FoamLogix
TM
Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
Description, Installation and
Operation Manual
HALE PRODUCTS, INC / CLASS 1
607 NW 27th Avenue ● Ocala, FL 34475
U.S.A. Telephone: 352-629-5020
FAX: 800-533-3569
GODIVA LTD.
Charles Street ● Warwick, England CV34
5LR Phone: 44-1-926-623600
5LR Phone: 44-1-926-623600
IDEX DINGLEE TECHNOLOGY (Tianjin) Co. Ltd.
No.9, 2nd Haitai Fazhan Road Huayuan Industrial Development Area (outside of ring road)
Tianjin High-Tech Industrial Park Tianjin China
Telephone: 011-86-22-8568-9800
FAX: 011-862285689808
Manual p/n: 029-0020-74-0-F
FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
2
APPARATUS INFORMATION
Hale FoamLogix System Serial Number
In Service Date
Fire Department
Engine Number
Calibration Factors:
Water Flow Factor
Class A Foam Factor
NOTICE!
Hale Products does not assume responsibility for product failure resulting from improper maintenance or operation. Hale Products
is responsible only to the limits stated in the product warranty. Product specifications contained in this manual are subject to change
without notice.
All Hale 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
CHANGED FROM
BY
DATE
APVD
03-110 A RELEASED FOR PRINTING
PRW
6/1/2003
MAL
03-215
B
UPDATED FOR DESIGN CHANGE
PRW
6/30/2003
MAL
04-236
C
UPDATE FOR DESIGN CHANGE
LWH
10/05/04
MAL
ECR 2743
D
UPDATE TO INCLUDE 1.7ahp
RLL
1/15/09
DC
E
CHANGE INFO ON FOAM FLOW SENSOR
REPLACEMENT
RLL
8/10/09
DC
F
UPDATED INFORMATION AND DRAWINGS
TO INCLUDE NEW MOTOR DRIVER
JDF
11/1/18
JLS
Manual P/N: 029-0020-74-0, Rev F
FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
3
HOW TO USE THIS MANUAL
This manual is divided into seven sections for clarity and ease of use. Each of the following manual sections
can be a stand alone section or can be used in conjunction with each other.
SECTION 1 SAFETY
This section must be carefully read, understood and adhered to strictly by all installer/builders, operators and
service personnel using the Hale FoamLogix 2.1A and 1.7AHP Foam Proportioning Systems. Do not use or
install the system until you have thoroughly read this section. Failure to comply could cause risk of serious
injury to yourself and others, or damage to the system.
SECTION 2 DESCRIPTION
Provides an introduction to the Hale foam proportioning system along with guidelines for designing and
ordering a complete system.
SECTION 3 INSTALLATION
Provides information to assist the OEM with installation and initial setup of Hale foam proportioning systems
on an apparatus.
SECTION 4 SETUP AND CALIBRATION
Is used by the installer and end user for start-up and calibration of the Hale foam proportioning system.
SECTION 5 OPERATION
Is primarily used by the apparatus user for proper operation and maintenance of the Hale foam proportioning
system.
SECTION 6 TROUBLESHOOTING
If a problem developes, see this section for troubleshooting procedures.
SECTION 7 PARTS IDENTIFICATION
Section 7 includes a parts breakdown of the most commonly used parts of the FoamLogix System.
FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
4
NOTES
FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
5
CONTENTS PAGE
HOW TO USE THIS MANUAL ........................................................................................3
SECTION 1 SAFETY .................................................................................................................................... 3
SECTION 2 DESCRIPTION .......................................................................................................................... 3
SECTION 3 INSTALLATION ............................................................................................................................... 3
SECTION 4 SETUP AND CALIBRATION .......................................................................................................... 3
SECTION 5 OPERATION ................................................................................................................................... 3
SECTION 6 TROUBLESHOOTING .............................................................................................................. 3
SECTION 7 PARTS IDENTIFICATION .............................................................................................................. 3
SECTION 1 SAFETY ..................................................................................................... 11
Guidelines ................................................................................................................................................... 11
SECTION 2 DESCRIPTION ........................................................................................... 15
Rotary Plunger Pump .................................................................................................................................. 15
Control Unit .................................................................................................................................................. 15
Water Flow Sensor ...................................................................................................................................... 15
Feed Back Sensor ....................................................................................................................................... 15
Low Pressure Strainer ................................................................................................................................. 16
Table 1: Maximum Foam Solution Flows .............................................................................................. 16
Ordering Information ................................................................................................................................... 16
HALE FOAM SYSTEM SPECIFICATIONS ...................................................................... 18
Figure 2: Foam Pump Installation Envelope Dimensions .................................................................... 19
SYSTEM CONFIGURATION ............................................................................................ 20
PACKAGE “A” ........................................................................................................................................... 20
PACKAGE “B” ........................................................................................................................................... 20
Figure 3: Typical Hale FoamLogix 2.1A and 1.7AHP System Layout .................................................... 21
Hale FoamLogix 2.1A Foam Proportioner System ...................................................................................... 22
Low Tank Level Sensor Options .................................................................................................................. 23
Flow Sensors ............................................................................................................................................... 24
Figure 4: Pipe Size vs. Flow Range ....................................................................................................... 24
Check Valve Manifolds, Flanges and Gaskets ............................................................................................ 25
Elbows and Mini-Manifolds ......................................................................................................................... 26
Remote Start Option .................................................................................................................................... 27
SECTION 3 INSTALLATION ................................................................................................ 29
Foam Pump and Motor Assembly ............................................................................................................... 29
Control Unit and Instruction/System Diagram Placard ................................................................................ 30
Installer Supplied Components ................................................................................................................... 30
Foam Concentrate Suction Hose ................................................................................................................ 30
Recommended Components .................................................................................................................. 30
Foam Concentrate Discharge Hose ............................................................................................................ 31
Recommended Components .................................................................................................................. 31
Foam Concentrate Bypass Hose ................................................................................................................ 31
Recommended Components .................................................................................................................. 31
Check Valves ............................................................................................................................................................. 31
Flushing Water Hose ................................................................................................................................... 32
Foam Discharge Drains ............................................................................................................................... 32
Freeze Protection ........................................................................................................................................ 32
Electrical Requirements .............................................................................................................................. 32
Figure 5: Recommended Relay Wiring Schematic ................................................................................ 33
Table 6: Recommended Primary Power Cable Sizes ............................................................................. 33
Foam Concentrate Tank ................................................................................................................................................ 33
FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
6
Contents -continued ....................................................................... Page
SECTION 3 INSTALLATION Continued
FOAM PUMP MOUNTING ........................................................................................................ 34
Figure 7: FoamLogix Pump Installation.................................................................................................. 34
PLUMBING INSTALLATION ............................................................................................................. 34
Figure 8: Base Plate Mounting Hole Locations ...................................................................................... 35
Water and Foam Solution Plumbing ............................................................................................................ 35
Check Valve Manifold .................................................................................................................................. 35
Figure 9: Check Valve Manifold Installation ........................................................................................... 36
Optional Hale Piping Components .............................................................................................................. 36
“Waterway” Check Valves ........................................................................................................................................ 36
Figure 10: Typical Midship Pump Installation ......................................................................................... 37
Figure 11: “Typical 4” Check Valve Installation, Midship Pump” ............................................................. 37
Flow Sensor ................................................................................................................................................ 38
Figure 12: Flow Sensor Tee Position Range .......................................................................................... 38
Table 13: Pipe Size vz. Minimum Straight Run ..................................................................................... 38
Figure 14: Typical Reduced Size Sensor Piping Arrangement .............................................................. 39
Figure 15: Flow Sensor Placement ........................................................................................................ 39
Saddle Clamp Installation............................................................................................................................ 39
Foam Pump Flush System .......................................................................................................................... 40
Figure 16: Flow Sensor/Saddle Clamp Installation ................................................................................ 40
FOAM CONCENTRATE PLUMBING. ......................................................................................................... 40
Foam Strainer Connection .......................................................................................................................... 40
Check Valve/Injector Fitting ......................................................................................................................... 41
Figure 17: Check Valve Injector Fitting Installation ................................................................................ 41
Figure 18: Injection and Bypass Hose Connections............................................................................... 42
Foam Concentrate Injection Hose ............................................................................................................... 42
Bypass Hose Connection ............................................................................................................................ 42
ELECTRICAL INSTALLATION ......................................................................................................... 43
Electrical Connections ................................................................................................................................. 43
Figure 19: Control Unit Mounting Dimension ......................................................................................... 44
Control Unit .................................................................................................................................................. 44
Display Unit Power and Ground Connections ............................................................................................. 44
Figure 20: Control Harness Connections ............................................................................................... 45
Figure 21: System Power and Ground Connections .............................................................................. 45
Motor Ground/Primary Power ..................................................................................................................... 46
Ground Connection ..................................................................................................................................... 46
Primary Power Supply Connection.............................................................................................................. 46
RFI/EMI ...............................................................................................................................................................
46
Figure 22: Extra Cable Storage .............................................................................................................. 47
FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
7
Contents -continued ................................................................... Page
START-UP CHECKLIST ................................ ................................ ................................ 48
Electrical ...................................................................................................................................................... 48
Liquid ........................................................................................................................................................... 48
Foam Pump ................................................................................................................................................. 48
SYSTEM INSTALLER START-UP ....................................................................................... 49
Initial System Power Check......................................................................................................................... 49
Initial System Check .................................................................................................................................... 49
Figure 23: Control Unit Ready Indication ............................................................................................... 49
Figure 24: Simulated Flow Display ......................................................................................................... 50
INSTALLATION AND DELIVERY CHECK LIST ................................ ............................ 51
Installation ................................................................................................................................................... 51
Delilvery ....................................................................................................................................................... 51
USER CALIBRATION ....................................................................................................... 53
Entering Passwords .................................................................................................................................... 53
Table 25: Password Sequence ............................................................................................................... 53
Restore Factory Defaults ............................................................................................................................. 53
Calibration ................................................................................................................................................... 53
Figure 26: Display - Password and Calibration Modes .......................................................................... 54
Figure 27: Display - Flow Sensor Calibration ......................................................................................... 54
Flow Sensor Calibration .............................................................................................................................. 54
Record Flow and Sensor Calibration Factors .............................................................................................. 55
Figure 28: Display - Flow Sensor Calibration Factor .............................................................................. 55
Figure 29: Display - Simulated Flow Calibration .................................................................................... 55
Simulated Flow ............................................................................................................................................ 55
Foam Concentrate injection Rate ................................................................................................................ 55
Foam Pump Feedback Calibration .............................................................................................................. 56
Figure 30: Display - Foam Concentrate Injection Rate Default Value ......................................................... 56
Figure 31: Display - Foam Pump Feedback Calibration......................................................................... 56
Figure 32: Foam Concentrate Collection ................................................................................................ 56
Record Foam Pump Feedback Calibration Factor ...................................................................................... 57
Exit and Save Calibration ............................................................................................................................ 57
Figure 33: Display - Foam Pump Feedback Calibration Factor ............................................................. 57
Figure 34: Display - Exit and Save Calibration ....................................................................................... 57
Relief Valve ................................................................................................................................................................ 58
English to Metric Units ................................................................................................................................. 58
Figure 35: Relief Valve ....................................................................................................................................... 58
To convert to Metric units: ........................................................................................................................... 58
SECTION 4 OPERATION ............................................................................................................. 59
Description ................................................................................................................................................... 59
Figure 36: Digital Display Control Unit Overview ................................................................................... 59
Display Information ...................................................................................................................................... 60
Control Unit Functions ................................................................................................................................. 60
Flow ............................................................................................................................................................. 60
FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
8
% Foam ....................................................................................................................................................... 60
Total Flow ................................................................................................................................................... 60
Figure 37: Display - Function Modes ..................................................................................................... 60
Bar graph ..................................................................................................................................................... 61
Reset Functions .......................................................................................................................................... 61
Foam Concentrate Injection Rate ................................................................................................................ 61
Warning Messages ...................................................................................................................................... 61
Low Foam Tank Level .................................................................................................................................. 62
Figure 38: Diaplay - Low Foam Tank Display ......................................................................................... 62
Priming Error ............................................................................................................................................... 62
High Ambient Temperature ............................................................................................................................... 62
Figure 39: Display - Priming Error .......................................................................................................... 62
Priming the Foam Pump ............................................................................................................................. 63
Figure 40: Display - High Temperature and Low Battery ........................................................................ 63
NORMAL OPERATION SUMMARY ......................................................................................... 64
SIMULATED FLOW OPERATION ............................................................................................. 66
Figure 41: Display - Simulated Flow Operation ..................................................................................... 66
Simulated flow sequence ............................................................................................................................ 66
To End Simulated Flow................................................................................................................................ 67
SECTION 5 MAINTENANCE ...................................................................................................69
Maintenance Procedures ............................................................................................................................ 69
Freeze Protection ........................................................................................................................................ 69
SECTION 6 TROUBLESHOOTING ........................................................................................71
User Diagnostics ......................................................................................................................................... 71
Figure 42: Distribution Box Overview ..................................................................................................... 71
System Overview ........................................................................................................................................ 72
Figure 43: FoamLogix 2.1A & 1.7AHP System Closed-Loop Flow Diagram ......................................... 72
Distribution Box ........................................................................................................................................... 72
Pump/Motor ................................................................................................................................................. 72
Bar Graph .................................................................................................................................................... 73
Summary ..................................................................................................................................................... 73
Problem Isolation......................................................................................................................................... 73
Troubleshooting charts ................................................................................................................................ 74
Chart 44: Hale FoamLogix System Troubleshooting Flow Diagram ................................................... 74
Contents -continued .................................................................................... Page
SECTION 7 ILLUSTRATED PARTS BREAKDOWN ................................................................76
General ...................................................................................................................................................................
76
Abbreviations ..........................................................................................................................................................
76
Foam Pump Assembly .................................................................................................................................... 78
Figure 7-1: Foam Pump Assembly ............................................................................................................. 79
Foam Flow Meter Assembly ............................................................................................................................ 80
Figure 7-2: Foam Flow Meter Assembly ................................................................................................ 81
Flow Sensor components ................................................................................................................................ 82
Figure 7-3: Flow Sensor Components........................................................................................................ 83
FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
9
ADDITIONAL FOAMLOGIX COMPONENTS .................................................................................................. 84
Figure 7-4: Additional FoamLogix Components. ........................................................................................ 85
Figure 7-5: Additional FoamLogix Components ......................................................................................... 85
FoamLogix 2.1A Pump Repair Kit. .................................................................................................................. 86
APPENDIX A
HALE FOAM CONCENTRATE COMPATIBILITY .....................................................................87
Table A-1: Hale Foam Concentrate Compatibility...................................................................................... 87
Reference .................................................................................................................................................. 88
Distribution Box Replacement - Required Checks ........................................................................89
Foam Flow Sensor Replacement Instructions ................................................................................93
Warranty ..............................................................................................................................................................
95
FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
10
FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
11
SECTION 1 SAFETY
IMPORTANT!
THE HALE “FOAMLOGIX™” MODELS 2.1A
AND 1.7AHP CLASS “A” ELECTRONIC FOAM
PROPORTIONING SYSTEMS ARE DESIGNED
FOR OPTIMUM SAFETY OF ITS OPERATORS
AND TO PROVIDE RELIABLE AND SAFE FOAM
CONCENTRATE INJECTION. FOR ADDED
PROTECTION AND BEFORE ATTEMPTING
INSTALLATION OR OPERATION PLEASE FOLLOW
THE SAFETY GUIDELINES LISTED IN THIS SECTION
AND ADHERE TO ALL WARNING, DANGER, CAUTION
AND IMPORTANT NOTES FOUND WITHIN THIS
GUIDE.
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
FOAMLOGIX PROPORTIONING SYSTEM.
WHEN DEVELOPING DEPARTMENTAL APPARATUS
OPERATING PROCEDURES, INCORPORATE THE
WARNINGS AND CAUTIONS AS WRITTEN.
FoamLogix is a trademark of Hale Products,
Incorporated. All other brand and product
names are the trademarks of their respective
holders.
GUIDELINES
READ ALL INSTRUCTIONS THOROUGHLY BEFORE
BEGINNING ANY INSTALLATION OR OPERATION
PROCESS.
❑ Installation should be performed by a trained
and qualified installer, or your authorized Hale
Products service representative.
❑ Be sure the installer has sufficient knowledge,
experience and the proper tools before
attempting any installation.
❑ Make sure proper personal protective equipment
is used when operating or servicing apparatus.
❑ A foam tank low level sensor must be utilized
to protect the Hale Foam proportioner from dry
running. Failure to use a low level sensor with
the Hale Foam system voids warranty.
❑ DO NOT permanently remove or alter any
guard or insulating devices, or attempt to
operate the system when these guards are
removed.
Make sure all access/service panels and
covers are installed, closed and latched tight,
where applicable.
❑ DO NOT remove or alter any hydraulic or
pneumatic connections, electrical devices,
etc. DO NOT tamper with or disconnect safety
features or modify protective guards (such
as covers or doors). DO NOT add or remove
structural parts. Doing so voids the warranty.
Any of the above could affect system capacity
and/or safe operation of the system and is
a serious safety violation which could cause
personal injury, could weaken the construction
of the system or could affect safe operation of
the FoamLogix Proportioning System.
WARNING!
NO MODIFICATIONS OR ADDITIONS MAY BE MADE
TO THE FOAMLOGIX PORPORTIONING SYSTEM
WITHOUT PRIOR WRITTEN PERMISSION FROM:
Hale Products, Incorporated
700 Spring Mill Avenue
Conshohocken, PA 19428
Telephone: 610-825-6300
Fax: 610-825-6440
❑ To prevent electrical shock always
disconnect the primary power source
before attempting to service any part of the
Hale Foam system.
FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
12
❑All electrical systems have the potential to
cause sparks during service. Take care to
eliminate explosive or hazardous environments
during service and/or repair.
❑To prevent system damage or electrical
shock the main power supply wire is the last
connection made to the Hale Foam proportioner
distribution box.
❑Release all pressure then drain all concentrate
and water from the system before servicing any
of its component parts.
❑Do not operate system at pressures higher than
the maximum rated pressure.
❑Use only pipe, hose, and fittings from the foam
pump outlet to the injector fitting, which are rated
at or above the maximum pressure rating at
which the water pump system operates.
❑Hale Foam proportioning systems are designed
for use on negative ground direct current
electrical systems only.
❑Do not mount radio transmitter or transmitter
cables in direct or close contact with the
FoamLogix control unit.
❑Before connecting the cord sets and wiring
harnesses, inspect the seal washer in the female
connector. If the seal washer is missing or
damaged, water can enter the connector causing
corrosion of the pins and terminals. This could
resulting in possible system failure.
❑Always disconnect the power cable, ground
straps, electrical wires and control cables from
the control unit or other Hale Foam 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.
❑DO NOT connect the main power lead to small
leads that are supplying some other device, such
as a light bar or siren.
The Hale FoamLogix, Models 2.1A and
1.7AHP require 40 AMP minimum current.
❑When operating 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.
❑Make sure the foam tank and foam concentrate
suction hoses are clean before making final
connection to foam pump. If necessary flush
tank and hoses prior to making connection.
❑Check all hoses for weak or worn conditions
after each use. Ensure that all connections and
fittings are tight and secure.
❑Ensure that the electrical source of power for
the unit is a negative (–) ground DC system, of
correct input voltage, with a reserve minimum
current available to drive the system.
❑The in-line strainer/valve assembly is a low
pressure device and WILL NOT withstand
flushing water pressure in excess of 45 PSI (3
BAR).
❑When determining the location of Hale Foam
system components keep in mind piping runs,
cable routing and other interferences that
could hinder or interfere with proper system
performance.
❑Always position the check valve/injector fitting
at a horizontal or higher angle to allow water
to drain away from the fitting. This avoids the
possibility of sediment deposits or the formation
of an ice plug.
❑The cord sets provided with each Hale Foam
system are indexed to ensure correct receptacle
installation (they insert one way only). When
making cord set connections DO NOT force
mismatched connections as damage can result
in improper system operation.
❑Make sure all connections are sound, and that
each connection is correct.
❑The cables shipped with each Hale Foam
system are 100% tested at the factory with that
unit. Improper handling and forcing connections
can damage these cables which could result in
other system damage.
FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
13
❑There are no user serviceable parts inside Hale
Foam system electrical/electronic components.
Opening of the distribution box or control unit
voids the warranty.
❑Use mounting hardware that is compatible with
all foam concentrates to be used in the system.
Use washers, lock washers and cap screws
made of brass or 300 series stainless steel.
❑When making wire splice connections, make
sure they are properly insulated and sealed using
an adhesive filled heat shrink tubing.
❑ALWAYS connect the primary positive power
lead from the terminal block to the master switch
terminal or the positive battery terminal.
Use a minimum 8 AWG type SGX (SAE J1127)
chemical resistant battery cable and protect with
wire loom.
❑ Prevent corrosion of power and ground
connections by sealing these connections with
silicone sealant provided.
❑ Prevent possible short circuit by using the rubber
boot provided to insulate the primary power
connection at the Hale FoamLogix distribution
box.
FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
14
NOTES
FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
15
SECTION 2 DESCRIPTION
The Hale FoamLogix 2.1A and 1.7AHP Foam
Proportioning Systems are completely engineered,
factory matched foam proportioning systems that
provides reliable, consistent foam concentrate
injection for Class “A” foam operations.
Hale FoamLogix Foam systems accurately deliver
from 0.1% to 10.0% (up to the capacity of the foam
pump) foam concentrate through a check valve/
injector fitting, directly into the water discharge
stream. It is then fed as foam solution into a
standard fog nozzle, an air aspirated nozzle, or
CAFS equipment, through the apparatus discharge
piping. A properly configured and installed foam
system with Hale recommended components
virtually eliminates contamination of the booster
tank, fire pump and relief valve with foam
concentrate.
ROTARY PLUNGER PUMP
The heart of the Hale FoamLogix 2.1A and 1.7AHP
systems are an electric motor driven rotary plunger
pump. The pump is constructed of anodized
aluminum and stainless steel and is compatible
with most Class “A” foam concentrates. The pump
is close coupled to the electric motor thereby
eliminating maintenance of an oil filled gearbox.
A relief valve mounted on the foam pump and
constructed of brass, protects the foam pump
and foam concentrate discharge hoses from over
pressurization and damage.
CONTROL UNIT
The control unit, mounted on the operator panel, is
the single control point for the FoamLogix system.
Pressing the ON button starts foam concentrate
injection. A super bright digital LED display shows
the:
❑ Water flow rate
❑ Total water flow
❑ Foam concentrate injection percentage
❑ Total foam concentrate used, depending on the
display mode selected.
A bar graph indicates the approximate system
capacity being used. Adjustment of the foam
concentrate injection rate is accomplished by
pressing the appropriate button.
The control unit display also warns the operator if
errors or abnormal operations occur in the system,
such as low foam level.
WATER FLOW SENSOR
Foam concentrate injection rate is controlled by
a computer chip in the control unit for accurate,
repeatable, reliable foam concentrate injection. A
water flow sensor constantly monitors water flow
through the discharge piping. The information from
the flow sensor is provided to the control unit by
a shielded cable. When the FoamLogix system is
activated at the control unit a signal is sent through
the control cable to the distribution box to begin
foam concentrate injection. The distribution box then
provides power to the electric motor. As the motor
rotates the pump, foam concentrate flows through
the foam pump discharge to the one piece check
valve/ injector fitting into the water discharge stream.
Note: All Hale FoamLogix Foam systems
require a flow sensor for operation.
FEED BACK SENSOR
A feedback sensor in the foam pump discharge
measures foam concentrate flow. The water flow
rate and foam concentrate flow rate are constantly
compared by the computer chip in the control unit.
FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
16
The motor speed is constantly adjusted to maintain
the operator selected foam concentrate injection
rate. Since the system is flow based, injection rate
remains constant regardless of changes in system
pressure or the number of discharges that are open
(within the limits of the sytem).
The maximum rated foam concentrate flow, in
gallons per minute, is denoted by the model
number. Table 1: “Maximum Foam Solution Flows”
shows the system capacity at various foam
concentrate injection rates for the Hale FoamLogix
2.1A and 1.7APH units.
Table 1: Maximum Foam Solution Flows
The Hale FoamLogix 2.1A & 1.7A Foam system
configuration is shown in Figure 2-3: “Typical
System Layout” on page 21.
LOW PRESSURE STRAINER
A low pressure foam concentrate strainer is mounted
at the inlet of the foam pump. The strainer protects
the pump from debris that might accumulate in the
foam concentrate tank. The strainer/valve assembly
has a composite nonmetallic housing with stainless
steel mesh strainer element and includes a service
shut-off valve.
The valve inlet offers 1/2” NPT (13 mm) threads,
with a fitting to connect a 1/2” (13 mm) ID foam
concentrate suction hose.
The strainer and valve are low pressure devices
and are designed for installations where the
strainer IS NOT subject to HIGH pressure flushing
water.
ORDERING INFORMATION
Ordering Hale FoamLogix 2.1A and 1.7AHP
Foam Systems is simple. Using the current Hale
FoamLogix 2.1A Foam System Price List and
Order Form helps ensure a complete matched
system is provided to the end user.
Use the following procedure when ordering a
Hale FoamLogix 2.1A Foam system. Following
all steps to ensure that a complete system is
ordered:
1.
Check Hale Foam system product information update (Bulletin #961) for the latest
information and advice for foam system
selection.
2.
Determine the Class “A” foam concentrate
to be used in the system and ensure system
compatibility by referring to the Hale Foam
Concentrate Compatibility list (Bulletin #650).
3.
Consult the current Hale FoamLogix 2.1A/
1.7AHP Price List and Order Form for
ordering of the system.
The Hale FoamLogix 2.1A and 1.7AHP can be
ordered as one of two pre-configured packages
that include the pump and motor assembly,
control unit, flow sensor cable, stainless steel
check valve and injection manifold, and an
installation kit.
Package “A” includes the single check
valve manifold.
Maximum Foam Solution Flow
Injection Rate
Percent (%)
Gallons per
Minute (GPM)
Liters Per Minute
(LPM)
2.1A
1.7AHP
2.1A
1.7AHP
0.1
2,100
1,700
7,949
6,426
0.2
1,050
850
3,974
3,213
0.3
700
567
2,650
2,143
0.5
420
340
1,590
1,285
1.0
210
170
795
643
FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
17
Package “B” includes dual check valve
manifold.
Note: If package “A” is selected an additional check valve
is required where the foam manifold attaches to the pump
discharge for NFPA compliance.
4.
The Hale FoamLogix 2.1A and 1.7AHP may also
be ordered “a-la-carte” if one of the standard
packages does not meet end user requirements.
When ordering the system “a-la-carte” for a
complete system the Pump and motor assembly,
flow sensor, flow sensor cable, low tank sensor
and check valve injector fitting must be ordered
as a minimum.
Ordering the components as a complete system
allows Hale to configure and test the complete
order, to ensure a problem-free system.
5.
Additional Hale components available to
enhance system operation and ease installation
include:
❑ Control Cable Extension
❑ Waterway Check Valves
❑ Manifolds
❑ Flanges
System components are shown in the following
heading “System Configuration,” beginning on
page 20.
All components listed are engineered and tested
with Hale Foam systems to provide optimum system
performance. Using the information provided in this
manual and the detailed ordering procedures on
the option order form ensures that a complete Hale
Foam system is ordered thus eliminating delays
caused by missing components.
FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
18
HALE FOAM SYSTEM SPECIFICATIONS
2.1A
1.7AHP
Foam Pump
Dual Plunger
Dual Plunger
Maximum Foam Concentrate Output
2.1 GPM (8 LPM)
1.7 GPM (6.5 LPM)
Maximum System Operating Pressure
250 PSI (17 BAR)
400 PSI (27.5 BAR)
Maximum Operating Temperature
160o F (71o C)
160o F (71o C)
Pump Motor
0.44 HP (0.3 Kw), 12 VDC
0.44 HP (0.3 Kw), 12
VDC
Operating Ampere Draw
25 AMPS @ 12 VDC
30 AMPS @ 12 VDC
Maximum Ampere Draw
40 AMPS @ 12 VDC
40 AMPS @ 12 VDC
FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
19
Figure 2: Foam Pump Installation Envelope Dimensions
FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
20
SYSTEM CONFIGURATION
Package A
Part Number: (Choose One)
FLX21-12-1-10-1 (2.1A 12 Volt) FLX17-12-1-10-1 (1.7AHP 12 Volt)
FLX21-24-1-10-1 (2.1A 24 Volt) FLX17-24-1-10-1 (1.7AHP 24 Volt)
Description: FoamLogix Kit with single stainless steel check valve manifold
Includes the following:
(1) FoamLogix full function digital display control that displays flow, foam %, total flow and total foam
(1) Foam pump assembly with bypass and strainer service valves
(1) 15 feet of cable between display and pump and 10 feet of cable between display and flow sensor
(1) Compact foam manifold assembly with a single waterway check valve, flow sensor and foam
injection check valve installed. 3 inch grooved victaulic connections
Flow range 30 - 750 GPM
Note: A second check valve is recommended to avoid pump/water tank contamination.
(1) Installation kit includes clear reinforced foam inlet hose, hose clamps, positive and ground
terminal insulation kit
(2) Operation and Installation manuals
(1) Single tank system instruction placard
(1) Side mount low level tank sensor
Package B
Part Number: (Choose One)
FLX21-12-2-10-1 (2.1A 12 Volt) FLX17-12-2-10-1 (1.7AHP 12 Volt)
FLX21-24-2-10-1 (2.1A 24 Volt) FLX17-24-2-10-1 (1.7 AHP 24 Volt)
Description: FoamLogix Kit with dual stainless steel valve manifold (recommended for NFPA backflow
prevention compliance):
Includes the following:
(1) FoamLogix full function digital display control that displays flow, foam %, total flow and total foam
(1) Foam pump assembly with bypass and strainer service valves
(1) 15 feet of cable between display and pump and 10 feet of cable between display and flow sensor
(1) Foam manifold assembly with dual waterway check valves, flow sensor and foam injection check
valve installed. 3 inch grooved Victaulic connections
Flow range 30 - 750 GPM
(1) Installation kit includes clear reinforced foam inlet hose, hose clamps, positive and ground terminal
insulation kit
(2) Operation and Installation manuals
(1) Single tank system instruction placard
(1) Side mount low level tank sensor
FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
21
(Supplied
by system
installer)
Double Check
Valve Assembly
Figure 3: Typical Hale FoamLogix 2.1A and 1.7AHP System Layouts
(Also see Figure 20: “Control Harness Connections” on page 45)
FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
22
Hale FoamLogix 2.1A and 1.7AHP Foam Proportioner Systems
All Hale FoamLogix 2.1A and 1.7AHP systems include: Foam Pump/Motor Assembly and Control Unit
FoamLogix Base Unit,
Foam Pump/Motor Assembly
2.1A - 12V: 115498
2.1A - 24V: 115499
1.7AHP - 12V: 119276
1.7AHP - 24V: 119277
Control Display Unit p/n: 111530
Check Valve/Injector Fitting
p/n: 038-1790-00-0
FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
23
Bottom Mount Low Level Tank Sensor
Top Mount Low Level Tank Sensor
Low Tank Level Sensor Options
One Low Tank Level Sensor is Required
p/n: 200-2100-04-0
(1” NPT threaded bushing to mount from outside
foam tank.)
p/n: 200-2110-06-0
(Extends from 2-1/2’ to 5’ (0.8 to 1.5 meters) - may
be cut shorter if required.)
FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
24
1
A
20"
1'
B
Flow Sensors
Each Hale foam system requires a flow sensor for operation. Pipe size must be selected based on the
minimum and maximum water flow in the foam capable discharge. Following is a list of pipe size and rated flow
ranges, along with flow sensor saddle clamp part number. In all instances, a weld fitting may be substituted for
the saddle clamp.
Pipe Size
Flow Range
GPM
LPM
1.5”
10 - 350
38- 1,219
2”
20 - 550
76 - 2,082
2.5”
30 - 800
114 - 3,028
3”
50 - 1,250
189 - 4,731
4”
75 - 1,800
284 - 6,813
SCV or DCV
30 - 750
114 - 2,839
Figure 4: Pipe Size vs. Flow Range
Flow Sensor Paddle Wheel
p/n: 102714
Flow Sensor Saddle Clamp
Threads (NPT) Part Number
2” – p/n: 4842010
2.5” – p/n: 4843010
3” – p/n: 4844010
4” – p/n: 4846010
Flow Sensor Weld Fitting
Stainless Steel, p/n: 082-3060-00-0
Steel, p/n: 309020
Aluminium, p/n: 309010
Flow Sensor Cable
Dimension A & B
Part Number
10’ x 14’
(3.05m x 4.27m)
113438
15’ x 19’
(4.57m x 5.79m)
113439
FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
25
p/n 038-1570-08-0
FoamLogix, Model 2.1A and 1.7AHP Class "A"
Electronic Foam Proportioning
Systems
26
HALE
Classf
Elbows and Mini-Manifolds
Close Fit Flanged Elbow
p/n:
098-0140-00-0
(115 flange inlet with 3" Victaulic outlet)
Close Fit Flanged Elbow
p/n:
098-0190-00-0
24330 flange inlet with 3• NPT female
and 4" Victaulic outlet)
Close Fit Flanged Elbow
pin:
098-0050-00-0
(115 flange inlet with 2.5" NPT female outlet)
Close Fit Flanged Elbow
p/n:
098-0020-00-0
(115 flange inlet with 115 flange outlet)
Mini-Manifold p/n:
178-0320-02-0
FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
27
Remote Start Option
Switch
p/n: 513-0330-01-0
Remote Start Option
Harness
p/n: 513-0680-00-0
(5m)
FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
28
NOTES
FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
29
SECTION 3 INSTALLATION
To simplify installation selection, one of the two
packages described in previous Section 2 should
be ordered. While either package provides most
of the components required for installation, the
following guidelines are offered to assist the system
installer with a complete system installation.
Carefully review the procedures that follow to
ensure the system is properly designed. This
section lists components that have been tested
with Hale FoamLogix and provide the best
system performance. Use of the recommended
materials and specified parts ensures a virtually
maintenance free installation.
Differences in apparatus plumbing and foam
system configuration make it impractical to show
exactly how the Hale FoamLogix 2.1A and 1.7AHP
systems are installed on a particular apparatus.
The information contained in this section, however,
applies to most situations and should be used
when designing and installing Hale FoamLogix
2.1A and 1.7AHP systems. A system plumbing and
electrical diagram is provided at the end of this
section to assist with installation.
Before proceeding with system installation,
carefully review the procedures that follow to
ensure the system is properly designed.
The Hale FoamLogix system is supplied with five
major components that must be located on the
apparatus.
❑ Foam pump and motor assembly
❑ Control unit
❑ Instruction/system diagram placard
❑ Flow Sensor
❑ Check valve injector fitting
Notes: The flow sensor and check valve
injector fitting may be pre-mounted, if a
manifold or pre-configured package is
ordered.
Optional components that require mounting on
the apparatus include:
❑ Mini Manifold
❑ Flanged elbows
IMPORTANT !
WHEN DETERMINING THE LOCATIONS OF HALE
FOAMLOGIX COMPONENTS BEING INSTALLED
KEEP IN MIND PIPING RUNS, CABLE ROUTING
AND OTHER INTERFERENCES THAT COULD
HINDER OR INTERFERE WITH PROPER SYSTEM
PERFORMANCE.
FOAM PUMP AND MOTOR ASSEMBLY
The foam pump and motor assembly must be
located in an area that is protected from road
debris and excessive heat buildup. The back of a
compartment or a compartment shelf is often an
ideal location. The foam system, bypass valve,
strainer and shut-off valve are located on the foam
pump and motor assembly and access to these
components must be provided.
The foam pump and motor assembly must be
mounted below the discharge of the foam tank to
provide for gravity feed to the foam pump. The foam
tank must be located where refilling can be easily
accomplished with 5 gallon (19 liters) pails and other
methods suitable to the end user. Most water tank
manufacturers build the foam tank into the booster
tank.
When specifying a foam tank, make sure provisions are made for:
❑ Installation of the low tank level sensor
FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
30
❑ Foam suction connections
❑ Tank drainage
❑ Proper fill openings, per NFPA requirements.
In addition, a foam tank refill system may
be required. See Hale EZFill system for
installation requirements.
CONTROL UNIT AND INSTRUCTION/
SYSTEM DIAGRAM PLACARD
Determine a location on the operator panel of the
apparatus for the control unit and instruction/ system
diagram placard, if provided. These components
must be located at the main pump operator position
in close proximity to each other. Consideration
must be given for routing the control cable from the
control unit to the distribution box on the foam pump
and motor assembly. If necessary, order longer
or shorter cable assemblies to suit the location
demands.
INSTALLER SUPPLIED COMPONENTS
Due to the many differences in apparatus configurations and design requirements the Hale
FoamLogix system installer must supply components, such as,
❑ mounting brackets
❑ piping
❑ hoses
❑ fittings
❑ electrical wiring
❑ foam tank(s)
The following guidelines are recommendations for
selection of additional components for a complete
system installation. These recommendations
reflect materials and components that are tested
extensively with Hale FoamLogix systems and
provide proven reliable performance.
Foam Concentrate Suction Hose
The Hale FoamLogix 2.1A and 1.7 AHP Foam
systems are provided with 15’ (4.6 meters) of 1/2”
(13mm) ID reinforced PVC foam concentrate suction
hose. The system installer may need to supply
additional fittings and hose from the foam tank to the
inlet of the foam pump.
All components selected transfer foam concentrate,
therefore they must be compatible with the foam
concentrates being used in the system. Hoses for
Class A foam concentrates have minimum 1/2”
(13mm) inside diameter.
Hoses for the foam concentrate suction must have
a rating of 23” (584 mm) Hg vacuum and 50 PSI
(3.5 BAR) pressure or greater.
Note: NFPA requires that foam concentrate suction
hose be clear to observe foam concentrate flow
during foam pump operation.
Recommended Components
❑Hose: PVC, Kuriyama Kuri-Tec K3130 or K7130
series
❑Fittings: Hose Barb Type; Brass, Stainless
Steel or Nylon
A tee with foam tank shut-off valve and a drain
valve is recommended in the foam tank suction
hose to allow, tank drainage and easier priming.
These components are subject to the same material
characteristics and pressure ratings as stated
above.
The foam concentrate strainer includes a shutoff valve. This valve is used to shut off foam
concentrate flow to service the strainer.
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