Elkhart Brass 7400 EXM User Manual
PHYSICAL: 1302 WEST BEARDSLEY AVE • ELKHART, IN 46514 • WWW.ELKHARTBRASS.COM © 2014 ELKHART BRASS MFG. CO., INC.
MAILING: P.O. BOX 1127 • ELKHART, IN 46515 • 1-574-295-8330 • 1-800-346-0250 98342000 REV F
7400 EXM Monitor
Installation, Operating, & Maintenance Instructions
2
TABLE OF CONTENTS
PRODUCT SAFETY INFORMATION 3
MONITOR CALLOUT DRAWING 4
SYSTEM COMPONENTS 5
INSTALLATION INSTRUCTIONS 9
Installation Step 1: Mount and Wire all System Components 10
Installation Step 2: Configure the EXM System 17
Installation Step 3: Calibrate the EXM System 18
Installation Step 4: Check Installation 20
OPERATING INSTRUCTIONS 21
MAINTENANCE INSTRUCTIONS 28
SYSTEM SPECIFICATIONS 30
MONITOR AND NOZZLE HYDRAULIC DATA 34
COMPONENT MOUNTING TEMPLATES 36
To view the most current parts list, drawings, or demonstrations of common EXM commands,
please visit www.elkhartbrass.com
3
PRODUCT SAFETY INFORMATION
Important: Before installing and operating provided equipment, read this manual
thoroughly. Proper installation is essential to safe operation.
All personnel who may be expected to use this equipment must be thoroughly trained in its safe and
proper use.
Before flowing water from this device, check that all personnel (fire service and civilian) are out of
the stream path. Also, check to make sure stream direction will not cause avoidable property
damage.
Become thoroughly familiar with the hydraulic characteristics of this equipment, and the pumping
system used to supply it. To produce effective fire streams, operating personnel must be properly
trained.
Whenever possible, this equipment should be operated from a remote location. Do not needlessly
expose personnel to dangerous fire conditions.
Open water valves supplying this equipment slowly so that piping fills slowly, thus preventing
possible water hammer occurrence.
After each use, and on a scheduled basis, inspect equipment per instructions in the Maintenance
section.
Any modifications to the electrical enclosures will destroy the NEMA 4 rating and void warranty
coverage of the enclosure and all components within.
SYSTEM INFORMATION:
MONITOR SERIAL NUMBER:________________________________________________________
MONITOR ACCESSORIES (NOZZLE GALLONAGE AND TYPE, TYPES OF TRANSMITTERS, WATER
VALVE, ETC.):
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
4
MONITOR CALLOUT DRAWING
X-Stream Series Electronically Actuated Nozzle
3.5” NHT Discharge
Fully Vaned Cast Aluminum Waterway
Manual Override
Double Race Bearings
4”-150# Flange Base
Sealed High-Torque Gearmotor
Absolute Position Feedback
Double Race Bearings
7400 Monitor
RF Antenna
5
SYSTEM COMPONENTS
MONITOR
Caution: All EXM monitor motors are 12VDC. If using a non-EXM nozzle, another
12VDC nozzle should be used, or nozzle control may not function properly.
NOZZLE
SM-1250E (P/N: 03781211) &
SM-2000E (P/N: 03990201)
Monitor – 7400
The monitor is specially designed for severe
duty cycles. Unique waterway swivel joints utilize stainless steel
thrust rods and needle roller thrust bearings for unprecedented
durability in all firefighting applications. The monitor can be
controlled by hardwired input devices via CAN bus or by an optional
upgraded Radio Frequency (RF) device. The monitor may be
powered with 12 or 24 Volts.
High power, permanent magnet variable speed DC gear motors that
drive the left-right and up-down monitor motions are NEMA 4 rated
for use in harsh environments. The monitor
has a flow efficient 3½” vaned waterway to minimize turbulence and
provide superior nozzle streams. The water supply connection in the
monitor base is a 4”-150# flange, and the discharge nozzle
connection has a 3½” national hose male thread.
An optional 4” electric valve kit is available to allow the user to control water flow directly from the EXM
input device. This enables “pump and roll” functionality with complete control by the operator in the
cab.
Nozzles –
There are two nozzles available for the .
SM-1250E & SM-2000E
Each nozzle automatically adjusts to maintain effective stream
and maximum reach at variable flows. These nozzles have
been calibrated to work at lower pressures, from 75 to 80
PSI, to better suit real world conditions.
SM-1250E; 350 GPM @ 50 PSI - 1250 GPM @ 75 PSI
SM-2000E; 500 GPM @ 50 PSI - 2000 GPM @ 80 PSI
6
CONTROL
Caution: Any modification of the Joystick, Panel Mount, or Handheld Controller
enclosures will destroy the NEMA 4 rating to that piece of equipment and will void the
warranty coverage.
Joystick Controller - 7030
The Joystick Controller must be used in conjunction with the 7070 OEM
Interface Module (Joystick and OEM Interface Module can be ordered
together as the 7035 package). The Joystick Controller can be mounted
inside the apparatus cab to control all monitor functions, including
oscillation. The monitor direction (both vertical and horizontal
movement) is changed by moving the joystick in the desired direction of
travel. The up-down and left-right motions can be operated
simultaneously with pressure sensitive speed, moving the monitor faster
or slower depending on how far the joystick is pushed and pulled. The
water valve can be opened with a trigger switch located on the front of
the joystick or can be locked into position through the use of the valve
buttons on the joystick. Nozzle pattern can be changed using the thumb
wheel on the top of the joystick. Oscillation is programmed by using the
joystick in conjunction with the oscillate button.
Panel Mount Controller – 7010
The Panel Mount Controller is a sealed controller for operation of the
monitor, nozzle, and water valve (optional). Separate push button
switches are provided for up, down, left, right, fog and straight stream,
valve open, valve close, valve preset, oscillation, and auxiliary functions.
The Panel Mount may be powered with 12 or 24 Volts.
Handheld Controller with Docking Station– 7015
When paired with battery pack, docking station, and RF transceiver
module, the Panel Mount Controller becomes a Handheld Controller.
The Handheld Controller is a sealed remote control that contains all the
controls necessary for operation of the monitor, nozzle, and water valve
(optional). The handheld wireless remote allows the operator to control
the monitor from a significantly improved point of view, allowing the
operator to confirm that they are hitting the desired target. Separate
push buttons are provided for up, down, left, right, fog and straight
stream, valve open, valve close, valve preset, oscillation, and auxiliary
functions. The handheld remote, through the use of frequency hopping
techniques, allows multiple transmitters to operate on a common site
without interference. The remote also has an automatic power down
feature that will shut down the power after 5 minutes of no activity. As
an additional power saving feature, the radio signal is only transmitted
while buttons are pushed. The handheld remote case has a NEMA 4
rating. The Handheld may be powered with 12 or 24 Volts.
7
MONITOR ACCESSORY
OEM Interface Module - 7070
The OEM Interface Module is used in conjunction with either the Elkhart
Brass or customer supplied joystick, or OEM installed switches. The
OEM Interface Module may be configured to handle switching power or
ground. The Interface Module provides the option of mounting a joystick
or switches in the apparatus cab to control all monitor functions,
including oscillation. The OEM Interface Module may be powered with
12 or 24 Volts.
Position Feedback Display - 7051
All EXM monitors come with Absolute Position Feedback sensors. These
sensors provide constant feedback to the monitors’ processor even
when the monitor is moved via manual override. This information is
then transmitted to the Position Feedback Display.
EXM CAN Stow Module- 7095
The EXM CAN Stow Module provides electrical outputs to which an OEM
can connect to in order to enable/disable truck operations based on
whether an EXM monitor is stowed or not stowed. This could be used,
for example, for a truck that has an aerial or other movable object that
may hit the monitor if moved when the monitor is not stowed. These
outputs could also be used to turn OEM-supplied indicator lights on or
off depending on the monitor stow state.
External RF Antenna Module - 7062
The External RF Antenna Module can be utilized with an RF equipped
7070 OEM Interface Module. The 10ft. extension harness allows the
antenna to be mounted in a position with a better line of sight to the
monitor. Use of the external RF antenna module is required for aerial
applications. The external antenna should also be used with the OEM
interface module when RF interference is likely.
RF Transceiver Module - 7061
The RF Transceiver Module can be used with any input controller to
enable RF communication within the EXM system.
Light Kit - 7085
The Light Kit provides illumination specifically for the areas targeted by
EXM monitors. The Light Kit is mounted on top of the discharge elbow
and follows the aim of the monitor. Installation instructions are included
with the light kit.
8
VALVE
CAN Connector Kit - 37221000
This kit provides the wired connectors needed to branch off the main
CAN communication line, and allows you to connect another EXM
component between the two EXM components at the ends of the main
line. One kit is needed for each additional EXM component that is
added to the main CAN line.
Unibody Valve with E3F Electric Actuator -
The water valve kit provides a convenient remote
open, close, and preset valve positioning control of the water supply to
the . This allows the operator complete control of
the unit from the safety of the vehicle cab or handheld radio controller.
The water valve motor speed prevents water hammer, yet closes quickly
enough to help preserve the limited on-board water supply. The electric
actuated Unibody Valve may be powered with 12 or 24 Volts.
9
INSTALLATION INSTRUCTIONS
Step 1 – Mount and Wire All System Components
Step 2 – Configure the EXM System (If Required)
Step 3 – Calibrate the EXM System
Step 4 – Check Installation
Installation Overview:
Recommended electrical requirements for monitor:
Power and Ground wire gauge and length: Distance Ft. (m) Wire Gauge (AWG)
100 (30.5) – 150 (45.7) 8
< 100 (30.5) 12
Power and Ground wire type: Cross Link or equivalent (Must meet or exceed NFPA 1901 Section 13)
Maximum monitor amperage draw: 20 AMPS (35 AMPS for Foam Tube Expansion)
CAN wire gauge and length:
o Main Line: 131 ft. (40 m) – 18-20 AWG (Must meet J1939 specification)
o Branch (node) Line: 3ft. (1 m) – 18-20 AWG (Must meet J1939 specification)
CAN wire type and shielding: Twisted shielded pair - 105°C 150V (Belden 9841 series or equivalent)
o Shield Drain: Connect shield/drain to pin C of J1939 connector
Recommended electrical requirements for the 7000 series input devices:
Power and Ground wire gauge and length: 18-20 AWG 105°C 150V up to 150 ft. (45.7 m)
Maximum input controller amperage draw: 500mA
CAN wire gauge and length: 3 ft. (1 m) – 18-20 AWG
CAN wire type and shielding: Twisted shielded pair - 105°C 150V (Belden 9841 series or equivalent)
o Shield Drain: Connect shield/drain to pin C of J1939 connector
Docking station wire gauge type: 20 AWG cross link or equivalent
Termination Points:
When using CAN lines for communication there must be 2 termination points within the system.
Termination points are explained further in the Configuration section (installation step 2). What is
important at this time is that in order to maximize the efficiency of communication in your CAN
network, you must terminate the two components at the extreme ends of your main CAN line. This
should be taken into consideration as you setup your EXM system. Each additional EXM component that
requires connection to the main CAN communication line between the two end components will
require the use of CAN Connector Kit (P/N 37221000). The maximum length of wire from the main
CAN line is 3ft. and would be considered a branch (node) off the main CAN line.
CAN Connector Kit:
You may install any of the EXM CAN components that require
the use of a CAN Connector Kit (P/N 37221000) by plugging
the tri-pin CAN connector from the EXM component directly into
the wye connector (Deutsch DT04-3P-P007) of the CAN
Connector Kit. You can also use the crimp connectors on the
mating connector leads to make your own connection.
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Installation Step 1: Mount and Wire All System Components
Caution: Do NOT use motors or discharge as leverage to tighten monitor.
Warning: When installing the monitor on a raised face companion flange, it is critical
that the bolts be tightened uniformly to prevent misalignment of the monitor relative to
the flange or valve. If the monitor becomes misaligned, the base flange will fracture and
fail when the bolts on the “high” side are tightened.
1
2 1 2
Installation instructions have been included for all EXM components.
Monitor –
Before mounting the monitor, ensure that space allows for monitor to be
rotated and calibrated. Disconnect all electrical connections.
Mount the monitor onto an appropriate flange with eight (8) 5/8-11
UNC grade 5, carbon steel or stainless steel bolts & nuts. Seal
flange joint with gasket or suitable flange sealant, and torque bolts
uniformly (20 ft-lbs at a time in a crisscross pattern) to 60-70 ft-lbs.
using blue Loctite 242 or equivalent.
If the monitor will use a CAN line to communicate with other EXM
components, connect plug 1 leads to the appropriate CAN line leads.
o If the monitor will use RF (radio frequency) to communicate
with other EXM components, no preparations are required.
The monitor is already RF enabled.
o If the CAN leads will not be used, replace wires with appropriate plugs.
Supply power to the monitor by connecting the red and black leads from the 6 pin connector to
an appropriate power source. Install a 20 Amp fuse into the positive power lead for a 12V
system (10 Amp for 24V system) to protect the monitor electrical components.
Refer to the respective plug figures for information on the plugs’ pins.
11
1
2
1
2
RF Transceiver in Panel Mount
1
2
Panel Mount Controller -
Using the Panel Mount Controller template in the
Component Mounting Templates section, drill any 4 of
the 7/32” holes shown through the panel intended to
hold the Panel Mount.
Mount the controller with four (4) 10-24 x ½” screws
using blue Loctite 242 or equivalent. Screw length
should provide 0.187”-0.25” thread engagement into
panel mount. Torque screws to 50-60 in-lbs.
If the Panel Mount will use the CAN line to communicate
with the other EXM components, connect plug 1 leads to
the appropriate CAN line.
If the Panel Mount will use RF communication, install the
RF Transceiver Module into the controller.
o Remove the back cover from the Panel Mount
Controller using a flathead screwdriver.
o Connect the RF Transceiver with the wires running the
length of the board as shown in the picture to the right.
o Reattach the back cover of the Panel Mount. Ensure no
wires are pinched.
o If the CAN leads will not be used, replace wires with
appropriate plugs.
Supply power to the controller by connecting plug 2 leads to an appropriate power source.
Install a 1 Amp fuse into the positive power lead for a 12V system (1/2 Amp for 24V system).
Refer to the respective plug figures for information on the plugs’ pins.
Handheld Controller and Docking Station –
Using the Docking Station template shown in the
Component Mounting Templates section, drill all 7/32”
holes shown through the panel intended for mounting
the Docking Station.
Mount the Docking Station with the supplied 10-24 x
3/8” screws using blue Loctite 242 or equivalent.
Torque screws to 50-60 in-lbs. The screw length allows
for a panel thickness range of 0.046”-0.125”.
Supply power to the Docking Station by connecting the plug leads shown to an appropriate
unswitched power source.
12
1
2
Valve Plug
Converting the Panel Mount Controller into a
Handheld Controller –
(Using Handheld Conversion Kit)
Handheld Conversion Kit will include Battery
Pack, Docking Station, and all hardware.
Install a RF Transceiver Module into the back of
the Panel Mount Controller as instructed in the
Panel Mount installation section.
Connect Battery Pack plugs to the Panel Mount
Controller as shown.
The CAN connector will not be used and should
be placed inside the Battery Pack as shown.
Attach Battery Pack to the Panel Mount
Controller using the provided 10-24 x ¾”
screws. Torque screws to 50-60 in-lbs.
Install a 1 Amp fuse into the positive power lead of the Docking Station for a 12V system (1/2
Amp for 24V system).
Lift the Docking Station top and place the Handheld Controller into the station. Then push the
top down until the contacts connect with the handheld. (see maintenance instructions section B
for LED signals)
For instructions on converting a Panel Mount Controller to a Handheld Controller, refer to the
steps below.
Joystick Controller and OEM Interface Module –
Using the Joystick Controller template shown in the
Component Mounting Templates section, drill all holes shown
through the panel intended for mounting the Joystick
Controller.
Mount the Joystick Controller using 10-24 x ½” fasteners
secured with blue Loctite 242 or equivalent.
Using the OEM Interface template shown in the Component
Mounting Templates section, drill all 4 of the 7/32” holes
shown.
Mount the OEM Interface Module with four (4) 10-24 x ½”
fasteners secured with blue Loctite 242 or equivalent.
Connect the plug coming from the valve buttons on the
Joystick Controller to the valve plug on the OEM Interface
Module. (See picture to the right)
Connect the plug coming from the Joystick Controller stick to plug 2 on the OEM Interface
Module. (See picture to the right)
If the Joystick/OEM will use CAN communication, connect the green, black, and blue leads
coming from plug 1 to the appropriate CAN line. If the CAN leads will not be used, replace
wires with plugs.
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