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System 1600 and 1601
All quality FoamPro products are ruggedly designed, accurately machined, carefully assembled, thoroughly inspected
and tested. In order to maintain the high quality of your unit, and to keep it in a ready condition, it is important to follow
the instructions on care and operation. Proper use and good preventive maintenance will lengthen the life of your unit.
ALWAYS INCLUDE THE UNIT SERIAL NUMBER IN CORRESPONDENCE.
FoamPro • 26 Southern Blvd. • Nesconset, NY 11767 USA • 800-533-9511 • FAX 816-892-3178
INSTALLATION AND
OPERATION MANUAL
Unit
Serial
Number
Form 850
11/17
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Table of Contents
Troubleshooting
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Summary of Contents for Safe Fleet FoamPRO 1600 System
- Page 1 Form 850 11/17 System 1600 and 1601 INSTALLATION AND OPERATION MANUAL Unit Serial Number All quality FoamPro products are ruggedly designed, accurately machined, carefully assembled, thoroughly inspected and tested. In order to maintain the high quality of your unit, and to keep it in a ready condition, it is important to follow the instructions on care and operation.
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Page 2: Table Of Contents
Installation and Operation Manual Installation and Operation Manual TABLE OF CONTENTS SECTION PAGE SAFETY ........................3 A QUICK LOOK AT HOW THE SYSTEM WORKS ............ 4 SYSTEM COMPONENT DESCRIPTION ..............5 INSTALLER SUPPLIED PARTS ................7 INSTALLATION PLANNING ..................8 PLUMBING COMPONENT INSTALLATION ............. -
Page 3: Safety
System 1600/1601 Installation and Operation Manual Installation and Operation Manual Before attempting to install a FoamPro System 1600 and/or 1601, Safety read all of the following safety precautions and follow carefully. D o n o t p u m p a t p r e s s u r e s h i g h e r t h a n 10. -
Page 4: A Quick Look At How The System Works
Installation and Operation Manual Installation and Operation Manual A Quick Look at How the System Works The FoamPro System 1600/1601 is an electric motor Since foam is injected on the discharge side of the fire driven flow-based proportioning system that measures pump, and check valves are to be used at installation, water flow and then injects the proportional amount of there is no foam concentrate contamination of the... -
Page 5: System Component Description
System 1600/1601 Installation and Operation Manual Installation and Operation Manual System Component Description STANDARD FOAMPRO 1600/1601 EQUIPMENT The following components are packaged with the 6. Inlet Line Strainer with Nipple FoamPro 1600/1601: 1. Control Module with Instructions 7. FoamPro 1” bore x 1-1/2” NPT size, 1-1/2” 2. - Page 6 Installation and Operation Manual Installation and Operation Manual SYSTEM ACCESSORIES AVAILABLE Polypropylene Foam Tank(s) 8 gallon, P/N 1530-0005 System Rating Placards 12 gallon, P/N 1530-0012 System Placard Model 1600, P/N 6032-0018 20 gallon, P/N 1530-0022 Single Tank, P/N 6032-0015 Model 1601, P/N 6032-0019 Nesconset, NY 11767 USA CAFS Power-Link Single Tank Flush Kits...
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Page 7: Installer Supplied Parts
System 1600/1601 Installation and Operation Manual Installer Supplied Parts The FoamPro 1600/1601 system is provided with the major components and accessories required for installation. Due to differences in chassis and apparatus configurations, the installer must provide pipe, hoses, tubing, wire and fittings to satisfy installation requirements. -
Page 8: Installation Planning
Installation and Operation Manual Installation Planning Because of the potential differences in apparatus Although the foam pump unit can be positioned with plumbing and foam system configuration, it is not a suction lift not to exceed 3 ft. (0.9 meters), the unit practical to depict exactly how each FoamPro unit can can be positioned below the discharge of the foam best be installed onto a particular apparatus. -
Page 9: Plumbing Component Installation
System 1600/1601 Installation and Operation Manual Plumbing Component Installation The following diagram (Figure 3) provides recommended guidelines for the location of the system components that handle water, foam concentrate and foam solution. To Calibration Container Foam Tank Calibrate/ Inject Valve Foam Pump Motor Shut-off Check... - Page 10 Installation and Operation Manual D. LINE STRAINER Protect the foam pump base unit from excessive road spray and debris. Although the system is sealed and The line strainer that is provided with the FoamPro designed to be resistant to the harsh environment of fire unit has 3/4-inch NPT female threaded ports and is fighting apparatus, a protected compartment with easy installed on the inlet port of the foam pump.
- Page 11 System 1600/1601 Installation and Operation Manual F. INJECTOR FITTING (optional) The brass injector fitting ensures the foam concentrate is injected into the center of the water flow. The inlet of the fitting is 1/2-inch NPT female thread, and the outer threads are 1-inch NPT designed to fit a pipe tee that is installed in the discharge piping of the fire pump (see Figure 7).
- Page 12 Installation and Operation Manual DO NOT OVER TIGHTEN. apparatus water tank, resulting in contamination of The check valve in the water way is required to keep the water tank with foam. A separate drain system foam solution out of the main pump and allow pump should be provided for foam solution piping to prevent contamination of the water tank and fire pump.
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Page 13: Electrical Equipment Installation
System 1600/1601 Installation and Operation Manual Electrical Equipment Installation ELECTRICAL CONNECTIONS power or ground cables to other components with high amperage outputs. Follow the system electrical diagram (Figure 11) for proper • DO NOT cut molded cables. hookup of each of the electrical components. Complete molded cable sets are provided with each FoamPro •... - Page 14 Installation and Operation Manual • Use care when installing molded cables. Count pins or check color codes before connecting. Bent pins caused by improper hookup can prevent proper operation even when cables are reattached properly. 5-pin Connector • Before connecting the molded cables, inspect the yellow seal washer in the female connector.
- Page 15 System 1600/1601 Installation and Operation Manual B. FLOWMETER CONNECTION A molded cable is supplied, which connects from the flowmeter to the 3 pin connector on the motor driver module. Top Mount C. FOAM TANK CONNECTIONS Side Mount The foam tank low-level sensor must be mounted into the Low-Level Sensor Low-Level Sensor (Optional)
- Page 16 Installation and Operation Manual • Always connect the primary 12 or 24 VDC positive lead Power and ground connections must come directly from the battery to the connections shown in figure 11. for the system directly to the battery or power switch These connections must come directly from the battery using appropriate AWG wire that is chemical resistant without any connections to other high power devices such...
- Page 17 System 1600/1601 Installation and Operation Manual Electrical Power Supply Schematic To Other Devices System Z Bracket Assy Master Disconnect Switch, PTO Switch, or Manual Switch Controller Power Lead (+) Battery Common Power Connection for other FoamPro Accessories Ground Lead (-) Relay, or Solid Common Ground Connection State Contactor...
- Page 18 Installation and Operation Manual G. EMI/RFI SUPPRESSION FLOWMETER AND CABLES A n E M I / R F I ( R a d i o F r e q u e n c y I n t e r f e r e n c e ) The flowmeter tee must be grounded.
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Page 19: Making Sure Everything Is Working Right
System 1600/1601 Installation and Operation Manual Making Sure Everything is Working Right Electrical • Low-level sensor is connected and the connections are sealed from moisture. • Module connectors are correct and tight. • Cable connections at the motor driver box are correct and tight. •... -
Page 20: Calibration And Setup
Installation and Operation Manual • Foam concentrate should begin flowing into the If you are still having difficulty priming the foam pump in container. If concentrate is not being pumped, your FoamPro system, do the following: check first to make sure the foam pump is running. •... -
Page 21: Operating Instructions
System 1600/1601 Installation and Operation Manual 2. Gather the items required for reading concentrate injection pressure. A 0-500 psi [0 to 34.5 BAR] test quality gauge, 500 psi [34.5 BAR] hoses and fittings to connect to the injector line from the foam pump. 3. - Page 22 Installation and Operation Manual LIGHT STATUS SYSTEM CONDITION Light blinks on and then goes out. System is activated and ready to run, and/or running depending on the main water flow conditions. Light goes on and stays on. System is activated and ready to run, but it has insufficient concentrate in the tank.
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Page 23: Operation Options
System 1600/1601 Installation and Operation Manual Operation Options • Remote Start/Stop • Remote Simulated Flow Remote Start/Stop Option the system is in the ON or run position, both buttons The Remote Start/Stop option allows the FoamPro will illuminate. The concentrate INJECTION RATE is 1600/1601 to be switched ON or OFF from two still controlled from the knob on the control panel. - Page 24 Installation and Operation Manual Remote Simulate Flow Option from the control panel or wherever the remote switch is mounted. Like the standard system switch, the A standard FoamPro 1600/1601 system requires Remote Simulated Flow switch is a momentary switch. the operator to toggle a switch located on the Acutating the switch will toggle the FoamPro 1600/1601 Driver Box at the foam pump and motor to actuate SIMULATED FLOW mode between OFF and ON.
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Page 25: Maintenance
System 1600/1601 Installation and Operation Manual Maintenance 1. Monthly: Inspect wiring, hoses, flow meters, and Lubricate every 50 hours of usage or monthly. connections for tightness, corrosion, leaks and/or damage. With a screwdriver or flat tool, apply a generous dab of grease to outer diameter surface of cam bearing at top 2. -
Page 26: Troubleshooting
Installation and Operation Manual Troubleshooting The FoamPro 1600/1601 System is designed to be easy to diagnose and service. There are several major components. Servicing the system involves isolation of the failed component and replacing it. There are no user serviceable internal components in the electronic modules. Due to the reliable nature of modern electronics, most failures are traced to faulty cables or wiring problems. -
Page 27: Troubleshooting Guide
System 1600/1601 Installation and Operation Manual TROUBLESHOOTING GUIDE Symptom Probable Cause(s) Corrective Action Pump runs but produces no flow. Pump is not primed. See Foam Pump Priming Check section on Page 18. Pump loses prime, Air leak in suction hose or inlet fittings. Remove suction hose and test for leaks by chattering noise, pressure fluctuates. -
Page 28: Parts Identification
Installation and Operation Manual Standard 1600/1601 Parts Identification 22 21 Ref. Part No. Description Qty. Ref. Part No. Description Qty. 53709 Plunger Pump for Model 1600 53708 Plunger Pump for Model 1601 1510-0089 Mounting Bracket 2401-0035 Elbow, 1/2-inch NPT 2510-0028 Tank Level Sensor (Vertical) 2510-0032 Tank Level Sensor (Side) - Page 29 System 1600/1601 Installation and Operation Manual Remote Start/Stop Parts Identification Ref. Part No. Description Qty. Ref. Part No. Description Qty. 53709 Plunger Pump for Model 1600 2510-0028 Tank Level Sensor (Vertical) 53708 Plunger Pump for Model 1601 2510-0032 Tank Level Sensor (Side) 2401-0035 Elbow, 1/2-inch NPT 2520-0120...
- Page 30 Installation and Operation Manual Remote Simulated Flow Parts Identification 22 21 Ref. Part No. Description Qty. Ref. Part No. Description Qty. 53709 Plunger Pump for Model 1600 2510-0028 Tank Level Sensor (Vertical) 2510-0032 Tank Level Sensor (Side) 53708 Plunger Pump for Model 1601 2520-0048 Control Cable (6 ft.
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Page 31: Control Module Template/Installation Drawings
System 1600/1601 Installation and Operation Manual Control Module Template Mounting Location for 3 1/2" Thru Holes or Tapped Holes 1 3/4" for a #10 Fastener Terminal Block for Float Switch 5-Pin Connector Connection 1 15/32" 1 3/4" Ø 3 3/4" FOR 2001/2002 3 1/2"... - Page 32 Installation and Operation Manual FoamPro Flowmeter Sensor Assembly O-Rings 4.00" min.* (102 mm) Retaining Pin 85° max. Note #3 Female Pipe Threads 3.12" min.* (79 mm) Grooved for B Pipe * = Minimum sensor service clearance. NOTE: 1. Use CAUTION not to damage sensor during assembly. 2.
- Page 33 System 1600/1601 Installation and Operation Manual NOTES...
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Page 36: Limited Warranty
Installation and Operation Manual Limited Warranty Fire Research Corp. (FRC), as supplier of FoamPro, warrants to the original purchaser, each new pump, system or other product of its own manufacture, for a period of two years from the date of shipment from the factory, to be free from defects in material and workmanship under normal use and service.
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