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Installation and Operation Manual

Hydraulic Plumbing Installation

Figure 7-1 FoamPro AccuMax SP Hydraulic System Diagram

Hydraulic

Reservoir

Hydraulic

Pump Suction

Hydraulic Pump

Cooler Inlet

Motor Inlet

Motor Return

System Return

Hydraulic

Oil Cooler

Foam

Pump/Motor

Assembly

Hydraulic Motor

Case Drain

Hydraulic Pump

Upper Case Drain

Hydraulic Pump

Bottom Case Drain

Figure 7-1 provides some recommended guidelines for

the location of the hydraulic system components. When

making hydraulic component connections ensure all

applicable DOT and SAE standards are followed. Use

hoses and fittings rated at least the maximum working

pressure listed in Section 15 for the hydraulic oil high

pressure lines. See Section 15 for required fitting sizes,

minimum hose size, and minimum pressure ratings.

The fittings required to connect the hydraulic hoses to

the FoamPro AccuMax SP foam pump motor and

hydraulic supply pump are SAE ORB (O-Ring Boss)

fittings with SAE JIC 37° flare swivel, and SAE Split

Flange port connections.

CAUTION: To ensure the integrity of fitting

connections in the hydraulic system, use only SAE

JIC 37° flare, SAE O-Ring Boss, or SAE Split Flange-

type hose connections.

CAUTION: Use only approved petroleum-based

hydraulic fluids as described in Section 4. Never mix

fluid types. Ensure all hoses and seals are

compatible with fluids used. Do not use water or

glycol-based fluids. Do not use phosphate ester-

type fluids. Other hydraulic fluids such as SAE 10W-

40HD motor oil are too viscous for proper pump

performance.

Hydraulic Power Source

The hydraulic power for the FoamPro AccuMax SP

system is supplied by a hydraulic pump mounted on the

fire apparatus engine, transmission, or auxiliary PTO.

The hydraulic pump supplied with the system has been

chosen to provide the required flow and pressure to

drive the FoamPro system.

Refer to Section 4 of this manual for further pump and

PTO information and Section 15 for detail dimensions of

the pump. See the table in Section 15 for all proper hose

sizes, pressure ratings, and fittings for the various

hydraulic components supplied by FoamPro.

Содержание AccuMax 3040

Страница 1: ...roughly inspected and tested In order to maintain the high quality of your unit and to keep it in a ready condition it is important to follow the instructions on care and operation Proper use and good...

Страница 2: ...ION 18 9 ELECTRICAL EQUIPMENT INSTALLATION 23 10 MAKE SURE EVERYTHING IS WORKING RIGHT 30 11 CALIBRATION AND SETUP 33 12 OPERATION INSTRUCTIONS 36 13 MAINTENANCE 43 14 TROUBLESHOOTING 44 15 SPECIFICAT...

Страница 3: ...only pipe hose and fittings from the foam pump outlet to the injection point which are rated at or above 400 PSI 28 BAR minimum rating at which the water pump system operates Use only pipe hose and f...

Страница 4: ...tions CAUTION The cables shipped with each FoamPro system are tested at the factory with that unit Improper handling and forcing connections can damage these cables which could result in other system...

Страница 5: ...e of the desired proportion of foam concentrate at all times based on water flow rate independent of any variations in fire pump intake or discharge pressures As water flow increases or decreases the...

Страница 6: ...6 Hydraulic Pump and ground Hydraulic Control Driver Figure 2 1 FoamPro 3000 System Layout Installation and Operation Manual...

Страница 7: ...NFPA 1906 draft required check valve prevents water back flowing into foam system 10 RFI EMI Suppression Beads 11 FoamPro Paddelwheel Flowmeter The flowmeter is a required component The size is speci...

Страница 8: ...the discharge piping The FoamPro MultiFlo Interface allows a total of four flowmeters to be used The display will show the discharge flow on the selected flowmeter Part Number 2527 0140 System Placar...

Страница 9: ...ange size and shaft configuration Other shaft configurations are available The shaft rotation of the pump is clockwise when looking at the pump shaft or counterclockwise when facing the rear of the pu...

Страница 10: ...te Suction Lines Fittings and hoses from the foam tank to the inlet of the foam pump must be supplied Use the minimum inside diameter or larger clear suction hose shown below for the corresponding sys...

Страница 11: ...hat may be available Drain lines must be provided from all water and foam solution piping components to prevent freezing in cold weather Multiple drain systems that allow individual drain lines to con...

Страница 12: ...gral foam tank s make sure provisions are made for installation of the low tank level sensor as well as foam suction connections and tank drainage Determine a location on the operator panel of the app...

Страница 13: ...nts and the main water system Do not hard plumb the system Be sure the hydraulic hoses and the foam concentrate hoses can be properly routed to the inlets and outlets on the foam pump Foam concentrate...

Страница 14: ...Code 62 Port A 1 Split Flange Boss SAE J518 Code 62 Port A 12 SAE O ring Port 2 NPT Suction Port 2 NPT Discharge Port 531 20 9 226 8 9 51 2 0 200 7 9 251 9 9 169 6 6 789 31 1 308 12 1 142 5 6 203 8 0...

Страница 15: ...r Thd Case Outlet Port B 1 Split Flange Boss SAE J518 Code 62 Port A 1 Split Flange Boss SAE J518 Code 62 1 SAE Split Flange Port A 1 SAE Split Flange Port B 3 NPT Inlet 3 NPT Outlet 476 18 7 601 23 7...

Страница 16: ...ngs with SAE JIC 37 flare swivel and SAE Split Flange port connections CAUTION To ensure the integrity of fitting connections in the hydraulic system use only SAE JIC 37 flare SAE O Ring Boss or SAE S...

Страница 17: ...is supplied with these systems CAUTION Ensure all hydraulic hoses and components are clean and free of debris CAUTION Ensure hydraulic fluid is clean and free from contamination when filling and chan...

Страница 18: ...lation The following diagram Figure 8 1 provides recommended guidelines for the installation of the system components that handle water foam concentrate and foam solution Note that additional options...

Страница 19: ...stem are sized properly for most applications See Section 4 for further information The appropriate strainer is to be installed on the inlet side of the foam pump The hose from the foam tank should ha...

Страница 20: ...is common to all discharges which require foam capability This position may be before or after the main water flowmeter but not within the straight run distance required for the flowmeter as previous...

Страница 21: ...s or other means of isolation are not to be used as a substitute for proper flushing of apparatus lines after usage Figure 8 6 Recommended Midship Pump Installation Flushing System Depending on the co...

Страница 22: ...oam pump inlet The pickup should be positioned between the foam tank shut off valve and the foam inlet line strainer A tee the same size as the tank to pump line may be placed in the suction line with...

Страница 23: ...ook up the main power cables until all connections are made to each of the electrical components The last connection should be the power cable to foam pump motor base assemblies Warning The electric m...

Страница 24: ...ds on the back of the front plate see Section 15 for a mounting template The display requires 5 inches 127 mm minimum clearance from the back of the operator panel to clear wires and connectors Make s...

Страница 25: ...ctions must be made inside the pipe nipple a 3 8 NPT pipe nipple with a 3 8 by 1 8 NPT reducer at the lower end is the minimum size recommended When the foam tank low level sensor is suspended for the...

Страница 26: ...ire protected with a wire loom Install a 5 amp fuse to the power line to the valve driver Always connect the ground lead from the valve driver to the chassis or to a good solid ground location Never c...

Страница 27: ...h the AMP connector attaches to the flowmeter This foam flowmeter will also need a separate power and ground line that will connect with the 2 pin Weatherpak connector as shown in Fig 9 10 The wiring...

Страница 28: ...pressure in the manifold is maintained at 218 PSI 15 BAR If foam is drained from the manifold the foam pump will run to ensure the pressure is maintained The foam pump will maintain the set pressure i...

Страница 29: ...out 1 4 of the way open 4 Turn the Override switch from OFF to MANUAL 5 The foam pump will deliver foam to the override manifold and injection line The foam pump will deliver enough foam to maintain a...

Страница 30: ...ured radio antennas power lines and equipment are away from control cables and flowmeter cables All components Digital Display Control Module Flowmeter Tee and Pump Base are properly grounded using fl...

Страница 31: ...on The hydraulic motor driven foam pump should begin to operate and foam concentrate should begin flowing into the container If concentrate is not being pumped first check to make sure the hydraulic m...

Страница 32: ...ll the pump with concentrate 3 Replace the pipe plug CAUTION When pouring foam concentrate directly into the foam pump the inlet strainer is bypassed Make sure contaminates are not poured into the pum...

Страница 33: ...enter the setup and diagnostic modes See Figure 11 1 Enter the setup mode by pressing the internal button on the left side of the controller Enter the diagnostics mode by pressing the internal button...

Страница 34: ...th an accurate flow measuring device Determine the water flow normally expected from that flowmeter discharge outlet For example actually establish a flow of 150 gpm 568 L min of water through a nozzl...

Страница 35: ...tem Reset During calibration procedures it may be necessary to return the system to the original factory default settings if errors are made and the system locks up To return to the factory default va...

Страница 36: ...foam injection at the specified concentrate injection rate The system responds to variations in water flow by increasing or decreasing the speed of the foam pump When the FOAM button is again pressed...

Страница 37: ...ed to keep a record of how many units of water and or foam is used per incident Foam Percentage When the concentrate percentage is selected the up and down buttons will respectively increase or decrea...

Страница 38: ...OW labels will illuminate and the lamp below the ON label will flash The rate of water flow will be displayed in units per minute 3 Press the SELECT button white upper right button until the LED lamp...

Страница 39: ...on press the FOAM button the foam injection will stop Press the SELECT button white upper right button until the LED lamp below FLOW is illuminated The water flow rate through the foam discharge s wil...

Страница 40: ...UP or DOWN to select the desired simulated water flow rate The FoamPro will respond and immediately begin operating at the new flow rate CAUTION Be certain that an outlet is provided for the foam conc...

Страница 41: ...utlet tube NOTE FoamPro must be in Simulated Flow Mode 5 Press both rate adjustment buttons at the same time The symbol will leave the display and the FoamPro will operate automatically from the flow...

Страница 42: ...discharge and shut down apparatus 6 Open foam concentrate tank shut off valve 7 Perform required maintenance checks on the FoamPro AccuMax SP Priming the Foam Pump When Foam Tank Has Run Dry In some...

Страница 43: ...ydraulic oil reservoir with proper hydraulic oil as noted in Section 4 NOTE Other types of hydraulic fluids are too viscous for proper load sense compensator operation Do not mix hydraulic fluid types...

Страница 44: ...lue shown reflects the level of the liquid foam concentrate in the tank Lo Con indicates that the tank is empty Hi Con indicates a satisfactory level for operation This is a test of the low tank level...

Страница 45: ...ctuates fittings for leaks by pressurizing hose with water Make sure thread sealant has been used on all fittings Suction line is blocked collapsed Remove suction line and inspect it for a loose liner...

Страница 46: ...Replace control cable Digital display has been damaged Replace the digital display Poor ground on system or controller Make sure screws are tight and a good ground is maintained System is powered up...

Страница 47: ...precise proportioning Check flowmeter calibration Foam pump capacity below rating Inlet strainer obstructed Remove and clean inlet strainer Inlet plumbing obstructed Check all piping valves and hoses...

Страница 48: ...values selected are out Perform system reset as of range of system or setup memory described in Calibration Section is full and recalibrate Cannot enter Calibration Mode Truck hydraulics and hydraulic...

Страница 49: ...7 29 5 111 7 47 4 179 4 PTO Pump RPM for Max Performance RPM 1381 1336 1579 1200 1485 1387 PTO HP HP kW at Max Performance 20 5 21 0 29 5 22 0 53 3 39 8 70 5 52 8 85 3 63 6 185 1 138 1 PTO Torque at M...

Страница 50: ...g Motor Port B 3060 1 3600 PSI 1 SAE Split Flange 12 SAE O Ring Hydraulic Pump Port A to 3090 1 4500 PSI 1 SAE Split Flange 1 SAE Split Flange Motor Port A 3150 1 4500 PSI 1 SAE Split Flange 1 SAE Spl...

Страница 51: ...51 RFI Kit for Controller 3430 0353 RFI Kit for Flowmeter 8 6032 0012 Instruction Placard Ref Part No Description 9 3320 0046 Check Valve 3020 3040 3320 0041 Check Valve 3060 3320 0047 Check Valve 309...

Страница 52: ...2740 0014 Coupling Pump 3020 3040 1 2740 0008 Coupling Pump 3060 1 2740 0012 Coupling Pump 3090 3150 3300 1 3 2729 0007 Insert Coupling 1 4 2740 0013 Coupling Motor 3020 3040 1 2740 0009 Coupling Moto...

Страница 53: ...s for Display Control Module Cutout Dimensions for Instruction System System Spec Placards Display Requires 3 7 8 98 mm Diameter Hole 68 7 88 9 88 9 108 4 25 108 4 25 4 25 4 25 2 81 20 DIA THRU 3 50 1...

Страница 54: ...16 mm 20 750 8 900 2660 0034 3 8 NPT 4 Pipe 5 1 2 140 mm 4 7 8 124 mm 30 1150 12 1380 2660 0034B 3 11 BSP 4 Pipe 5 1 2 140 mm 4 7 8 124 mm 30 1150 12 1380 2660 0035 4 8 NPT 5 Pipe 5 1 2 140 mm 5 3 8 1...

Страница 55: ...et Root Side Fit 4 00 Dia 38 1 59 Port A Pressure Port 6 SAE ORP 10 26 Port B Pressure Port 6 SAE ORP 1 32 5 66 8 34 Case Drain Port 12 SAE ORP Charge Inlet Port 16 SAE ORP 56 Dia 5 75 6 87 6 85 4 73...

Страница 56: ...1 1 16 12 SAE O ring Port Port B Outlet 1 SAE Split Flange Port Charge Pump Inlet 1 5 16 12 SAE O ring Port Port A Return 1 SAE Split Flange Port Flat Root Side Fit 12 24 Pitch 14 Tooth SAE Splined Sh...

Страница 57: ...m Gauge Port M2 9 16 18 SAE Ring Port 1 SAE Split Flange Port Outlet SAE O ring Port 1 5 16 12 Charge Pump Inlet 1 SAE Split Flange Port Return Electric Control Valve SAE C Mounting Flange Rotation CW...

Страница 58: ...9 16 18 SAE O Ring Port Port B 1 1 4 6000 PSI Split Flange Port Code 62 Port A 1 1 4 6000 PSI Split Flange Port Code 62 Charge Port 1 5 8 12 SAE O Ring Port Case Drain 1 5 16 12 SAE O Ring Port Note...

Страница 59: ...59 Installation and Operation Manual AccuMax SP Notes...

Страница 60: ...ated THERE ARE NO OTHER EXPRESS WARRANTIES ANY IMPLIED WARRANTIES INCLUDING IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO ONE YEAR FROM THE DATE...

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