Hale CAFS Attack User Manual
Compressed Air Foam System
Installation / Operation Manual
Class1 ◆ A Unit of IDEX Corporation
607 NW 27th Avenue
Telephone: 352-629-5020
Web..........www.class1.com
◆ Ocala, FL 34475 U.S.A.
◆ FAX: 352-629-3569
Manual p/n: 029-0020-85-0
APPARATUS INFORMATION
ENGINE ______________________________________________
TRANSMISSION _______________________________________
MAXIMUM CAFS ENGINE RPM ___________________________
CAFS ENGINE SPEED RANGE ___________________________
NOTICE !
Class1 cannot assume responsibility for product failure resulting from improper
maintenance or operation. Class1 is responsible only to the limits stated in the
product warranty. Product specifications contained in this manual are subject to
change without notice.
All Class1 products are quality components -- ruggedly designed, accurately
machined, precision inspected, carefully assembled and thoroughly tested. In
order to maintain the high quality of your unit, and to keep it in a ready condition, it
is important to follow the instructions on care and operation. Proper use and good
preventive maintenance will lengthen the life of your unit.
ALWAYS INCLUDE THE UNIT SERIAL NUMBER
IN YOUR CORRESPONDENCE.
ECO NO REV CHANGE FROM BY DATE APVD
0000 A INITIAL RELEASE LwH 02/00/2006
Manual p/n: 029-0020-85-0, Rev. -A
Printed in U.S.A.
Class 1
A Unit of IDEX Corporation
Ocala, FL 34475 USA
DRAWN BY LwH ISSUE DATE COPYRIGHT ©
CHECKED BY 02/00/2006
NOT TO BE REPRODUCED OR USED TO
MAKE OTHER DRAWINGS OR MACHINERY.
© Class 1 2006
All Rights Reserved
Table of Contents ❑
Contents Page
CAFSAttack Air Bottle System
1 Safety precautions ................................................................................................... 7
1.1 General Guidelines............................................................................................................. 7
1.2 Air Bottle Cylinders.......................................................................................................... 12
Brief Overview ..................................................................................................................................12
SCBA Fill Station ..............................................................................................................................14
1.3 Air Filter Element.............................................................................................................. 14
1.4 Emergency Shut-Down .................................................................................................... 14
2 Introduction........................................................................................................... 15
2.1 Overview ........................................................................................................................... 15
Figure 2-1: CAFSAttack System Overview.........................................................................16
2.2 Smart-Switch Controller (SPC) ....................................................................................... 18
OPEN Button, Discharge Valve........................................................................................................18
Figure 2-2: Smart-Switch Controller - SPC......................................................................... 19
CLOSE Button, Discharge Valve......................................................................................................19
LED Indicator Array (Bar Graph) ...................................................................................................... 19
WET (+) Button.................................................................................................................................19
Press and Release..................................................................................................................... 19
Press and Hold...........................................................................................................................20
LED Indicator .............................................................................................................................20
DRY ( - ) Button ................................................................................................................................ 20
Press and Release..................................................................................................................... 20
Press and Hold...........................................................................................................................20
LED Indicator .............................................................................................................................20
2.3 CAFSAttack Operator Control Panel.............................................................................. 21
Figure 2-3: CAFSAttack Operator Control Panel ................................................................21
CAFS Enable ON/OFF Switch..........................................................................................................21
HIGH Pressure Indicator...................................................................................................................22
Air Bottle OPEN/CLOSE Valve.........................................................................................................22
Intelli-Tank Air Level Indicator ..........................................................................................................22
Air Bottle FILL Coupling....................................................................................................................22
3 Receiving and inspection ...................................................................................... 23
3.1 Receiving .......................................................................................................................... 23
Items Furnished................................................................................................................................23
Items Required, by Builder/Installer..................................................................................................23
CAFSAttack Air Bottle System Installer / Operator’s Guide
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3
❑ Table of Contents
Contents - continued Page
3.1 Receiving - continued
Unpacking......................................................................................................................................... 24
Lifting The System............................................................................................................................ 24
4 Installation - Retrofit Full Size Pumper..............................................................25
4.1 General.............................................................................................................................. 25
Figure 4-1: CAFSAttack System Overview......................................................................... 25
4.2 DOT Air Bottle Cylinder Assembly................................................................................. 26
Figure 4-2: DOT Air Bottle Cylinder Assembly Layout Dimensions.................................... 26
4.3 Pressure Balancing Valve Assembly............................................................................. 27
Figure 4-3: Pressure Balancing (Regulator) Valve Assembly Layout.................................28
4.4 Foam Pump Installation .................................................................................................. 28
4.5 CAFSAttack Operator Panel Layout............................................................................... 29
Figure 4-4: Operator’s Panel Layout Dimensions............................................................... 29
4.6 SVS Discharge Manifold ................................................................................................ 30
Figure 4-5: Typical CAFSAttack SVS Discharge Manifold Assembly.................................30
4.7 Plumbing........................................................................................................................... 31
CAFSAttack Operator’s Control Panel .............................................................................................32
Figure 4-6: Typical HIGH Air Pressure Connections.......................................................... 32
Figure 4-7: 4,500 PSI HIGH Pressure Balancing Regulator and Dome Connections ........ 34
Figure 4-8: Pump-to-Balancer Valve Dome Connection .................................................... 34
Intake Air Pressure Gauge Layout Option ........................................................................................ 35
Figure 4-9: Typical Intake Air Pressure Gauge Layout....................................................... 35
Low Pressure CAFS Connect (2) ..................................................................................................... 35
Figure 4-10: Typical LOW Pressure CAFS Air Connections .............................................. 36
Air Discharge Moisture Drain............................................................................................................ 37
Figure 4-11: Typical Discharge Drain................................................................................. 37
Table 4-12: Tubing Size vs. Color ......................................................................................37
CAFS Air LOW Pressure Gauge Layout Option ...............................................................................38
Figure 4-13: CAFS Air LOW Pressure Layout Option ........................................................ 38
4.8 Electrical ........................................................................................................................... 38
Smart-Switch Controller - SPC (S1 and S2)..................................................................................... 40
Figure 4-14: Smart-Switch Controller Panel Cutout ........................................................... 40
Figure 4-15: SPC Connector, Back View ........................................................................... 40
CAFSAttack Main Wire Harness....................................................................................................... 41
Figure 4-16: Primary CAFS Wire Harness .........................................................................41
Primary Power and Ground ..............................................................................................................42
RFI / EMI .......................................................................................................................................... 43
Figure 4-17: Extra Cable Storage....................................................................................... 43
4
CAFSAttack Air Bottle S ystem Installer / Operator’s Guide
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Table of Contents ❑
Contents - continued Page
4.8 Electrical - continued
Flow Sensor Connections (FM1 and FM2) .......................................................................................43
Air Supply Valve, Electric Motor (MV2).............................................................................................43
Discharge Valve, Electric Motor (MV1).............................................................................................44
On/Off Switch (SA3), Operator Control Panel .................................................................................. 44
Figure 4-18: On/Off Switch Connection..............................................................................44
4.9 Installation and Delivery Check List...............................................................................45
4.10 Start Up Check List .......................................................................................................... 46
Electrical ........................................................................................................................................... 46
Air and Water.................................................................................................................................... 46
4.11 System Installer Start-Up................................................................................................. 48
Initial System Power Check..............................................................................................................48
System Operation Check..................................................................................................................48
For FoamLogix...........................................................................................................................48
For CAFSAttack ......................................................................................................................... 49
5 Preset calibration .................................................................................................. 51
5a.1 Smart-Switch calibration ................................................................................................. 51
Figure 5-1: Smart-Switch Calibration Overview..................................................................51
To calibrate a WET consistency... ....................................................................................................52
To calibrate a DRY consistency........................................................................................................53
5a Basic operation ...................................................................................................... 54
5a.1 Starting CAFSAttack ........................................................................................................ 54
5a.2 Shutting-down CAFSAttack ............................................................................................ 56
5a.3 Emergency Shut-Down .................................................................................................... 56
6 Routine maintenance ............................................................................................ 57
6.1 Maintenance Procedures.................................................................................................57
After each use...................................................................................................................................57
Monthly .............................................................................................................................................57
Every Two (2) Months.......................................................................................................................57
Annually ............................................................................................................................................58
6.2 Replace Filter Element..................................................................................................... 58
Figure 6-1: Filter Pressure Contamination Gauge ..............................................................58
6.3 Relieving HIGH PRessure................................................................................................ 59
Figure 6-2: Relieving HIGH Pressure .................................................................................59
CAFSAttack Air Bottle System Installer / Operator’s Guide
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5
❑ Table of Contents
Contents - continued Page
Appendix B: Foam Concentrate Compatibility..................................................61
Reference......................................................................................................................................... 63
Express Warranty .................................................................................65
Class 1..............................................................................................................................................66
7 Drawing / Manual Package ..................................................................................67
Drawings........................................................................................................................................... 68
Manuals............................................................................................................................................68
6
CAFSAttack Air Bottle S ystem Installer / Operator’s Guide
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1 Safety precautions
THE CLASS1 CAFSATTACK™ AIR BOTTLE COMPRESSED AIR FOAM
SYSTEM IS DESIGNED FOR OPTIMUM OPERATOR SAFETY. FOR ADDED
PROTECTION, PLEASE FOLLOW THE SAFETY GUIDELINES LISTED IN THIS
SECTION AND ADHERE TO ALL WARNING, DANGER, CAUTION AND
IMPORTANT NOTES FOUND WITHIN THIS MANUAL.
THIS SECTION ON SAFETY MUST BE CAREFULLY READ, UNDERSTOOD
AND ADHERED TO STRICTLY BY ALL INSTALLERS AND OPERATORS
BEFORE ATTEMPTING TO INSTALL OR OPERATE THE CAFSATTACK
AIR BOTTLE SYSTEM.
WHEN DEVELOPING DEPARTMENTAL APPARATUS OPERATING PROCEDURES, INCORPORATE THE WARNINGS AND CAUTIONS AS WRITTEN.
Safety Precautions ❑
IMPORTANT !
CAFSAttack is a trademark of Class1. All other brand and product names are the
trademarks of their respective holders.
1.1 GENERAL GUIDELINES
NOTICE !
THE PROCEDURES IN THIS MANUAL ARE GENERAL INSTALLATION AND
OPERATING PROCEDURES. THEY DO NOT REPLACE THE PROCEDURES,
POLICIES OR GUIDELINES ESTABLISHED BY THE AUTHORITY HAVING
JURISDICTION, NOR DO THEY REPLACE THE RECOMMENDATIONS AND
PROCEDURES PROVIDED IN THE APPARATUS MANUFACTURER'S
MANUAL.
REFER TO THE PROCEDURES PROVIDED BY THE AUTHORITY HAVING
JURISDICTION ON SETTING WHEEL CHOCKS (TO PREVENT ANY MOVEMENT OF THE APPARATUS), AS WELL AS LAYOUT AND CONNECTION OF
HOSES, VALVES AND DRAIN COCKS.
Read all instructions thoroughly before beginning
any installation and operation process.
CAFS Air Bottle Installer/Operation Guide
p/n: 029-0020-85-0
❑ Use care when removing the CAFSAttack system from its packaging
(skid) to prevent personal injury and/or damage to the system, especially
the external system connections.
7
❑ Safety Precautions
THE CAFSATTACK AIR BOTTLE (H-CYLINDER) ASSEMBLY IS HEAVY AND
BULKY, WEIGHING OVER 500 LBS. (227 KGS.). ALWAYS REFER TO YOUR
BILL OF LADING FOR THE ACTUAL WEIGHT.
USE PROPER LIFTING SUPPORT DEVICES (OVERHEAD CRANE, STRAPS /
CHAINS, ETC.) CAPABLE OF HANDLING THE LOAD WHEN MOVING OR
INSTALLING THE ASSEMBLY. ATTACH LIFTING APPARATUS TO THE CYLINDER FRAME ONLY. DO NOT ATTACH STRAPS AROUND THE CYLINDERS.,
ESPECIALLY AT THE SHUT-OFF VALVE AREA. ALSO SEE FIGURE 4-2:
“DOT AIR BOTTLE CYLINDER ASSEMBLY LAYOUT DIMENSIONS” ON PAGE
26.
❑ Installation, maintenance and repairs should be performed by a trained
and qualified installer, or your authorized Class1 service representative.
Be sure the installer has sufficient knowledge, experience and the proper
tools before attempting any installation. DO NOT permit untrained personnel to install, use or maintain the CAFSAttack system.
WARNING !
Installation, use or repairs performed by persons not properly trained
may cause equipment failure that could result in serious bodily injury,
sickness or death.
❑ The installer is responsible for observing all instructions and safety
precautions in his or her daily routine as dictated by regional safety
ordinances or departmental procedures.
❑ Periodic inspection and scheduled maintenance of the equipment is
required for continued safe operation. A separate label is affixed to the
operator’s panel indicating the test date stamped on the cylinders and
the date the cylinders next require testing.
❑ Read and follow the precautions on all compressed gas cylinder labels.
❑ The frequency of servicing is the responsibility of the end-user based
upon the application.
❑ Never allow problems or lack of maintenance to go unreported.
❑ DO NOT permanently remove or alter any guarding or insulating devices,
labels, plates or instruction plates, or attempt to operate the system
when these items are removed. Various labels and/or instruction plates
are also located on the apparatus operator’s panel.
Make sure all access/service panels, covers, labels and plates are
installed, closed and latched tight, where applicable.
❑ DO NOT remove or alter any hydraulic or pneumatic connections, electri-
cal devices, etc. DO NOT tamper with or disconnect safety features. DO
NOT add or remove structural parts. Doing so voids the CAFSAttack
warranty.
8
CAFS Air Bottle Installer/Operation Guide
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Safety Precautions ❑
Any of the preceding could effect system capacity and/or safe operation
of the system and is a serious safety violation which could cause personal injury or death, could weaken the construction of the system or
could affect safe operation of the CAFSAttack Air Bottle System.
WARNING !
NO MODIFICATIONS OR ADDITIONS MAY BE MADE TO THE CAFSATTACK
AIR BOTTLE SYSTEM WITHOUT PRIOR WRITTEN PERMISSION FROM:
Class1
A Unit of IDEX Corporation
607 NW 27th Avenue
Ocala, FL 34475 U.S.A.
Telephone ......352-629-5020
Fax................. 352-629-3569
Web:...............www.class1.com
❑ Nozzle selection – Class1 does not recommend any specific type or
brand of nozzle for use with the CAFSAttack system.
Each fire department must conduct its own evaluation to ensure an
appropriate nozzle choice for the various types of hazards encounter.
Each fire department must develop associated operational procedures
and guidelines. Class1 does not recommend or claim suitability or fitness for any given nozzle brand or style.
WARNING !
ONCE A NOZZLE HAS BEEN SELECTED IT IS IMPERATIVE TO PROVIDE
AMPLE TRAINING IN THE USE OF THE NOZZLE.
OPEN CAFS NOZZLES “SLOWLY” AND MAKE SURE THE NOZZLE IS
SECURED AGAINST REACTION FORCES.
❑ Inspect the pressure balancing regulator valves and interconnecting
components (HIGH pressure side) for leaks before each use.
CAFS Air Bottle Installer/Operation Guide
p/n: 029-0020-85-0
WARNING !
BE SURE TO WEAR SAFETY GLASSES WHEN SERVICING THE HIGH
PRESSURE SYSTEM OR WHEN REMOVING AND/OR INSTALLING HIGH
PRESSURE PARTS.
9
❑ Safety Precautions
Also see Tescom “Safety, Installation and Operation Precautions” guide
lines, located at the back of this manual.
If a balancing regulator valve or other component in the system shows
signs of a leak or malfunction, the CAFSAttack system must be removed
from service immediately and repaired and tested before retuning to
service.
ONCE THE AIR CYLINDERS ARE FULLY CHARGED AND THE SYSTEM IS
ENERGIZED, ALL HIGH PRESSURE LINES BETWEEN THE CYLINDER SHUTOFF VALVES AND THE PRESSURE BALANCING REGULATOR VALVES,
INCLUDING THE AIR FILTER, ARE EXPOSED TO HIGH PRESSURES (4,500
PSI / 310 BAR).
DO NOT PERFORM ANY SERVICE TO THE HIGH PRESSURE SIDE UNTIL THE
SYSTEM PRESSURE IS RELIEVED. SEE SECTION “6.3 RELIEVING HIGH
PRESSURE,” ON PAGE 59 FOR ADDITTIONAL INFORMATION.
DANGER !
❑ DO NOT operate the system with just air and water. Shut off the air sup-
ply whenever the foam tank is empty.
CAUTION !
COLD WEATHER ENVIRONMENTS CAN CAUSE SOME COMPONENTS TO
FREEZE AND RESTRICT AIR FLOW. COMPONENTS MUST BE THAWED
BEFORE CONTINUING CAFS OPERATION.
❑ NEVER fully empty the air-bottle cylinders. Always maintain a positive
pressure (approximately 50 to 100 PSI / 4 to 7 BAR) within the cylinders.
Positive pressure ensures against moisture and/or dirt contamination in
the tanks, which could also flow back and contaminate the SCBA
recharging cylinders.
Failure to comply could result in serious bodily injury, sickness or
death.
❑ To prevent electrical shock always disconnect the primary power source
before attempting to service any part of the CAFSAttack system.
❑ All electrical systems have the potential to cause sparks during service.
Take the necessary precautions to eliminate explosive or hazardous
environments during any installation and/or service.
10
❑ To prevent system damage or electrical shock, the main power supply
wire must be the last connection made to the CAFSAttack system.
❑ The CAFSAttack system is designed for use on negative (-) ground,
direct current, electrical systems only.
CAFS Air Bottle Installer/Operation Guide
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Safety Precautions ❑
❑ Always disconnect the power cable, ground straps, electrical wires and
control cables from the smart-switch control unit or other CAFSAttack
system equipment before electric arc welding at any point on the apparatus. Failure to do so could result in a power surge through the unit that
could cause irreparable damage.
❑ Before connecting the cord sets and wiring harnesses, inspect the seal
washer in the female connectors. If the seal washer is missing or damaged water can enter the connector causing pin and terminal corrosion.
This could cause possible system failure.
❑ DO NOT operate or fill (recharge) the air system at pressures higher than
the maximum rated system pressure of 4,500 PSI (310 BAR), as stated
on the WARNING placard located near the air cylinders.
If the “Rupture Disk” has ruptured due to over pressurization, the reason
for the rupture mst be determined and the cylinders must be visually
inspected and re-hydrostatic tested as stated in regulation 49 CFR
178.37. Failure to comply and re-certify the cylinders could lead to catastrophic failure resulting in serious bodily injury, sickness or death.
❑ DO NOT operate the CAFS system at pressures above 150 PSI (10
BAR), as stated on the WARNING placard on the operator’s panel.
❑ Use only piping or tubing, hose and fittings which are rated at or above
the maximum pressure rating at which the CAFSAttack system operates.
Also see heading “Air Bottle Cylinders” on page 12.
❑ Relieve all system pressure, then drain all foam concentrate and water
from the system before servicing any of its component parts.
❑ DO NOT mount a radio transmitter or transmitter cables in direct or close
contact with the CAFSAttack smart-switch controllers. Direct contact
could cause electrical interference and disrupt controller operations.
❑ DO NOT connect the CAFSAttack main power lead to small leads that
are supplying some other device, such as a light bar or siren. The
CAFSAttack requires ?? AMP minimum current.
❑ When operating the CAFSAttack and the Hale FoamLogix in Simulated
Flow Mode an outlet for the foam concentrate must be provided to prevent excessive pressure buildup in the discharge piping or hoses.
❑ Foam tank “low level” sensors must be utilized to protect the foam pro-
portioner from dry running. Failure to use “low level” sensors voids the
warranty.
❑ Make sure the foam tank and foam concentrate suction hoses are clean
before making the final connection to the foam pump. If necessary, flush
the tank and hoses prior to making any connections.
CAFS Air Bottle Installer/Operation Guide
p/n: 029-0020-85-0
❑ Also review your specific FoamLogix Installation and Operation Manual
(FoamLogix Model 2.1A, Hale p/n: 029-0020-74-0; FoamLogix Model 3.3
and 5.0, Hale p/n: 029-0020-68-0) for additional safety information.
11
❑ Safety Precautions
1.2 AIR BOTTLE CYLINDERS
The CAFSAttack system uses HIGH pressure, compressed air storage cylinders (4,500 PSI / 310 BAR) which are in compliance with NFPA 1989
“Standard on Breathing Air Quality for Fire and Emergency Services Respiratory Protection.” For NFPA 1901 compliance, when a breathing air system
or a utility air system is mounted on fire apparatus the following requirements must apply:
CAUTION !
INSTALLATION OF THE CAFSATTACK SYSTEM MUST MEET NFPA #1901,
CHAPTER 25 “AIR SYSTEMS” REGULATIONS, INCLUDING ALL
SUBSEQUENT CHAPTERS OR REGULATIONS, I.E., “ASME” AND/OR “DOT”
AS STATED IN NFPA 1901 REGULATION. A SAMPLE LISTING FROM CHAPTER 25 “AIR SYSTEMS REGULATIONS” THAT APPLY AND MUST BE
ADHERED FOLLOWS:
CHAPTER # ........................... TITLE
25.2 ........................................ Provisions Applying to All Air Systems
25.2.5 ..................................... Assembly and Installation Practices
25.2.5.2 .................................. Hot Surface
25.2.5.4 .................................. Locking Devices
25.2.7 ..................................... General Piping Installation
25.2.8 ..................................... Flexible Hose
25.2.9 ..................................... Operator’s Panel and Controls
25.2.‘0 .................................... Maintainability
25.2.11 ................................... Labels and Plates
25.2.12 ................................... Documentation
25.2.13 ................................... Training and Instructions
25.5 ........................................ Air Storage Systems
25.5.1 ..................................... Transportable Air Tanks
25.5.7 ..................................... Air Tank Mounting
25.5.8 ..................................... Air Tank Valve Control and Monitoring
25.7 ........................................ Air Supply Regulation
25.11 ...................................... Air Hose
25.14 ...................................... Testing
12
Brief Overview
❑ Air tanks must comply with regulation 49 CFR 178.37, “Specification
3AAA and 3AAAX Seamless Steel Cylinders” or 29 CFR 1910.169, “Air
Receivers.”
CAFS Air Bottle Installer/Operation Guide
p/n: 029-0020-85-0
Safety Precautions ❑
Also review and adhere to regulation NFPA 55: “Standard for the Storage, Use and Handling of Compressed Gases and Cryogenic Fluids in
Portable and Stationary Containers, Cylinders, and Tanks.”
CAUTION !
THE AIR CYLINDERS MUST BE FILLED WITH “BREATHING AIR” QUALITY
AIR. HOWEVER, THIS AIR IS “NOT SUITABLE” FOR BREATHING AIR APPLICATIONS (SCBA). OPEN AND CLOSE AIR CYLINDER VALVES “SLOWLY.”
ALWAYS “CLOSE” THE AIR VALVE WHEN THE CAFSATTACK SYSTEM IS
NOT IN USE.
❑ The air system must be designed and constructed to withstand the
stresses, vibrations and other conditions found when mounted on a fire
apparatus and being used in mobile service.
❑ Air tanks must be mounted in an arrangement that will hold the tanks in
all types of mobile use. Protective devices must be provided to protect
the air tanks, valves and associated piping and/or hoses from damage as
a result of accidental impact.
❑ Each DOT cylinder, valve, hose and/or tubing must successfully with-
stand a “Hydrostatic Test” as stated in regulation 49 CFR 178.37.
The Hydrostatic Test must be performed at least once every five (5)
years.
Failure to successfully meet the test criteria as stated in regulation 49
CFR 178.13 indicates a system failure. The CAFSAttack system must
be removed from operation immediately and repaired and re-tested
before retuning to service.
❑ Valving used on transportable air tanks must be of the ASME type on
ASME cylinders and of the DOT type on DOT cylinders, or equal, for the
rated system pressure.
❑ The air system must be designed so that it can be stored and operated in
environments with relative humidity up to and including 100% (percent).
❑ Surfaces over 142° F (61° C) must be covered with a thermal insulating
material or must be mechanically guarded to protect the operator. If covering or guarding the surface affects the operation of the component, a
label must be provided that states “CAUTION!: Hot Surfaces When
Operating.”
❑ The air tanks must be located away from any heat-producing devices,
such as the generator engine or exhaust.
CAFS Air Bottle Installer/Operation Guide
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❑ Locking devices - All screws, pins, bolts or other fasteners whose failure
could create a hazardous condition for personnel or equipment must be
equipped with locking devices. Safety wire, self-locking nuts, cotter pins,
lock washers and liquid-locking compounds are acceptable.
13
❑ Safety Precautions
❑ All materials used in the air system must be corrosion resistant or treated
to resist corrosion unless the finished product is in continual contact with
a noncorrosive lubricant.
All pneumatic fittings, tubing and hoses must also be rated for the maximum allowable working system pressure.
❑ Flexible hose must be installed to prevent cuts, abrasions, exposure to
damage, excessive temperatures, damage from loose equipment and
excessive bending.
SCBA Fill Station
THE CAFSATTACK SYSTEM IS NOT DESIGNED OR INTENDED TO BE USED
AS A “SCBA FILL STATION.” THE CAFSATTACK SYSTEM MUST NOT BE
USED FOR OTHER THAN ITS INTENDED USE. DO NOT FILL SCBA BOTTLES
USING THE CAFSATTACK AIR CYLINDERS AS YOUR AIR SOURCE.
DANGER !
1.3 AIR FILTER ELEMENT
A visual differential pressure indicator enables the operator to read contaminated build up before the element is plugged, and includes an automatic
reset.
DANGER !
THE FILTER IS LOCATED IN THE SYSTEM HIGH PRESSURE LINE. YOU
MUST FIRST BLEED-OFF THE HIGH PRESSURE BEFORE ATTEMPTING TO
CHANGE AND/OR CLEAN THE FILTER ELEMENT. TO RELIEVE (BLEED-OFF)
THE SYSTEM HIGH PRESSURE, SEE SECTION 6.3 “RELIEVING HIGH PRESSURE” ON PAGE 59.
1.4 EMERGENCY SHUT-DOWN
1. Manually shut-off the air supply to the system - turn the CAFSAttack air
bottle valve, on the operator’s control panel, to the CLOSE position (O).
2. Set the CAFS ENABLE switch, on the operator’s control panel, to OFF (O).
3. Close the air bottle shut-off valves for each cylinder.
4. Also see heading “Emergency Shut-Down” on page 56.
14
CAFS Air Bottle Installer/Operation Guide
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2Introduction
2.1 OVERVIEW
The CAFSAttack Air Bottle Compressed Air Foam Pumping System is
designed for installation on new or for retrofit onto existing fire apparatus.
The CAFSAttack system must be considered an additional option on a fire
fighting apparatus and must not impair the operation of the basic system.
The performance of the original fire fighting system, as well as personal
safety, must not be compromised.
CAFSAttack offers accurate push-button, compressed air foam from a
stored air supply using Class1 “Smart-Switch” electronic technology. The
Class1 Smart-Switch provides enhanced fire fighter safety, performance
and ease of use. Two 200 cfm capacity pressure “balancing regulator”
valves “balance” water and air pressures.
Description ❑
Dual compressed air foam discharges provide variable foam consistancies. For example, one line can generate a “WET” quick draining foam blanket; while the second line could discharge “DRY,” shaving cream-like foam
for exposure protection.
The CAFSAttack DOT high pressure compressed air bottle cylinders are in
compliance with NFPA 1989 “Standard on Breathing Air Quality for Fire and
Emergency Services Respiratory Protection” regulations.
The CAFSAttack system is shipped in modular assembly form, completely
tested and ready for installation on full size municipal, forestry and skid
units. (See Figure 2-1: “CAFSAttack System Overview,” on page 16.)
The CAFSAttack System includes the following modular assemblies:
❑ Dual DOT high pressure (4,500 PSI / 310 BAR) compressed air bottle
cylinders (H-cylinder type) having a capacity of over 440 cubic feet
of storage, fully assembled as a complete unit.
❑ Dual HIGH pressure (4,500 PSI / 310 BAR and 1,000 PSI / 69 BAR)
valve assembly
● The first high-to-low air pressure “balancing” regulator valve (4,500
PSI) is direct acting and dome loaded to provide constant discharge
pressure - 200 cfm capacity. The second valve (1,000 PSI) is also
direct acting and reduces pressure to 1,000 PSI for best overall
performance.
CAFS Air Bottle Installer/Operation Guide
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15
❑ Description
Figure 2-1: CAFSAttack System Overview
❑ HIGH pressure valve assembly - continued
● Tee-type air filter - used to remove any particulate contaminates from
the system. A multi-layered glass fiber element produces high efficiency silt-control filtration and provides for extended service intervals
and reduced maintenance cost.
A visual pressure indicator enables the operator to read contaminated
build up before the element is plugged, with an automatic reset.
● Two electrically-controlled open/close air shut-off valves.
● Pressure safety relief valve, set at 165 PSI (11.4 BAR).
● Pressure safety relief Rupture Disc, set at 350 PSI (24 BAR).
● Check valves to ensure separation of water, foam solution, foam con-
centrate and air.
❑ Discharge Manifold
● Two electrically-controlled shut-off valves, with valve position
indicator.
See separate SVS manual provided (Hale p/n: 209-0020-90-0) for
additional valve information.
16
● Mixing chambers.
CAFS Air Bottle Installer/Operation Guide
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Description ❑
● Paddle wheel flow sensors.
❑ CAFSAttack operator control panel
● Two Class1 “Smart-Switch” Controllers with LED bar graph array.
● Inteli-Tank high pressure air tank level indicator - four (4) RED indica-
tors lights, indicates cylinder tank charge remaining.
● On/Off CAFSAttack air enable switch, to activate the CAFSAttack
system.
● Amber HIGH pressure warning light, illuminates at pressures above
150 PSI (10 BAR).
● Quick connect high pressure air cylinder refill connection for an SCBA
Breathing Air High Pressure 4,500 PSI (310 BAR) Compressor System. SCBA station not included.
● Main air bottle open/close valve - introduces HIGH pressure air into
the system.
❑ HIGH pressure hose (2) - air bottle cylinders-to-pressure valves.
❑ LOW pressure hose (2) - high pressure air shut-off valves-to-SVS dis-
charge valves.
❑ FoamLogix foam pump, Model 2.1A - standard (not shown)
See separate manual for description, installation and operation of FoamLogix Electronic Foam Proportioning System (Hale p/n: 029-0020-74-0).
❑ CAFSAttack Installer / Operation Manual, Hale p/n:209-0020-85-0
Additional options, such as; FoamLogix Models 3.3 or 5.0, for higher foam
solution applications or the use of Class “B” type foams are available to further meet customer requirements.
IMPORTANT!
COMPONENTS ARE INSTALLED WHERE REQUIRED, PER CUSTOMER
ORDER AND/OR OPERATIONAL REQUIREMENTS. NOT ALL INSTRUCTIONS
HEREIN ARE INCLUSIVE. THEY ARE GENERAL GUIDELINES ONLY. INDIVIDUAL CHASSIS CONFIGURATION, BUILDER PRACTICES, ETC. DICTATE
WHEN AND WHERE COMPONENTS ARE INSTALLED.
CAFS Air Bottle Installer/Operation Guide
p/n: 029-0020-85-0
Using accepted assembly procedures, the CAFSAttack air cylinders may be
mounted on the apparatus in an arrangement that secures the cylinders in
all types of mobile use and where they are least susceptible to accidental
impact.
Once the cylinders are in place, the interconnecting valving, pressure
gauges, pneumatic lines and related components must be installed.
17
❑ Description
Since the system is of the modular design, a minimum number of pneumatic
and electrical connections are required.
Mounting the FoamLogix 2.1A, 3.3 or 5.0 System includes installation of
the foam pump and motor assembly, in-line strainer and valve assembly and
low tank sensor. Refer to the following manual, based on the specific model
FoamLogix included with your system:
❑ FoamLogix Model 2.1A Installation and Operation Manual,
Hale p/n: 029-0020-74-0
❑ FoamLogix Model 3.3 and 5.0 Installation and Operation Manual,
Hale p/n: 029-0020-68-0
The CAFSAttack smar t-switches and air pressure level indicator are to be
mounted on the apparatus pump operator’s panel.
Once the major components are installed, see separate headings for pneumatic plumbing and electrical hookup instructions.
❑ Plumbing - see 4.7 “Plumbing” on page 31.
❑ Electrical - see 4.8 “Electrical” on page 38.
WARNING !
WHILE INSTALLING A CAFSATTACK SYSTEM MAKE SURE ALL SAFETY
REGULATIONS AND INSTRUCTIONS ARE FOLLOWED TO PROVIDE A SAFE
INSTALLATION. THOROUGHLY REVIEW SECTION 1 “SAFETY PRECAUTIONS” BEGINNING ON PAGE 7.
2.2 SMART-SWITCH CONTROLLER (SPC)
The “Smart-Switch” Panel Controller (SPC) is the primary controller for both
compressed air injection and discharge valve control. The SPC allows the
operator to inject air and control the consistency of the discharged finished
foam. (See Figure 2-2: “Smart-Switch Controller - SPC,” on page 19.)
OPEN Button, Discharge Valve
18
(See Figure 2-2: “Smart-Switch Controller - SPC,” on page 19.)
The OPEN button opens the water discharge valve to increase water or
foam solution (making a wetter solution). Holding the button pressed opens
the valve until the internal limit switch activates, indicating the fully OPENED
position.
CAFS Air Bottle Installer/Operation Guide
p/n: 029-0020-85-0
Description ❑
Figure 2-2: Smart-Switch Controller - SPC
The OPEN button LED is ON steady during operation and flashes during
setup.
CLOSE Button, Discharge Valve
The CLOSE button closes the water discharge valve to decrease the water
or foam solution (making a dryer solution). Holding the button pressed
closes the valve until the internal limit switch activates, indicating the fully
CLOSED position. The CLOSE button LED is ON steady during operation
and flashes during setup.
LED Indicator Array (Bar Graph)
The OPEN / CLOSE bar graph LED indicator array illuminates from the bottom (O - fully closed) to the top (I - fully opened). It sequentially indicates
the approximate open / close position of the valve.
CAFS Air Bottle Installer/Operation Guide
p/n: 029-0020-85-0
WET (+) Button
Press and Release
Pressing and RELEASING the WET button sets and maintains the air injection rate at the Preset 2 * value, producing a WET foam concentrate.
19
❑ Description
Pressing the WET button also immediately activates the FoamLogix controller in preparation for foam injection. When the system detects water is flowing, the appropriate air valve is opened.
Press and Hold
Press and HOLD the WET button for about ten (10) seconds to store a new
WET CAFS consistency at Preset 2. The entire display blinks once when
the setting is stored. Use the OPEN and CLOSE buttons to adjust the airto-foam solution ratio, thus the foam consistency.
LED Indicator
The WET button LED FLASHES when in the WET position and is ON
steady if the CAFS system is active and air is flowing into the corresponding
discharge.
DRY ( - ) Button
(See Figure 2-2: “Smart-Switch Controller - SPC,” on page 19.)
Press and Release
Pressing and RELEASING the DRY button sets and maintains the air injection rate at the Preset 1 * value, producing a DRY foam concentrate. Press-
ing the DRY button also immediately activates the FoamLogix controller in
preparation for foam injection.
When the system detects water is flowing, the appropriate air valve is
opened.
Press and Hold
Press and HOLD the DRY button for ten (10) seconds to store a new DRY
CAFS consistency at Preset 1. The entire display blinks once when the setting is stored. Use the OPEN and CLOSE buttons to adjust the air-to-foam
solution ratio, thus the foam consistency.
LED Indicator
The DRY button LED FLASHES when in the DRY position and is ON
steady if the CAFS system is active and air is flowing into the corresponding
discharge.
* Presets 1 and 2 are an established value by the end user and the installer/builder at
the time of installation to produce the required CAFS discharge. This assures the
correct DRY and WET consistency ever time the appropriate CAFS button is pressed.
20
CAFS Air Bottle Installer/Operation Guide
p/n: 029-0020-85-0
Description ❑
IMPORTANT !
THE DUAL DISCHARGES AND SMART-SWITCH CONTROLLERS OFFER SEPARATE CONTROL FOR EACH DISCHARGE, I.E., ONE DISCHARGE CAN BE
SET FOR WET CAFS WHILE THE OTHER IS SET FOR DRY CAFS.
2.3 CAFSATTACK OPERATOR CONTROL PANEL
The CAFSAttack Operator Control Panel provides the means to enable
(turn ON) the CAFSAttack system and to supply, monitor and charge the air
pressure in the two DOT air cylinders. (See Figure 2-3: CAFSAttack Operator Control Panel.)
CAFS Air Bottle Installer/Operation Guide
p/n: 029-0020-85-0
Figure 2-3: CAFSAttack Operator Control Panel
The CAFSAttack operator control panel is a complete assembly. It must be
installed in a convenient location on the apparatus operator’s control panel.
CAFS Enable ON/OFF Switch
The CAFS Enable On/Off Switch allows the electrical power to the
CAFSAttack system components (0 = OFF; I = ON).
21
❑ Description
HIGH Pressure Indicator
Also see Figure 2-3: “CAFSAttack Operator Control Panel” on page 21.
The HIGH pressure indicator (YELLOW) illuminates when the water/air
pressure is greater than 150 PSI (10 BAR). Pressure in excess of 160 PSI
(11 BAR) is discharged through the safety relief valve.
Air Bottle OPEN/CLOSE Valve
This open/close shut-off valve introduces HIGH air pressure to the system
(0 = CLOSED; I = OPEN).
Intelli-Tank Air Level Indicator
The 4-light air level indicator visually shows the air remaining in the HIGH
pressure air cylinders (bottles). See separate manual, located at the back
of this manual, for additional information.
CAUTION !
SYSTEM MAXIMUM PRESSURE MUST NOT EXCEED 4,500 PSI (311 BAR).
ALSO SEE HEADING “AIR BOTTLE CYLINDERS” ON PAGE 12.
Air Bottle FILL Coupling
The air FILL coupling allows charging of the 4,500 PSI (310 BAR) HIGH
pressure cylinders with a SCBA compressor system.
DANGER !
THE CAFSATTACK AIR BOTTLE FOAM PUMP SYSTEM IS NOT DESIGNED
OR INTENDED TO BE USED AS A “SCBA FILL STATION.” THE CAFSATTACK SYSTEM MUST NOT BE USED FOR OTHER THAN ITS INTENDED
USE.
22
DO NOT FILL SCBA BOTTLES USING THE CAFSATTACK AIR CYLINDERS AS
YOUR AIR SOURCE.
CAFS Air Bottle Installer/Operation Guide
p/n: 029-0020-85-0
3 Receiving and inspection
3.1 RECEIVING
Before shipping from Class1 the CAFSAttack Compressed Air Foam Pumping System is factory inspected and tested. However, we recommend that
you:
1. Inspect the packaging for any signs of physical damage during shipment. Note
any apparent damage on the bill of lading and request the delivery agent to
sign it. Report the damage to Class1, Ocala, FL. and the shipping company.
2. Verify that the system configuration and options match your purchase order.
Report any discrepancies to Class1.
Receiving and Inspection ❑
Class1
A Unit of IDEX Corporation
607 NW 27th Avenue
Ocala, FL 34475 U.S.A.
Telephone . 352-629-5020
Fax ............ 352-629-3569
Web:.......... www.class1.com
Items Furnished
The CAFSAttack system is shipped with all OEM required connections
tagged for easy identification. For a listing of items furnished, see Section
2.1 “Overview,” beginning on page 15.
Also included are the necessary labeling, plates and instruction plates
which must be installed in their appropriate locations to ensure proper personal and system operating safety.
CAFS Air Bottle Installer/Operation Guide
p/n: 029-0020-85-0
Items Required, by Builder/Installer
The following items are a sampling of what might be required to complete
the installation, connecting the system to your apparatus. The items
required vary depending on your system configuration. Also see the FoamLogix Model 2.1A, 3.3 or 5.0 Manual for additional information.
23
❑ Receiving and Inspection
❑ Appropriate air injection hose, 1/4” (6 mm), up 6,000 PSI (414 BAR)
❑ Appropriate discharge hose or piping, 1/4” (6 mm), up ??? PSI (???
BAR)
❑ Appropriate electrical wire, Type SXL, GXL or TXL
❑ Appropriate DOT air injection tube, 3/8” (9.5 mm)
❑ Appropriate LOW pressure drain and HIGH pressure tubing / hose, rec-
ommended - 3/8” (10 mm), up 6,000 PSI (414 BAR)
Unpacking
The CAFSAttack system is shipped partially assembled on two skids. One
skid contains the CAFSAttack air bottle cylinder module assembly. The
second skid contains the FoamLogix Pump Unit along with all supplied
loose items.
Use care when removing the CAFSAttack from its packaging (skid) to prevent injury and/or damage to the system, especially the external system
connections.
IMPORTANT!
EXERCISE CARE DURING UNPACKING AND INSTALLATION TO ENSURE
THAT THE IDENTIFICATION TAGS ARE NOT REMOVED BEFORE THE CONNECTIONS ARE MADE.
DO NOT REMOVE OR ALTER ANY HYDRAULIC OR PNEUMATIC CONNECTIONS WITHOUT WRITTEN APPROVAL FROM CLASS1. ALSO REVIEW SECTION 1 “SAFETY PRECAUTIONS” BEGINNING ON PAGE 7.
Lifting The System
WARNING!
THE CAFSATTACK AIR BOTTLE (H-CYLINDER TYPE) ASSEMBLY IS HEAVY
AND BULKY, WEIGHING OVER 500 LBS. (227 KGS.). SEE BILL OF LADING
FOR ACTUAL WEIGHT. USE PROPER LIFTING SUPPORT DEVICES (OVERHEAD CRANE, STRAPS/CHAINS, ETC.) CAPABLE OF HANDLING THE LOAD
WHEN MOVING OR INSTALLING THE SYSTEM. ATTACH LIFTING APPARATUS TO THE CYLINDER FRAME ONLY. DO NOT ATTACH STRAPS AROUND
THE CYLINDERS, ESPECIALLY THE SHUT-OFF VALVE AREA. ALSO SEE
FIGURE 4-2: “DOT AIR BOTTLE CYLINDER ASSEMBLY LAYOUT DIMENSIONS” ON PAGE 26.
24
CAFS Air Bottle Installer/Operation Guide
p/n: 029-0020-85-0
Installer Installation ❑
4 Installation - Retrofit Full Size Pumper
4.1 GENERAL
Since most truck configurations are not the same, this section serves only
as a general guide for installation.
When installing the CAFSAttack system use the best accepted practices for
mounting. Review previous Section 3 “Receiving and inspection,” beginning
on page 23. Also see Figure 4-1: “CAFSAttack System Overview.”
CAFS Air Bottle Installer/Operation Guide
p/n: 029-0020-85-0
Figure 4-1: CAFSAttack System Overview
25
❑ Installer Installation
4.2 DOT AIR BOTTLE CYLINDER ASSEMBLY
DANGER !
ALWAYS TREAT COMPRESSED AIR CYLINDERS WITH RESPECT. THEY
CONTAIN VERY HIGH PRESSURES (UP TO 4,500 PSI / 310 BAR). READ THE
MSDS AND FOLLOW PROPER PROCEDURES WHEN HANDLING AND USING
THESE CYLINDERS. ALWAYS FOLLOW THE RECOMMENDED SAFETY
PROCEDURES.
26
Figure 4-2: DOT Air Bottle Cylinder Assembly Layout Dimensions
CAFS Air Bottle Installer/Operation Guide
p/n: 029-0020-85-0
Installer Installation ❑
IMPORTANT!
(SEE FIGURE 4-2: “DOT AIR BOTTLE CYLINDER ASSEMBLY LAYOUT DIMENSIONS,” ON PAGE 26.)
WHEN DETERMINING THE LOCATION FOR THE AIR BOTTLE CYLINDER
ASSEMBLY (WITH THE HIGH PRESSURE VALVE ASSEMBLY), IT IS RECOMMENDED TO INSTALL THE SYSTEM “ABOVE” THE PUMP WITH DOWNWARD
SLOPPING LINES TO PROMOTE POSITIVE DRAINAGE.
KEEP IN MIND PIPING RUNS, CABLE ROUTING, VISIBILITY, REQUIRED
OPERATOR ACCESS TO VALVE SHUT-OFFS AND OTHER INTERFERENCES
THAT COULD HINDER OR INTERFERE WITH PROPER SYSTEM
PERFORMANCE.
ALSO ENSURE THE ASSEMBLY IS INSTALLED IN AN AREA AFFORDING PROTECTION FROM ROAD DEBRIS AND EXCESSIVE HEAT BUILDUP AND WITH
THE LEAST EXPOSURE TO ACCIDENTAL IMPACT.
Drill the corresponding mounting holes and use minimum 5/8”, Grade 8
bolts with flat washers and lock nuts to bolt-down the air cylinder bracketry.
(See Figure 4-2: “DOT Air Bottle Cylinder Assembly Layout Dimensions,” on
page 26.)
An installation diagram is also located at the back of this manual to assist
with overall dimensions and clearances required for the various mounting
configurations. See Contents for a listing of the drawings.
For plumbing requirements, proceed to heading 4.7 “Plumbing” on page 31.
For electrical requirements, proceed to heading 4.8 “Electrical” on page 38.
4.3 PRESSURE BALANCING VALVE ASSEMBLY
The high pressure balancing regulator valve assembly is pre-mounted to
the front of the air cylinder tank assembly. The module is mounted using
three 5/8”, Grade 8 bolts with flat washers and lock nuts. (See Figure 4-3:
“Pressure Balancing (Regulator) Valve Assembly Layout,” on page 28.)
Additionally, there must be room for the WARNING ! placards as provided.
CAFS Air Bottle Installer/Operation Guide
p/n: 029-0020-85-0
IMPORTANT !
SHOULD IT BE REQUIRED TO RELOCATE THIS ASSEMBLY, IT IS RECOMMENDED TO INSTALL THE PRESSURE BALANCING VALVE ASSEMBLY
“ABOVE” THE PUMP WITH DOWNWARD SLOPING LINES TO INSURE POSITIVE DRAINAGE.
27
❑ Installer Installation
Figure 4-3: Pressure Balancing (Regulator) Valve Assembly Layout
WARNING !
EXERCISE CARE NOT TO DAMAGE OR TWIST INTERCONNECTING HIGH
PRESSURE PNEUMATIC PIPING OR ACCIDENTALLY LOOSEN FITTING CONNECTIONS DURING ASSEMBLY. REMEMBER, THE SYSTEM MUST BE
HYDROSTATIC TESTED BEFORE USE AND SHIPPING TO THE CUSTOMER.
4.4 FOAM PUMP INSTALLATION
Detailed foam pump installation instructions are found in the FoamLogix
Electronic Foam Proportioner Installation and Operation Manual, packaged
with the FoamLogix assembly. Refer to the specific model FoamLogix system included with your CAFSAttack system.
❑ FoamLogix Model 2.1A Installation and Operation Manual,
Hale p/n: 029-0020-74-0
❑ FoamLogix Model 3.3 and 5.0 Installation and Operation Manual,
Hale p/n: 029-0020-68-0
28
CAFS Air Bottle Installer/Operation Guide
p/n: 029-0020-85-0
Installer Installation ❑
Note: For CAFSAttack systems, the main cable harness included with the Foam-
Logix system differs from what is shown in the FoamLogix manual. For an overview of the replacement cable used with CAFSAttack, see Section 7, “Drawing /
Manual Package” on page 67.
4.5 CAFSATTACK OPERATOR PANEL LAYOUT
(See Figure 4-4: “Operator’s Panel Layout Dimensions.”)
CAFS Air Bottle Installer/Operation Guide
p/n: 029-0020-85-0
Figure 4-4: Operator’s Panel Layout Dimensions
The following components are pre-mounted on the CAFSAttack operator’s
panel assembly:
❑ Inteli-Tank high pressure air level indicator - four (4) RED indicator lights
❑ HIGH pressure WARNING ! indicator light (YELLOW)
❑ On/Off air enable switch
❑ HIGH pressure shut-off valve and handle
❑ Quick-connect HIGH pressure air cylinder refill connection
Also see Figure 2-3: “CAFSAttack Operator Control Panel” on page 21.
1. Determine the location on the apparatus operator’s control panel for the
CAFSAttack operator’s panel assembly, with placard. This assembly
must be located at the main pump operator’s position in close proximity
to the FoamLogix system controls.
29
❑ Installer Installation
2. Consideration must be given for routing the HIGH pressure tubing /
hoses and electrical harnesses. Make certain there is sufficient room
behind the assembly. If necessary, order a longer or shorter harness to
suit the location demands.
3. Modify the apparatus operator’s control panel to accept the CAFSAttack
operator’s panel and placard. (See Figure 4-4: “Operator’s Panel Layout
Dimensions.”) Use #10-24 screws and hardware to secure the panel the
apparatus control panel.
4. For plumbing, proceed to heading 4.7 “Plumbing” on page 31. For electrical, proceed to heading 4.8 “Electrical” on page 38.
4.6 SVS DISCHARGE MANIFOLD
30
Figure 4-5: Typical CAFSAttack SVS Discharge Manifold Assembly
CAFS Air Bottle Installer/Operation Guide
p/n: 029-0020-85-0
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