Line Strainers...

Page 25: ...Page 24 SmartFOAM Figure 15 SmartFOAM Dual Pump 1 Single Tank System with MST and FS Series Strainers...

Page 26: ...Page 25 SmartFOAM Figure 16 SmartFOAM Dual Pump 1 Dual Tank System with MDT II and FS Series Strainers...

Page 27: ...Page 26 SmartFOAM Figure 17 SmartFOAM Dual Pump 2 Single Tank System with valve options and In Line Strainers...

Page 28: ...Page 27 SmartFOAM Figure 18 SmartFOAM Dual Pump 2 Single Tank System with MST and FS Series Strainers...

Page 29: ...Page 28 SmartFOAM Figure 19 SmartFOAM Dual Pump 2 Dual Tank System with MDT II and FS Series Strainers...

Page 30: ...2 1A 24V 115499 1 7AHP 12V 119276 1 7AHP 24V 119277 SmartFOAM Base Unit Foam Pump Motor Assembly 6 5 12V 501 4480 06 0 SmartFOAM controller 610 00039 SmartFOAM Base Unit Foam Pump Motor Assembly 3 3 1...

Page 31: ...ump 10 x14 513 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...

Page 32: ...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 33: ...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 34: ...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 m...

Page 35: ...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 36: ...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 fe male output Clo...

Page 37: ...OTE START OPTION SAM OPTION NOTE Pins 2 and 3 modified from 513 00101 20X C6 connector adds SAM Green CAN bus to connector Switch with indicator 513 0330 01 0 Harness 513 0680 00 0 SAM Green CAN bus h...

Page 38: ...harness 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 INTER FERE WITH PROPER...

Page 39: ...appa ratus FOAM CONCENTRATE SUCTION HOSE SmartFOAM 2 1A and 1 7 AHP Foam systems These systems are provided with 15 ft 4 6 m of 1 2 in 13 mm ID reinforced PVC foam concentrate suction hose The system...

Page 40: ...h foam When a Hale SmartFOAM foam Injection system and related components are properly installed the required check valves are integral parts of the system NFPA standards require a check valve in the...

Page 41: ...ng when the unit is operating in high tem perature ambient environments ELECTRICAL REQUIREMENTS The system installer must provide the primary power wire and a ground strap for the Hale SmartFOAM syste...

Page 42: ...nd must also be provided for the display unit using the 2 pin Packard connector The power must be a minimum 5 amp dedicated and fused circuit The ground must be connected to the chassis ground stud an...

Page 43: ...led accordingly The base plate may be used as a template to mark mounting hole locations Figure 23 provides the mounting base dimensions for the SmartFOAM 1 7AHP and 2 1A foam pump and motor as sembly...

Page 44: ...Page 43 SmartFOAM Figure 23 Base Plate Mounting Hole Locations 1 7 and 2 1 Figure 24 Base Plate Mounting Hole Locations 3 3 5 0 and 6 5...

Page 45: ...ES ARE PROPERLY SUPPORTED USING THE BEST INDUSTRY PRACTICES USE A SUITABLE PIPE SEALING COMPOUND AT ALL JOINTS WATER AND FOAM SOLUTION PLUMBING Use best industry practices when installing the water an...

Page 46: ...Page 45 SmartFOAM Figure 26 Check Valve Manifold Installation Note When the manifold is installed the drain tap that must be placed in the down position and plumbed to an individual drain...

Page 47: ...of water and foam solution discharge piping The arrangement shown in Figure 27 provides accurate proportioning across a wide range for up to four discharges from the mini manifold The Hale mini manifo...

Page 48: ...Page 47 SmartFOAM Figure 28 Typical 4 Inch Check Valve Installation Midship Pump...

Page 49: ...mm 9 in 228 6 mm 2 in 50 8 mm 12 in 304 8 mm 2 1 2 in 63 5 mm 15 in 381 mm 3 in 76 2 mm 18 in 457 2 mm 4 in 101 6 mm 24 in 609 6 mm Pipe size for flow sensor mounting must be selected to provide accur...

Page 50: ...ure 32 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 32 Flow Sensor Saddle Clamp Installation The flow senso...

Page 51: ...tamination Flush water thread connections are ADT 1 2 in 13 mm NPT MDT II and MST 1 4 6 4 mm NPT The system installer must provide proper fittings for these connections FOAM CONCENTRATE PLUMBING CAUTI...

Page 52: ...a 1 00 25 mm inside diameter hose for Class B foams For high viscosity Class B foam concentrates use 1 1 4 32 mm or 1 1 2 in 38 mm inside diameter hose Figure 33 A bracket is included to permit instal...

Page 53: ...strainers are required The plumbing exposed to the flush water pressure must be rated at or above the oper ating pressure of all other discharge plumbing compo nents 500 PSI 34 BAR minimum To Install...

Page 54: ...nstall 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 TANK AND FOAM CONC...

Page 55: ...posits 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 require foam concentrate Figure 38 The Hale SmartFOAM syst...

Page 56: ...E Connect a hose from the foam pump inject port to the inlet of the check valve injector fitting Figure 38 or Figure 39 The hose and fittings from the INJECT port to the check valve injector fitting s...

Page 57: ...bypass valve is mounted on the discharge of the foam pump when the ADT option is not installed Figure 40 The bypass handle must be accessible by the pump operator during normal operations Figure 39 T...

Page 58: ...Figure 42 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 4 6...

Page 59: ...Page 58 SmartFOAM Figure 43 ADT Option Air Hose Connections Part 2...

Page 60: ...rtFOAM 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 the electri...

Page 61: ...of the pump harness are pre connected by Hale Products at the fac tory Dual tank models refer to Figure 46 shown with dual pump harness Connect C1 of the controller harness to the B connector on the r...

Page 62: ...black B wire to a chassis ground stud Protect the ground connection from corrosion Connect the red A wire to the power supply It is recom mended to connect the power wire to a minimum 5 AMP fused ded...

Page 63: ...Page 62 SmartFOAM Figure 47 SmartFOAM to SAM Harness Connections Figure 48 SmartFOAM Power and Ground Connections 1 7 2 1 Figure 49 SmartFOAM Power and Ground Connections 3 3 5 0 and 6 5 24VDC...

Page 64: ...e thick strap CAUTION DO NOT CONNECT THE MAIN POWER LEAD TO SMALL LEADS THAT ARE SUPPLYING SOME OTHER DEVICE SUCH AS A LIGHT BAR OR SIREN AS THE SMARTFOAM SYSTEMS HAVE A LARGE CURRENT DRAW PRIMARY POW...

Page 65: ...lat bundle instead of making a round coil Figure 51 Figure 51 Extra Cable Storage FOAM TANK LOW LEVEL SENSOR INSTALLATION The foam low tank level sensor s must be installed and wired to monitor the fo...

Page 66: ...ank sufficient foam concen trate should be present for one minute of operation at the rated flow 3 Coat the threads of the sensor with a suitable sealant and insert into tank fitting Tighten sensor ma...

Page 67: ...oat should be 1 1 2 in to 2 38 to 51 mm above the bottom of the foam tank 5 Loosen the strain relief gland nut to allow the sensor wire to slide through the strain relief 6 Adjust the telescoping sect...

Page 68: ...Page 67 SmartFOAM Figure 55 Top Mount Low Level Sensor Assembly...

Page 69: ...must cut off the ferrule from both ends Deburr the cuts using a fine emery paper 6 Install a new 1 2 in 13 mm compression ferrule on the end of the 1 2 in O D tube Carefully thread the sensor wire thr...

Page 70: ...ard 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 We...

Page 71: ...h Make sure the switch is accessible to the operator without interfering with other controls on the appa ratus Install the remote activation switch as follows 1 Cutout the panel and drill the four 0 2...

Page 72: ...converter 24V when installing the 501 4480 06 0 system on a 12V apparatus NOT connected anywhere other than motor Primary electrical and ground connections tight and protected from corrosion with sili...

Page 73: ...57 If a default display does not appear refer to the TROU BLESHOOTING section for possible WARM UP SYS TEM CHECKING causes and solutions INITIAL SYSTEM CHECK After initial system power up the low tan...

Page 74: ...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 75: ...r The TOTAL FOAM display reads approximately 1 00 7 Exit simulated water flow Use the steps de scribed in step 3 and Figure 59 8 Drain water from the foam tank and concentrate lines and return the byp...

Page 76: ...tem Foam tank filled with user specified foam concentrate Complies with Hale ap proved concentrate compatibility list Foam pump priming checked Water flow sensor calibration verified with Pitot and sm...

Page 77: ...Page 76 SmartFOAM NOTES...

Page 78: ...changes are made to the Hale SmartFOAM foam system Different viscosity foam concentrates may also require recalibration ENTERING PASSWORDS System calibration and configuration is accomplished by acce...

Page 79: ...o non volatile memory Record the calibrated values in the section below These values can be entered manually if the controller unit ever needs to be replaced Flow Rate Flow Pulses High rate cal Low ra...

Page 80: ...toggles the remote activated value YES or NO o The SmartFOAM system can be remotely activated de activated with an external switch When the system is remotely activated it will use the foam concentrat...

Page 81: ...ls 3 3 5 0 6 5 The pressure relief valve is factory tested and set to Model 3 3 400 PSI 28 BAR Model 5 0 300 PSI 21 BAR Model 6 5 250 PSI 17 BAR Figure 65 Relief Valve 3 3 5 0 and 6 5 During normal in...

Page 82: ...ong as power is applied 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...

Page 83: ...y 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 the...

Page 84: ...ssage will appear informing the oper ator how many seconds the system will continue to run be fore shutting down due to loss of foam prime If the system operates for a period of 35 seconds configura b...

Page 85: ...UILDUP IN DISCHARGE PIPING OR HOSES SIMULATED FLOW SEQUENCE Refer to Figure 59 for image steps of how to start simulated water flow 1 Uncoil and place the end of the bypass hose into a suitable contai...

Page 86: ...opping With the fire pump dis charging 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 87: ...own injection check valve and injection point and they utilize their own separate water flow paddlewheels The graphic on the display Figure 72 indicates two separate control systems with two individu...

Page 88: ...low Hale Smart FOAM and discharge to run for several seconds 5 After several seconds place the Hale ADT or MDT II to the TANK A position and allow the system to run until all foam solution is discharg...

Page 89: ...SmartFOAM controller Refer to Figure 50 Remote Activation Switch Installation Dimensions To operate 1 Press the switch down and release to activate The LED turns ON SOLID indicating the Hale Smart FOA...

Page 90: ...89 Page 89 SmartFOAM NOTES...

Page 91: ...can be viewed by going to the main menu and then selecting the Maintenance Minder button Figure 76 Navigate To Maintenance Minder Screen The Maintenance Minder screen contains three intervals one mont...

Page 92: ...ter empty close all drain valves 2 Pour in five gallons 18 93L of an appropriate anti freeze solution in the foam concentrate reservoir Consider using an environmentally friendly biodegrada ble formul...

Page 93: ...ide and are re placed 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...

Page 94: ...e recognized within the unit DPWR is illuminated when the IN power stud is en ergized with system voltage This power is required to drive the motor attached to the pump COM is illuminated when the dis...

Page 95: ...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 96: ...Total Foam flow display is useful in this scenario to de termine if the foam sensor is detecting any foam flow PROBLEM ISOLATION SmartFOAM replacement parts are plug and play type de vices that do not...

Page 97: ...rd 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 Jo...

Page 98: ...ly 1 7AHP 24 Volt A 110521 1 Motor 1 2 HP 2 1A 1 7AHP 12 Volt 110393 1 Motor 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 17...

Page 99: ...in 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 4...

Page 100: ...Page 99 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 101: ...045 0770 01 0 1 Motor 3 4 HP 3 3 5 0 24VDC 045 0770 02 0 1 Motor 1 1 4 HP 24VDC used on both 6 5 systems B 610 00044 1 Motor Controller C 501 3110 00 0 1 Pump 3 3 501 3130 00 0 1 Pump 5 0 501 4480 00...

Page 102: ...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...

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