Page 1 TECHNICAL MANUAL FOR HALE SAM HALE PRODUCTS, INC. A Unit of IDEX Corporation 607 NW 27th Ave, Ocala, FL 34475 (800) 533.3569 (800) 520.3473 (FAX) www.haleproducts.com MANUAL P/N FSG–MNL–00211 Revision A COPYRIGHT © 2019 – 2020 BY HALE PRODUCTS, INC. ALL RIGHTS RESERVED...
Page 3: Table Of Contents
TABLE OF CONTENTS Section Title Page 1. SAFETY ............................. 1 1.1. PPE ............................1 1.2. Environmental Protection ......................2 1.3. Training ............................. 2 1.4. Safety Summary ........................2 2. INTRODUCTION..........................9 2.1. How To Use This Manual ......................9 2.2. Disclaimer ..........................
Page 4 TABLE OF CONTENTS – CONTINUED Section Title Page 2.4.3.6 Water Detection Sensors ..................25 2.4.3.6.1 Autolube Water Detection Sensor Protection Solenoid ........25 2.4.4 Pump Priming And Air Bleed ................... 25 2.4.4.1 Pump Primer (ESP) ....................25 2.4.4.2 Priming Feature Valve Assembly ................25 2.4.4.3 Air Bleed And Check Valves ..................
Page 5 TABLE OF CONTENTS – CONTINUED Section Title Page 3. PREVENTIVE MAINTENANCE ....................... 39 3.1. Preventive Maintenance Plan And Schedule ............... 39 3.2. Reset Gearbox Oil Life ......................41 4. CORRECTIVE MAINTENANCE ....................... 43 4.1. General Repair Guidelines ....................43 4.1.1 Match Mark Or Note Component Orientation ...............
Page 6 TABLE OF CONTENTS – CONTINUED Section Title Page 4.7. Removal And Replacement Of SAM Sensors ............... 72 4.7.1 Barometer (Atmospheric Pressure) ................72 4.7.2 Flowmeter (Optional – Used with SAM Or Navigator Pro 9335 Only) ......74 4.7.3 Pressure Sensors/Transducers ..................75 4.7.3.1 AB Swing-out Valve Pressure Sensor ...............
Page 7 TABLE OF CONTENTS – CONTINUED Section Title Page 4.11. Bench Procedures ....................... 123 4.11.1 AB Swing-out Valve Motor Rotation ................123 4.11.2 4-Way Air Valve R&R ..................... 123 4.11.3 PF Air Cylinder R&R ....................... 126 4.11.4 PF Valve Assembly R&R ....................127 4.12.
Page 8 TABLE OF CONTENTS – CONTINUED Section Title Page 4.16.2 Error Messages And System Level SCR Table ............152 4.16.2.1 Barometric Sensor Troubleshooting ..............165 4.16.2.2 Flowmeter Troubleshooting ................... 166 4.16.2.3 Level Sensor Troubleshooting ................167 4.16.2.4 PF Valve Troubleshooting ..................167 4.16.2.5 Pressure Sensor Troubleshooting .................
Page 9 TABLE OF CONTENTS – CONTINUED Section Title Page 6.6. How To Assign/Change Low Tank Water Alarm Trigger Level .......... 189 6.7. How To Assign/Change A Valves Friendly Name ............... 189 6.7.1 How To Change A Friendly Name ................. 190 6.8. How To Assign/Change A Valves Index Number ..............
Page 10 LIST OF FIGURES – CONTINUED Section Title Page Figure 11. PUMP INFO Screen (Maintenance Required) ............15 Figure 12. ENGINE DATA Screen ....................15 Figure 13. VIDEO Screen ......................16 Figure 14. SAM Blue CAN Buss Architecture (With Three SAM Control Centers) Diagram ..17 Figure 15.
Page 11 LIST OF FIGURES – CONTINUED Section Title Page Figure 41. Hale Pressure Transducer And Pin Layout ..............61 Figure 42. MIV–E Override Panel ....................62 Figure 43. MIV–E Override Panel Air Bleed Valve Assembly ............64 Figure 44. Hale MIV Activation Button ..................64 Figure 45.
Page 12 LIST OF FIGURES – CONTINUED Section Title Page Figure 71. MIV–A Module ......................98 Figure 72. SAM Module (MIV–A) ....................98 Figure 73. MIV–A Drive Module ....................100 Figure 74. PF Valve Diode ......................102 Figure 75. Priming Feature Assembly ..................103 Figure 76.
Page 13 LIST OF FIGURES – CONTINUED Section Title Page Figure 101. MENU Screen ......................132 Figure 102. Enter Password Screen .................... 132 Figure 103. System Option Screen (BAM Tab Selected) ............133 Figure 104. SELECT DEVICE MENU Screen ................. 133 Figure 105. Configuration Mode MENU Screen ................
Page 14 LIST OF FIGURES – CONTINUED Section Title Page Figure 131. SAM Speaks Verbal Alerts (Page 2) ................ 151 Figure 132. Barometric Sensor Check/Test ................165 Figure 133. Calibrate Valve Flow Screen ..................166 Figure 134. Level Sensor Troubleshooting ................. 167 Figure 135.
Page 15 LIST OF FIGURES – CONTINUED Section Title Page Figure 161. Edit Valve Screen –Number Pad, CLEAR And ENTER Buttons ......191 Figure 162. Valve Edit – Color Assignments ................194 Figure 163. Color Assignment Swatches ..................194 Figure 164. Update Network With New Configuration Information Screen ......198 Figure 165.
Page 16 LIST OF TABLES – CONTINUED Section Title Page Table 21. MIV–E Override Panel Tools And Consumables List ..........63 Table 22. MIV Activation Button Wiring (From/To Listing) ............65 Table 23. MIV Activation Button Tools And Consumables List ..........66 Table 24.
Page 17 Priming And Air Bleed Component Testing ............. 149 Table 77. Audio Files Useful For Audio Testing/Adjustment ..........152 Table 78. Hale SAM System Level SCR Table ................. 153 Table 79. Barometric Sensor Output ..................165 Table 80. SAM Discharge Valve Function Defaults ..............192...
Page 18 LIST OF TABLES – CONTINUED Section Title Page Table 81. SAM Discharge Valve Max PSI Defaults ..............192 Table 82. SAM SCC Balloon Types ................... 193 Table 83. SAM Valve Capability Settings ................. 193 Table 84. Captium To SAM Wiring (From/To Listing).............. 197 Table 85.
Page 19 Abbreviations And Acronyms The abbreviations used in this manual (and Appendices) are limited to standard (commonly used and accepted) scientific units of measure and therefore are NOT defined or listed. The acronyms used in this manual (and Appendices) are defined in this listing (in numerical-alphabetical order) and are NOT defined within the text.
Page 20 Abbreviations And Acronyms – CONTINUED Society of Automotive Engineers Scene Apparatus Management Starter or Ground Cross-Linked Polyethylene Unit ID xviii...
Page 21: Safety
1. SAFETY This section provides definitions and a listing of the safety headings used in the SAM Operation Installation Maintenance (FSG-MNL–00210), Technical (FSG-MNL–00211), and the Parts (FSG- MNL–00212),manuals. For added protection and before attempting installation, repair, or operation, please follow the safety guidelines listed in this section and adhere to all cautions, dangers, notices, and warnings found in the manuals.
Page 22: Environmental Protection
Agency for advice regarding disposal policies. 1.3. Training The Hale SAM must ONLY be operated and maintained by trained personnel. Training is available via the Hale Products Inc. website (https://haleproducts.com), Godiva √erified Training (go- diva.co.uk), or through your local dealer or vehicle manufacturer. The Hale website provides a de- scription of the course content and general information about the training, including an invitation to register with the EVT Certification Commission (www.evtcc.org) to take one EVT exam at the...
Page 23 CHECK THE BILL OF LADING FOR THE WEIGHT BEFORE LIFTING. ONLY USE APPROPRI- ATE LIFT METHODS AND EQUIPMENT TO MOVE OR HANDLE SAM PUMP KIT OR MOD- ULE. (TYPICAL PUMP KIT WEIGHT IS APPROXIMATELY 1200 LBS. (545 KG) TYPICAL MODULE WEIGHT IS 2800 LBS. (1270 KG) ELECTRICAL POWER TO THE VALVE MOTOR SHOULD BE DISCONNECTED BEFORE OP- ERATING THE VALVE PHYSICALLY USING THE MANUAL OVERRIDE HANDWHEEL.
Page 24 ALWAYS STOP THE ENGINE, SET THE PARKING BRAKE, AND CHOCK THE WHEELS BE- FORE GOING UNDER THE TRUCK FOR ANY REASON. AVOID CONTACT WITH HOT SURFACES. THE PACKING GLAND AND PUMP BODY MAY PRESENT A TEMPERATURE HAZARD. OVERHEATING MAY RESULT IN A SCALDING WA- TER HAZARD.
Page 25 AKRON BRASS SWING-OUT VALVES FROM A DISCHARGE PORT WILL NOT FUNCTION IN THE PLACE OF ANY SPECIAL PURPOSE VALVE (TF, T2P, PONY) IN A HALE SAM SYS- TEM. DO NOT USE ONE FOR SUBSTITUTION OR REPLACEMENT PURPOSES. ALL SAM TOUCHSCREENS ARE WATER RESISTANT.
Page 26 ALWAYS DISCONNECT THE POWER CABLE, GROUND STRAPS, ELECTRICAL WIRES AND CABLES FROM THE CONTROL UNIT OR OTHER HALE SAM EQUIPMENT BEFORE ELEC- TRIC ARC WELDING AT ANY POINT ON THE APPARATUS. ALWAYS TURN OFF CAFS FROM THE SMARTCAFS CONTROL DISPLAY.
Page 27 SUPPORT MULTI-TOUCH. OTHER ELECTRICAL COMPONENTS MUST NOT BE SUPPLIED FROM THE SAM SYSTEM SUPPLY. DO NOT CONNECT THE PRIMER AND HALE SAM TO THE SAME POWER WIRE. PERFORMING ANY PROCEDURE IN THIS SECTION CAUSES SAM TO EXIT BOTH AUTO AND MANUAL MODES AND ENTER CONFIGURATION MODE.
Page 28 THE MODULE DEUTSCH CONNECTORS ARE KEYED TO PREVENT INTERCHANGE (ON THAT MODULE) OR REVERSE DIRECTION INSERTION. DO NOT FORCE A CON- NECTOR WITHOUT FIRST VERIFYING THE CONNECTORS ORIENTATION AND THE MAT- ING MODULES LOCATION IS CORRECT. THE SAM CONTROL CENTER WILL NOT FUNCTION PROPERLY WITHOUT ONE OF THE DISPLAYS CONFIGURED AS THE MASTER.
Page 29: Introduction
2. INTRODUCTION This section provides a 10,000-foot-view of the SAM system and a how to use this manual expla- nation; including SAM network and system diagrams, interface descriptions, and very top level principles of operations. 2.1. How To Use This Manual This manual was developed for the purposes of FAST team and OEM support.
Page 30: Disclaimer
2.2. Disclaimer Our policy is one of continuous development. We therefore reserve the right to amend specifica- tions without notice or obligation. NOTE: Using the pump serial number (from your SAM system) and the Hale website (or calling Customer Service) is the best way to ensure you receive/utilize the correct replacement parts for your pump and your SAM system.
Page 31: Sam Auto Mode Interface
2.3.1.1.1 SAM Auto Mode Interface Use Auto Mode to verify the existence of an indicated SYMPTOM. Then after troubleshooting, re- pair, and testing; use Auto Mode to verify SAM automation has been restored. Refer to the local guidelines provided by the AHJ, OEM documentation/manuals, and then if other instruction is NOT available use the SAM OIM (FSG-MNL-00210), section 6, for general operating instructions for SAM automated operation of the apparatus.
Page 32: Sam Control Center Menu Tabs
2.3.1.1.3 SAM Control Center Menu Tabs Entering an OEM/technician password displays the tabs shown on Figure 3. Entering an OEM/technician password also requires a USB Key be connected to the USB dongle on the rear of the SAM Control Center. See section 2.6 (page 33) for instructions to use the System Options button to access the SAM password screens and a list of SAM passwords for an OEM and/or a technician.
Page 33: Calibration
2.3.1.1.3.2 Calibration Touch the Calibration tab (Figure 5) to enter the CALIBRATION MENU screen. See Figure 5. See Section 5, Adjustments (page 173), for a description of each calibration and instructions to per- form the desired/required calibration(s). Figure 5. Calibration Tab 2.3.1.2 Pump Controller Interfaces The Pump Controller interface will be a primary tool for maintaining a SAM system.
Page 34: Tank
The Pump Controller tabs change color to indicate maintenance is required. See Figure 7. Figure 7. Pump Controller Tabs (Indicating Maintenance Required) 2.3.1.2.1.1 TANK The TANK tab (Figure 8) provides the following read-only SAM system information. • • Water Tank Status Master Intake Pressure •...
Page 35: Pump Info
2.3.1.2.1.2 PUMP INFO The PUMP INFO tab (Figure 10) display varies by the pump model ordered with the SAM system. Anode status, temperature (gearbox and pump), and hours (pump and gearbox oil remaining life) status are available for all models. Unique to Q series pumps, Autolube oil status (water detec- tion) is provided.
Page 36: Video
2.3.1.2.1.4 VIDEO Typically, a maintainer would not use the VIDEO tab unless one (or more) images from the in- stalled camera(s) fails to display. Figure 13. VIDEO Screen 2.3.2 SAM System Diagrams Figure 14 thru Figure 18 shows the bus architecture, interface layouts, and miscellaneous dia- grams of the system.
Page 37: Figure 14. Sam Blue Can Buss Architecture (With Three Sam Control Centers) Diagram
Figure 14. SAM Blue CAN Buss Architecture (With Three SAM Control Centers) Diagram...
Page 38: Figure 15. Sam Green Can Buss Architecture (With Three Sam Control Centers) Diagram
Figure 15. SAM Green CAN Buss Architecture (With Three SAM Control Centers) Diagram...
Page 39: Figure 16. Sam Red Can Buss Architecture (With Three Sam Control Centers) Diagram
Figure 16. SAM Red CAN Buss Architecture (With Three SAM Control Centers) Diagram...
Page 40: Figure 17. Sam System Drain And Pneumatic Diagram
Figure 17. SAM System Drain And Pneumatic Diagram...
Page 41: Figure 18. Sam Speaks Diagram
Figure 18. SAM Speaks Diagram...
Page 43: Principles Of Operation
2.4. Principles Of Operation This section provides the principles of operation (description of the key SAM components) for maintainers to use when troubleshooting or communicating with an OEM/apparatus manufac- turer or a Hale Customer Support representative. 2.4.1 System Power SAM system power consists of an OEM connection stud for battery POSITIVE (+12 VDC) and an OEM connection stud for battery NEGATIVE (ground/system ground/return).
Page 44: Miv Valve Drive
2.4.2.4 MIV Valve Drive The SAM system utilizes one [1] MIV valve drive module to support the operation of each Hale master intake valve installed in the SAM system. See paragraph 4.8.4 (page 100) for all other MIV valve drive module information. 2.4.3 System Sensors The SAM system consists of the sensors described in the following subparagraphs.
Page 45: Water Detection Sensors
2.4.3.6 Water Detection Sensors The water detection sensor detects the presence or absence of water. Do NOT attempt to R&R the sensor before seeing paragraph 4.7.6 (page 84) to prevent sensor damage and for other sensor information. See paragraph 4.15.2 (page 145) to check/test the sensor. 2.4.3.6.1 Autolube Water Detection Sensor Protection Solenoid The water detection sensor protection solenoid installs in a special tap in the autolube assembly...
Page 46: Manual Prime/Air Bleed
2.4.4.4 Manual Prime/Air Bleed In the event that SAM automated priming is inoperative, SAM provides a traditional PRIME button (wired direct to primer). To provide traditional air bleed for the Hale MIV 2.0s, each SAM MIV override panel houses a mechanical air bleed valve (Blue handle). 2.4.4.4.1 Manual Pump Priming SAMs traditional PRIME button wiring differs slightly from typical wiring, in that blocking diodes...
Page 47: Sam Pump Controller Tank Screen
Table 1. Akron Brass Valve Applications (Intake/Special) – CONTINUED SAM Application Akron Brass Valve Static (Position) (Size) 1/ Address Tank-To-Pump 3 in (0xA7) (Refer to FSG-MNL-00212, Table 1, Tank-To-Pump) 4 in (Refer to FSG-MNL-00212, Table 1, Tank-To-Pump) 2.5 in Auxiliary Intake (Pony) (0xA8) (Refer to FSG-MNL-00212, Table 1, (Left Rear)
Page 48: Master Intake Valves
Figure 20. SAM Pump Controller Tank Screen – Optional Water Level Graphical Indicator The tank info portion of the screen (bottom left) can show tank fill as open (green), auto (orange) or closed (no color shown). Additionally, if the auxiliary cooling solenoid is open the auxiliary cool- ing icon (rotating orange and green arrows) is displayed on the SAM Pump Controller (superim- posed over the TANK FILL and TANK-TO-PUMP valve position icons).
Page 49: Navigator (Optional Equipment)
Reference section 5, System Installation, of Style 9335 Navigator Pro With Pressure, Flow CAFS And Valve Control Installation, Operating, And Maintenance Instructions (P/N 126914) found on the flash drive provided with the system or on the Hale website (www.haleproducts.com). 2.4.8 Navigator (Optional Equipment) One Navigator for every Akron Brass Swing-Out™...
Page 50: Emergency Idle Switch
the pumps discharge pressure as set at SAM Pump Control (Operators) Panel similar to tradi- tional governor operations. The following governor modes are provided by SAM: PSI Mode PSI mode displays the pump pressure set point and actual pressure for operator control. PSI mode is the default governor mode when SAM exits automated water only or FOAM pumping op- erations.
Page 51: Speakers
2.4.10.2 Speakers The audio amplifier outputs are wired to each of the four speakers. For best sound clarity/quality maintain the same polarity for all four speakers. Speakers should be mounted two on each side of the apparatus, one high and the other low, and out of the path of direct water/road splash. Do NOT attempt to R&R an audio speaker before seeing paragraph 4.10.2 (page 110) to prevent assembly damage and for other panel information.
Page 52: Sam Auto Mode
remote capability supporting component(s) has (have) been installed, configured, or removed and replaced and the apparatus is ready to be returned to the department for firefighting pur- poses. Figure 23. SAM Tablet 2.4.12 SAM Auto Mode OPERATORS SHOULD FIRST BE TRAINED TO OPERATE THE FIRE PUMP MANUALLY (US- ING PUSH BUTTONS, CONTROL RODS, AND MANUAL [NOT ELECTRICAL] VALVE OVER- RIDES.) •...
Page 53: Sam Manual Mode
Numbering and Specifications References, for how to locate the serial number for your SAM sys- tem. Hale SAM performance per NFPA 1901 (and/or NFPA 1906 as appropriate) is provided on the Hale Products website (www.haleproducts.com) or by contacting Hale Customer Service (800- 533- 3569).
Page 54: Sam Control Center Password Screen
D. Touch and hold system options button until loading icon completes circle (see Figure 25) and password screen is displayed (see Figure 26). Figure 25. SAM Control Center System Options Button And Loading Icon Figure 26. SAM Control Center Password Screen 2.6.1.1 SAM Control Center Password Screen Perform the following to enter a password.
Page 55: Sam Control Center Password List
Table 2 provides a list of the passwords for entry on a SAM Control Center. NOTES All technician level passwords require a Hale SAM USB Key (ONLY available thru at- tending a Hale SAM training class). Refer to the Hale website (www.haleproducts.com) for videos containing password us- age details.
Page 56: Sam Pump Controller Password List
Figure 29. SAM Pump Controller Menu Screen D. On SAM Pump Controller menu screen, touch Password Entry button. E. Using password icon group (with USB Key attached) and Table 3, touch desired passwords digits. F. Touch ENTER button. NOTE Actionable passwords do NOT display an associated (different) screen, all other pass- words display a separate yet associated screen (or series of screens).
Page 57: Table 3. Sam Pump Controller Password List
Table 3. SAM Pump Controller Password List – CONTINUED Password Menu/Page Description 7474 ITL-40 Calibration Onboard Water Tank Level Display Calibration 7575 Voltage Calibration Match SAM Display To Apparatus Voltage (Includes Alarms Set Levels) 43275 Actionable Password (Resets Gearbox Oil Life 1) 43276 Actionable Password (Resets Gearbox Oil Life 2) * 59326...
Page 58 THIS PAGE INTENTIONALLY BLANK.
Page 59: Preventive Maintenance
3. PREVENTIVE MAINTENANCE Regular preventive maintenance assures continued dependable operation. Hale Products recom- mends the preventive maintenance and inspections listed in paragraph 3.1 be performed in ac- cordance with the Preventive Maintenance Plan And Schedule provided. 3.1. Preventive Maintenance Plan And Schedule Hale Products recommends the preventive maintenance and inspections listed in Table 4 be per- formed as scheduled.
Page 60: Table 5. Pump Preventive Maintenance Cross References
Table 4. Recommended Preventive Maintenance – CONTINUED Interval Check/Test Action Required Item(s) Required Annually (Every 12 Months) NOTE 1/ Calibrate Verify foam flow calibration and water Supply of clean water flow calibration. Acceptable Foam (Reference FSG-MNL–00186 and see Flowmeter the Flow Calibration paragraph.) Autolube Oil Check Check Autolube oil level and condition, if 1/4-in Allen Wrench...
Page 61: Reset Gearbox Oil Life
3.2. Reset Gearbox Oil Life Perform the following to reset the gearbox oil life remaining counter when the gearbox oil is changed per the schedule listed in Table 4. A. On SAM Control Center/SAM Pump Controller, access password screen. B. Sequentially, touch digits of actionable password to reset gearbox oil life 1. See Table 3 (page 36).
Page 62 THIS PAGE INTENTIONALLY BLANK.
Page 63: Corrective Maintenance
The following subparagraphs provide general guidelines to be utilized and/or followed whenever the maintenance procedure being performed is associated with the type of information/ instruc- tions provided in these subparagraphs. NOTE Unless otherwise indicated, these instructions apply to all Hale SAM systems.
Page 64: Match Mark Or Note Component Orientation
4.1.1 Match Mark Or Note Component Orientation As a general maintenance practice, match mark and/or note (document/record) the orientation of a component before disconnecting or removing it. 4.1.2 Recommended Tools Individual tool and consumable lists are NOT provided for each bench procedure. The following tools are the minimum required to perform maintenance/repairs on the SAM.
Page 65: Cleaning And Inspection Guidelines
The bench procedures are written to typically provide three layers of detail. The “A” steps provide an experienced technician (who is very familiar with a Hale SAM) a Top Level View of the steps required to R&R the titled component. The “A” steps along with the “1” steps provide an experi- enced technician (who is NOT familiar with a Hale SAM but is familiar with foam systems in gen- eral) a more detailed set of steps to R&R the titled component.
Page 66: Tag And Disconnect Electrical Connections
KEEP ALL I/O PORT COVERS IN PLACE DURING USE TO PREVENT WATER DAMAGE. OTHER ELECTRICAL COMPONENTS MUST NOT BE SUPPLIED FROM THE SAM SYSTEM SUPPLY. DO NOT CONNECT THE PRIMER AND HALE SAM TO THE SAME POWER WIRE. THE CONTROLLER UNIT DEUTSCH CONNECTORS ARE KEYED TO PREVENT INTER- CHANGE OR REVERSE DIRECTION INSERTION.
Page 67: Datalogger Guidelines
As a general maintenance practice, tag (document/photograph/record) the pipe routing and lo- cation (including the mating connector) for each drain line before disconnecting or removing it. When replacing drain lines ensure service loops do NOT allow water to be trapped and cause damage from freezing water.
Page 68: Export Datalogger From Sam Pump Controller
4.3.4.2 Export Datalogger From SAM Pump Controller When directed by Hale Customer Service, download the data log file from the SAM Pump Control- ler by performing the following. A. Open pump operator panel. B. Gain access to USB dongle on rear of SAM Pump Controller. C.
Page 69: Removal And Replacement Of Sam Panel Components
• UV SmartCAFS Installation and Operation Manual (FSG-MNL-00157) 4.4. Removal And Replacement Of SAM Panel Components The SAM system houses the following components on the apparatus; typically, on the pump oper- ator panel. See Figure 32. Figure 32. SAM Panel Components Locations (Operator Panel) •...
Page 70: Figure 33. Sam Panel Components Locations (Officer Side)
The SAM system houses the following components on the apparatus; typically, on the officer side panel. See Figure 33. Figure 33. SAM Panel Components Locations (Officer Side) • • Audio Speaker Buzzer • SAM Control Center (Auxiliary) • Emergency Idle •...
Page 71: Sam Control Center (Master Or Auxiliary)
4.4.1 SAM Control Center (Master Or Auxiliary) A SAM system always provides at least one (1) SAM Control Center touchscreen (the master, Fig- ure 32), and optionally, up to two (2) more SAM Control Center touchscreens (the auxiliary SAM Control Centers). If the master (or an auxiliary) touchscreen (Figure 34) fails to function (the touchscreen provides program storage and execution, touch type man/machine interface, and Wi-Fi [master only] for the mobile tablet) or is damaged;...
Page 72: Figure 34. Sam Control Panel R&R
Figure 34. SAM Control Panel R&R Installation THE CONTROLLER UNIT DEUTSCH CONNECTORS ARE KEYED TO PREVENT INTER- CHANGE OR REVERSE DIRECTION INSERTION. DO NOT FORCE A CONNECTOR WITH- OUT FIRST VERIFYING THE CONNECTORS ORIENTATION AND PLACEMENT. NOTE SAM Control Center orientation is connectors toward the bottom of the panel. A.
Page 73: Sam Pump Controller
4.4.2 SAM Pump Controller A SAM system provides only one (1) SAM Pump Controller touchscreen, if the touchscreen fails to function (the touchscreen provides program storage and execution, touch type man/machine in- terface, governor control, and engine/pump/miscellaneous statuses) or is damaged; replace the SAM Pump Controller as follows.
Page 74: Figure 35. Sam Pump Controller R&R
Figure 35. SAM Pump Controller R&R Installation THE CONTROLLER UNIT DEUTSCH CONNECTORS ARE KEYED TO PREVENT INTER- CHANGE OR REVERSE DIRECTION INSERTION. DO NOT FORCE A CONNECTOR WITH- OUT FIRST VERIFYING THE CONNECTORS ORIENTATION AND PLACEMENT. NOTE SAM Control Center orientation is connectors toward the bottom of the panel. See Figure 35.
Page 75: Buzzer
4.4.3 Buzzer A SAM system provides a warning buzzer on the operators panel to notify the operator the SAM Control Center (or SAM Pump Controller) requires attention. Table 10 provides the SAM system from/to wire listing. Table 10. Buzzer Wiring (From/To Listing) From (Pin) System Power (+12 VDC) SAM Pump Controller, Connector A, Pin 22...
Page 76: Emergency Idle Switch
D. Align and push buzzer thru panel. E. Install ring. (Use slip joint plyers to tighten nut.) F. Connect two [2] wires according to tags. G. Install cable ties cut to R&R buzzer as noted. 4.4.4 Emergency Idle Switch An emergency idle switch (Figure 37) is collocated with each auxiliary SAM Control Center. The switch is a single pole normally open momentary switch.
Page 77: Twister Throttle Controller
NOTE If switch terminals are NOT numbered/marked, there is no need to tag the wires. C. Using screwdriver, at rear of switch, tag and disconnect two [2] wires. D. Using 7/8-in wrench, loosen jam nut from rear of switch. E. Using slip joint plyers, remove protective shroud from front of switch. F.
Page 78: Table 14. Twister Wiring (From/To Listing)
Table 14 provides the SAM system from/to wire listing. Table 14. Twister Wiring (From/To Listing) From Twister To SAM To Control Center (Pin) Breaker Box Black Connector (Power) [Input] Connector 1, Pin 3 (Ground) [Input] Main Ground Stud (On Pump Body) Interlock [Input] (CAN High)
Page 79: Tank Level (Onboard Water Or Foam Tank)
4.4.6 ITL–40 Tank Level (Onboard Water or Foam Tank) SAM utilizes the HALE ITL–40 tank level display system (Figure 39). The SAM operator panel houses the master display unit, the sensor is tank mounted, and optional remoted displays are supported. Refer to the Intelli-Tank Level Operation Manual (P/N 118253) for ITL-40 installation and integration details.
Page 80: Table 17. Itl-40 Tools And Consumables List
NOTES The ITL-40 is shipped already configured and tested to work with SAM. The ITL-40 ONLY requires calibration, do NOT reset the ITL-40 configuration. For square (or rectangular) tanks Hale recommends a 2-point calibration, for T-shaped, oval, or round tanks Hale recommends the appropriate volume calibration (5 or 9-point).
Page 81: Onboard Tank Water Or Foam Tank Level Sensor
4.4.6.1 Onboard Tank Water Or Foam Tank Level Sensor Refer to the ITL–40 Tank Level Quick Start Guide (P/N 118252) or Class 1 Operation Manual, Intelli-Tank Level 40 (P/N 118253) to locate the onboard tank water level pressure transducer (see Figure 40). Figure 40.
Page 82: Miv-E Override Panel
If the ITL–40 fails to display the water level or the transducer is damaged; replace the transducer as follows. Removal A. Locate transducer. B. Note cable tie locations, cut ONLY ties required to R&R ITL–40 pressure trans- ducer. C. Tag and disconnect electrical connector. D.
Page 83: Table 20. Miv-E Override Switch Wiring (From/To Listing)
Table 20 provides the SAM system from/to wire listing. Table 20. MIV–E Override Switch Wiring (From/To Listing) From MIV–E Override To MIV Valve To Breaker Box Switch Connector Pin Drive Module Pin Connector 3 Pin (SYSTEM GROUND) Main Ground Stud (On Pump Body) (DIRECTION SW SIGNAL) 10 (DIRECTION SW SIGNAL)
Page 84: Miv Activation Button
NOTE If the air bleed valve from the kit requires assembly, connect the check valve to the straight thru port on the air bleed valve with the flow indicator (arrow) pointing away from the air bleed valve and connect the adapter to the check valve output (output of adapter goes to atmosphere), then connect the 90 degree elbow to the top center port of the air bleed valve and the tubing to the input of the elbow as tagged.
Page 85: Table 22. Miv Activation Button Wiring (From/To Listing)
The LIGHTED PB SWT # X (X = 1 thru 3) four [4] pin Deutsch connector (female) connects to the corresponding MIV-Auto Module harness, LIGHTED PUSHBUTTON SWT # X connector (Male) and the primary MIV–A module. See Table 22 for the MIV activation button from/to wire listing. NOTE If equipped with a fourth master intake valve, connect the fourth MIV Activation Button per 513-00145-004 (This harness is only used when four or more master intake valves...
Page 86: Table 23. Miv Activation Button Tools And Consumables List
Refer to Table 23 for a list of tools and/or consumables required for this procedure. Table 23. MIV Activation Button Tools And Consumables List Standard Tools Special Tools Consumables PPE (Eye and Hand Protection) None Shop Rag(s) (As Required) 1-in Wrench Cleaner (See paragraph 4.1.3, page 44.) Wire Cutter...
Page 87: Optional Navigator Controllers
Gen 2 valves and as long as physical space allows the valves are interchangeable. AN OFF-THE-SHELF AKRON BRASS SWING-OUT VALVE WILL NOT FUNCTION IN A HALE SAM SYSTEM. DO NOT USE ONE FOR SUBSTITUTION OR REPLACEMENT PUR- POSES. 4.5.1 Recording SAM System Information Parameters IF THE SAM SYSTEM IS TURNED OFF IN CONFIGURATION MODE, WHEN TURNED ON, THE SYSTEM WILL RETURN TO CONFIGURATION MODE.
Page 88: Discharge And Special Purpose Valve Removal And Replacement
AKRON BRASS SWING-OUT VALVES FROM A DISCHARGE PORT WILL NOT FUNCTION IN THE PLACE OF ANY SPECIAL PURPOSE VALVE (TF, T2P, PONY) IN A HALE SAM SYS- TEM. DO NOT USE ONE FOR SUBSTITUTION OR REPLACEMENT PURPOSES. Tank Fill Valve The tank fill supports water supply management (intake) even though it connects to a pump dis- charge port (it is used to replenish the water supply provided by the onboard water tank).
Page 89: Table 24. Akron Brass Valve R&R Tools And Consumables List
(refer to FSG-PL-01209) and Qmax (refer to FSG-PL-01510) port diagram located on the flash drive provided with the pump or available from the Hale Products website (www.hale- products.com). Refer to Table 24 for a list of tools and/or consumables required for this procedure. Table 24.
Page 90 For all except 4-in valves, use a 9/16-in socket and driver (or socket and ratchet, or wrench), remove four [4] 3/8–16 X 1 1/2-in long screws (with lock and flat washers). For 4-in valves, use 3/4-in socket and driver (or ratchet, or wrench) to remove four [4] 1/2–13 X 1 1/ 2-in long screws (with lock and flat washers).
Page 91: Verifying Valve Operation After Valve Clocking
C. If required, perform paragraph 6.1.3.1 (page 188) to update new valves memory/parameters. (The information required to perform an update [using the Device Select Menu procedure] was noted/recorded in paragraph 4.5.1 [page 67]). D. Perform paragraph 6.2, Identifying Which Physical Valve A UID Corresponds To, (page 187) to verify replacement valve contains correct programming/software.
Page 92: Removal And Replacement Of Sam Mivs
If a valve fails to rotate in the correct direction, jams, or when the motor shaft is rotated in the correct direction the valve ball rotates in the wrong direction; reference Akron Brass installation instructions for Style 8600 Electric Actuator With Motor Driver (P/N 123248) and correct valves sector gear location/orientation and then perform this procedure again.
Page 93: Figure 46. Barometric Sensor R&R
Refer to Table 27 for a list of tools and/or consumables required for this procedure. Table 27. Barometer Sensor Tools And Consumables List Standard Tools Special Tools Consumables PPE (Eye and Hand Protection) None Shop Rag(s) (As Required) 7/16-in Wrench Barometric Sensor <See FSG-MNL-00212, Table 1, Barometer Sensor>...
Page 94: Flowmeter (Optional - Used With Sam Or Navigator Pro 9335 Only)
C. Install two (2) 1/4–20 X 1-1/2-in long machine screws (each with one lock and one flat washer). NOTE: Do NOT over tighten screws. D. Connect electrical connector according to tags. 4.7.2 Flowmeter (Optional – Used with SAM Or Navigator Pro 9335 Only) Reference section 5, System Installation, of Style 9335 Navigator Pro With Pressure, Flow CAFS And Valve Control Installation, Operating, And Maintenance Instructions (P/N 126914) found on the flash drive provided with the system or on the Hale website (www.haleproducts.com).
Page 95: Pressure Sensors/Transducers
E. Remove flowmeter from piping/manifold/spacer. F. Note flowmeter orientation (specifically – locator pin). Installation A. Lubricate flowmeter O-rings. (See Table 6.) B. Install new flowmeter. (Orient flowmeter so locator pin fits into adaptor/saddle clamp.) C. Install retaining nut over flowmeter (thread electrical cable thru nut) and hand start threads.
Page 96: Ab Swing-Out Valve Pressure Sensor
Table 30. Pump Intake/Discharge Pressure Sensor Wiring (From/To Listing) From Pressure Transducer Pin To MatrIIX/Pressure Governor Connector B Pin Pump Intake Side (Ground) (Power) (Sensor Negative Reference) [Output] (Pressure Signal) (Intake Signal) [Input] Pump Discharge Side (Ground) (Power) (Sensor Positive Reference) [Output] (Pressure Signal) (Discharge Signal)
Page 97: Table 32. Discharge Valve Pressure Sensor Tools And Consumables List
Refer to Table 32 for a list of tools and/or consumables required for this procedure. Table 32. Discharge Valve Pressure Sensor Tools And Consumables List Standard Tools Special Tools Consumables PPE (Eye and Hand Protection) None Shop Rag(s) (As Required) Wire Cutter Cable Ties (As Required) 3/4-in Wrench...
Page 98: Legacy Ab Valve Pressure Sensor
4.7.3.1.1 Legacy AB Valve Pressure Sensor Legacy SAM systems utilized Akron Brass pressure sensors (Figure 49). When these sensors fail, replacement with the newer Hale sensor is required. The legacy and new sensor wiring is the same. See Table 29 (page 75) and Table 33. Figure 49.
Page 99: Water Column Sensor
4.7.3.3 Water Column Sensor The SAM system water column sensor utilizes the same Hale pressure transducer as the ITL-40 tank level transducer except the transducer is mounted on the SAM drain assembly (located at the bottom of the gearbox). Electrically the transducer connects to the MIV–A module, see Table 31, page 76.
Page 100: Gearbox Oil Level
4.7.4 Gearbox Oil Level Hale ships the gearbox with all gear oil drained and the gearbox must be filled with the correct amount of oil prior to operation. When oil covers the tip of the level sensor, the sensor outputs a +5 VDC signal.
Page 101: Figure 51. Gearbox Oil Level Sensor R&R
Gearbox Oil Lever Sensor Cleaning Prior to R&R, clean the gearbox oil level sensor prism surface as follows. A. Note cable tie locations, cut ONLY ties required to remove sensor. B. At sensor, tag and disconnect electric connector. C. Using 7/8-in wrench, remove sensor. See Figure 51. D.
Page 102: Temperature
Only torque the sensor one turn (maximum) past the hand tight engagement. Over torqueing the sensor can result in permanent damage to the sensor. C. Hand tighten sensor until snug. D. Using 7/8-in wrench, torque an additional 1 turn. E. Connect electric connector according to tags. F.
Page 103: Gearbox Temperature Sensor
4.7.5.1 Gearbox Temperature Sensor If a gearbox temperature sensor fails or is damaged, replace the sensor as follows. See Figure 52. Removal A. Note cable tie locations, cut ONLY ties required to R&R sensor. B. At sensor, tag and disconnect electric connector. C.
Page 104: Water Detection Sensors
C. Hold reducer bushing stationary. D. Remove sensor. Installation If the brass reducer bushing is damaged, replace the bushing. See Table 39. A. Apply Loctite 580 to threads of new sensor. B. Install sensor. C. Connect electric connector according to tags. D.
Page 105: Figure 55. Water Detection Sensor R&R (Autolube And Gearbox)
Table 42. Water In Primer Sensor Wiring (From/To Listing) From Sensor Pin To MIV–A Module Connector B Pin To Breaker Box (Power) Connector 1 Pin 3 (Ground) (Signal) WTR COLUMN SIGNAL [Input] Connects to system ground (NOT Sensor Module). Refer to Table 43 for a list of tools and/or consumables required for this procedure. Table 43.
Page 106: Zero Pressure Solenoid
Installation If the brass reducer bushing at the primer is damaged, replace the bushing. See Table 43 and Figure 56. A. Apply Loctite 580 to threads of new sensor. (Use sealant sparingly to prevent sensor damage.) B. Install sensor. Figure 56. Water Detection Sensor R&R (Primer) NOTE Do NOT overtighten sensor.
Page 107: Figure 58. Removal Of The Module Mounting Brackets
Table 44 provides the solenoids electrical connections. Table 44. Zero Pressure Solenoid Wiring (From/To Listing) From To Sensor Module, Connector A, Pin To Breaker Box Connector 1 Pin 3 AUTOLUBE SOL NEG [Output] Refer to Table 45 for a list of tools and/or consumables required for this procedure. Table 45.
Page 108: Figure 59. Circuit Breaker Box Removal
D. Perform removal portion of circuit breaker box R&R procedure. (See Figure 59) and section 4.10.6, page 115.) Figure 59. Circuit Breaker Box Removal E. Perform removal portion of Autolube assembly R&R. See Figure 60 and reference Midship Pump Technical Manual (FSG-MNL-00200). Figure 60.
Page 109: Smart Anode Removal And Replacement
NOTE Do NOT overtighten solenoid. C. Hand tighten solenoid until snug. D. Using slip joint plyers, torque an additional 1 turn (2 turns maximum) past hand tight engagement. E. Install solenoid on nipple. F. Perform installation portion of Autolube assembly R&R. Reference Midship Pump Technical Manual (FSG-MNL-00200).
Page 110: Figure 62. Indication Of Failed Smart Anode
Refer to Table 47 for a list of tools and/or consumables required for this procedure. Table 47. Smart Anode Tools And Consumables List Standard Tools Special Tools Consumables PPE (Eye and Hand Protection) None Shop Rag(s) (As Required) Wire Cutter Cable Ties (As Required) 1-3/4-in Wrench Smart Anode...
Page 111: Removal And Replacement Of Sam Modules
Figure 63. Indication Of Good Smart Anode Install cable ties cut to R&R sensor as noted. 4.8. Removal And Replacement Of SAM Modules All SAM modules provide a power (PWR), buss (BUS), and communication (COM) indication. See Figure 64. Verify the red PWR, amber (BUS) and Green (COM) LEDs are illuminated steady. If the Green (COM) LED is flashing slowly (2 Hz) the module is communicating with the CAN bus how- ever the module is not receiving messages.
Page 112: Matriix/Pressure Governor Module
Figure 65. SAM Module Locations The system is designed with this limitation in mind; harnesses are clearly labeled, routed, and split out so that only the correct harness connector reaches the correct module location (provid- ing the correct module is installed in that position) to assure proper connections. See Figure 66 for the general appearance of the two types of SAM modules.
Page 113: Figure 67. Matriix Pressure Governor Module
Figure 67. MatrIIX Pressure Governor Module Figure 68. Governor Module Interface Layout The matrIIx/pressure governor module installs on the Hale provided bracket located on the front of the pump directly above the circuit breaker box and Autolube assemblies (right most module). Connect the module according to Table 48.
Page 114: Table 49. Matriix Pressure Governor Module Tools And Consumables List
Table 48. MatrIIx/Pressure Governor Module Wiring (From/To Listing) – CONTINUED Module Connector/Pin (From) Sensor Connector/Pin (To) B Keyed Connector (Mates with Black Harness Connector) (Sensor Positive Reference) [Output] (High Pressure Signal) [Input] (Sensor Negative Reference) [Output] (Sensor Positive Reference) [Output] (Intake Signal) [Input] C (Intake Pressure Sensor Signal)
Page 115: Sensor Module
THE MODULE DEUTSCH CONNECTORS ARE KEYED; HOWEVER, ALL MODULES UTILIZE THE SAME TWO KEYS. VERIFY THE HARNESS LABEL AND THE MODULE PART NUMBER TO ENSURE THE CORRECT MODULE AND HARNESS CONNECTOR ARE BEING CON- NECTED. D. Connect electrical connectors according to tags. E.
Page 116: Table 50. Sensor Module Wiring (From/To Listing)
Table 50. Sensor Module Wiring (From/To Listing) Module Connector/Pin (From) Sensor Connector/Pin (To) A Keyed Connector (Mates with Grey Harness Connector) (GB Oil Level Signal) [Input] Gearbox Oil Level (CAN High) [Buss] Green CAN Bus Connector (CAN Shield) [Buss] Green CAN Bus Connector (Auxiliary Input 1) [Input] (Auxiliary Input 2)
Page 117: Sam Miv-A Module
Refer to Table 51 for a list of tools and/or consumables required for this procedure. Table 51. Sensor Module Tools And Consumables List Standard Tools Special Tools Consumables PPE (Eye and Hand Protection) None Cable Ties (As Required) Wire Cutter Sensor Module <See FSG-PL-01501, -01502, or -01513, Sheet 3>...
Page 118: Figure 71. Miv-A Module
Figure 71. MIV–A Module NOTES When the master MIV–A module is replaced, the new modules address switch must be set to A. See paragraph 4.12.5, page 140. When the slave MIV–A module is replaced, the new modules address switch must be set to 0.
Page 119: Table 53. Miv-A Module Tools And Consumables List
Table 52. MIV–A Module Wiring (From/To Listing) – CONTINUED Module Connector/Pin (From) Sensor Connector/Pin (To) A Keyed Connector (Mates with Grey Harness Connector) – CONTINUED (Pump Body Prime) [Output] 4-Way Valve (Pump Body Prime) See Table 69 Diode 2 See Table 56 (PB SW LED #2) [Output] MIV-Auto Placard For LH MIV...
Page 120: Miv 2.0 Drive Module
C. Tag and disconnect (#2 Phillips screwdriver) POWER connection. D. Using 7/16-in wrench, remove two [2] 1/4–20 x 1.25-in hex head screws (each with one [1] lock and one [1] flat washer). E. Remove module. Installation Visually inspect MIV–A module address switch as follows. •...
Page 121: Table 54. Miv-A Drive Module Wiring (From/To Listing)
Table 54. MIV–A Drive Module Wiring (From/To Listing) Module Pin (From) MIV/Harness Pin (To) (Power) [Input] System Power Refer to FSG-PL-01507 (CAN High) [Buss] Green CAN Bus Connector (Motor A) [Output] A (MIV Motor) (Motor B) [Output] B (MIV Motor) (Open Indicator) [Output] 6 (MIV–Rocker Switch)
Page 122: Removal And Replacement Of Pump Primer And Air Bleed Components
Verify drive module address, see Table 56 and refer to FSG-MNL-00162 (MIV Control Module Op- eration Manual). Table 56. MIV–A Drive Module Address List Associated MIV Location Drive Module Address LH MIV RH MIV RH Bottom MIV T Port Remote Mounted MIV 4.9.
Page 123: Priming Feature Assembly
4.9.2 Priming Feature Assembly The priming feature assembly consists of a large bracket that uses multiple components to route the ESP primers vacuum to the selected MIV for drafting purposes. Refer to FSG-PL-01514 for a priming (including air bleed) tube routing diagram. The number of each component varies de- pending on the number of Hale MIVs order for that specific SAM system, in general the bracket houses: multiple 4-way air valves, multiple PF valve assemblies, and the pump body air bleed so- lenoid.
Page 124: Table 58. Priming Feature Assembly Tools And Consumables List
Refer to Table 58 for a list of tools and/or consumables required for this procedure. Table 58. Priming Feature Assembly Tools And Consumables List Standard Tools Special Tools Consumables PPE (Eye and Hand Protection) None Shop Rag(s) (As Required) Wire Cutter Cable Ties (As Required) 15/16-in Wrench (or Socket And Priming Feature Assembly Bracket...
Page 125: Sam Drain Valve Block Assembly
F. Connect pneumatic tubing (1/4-in tubing) according to tags. G. Restore truck air pressure to assembly and check for leaks. H. Connect priming/drain tubing (3/4-in tubing) according to tags. Install cable ties cut to R&R module as noted. 4.9.3 SAM Drain Valve Block Assembly The SAM drain valve block mounts at the bottom rear of the gearbox (Figure 76) and requires flex tube plumbing, truck compressed air, and harness connection.
Page 126: Air Bleed Valves (Miv And Pump Body)
D. Tag and disconnect pneumatic tubing (1/4-in tubing). E. Tag and disconnect priming/drain tubing (3/4-in tubing). F. Using 15/16-in wrench, remove two [2] 5/8–11 x 1-1/2-in long screws (each with one lock and one flat washer). G. Remove SAM drain valve block assembly. H.
Page 127: Table 59. Air Bleed Valve (Solenoid) Wiring (From/To Listing)
Table 59. Air Bleed Valve (Solenoid) Wiring (From/To Listing) From ABV To MIV 2.0 Drive Module Circuit Breaker Box Connector 1– Pin System Power (Bottom MIV) (LH MIV) (RH MIV) (T-Port MIV) Earth Ground ABV Solenoid — ABV Solenoid — [Output] Refer to Table 60 for a list of tools and/or consumables required for this procedure.
Page 128: Removal And Replacement Of Miscellaneous Sam Components
F. Using 7/16-in wrench, remove 1/4–20 X 0.75 in long hex head screw from mounting clamp. G. Remove solenoid (with clamp attached). H. Remove clamp. Verify check valve is functional. Installation A. Install mounting clamp on solenoid. B. Position solenoid/clamp on applicable MIV. C.
Page 129: Figure 77. Audio Amplifier
Figure 77. Audio Amplifier Figure 78. Ground Loop Isolator Connect the amplifier according to Table 61. Table 61. Audio Amplifier Wiring (From/To Listing) From Audio To Ground To SAM To Circuit Amplifier Loop Isolator Speakers Breaker Box Pwr Neg (Black Wire) Ground Stud (Pump Body) Pwr Pos (Red Wire)
Page 130: Audio Speakers
4.10.2 Audio Speakers SAM utilizes four sealed, waterproof surface mounted speakers. See Figure 79. The speakers mount (behind both pump panels and beneath the apparatus body) and provides an enhanced audible alert in the form of a verbal announcement when the SAM Control Center requires opera- tor attention.
Page 131: Figure 80. Auxiliary Cooling Solenoid And Fittings
Refer to Table 63 for a list of tools and/or consumables required for this procedure. Table 63. Auxiliary Cooling Solenoid Tools And Consumables List Standard Tools Special Tools Consumables PPE (Eye and Hand Protection) None Shop Rag(s) (As Required) Wire Cutter Cable Ties (As Required) 9-16-in Wrench Auxiliary Cooling Solenoid...
Page 132: Dc-To-Dc Converter
C. Using 9/16-in wrench, tighten elbow. (Use vise or 13/16-in wrench to hold sole- noid.) D. Apply Loctite 580 to threads of existing/new nipple. (Use sealant sparingly to prevent check valve/solenoid damage.) E. Install solenoid. NOTE Do NOT overtighten solenoid. F.
Page 133: Wi-Fi Router
4.10.5 Wi–Fi Router The Wi-Fi router/antenna (Figure 82) utilizes the ethernet POE electric harness. Antenna place- ment is important for Wi-Fi reception. The antenna needs to mount high on the apparatus, how- ever the antenna should NOT alter the trucks height. Mounting the antenna in a metal en- closed/surrounded area may result in poor Wi-Fi reception (canyon effect).
Page 134: Figure 83. Wi-Fi Router/Antenna Connectors
Figure 83. Wi-Fi Router/Antenna Connectors D. Slide seal down harness. E. Remove seal housing. (Same as cover, see above.) F. At antenna/router, tag and disconnect electric connectors. NOTES Hale recommends replacing the housing, seal, and cover when replacing the antenna, however, if the existing housing, seal, and cover are NOT broken/cracked/damaged /discolored/hardened/leaking/etc.
Page 135: Sam System Power
NOTE The antennas are labeled (2.4 and 5 Ghz) and must be installed on the correct output stud. The antenna simultaneously outputs on the 2.4 and 5 Ghz bands (up to 600 Mbps) at 600 mW. J. Install new 2.4 and 5 Ghz antennas on top of new antenna/router. K.
Page 136: Table 66. Circuit Breaker Box Wiring (From/To Listing)
Table 66. Circuit Breaker Box Wiring (From/To Listing) Connector 3 Connector 2 Connector 1 CB # CB # CB # See Table 67 for circuit breaker number 1 connectivity details. Refer to FSG-PL-01507 for all AB Swing-out vale and Hale MIV circuits. Table 67.
Page 137: Table 68. Circuit Breaker Box Tools And Consumables List
Refer to Table 68 for a list of tools and/or consumables required for this procedure. Table 68. Circuit Breaker Box Tools And Consumables List Standard Tools Special Tools Consumables PPE (Eye and Hand Protection) None Heavy Duty Cable Ties (As Required) Wire Cutter Circuit Breaker Box <See FSG-PL-01501, or -01502, Sheet 3 or FSG-PL-01513, Sheet 5>...
Page 138: Legacy Circuit Breaker Junction Box
Place first 6–32 X 1/2-in mounting screw in easiest to access corner of circuit breaker box. Using #2 Phillips screwdriver, hold screw in place while mounting circuit breaker box onto bracket with screw thru associated hole in bracket. Place new locking nut against screw and start screw into nut, do NOT tighten. Place next screw into next corner of circuit breaker box, using #2 Phillips screwdriver, push screw thru box and bracket, then start new locking nut on screw.
Page 139: Figure 87. Oem Located Legacy Cb Junction Box
For legacy SAM systems utilizing RME or DSD pumps, the OEM locates the circuit breaker junc- tion box utilizing the generic power stud/circuit breaker junction box bracket. See Figure 87. Figure 87. OEM Located Legacy CB Junction Box For legacy circuit breaker junction boxes, a maximum of two [2] AB Swing-out vales are con- nected to each circuit breaker (MIVs may connect to the bus bar or have been externally powered by the OEM).
Page 140: Circuit Breaker Checks
The legacy circuit breaker box houses seven [7] 30 Amp auto resetting circuit breakers (always check for a failed breaker prior to replacing the entire circuit breaker box) however if the box fails it must be replaced with the current circuit breaker box. This requires a new mounting bracket and harnesses which must be ordered by contacting Hale Customer Service (800-533-3569) and providing the information from the systems ID tag.
Page 141: Sam Tablet Replacement
Figure 89. Tablet Power Supply Converter/Fuse • Check for 20 VDC at tablet docking station (Figure 90). Figure 90. Tablet Docking Station/Mount 4.10.7.1 SAM Tablet Replacement Refer to FSG-MNL-00210 (SAM OIM), section 6.3.1.6 (Mobile Operations – From Tablet) for SAM tablet power on and unlocking information.
Page 142: Figure 91. Tablet Password Screen
Figure 91. Tablet Password Screen C. Go to Wi-Fi settings. D. Input SSID and Wi-Fi password provided by Hale. (The SSID and password may have been pre-configured before delivery.) E. If required, touch save. F. Touch home button. G. Power on apparatus (do not engage the pump) and wait for manual mode screen (Figure 92) to appear.
Page 143: Bench Procedures
M. Place apparatus in pump gear. SAM enters Auto Mode. N. Verify tablet mirrors SAM Control Center display. See Figure 93. Figure 93. Auto Mode Screen (Tablet/SAM Control Center) O. Using tablet, open an intake. P. Then open a discharge. If SAM functions properly, the tablet is ready for use.
Page 144: Figure 94. 4-Way Air Valve
Figure 94. 4-Way Air Valve Table 69. 4-Way Air Valve Wiring (From/To Listing) Air Bleed Drain 4-Way Air Valve From 4-Way Air Valve Pin To MIV–A Module Connector B Pin AB Drain (AB Drain) [Output] System Ground (Blk Wire) Pump Body PF Valve 4-Way Air Valve From 4-Way Air Valve Pin To MIV–A Module Connector A Pin PUMP BODY PRIME...
Page 145: Figure 95. 4-Way Valve Air Line Labels And Mounting
Perform the Removal portion of paragraph 4.9.2 (page 103), Priming Feature Assembly, and take the removed assembly to a stable work surface or bench. Refer to Table 70 for a list of tools and/or consumables required for this procedure. Table 70. 4-Way Air Valve Consumables List Standard Tools Special Tools Consumables...
Page 146: Pf Air Cylinder R&R
4.11.3 PF Air Cylinder R&R Perform the Removal portion of paragraph 4.9.2 (page 103), Priming Feature Assembly, and take the removed assembly to a stable work surface or bench. Refer to Table 71 for a list of tools and/or consumables required for this procedure. Table 71.
Page 147: Pf Valve Assembly R&R
4.11.4 PF Valve Assembly R&R To determine whether each PF assembly is functioning properly, use the SAM Pump Controller MIV Diagnostic Screen (password 6060). Select the OUTPUT screen and look for the Pre-Prime 1 thru 4, Prime Body, or AB Drain icons. With the 4-way air valve connected to the SAM harness, touch the applicable icon.
Page 148: Figure 97. Pf Valve Block Mounting Screw Access
Figure 97. PF Valve Block Mounting Screw Access Removal A. Match mark blank plate to top PF valve, and cover to bottom PF valve. B. Using two 7-16-in wrenches, remove PF valve block, blank plate, and cover re- taining bolts. Hold nut (with washers), remove bolt (with washer). See Figure 98. Figure 98.
Page 149: Figure 99. Pf Valve Block Removal From Bracket
NOTE If ONLY replacing the top or bottom most PF valve, ONLY remove that valves mounting hardware. Otherwise, remove all mounting hardware. There is one spacer for each mounting screw, the spacers are located between the valve body and the bracket. C.
Page 150: Figure 100. Pf Valve R&R
G. At bottom of valve stack, remove cover (with fitting in place). Figure 100. PF Valve R&R H. Remove top and bottom O-rings. (The top O-ring may be on the blank plate or on the top valve; the other O-ring may be on the cover or on the bottom valve; see Figure 100.) Separate failed PF valve from stack.
Page 151: Post Removal And Replacement Configuration Procedures
N. Connect all air lines according to notes/tags. O. Install all cable ties cut to R&R PF valve. Perform the Installation portion of paragraph 4.9.2 (page 103), Priming Feature Assembly. 4.12. Post Removal And Replacement Configuration Procedures Following the R&R of specific SAM components, configuration/settings require change/update. Perform the referenced configuration procedure, then perform all referenced adjustments, SAM setup/configuration, and/or post R&R Testing before returning the apparatus to service.
Page 152: Auxiliary Sam Control Center Setup
Figure 101. MENU Screen G. Touch Send BAM + Reboot To GUI button. Wait for SAM Landing Screen to dis- play. H. Perform Updating The Tablet After SAM Setup/Configuration Changes (see para- graph 4.13, page 143) to verify secure Wi-Fi connection/communication with SAM Tablet.
Page 153: Figure 103. System Option Screen (Bam Tab Selected)
NOTE If the Loading Icon (see Table 1) is displayed when the System Options button is touched, hold the System Options button until the Loading Icon completes the circle and the Enter Password screen is displayed. Enter technician level 2 password (See Table 2, page 35). On System Options screen (Figure 103) Touch BAM menu tab.
Page 154: Figure 105. Configuration Mode Menu Screen
Figure 105. Configuration Mode MENU Screen D. Exit Configuration Mode as follows. At top center of screen, touch home icon. DEVICE SELECT screen is displayed. At top right of screen, touch Retrieve BAM button. At top center of screen, touch Menu icon. Configuration Mode MENU Screen is dis- played.
Page 155: Configuration/Setup For Sam Pump Controller
4.12.3 Configuration/Setup For SAM Pump Controller See applicable titled paragraph below for instructions for each item. • Set Date • Set Time • Set Language • Set Units • Setup Governor Presets • Set Voltage 4.12.3.1 How To Set Time And Date Perform the following to set the time and date for SAM.
Page 156: Enable/Disable Suction Pressure Governor
Figure 108. Governor Menu Screen (Set Units) Touch Unit of Measure row. J. Touch wrench and gears button (lower right-hand corner). Figure 109. Select Units Screen K. Touch applicable text box (right-hand half of screen). L. Touch check mark button (lower right side of left-hand half of screen). Governor Menu screen (Figure 109) is displayed.
Page 157: Figure 110. Suction Pressure Governor Enable Row Selected
D. Touch SPG Enable row (see Figure 110). Figure 110. Suction Pressure Governor Enable Row Selected E. Touch wrench and gears button (lower right-hand corner). F. On Suction Pressure Governor Enable Setting screen (Figure 111), touch Suction Pressure Governor Enabled button (Figure 112). Figure 111.
Page 158: How To Change/Set Low Intake Alert Trigger Point
4.12.3.4 How To Change/Set Low Intake Alert Trigger Point The low intake alert trigger point is set from the Pump Controller, Governor Menu, page 4 screen (see Figure 157) by setting the suction pressure governor enable pressure (PSI). Perform the fol- lowing to change or set the low intake alert trigger point for SAM.
Page 159: Suction Pressure Hysteresis (Psi)
G. Touch check mark button (lower right-hand corner of SPG User Set Point portion of screen). H. Touch Save button (lower right-hand corner of screen). Touch Back Arrow button (lower left-hand corner of screen). 4.12.3.5 Suction Pressure Hysteresis (PSI) Increase the Suction Pressure Governor Hysteresis pressure to prevent undesirable toggling in and out of Suction Pressure Governor mode due to small changes in pump pressure.
Page 160: Set Miv-A Module Address (Master) (Slave)
Touch desired value (use number buttons on right-hand side of screen). Touch ENTER button. (Touch CLEAR ALL or BACK SPACE button to delete all text box data or delete only last data entry.) G. Touch check mark button (lower right side of left-hand half of screen). Updated Governor Menu screen (Figure 115) is displayed.
Page 161: Wi-Fi Router Configuration
C. Set dial to required address as follows. See Figure 117. Figure 117. MIV–A Module Address Switch If Master: using a 1/16-in straight blade screwdriver, turn center of address switch until arrow points to position A. (Switch is shown in position A on Figure 117.) If Slave: using a 1/16-in straight blade screwdriver, turn center of address switch until arrow points to position 0.
Page 162: Configuration Procedures
If the Wi-Fi antenna/router you received does NOT automatically pair with your SAM Control Cen- ter and/or your SAM tablet contact Hale Customer Service (800-533-3569) and inform Hale of the problem. 4.12.6 ITL–40 Configuration Procedures SAM uses the ITL–40 CAN address to display the tank level data of that ITL–40. The water tank, foam tank A, and foam tank B should all have different addresses.
Page 163: Foam Tank A
A. Touch System Options button (or touch and hold if loading icon appears, see Fig- ure 119). System Options screen (Figure 120) is displayed. Figure 119. System Options Loading Icon B. When System Options screen (Figure 120) displays, enter BAM/Wi-Fi password. (This password is ONLY available via attending the Hale SAM Training course.)
Page 164: Updating Another Sam Control Center After Sam Setup/Configuration Changes
Figure 120. System Options Screen C. On BAM Request/Wi-Fi Options screen (Figure 121), touch BAM REQUEST button. Wait for progress bar (black bar below button turns green to indicate progress) to complete. Figure 121. BAM Request Screen D. When complete, DONE is displayed (replaces progress bar) to indicate update was successful.
Page 165: Post Removal And Replacement Testing
C. On updated SAM Control Center, touch System Options button (or touch and hold if loading icon appears). See Figure 25 (page 34). Wait for Enter Password screen to be displayed. D. On Enter Password screen, enter Level 2 password. (All OEM/Technician pass- words are ONLY provided at Hale training.) E.
Page 166: Testing Master Intake Valve Inputs/Outputs
A. Using the SAM Pump Controller, access the SAM Pump Controller Menu and Password Enter screens. See paragraph 2.6.1.2, page 35. B. On Password Enter screen, touch Output/Input password digits (see Table 3, page 36) and then touch Enter button. Input screen displays (see Figure 122). Figure 122.
Page 167: Figure 123. Sam Pump Controller I/O Testing (Outputs Screen)
• CAN Outputs The MIV–A Outputs/Inputs can be individually controlled and tested. See Figure 123 thru Figure 126. Figure 123. SAM Pump Controller I/O Testing (Outputs Screen) Figure 124. SAM Pump Controller I/O Testing (Inputs Screen) Figure 125. SAM Pump Controller I/O Testing (CAN Outputs Screen)
Page 168: Testing Miv Outputs
Figure 126. SAM Pump Controller I/O Testing (With Active Output) Touch the red bubble to activate the desired output and it will turn from red to green to show that the output signal is being sent. Touch again to turn off signal. Note that the output buttons are not getting feedback from the corresponding SAM component so the device must be checked for activation.
Page 169: Testing Miv Inputs
Figure 127. TS Outputs Screen – Pre-Prime #1 Active 4.15.3.2 Testing MIV Inputs When an Input is triggered, the red bubble turns green. See Table 75 below for how to trigger the corresponding inputs. Table 75. MIV–A Input Testing Button Name Function Comments Button 1...
Page 170: Testing Priming And Air Bleed Component (Can Outputs)
Figure 128. TS Input Screen C. Observe solenoid activates. (When button is pressed a small click can be heard and felt.) D. Verify solenoid clicking (under test) is plumbed to desired MIV. E. If successful, cycle SAM power. Otherwise, verify power and CAN status on Green bus. If both are good, replace the solenoid un- der test.
Page 171: Testing Sam Speaks (Audio Alerts)
4.15.7 Testing SAM Speaks (Audio Alerts) The TEST AUDIO page is (or pages are- there are two) used to verify the audio portion of SAM is functioning correctly, when activated the alarms, warnings and spoken audio files will broadcast through the speakers. This page is useful after replacing an audio system component. This page is also useful to check audio volume adjustment.
Page 172: Troubleshooting
Table 77 provides a list (by file name and audio type) for use in selecting the files that are useful for checking the audio components and setting the SAM volume level. Table 77. Audio Files Useful For Audio Testing/Adjustment File Name Audio Type LOW FOAM TANK Spoken Audio...
Page 173: Table 78. Hale Sam System Level Scr Table
Table 78. Hale SAM System Level SCR Table SYMPTOM CAUSE REMEDY AUXILIARY INTAKE LOST USE MANUAL Wire Harness Discon- Check harness power connections OVERRIDE nected/Damaged and circuit breakers. See para- graph 4.3.5 (page 48) and sec- tion 4.10.6 (page 115).
Page 174 Table 78. Hale SAM System Level SCR Table – CONTINUED SYMPTOM CAUSE REMEDY DISCHARGE VALVE NETWORK Wire Harness Discon- Check harness power connections ERROR, USE MANUAL OVERRIDE nected/Damaged and circuit breakers. See para- (CAN Communication Lost With Multi- graph 4.3.5 (page 48) and sec- ple Discharges) tion 4.10.6 (page 115).
Page 175 Table 78. Hale SAM System Level SCR Table – CONTINUED SYMPTOM CAUSE REMEDY FOAM COMM LOSS, USE SMART- Wire Harness Discon- Check Foam System harness power FOAM DISPLAY – CONTINUED nected/Damaged connections. Refer to SmartFOAM – CONTINUED manual (FSG-MNL-00158). Check harness Orange CAN bus con- nections.
Page 176 Table 78. Hale SAM System Level SCR Table – CONTINUED SYMPTOM CAUSE REMEDY HIGH GEARBOX TEMPERATURE Equipment Failure Verify gearbox cooling tubes are con- (SAM reported gearbox oil tempera- nected and flowing water. Install or ture exceeded 215 °F [102 °C])
Page 177 Table 78. Hale SAM System Level SCR Table – CONTINUED SYMPTOM CAUSE REMEDY INTAKE MODULE SIGNAL LOST MIV–A Slave Lost Comm Check harness power connections - OPERATE REAR AND IN-LINE IN- (Controls Bottom And and circuit breakers. See para- TAKES WITH PANEL SWITCHES T-port MIVs) graph 4.3.5 (page 48) and sec-...
Page 178 Table 78. Hale SAM System Level SCR Table – CONTINUED SYMPTOM CAUSE REMEDY LH INTAKE MIV MODULE SIGNAL LH MIV Valve Drive Check harness power connections LOST - OPERATE LH MIV WITH MAN- Module Lost Comm and circuit breakers. See para- UAL OVERRIDE KNOB graph 4.3.5 (page 48) and sec-...
Page 179 Table 78. Hale SAM System Level SCR Table – CONTINUED SYMPTOM CAUSE REMEDY LOW VOLTAGE CRITICAL Apparatus Charging Sys- Check system voltage with multime- ter: If voltage is low, troubleshoot and re- pair apparatus charging system. If voltage is fine, perform Voltage Calibration (see paragraph 5.6,...
Page 180 Table 78. Hale SAM System Level SCR Table – CONTINUED SYMPTOM CAUSE REMEDY PRESSURE CONTROL SIGNAL LOST Wire Harness Discon- Check harness power connections (Matrix Governor Signal Lost) nected/Damaged and circuit breakers. See para- Does Twister work? graph 4.3.5 (page 48) and sec- tion 4.10.6 (page 115).
Page 181 Table 78. Hale SAM System Level SCR Table – CONTINUED SYMPTOM CAUSE REMEDY REAR INTAKE MODULE SIGNAL LOST - Equipment Failure If failed, R&R failed SAM slave MIV–A OPERATE REAR MIV WITH MANUAL – CONTINUED module. See paragraph 4.8.3 OVERRIDE KNOB – CONTINUED (page 97).
Page 182 Table 78. Hale SAM System Level SCR Table – CONTINUED SYMPTOM CAUSE REMEDY SENSOR MODULE SIGNAL LOST Wire Harness Discon- Check harness power connections (The SAM sensor module has lost nected/Damaged and circuit breakers. See para- power or the communication to the graph 4.3.5 (page 48) and sec-...
Page 183 Table 78. Hale SAM System Level SCR Table – CONTINUED SYMPTOM CAUSE REMEDY SIGNAL LOST- OPERATE IN MANUAL Equipment Failure R&R Sam Control Center See para- MODE OR USE REMOTE SCREEN – CONTINUED graph 4.4.1 (page 51). (CAN Communications Lost) Confirm Sam Pump Controller CAN –...
Page 184 Table 78. Hale SAM System Level SCR Table – CONTINUED SYMPTOM CAUSE REMEDY TWISTER SIGNAL LOST- OPERATE SAM communication with Confirm Twister is operational. WITH SCREEN the Twister control has Confirm MatrIIX Pressure Governor is been lost. operational. Wire Harness Discon- Check wiring continuity.
Page 185: Barometric Sensor Troubleshooting
Table 78. Hale SAM System Level SCR Table – CONTINUED SYMPTOM CAUSE REMEDY WATER TANK IS EMPTY SAM Reports Water Tank Check ITL-40 harness connections. Level Incorrectly Or ONLY As Empty Water Tank Level Trans- Refer to Intelli-Tank Level 40 (ITL-40)
Page 186: Flowmeter Troubleshooting
Table 79 Barometric Sensor Output – CONTINUED Atmospheric Pressure inHg (mb) Output Voltage VDC 29.0 (982.1) 2.30 29.2 (988.8) 2.32 29.4 (995.6) 2.33 29.6 (1002.4) 2.35 29.8 (1009.1) 2.37 30.0 (1015.9) 2.39 30.2 (1022.7) 2.40 30.4 (1029.5) 2.42 30.6 (1036.2) 2.44 30.8 (1043.0) 2.46...
Page 187: Level Sensor Troubleshooting
4.16.2.3 Level Sensor Troubleshooting The gearbox oil level sensor is an optical fluid level switch. It is positioned on SAM gearboxes to alert the operator if a low- or-no oil condition is active. The gearbox must initially be filled with the correct amount of oil, checked through the fill plug.
Page 188: Temperature Sensor Troubleshooting
• 0-300 psiA sensor • an average signal voltage of 0.5 VDC equals 0.0 psiA • an average signal voltage of 4.5 VDC equals 300.0 psiA 4.16.2.6 Temperature Sensor Troubleshooting There are two [2] temperature sensor on a SAM system. One for gearbox temperature and one for pump water temperature.
Page 189: Diode Troubleshooting
On the SAM Pump Controller, CAN troubleshooting diagnostic screen (Output/Input password), select the INPUTS screen and look for the autoLube Water in Oil and “Gear Water in Oil” icons. On the SAM Pump Controller MIV TS Diagnostic Screen (password 6060), select the INPUT screen and look for the “Water Detect”...
Page 190: General Can Troubleshooting
Shorted Diode If the diode reads low resistances in both directions, this is a sign that the diode is shorted. A di- ode should not measure low resistance in the reverse biased direction. The diode should be re- placed in the circuit. 4.16.3 General CAN Troubleshooting DO NOT ALTER THE CAN NETWORK COMMUNICATIONS (SAE J1939 CAN BUS) OR CON-...
Page 191: Verify Sam Ready To Return To Service
4.17. Verify SAM Ready To Return To Service Prior to returning the apparatus to service the maintainer must meet NFPA 1901 and 1911 re- quirements for testing an apparatus after a major repair. Utilize the following listing as a mini- mum checklist when returning a SAM system to service.
Page 192 THIS PAGE INTENTIONALLY BLANK.
Page 193: Adjustments
Reference Figure 118 for an example of the serial number markings. Reference section 8.1, Calibration Of AB Swing-Out™ Valves, in the OIM Manual For Hale SAM (Generation 2) (P/N FSG-MNL-00210) to calibrate the SAM electric valves.
Page 194: Sam Control Center
Figure 141. Valve Calibrate Menu The VALVE POSITION CALIBRATION button calibrates the valves position sensor. (See below.) The CALIBRATE PRESSURE SENSOR button calibrates discharge and master pressure sensors. The FLOW METER CALIBRATION calibrates the flowmeters and the FLOW FACTORY DEFAULT resets the flow meter calibration back to default calibration for the valve size.
Page 195: Figure 142. Calibrate Valve Stops Screen-Red Bus
PERFORMING THIS PROCEDURE CAUSES SAM TO EXIT AUTO MODE. One, multiple, or all valves on the selected bus may be calibrated at one time (multiple calibra- tions occur in sequence). Always select any valve with a Not Calibrated status. Perform the following to calibrate the valve position sensor for the selected valve(s). NOTES The Valve Stops calibration should be performed with NO water in the valves, open all drains before touching the START button.
Page 196: Figure 143. Calibrate Valve Stops Screen-Green Bus
Figure 143. Calibrate Valve Stops Screen–Green Bus Figure 144. Calibrate Valve Stops Screen–Selected And Active E. When selected valve(s) indicate Calibrated, perform one of following: Touch Red dot next to another valve, and repeat steps above to calibrate another valve. Or, return to CALIBRATION MENU screen (touch Calibration tab) to select opposite bus.
Page 197: Pressure Procedures (Sam Control Center)
5.2.2 Pressure Procedures (SAM Control Center) DISENGAGE PUMP BEFORE PERFORMING CALIBRATION, OTHERWISE UNEX- PECTED/UNDESIRABLE AUTOMATED OPERATIONS MAY OCCUR DURING CALIBRATION. DO NOT EXCEED OPERATING PRESSURE LIMITS OF PUMP, INSTALLED PLUMBING, HOSE(S), OR EQUIPMENT IN USE DURING CALIBRATION. NOTES The Valve Pressure calibration will calibrate all pressure sensors in the system at the same time , including the intake and discharge pressure sensors.
Page 198: Flowmeter Calibration Procedures
Figure 146. Span Pressure Sensor Screen 5.3. Flowmeter Calibration Procedures The following subparagraphs provide flowmeter calibration and reset procedures. 5.3.1 Set Flow To Factory Defaults NOTES This procedure is only required if a valves flow calibration errors/fails (becomes unre- sponsive or gives obviously abnormal values). (All flows readings are displayed using /hr units.) An OEM/Technician password is required to access the screens to perform this proce- dure.
Page 199: Figure 147. Calibrate Valve Flow Screen
The SAM discharge flow calibration requires each discharge be calibrated individually (only one open discharge at one time) using an external calibrated Pitot gauge (or a calibrated flowmeter) to determine the actual water flow. This procedure does NOT include setup for the calibrated Pi- tot or flowmeter.
Page 200: Calibration With Akroview Diagnostic Software
F. Touch red dot (next to Friendly Name) to select valve for testing. (See Figure 148.) Figure 148. Enter Externally Determined Flow Rate G. Touch and hold Run Open button (see bottom of Figure 148) to fully open valve under test. H.
Page 201: Calibration Procedure
Kit (P/N 60460001) documentation and contact Customer Service (800–228–1161) for SAM specific instructions/methodology. Be ready to provide the serial numbers of the valve(s) that re- quire connection to/interface with Akroview. 5.4. ITL-40 Calibration Procedure The ITL-40 tank level gauges must be calibrated in order for the SAM Control Center to show ac- curate tank level.
Page 202: Foam Tank A
E. Touch save button. (Saves and sends calibration data to the ITL-40 when com- plete.) NOTES If calibration fails, touch redo button (top right) of screen). If there is no communication with ITL or if the calibration was done improperly, the status will say ERROR in the bottom right corner of the screen.
Page 203: Figure 152. Sam Pump Controller System Options Menu Screen
Figure 152. SAM Pump Controller System Options Menu Screen B. Touch Password Entry button. C. When password screen appears, enter Governor Settings password (see Table 3, page 36) as follows. Using key pad, sequentially touch digits of password. Touch Enter button. D.
Page 204: Temperature Sensor Calibration
G. Touch Home button. H. Cycle SAM system power. 5.6. Temperature Sensor Calibration To correct the SAM temperature readout (calibrate temperature), perform the following. A. On SAM Pump Controller, touch and hold System Options button until loading icon completes circle and Menu screen is displayed. B.
Page 205: Figure 155. Voltage Adjustment Screen
The purpose here is to adjust for voltage drop SAM is experiencing. To correct for the drop, input the difference in voltage readings between the SAM displayed voltage (left-most column) and the desired voltage (displayed on the test equipment or other voltage readout from apparatus) under the New Value column (right-most column).
Page 206 THIS PAGE INTENTIONALLY BLANK.
Page 207: Sam Setup/Configuration
6. SAM SETUP/CONFIGURATION The following subparagraphs explain the advanced settings available on the SAM Control Center and the SAM Pump Controller. PERFORMING ANY PROCEDURE IN THIS SECTION CAUSES SAM TO EXIT BOTH AUTO AND MANUAL MODES AND ENTER CONFIGURATION MODE. LEAVING SAM IN CONFIGURATION MODE PREVENTS SAM FROM ENTERING AUTO OR MANUAL MODES.
Page 208: How To Set Units
6.1.2 How To Set Units SAM automatically sets the SAM Control Center Units to match the SAM Pump Controller setting when the Pump Controller units are changed. To see how to change/set the units for the Pump Controller, see paragraph 4.12.3.2 (page 135). 6.1.3 Setup And Configurations Using The BAM Tab (Configuration Mode) The following subparagraphs provide information/instruction to configure a SAM system using...
Page 209: Identifying Which Physical Valve A Uid Corresponds To
B. Touch row of desired device. Edit Valve screen (Figure 159) appears. Figure 159. Edit Valve Screen Perform the appropriate/desired procedure (or procedures) from the following subparagraphs. 6.2. Identifying Which Physical Valve A UID Corresponds To Touch the Run Close Run or Open button while physically monitoring the valve(s) for movement to identify/verify valve and entry item association.
Page 210: How To Change A Friendly Name
Figure 160. Edit Valve Screen – Keyboard, Number Pad, And DONE Buttons The existing (default or previously entered) Friendly Name may be appended to (adds on to exist- ing text) by simply typing. To delete the existing name, use the backspace key. 6.7.1 How To Change A Friendly Name Perform the following to change the friendly name of a discharge valve or an intake valve dis-...
Page 211: How To Assign/Change A Valves Index Number
6.8. How To Assign/Change A Valves Index Number After selecting the desired valve, touch the Index (0-11) text box (see Figure 161). The number pad, CLEAR, and ENTER buttons appear (on the right-hand side of the screen). Figure 161. Edit Valve Screen –Number Pad, CLEAR And ENTER Buttons Touch the desired index number digit(s) then touch ENTER button.
Page 212: How To Assign/Change A Valves Max Psi
• Assign a 2 to all Hale MIVs and Akron Brass Swing-Out™ valves used as an auxiliary intake (Pony). • Assign a 3 to the Tank-To-Pump valve. (Special purpose there is only one.) • Assign a 4 to the Tank Fill valve. (Also a special purpose valve and again there is only one.) Table 80 lists the Hale recommended function (factory defaults) for SAM discharges.
Page 213: How To Assign/Change A Valves Preset Pressure (Preset Psi)
6.11. How To Assign/Change A Valves Preset Pressure (Preset PSI) After selecting the desired valve, touch the Preset PSI (0-300) text box (see Figure 161, except Preset PSI (0 to 300) is highlighted). The number pad, CLEAR, and ENTER buttons appear. touch the number(s) for the desired pressure then touch ENTER button.
Page 214: Figure 162. Valve Edit - Color Assignments
A. After selecting desired valve, touch text box of desired area of icon to assign/ change a color. Color swatches and NONE buttons are displayed. NOTE Left-most box = solid fill color; Center box = border color; Right-most box = stripe color. Figure 162.
Page 215: How To Change The Order Of Intakes On The Home Screen
C. Touch DONE button. D. Verify text representing color/none is displayed in associated Color: text box (left- hand bottom of screen), E. Perform Saving The Configuration Changes, paragraph 6.19 (page 197). 6.16. How To Change The Order Of Intakes On The Home Screen Perform the following to change the order in which the friendly name of an intake valve is dis- played on any of the SAM Control Center screens (quicksets, discharge settings, or manual valve control screens).
Page 216: Configuring A Foam Quickset
D. If applicable, assign color(s) to discharge icon, see paragraph 6.7, How To Change/Set Discharge Colors (page 189). E. Perform Saving The Configuration Changes, paragraph 6.19 (page 197). 6.17.2 Configuring A Foam Quickset If a foam discharge is used often and is typically initialized by SAM create a foam Quickset for the discharge as follows.
Page 217: Configuring A Foam Quickset
6.17.4 Configuring A Foam Quickset If a foam discharge is used often and is typically initialized by SAM create a foam Quickset for the discharge as follows. A. Enter system options. Touch (and hold if required) until loading icon completes a circle. Enter appropriate password to access Display Menu (see Table 6).
Page 218: Figure 164. Update Network With New Configuration Information Screen
C. Touch Send BAM + Reboot To GUI button (Figure 164) to reboot system to user interface. Figure 164. Update Network With New Configuration Information Screen The button remains highlighted (see Figure 165) until the user interface reboots and displays the SAM Auto Mode Home or Landing screen (Figure 1, page 11).
Page 219: Software Updates
7. SOFTWARE UPDATES The SAM system software is subject to periodically updated to account for any of the following: • New Features • Current Feature Enhancements • Minor Bug Fixes When a new software update is available, Hale Products will post a news bulletin. The bulletin will provide information about the changes in software the update provides along with how to ac- quire and install the new update.
Page 220 THIS PAGE INTENTIONALLY BLANK.
Page 221: Appendix A. Torque Specification
APPENDIX A. TORQUE SPECIFICATION A.1 Hale General Torque Recommendations When a specific torque value is NOT specified in a procedure, Hale recommends following the recommendations in Table 85. Always utilize a minimum of Grade 8 (SAE) or class 10.9 (metric) for all flange and/or drive line mounting fasteners.
Page 222 Table 85. Hale General Torque Recommendations – CONTINUED Bolt Size Carbon Steel Silicon Nylon 2024-T Brass Bronze Lock GRD 2 GRD 5 GRD 8 18-8 Values are stated in Inch- Pounds – CONTINUED 10-24 22.8 23.8 13.8 18.6 21.2 10-32 31.7 33.1 19.2...
Page 223: Appendix B. Manufacturer's Information
(800) 533-3569 607 NW 27th Ave, Ocala, FL 34475 Email: https://www.haleproducts.com Godiva LTD Mailing: Tel: +44 (0) 1926 623600 (A Unit of IDEX Corp.) Charles Street, Warwick, England, CV34 5LR FAX: +44 (0) 1926 623666 Email: godiva@idexcorp.com B.2. WARRANTY See the Hale website (www.haleproducts.com) for product specific warranty and warranty proce- dures.

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