Hale FoamLogix 6.5 User Manual

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Page 1

FoamLogix

Models 3.3 / 5.0 / 6.5 Electronic

Foam Proportioning System

Installation and Operations Manual

Hale Products Inc. ◆ A Unit of IDEX Corporation

700 Spring Mill Avenue

Telephone: 610-825-6300

Web: www.haleproducts.com

◆ Conshohocken, PA 19428 U.S.A.

◆ FAX: 610-825-6440

Manual p/n: 029-0021-68-0

Page 2

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

0602 A Initial Release, for Printing LwH 08/10/2007 MAL

Manual p/n: 029-0021-68-0, Rev. -A Printed in U.S.A.

HALE PRODUCTS, INC.

A Unit of IDEX Corporation

Conshohocken, PA 19428 USA

DRAWN BY LwH ISSUE DATE

NOT TO BE REPRODUC ED OR USED TO

MAKE OTHER DRAWI NGS OR MACHINE RY.CHECKED BY PRW 08/10/2007

COPYRIG HT ©

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Table of Contents ❑

Contents Page

FoamLogix 3.3 / 5.0 / 6.5 Installation and Operations

How to use this manual ........................................................................................ 11

1 Safety Precautions................................................................................................. 13

1.1 Definitions......................................................................................................................... 13

1.2 Guidelines ......................................................................................................................... 14

1 System Overview................................................................................................... 19

2.1 Rotary Gear Pump............................................................................................................ 19

2.2 Control Unit....................................................................................................................... 19

2.3 Water FLow Sensor.......................................................................................................... 20

2.4 Feed Back Sensor ........................................................................................................... 20

Table 2-1: Maximum Foam Solution Flows..........................................................................20

2.5 Tank Selector Valves ....................................................................................................... 21

Air Dual Tank Selector (ADT) ...........................................................................................................21

Manual Dual Tank Selector (MDT II) ................................................................................................ 21

Manual Single Tank (MST)...............................................................................................................22

2.6 Low Pressure Strainer ..................................................................................................... 22

Hale FS Series Strainers ..................................................................................................................22

2.7 Ordering Information ....................................................................................................... 23

2.8 Hale Foam System Specifications .................................................................................. 24

Figure 2-2: Foam Pump Installation Envelope Dimensions.................................................25

Figure 2-3: Foam Pump Installation Envelope Dimensions, ADT Option Only....................26

2.9 System Configuration ...................................................................................................... 27

Hale Foam Proportioner System, Models 3.3, 5.0 or 6.5..................................................................27

Figure 2-4: FoamLogix Available Models ............................................................................ 27

Figure 2-5: Hale Foam Proportioner Systems, Models 3.3, 5.0 and 6.5.............................. 27

2.10 Cable Harness .................................................................................................................. 28

Figure 2-6: Power Connection Wire Harness ..................................................................... 28

2.11 Dual Foam Concentrate Tank System Options ............................................................ 29

Figure 2-7: Dual Tank Foam Concentrate Tank System Options........................................29

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❑ Table of Contents

Contents - continued Page

2.12 Dual Foam Concentrate Tank Options........................................................................... 30

2.13 Single Foam Concentrate Tank Options ....................................................................... 31

2.14 Strainer Options .............................................................................................................. 32

2.15 Low Tank Level Sensor Options ................................................................................... 33

2.16 Flow Sensors.................................................................................................................... 34

2.17 Check Valve Manifolds .................................................................................................... 35

2.18 Remote Activation Switch Option ................................................................................. 36

2.19 Check Valves, Flanges, Gaskets ................................................................................... 37

2.20 Elbows and Mini Manifolds ............................................................................................ 38

2.21 Hale Foam System Layout Drawings ............................................................................ 39

Figure 2-10: Typical Single Foam Concentrate Tank ..........................................................39

Figure 2-11: Single Foam Tank with MST and In-Line Strainer/Valve Assembly ................ 40

Figure 2-12: Single Foam Tank with MST and FS Series Strainers .................................... 41

Figure 2-13: Dual Foam Concentrate Tanks, with MDT II and In-Line

Strainer/Valve Assembly.................................................................................................42

Figure 2-14: Dual Foam Concentrate with MDT II and FS Series Strainer Assembly ......... 43

Figure 2-15: Dual Foam Concentrate Tanks, with ADT and In-Line

Strainer/Valve Assemblies..............................................................................................44

Figure 2-16: Dual Foam Concentrate Tanks with ADT and FS

Series Strainer Assemblies............................................................................................. 45

3 Installation ............................................................................................................. 47

3.1 Foam Pump and Motor Assembly .................................................................................. 48

3.2 Foam Concentrate Strainer............................................................................................. 48

3.3 Control Unit / Instruction Placard................................................................................... 49

3.4 Installer Supplied Components ...................................................................................... 50

Foam Concentrate Suction Hose ..................................................................................................... 50

Recommended Components .................................................................................................... 50

Recommended Components .................................................................................................... 51

Foam Concentrate Discharge Hose .................................................................................................51

Recommended Components .................................................................................................... 51

Foam Concentrate Bypass Hose...................................................................................................... 52

Recommended Components .................................................................................................... 52

Check Valves....................................................................................................................................52

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Table of Contents ❑

Contents - continued Page

3.4 Installer Supplied Components - continued

Flushing Water Hose ........................................................................................................................ 5 3

Foam Discharge Drains.................................................................................................................... 54

Electrical Requirements.................................................................................................................... 54

Figure 3-1: Recommended Relay Wiring Schematic ...........................................................55

Table 3-2: Primary Power Cable Sizes................................................................................ 55

FoamLogix Display ........................................................................................................................... 56

Foam Concentrate Tanks(s)............................................................................................................. 56

Table 3-3: Recommended Foam Tank Capacity .................................................................57

Foam Pump Mounting .....................................................................................................................57

Figure 3-4: FoamLogix Pump Installation ............................................................................ 57

Figure 3-5: Base Plate Mounting Hole Locations ................................................................ 58

Plumbing Installation......................................................................................................................... 59

Water and Foam Solution Plumbing .................................................................................................59

Figure 3-6: Typical Check Valve Manifold Installation ........................................................59

Optional Hale Piping Components....................................................................................................60

Figure 3-7: Typical Midship Pump Installation ....................................................................61

Figure 3-8: 4” (102mm) Check Valve Installation.................................................................61

“Waterway” Check Valves ................................................................................................................62

Flow Sensor ..............................................................................................................................62

Figure 3-9: Flow Sensor Tee Position Range ......................................................................62

Table 3-10: Pipe Size vs. Minimum Straight Run ................................................................63

Figure 3-11: Typical Reduced Size Sensor Piping Arrangement.........................................63

Figure 3-12: Flow Sensor Placement ..................................................................................64

Saddle Clamp Installation ..........................................................................................................64

Figure 3-13: Flow Sensor/Saddle Clamp Installation...........................................................65

Foam Pump Flush System ...............................................................................................................65

Dual Tank System .....................................................................................................................65

Single Tank System ..................................................................................................................65

No Tank Option .........................................................................................................................65

Foam Concentrate Plumbing............................................................................................................66

Foam Strainer Connection (In-Line Strainer/Valve).......................................................................... 66

Figure 3-14: In-Line Strainer/Valve Installation....................................................................67

To Install the In-Line Strainer/Valve Assembly ..........................................................................67

Figure 3-15: In-Line Strainer Mounting Bracket Layout ....................................................... 68

FS Series Strainer ............................................................................................................................69

To Install FS Series Strainers ....................................................................................................69

Figure 3-16: FS Strainer Orientation....................................................................................69

Figure 3-17: FS Strainer Mounting Dimensions...................................................................70

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❑ Table of Contents

Contents - continued Page

3.4 Installer Supplied Components - continued

Check Valve / Injector Fitting ....................................................................................................71

Figure 3-18: Check Valve/Injector Fitting Orientation.......................................................... 71

Figure 3-19: Check Valve / Injector Fitting Installation ........................................................71

Foam Concentrate Injection Hose.................................................................................................... 72

Figure 3-20: Injection and Bypass Hose Connections ......................................................... 72

Bypass Hose Connection .................................................................................................................72

Figure 3-21: Bypass Valve Assembly ..................................................................................73

ADT Option Air Connections ............................................................................................................ 73

Figure 3-22: ADT Option Panel Placard Layout Dimensions...............................................74

Figure 3-23: ADT Air Hose Connections, Part 1..................................................................74

Figure 3-24: ADT Option Air Hose Connections, Part 2 ...................................................... 75

3.5 System Plumbing Diagrams ........................................................................................... 77

Figure 3-25: Typical Single Foam Concentrate Tank ..........................................................78

Figure 3-26: Typical Single Foam Tank with MST and In-Line

Strainer/Valve Assembly................................................................................................. 79

Figure 3-27: Typical Single Foam Tank, with MST and FS Series Strainers....................... 80

Figure 3-28: Single Foam Tank with MST II and In-Line Strainer/Valve Assembly ............. 81

Figure 3-29: Typical Single Foam Tank with MST II and FS Series Strainers.....................82

Figure 3-30: Typical Single Foam Tank with ADT and In-Line

Strainer/Valve Assemblies.............................................................................................. 83

Figure 3-31: Typical Dual Foam Tanks, with ADT and FS Series Strainer Assemblies ...... 84

3.6 Electrical ........................................................................................................................... 85

Single and Dual Tank Electrical Harness Overview ........................................................................ 87

Figure 3-32: Single Tank Electrical Harness Overview .......................................................87

Figure 3-33: Dual Tank Electrical Harness Overview ..........................................................88

Control / Display Unit........................................................................................................................ 88

Figure 3-34: Control/Display Unit Mounting Dimensions ..................................................... 89

Figure 3-35: Distribution Box Connections .......................................................................... 90

Distribution Box Ground / Primary Power .........................................................................................90

RFI / EMI ..........................................................................................................................................91

Figure 3-36: Extra Cable Storage........................................................................................ 92

Flow Sensor Connections................................................................................................................. 92

“Low Level Sensor” Installation (Foam Tank)...................................................................................92

Figure 3-37: Low Level Sensor Mounting Options............................................................... 93

Figure 3-38: Side Mount Sensor Location Dimensions .......................................................93

Figure 3-39: Top Mount Sensor Dimensions ....................................................................... 95

Figure 3-40: Top Mount Low Level Sensor Assembly ......................................................... 97

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Table of Contents ❑

Contents - continued Page

3.6 Electrical - continued

Low Level Sensor Wiring.................................................................................................................. 97

Remote Activation Switch Option .....................................................................................................99

Figure 3-41: Remote Activation Switch Installation Dimensions........................................100

3.7 Start Up Check List ........................................................................................................ 101

Electrical .........................................................................................................................................101

Liquid ..............................................................................................................................................102

Foam Pump .................................................................................................................................... 103

Optional ADT ..................................................................................................................................103

3.8 Installation and Delivery Check List............................................................................. 104

3.9 System Installer Start-UP .............................................................................................. 105

Initial System Power Check............................................................................................................105

Figure 3-43: Initial Start-Up, System Ready Displays........................................................105

System Operation Check................................................................................................................106

Figure 3-44: Simulated Flow Mode Display ....................................................................... 107

4 User Setup and Calibration ............................................................................... 109

4.1 Initial End User Setup .................................................................................................... 109

Figure 4-1: Initial Start-Up, System Ready Displays..........................................................109

System Power Check ..................................................................................................................... 109

Priming the Foam Pump.................................................................................................................110

Figure 4-2: Simulated Flow Mode Display .........................................................................110

4.2 User Calibration.............................................................................................................. 111

Entering Passwords........................................................................................................................112

Figure 4-3: Password Sequence ....................................................................................... 112

Restoring Factory Defaults ............................................................................................................. 113

Figure 4-4: Password and Calibration Modes - Display..................................................... 113

Calibration....................................................................................................................................... 113

Flow Sensor Calibration.................................................................................................................. 114

Figure 4-5: Flow Sensor Calibration - Display ...................................................................114

Record Calibration Factors ............................................................................................................. 115

Figure 4-6: Flow Sensor Calibration Factor.......................................................................115

Simulated Flow ...............................................................................................................................115

Figure 4-7: Simulated Flow Calibration..............................................................................115

Foam Concentrate Injection Rate...................................................................................................116

Figure 4-8: Foam Concentrate Injection Rate Default Value, Tank “A” Shown ................. 116

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❑ Table of Contents

Contents - continued Page

4.2 User Calibration - continued

Foam Pump Feedback Calibration ................................................................................................. 116

Figure 4-9: Foam Pump Feedback Calibration, Tank “A” Shown ...................................... 117

Figure 4-10: Foam Concentrate Collection........................................................................117

Figure 4-11: Feedback Calibration Factor, Tank “A” Shown .............................................118

Exit and Save Calibration ............................................................................................................... 118

Figure 4-12: Exit and Save Calibration .............................................................................. 119

Relief Valve ....................................................................................................................................119

Figure 4-13: Relief Valve ...................................................................................................119

English to Metric Units....................................................................................................................120

5 Operation ............................................................................................................. 121

5.1 Description ..................................................................................................................... 121

Figure 5-1: Control Unit Identification ................................................................................ 121

5.2 Control Display Unit ...................................................................................................... 122

Control Unit Functions ....................................................................................................................122

Figure 5-2: Function Modes............................................................................................... 123

5.3 Reset Functions ............................................................................................................. 124

5.4 Foam Concentrate Injection Rate................................................................................. 124

5.5 Flush ............................................................................................................................... 125

Figure 5-3: Flush................................................................................................................ 125

5.6 Warning Messages ........................................................................................................ 125

Low Foam Tank Level Message.....................................................................................................126

Figure 5-4: Low Foam Tank Message, Tank “A” Shown ................................................... 126

Priming Message............................................................................................................................126

High Ambient Temperature Message............................................................................................. 127

Figure 5-5: Priming, HIGH Temperature and LOW Battery Messages.............................. 127

5.7 Priming the Foam Pump................................................................................................ 128

5.8 Normal Operation Summary ........................................................................................ 129

Energize System....................................................................................................... 129

Select Foam Tank..................................................................................................... 129

Figure 5-6: Normal Operation Summary Chart..................................................................129

Begin Foam Injection. ............................................................................................... 130

Change Injection Rate. ............................................................................................. 130

Read Injection Rate. ................................................................................................. 130

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Table of Contents ❑

Contents - continued Page

5.8 Normal Operation Summary - continued

Read Total Water or Foam Solution. ...................................................................... 130

Read Total Foam Concentrate .................................................................................. 131

Reset Totalized Values ............................................................................................. 131

End Foam Injection ................................................................................................... 131

5.9 Simulated Flow Mode Operation................................................................................... 131

Simulated Flow Sequence ............................................................................................................. 132

Figure 5-7: Simulated Flow Display Sequence ..................................................................132

5.10 Dual Tank System Selection ......................................................................................... 133

Figure 5-8: Dual Tank Selector Operating Positions .........................................................134

5.11 Flushing Hale FoamLogix.............................................................................................. 135

Figure 5-9: Hale MST Selector Operation .........................................................................136

5.12 Remote On/Off Switch Option....................................................................................... 137

To operate: .....................................................................................................................................137

Figure 5-10: Remote Activation Switch..............................................................................137

6 Maintenance ........................................................................................................ 139

6.1 Maintenance Procedures............................................................................................... 139

After each use.................................................................................................................................139

Monthly ...........................................................................................................................................139

Every Two (2) Months..................................................................................................................... 139

Annually .......................................................................................................................................... 139

7 Troubleshooting .................................................................................................. 141

7.1 User Diagnostics ............................................................................................................ 141

Figure 7-1: Distribution Box Overview ...............................................................................141

7.2 System Overview............................................................................................................ 142

Figure 7-2: FoamLogix, Closed Loop Flow Diagram ......................................................... 142

Distribution Box...............................................................................................................................143

Pump / Motor ..................................................................................................................................143

Bar Graph .......................................................................................................................................143

Summary ........................................................................................................................................ 144

7.3 Problem Isolation ........................................................................................................... 144

7.4 Flow Charts..................................................................................................................... 146

Chart 7-3: Hale FoamLogix System Troubleshooting Flow Chart...................................... 146

Chart 7-4: Power System Troubleshooting........................................................................ 147

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Contents - continued Page

Appendix A: Foam Concentrate Compatibility ............................................... 149

Chart A-1: Hale Class “A” Foam Concentrate Compatibility.............................................. 149

Chart A-2: Hale Class “B” Foam Concentrate Compatibility.............................................. 150

Reference ....................................................................................................................................... 151

Express Warranty................................................................................................153

8 Illustrated Parts Breakdown..............................................................................157

General............................................................................................................................ 157

Abbreviations ................................................................................................................. 157

8.1 Air Dual Tank Valve (ADT) Option ................................................................................ 158

8.2 Harness Components.................................................................................................... 160

8.3 Dual Foam Concentrate Tank Options......................................................................... 161

8.4 Single Foam Concentrate Tank Options ..................................................................... 162

8.5 Low Tank Level Sensor Options ................................................................................. 163

8.6 Flow Sensors.................................................................................................................. 164

8.7 Main Cable Harness, Single and Dual Tank ................................................................ 165

8.8 Check Valve Manifolds .................................................................................................. 166

8.9 Remote Activation Switch Option ............................................................................... 167

8.10 Check Valves, Flanges, Gaskets ................................................................................. 168

8.11 Elbows and Mini Manifolds .......................................................................................... 169

9 Plate Drawings..................................................................................................... 170

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How to use this manual

This manual is divided into eight (8) sections for clarity and ease of use. Each of the following sections can be stand alone or used in conjunction with each other.

1SAFETY

This section must be carefully read, understood and adhered to strictly by all installer/builders, operators and service personnel using the Hale FoamLogix, Models 3.3, 5.0 and 6.5, Electronic Foam Proportioning System. Do not use or install the system until you have thoroughly read this section. Failure to comply could cause serious injury to yourself and others, or damage to the system.

How To Use This Manual ❑

2 INTRODUCTION

System overview provides an introduction to the Hale FoamLogix Proportioning System along with guidelines for designing and ordering a complete system.

3 INSTALLATION

This section offers installer/builder installation procedures, plumbing overview diagrams, electrical installation and startup and delivery check lists, to assist the OEM with installation and initial setup of Hale FoamLogix Proportioning System on an apparatus.

4 USER CALIBRATION

User calibration is used by the installer and the end user for start-up and calibration of the Hale FoamLogix Proportioning System to produce the proper foam flow.

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❑ How To Use This Manual

5 OPERATION

The Operation section primarily used by the apparatus user for proper operation and maintenance of the Hale FoamLogix Proportioning System. It is a guide to the operation of the system and includes operating procedures for the most commonly used options.

6 GENERAL MAINTENANCE

This section describes the routine inspection and maintenance requirements for the Hale FoamLogix System.

7 TROUBLESHOOTING

If a problem develops, see this section for troubleshooting procedures.

8 PARTS IDENTIFICATION

Section 8 includes a parts breakdown of the most commonly used parts of the FoamLogix 3.3, 5.0 and 6.5 Systems. Also see Section 8, Parts Identification and Drawing Package, heading “Illustrated Parts Breakdown” on page 157.

9 PLATE DRAWINGS

Section 9 includes a listing of required installation and parts identification drawings for the FoamLogix 3.3, 5.0 and 6.5 Systems. Also see Section Parts Identification and Drawing Package, heading “9 Plate Drawings” on page 170.

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1 Safety Precautions

THE HALE “FOAMLOGIX™” MODELS 3.3, 5.0 and 6.5 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 INSTAL LATION OR OPERATION PLEASE FOLLOW THE SAFETY GUIDELINES LISTED IN THIS SECTION. 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 SYSTEM OPERATORS BEFORE ATTEMPTING TO INSTALL OR OPERATE THE FOAMLOGIX FOAM PROPORTIONING SYSTEM.

WHEN DEVELOPING DEPAR TMENTAL APPARATUS OPERATING PROCEDURES, INCORPORATE THE WARNINGS AND CAUTIONS AS WRITTEN.

Safety Precautions ❑

IMPORTANT !

FoamLogix is a trademark of Hale Products, Incorporated. All other brand and product names are the trademarks of their respective holders.

1.1 DEFINITIONS

DANGER – Immediate hazard which WILL result in severe personal injury or death if the warning is ignored.

WARNING – Hazards or unsafe practices which COULD result in severe personal injury or death if the warning is ignored.

DAN GER !

WARNING !

CAUTION – Hazards or unsafe practices which COULD result in minor or

moderate personal injury if the warning is ignored.

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CAUTION !

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❑ Safety Precautions

NOTICE – Practices which could result in damage to the apparatus or other

property.

1.2 GUIDELINES

READ ALL INSTRUCTIONS THOROUGHLY BE FORE

BEGINNING ANY INSTAL LATION 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 the apparatus.

NOTICE !

❑ 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, electri-

cal 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 PROPORTIONING SYSTEM WITHOUT PRIOR WRITTEN PERMISSION FROM:

Hale Products, Incorporated

Fire Suppression Division

700 Spring Mill Avenue

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Safety Precautions ❑

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 FoamLogix System.

❑ 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 Propor tioner Distribution Box.

❑ Release all pressure then drain all concentrate and water from the sys-

tem before servicing any of its component parts.

❑ Do not operate the 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 transmitters 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. 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 3.3, 5.0 and 6.5, require 60 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.

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❑ Safety Precautions

❑ Unless engaged in Class “B” foam operations, the air dual tank (ADT)

toggle switch, or the manual dual tank (MDT) II selector handle must be in the TANK “A” or FLUSH position. If either is in the FLUSH position when the foam system is started, the foam pump runs for approximately twenty (20) seconds, then SHUTS DOWN.

❑ Make sure the foam tank and foam concentrate suction hoses are clean

before making final connections to the foam pump. If necessary flush the 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 CAN-

NOT withstand flushing water pressure in excess of 45 PSI (3 BAR).

When installing the in-line strainer in systems equipped with the Hale MDT II or MST, make sure the in-line strainer/valve assembly is installed on the “inlet” side of the valve.

If the strainer is subjected to flushing water, install Hale FS Series strainers.

❑ When determining the location of the Hale FoamLogix System compo-

nents 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 100% electri-

cally shielded assemblies.

NEVER attempt to shorten or lengthen the molded cables. If necessary, order longer or shorter cord sets to suit your application needs.

❑ Each cord sets provided is indexed to ensure correct receptacle installa-

tion (they inser t 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 the unit. Improper handling and forcing connections can damage these cables which could result in other system damage.

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Safety Precautions ❑

❑ There are no user serviceable parts inside Hale Foam system electrical/

electronic components.

Opening the distribution box, control unit, foam multiplexing display unit, etc., 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 insu-

lated 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 4 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 the silicone sealant provided.

❑ Prevent possible short circuit by using the rubber boot provided to insu-

late the primary power connection at the Hale FoamLogix Distribution Box.

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❑ Safety Precautions

Notes

______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________

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1 System Overview

The Hale FoamLogix Models 3.3, 5.0 and 6.5 Foam Proportioning Systems are completely engineered, factory matched foam proportioning systems that provide reliable, consistent foam concentrate injection for Class “A” and Class “B” foam operations.

Hale FoamLogix Foam Systems accurately deliver from 0.1% to 10.0% 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.

Introduction ❑

2.1 ROTARY GEAR PUMP

The hear t of the Hale FoamLogix 3.3, 5.0 and 6.5 systems is an electric motor driven rotary gear pump. The pump is constructed of bronze and stainless steel and is compatible with almost all 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 stainless steel, protects the foam pump and foam concentrate discharge hoses from over pressurization and damage.

2.2 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 while the system is operating.

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❑ Introduction

The control unit display also warns the operator if errors or abnormal operations occur in the system, such as low foam level.

2.3 WATER FLOW SENSOR

The 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.

2.4 FEED BACK SENSOR

Injection

Rate

(Percent

0.1 3,300 12,492 5,000 18,927

0.2 Not 6,245 2,500 9,464

0.3 1,100 4,164 1,667 6,310

0.5 660 2,498 1,000 3,785 1,300 4,921

1.0 330 1,249 500 1,893 650 2,461

3.0 110 416 167 632 216 818

6.0 55 208 83 314 108 409

GPM LPM GPM LPM GPM LPM

Table 2-1: Maximum Foam Solution Flows

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.

Maximum Foam Solution Flows

Model 3.3 Model 5.0 Model 6.5

Not

Applicable

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 system).

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There are three models of Hale Foam systems covered by this manual. The Hale FoamLogix Model 3.3 (3.3GPM / 12.5LPM), Model 5.0 (5.0GPM / 19LPM) and Model 6.5 (6.5GPM / 24.6LPM).

The maximum rated foam concentrate flow in gallons per minute is denoted by the model number. Table 2-1: “Maximum Foam Solution Flows” on page 20 shows the system capacities at various foam concentrate injection rates for each Hale FoamLogix Model.

The Hale FoamLogix 3.3, 5.0 and 6.5 system configuration is shown in Figure 2-2: “Foam Pump Installation Envelope Dimensions“ on page 25. Also see Figure 2-3: “Foam Pump Installation Envelope Dimensions, ADT Option Only” on page 26.

2.5 TANK SELECTOR VALVES

Selection of the desired foam concentrate tank with the ADT panel mounted toggle switch or MDT II selector automatically changes the foam concentrate injection rate to the preset default rate for the selected foam tank. No further operator intervention is required.

Introduction ❑

The ADT, MDT II and MST include the check valves and connection points to provide foam pump flushing capabilities.

Air Dual Tank Selector (ADT)

The Air Dual Tank (ADT) valve is an air operated foam tank selector valve that enables selection of foam concentrate dependent on fire ground operational demands.

The ADT is an integral par t of the foam pump and provides an electrical interlock for the low tank level sensors and concentrate injection rate. A panel mounted selector toggle switch with indicator lights controls foam concentrate tank selection and shows which foam concentrate tank is in use.

Manual Dual Tank Selector (MDT II)

The Manual Dual Tank (MDT II) selector valve is available for the Hale Foam systems with dual tanks. The MDT II is a panel mounted, manually operated selector that provides selection of foam concentrate dependent on fire ground operational demands.

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❑ Introduction

The MDT II also provides an electrical interlock for the low tank level sensors and concentrate injection rate. The MDT II is not suitable for top mount operator panel installations and some side operator panels due to gravity feed requirements of foam concentrate to the foam pump.

Manual Single Tank (MST)

Single tank foam systems can be configured with a Manual Single Tank (MST) selector, which provides a flush function connection to the foam system electronic controls.

2.6 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 and valve assembly has a composite nonmetallic housing with stainless steel mesh strainer element and includes a service shut-off valve and mounting bracket.

The assembly uses a 1-1/4” (32mm) NPT thread and is supplied with fittings for connection of either 1-1/4” (32mm) ID, 1” (25mm) ID or 3/4” (19mm) ID foam concentrate suction hose. The in-line strainer and valve assembly is suitable for use with both Class “A” and Class “B” foam concentrates and is designed for installations where the strainer is mounted in the foam pump suction line.

The strainer and valve are low pressure devices and are designed for installations where the strainer IS NOT subject to HIGH pressure flushing water.

Hale FS Series Strainers

Hale FS series strainers (FS15 and FS25) are panel mounted with a 500 PSIG (34 BAR) pressure rating, suitable for use where flushing water pressure must pass through the strainer.

The FS15 strainer uses 3/4” (19mm) NPT connection ports and a 1-1/2” NST cap. It is suitable for use with Class “A” and low viscosity Class “B” foam concentrates.

The FS25 strainer uses 1” (25mm) NPT connection ports and a 2-1/2” NST cap. It is suitable for use with both Class “A” and Class “B” foam concentrates.

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Introduction ❑

2.7 ORDERING INFORMATION

Use the current Hale FoamLogix Foam System Price List and Order Form to help ensure a complete matched system is provided to the end user.

Use the following procedure when ordering a Hale FoamLogix Foam System. Follow 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. A copy of Bulletin #961 is located at the back of this manual.

2. Determine the type of foam concentrate being used in the system and ensure system compatibility by referring to the Hale Foam Concentrate Compatibility Char t. Also see Heading “Appendix A: Foam Concentrate Compatibility” on page 149.

3. Determine the Hale Foam system needed.

❑ Model 6.5 (24VDC motor only)

❑ Model 5.0

❑ Model 3.3

❑ 12 VDC

❑ 24 VDC motor

4. Determine tank selector needed based on the number of foam concentrate tanks installed.

❑ ADT........... for dual tank systems

❑ MDT II ....... for dual tank systems (not available for model 6.5)

❑ MST .......... for single tank systems

❑ No Select .. for single tank systems –

System installer/builder must provide flushing water connection to the foa m pump.

5. Determine strainers needed.

❑ In-line Strainer and Valve Assembly

❑ FS 15 Strainer

❑ FS 25 Strainer

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❑ Introduction

6. Determine the low tank level sensors needed.

❑ Side Mount

❑ Bottom Mount

❑ Top Mount Assembly

7. Select the flow sensor, then the mounting weld fitting or saddle clamp based on discharge pipe size.

8. Select harness length.

❑ 10 feet flow sensor x 15 feet controller

❑ 15 feet flow sensor x 20 feet controller

9. Additional Hale components available to enhance system operation and ease installation include:

❑ Waterway Check Valves

❑ Manifolds

❑ Flanges

❑ Foam Tanks, etc.

10. Components shown in bold type represent the best value performance system. All components listed have been engineered and tested with Hale foam systems to provide optimum system performance. Using the information provided and the detailed ordering procedures on the option order form ensures a complete Hale foam system is ordered, thus eliminating delays caused by missing components.

11. System components are shown in the following heading “Hale Foam System Specifications.”

2.8 HALE FOAM SYSTEM SPECIFICATIONS

(See Figure 2-2: “Foam Pump Installation Envelope Dimensions,” on page

25.) Also see Figure 2-3: “Foam Pump Installation Envelope Dimensions, ADT Option Only” on page 26.

Foam Pump ....................................... Rotary Gear Positive Displacement

Rated Foam Concentrate Output

Model 3.3 ......................................................................3.3 GPM (13 LPM)

Model 5.0 ......................................................................5.0 GPM (19 LPM)

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Introduction ❑

Rated Foam Concentrate Output - continued

Model 6.5 ...................................................................... 6.5 GPM (25 LPM)

Maximum System Operating Pressure

Model 3.3 ....................................................................... 350 PSI (24 BAR)

Model 5.0 ....................................................................... 200 PSI (14 BAR)

Model 6.5 ....................................................................... 200 PSI (14 BAR)

Maximum Operating Temperature.................................... 160° F (71° C)

Pump Motor

Standard - Models 3.3 and 5.0 ........................... 3/4 HP (0.6 kW), 12 VDC

Standard - Model 6.5 .......................................1-1/4 HP (0.9 kW), 24 VDC

Optional .............................................................. 3/4 HP (0.6 kW), 24 VDC

Operating Ampere Draw...... 30 AMPS at 12 VDC (15 AMPS at 24 VDC)

Maximum Ampere Draw ...... 60 AMPS at 12 VDC (30 AMPS at 24 VDC)

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Figure 2-2: Foam Pump Installation Envelope Dimensions

(Configured for use with MDT II, MST or No Tank Selection Options.)

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❑ Introduction

Figure 2-3: Foam Pump Installation Envelope Dimensions, ADT Option Only

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2.9 SYSTEM CONFIGURATION

Hale Foam Proportioner System, Models 3.3, 5.0 or 6.5

All Hale Foam systems include a: Foam Pump/Motor Assembly, Control Unit, Main Harness and Check Valve/Injector Fitting. Also see Section 8 “Illustrated Parts Breakdown” on page 157.

Introduction ❑

Foam Pump/Motor Assembly

(Shown with Bypass Valve when configured

for MDT II, MST or No Tank Selector Option)

Check Valve/Injector Fitting

p/n: 038-1790-00-0

Control Unit

p/n: 111530

FoamLogix Model Part Number

Model 6.5, with 24VDC Motor 501-4480-04-0

Model 5.0, with 12VDC Motor 501-3130-04-0

Model 5.0 with 24VDC Motor 501-3130-03-0

Model 3.3 with 12VDC Motor 501-3120-03-0

Model 3.3 with 24VDC Motor 501-3120-04-0

Figure 2-4: FoamLogix Available Models

Figure 2-5: Hale Foam Proportioner Systems, Models 3.3, 5.0 and 6.5

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❑ Introduction

2.10 CABLE HARNESS

For cable harness overviews, see Section “ 9 Plate Drawings,” beginning on page 170. Also see Figure 2-6: “Power Connection Wire Harness” on page

28.

p/n: 113436 ...Control Head Harness, 10’ x 4’ (3.1 x 1.2 m)

10’ - Flow Sensor x 4’ - Motor Control

p/n: 113438 ...Control Head Harness, 10’ x 14’ (3.1 x 4.3 m)

10’ - Flow Sensor x 14’ - Motor Control

p/n: 113439 ...Control Head Harness, 15’ x 19’ (4.6 x 5.8 m)

15’ - Flow Sensor x 19’ - Motor Control

p/n: 113437 ...Control Head Harness, 32” x 5.5’ (0.81 x 1.7 m)

32” - Flow Sensor x 5.5’ - Motor Control

p/n: 113434 ...Single Tank Moto Control

p/n: 113435 ...Dual Tank Motor Control

p/n: 113437 ...Control Head Harness, 32” x 5.5’ (0.81 x 1.7 m)

32” - Flow Sensor x 5.5’ - Motor Control

p/n: 113437 ...Control Head Harness, 32” x 5.5’ (0.81 x 1.7 m)

32” - Flow Sensor x 5.5’ - Motor Control

Figure 2-6: Power Connection Wire Harness

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Introduction ❑

2.11 DUAL FOAM CONCENTRATE TANK SYSTEM OPTIONS

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Figure 2-7: Dual Tank Foam Concentrate Tank System Options

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❑ Introduction

2.12 DUAL FOAM CONCENTRATE TANK OPTIONS

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2.13 SINGLE FOAM CONCENTRATE TANK OPTIONS

Introduction ❑

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❑ Introduction

2.14 STRAINER OPTIONS

Note: For Hale FS Series Strainers, use when Strainer is subjected to flushing water pressure.

Also see Figure 3-14: “In-Line Strainer/Valve Installation” on page 67.

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Introduction ❑

2.15 LOW TANK LEVEL SENSOR OPTIONS

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❑ Introduction

2.16 FLOW SENSORS

Each Hale foam system requires a flow sensor to operate. 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 numbers. In all instances a weld fitting may be substituted for the saddle clamp.

Pipe Size

1½” (38mm) 10 - 330 38 - 1,249

2” (50mm) 20 - 550 76 - 2,082

2½” (64mm) 30 - 800 114 - 3,028

3” (76mm) 50 - 1,250 189 - 4,732

4” (102mm) 75 - 1,800 284 - 6,814

SCV or DCV 30 - 750 114 - 2,839

Flow Range

GPM LPM

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2.17 CHECK VALVE MANIFOLDS

The check valve manifolds include flow sensors, check valve/injector fittings and single or dual waterway check valve flappers. End connections for the manifolds are 3” (76mm) Vitaulic.

Introduction ❑

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❑ Introduction

2.18 REMOTE ACTIVATION SWITCH OPTION

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Introduction ❑

2.19 CHECK VALVES, FLANGES, GASKETS

Threads Part Number

3” (76mm) 115-0080-00-0

2-1/2” (64mm) 115-0070-00-0

2” (51mm) 115-0060-00-0

Blank 115-0050-00-0

Threads Part Number

4” (102mm) 115-0040-00-0

3” (76mm) 115-0030-00-0

2-1/2” (64mm) 115-0020-00-0

Blank 115-0010-00-0

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❑ Introduction

2.20 ELBOWS AND MINI MANIFOLDS

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System Layout ❑

2.21 HALE FOAM SYSTEM LAYOUT DRAWINGS

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Figure 2-10: Typical Single Foam Concentrate Tank

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❑ System Layout

Figure 2-11: Single Foam Tank with MST and In-Line Strainer/Valve Assembly

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System Layout ❑

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Figure 2-12: Single Foam Tank with MST and FS Series Strainers

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❑ System Layout

Figure 2-13: Dual Foam Concentrate Tanks, with MDT II and In-Line Strainer/Valve Assembly

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System Layout ❑

Figure 2-14: Dual Foam Concentrate with MDT II and FS Series Strainer Assembly

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❑ System Layout

Figure 2-15: Dual Foam Concentrate Tanks, with ADT and In-Line Strainer/Valve Assemblies

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System Layout ❑

Figure 2-16: Dual Foam Concentrate Tanks with ADT and FS Series Strainer Assemblies

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❑ System Layout

Notes

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3 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. Using 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 3.3, 5.0 or 6.5 system is installed on a particular apparatus. The information contained in this section applies to most situations and should be used when designing and installing a Hale FoamLogix 3.3,

5.0 or 6.5 system. System plumbing and electrical diagrams are provided to assist with installation.

Before proceeding with system installation, carefully review the procedures that follow to ensure the system is properly designed.

Installer Installation ❑

The Hale FoamLogix system is supplied with six major components that must be located on the apparatus.

❑ Foam pump and motor assembly

❑ Control unit

❑ In-Line foam strainer/valve assembly

❑ 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:

❑ ADT operating switch and indicator lights

❑ Flanged elbows

❑ Foam tank(s)

❑ FS-15 or FS-25 panel mounted foam strainers

❑ Manual “dual” tank (MDT II) selector valve

❑ Manual “single” tank (MST) selector valve

❑ Mini Manifold

❑ Remote activation switch

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❑ Installer Installation

IMPORTANT !

WHEN DETERMINING THE LOCATION OF THE HALE FOAMLOGIX COMPONENTS BEING INSTALLED KEEP IN MIND PIPING RUNS, CABLE ROUTING AND OTHER INTERFERENCES THAT COULD HINDER OR INTERFERE WITH PROPER SYSTEM PERFORMANCE.

3.1 FOAM PUMP AND MOTOR ASSEMBLY

Ideally, the foam pump and motor assembly should 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 master power switch and bypass valve are located on the foam pump and motor assembly. Access to these components must be provided.

The foam pump and motor assembly must be mounted below the discharge of the foam tank(s) to provide for gravity feed to the foam pump. The foam tank(s) must be located where refilling can be easily accomplished with 5 gallon (19 liter) 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(s), make sure provisions are made for:

❑ Installation of the low tank level sensor

❑ Foam suction connections

❑ Tank drainage

❑ Proper fill openings, per NFPA requirements

In addition, a foam tank refill system may be required. See Hale EZFill Foam Tank Refill System for these installation requirements.

3.2 FOAM CONCENTRATE STRAINER

Determine a location on the apparatus to mount the foam strainer.

CAUTION !

THE IN-LINE STRAINER/VALVE ASSEMBLY IS A LOW PRESSURE DEVICE THAT WILL NOT WITHSTAND FLUSHING WATER PRESSURE. WHEN INSTALLING THE IN-LINE STRAINER IN SYSTEMS EQUIPPED WITH HALE “MDT II” OR HALE “MST,” MAKE SURE THE IN-LINE STRAINER/VALVE ASSEMBLY IS IN THE HOSE ON THE INLET SIDE OF THE VALVE.

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Installer Installation ❑

CAUTION ! - continued

IF THE STRAINER IS SUBJECT TO FLUSHING WATER PRESSURE, USE HALE “FS” SERIES STRAINERS.

Mount the in-line foam strainer/valve assembly in the foam concentrate hose from the foam tank to the foam pump suction connection, ADT, MDT II or MST.

If panel mounted FS series strainers are installed, mount the strainer in the foam concentrate hose that supplies concentrate to the ADT, MDT II or MST. The FS series strainer may also be mounted in the outlet hose of the MDT II or MST.

IMPORTANT !

WHEN DETERMINING THE STRAINER LOCATION KEEP IN MIND THE REQUIREMENT FOR GRAVITY FEED OF FOAM CONCENTRATE TO THE FOAM PUMP THROUGH THE STRAINER AND AVOID AIR TRAPS IN THE HOSES. ALSO, CLEARANCE MUST BE PROVIDED TO ALLOW REMOVAL OF THE BOWL ASSEMBLY TO CLEAN THE STAINLESS STEEL MESH, TO MAKE HOSE CONNECTIONS TO THE STRAINER AND FOR OPERATION OF THE SERVICE VALVE.

The installer must provide a strainer service isolation valve in the foam concentrate hose to prevent spillage during service. An MST or MDT II can serve this purpose.

3.3 CONTROL UNIT / INSTRUCTION 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.

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3.4 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

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 system installer must supply fittings and hoses 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 3/4” (19mm) inside diameter. Hoses for Class “B” foam concentrates must have a minimum 1” (25.4mm) inside diameter due to higher viscosity of the concentrate.

Note: Certain types of Class “B” AFFF-ARC or ATC concentrates require a 1-1/4” or 1-1/2” (32mm or 38mm) ID foam concentrate supply line.

Hoses for the foam concentrate suction that are not subject to high pressure, i.e., flushing water or foam concentrate discharge, must have a rating of 23” (584.2mm) 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 operations.

Recommended Components

❑ Hose: PVC, Kuriyama Kuri-Tec K7130 series

❑ Fittings: Hose Barb Type; Brass, Stainless Steel or Nylon

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Installer Installation ❑

Foam concentrate suction hose subjected to flushing water pressure must be rated for 23 in (584.2mm) Hg vacuum and the maximum discharge pressure of the fire pump (500 PSI [34 BAR] minimum). These hoses include the hose from the outlet of the MDT II or MST to the foam pump inlet.

Recommended Components

❑ Hose: Aeroquip 2580 Series or equivalent reinforced hydraulic hose

❑ Fittings: Brass or stainless steel hose end crimp or reusable type

(Aeroquip 412 Series or equivalent)

A foam tank shut-off valve and drain valve should be provided in the foam tank suction hose to allow strainer service, tank drainage and easier priming. These components are subject to the same material characteristics and pressure ratings as stated above. When the In-line strainer/valve assembly option is installed the shut-off valve is included. A separate valve is not required.

Foam Concentrate Discharge Hose

The system installer must supply fittings and hoses from the foam pump inject connection to the check valve/injector fitting inlet. All components must be compatible with the foam concentrates being used in the system.

The foam pump discharge connection and the check valve injector fitting connection port is 1/2” (13mm) NPT threads. Hoses and fittings of 1/2” (13mm) inside minimum diameter rated at 500 PSI (34.5 BAR) working pressure or maximum discharge pressure of the fire pump must be used. Fittings and hoses must be compatible with all foam agents being used.

Recommended Components

❑ Hose: Aeroquip 2580-8 or equivalent reinforced hydraulic hose

❑ Fittings: Brass or stainless steel hose end crimp or reusable type

(Aeroquip 412-9-8 or equivalent)

Note: Although air brake tubing has been used for foam concentrate discharge hose, it is not as flexible as the hydraulic hose and readily kinks during installation. Additionally, the air brake tubing may not meet NFPA 500 PSI (34 BAR) test requirements.

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Foam Concentrate Bypass Hose

The foam concentrate bypass hose connection is 1/2” (13mm) NPT threads. Hoses and fittings of nominal 1/2” (13mm) inside diameter must be used as bypass hose. Since the bypass hose is used for calibration and draining the system it does not see high operating pressures; therefore, a hose with a lower pressure rating than the inject hose may be used.

Fittings and hoses used must be compatible with all foam agents expected to be used. Use fittings made of brass or 300 series stainless steel compatible with all foam concentrates.

Recommended Components

❑ Hose: Low pressure hydraulic hose (or air brake tubing. See Note on

preceding page)

❑ Fittings: Brass or stainless steel

It is recommended that the foam concentrate bypass hose be long enough to extend past the apparatus running board to reach five (5) gallon (19 liter) containers, making foam pump setup and calibration simpler.

Check Valves

Check valves must be installed on the apparatus to prevent contamination of the foam concentrate with water and contamination of the fresh water tank with foam. For a typical system layout, see heading 2.21 “Hale Foam System Layout Drawings” on page 39.

NFPA standards require a check valve in the foam concentrate injection line at the injection point. The Hale p/n: 038-1790-00-0 Integral Check Valve/ Injector Fitting, a standard component included with the Hale FoamLogix

3.3, 5.0 or 6.5 system and installed when a manifold kit is ordered, meets these requirements and threads directly into the foam injection port on Hale manifolds.

Check valves must be installed in all water piping locations where foam concentrate could drain back into pumps or other components of the fire apparatus. As a minimum one check valve must be installed where the water piping that supplies foam solution connects to the fire pump discharge.

To more effectively keep foam contamination out of the fire pump and water tank, double check valves should be used. Separate two check valves by at least 6” to 8” (152 to 203mm) of piping to form a dead zone between the valves.

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Individual drain lines should be used on each check valve. The waterway check valves must be rated for 500 PSIG (34.5 BAR) test pressure.

Hale 3” (76mm) “115” flange-type check valves (p/n: 038-1570-00-0) can be used for most installations on pumps with “115” style flanges. The Hale “115” flange type check valve has a 4-3/8” (111mm) bolt circle that fits standard Hale “115” flanges, as well as 4-3/8” (111mm) bolt circle discharge flanges on other pumps. These check valves are rated for pressures up to 500 PSI (34 BAR) and flows up to 750 GPM (2,839 LPM). Use 2-1/2” or 3” (64mm or 76mm) NPT threaded “115” flanges for mounting these check valves in piping runs.

Where higher flows and larger diameter piping is required, Hale offers a 4” (102mm) “2433” flange-type check valve (p/n: 038-1570-04-0). The “2433” valve has an 8 bolt, 5-3/4” (146mm) bolt circle and fits pump discharge openings and flanges having this configuration. The “2433” check valve has a pressure rating of 500 PSI (34 BAR) and a flow rating of 1,250 GPM (4,731 LPM). The Hale “2433” style flange (p/n: 115-0040-00-0) has an 8 bolt, 5-3/4” (146mm) bolt circle and 4” (102mm) NPT threads for in-line mounting of the 4” (102mm) check valve.

Flushing Water Hose

Flushing water connections for the Hale ADT, MDT II or MST require using 1/2” (13mm) inside diameter tubing and appropriate fittings. The tubing and fittings used must be capable of withstanding the maximum fire pump discharge pressure (500 PSI [34 BAR] minimum) and must be compatible with foam concentrates being used in the system.

When the ADT, MDT II or MST is installed, a check valve is used integral to the flushing water line connection. This provides protection against water system contamination with foam concentrate.

Note: The installer/builder should provide an additional check valve and shut-off valve where the flushing water hose connects to the water pump.

Hale recommends the use of one of the above selector options to provide foam system flushing capabilities. However, if the Hale FoamLogix system is ordered with the “no tank” option the system installer must maintain NFPA compliance. To be NFPA compliant, when flushing is required, the system installer must provide proper

❑ Hoses

❑ Shut-off valves

❑ Check valves

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❑ Reducer/regulator

❑ Connections for flushing water for the system

Additionally, when the Hale FoamLogix is installed without a Hale provided selector some operating and system protection features are not available.

Foam Discharge Drains

Drains must be provided from foam capable discharge piping components to prevent freezing in cold weather. When designing the drain system care must be taken to prevent contamination of the water system with foam and the foam concentrate with water. Some multiple drain systems that allow individual drain lines to communicate also allow foam to bypass the installed check valves causing contamination of fire pump and the water or foam concentrate storage tanks.

Hale offers an optional manual or air-operated 6-port drain valve, Class1 Model MMD6 (p/n: 104961). The valve provides individual drains with a single control and is used for applications where a single point for multiple drains is required. If a Hale MMD6 drain valve is not used, individual drain lines and valves for foam capable discharge piping is recommended.

Electrical Requirements

The system installer must provide the primary power wire and a ground strap for the Hale FoamLogix system.

Primary power must be supplied from the main apparatus battery to the motor connectors on the foam pump and motor assembly. The Hale FoamLogix 3.3, 5.0 or 6.5 requires minimum 60 AMP electrical service.

Primary electrical power must be supplied directly from the battery or the battery master disconnect switch or solenoids to the Hale FoamLogix.

IMPORTANT !

OTHER ELECTRICAL COMPONENTS MUST NOT BE SUPPLIED FROM THIS WIRE. DO NOT CONNECT THE PRIMER AND HALE FOAMLOGIX TO THE SAME POWER WIRE.

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The primary power connection must be made so that power is supplied to the Hale FoamLogix when the main apparatus electrical system is energized and the pump is in gear. Use of a solenoid with a 150 AMP peak, 85 AMP continuous rating is recommended. (See Figure 3-1: “Recommended Relay Wiring Schematic,” on page 55.)

Figure 3-1: Recommended Relay Wiring Schematic

Note: This ensures immediate operation when the operator places the apparatus in PUMP mode, and to prevent battery power drain when the apparatus is not running.

With Hale FoamLogix 3.3, 5.0 or 6.5, cable lengths up to 6’ (1.8 meters) require a minimum 4 AWG type SGX (SAE J1127) battery cable. (See Table 3-2: “Primary Power Cable Sizes.”) Use solder lugs on cable ends with a 5/16” (8mm) diameter hole.

When planning cable runs

Recommended Primary Power Cable Sizes

Wire Gauge Maximum Length

4 AWG (21.1mm2) 6 Feet (1.8 meters) or Less

0 AWG (53.5mm2)

00 AWG (67.5mm2)

Table 3-2: Primary Power Cable Sizes

6 Feet (1.8 meters) to 15 Feet (4.6 meters)

15 Feet (4.8 meters) or Longer

make sure the primary wires are routed by the shortest most direct route.

A braided flat ground strap connected to the apparatus chassis is recommended for the ground connection. This limits the RFI/EMI interference encountered with radios, computers or other sensitive electronic equipment.

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The ground strap should be a minimum of 1-1/4” (32mm) wide and no longer than 18” (457mm). It must have soldered flat lug ends with 3/8” (10mm) diameter holes.

If the ground strap length exceeds 18” (457mm), a wider ground strap should be used or use a double thickness of 1-1/4” (32mm) wide ground strap. The ground strap must be connected to the chassis. Use minimum 5/16” (8 mm) diameter bolt or mounting to secure the strap.

Make sure the ground is attached directly to the chassis frame and not to the apparatus body work.

BEFORE MAKING GROUND CONNECTIONS REMOVE ALL PAINT, GREASE AND COATINGS FROM THE CONNECTION AREA. AFTER MAKING CONNECTION, SEAL AGAINST CORROSION. WHEN A FLAT GROUND STRAP IS NOT AVAILABLE USE A BATTERY CABLE ONE SIZE LARGER THAN THE POWER CABLE USED.

IMPORTANT !

FoamLogix Display

Power must be supplied to the FoamLogix display. The power required should be a clean power supply and should only be provided after the pump is placed in gear. Make display power and ground connections. Use minimum 16 AWG Type SXL or GXL (SAE J1127) wire. Using the harness provided:

❑ Connect the BLACK wire to a chassis ground stud

❑ Connect the RED wire to a minimum 5 AMP fused dedicated circuit. If a

dedicated circuit is not available, connect to a terminal that has LOW current load items, such as ENFO IV, governor and tank level gauge, etc.

Foam Concentrate Tanks(s)

A foam concentrate tank(s) must be supplied to suit the capacity required for the apparatus application. The tank(s) must meet NFPA minimum standards for their design capacity, including:

❑ Filler size

❑ Vapor pressure venting

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❑ Baffling

❑ Drain facilities

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FoamLogix

Recommended Tank

Capacity

Foam tank capacities for the Hale FoamLogix 3.0, 5.0 or 6.5 are based on NFPA requirements for flammable liquid (Class “B”) fire suppression. (See Table 3-3: “Recommended Foam Tank Capacity.”)

Foam Pump Mounting

Position the foam pump and motor assembly in the desired location on the apparatus. When installing the foam pump and motor assembly, the assembly must be kept in a HORIZONTAL position with the base plate on the bottom. (See Figure 3-4: “FoamLogix Pump Installation.”)

Although the system is sealed and designed to be resistant to the harsh environment of fire fighting apparatus, a compartment with easy operator access is recommended.

Model 6.5 100 Gallons (379 Liters)

Model 5.0 100 Gallons (379 Liters)

Model 3.3 66 Gallons (250 Liters)

Table 3-3: Recommended Foam Tank

Capacity

The base plate of the foam pump and motor assembly must be anchored to a surface or structure that is rigid and of adequate strength to withstand the vibration and stresses of apparatus operation.

For mounting envelope dimensions of the FoamLogix 3.3, 5.0 or 6.5 foam pump and motor assembly see Figure 2-2: “Foam Pump Installation Envelope Dimensions” on page 25.

Also see Figure 2-3: “Foam Pump Installation Envelope Dimensions, ADT Option Only” on page 26.

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Figure 3-4: FoamLogix Pump Installation

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Position the foam pump so the bypass valve is easily accessible. When the Hale FoamLogix system is ordered without the ADT option, a separate bypass valve is included that may be removed from the foam pump and mounted on a truck panel for easier access.

When ordered with the ADT option, the operating knob may be removed from the bypass valve actuator and an extension rod installed to permit remote operation. In either instance, the foam pump and motor assembly must be located to permit proper operation of the bypass valve.

Make sure the foam concentrate hoses are properly routed to the inlet and outlet on the foam pump. Foam concentrate must gravity feed to the foam pump inlet from the foam tank(s).

The foam pump must be mounted in an area to avoid excessive engine exhaust system heat or accessory heat buildup.

The base of the foam pump and motor assembly includes 5/16” (8mm) diameter predrilled mounting holes. The apparatus mounting location must to be drilled accordingly. The base plate may be used as a template to mark mounting hole location. (See Figure 3-5: “Base Plate Mounting Hole Locations.”)

Figure 3-5: Base Plate Mounting Hole Locations

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Plumbing Installation

Hale FoamLogix System plumbing diagrams are located in this section. The diagrams provide recommended guidelines for the installation of system components that handle water, foam concentrate and foam solution. The sequence in which the plumbing installation is performed depends on your individual installation requirements.

IMPORTANT !

AFTER INSTALLATION, MAKE SURE ALL PIPES, HOSES AND TUBES ARE PROPERLY SUPPOR TED USING THE BEST INDUSTRY PRACTICES. USE A SUITABLE PIPE SEALING COMPOUND AT ALL JOINTS.

Water and Foam Solution Plumbing

When installing water and foam solution piping runs use the best industry practices. Use a suitable pipe sealing compound at all joints.

Check Valve Manifold

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Figure 3-6: Typical Check Valve Manifold Installation

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The Hale pre-made stainless steel foam manifolds are recommended. The manifolds are available in kits and eliminate the extra labor and leaks from large pipe thread connections.

The manifolds use 3” (76mm) Victaulic connections and are available in single or dual check valve configurations. (See Figure 3-6: “Typical Check Valve Manifold Installation,” on page 59.)

Note: When the manifold is installed, the drain tap must be placed in the “down” position and plumbed to an individual drain.

When properly mounted, the flow sensor and check valve/injector fitting are on the side of the manifold and one of the drain por ts is on the bottom. The flow sensor should point upwards slightly to allow drainage of water and sediment. (See Figure 3-9: “Flow Sensor Tee Position Range,” on page 62.)

Optional Hale Piping Components

Hale piping components, such as 3” (76mm) and 4” (102mm) wafer-type check valves, “115” and “2433” series flanges, mini manifold, etc. are available to simplify installation of water and foam solution discharge piping.

The arrangement shown in Figure 3-7: “Typical Midship Pump Installation” on page 61, provides accurate proportioning across a wide range for up to four discharges from the mini manifold.

The Hale mini manifold provides a 1” (25.4mm) NPT tap for installation of the check valve/injector fitting.

The Hale mini manifold and elbow components offer 4-3/8” (111mm) diameter bolt circles and minimize fabrication and pipe work.

Figure 3-8: “4” (102mm) Check Valve Installation” on page 61 shows a suggested installation arrangement using Hale 4” check valves, pipe and Hale “2433” flanges.

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Figure 3-7: Typical Midship Pump Installation

Figure 3-8: 4” (102mm) Check Valve Installation

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“Waterway” Check Valves

Check valves in the waterway, rated at 500 PSI (34.5 BAR), are required to keep foam solution out of the main pump and allow pump priming without drawing foam into the piping.

Using double check valves, separated by at least 6” to 8” (152 to 203mm) of pipe before the foam injection point ensures that the pump and tank water remain uncontaminated.

Flow Sensor

The Hale FoamLogix flow sensor is specially designed to enable quick and easy sensor inspection and maintenance. The flow sensor paddle wheel is installed on a saddle clamp or weld fitting to the foam-capable discharge piping of the apparatus.

In horizontal piping runs, the flow sensor is mounted within the range shown in Figure 3-9: “Flow Sensor Tee Position Range.”

The flow sensor is installed in the piping before the foam concentrate injection point.

Figure 3-9: Flow Sensor Tee Position Range

When selecting a flow sensor, it is important to consider the minimum and maximum flow requirements during operation. Also see Table 3-10: “Pipe Size vs. Minimum Straight Run” on page 63.

Some applications may require flow sensor accuracy that is not within the range specified for the discharge piping. This is true in applications where the foam system needs to supply a 3” (76mm) deck gun, as well as a 1” (25.4mm) booster line.

Pipe size for flow sensor mounting must be selected to provide accuracy at the lowest flow rate. Mounting the flow sensor in a short section of pipe, one pipe size smaller (e.g., 4” to 3”; 3” to 2-1/2”, etc.), provides better accuracy at the lower flows.

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Refer to Table 3-10: “Pipe Size vs. Minimum Straight Run” for pipe size. Selecting the next smaller pipe permits reducing the straight pipe run the required distance prior to the flow sensor paddle wheel.

Installer Installation ❑

Minimum

Pipe Sizes

1-1/2" (38mm) 9" (229mm)

2" (51mm) 12" (305mm)

Recommended Straight

Run Pipe

In the short length of reduced pipe pressure loss is minimal and there is minimal pressure loss through elbows and fittings. (See Figure 311: “Typical Reduced Size Sensor Piping Arrangement.”)

2-1/2" (64mm) 15" (381mm)

3" (76mm) 18" (457mm)

4" (102mm) 24" (610mm)

Table 3-10: Pipe Size vs. Minimum

Straight Run

Excessive turbulence in the flow sensor may produce unstable and inaccurate flow readings. The length of straight pipe prior to the flow sensor must be sufficient to reduce any turbulence in the pipe.

The following guidelines help attain the best readings, and maintain Hale FoamLogix system accuracy.

A minimum of 6 times the pipe diameter of straight run pipe without any fittings is necessary prior to the flow sensor paddle wheel. (See Figure 3-12: “Flow Sensor Placement,” on page 64.)

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Figure 3-11: Typical Reduced Size Sensor Piping Arrangement

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The downstream piping length is not as critical, but there must be a short length of straight pipe with no fittings or valves immediately after the flow sensor paddle wheel. Two to three times the pipe diameter is recommended.

Do not mount a flow sensor directly after an elbow or valve. Valves create severe turbulence when they are “gated.”

Figure 3-12: Flow Sensor Placement

Saddle Clamp Installation

(See Figure 3-13: “Flow Sensor/Saddle Clamp Installation,” on page 65.)

IMPORTANT !

THE PADDLE WHEEL SHOULD BE INSTALLED AS CLOSE TO UPRIGHT AS POSSIBLE WITHIN THE RANGE SHOWN FIGURE 3-9: “FLOW SENSOR TEE POSITION RANGE” ON PAGE 62. FOR PROPER OPERATION DO NOT LET THE FLOW SENSOR ROTATE MORE THAN 85° IN EITHER DIRECTION.

Installation of the Paddle Wheel Flow Sensor using a saddle clamp requires a 1.385”/1.390” (35/35.3mm) bored hole in the pipe. A minimum of six (6) times the pipe diameter of straight run pipe without any fittings is necessary prior to the position of this hole.

The flow sensor requires a spacer and eight stainless steel internal hex head screws. These are supplied with the sensor.

Four 6-32 x 1/2” screws attach the spacer to the saddle clamp mount, and four 6-32 x 3/4” screws with lock washers attach the paddle wheel to the spacer.

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Align the indexing pin of the saddle clamp to the indexing hole of the spacer to align the saddle clamp mount. Secure with four 1/2” (13mm) machine screws, without lock washers. Torque to 8.5 in.lbs. (1.0 N-m).

Align the paddle wheel indexing pin to the indexing hole in the spacer and secure using four 3/4” screws and lock washers. Torque to 7.5 in.-lbs. (0.9 N-m).

Apply a small amount of grease to the saddle clamp gasket before the final installation of the assembly onto the pipe. Firmly tighten the saddle clamp onto the pipe.

Installer Installation ❑

Foam Pump Flush System

Figure 3-13: Flow Sensor/Saddle Clamp

Installation

Dual Tank System

Flushing water must be provided to flush the system of foam concentrate after each use. This prevents adverse reactions of some foam concentrates should they mix together. The Hale ADT and MDT II each have provisions for connecting flushing water to the foam concentrate injection system.

Single Tank System

The Hale MST provides a selector valve and gives the system flush capabilities for NFPA compliance. A fitting provided on the Hale MST simplifies the flushing water connection.

No Tank Option

The system installer must provide a flushing water supply to comply with NFPA standards.

The flushing water hose must be a minimum of 1/2” (12 mm) inside diameter and capable of withstanding the maximum fire pump discharge pressure, 500 PSI (34 BAR) minimum. The flush water supply should be provided from one of the pressure taps on the discharge of the fire pump.

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It is recommended that a check valve be installed at the pressure tap to prevent contamination. Flush water thread connections are:

❑ ADT - 1/2” (13mm) NPT

❑ MDT II and MST - 1/4” (6.4mm) NPT

The system installer must provide proper fittings for these connections.

Foam Concentrate Plumbing

MAKE SURE THE FOAM TANK AND FOAM CONCENTRATE SUCTION HOSES ARE CLEAN BEFORE MAKING FINAL CONNECTIONS TO FOAM PUMP.

CAUTION !

FLUSH TANK AND HOSES PRIOR TO MAKING CONNECTIONS. MAKE SURE FOAM CONCENTRATE IS GRAVITY FED FROM THE TANK TO THE PUMP.

Foam concentrate plumbing consists of:

❑ Foam concentrate suction hose

❑ Foam strainer

❑ Foam concentrate discharge hose

❑ Check valve/injector fitting

Foam Strainer Connection (In-Line Strainer/Valve)

CAUTION !

THE IN-LINE STRAINER/VALVE ASSEMBLY, MOUNTED ON THE FOAM PUMP INLET, IS A LOW PRESSURE DEVICE. IT CANNOT WITHSTAND FLUSHING WATER PRESSURE. WHEN INSTALLING THE IN-LINE STRAINER EQUIPPED WITH HALE MDT II OR MST, MAKE SURE THE IN-LINE STRAINER/VALVE ASSEMBLY IS IN THE HOSE ON THE INLET SIDE OF THE VALVE. IF THE STRAINER IS SUBJECT TO FLUSHING WATER PRESSURE, USE HALE FS SERIES STRAINERS.

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The strainer/valve assembly has 1-1/4” (32mm) NPT female threaded ports. Fittings are supplied for connection to the following inside diameter hose, depending on the viscosity of foam concentrates used. (See Figure 3-14: “In-Line Strainer/Valve Installation,” on page 67.)

❑ 3/4” (19mm)

❑ 1.00” (25mm)

❑ 1-1/4” (32mm)

Use 3/4” (19mm) inside diameter hose for Class “A” foam and a 1.00” (25mm) inside diameter hose for Class “B” foams. For high viscosity Class “B” foam concentrates use 1-1/4” (32mm) or 1-1/2” (38mm) inside diameter hose. (See Figure 3-14: “In-Line Strainer/Valve Installation,” on page 67.) A bracket is included to permit installation on the apparatus.

To Install the In-Line Strainer/Valve Assembly

1. Choose a location on the apparatus that allows gravity feed from the foam tank to the strainer inlet and from the strainer outlet to the foam pump suction connection.

Notes: When selecting the strainer location make sure there is sufficient space above and below the strainer.

❑ A minimum of 5” (127 mm) below for removal of the strainer basket

❑ 2” (51 mm) above to permit operation of the service valve

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Figure 3-14: In-Line Strainer/Valve Installation

and screen for cleaning

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2. Mark 4 holes to mount the foam strainer bracket. Drill tapped holes for 1/4”-20 UNC screws (#7 drill for ¼-20 UNC tap)...or...drill clearance holes for 9/32” (7 mm) for 1/4”-20 UNC screws. (See Figure 3-15: “InLine Strainer Mounting Bracket Layout.”)

3. Secure the bracket and strainer/valve assembly to the apparatus.

4. Select the appropriate fittings from the bag attached to the strainer assembly. Two of each fitting are included with the strainer assembly. For fitting selection vs. type of foam concentrate see Figure 3-14: “In-Line Strainer/Valve Installation.”

5. Coat all fitting threads with Permatex #80724

Figure 3-15: In-Line Strainer Mounting Bracket

Layout

(or equal) plastic pipe thread sealant. Install the fittings into the strainer/ valve assembly ends and tighten.

6. Install the clear plastic hose from the foam tank outlet to the inlet of the strainer/valve assembly. (See Figure 3-14: “In-Line Strainer/Valve Installation,” on page 67.) Wet the ends of the hose and fittings to make the installation easier.

CAUTION!

MAKE SURE THE FOAM TANK AND FOAM CONCENTRATE SUCTION HOSES ARE CLEAN BEFORE MAKING FINAL CONNECTION TO FOAM PUMP. IF NECESSARY FLUSH THE TANK AND HOSES PRIOR TO MAKING THE CONNECTION.

7. Install the clear plastic hose from the in-line strainer/valve assembly outlet to the inlet of the Hale MDT II, Hale MST, foam concentrate pump, or the correct fitting on Hale ADT.

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FS Series Strainer

When a pressurized water flush is provided to the strainer from one of the discharges, Hale FS series strainers are required. The plumbing exposed to the flush water pressure must be rated at or above the operating pressure of all other discharge plumbing components (500 PSI/34 BAR minimum).

To Install FS Series Strainers

1. Choose a location on the apparatus that allows gravity feed from the foam tank to the strainer inlet and from the strainer outlet to the foam pump suction connection.

2. When selecting the strainer location make sure there is sufficient space behind the pump panel to attach hoses and fittings. Also make sure the inlet connection port is oriented correctly. (See Figure 3-16: “FS Strainer Orientation.”)

Figure 3-16: FS Strainer Orientation

3. Remove the strainer cap, mounting screws and nameplate from the strainer assembly.

4. Mark holes for mounting the foam strainer by using the nameplate as a guide, or see Figure 3-17: “FS Strainer Mounting Dimensions” on page

70.

5. Select the appropriate fittings to attach the hoses to the strainer. Two of each fitting are included with the strainer assembly. The fittings and hoses must be capable of withstanding the vacuum generated by the foam pump (23 inches [584 mm] Hg) and the maximum flushing water pressure (500 PSI [34 BAR]).

6. For FS-15 strainers use 3/4” (19mm) NPT x 3/4” hose fittings. For FS25 strainers use 1” (25mm) NPT x 1” hose fittings.

7. Coat all fitting threads with a suitable thread sealant. DO NO USE Teflon Tape. Install the fittings into the strainer/valve assembly ends and tighten.

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Figure 3-17: FS Strainer Mounting Dimensions

8. Make sure the strainer is properly oriented. (See Figure 3-16: “FS Strainer Orientation.”) Apply Loctite #242 Threadlock Compound (or equal) to the screws, then secure the strainer body and nameplate to the apparatus. Install the strainer cap.

9. Install the clear plastic hose from the foam tank outlet to the inlet of the strainer. (See Figure 3-14: “In-Line Strainer/Valve Installation,” on page

67.) Wet the ends of the hose and fittings to make the installation easier.

CAUTION !

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.

10. Install the clear plastic hose from the strainer outlet to the inlet of the Hale FoamLogix foam pump, or the selector valve.

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Check Valve / Injector Fitting

The Hale check valve/ injector fitting, supplied with the Hale FoamLogix system, meets NFPA requirements for a nonreturn device in the foam injection system. It prevents back flow of water into the foam concentrate tank.

When properly installed the brass and stainless steel construction check valve/injector fitting ensures foam concentrate is injected into the

Figure 3-18: Check Valve/Injector Fitting

Orientation

center of the water flow for better mixing. (See Figure 3-18: “Check Valve/ Injector Fitting Orientation.”)

Note: Always position the check valve/injector fitting at a horizontal or higher angle to allow water to drain away from the fitting. This avoids sediment deposits or the formation of an ice plug.

The check valve/injector fitting must be mounted in a location that is common to all discharges which require foam concentrate. (See Figure 3-19: “Check Valve / Injector Fitting Installation.”)

The Hale FoamLogix system DOES NOT permit a separate injection point for each foam capable discharge.

The check valve/injector fitting has 1” NPT (25.4mm) threads on the outside, to fit into the 1” NPT threaded connection on the Hale mini manifold, a pipe tee, or a 1” NPT weld fitting installed in the discharge piping of the fire pump. (See Figure 3-19: “Check Valve / Injector Fitting Installation.”)

The inlet connection of the check

Figure 3-19: Check Valve / Injector Fitting

Installation

valve/injector fitting uses a 1/2” (13mm) NPT female threads.

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❑ Installer Installation

Foam Concentrate Injection Hose

Connect a hose from the foam pump inject port to the inlet of the check valve injector fitting. (See Figure 3-20: “Injection and Bypass Hose Connections.”)

Figure 3-20: Injection and Bypass Hose Connections

The hose and fittings from the INJECT port to the check valve injector fitting should have a minimum 1/2” (13 mm) inside diameter and be rated at 500 PSI (34 BAR) working pressure (Aeroquip 2580-10 or equal).

Bypass Hose Connection

A bypass port is provided on the discharge side of the ADT, or a 1/4 turn bypass valve is mounted on the discharge of the foam pump when the ADT option is not installed. (See Figure 3-21: “Bypass Valve Assembly,” on page

73.)

The bypass handle must be accessible by the pump operator during normal operations. (See Figure 3-20: “Injection and Bypass Hose Connections.”)

The bypass is a 3-way directional valve. Determine which port is the INJECT port and which port is the BYPASS. (See Figure 3-21: “Bypass Valve Assembly,” on page 73.)

Bypass hose connections are 1/2” (13mm). Hose fittings compatible with all foam concentrates must be provided. The hose from the BYPASS port is plumbed to the atmosphere and should not receive HIGH pressure.

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This hose is used for calibrating the foam pump, pumping the concentrate into a container to empty the foam tank or to assist in priming of the foam pump. The hose from the BYPASS port, must be long enough to reach a container outside the truck.

Note: If the handle or placard is removed from the bypass valve for repairs or to facilitate remote mounting make sure they are installed on the valve correctly. Make sure the tang on the handle engages the cast stops. (See Figure 3-21: “Bypass Valve Assembly.”)

Installer Installation ❑

Figure 3-21: Bypass Valve Assembly

ADT Option Air Connections

If the ADT option is used, install the operating switch and indicator light placard on the apparatus operator panel. A mounting cutout diagram is provided. (See Figure 3-22: “ADT Option Panel Placard Layout Dimensions.”)

After mounting the placard assembly install the air hoses from the ADT to the placard assembly. Make sure proper connections are made at the placard assembly. (See Figure 3-23: “ADT Air Hose Connections, Part 1,” on page 74.)

A color coded decal attached to the ADT valve assembly along with an optional color coded air hose harness simplifies air hose connections. If the optional air hose harness is not used, 1/4” (6mm) inside diameter air brake tubing can be substituted. Make sure the air brake tubing selected has the proper DOT approval.

(See Figure 3-23: “ADT Air Hose Connections, Part 1,” on page 74.) Also see Figure 3-24: “ADT Option Air Hose Connections, Part 2” on page 75.

When cutting the air harness or air brake tubing to size make sure the ends are square using a tubing cutter or razor knife.

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❑ Installer Installation

Figure 3-22: ADT Option

Panel Placard Layout

Dimensions

Figure 3-23: ADT Air Hose Connections, Part 1

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Installer Installation ❑

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Figure 3-24: ADT Option Air Hose Connections, Part 2

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❑ Installer Installation

Notes

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Plumbing Installation ❑

3.5 SYSTEM PLUMBING DIAGRAMS

The following pages contain sample Hale FoamLogix system plumbing diagrams for various system configurations. Due to variations in apparatus configuration and individual component locations, the lengths of hoses and piping is not provided. The material described and component sizes shown provide optimum performance for a Hale FoamLogix system.

These diagrams are intended as guidelines to assist the system installer with the selection of hoses and fittings along with the connections required.

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(For barb fitting sizes, see Figure 3-14: “In-Line Strainer/Valve Installation” on page 67.)

Figure 3-25: Typical Single Foam Concentrate Tank

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(For barb fitting sizes, see Figure 3-14: “In-Line Strainer/Valve Installation” on page 67.)

Plumbing Installation ❑

Figure 3-26: Typical Single Foam Tank with MST and In-Line Strainer/Valve Assembly

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Figure 3-27: Typical Single Foam Tank, with MST and FS Series Strainers

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(For barb fitting sizes, see Figure 3-14: “In-Line Strainer/Valve Installation” on page 67.)

Plumbing Installation ❑

Figure 3-28: Single Foam Tank with MST II and In-Line Strainer/Valve Assembly

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Figure 3-29: Typical Single Foam Tank with MST II and FS Series Strainers

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(For barb fitting sizes, see Figure 3-14: “In-Line Strainer/Valve Installation” on page 67.)

Plumbing Installation ❑

(For barb fitting sizes, see Figure 3-1 4: “I n-Li ne St rai ner/V alv e Installation” on page 67.)

Figure 3-30: Typical Single Foam Tank with ADT and In-Line Strainer/Valve Assemblies

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Figure 3-31: Typical Dual Foam Tanks, with ADT and FS Series Strainer Assemblies

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3.6 ELECTRICAL

See Figure 3-32: “Single Tank Electrical Harness Overview,” on page 87. Also see Figure 3-33: “Dual Tank Electrical Harness Overview” on page 88.

Complete system electrical diagrams are provided at the end of this manual. Refer to these diagrams for proper installation of each of the electrical components.

The Hale FoamLogix 3.3, 5.0 or 6.5 system is designed to be installed with a minimum of electrical connections. Cables are provided with each Hale FoamLogix system to make the flow sensor, control unit and motor distribution box connections.

The system installer must supply primary power wire, low tank level sensor wire and flat braided ground straps.

Electrical Installation ❑

CAUTION !

❑ Review the “Safety” section of this manual, beginning on page 13,

in its entirety before proceeding with electrical connections.

❑ To prevent system damage or electrical shock the main power sup-

ply wire must be the last connection made to the Hale FoamLogix motor distribution box. Also see heading “Hale Foam System Layout Drawings” on page 39.

❑ The cables provided with each Hale FoamLogix system contain

shielded assemblies.

NEVER attempt to shorten or lengthen these shielded cables.

If necessary order longer or shorter cables from Hale Products to suit your particular installation.

❑ The cables are indexed so they connect to the correct receptacle

one way only. The cables shipped with each Hale FoamLogix system are tested at the factory with the specific unit. When making cable connections DO NOT force mismatched connections as damage can result, causing improper system operation.

❑ The system can only perform when electrical connections are

sound.

Make sure each electrical connection is correct.

❑ Hale FoamLogix systems are designed for use on direct current,

negative (–) ground apparatus electrical systems only.

❑ Do not mount a radio transmitter or transmitter cables in direct or

close contact with the Hale FoamLogix unit.

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❑ Electrical Installation

❑ Before connecting the cables, inspect the O-ring seal in the female

connector. If the seal washer is missing or damaged, water can enter the connector causing corrosio, resulting in possible system failure.

❑ The ground strap must be a minimum of 1-1/4” (32mm) wide and no

longer than 18” (457mm).

A longer ground strap must be wider or a double thickness strap must be used.

Make sure the ground strap is attached to the chassis frame. Grounding to the body IS NOT acceptable.

❑ Always disconnect the power cable, ground straps, electrical wires

and cables from the control unit or other Hale FoamLogix 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.

CAUTION ! - continued

❑ There are no user serviceable parts inside Hale FoamLogix system

electrical/electronic components. Opening of these components (motor distribution box or control unit) voids the warranty.

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Electrical Installation ❑

Single and Dual Tank Electrical Harness Overview

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Figure 3-32: Single Tank Electrical Harness Overview

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❑ Electrical Installation

Figure 3-33: Dual Tank Electrical Harness Overview

Control / Display Unit

The control/display unit mounts in the operator panel of the apparatus. The display is secured with four #10 socket head screws. (See Figure 3-34: “Control/Display Unit Mounting Dimensions” on page 89.)

The display requires a 7.00” (178mm) minimum clearance from the back of the operator panel to allow proper cable connection. Once the control unit is mounted on the operator panel, attach the 14 pin AMP connector on the cable assembly to the back of the display. For harness overview, see Section 8 “ Drawing Package,” on page 155. Also see Figure 3-35: “Distribution Box Connections” on page 90.

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Electrical Installation ❑

Notes: Ensure that the panel where the control unit is mounted has an adequate

ground. For stainless steel and vinyl coated panels a ground strap, 1/2” (13mm) wide, must be attached from one of the four screws securing the control unit in place to the frame of the fire truck to ensure adequate grounding.

Add a service loop to avoid strain on the wires or connectors during body and frame flex. Also see Figure 3-36: “Extra Cable Storage” on page 92.

Control / Display Unit Connection

The main control cable harness connects to the 14-pin AMP connector or pigtail on the back of the control unit. For harness overview, see Section 8 “ Drawing Package,” on page 155. Also see Figure 3-34: “Control/Display Unit Mounting Dimensions” on page 89.

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Figure 3-34: Control/Display Unit Mounting Dimensions

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❑ Electrical Installation

Figure 3-35: Distribution Box Connections

Distribution Box Ground / Primary Power

CAUTION !

CONNECT THE PRIMARY POSITIVE LEAD FROM THE TERMINAL BLOCK TO THE MASTER SWITCH TERMINAL OR RELAY TERMINAL USING MINIMUM 4 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 THE SILICONE SEALANT PROVIDED.

Ground Connection

Be sure the Hale FoamLogix system is grounded to the chassis. Use a short length of wide flat ground strap, at least 1-1/4” (32mm) wide and less than 18” (457 mm) long, to reduce the potential of RFI emitted by this connection.

A stud is located on the mounting base, labeled NEG (-), to attach the chassis ground strap to the Hale FoamLogix system. (See Figure 3-35: “Distribution Box Connections” on page 90.)

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Electrical Installation ❑

When making the ground strap connections make sure lugs are soldered to the strap ends for trouble free connections. Seal all connection against corrosion. When the length of the ground strap exceeds 18” (457mm) use a wider strap or a double thick strap.

CAUTION !

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 3.3, 5.0 AND 6.5 REQUIRE 60 AMP MINIMUM CURRENT.

Primary Power Supply Connection

Make sure adequate switched electrical power from the battery + terminal to the battery connection stud on the motor distribution box is provided. (See Table 3-2: “Primary Power Cable Sizes” on page 55.)

Use 4 AWG minimum type SGX (SAE J1127) battery cable directly to the battery, battery switch or solenoids for cable runs up to 6’ (1.8 meters) long. Longer wire runs may require larger battery cable for proper operation. DO NOT connect power to the same connection as the pump primer.

Display Power Connection

Use 16 AWG minimum type SGX (SAE J1127) wire for the display power and ground connections. Using the harness provided, Hale p/n: 513-027004-4:

❑ Connect the BLACK wire to a chassis ground stud

❑ Connect the RED wire to a minimum 5 AMP fused dedicated circuit. If a

dedicated circuit is not available, connect to a terminal that has LOW current load items, such as ENFO IV, governor and tank level gauge, etc.

❑ Connect this harness to connector C5 on the FoamLogix main harness.

RFI / EMI

A 100% electrically shielded main cable harness is provided with the Hale FoamLogix system to eliminate the potential problem of RFI / EMI.

Proper installation of system components and cables, along with proper grounding, limits radio interference caused by the Hale FoamLogix system. Additionally, make sure radio cables and hardware are not located in the immediate area where the FoamLogix system is mounted.

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Making round coils of extra control and flow sensor cables in the pump compartment can act as an antenna. While the control and flow sensor cables cannot be shortened, various lengths of cable are available to minimize the “extra” cable in the apparatus.

Figure 3-36: Extra Cable Storage

When routing control and flow sensor cables take care to avoid routing them next to antenna wires, radio power lines and radio components. When there is extra cable, double the cable back on itself and secure with plastic wire ties in a flat bundle instead of making a round coil. (See Figure 3-36: “Extra Cable Storage.”)

Make sure the flow sensor tee is grounded. If metal piping is used sufficient grounding may be present. However, Victaulic joints, plastic pipe and rubber mounted pumps interfere with proper grounding and an additional ground strap may be required. If necessary, connect a flat braided ground strap at least 1/4” (7mm) wide from the flow sensor tee to the apparatus frame to ensure proper grounding.

The #6-32 UNC screw that holds the spade terminal to the flow sensor tee can be used to attach the ground strap to the tee. (See Figure 3-13: “Flow Sensor/Saddle Clamp Installation” on page 65.)

Flow Sensor Connections

The control cable harness (connector C3) connects to the 3-pin connector on the flow sensor. For cable harness overviews, see Section 9 “ 9 Plate Drawings,” on page 170.

“Low Level Sensor” Installation (Foam Tank)

The foam low tank level sensor(s) must be installed and wired to monitor the foam concentrate level. (See Figure 3-37: “Low Level Sensor Mounting Options” on page 93.)

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FOAM TANK LOW LEVEL SENSORS MUST BE USED TO PROTECT THE HALE FOAMLOGIX FROM DRY RUNNING. FAILURE TO USE LOW LEVEL SENSORS WITH THE HALE FOAMLOGIX SYST EM VOIDS THE WARRANTY.

Side Mount Installation

A side mount low tank level sensor is used if the bottom of the foam tank is not accessible.

Electrical Installation ❑

CAUTION !

Figure 3-37: Low Level Sensor Mounting Options

1. The sensor has 1/2” (13mm) NPT threads. If tank design and construction allows, the side mount sensor is threaded directly into the side of the tank at the proper height. (See Figure 3-38: “Side Mount Sensor Location Dimensions.”)

Figure 3-38: Side Mount Sensor Location Dimensions

Also, the sensor can be mounted on the foam tank using a 1/2” x 1” (13 x 25mm) NPT bushing and a bulkhead fitting with 1” (25mm) FNPT threads.

2. The center of the switch must be located at least 1-½ to 2 inches (38 to 51 mm) from the bottom of the foam tank with the float positioned on top of the switch to allow up and down movement.

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❑ Electrical Installation

Note: When the side mount low level sensor senses a low concentrate condition

the system operates for an additional one minute unless the foam concentrate level is restored. If the foam concentrate level is not restored the system SHUTS DOWN. When locating the side mount low tank level sensor on the tank sufficient foam concentrate should be present for one minute of operation at the rated flow.

3. Coat the threads of the sensor with a suitable sealant and insert into tank fitting. Tighten sensor making sure the float is on the top of the sensor. (See Figure 3-37: “Low Level Sensor Mounting Options” on page 93.)

4. After installation, check operation of the side mount low tank level sensor with a powered test light. With no foam in the tank, the light should be ON. If light does not illuminate, rotate the side mount low tank level sensor until the test light is ON.

Bottom Mount Installation

The bottom mount foam tank low level sensor must be mounted into the bottom of the foam tank. (See Figure 3-37: “Low Level Sensor Mounting Options” on page 93.)

1. The sensor, as supplied, is threaded into a bushing (1” [25mm] NPT threads) and is designed to be installed from the outside of the foam tank through a bulkhead fitting or boss with 1” (25mm) FNPT threads.

2. Mount the sensor in the bottom of the foam tank in an upright position. Use a suitable sealant to prevent concentrate leakage. (See Figure 337: “Low Level Sensor Mounting Options” on page 93.)

3. Check low tank level sensor operation with a powered test light. With no foam in the tank, the light should be ON.

4. If not, remove the clip from the end of the sensor. Remove float and reinstall 180° out of position. Re-install clip.

Top Mount Installation

The top mount low level sensor assembly is available for installations where the sides or bottom of the foam tank are not accessible or sensor service is required without draining the foam tank.

The sensor assembly is flange mounted in an access hole at the top of the foam tank. The two section telescoping assembly permits adjustment of the low tank level sensor position for various foam tank depths, from 31- 1/2” to 60” (800mm to 1,524mm). (See Figure 3-39: “Top Mount Sensor Dimensions” on page 95.)

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Flange cutout dimensions are shown in Figure 3-39: “Top Mount Sensor Dimensions.” The flange gasket can also be used as a template to mark hole location.

1. Layout and drill holes in the top of the foam tank. (See Figure 3-39: “Top Mount Sensor Dimensions.”)

2. The center of the sensor should be located at least 11/2” to 2” (38 to 51mm) from the sides of the foam tank.

Electrical Installation ❑

Figure 3-39: Top Mount Sensor Dimensions

Note: The minimum depth of the foam tank for installation of the top mount sensor is 31-1/2” (800mm). If the tank depth is less than 31-1/2” (800mm) cut the tubing accordingly. (See heading “Resizing the Top Mount Low Level Sensor” on page 96.)

3. Determine the approximate length of the low tank sensor extension by measuring from the top of the foam tank at the flange opening to the bottom of the tank.

4. When properly installed the center of the sensor float should be 1-1/2” to 2” (38 to 51mm) above the bottom of the foam tank.

5. Loosen the strain relief gland nut to allow the sensor wire to slide through the strain relief.

6. Adjust the telescoping section until the desired length is achieved as measured from the bottom of the flange to the bottom of the sensor. Tighten the compression fittings on the union to lock length setting.

7. Tighten the strain relief around the sensor wire.

8. Inser t the sensor assembly through the 1.31” (33mm) hole and align the screw holes on the flange and gasket with the holes on the tank. Secure the assembly in place using four 1/4-20 UNC x 1” (25mm) long cap screws, 1/4” (7mm) washers and lock washers.

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❑ Electrical Installation

USE MOUNT ING HARDWARE THAT IS COMPATIBLE WITH ALL FOAM CONCENTRATES BEING USED IN THE SYSTEM. USE WASHERS, LOCK WASHERS AND CAP SCREWS MADE OF BRASS OR 300 SERIES STAINLESS STEEL.

Resizing the Top Mount Low Level Sensor

Certain applications may require the top mounted sensor to be shorter than factory length. (See Figure 3-40: “Top Mount Low Level Sensor Assembly” on page 97.)

To resize -

(See Figure 3-40: “Top Mount Low Level Sensor Assembly” on page 97.)

CAUTION !

1. Loosen and remove the strain relief gland nut and strain relief from the top of the sensor assembly.

2. Loosen and remove the 1/4” (6mm) FNPT x 1/2” (13mm) tube compression fitting from the bottom of the assembly.

3. Slide the sensor assembly out from the bottom being careful not to damage the wiring as it is pulled from the assembly. DO NOT separate the 1/2” tube from the 5/8” tube.

4. Loosen the compression nut from the 1/2” (13mm) FNPT x 5/8” (16mm) tube compression fitting at the top of the assembly.

5. Using a tubing cutter, remove an “equal” amount from the end of each tube (5/8” and 1/2”). You must cut off the ferrule from both ends. Deburr the cuts using a fine emery paper.

6. Install a new 1/2” (13mm) compression ferrule on the end of the 1/2” O.D. tube. Carefully thread the sensor wire through the tube assembly.

7. Attach the 1/4” (6mm) FNPT x 1/2” (13mm) tube compression fitting, with sensor attached, to the end of the tube.

8. Install and tighten the 1/2” compression nut.

9. Install a new 5/8” (16mm) compression ferrule on the end of the 5/8” O.D. tube. Carefully thread the sensor wire through the flange and gasket assembly and install strain relief and strain relief gland nut. DO NOT tighten.

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10. Install and tighten the 5/ 8” (16mm) tube compression nut.

11. Slide the 1/2” diameter tube in the 5/8” (16mm) diameter tube and adjust the telescoping section until the desired length is achieved, as measured from the bottom of the flange to the bottom of the sensor. Tighten the compression fittings on the union to lock length setting.

Electrical Installation ❑

12. Tighten the strain relief gland nut and strain relief.

Low Level Sensor Wiring

WHEN EXTENDING THE LOW TANK SENSOR WIRES MAKE SURE THE SPLICES ARE PROPERLY SEALED USING AN ADHESIVE FILLED HEAT SHRINK TUBING.

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Figure 3-40: Top Mount Low Level Sensor Assembly

CAUTION !

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❑ Electrical Installation

Single Foam Tank System

For cable harness overviews, see Section 9 “ 9 Plate Drawings,” on page

170. Also see Figure 3-32: “Single Tank Electrical Harness Overview” on page 87.

Use a minimum 16 AWG type SXL or GXL (SAE J1128) wire to extend the low tank sensor wire to the 2-pin Packard WeatherPack connector C10 of the main cable harness. Low tank level sensors are not polarity sensitive therefore terminal connections are not specific.

When splicing wires make sure the splices are sealed using an adhesive filled heat shrink tubing. Where two wires exit the heat shrink tubing pinch the tubing while heating the it to make sure the adhesive seals around both wires.

CAUTION !

USE THE SILICONE SEALER PROVIDED TO INSULATE AND PREVENT CORROSION.

A connector kit (Hale p/n: 546-1780-00-0) is available that contains a Packard WeatherPack 2-contact shroud half, two (2) 14-16 gauge male terminals and two (2) 14-16 gauge cable seals. Assemble these components to the end of the low tank sensor wires.

Snap the two halves of the WeatherPack connector together making sure they are sealed.

Note: If a Hale MST is not used, install the tank select jumper plug, Hale p/n: 513-0320-23-0, to connector C8. (See Figure 3-32: “Single Tank Electrical Harness Overview” on page 87.)

Dual Foam Tank System

For cable harness overviews, see Section 9 “ 9 Plate Drawings,” on page

170. Also see Figure 3-33: “Dual Tank Electrical Harness Overview” on page 88.

CAUTION !

BEFORE RUNNING WIRES FROM THE LOW TANK SWITCHES TO THE MAIN CABLE HARNESS MAKE SURE THE WIRES FROM TANK “A” ARE IDENTIFIED AND PROPERLY LABELED.

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Electrical Installation ❑

Use a minimum 16 AWG type SXL or GXL (SAE J1128) wire to extend the low tank sensor wires to the 2-pin Packard WeatherPack the following connectors of the main cable harness:

❑ Tank “A” - C10

❑ Tank “B” - C11

Low tank level sensors are not polarity sensitive therefore terminal connections are not specific.

CAUTION !

USE THE SILICONE SEALER PROVIDED TO INSULATE AND PREVENT CORROSION.

Snap the two halves of the WeatherPack connector together making sure they are sealed.

Remote Activation Switch Option

(See Figure 3-41: “Remote Activation Switch Installation Dimensions” on page 100.)

Choose a location in the apparatus personnel compartment for mounting the remote activation switch. Make sure the switch is accessible to the operator without interfering with other controls on the apparatus.

Install the remote activation switch as follows:

Cutout the panel and drill the four 0.203 inch (5mm) diameter through holes. (See Figure 3-41: “Remote Activation Switch Installation Dimensions.”)

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❑ Electrical Installation

Figure 3-41: Remote Activation Switch Installation Dimensions

1. Insert switch assembly through the panel cutout and secure to using the #10-24 UNC x 1/2” (13mm) screws and nuts provided.

Note: When making cable connections, make sure the cable is routed by the shortest most direct route. A maximum of 40 feet (12 meters) of remote cable may be used.

2. Connect the remote activation switch cable from the main cable harness connector C2. (See Figure 3-32: “Single Tank Electrical Harness Overview” on page 87.) Also see Figure 3-33: “Dual Tank Electrical Harness Overview” on page 88.

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Hale FoamLogix 6.5 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

NOTICE !

Contents Page

How to use this manual

1SAFETY

2 INTRODUCTION

3 INSTALLATION

4 USER CALIBRATION

5 OPERATION

6 GENERAL MAINTENANCE

7 TROUBLESHOOTING

8 PARTS IDENTIFICATION

9 PLATE DRAWINGS

1 Safety Precautions

1.1 DEFINITIONS

1.2 GUIDELINES

1 System Overview

2.1 ROTARY GEAR PUMP

2.2 CONTROL UNIT

2.3 WATER FLOW SENSOR

2.4 FEED BACK SENSOR

Table 2-1: Maximum Foam Solution Flows

2.5 TANK SELECTOR VALVES

Air Dual Tank Selector (ADT)

Manual Dual Tank Selector (MDT II)

Manual Single Tank (MST)

2.6 LOW PRESSURE STRAINER

Hale FS Series Strainers

2.7 ORDERING INFORMATION

2.8 HALE FOAM SYSTEM SPECIFICATIONS

Figure 2-2: Foam Pump Installation Envelope Dimensions

Figure 2-3: Foam Pump Installation Envelope Dimensions, ADT Option Only

2.9 SYSTEM CONFIGURATION

Hale Foam Proportioner System, Models 3.3, 5.0 or 6.5

Figure 2-4: FoamLogix Available Models

Figure 2-5: Hale Foam Proportioner Systems, Models 3.3, 5.0 and 6.5

2.10 CABLE HARNESS

Figure 2-6: Power Connection Wire Harness

2.11 DUAL FOAM CONCENTRATE TANK SYSTEM OPTIONS

Figure 2-7: Dual Tank Foam Concentrate Tank System Options

2.12 DUAL FOAM CONCENTRATE TANK OPTIONS

2.13 SINGLE FOAM CONCENTRATE TANK OPTIONS

2.14 STRAINER OPTIONS

2.15 LOW TANK LEVEL SENSOR OPTIONS

2.16 FLOW SENSORS

2.17 CHECK VALVE MANIFOLDS

2.18 REMOTE ACTIVATION SWITCH OPTION

2.19 CHECK VALVES, FLANGES, GASKETS

2.20 ELBOWS AND MINI MANIFOLDS

2.21 HALE FOAM SYSTEM LAYOUT DRAWINGS

Figure 2-10: Typical Single Foam Concentrate Tank

Figure 2-11: Single Foam Tank with MST and In-Line Strainer/Valve Assembly

Figure 2-12: Single Foam Tank with MST and FS Series Strainers

Figure 2-13: Dual Foam Concentrate Tanks, with MDT II and In-Line Strainer/Valve Assembly

Figure 2-14: Dual Foam Concentrate with MDT II and FS Series Strainer Assembly

Figure 2-15: Dual Foam Concentrate Tanks, with ADT and In-Line Strainer/Valve Assemblies

Figure 2-16: Dual Foam Concentrate Tanks with ADT and FS Series Strainer Assemblies

3 Installation

3.1 FOAM PUMP AND MOTOR ASSEMBLY

3.2 FOAM CONCENTRATE STRAINER

3.3 CONTROL UNIT / INSTRUCTION PLACARD

3.4 INSTALLER SUPPLIED COMPONENTS

Foam Concentrate Suction Hose

Recommended Components

Recommended Components

Foam Concentrate Discharge Hose

Recommended Components

Foam Concentrate Bypass Hose

Recommended Components

Check Valves

Flushing Water Hose

Foam Discharge Drains

Electrical Requirements

Figure 3-1: Recommended Relay Wiring Schematic

Table 3-2: Primary Power Cable Sizes

FoamLogix Display

Foam Concentrate Tanks(s)