Idex Hale Sam Technical Manual Download Page 148

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128

Figure 97. PF Valve Block Mounting Screw Access

Removal
A.

Match mark blank plate to top PF valve, and cover to bottom PF valve.

Using two 7-16-in wrenches, remove PF valve block, blank plate, and cover re-

taining bolts. Hold nut (with washers), remove bolt (with washer). See Figure 98.

Figure 98. PF Valve Block Disassembly

Summary of Contents for Hale Sam

Page 1: ...ision A COPYRIGHT 2019 2020 BY HALE PRODUCTS INC ALL RIGHTS RESERVED TECHNICAL MANUAL FOR HALE SAM BY HALE PRODUCTS INC A Unit of IDEX Corporation 607 NW 27th Ave Ocala FL 34475 800 533 3569 800 520 3...

Page 2: ......

Page 3: ...3 2 Calibration 13 2 3 1 2 Pump Controller Interfaces 13 2 3 1 2 1 Pump Controller Tabs 13 2 3 1 2 1 1 TANK 14 2 3 1 2 1 2 PUMP INFO 15 2 3 1 2 1 3 ENGINE DATA 15 2 3 1 2 1 4 VIDEO 16 2 3 2 SAM Syste...

Page 4: ...r 28 2 4 7 3 Flowmeter 28 2 4 8 Navigator Optional Equipment 29 2 4 9 Governor Function 29 2 4 9 1 Emergency Idle Switch 30 2 4 9 2 Twister Electronic Throttle 30 2 4 10 SAM Speaks 30 2 4 10 1 Audio A...

Page 5: ...ns 46 4 3 4 Datalogger Guidelines 47 4 3 4 1 Export Datalogger From SAM Control Center 47 4 3 4 2 Export Datalogger From SAM Pump Controller 48 4 3 5 SAM Wire Harness Guidelines 48 4 4 Removal And Rep...

Page 6: ...acement 89 4 8 Removal And Replacement Of SAM Modules 91 4 8 1 MatrIIx Pressure Governor Module 92 4 8 2 Sensor Module 95 4 8 3 SAM MIV A Module 97 4 8 4 MIV 2 0 Drive Module 100 4 9 Removal And Repla...

Page 7: ...ration 141 4 12 6 ITL 40 Configuration Procedures 142 4 12 6 1 Water Tank 142 4 12 6 2 Foam Tank A 143 4 12 6 3 Foam Tank B 143 4 13 Updating The Tablet After SAM Setup Configuration Changes 143 4 14...

Page 8: ...2 2 Pressure Procedures SAM Control Center 177 5 3 Flowmeter Calibration Procedures 178 5 3 1 Set Flow To Factory Defaults 178 5 3 2 Flow Calibration 178 5 3 3 Calibration With AKROVIEW Diagnostic So...

Page 9: ...guring SAM For A Foam System 195 6 17 1 Configuring A Foam Preset 195 6 17 2 Configuring A Foam Quickset 196 6 17 3 Configuring A CAFS Preset 196 6 17 4 Configuring A Foam Quickset 197 6 18 Connecting...

Page 10: ...7 Mini Navigator Pro Display 29 Figure 23 SAM Tablet 32 Figure 24 SAM Control Center USB Dongle USB key Connected 33 Figure 25 SAM Control Center System Options Button And Loading Icon 34 Figure 26 SA...

Page 11: ...Figure 53 Pump Temperature Sensor 83 Figure 54 Water Detection Sensor 84 Figure 55 Water Detection Sensor R R Autolube And Gearbox 85 Figure 56 Water Detection Sensor R R Primer 86 Figure 57 Zero Pre...

Page 12: ...Circuit Breaker Box 115 Figure 85 Circuit Breaker Box Connector Pin Layout 115 Figure 86 Legacy CB Junction Box Location 118 Figure 87 OEM Located Legacy CB Junction Box 119 Figure 88 Legacy CB Junct...

Page 13: ...or Enable Row Selected 138 Figure 114 SPG User Set Point Screen 138 Figure 115 Suction Pressure Hysteresis PSI Row Selected 139 Figure 116 SPG Hysteresis Screen 139 Figure 117 MIV A Module Address Swi...

Page 14: ...re 144 Calibrate Valve Stops Screen Selected And Active 176 Figure 145 Zero Pressure Sensor Screen 177 Figure 146 Span Pressure Sensor Screen 178 Figure 147 Calibrate Valve Flow Screen 179 Figure 148...

Page 15: ...6 Recommended O ring Lubricant 44 Table 7 Recommended Thread Lock And Sealant Compounds 45 Table 8 SAM Control Center Master Or Auxiliary Tools And Consumables List 51 Table 9 SAM Pump Controller Tool...

Page 16: ...Wiring From To Listing 78 Table 34 Water Column Sensor Tools And Consumables List 79 Table 35 Gearbox Oil Level Sensor Wiring From To Listing 80 Table 36 Gearbox Oil Level Sensor Tools And Consumable...

Page 17: ...uxiliary Cooling Solenoid Tools And Consumables List 111 Table 64 DC To DC Converter Wiring From To Listing 112 Table 65 Wi Fi Router Antenna Tools And Consumables List 113 Table 66 Circuit Breaker Bo...

Page 18: ...itle Page Table 81 SAM Discharge Valve Max PSI Defaults 192 Table 82 SAM SCC Balloon Types 193 Table 83 SAM Valve Capability Settings 193 Table 84 Captium To SAM Wiring From To Listing 197 Table 85 Ha...

Page 19: ...sdiction AKA Also Known As AWG American Wire Gauge BAM Broadcast Announce Message CAFS Compressed Air Foam System CAN Controller Area Network DECR Decrease DG Deck Gun ECU Engine Control Unit EMI Elec...

Page 20: ...xviii Abbreviations And Acronyms CONTINUED SAE Society of Automotive Engineers SAM Scene Apparatus Management SGX Starter or Ground Cross Linked Polyethylene UID Unit ID...

Page 21: ...possible result if disregarded and a statement of the hazard that provides the minimum precautions The headings used and their definitions are INDICATES A HAZARDOUS SITUATION WHICH IF NOT AVOIDED WIL...

Page 22: ...RGANIZATION CONTACT INFORMATION STUDENT CONTACT INFOR MATION portions of the form Check the Captcha provides the proof of human input and then click the SUBMIT button at the bottom of the page NOTES U...

Page 23: ...HOSE LINES OR PUMPING AT ELEVATION SAM MAINTAINS PRESSURE SETTINGS BASED ON SENSORS MEASURING PRESSURE NEAR THE DISCHARGE VALVE THE SYSTEM CAN NOT ALLEVIATE STATIC PRESSURES RESIDUAL PRESSURE IN THE S...

Page 24: ...CTION IF COMPLETELY COVERED AND OR IM MERSED IN WATER DO NOT ALLOW THE TOUCHSCREENS TO BE COMPLETELY COV ERED IMMERSED WITH WATER OR ANY LIQUID DRY THE SCREEN TO RESTORE FUNCTIONALITY THE PROCEDURES I...

Page 25: ...ERATE AUTOMATICALLY REMOVE POWER BEFORE OVERRIDE ACTIVATING FOAM OFF FROM THE SAM CONTROL CENTER TURNS OFF THE SMART FOAM SYSTEM TURNING OFF FOAM TO ALL FOAM CAPABLE DISCHARGES HOWEVER THE DISCHARGE S...

Page 26: ...N USING THE OVERRIDE TO OPERATE THE VALVE DIRECTLY DO NOT ALTER THE CAN NETWORK COMMUNICATIONS SAE J1939 CAN BUS OR CON NECT OTHER DEVICES TO ANY OF THE CAFS CAPTIUM FOAM OR SAM CAN BUS BACK BONE S DO...

Page 27: ...NUAL MODES ALWAYS TOUCH THE SEND BAM REBOOT TO GUI OR REBOOT TO GUI BUTTON BEFORE RETURNING THE APPARATUS TO SERVICE ONLY TOUCH THE SCREEN IN ONE PLACE AT A TIME THE TOUCHSCREENS DO NOT SUPPORT MULTI...

Page 28: ...E PAIRS OF THE CAT 6 ETHERNET CABLE PORTION OF THE SAM HARNESS TO PREVENT PCB DAMAGE DO NOT REMOVE THE COVER OR CHANGE THE CAN AD DRESS WITH THE MODULE POWERED ON TOUCH ONLY THE SPECIFIED BUTTON S FAI...

Page 29: ...the Hale Training Academy Use Hale Training Academy Pumping And Maintenance and SAM training see paragraph 1 3 Training page 2 and the two Maintenance sections for all aspects of maintaining the SAM s...

Page 30: ...governor intakes Each CAN bus uses a sepa rate loom color red blue green to identify the back bone and most nodes However some nodes and most stubs use black loom Each bus utilizes and complies with J...

Page 31: ...ally for maintenance purposes exit Auto Mode and use Manual Mode to control the SAM system Hale also recommends exiting Auto Mode before entering any OEM technician password on either of the touchscre...

Page 32: ...3 1 BAM Touch the BAM tab Figure 4 to enter the BAM Menu screen Touch the Configuration Mode but ton to verify a desired devices UID Manufactures information Friendly name and or CAN ad dress Addition...

Page 33: ...ler Interfaces The Pump Controller interface will be a primary tool for maintaining a SAM system Many of the screens provided on this interface provide annual pump testing control support and results...

Page 34: ...e Position Master Discharge Pressure Tank To Pump Valve Position Engine Speed Figure 8 TANK Screen Additionally the TANK tab Figure 8 provides the following icon group controls These controls allow th...

Page 35: ...ion is provided Figure 10 PUMP INFO Screen No Maintenance Required When maintenance is required the tab highlights red along with the applicable item requiring at tention See Figure 11 for an example...

Page 36: ...paratus CAN buss Additionally the diagram shows the data path s to the SAM Control Center s and the remote SAM tablet along with the equipments supplied power and secure Wi Fi connections Figure 15 sh...

Page 37: ...17 Figure 14 SAM Blue CAN Buss Architecture With Three SAM Control Centers Diagram...

Page 38: ...18 Figure 15 SAM Green CAN Buss Architecture With Three SAM Control Centers Diagram...

Page 39: ...19 Figure 16 SAM Red CAN Buss Architecture With Three SAM Control Centers Diagram...

Page 40: ...20 Figure 17 SAM System Drain And Pneumatic Diagram...

Page 41: ...21 Figure 18 SAM Speaks Diagram...

Page 42: ......

Page 43: ...level information Figure 14 page 17 Figure 15 page 18 Figure 16 page 19 Figure 17 page 20 Figure 18 page 21 See section 4 8 page 91 for all other module information 2 4 2 1 AFS Sensor The SAM system u...

Page 44: ...nsor before seeing paragraph 4 7 2 page 74 to prevent sensor damage and for other sensor information 2 4 3 3 Gearbox Oil Level Sensor Single Point Level Switch The level sensor is physically positione...

Page 45: ...ft total length pos neg run capable of 300 Amps Reference Hale 029 0810 01 0 ESP Primer System Installation Operation and Service Maintenance Manual for primer information Do NOT connect the ESP to a...

Page 46: ...ny mix of master intake valve and pony intakes The pony intakes are optional for a SAM system and typically provide a 2 5 inch intake For a complete Akron Brass valve listing available for pony intake...

Page 47: ...ny positions due to MIV proximity 2 4 5 1 SAM Pump Controller Tank Screen The tank screen while SAM is in Auto mode provides control of the tank fill valve To provide addi tional cooling for the pump...

Page 48: ...e associated Hale MIV module must be installed on the new valve Refer to the MIV 2 0 OIM FSG MNL 00216 TM FSG MNL 00217 and or PM FSG MNL 00218 for MIV 2 0 information 2 4 7 Discharge Management The S...

Page 49: ...a Navigator pro vides redundant pressure indication for the associated Akron valve Figure 21 9323 And 9335 Navigator Pro Displays Additionally any Pony intake in addition to the first six intakes with...

Page 50: ...mation 2 4 9 2 Twister Electronic Throttle In addition to the SAM Pump Controller Manual Mode governor interface SAM provides a tradi tional Twister electronic throttle controller on the SAM Pump Cont...

Page 51: ...Wi Fi router antenna secures to Wi Fi network and connects the ruggedized tablet THE WI FI ROUTER ANTENNA IS A 24 VDC DEVICE REQUIRED TO BE ONLY WIRED TO THE OUTPUT OF THE DC TO DC CONVERTER WHICH SU...

Page 52: ...UMP SAFE BUT IF AN INADEQUATE WATER SUPPLY OR PUMP CAVITATION OCCURS THE OPERATOR MUST UNDERSTAND WHAT IS HAPPENING AND CORRECT THE PROBLEM SAM DOES NOT ADJUST FOR FRICTION LOSS ON HOSE LINES OR PUMPI...

Page 53: ...ions References for how to locate the serial number for your SAM sys tem Hale SAM performance per NFPA 1901 and or NFPA 1906 as appropriate is provided on the Hale Products website www haleproducts co...

Page 54: ...on And Loading Icon Figure 26 SAM Control Center Password Screen 2 6 1 1 SAM Control Center Password Screen Perform the following to enter a password A Using password icon group with USB Key attached...

Page 55: ...and A1 password 26634 Technician Level 1 Allows level 1 restricted technician access to the SAM systems 29512 Technician Level 2 Allows level 2 full technician access to the SAM sys tem 33578 Tablet...

Page 56: ...s Menu Provides Governor Settings and Password Access 5353 Write Field Data Input Sensor Data from Annual Test 5454 Read Factory Field Data Toggles Between Factory And Field Test Data 5555 Write Field...

Page 57: ...wnload 78674 N A Actionable Password Resets Pump Hours 82650 N A Actionable Password Sets Tank Level Display Type Displayed On TANK Tab To Text Box Default 82651 N A Actionable Password Sets Tank Leve...

Page 58: ...38 THIS PAGE INTENTIONALLY BLANK...

Page 59: ...th and dry water Reference FSG MNL 00210 and see the Display Cleaning para graph Water Soft Cloth Flush Flush pump thoroughly with clean water Reference FSG MNL 00210 and see the Flush Pump paragraph...

Page 60: ...able 5 Perform NFPA 1911 Performance Level Tests Check the pump at each capacity and compare the results to when the pump was first placed in service Supply of clean water Bi Annually Every 24 Months...

Page 61: ...e 1 See Table 3 page 36 C Verify GEARBOX OIL LIFE REMAINING resets to 200 hours See Figure 30 D If applicable sequentially touch digits of actionable password to reset gearbox oil life 2 See Table 3 p...

Page 62: ...42 THIS PAGE INTENTIONALLY BLANK...

Page 63: ...THE PARKING BRAKE AND CHOCK THE WHEELS BE FORE GOING UNDER THE TRUCK FOR ANY REASON AVOID CONTACT WITH HOT SURFACES THE PACKING GLAND AND PUMP BODY MAY PRESENT A TEMPERATURE HAZARD OVERHEATING MAY RE...

Page 64: ...ase is called for use lithium based grease with 1 to 3 Molybdenum Disulfate The fol lowing lists examples of approved greases Dow Corning BR2 PLUS Imperial 777 Lubriplate Fiske 3000 Mobil Grease Speci...

Page 65: ...rews that are torqued to greater than 100 ft lb with new hardware 4 2 1 Cleaning Required For Thread Lock Compounds Always clean the threads of all bolts fasteners screws as remnant compound causes fa...

Page 66: ...ODULE PART NUMBER TO ENSURE THE CORRECT MODULE AND HARNESS CONNECTOR ARE BEING CON NECTED Never attempt to tag disconnect or connect an energized circuit As a general maintenance practice tag document...

Page 67: ...age 33 do NOT connect the Hale USB Key for this purpose D Temporally close panel E On SAM Control Center touch MANUAL MODE button See Figure 1 page 11 F Touch YES button See Figure 2 page 11 G On SAM...

Page 68: ...rator panel 4 3 5 SAM Wire Harness Guidelines SAM utilizes three SAE J1939 compliant CAN 500 kbit s buses the Blue loom color indicates the associated bus bus interfaces the apparatus primarily the EC...

Page 69: ...onents The SAM system houses the following components on the apparatus typically on the pump oper ator panel See Figure 32 Figure 32 SAM Panel Components Locations Operator Panel Audio Speaker Buzzer...

Page 70: ...es the following components on the apparatus typically on the officer side panel See Figure 33 Figure 33 SAM Panel Components Locations Officer Side Audio Speaker Buzzer SAM Control Center Auxiliary E...

Page 71: ...y SAM Control Center Master Refer to FSG MNL 00212 Table 1 SAM Control Center Ratchet SAM Control Center Auxiliary Refer to FSG MNL 00212 Table 1 Auxiliary SAM Control Center SAM Control Center Mount...

Page 72: ...e 34 B From rear of panel place bracket over rear of SAM Control Center See Figure 34 C Support SAM Control Center and bracket hand start four 4 8 32 x 1 2 in long screws each with a lock washer See F...

Page 73: ...SAM Pump Controller See FSG PL 01505 Sheet 1 Ratchet If the SAM Pump Controller touchscreen fails or is damaged replace the touchscreen as follows Removal A Open SAM operator panel B Note cable tie lo...

Page 74: ...irst bracket B Place one bracket over rear of SAM Pump Controller C Align new SAM Pump Controller and bracket screw holes D Hand start two 2 8 32 x 1 2 in long button head hex screws each with a lock...

Page 75: ...Consumables PPE Eye and Hand Protection None Cable Ties As Required Wire Cutter Buzzer See FSG PL 01505 Sheet 1 Slip Joint Plyers At Least 40 mm Jaw Opening If the buzzer fails to produce sound or is...

Page 76: ...ails Table 12 provides the SAM system from to wire listing Table 12 Emergency Idle Switch Wiring From To Listing From Emergency Idle Button Pin To SAM Breaker Box To SAM Control Center Connector A Bla...

Page 77: ...rench tighten jam nut NOTE If switch terminals are NOT numbered marked connect as desired E Using screwdriver connect two 2 wires according to tags F Install cable ties cut to R R switch as noted 4 4...

Page 78: ...Wire Cutter If the Twister fails to control engine speed or activate an idle or is damaged replace the Twister as follows Removal A Open SAM panel B Note cable tie locations cut ONLY ties required to...

Page 79: ...as part of an optional FOAM or CAFS system the ITL 40 for foam tank A must be set to CAN device address 2 0xCC and the ITL 40 for foam tank B must be set to CAN device address 3 0xCD Table 16 provide...

Page 80: ...Special Tools Consumables PPE Eye and Hand Protection None Cable Ties As Required 5 16 in Nut Driver Or Wrench Twister See FSG PL 01505 Sheet 1 1 Phillips Screwdriver 6 32 Nyloc SS nut P N 102514 Wire...

Page 81: ...e 41 Hale Pressure Transducer And Pin Layout Table 18 Onboard Tank Water Level Sensor Wiring From To Listing From Pressure Transducer Pin To ITL 40 Pin A 5V Reference 5 5V Reference Output B Reference...

Page 82: ...override panel Figure 42 is provided for each MIV Each MIV E override panel houses an illuminated momentary contact rocker switch and a manually operated air bleed valve with a check valve attached Th...

Page 83: ...utter Cable Ties As Required 11 32 in Nut Driver Or Wrench Or Socket With Ratchet MIV E Override Panel See FSG PL 01505 Sheet 2 2 Phillips Screwdriver If the MIV E override panel switch or bleed valve...

Page 84: ...th panel B Insert four 4 8 32 x 0 75 in long pan head screws thru placard and panel C Install four 4 lock nuts at back of panel D Connect wire harness according to tags E Connect air bleed tubing acco...

Page 85: ...V A Module Connector Pin To Breaker Box LH MIV PB SWT 1 1 SYSTEM POWER N C Connector 3 Pin 1 2 SW MOMENTARY A 6 SW 1 MOMENTARY Input N C 3 SW LED B 5 PB SW LED 1 Output N C 4 SYSTEM GROUND N C Main Gr...

Page 86: ...ical connector from harness D At rear of switch using 1 in wrench remove nut E Remove switch NOTE If the placard is NOT damaged do NOT remove and replace the placard Placard Removal A Open remove MIV...

Page 87: ...n Brass motorized Swing Out valves used for the SAM system SAM utilizes both Gen 1 and or Gen 2 valves and as long as physical space allows the valves are interchangeable AN OFF THE SHELF AKRON BRASS...

Page 88: ...lve requires clocking for physical override access purposes perform paragraph 4 5 3 below to ensure the valve physically operates correctly after reassembly AKRON BRASS SWING OUTTM VALVES FROM A DISCH...

Page 89: ...Perform the following to remove and replace an Akron Brass motorized Swing Out valve used in a SAM system Removal A Tag and disconnect all electric valve actuator connections B If required tag and dis...

Page 90: ...ed to remove dirt and debris which may cause excessive Valve wear and premature failure Reversing the inlet and outlet of an 8840 4 in Akron Brass Swing Out Valve reduces the pressure rating of the va...

Page 91: ...8 4 5 3 Verifying Valve Operation After Valve Clocking NOTE All intake valves are clocked and tested by Hale and should NOT require clocking If a valves clocking is changed perform the following to en...

Page 92: ...red thru Hale or a FAST OEM builder to be plug and play ready for install in the SAM system Do NOT substitute other sourced sensors into a SAM system 4 7 1 Barometer Atmospheric Pressure The barometri...

Page 93: ...G MNL 00212 Table 1 Barometer Sensor Loctite 243 or Equivalent Cable Ties As Required If the barometric sensor fails or is damaged replace the sensor as follows See Figure 46 Removal A Tag and disconn...

Page 94: ...n the Hale website www haleproducts com Refer to Table 28 for a list of tools and or consumables required for this procedure Table 28 Flowmeter Tools And Consumables List Standard Tools Special Tools...

Page 95: ...ssure measurements for all the discharge valves and for the pump intake and pump discharge pressure measurements Hale low pressure trans ducers are used to detect prime and measure the various tank le...

Page 96: ...ground to operate The nominal output signal is linear between 0 5 VDC and 4 5 VDC where 0 5 psiG sensor a signal voltage of 0 5 VDC equals 0 0 psiG a signal voltage of 4 5 VDC equals 5 0 psiG 0 300 ps...

Page 97: ...ble tie locations cut ONLY ties required to R R pressure sensor C At sensor tag and disconnect electric connector D Using 3 4 in wrench remove sensor Installation A Apply Loctite 580 to threads of new...

Page 98: ...ilizes the same Hale pressure sensors as the discharge valves except the sen sors are mounted on the operator panel or pump body NOTE Hale recommends installing these sensors on the rear of the Class...

Page 99: ...Required Wire Cutter Cable Ties As Required 15 16 in Wrench Loctite 580 Pressure Transducer See 118253 Operation Manual If a water column sensor fails or is damaged replace the sensor as follows Remo...

Page 100: ...wire sensor connects as listed in Table 35 Table 35 Gearbox Oil Level Sensor Wiring From To Listing From Pin To A System Power CB1 B Main Ground Stud On Pump Body C Sensor Module A Connector Pin 1 On...

Page 101: ...l Turn SAM system on Check Pump Controller PUMP INFO tab gearbox REMAINING LIFE does NOT indicate LOW Turn SAM system off Disconnect sensor F If sensor is functional install sensor see below Figure 51...

Page 102: ...Pin A Gearbox Oil Temperature 11 Gearbox Oil Temperature Input B System Ground Connects to system ground Table 38 Suction Water Temperature Sensor Wiring From To Listing From Temperature Sensor Pin T...

Page 103: ...2 Gearbox Temperature Sensor Installation A Apply Loctite 580 to threads of new sensor B Install sensor C Connect electric connector according to tags D Install cable ties cut to R R sensor as noted 4...

Page 104: ...eries pumps only indicating an Autolube seal failure and to detect water in the priming system indicating a successful priming operation Figure 54 Water Detection Sensor See Table 40 for the water in...

Page 105: ...alent Water Detection Sensor Autolube See FSG PL 01501 1502 Sheet 3 Water Detection Sensor Gearbox See FSG PL 01501 1502 Sheet 4 Water Detection Sensor Primer See FSG PL 01501 1502 Sheet 5 Reducer Bus...

Page 106: ...sensor function See paragraph 4 15 2 page 145 F Turn SAM system off G Hand tighten sensor until snug H Using 7 8 in wrench torque an additional 1 turn 2 turns maximum past hand tight engagement I Ins...

Page 107: ...None Shop Rag s As Required Wire Cutter Cable Ties As Required Slip Joint Plyers Zero Pressure Solenoid See FSG PL 01501 01502 Sheet 3 9 16 in Wrench Brass Adapter Adjustable Wrench Optional Loctite 5...

Page 108: ...Figure 60 Autolube And Zero Pressure Solenoid Removal Removal A Using slip joint plyers hold nipple Autolube side of solenoid B Using adjustable wrench remove solenoid with water detection sensor C Ho...

Page 109: ...s J Install cable ties cut to R R sensor as noted K Pressurize system to check for leaks 4 7 7 Smart Anode Removal And Replacement The smart anode Figure 61 protect the pump from electrolysis and corr...

Page 110: ...anode as follows Figure 62 Indication Of Failed Smart Anode Removal A Locate failed anode B Note cable tie locations cut ONLY ties required to R R anode C At anode tag and disconnect electric connect...

Page 111: ...lth Indicators THE MODULE DEUTSCH CONNECTORS ARE KEYED TO PREVENT INTERCHANGE ON THAT MODULE OR REVERSE DIRECTION INSERTION DO NOT FORCE A CON NECTOR WITHOUT FIRST VERIFYING THE CONNECTORS ORIENTATION...

Page 112: ...right is provided by the stud located between the two connectors Figure 66 SAM Modules General Appearance 4 8 1 MatrIIx Pressure Governor Module The matrIIx pressure governor module Figure 67 connects...

Page 113: ...Pin From Sensor Connector Pin To A Keyed Connector Mates with Grey Harness Connector 1 Power Input Circuit Breaker Box Connector 1 Pin 3 2 CAN High Buss Green CAN Bus Connector 3 CAN Shield Buss Green...

Page 114: ...put N C NOTE Pin A on intake and discharge pressure sensor connects to system ground Refer to Table 49 for a list of tools and or consumables required for this procedure Table 49 MatrIIx Pressure Gove...

Page 115: ...or display of ap propriate alerts see Figure 15 page 18 Discrete inputs outputs are indicated by the direction of the arrow symbol provided with each signal name pin and buss connections are indicate...

Page 116: ...us Connector 12 Ground Input System Ground B Keyed Connector Mates with Black Harness Connector 1 Anode 1 Input Anode 1 Lead See Table 46 2 Anode 2 Input Anode 2 Lead See Table 46 3 Anode 3 Input Anod...

Page 117: ...screws THE MODULE DEUTSCH CONNECTORS ARE KEYED HOWEVER ALL MODULES UTILIZE THE SAME TWO KEYS VERIFY THE HARNESS LABEL AND THE MODULE PART NUMBER TO ENSURE THE CORRECT MODULE AND HARNESS CONNECTOR ARE...

Page 118: ...e circuit breaker box and Autolube assemblies middle module or modules left most module or modules on shared bracket Connect the module according to Table 52 Table 52 MIV A Module Wiring From To Listi...

Page 119: ...Momentary Input 2 MIV Auto Placard For RH MIV See Table 22 7 SW 2 Momentary Input 2 MIV Auto Placard For LH MIV See Table 22 8 SW 3 Momentary Input 2 MIV Auto Placard For Bottom MIV See Table 22 9 9 R...

Page 120: ...and one 1 flat washer C Using 7 16 in wrench tighten screws THE MODULE DEUTSCH CONNECTORS ARE KEYED HOWEVER ALL MODULES UTILIZE THE SAME TWO KEYS VERIFY THE HARNESS LABEL AND THE MODULE PART NUMBER T...

Page 121: ...e Module Tools And Consumables List Standard Tools Special Tools Consumables PPE Eye and Hand Protection None Shop Rag s As Required Wire Cutter Cable Ties As Required 2 Phillips Screwdriver MIV Contr...

Page 122: ...harness each via a keyed two pin Deutsch connector with one diode located be tween the Hale PRIME pushbutton and the AFS Sensor Module output driving the ESP priming pump and the other diode located b...

Page 123: ...included with every SAM system one controls the pump body priming quick prime and the other controls the SAM drain then one PF valve assembly is added to control pre priming for each MIV ordered with...

Page 124: ...sure See OEM apparatus builder documenta tion manuals for instructions D Tag and disconnect pneumatic tubing 1 4 in tubing E Tag and disconnect priming drain tubing 3 4 in tubing F Using 15 16 in wren...

Page 125: ...riming water to the onboard water tank Figure 76 SAM Drain Valve Block Assembly The SAM drain valve block is comprised of a mounting bracket and a PF valve assembly The PF valve assembly houses an air...

Page 126: ...essure to assembly and check for leaks H Connect water column tubing 3 4 in tubing and drains 3 8 in tubing according to tags Ensure elbow on bottom of PF vale assembly remains open to atmos phere I I...

Page 127: ...see NOTES below Check Valve See FSG PL 01501 01502 01503 Sheet 5 thru 7 Mounting Clamp See FSG PL 01501 01502 01503 Sheet 5 thru 7 If an ABV solenoid fails or is damaged replace the solenoid as follo...

Page 128: ...Install cable ties cut to R R solenoid as noted L Pressurize system to check for leaks M Perform Testing Priming And Air Bleed Component CAN Outputs See paragraph 4 15 7 page 150 Perform a NFPA pump v...

Page 129: ...Blue Wire N C N C N C Aux Input Left RCA White Female Audio Left RCA Black Male N C N C Aux Input Right RCA Red Female Audio Right RCA Red Male N C N C Audio Out Wire Pair White White Black N C White...

Page 130: ...r connection is modified the speakers may be connected to any of the audio amplifiers four channels however always connect all four of the speakers using the same polar ity 4 10 3 Auxiliary Cooling So...

Page 131: ...le tie locations cut ONLY ties required to R R solenoid B Tag and disconnect cooling water tube 3 8 in tubing as follows Push collar to release tubing Pull tubing out of elbow C At solenoid tag and di...

Page 132: ...To DC Converter The DC to DC 12 to 24 VDC converter Figure 81 which connects to the SAM power bus and provides 3 Amps 72 W of 24 VDC power to the Wi Fi router antenna via the ethernet POE elec tric h...

Page 133: ...R information Refer to Table 65 for a list of tools and or consumables required for this procedure Table 65 Wi Fi Router Antenna Tools And Consumables List Standard Tools Special Tools Consumables PP...

Page 134: ...g seal and cover off harness H If applicable discard antennas 2 4 and 5 Ghz antenna support seal housing seal and cover I Discard antenna router Installation A If applicable slide new cover on to harn...

Page 135: ...round stud and the three circuit breaker box connectors which supply all of the power required by the SAM system Additionally the OEM apparatus builder connects apparatus power 12 VDC negative and pos...

Page 136: ...Pressure Governor Module Connector A Pin 1 MIV 2 0 Control Valve Drive Module Pin 1 All present quantity varies MIV Activation Switch Pin 1 All present quantity varies MIV Rocker Switch Pin 3 All pres...

Page 137: ...lock nut on rear of circuit breaker box mounting bracket securing screw selected for removal G Using 2 Phillips screwdriver remove four 4 6 32 X 1 2 in mounting screws Screws are recessed deeply in ea...

Page 138: ...all the remaining two screws and nuts Using 2 Phillips screwdriver and 1 4 in wrench tighten all four 4 screws G Install cover H Using 2 Phillips screwdriver install four 4 cover screws I Connect elec...

Page 139: ...tion boxes a maximum of two 2 AB Swing out TM vales are con nected to each circuit breaker MIVs may connect to the bus bar or have been externally powered by the OEM See Figure 88 Figure 88 Legacy CB...

Page 140: ...breaker Bus bar removal is NOT required If current circuit breaker box perform following a Tag and disconnect electrical connectors b Use cover label see Figure 84 page 115 Figure 85 page 115 and Tab...

Page 141: ...n and unlocking information Then perform the following DO NOT HARD SHUTDOWN THE TABLET POWER OFF BY HOLDING THE POWER BUT TON FOR LONGER THAN 5 SECONDS A HARD SHUTDOWN MAY CORRUPT THE OPER ATING SYSTE...

Page 142: ...equired touch save F Touch home button G Power on apparatus do not engage the pump and wait for manual mode screen Figure 92 to appear Figure 92 Tablet Manual Mode Warning H Press and hold menu icon w...

Page 143: ...rocedure for the assembly of the same name 4 11 1 AB Swing out Valve Motor Rotation DO NOT USE A DRIVER AND SOCKET TO INITIALLY MOVE A CLOCKED VALVE To change the position of the motor on a valve to a...

Page 144: ...om 4 Way Air Valve Pin To MIV A Module Connector A Pin 1 PRE PRIME 1 9 Pre Prime 1 Output 2 System Ground Blk Wire RH MIV PF Valve 4 Way Air Valve From 4 Way Air Valve Pin To MIV A Module Connector B...

Page 145: ...4 way air valve Removal A At failed 4 way air valve tag and disconnect all remaining air hose B Tag note air hose fittings remove fittings from ports A B and IN See Figure 95 Figure 95 4 Way Valve Ai...

Page 146: ...00100 000 Wrench Wrench sizes NOT provided since fitting sizes vary by manufacturer Perform the following to R R an air cylinder Removal A If required tag and disconnect both air lines B Remove air fi...

Page 147: ...Square Seal Type Refer To 538 00097 000 7 16 in Wrench O ring Lubricant See Table 6 page 44 Wrench PF Valve Assembly Refer To 538 00099 000 No 2 Philips Screwdriver Cable Ties As Required Needle Nose...

Page 148: ...A Match mark blank plate to top PF valve and cover to bottom PF valve B Using two 7 16 in wrenches remove PF valve block blank plate and cover re taining bolts Hold nut with washers remove bolt with...

Page 149: ...e from valve stack Remove O ring The O ring may be on the failed valve or on the valve at the top of the stack see Figure 100 If ONLY removing bottom most PF valve at bottom of valve stack remove cove...

Page 150: ...all a new O ring on PF valve See Figure 100 E Align blank plate to top PF valve F At bottom of stack install a new O ring on PF valve G Align cover to bottom PF valve H Install four 4 bolts one 1 flat...

Page 151: ...paragraph 2 1 Hale ID Tag With Sample Markings Figure 1 for detailed Hale ID tag information Perform the following to enable the SAM Control Center Wi Fi A Power SAM system on B Go to Systems Options...

Page 152: ...act Hale Customer Service 800 533 3569 if the new SAM Control Center serial number does NOT end with TCLS or if the This Screen is Wi Fi Capable check box is NOT displayed 4 12 2 Auxiliary SAM Control...

Page 153: ...If SELECT DEVICE MENU Figure 104 is displayed touch MENU icon top center of screen Figure 104 SELECT DEVICE MENU Screen C When Home MENU is displayed Figure 105 if THIS SCREEN IS THE MASTER is displa...

Page 154: ...ouch More button Configuration Mode More Settings screen is displayed Figure 106 Configuration Mode More Settings Screen Touch Save List button If the button grays out wait until it returns to normal...

Page 155: ...rent Date password see Table 3 page 36 and then touch ENTER but ton Set Time And Date Screen Figure 107 is displayed Figure 107 Set Time And Date Screen D Touch arrow to set current date and time MONT...

Page 156: ...er left hand corner of screen 4 12 3 3 Enable Disable Suction Pressure Governor Prior to setting the Suction Pressure Governor enable pressure and Hysteresis enable the Suc tion Pressure Governor by p...

Page 157: ...utton Figure 112 Figure 111 SPG Enable Settings Screen Figure 112 SPG Enable Settings Screen Enable Button Selected G Touch check mark button lower right side of left hand half of screen Updated Gover...

Page 158: ...ings button Governor Menu screen Figure 113 is dis played C On Governor Menu screen touch Page Down button lower left hand side of screen until Page 4 is displayed highlighted in upper right hand corn...

Page 159: ...perform the following A On SAM Pump Controller Figure 28 page 35 display SAM Pump Controller Menu screen see paragraph 2 6 1 2 SAM Pump Controller Password Screen Ac cess page 35 B Touch Governor Set...

Page 160: ...PWR BUS and COM indications and the MIVs do NOT function then typically there is an address issue The module does NOT have to be removed if access permits setting the address with the module in place...

Page 161: ...e and can be very hard to remove from the case Only after ensuring PCB is between guides push PCB into case until tabs lock Perform the Installation portion of the R R procedure See paragraph 4 8 3 pa...

Page 162: ...te dot on each side of the label highlighted by the red circles on Figure 118 Enter a L R command string as provided in the following applica bly labeled subparagraphs Note the following information f...

Page 163: ...ter a LRRRLLLR command string 4 12 6 3 Foam Tank B The foam tank B ITL 40 address is set manually for the SAM system Perform the following for the ITL 40 to communicate with SAM A Power SAM system on...

Page 164: ...SAM Control Center After SAM Setup Configuration Changes Changes to Quicksets or other SAM customizable configurable items valve names and colors foam presets etc must be updated for the remaining SAM...

Page 165: ...e sensor accuracy is typically 2 4 15 2 Water Detection Sensor Tests The SAM system uses three 3 water detection sensors Figure 55 page 84 the gearbox water detector the Autolube water detector and th...

Page 166: ...ociated balloon Gear Water In Oil or autoLube water in oil turns red F If sensor test is successful perform Installation portion of paragraph 4 7 6 using existing sensor See page 85 G If sensor test f...

Page 167: ...be individually controlled and tested See Figure 123 thru Figure 126 Figure 123 SAM Pump Controller I O Testing Outputs Screen Figure 124 SAM Pump Controller I O Testing Inputs Screen Figure 125 SAM P...

Page 168: ...74 and Figure 127 Table 74 MIV A Output Testing Button Name Function Special Comments Pre Prime 3 RH Bot MIV PF Valve Air Pressure Required AUX Output N A Air Prime Optional Air Primer Pre Prime 1 LH...

Page 169: ...Water Detect Input See section 4 15 2 for water detect testing If the desired function does not work verify power harness connection and CAN connection to the component If all three items are good rep...

Page 170: ...Figure 129 Figure 129 TS CAN Output Screen 4 15 6 Testing MIV E Override Panel Manually Operated ABV To test the Manual MIV overrides for the SAM system locate the override placard on the Operator Pa...

Page 171: ...ile to play 4 15 7 1 Test Audio Page The SAM Pump Controller is the source of SAM audio and can be used to test the audio output and components Display the SAM Pump Controller Enter Password screen se...

Page 172: ...led calibrations communications errors and many other SAM issues 4 16 1 2 Akroview Akroview software on a laptop is not required or typically considered a special tool It can be pur chased from the Ak...

Page 173: ...n ual Wire Harness Discon nected Damaged Check wiring continuity Refer to FSG PL 01503 FSG PL 01504 and industry standard Deutsch connector practices Equipment Failure Failed SmartCAFS display Refer t...

Page 174: ...d Deutsch connector practices DISCHARGE VALVE SIGNAL LOST USE MANUAL OVERRIDE CONTINUED Wire Harness Discon nected Damaged CONTINUED Check harness Red CAN bus re sistance See paragraph 4 16 3 page 170...

Page 175: ...ontrol Center Refer to SmartFOAM manual FSG MNL 00158 FRONT INTAKE MIV MODULE SIGNAL LOST OPERATE FRONT MIV WITH MANUAL OVERRIDE KNOB Bottom MIV Valve Drive Module Lost Comm Check harness power connec...

Page 176: ...heck harness power connections and circuit breakers See para graph 4 3 5 page 48 and sec tion 4 10 6 page 115 Check harness Green CAN bus con nections Refer to FSG PL 01503 FSG PL 01504 and industry s...

Page 177: ...Equipment Failure Confirm both MIV A modules are op erational and addressed correctly See paragraph 4 8 3 page 97 R R failed SAM slave MIV A module See paragraph 4 8 3 page 97 R R failed SAM Valve Dr...

Page 178: ...R R failed LH MIV Refer to MIV 2 0 TM FSG MNL 00217 LOSS OF INTAKE RETURNING TO TANK Similar to above SAM reported not receiv ing enough water flow from off board water source See LOW INTAKE PRESSURE...

Page 179: ...d sec tion 4 10 6 page 115 Equipment Failure SAM Pump Controller analog to digi tal conversion circuit failed See par agraph 4 4 2 page 53 POSSIBLE CAVITATION During drafting SAM de tected cavitation...

Page 180: ...reset pressure limits for all LDH 4 and 5 in discharges NOTE Operating pressure limit is NOT 185 psi for all LDHs Set limit per AHJ Calibrate all SAM pressure readings See section 5 2 page 173 PRESSUR...

Page 181: ...Green CAN bus re sistance See paragraph 4 16 3 page 170 Equipment Failure Verify RH MIV Valve Drive module is addressed correctly See paragraph 4 8 4 page 100 R R failed RH MIV Valve Drive mod ule See...

Page 182: ...EN CAN Communications Lost CAN Communication Lost Due To Wire Harness Dis connected Damaged Check harness power connections and circuit breakers See para graph 4 3 5 page 48 and sec tion 4 10 6 page 1...

Page 183: ...s power connections and circuit breakers See para graph 4 3 5 page 48 and sec tion 4 10 6 page 115 Check harness Red CAN bus connec tions Refer to FSG PL 01503 FSG PL 01504 and industry standard Deuts...

Page 184: ...martCAFS Display Failure Refer to FSG MNL 00157 CAFS manual SAM Pump Controller Failure R R failed SAM Pump Controller See paragraph 4 4 2 page 53 SAM Control Center Failure R R failed SAM Control Cen...

Page 185: ...sensor using a Multimeter and a test harness see Figure 123 Dis connect the SAM harness connector from the barometric sensor and insert the test harness be tween the harness connector the sensor Refe...

Page 186: ...rate Is Erroneous A Remove flowmeter paddlewheel and verify paddlewheel is clean and spins freely B Recalibrate flowmeter see section 5 3 page 178 No Flowrate Is Displayed A Observe Flow column readin...

Page 187: ...ct the presence or absence of oil and actuates a solid state switched output volt age to SAM When no oil or liquid is detected the sensor outputs zero voltage Once oil or liquid is detected the sensor...

Page 188: ...ced See Table 78 page 153 HIGH GEARBOX TEMPERATURE under the SYMPTOM column Erroneous Temperature Ensure engine exhaust is NOT blowing directly on sensor Recalibrate the sensor using the Pump Controll...

Page 189: ...dicating that 4 16 2 8 Diode Troubleshooting Set multimeter to test a diode Plug test connector into multimeter black lead to common input Ensure SAM power is OFF no voltage at diode Plug test connect...

Page 190: ...erminating resistors Figure 138 Figure 138 Terminating Resistor C Measure resistance between CAN H and CAN L See Figure 139 Figure 139 Bus Termination Test Setup D Verify multimeter indicates 60 10 s...

Page 191: ...er column sensor hose 10 feet of 3 4 in flex tubing provided is con nected to onboard water tank Verify SAM system interlock wiring is connected to the apparatus Shift into pump gear and 4th gear lock...

Page 192: ...172 THIS PAGE INTENTIONALLY BLANK...

Page 193: ...RAINS AND AIR BLEED VALVES TO ENSURE THE SYSTEM IS NOT PRESSURIZED AND THE VALVE S CAN BE OPENED AND CLOSED SAFELY BEFORE PROCEEDING WITH VALVE CALIBRATION Reference paragraph 8 1 2 3 Akron Valve Firm...

Page 194: ...e pressure sensor associ ated with the selected valve While the SPAN PRESSURE SENSOR calibrates the high end accu racy of the pressure sensor associated with the selected valve Touch the button for th...

Page 195: ...ed valve will open and close twice The routine will run one valve at a time in sequence until all selected valves have been calibrated A Touch desired bus button Red or Green Green is the default sele...

Page 196: ...en selected valve s indicate Calibrated perform one of following Touch Red dot next to another valve and repeat steps above to calibrate another valve Or return to CALIBRATION MENU screen touch Calibr...

Page 197: ...e calibration will calibrate all pressure sensors in the system at the same time including the intake and discharge pressure sensors The Akron Brass Style 9327 Navigator Mini Valve Controller does NOT...

Page 198: ...ted on bottom of the EDIT VALVE screen in the SELECT DEVICE MENU Refer to FSG MNL 00211 for passwords screen navigation and detailed instructions Use this procedure to assign or reset to the default f...

Page 199: ...ure Contact the AHJ for applicable OEM Technician information Perform the following to calibrate the valve position sensor for the selected discharge valve A Close all discharge valves B On SAM Contro...

Page 200: ...equentially touch digits of flow value Touch DONE button Touch SEND FLOW button NOTE If entry errors are made that cause the calibration to fail or become unresponsive touch the perform Set Flow Facto...

Page 201: ...53 5 4 1 Water Tank The ITL 40 can be calibrated the traditional way using the 1 2 or 9 point calibration refer to ITL 40 manual P N 118253 Alternatively the water tank level can be calibrated automat...

Page 202: ...or module replacement otherwise cali brate the pump master intake and discharge pressure sensors using the Pressure Procedures SAM Control Center paragraph 5 2 2 1 page 177 DISENGAGE PUMP BEFORE PERFO...

Page 203: ...tton Figure 153 Governor Menu Screen E Zero pressure sensors as follows a Select Zero pressures b Touch settings button red button with gears and wrench c Touch desired sensor d Touch green check mark...

Page 204: ...n Screen Pump Shown E Using digits pad enter correct temperature form test equipment or calibrated thermometer into Desired Temperature F Touch enter button G Touch Save button disk icon at bottom rig...

Page 205: ...displayed voltage left most column and the desired voltage displayed on the test equipment or other voltage readout from apparatus under the New Value column right most column Do NOT enter the readout...

Page 206: ...186 THIS PAGE INTENTIONALLY BLANK...

Page 207: ...GUI OR REBOOT TO GUI BUTTON BEFORE RETURNING THE APPARATUS TO SERVICE 6 1 SAM Control Center Setup Configuration To access advanced settings for the SAM Control Center enter the Technician Level 2 pa...

Page 208: ...enu Many of the following assignments settings can only be accessed by an OEM apparatus builder or a Hale FAST center Many of the fields listed in this section are critical to the proper operation of...

Page 209: ...g valves for movement until the associated physical valve is located Update associated edit valve data entries according to the physical valve identified 6 3 Assigning Quicksets To The Home Screen Ref...

Page 210: ...Select Menu see para graph 6 1 3 1 page 188 to access SELECT DEVICE screen Figure 158 B On SELECT DEVICE screen touch desired Friendly Name the one to be changed to navigate to EDIT VALVE screen C On...

Page 211: ...OT index an auxiliary intake Pony as 0 thru 3 These valves can ONLY be draft operated in Manual Mode Additionally pony valves are NOT opened by SAM in the same way as MIVs in Auto Mode no automatic pr...

Page 212: ...gun 6 10 How To Assign Change A Valves MAX PSI After selecting the desired valve touch the MAX PSI 0 to 300 text box see Figure 161 except MAX PSI 0 to 300 is highlighted The number pad CLEAR and ENTE...

Page 213: ...AM Preset 6 13 How To Assign Change A Valves CAFS FOAM Capability After selecting the desired valve touch the CAFS Capable box and select a value of 0 to 4 See Table 83 for a description of each value...

Page 214: ...and assign change color as follows a If a color is desired touch desired swatch b If a change to no color is desired touch NONE button If border portion of icon is desired touch BORDER box and assign...

Page 215: ...ers for the same device Function Intakes are assigned a function number of two 2 D Touch DONE button E Perform Saving The Configuration Changes paragraph 6 19 page 197 6 17 Configuring SAM For A Foam...

Page 216: ...9 D Perform Assigning Quicksets To The Home Screen paragraph 6 2 2 1 page 189 6 17 3 Configuring A CAFS Preset If a discharge is to be used for CAFS and initialized by SAM create a foam preset for the...

Page 217: ...t each bus Relocate the termination resistor s if required Table 84 Captium To SAM Wiring From To Listing Captium Display Green Connector 1 Pin To SAM Control Center Black Connector To Pump Controller...

Page 218: ...user interface Figure 164 Update Network With New Configuration Information Screen The button remains highlighted see Figure 165 until the user interface reboots and displays the SAM Auto Mode Home or...

Page 219: ...y of the following New Features Current Feature Enhancements Minor Bug Fixes When a new software update is available Hale Products will post a news bulletin The bulletin will provide information about...

Page 220: ...200 THIS PAGE INTENTIONALLY BLANK...

Page 221: ...and self locking properties Do NOT reuse fasteners with self locking prop erties This coating conforms to MIL F 18240 MIL N 25207 and Industrial Fastener Institute IFI 124 and IFI 524 The torque value...

Page 222: ...3 8 24 23 35 50 21 6 22 6 13 1 17 7 20 2 7 7 16 14 30 50 70 31 3 32 8 19 26 4 29 1 3 3 7 16 20 35 55 80 33 3 34 8 20 2 27 3 30 9 3 3 1 2 13 50 75 110 43 1 45 2 26 1 35 2 40 5 1 2 20 55 90 120 45 1 47...

Page 223: ...ditionally included herein is warranty information B 1 MANUFACTURER S INFORMATION Division Address Telephone Class 1 Mailing 607 NW 27th Ave Ocala FL 34475 Email https www haleproducts com 800 533 356...

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