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Godiva Prima PC1 Installation And Operation Manual

With smartcafs50 or smartcafs100 control with foamlogix 2.1a, 3.3 or 5.0 systems
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Models: PC1_ or PC2_ with SmartCAFS50 or SmartCAFS100 Control
Installation and Operation Manual
Godiva Ltd.
A Unit of IDEX Corporation
Charles St
Warwick CV34 5LR
England
+44 (0)1926 623600
+44 (0)1926 623666 / 623689
www.godiva.co.uk
godiva@idexcorp.com
Prima
with FoamLogix 2.1A, 3.3 or 5.0 Systems
Pump with Integrated
GP/293
Issue 5, February 2014

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Summary of Contents for Godiva Prima PC1

  • Page 1 Prima Pump with Integrated Models: PC1_ or PC2_ with SmartCAFS50 or SmartCAFS100 Control with FoamLogix 2.1A, 3.3 or 5.0 Systems Installation and Operation Manual  Godiva Ltd. A Unit of IDEX Corporation Charles St Warwick CV34 5LR England  +44 (0)1926 623600 +44 (0)1926 623666 / 623689 ...

  • Page 2: Amendment Record

    Add details on new Interlock for compressor clutch Issue 6 control Feb 2014 9, 34 Insert minimum pump idle speed information Issue 6 ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 3: Table Of Contents

    HOWING PARTS SUPPLIED LOOSE WITH STANDARD PUMP SYSTEM OVERVIEW ....................18 ......................18 OMPRESSOR ........................19 ANIFOLD ..............19 OGIX ROPORTIONING YSTEM ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 4 OLUTION CAFS ....................39 ISCHARGING ....................40 VERHEAT HUT DOWN ................. 40 LUSHING OGIX ONLY MAINTENANCE SCHEDULE PC2_/PC1_..............41 ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 5 BASED ON PC2_3010) ................57 HEET BASED ON PC2_3010) ................58 HEET BASED ON FOAM CONCENTRATE COMPATIBILITY LIST ............59 ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 6: Introduction

    A = aluminium B = bronze 1 = single pressure 2 = twin pressure Compressed air foam Godiva Prima series pump ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 7: Safety

    Provision and Use of Work Equipment Regulations 1998. Risk Assessment It is the duty of the pump installer to make a method statement and risk assessment of their operations when installing the pump, please contact Godiva Ltd. if assistance is required. Transportation and Storage The pump is supplied mounted on a wooden pallet and covered with a tri-walled cardboard box.

  • Page 8: Gauges

    If in doubt, contact your Local Environmental Agency for advice regarding disposal policies. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 9: General Data

    Pump plus FoamLogix FoamLogix FoamLogix Compressor CAFS Prima Tamrotor 2.1A SmartCAFS50 Tempest 3 Prima Tamrotor 2.1A SmartCAFS100 Tempest 6 ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 10: Foam Proportioning System 2.1A - Classa Foam Compatible

    Max. Foam Agent Flow rate 19 l/min Direction of Rotation - Gearbox Input Flange Clockwise only - viewed on gearbox input drive flange ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 11: Lubricants

    FoamLogix user manual for additional information. Note: Valid from October 2008. Please contact your Hale representative if your foam is not listed. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 12: Major Components And Controls Prima Smartcafs50 System (Using Tempest 3 Compressor)

    Note: Hale FoamLogix 2.1A or 3.3 foam pump is fluid drain points. mounted in a separate location to the main pump. See page 20. Water/foam/air mixing manifold ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 13: Major Components And Controls Prima Smartcafs100 System

    Note: Hale FoamLogix 3.3 or 5.0 foam pump is mounted 20 and 23. in a separate location to the main pump. Water/foam/air mixing manifold ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 14: Interlock For Compressor Clutch Control - Prima Smartcafs50 And 100 Models

    11) – will be alight when circuit is closed (no pressure). Compressor hours run ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 15: Foamlogix 2.1A Foam Pump Component Group

    Quickstart guides off) with full manual on Foam supply Extension lead tube and fixings low foam level sensor ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 16: Foamlogix 3.3 Or 5.0 Foam Pump Component Group

    ADT – Air Dual Tank. Air operated valve, select one of two foam tanks or flush option (not shown) (2) High pressure switches only supplied loose when blue water panel is not fitted ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 17 High pressure stage strainer – PC2_ model only. 22 - *11,12,13 – on later models these switched fitted on top row. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 18: System Overview

    When the compressor is stationary, residual system pressure is vented by a blow-down valve. NOTE: The compressor should not be run without cooling water. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 19: Manifold

    0.1% to 6.0%. Further information is available in the FoamLogix Model 3.3/5.0 Description, Installation and Operation manual, part number 029-0021-68-0. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 20: Installation And Initial Set-Up Prima Smartcafs50 Using Tempest 3 Compressor And Foamlogix 2.1A Primasmartcafs100 Using Tempest 6 Compressor And Foamlogix 3.3 Or 5.0

    Secure handling of the unit for installation and maintenance is vital. Use only the lifting points provided on the unit. Fork Lift points ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 21: Prima Smartcafs50 System

    To foam be located above injection point FoamLogix unit on manifold. Tubing suitable for 22.5 bar FoamLogix filter pressure ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 22: Prima Smartcafs100 System

    Note: foam tank must be located above FoamLogix unit. Also Tubing suitable for 22.5 bar refer to installation notes in FoamLogix manual. pressure ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 23 Gearbox/heat exchanger coolant and the CAFS manifold drain points are located at the lower right hand side of the pump. Please note that both manifold drains must be utilized. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 24: Oil Filling Points - Prima Smartcaf50

    Compressor oil filter Compressor oil level – mid point on site glass (behind CAFS discharge connection) Bearing housing oil fill point ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 25: Oil Filling Points - Prima Smartcaf100

    Compressor oil filter Compressor oil level – mid point on site glass (behind CAFS discharge connection) Bearing housing oil fill point ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 26: Gearbox - Prima Smartcafs50 And Prima Smartcaf100

    Oil Fill Points Direction of rotation – Oil Level Check Clockwise only – viewed on gearbox input drive flange ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 27: Foam Injection Point

    Approximate capacity is 1.2 litres. Foam Injection Point – Foam injection point connect tubing suitable for 22.5 bar pressure ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 28: Optical Belt Tension Meter

    6. If the measured frequency is too high, loosen the belt via the tensioner. 7. Take another reading to confirm the frequency is 79 Hz. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 29: Compressor Drive Belt - Prima Smartcafs100

    6. If the measured frequency is too high, loosen the belt via the tensioner. 7. Take another reading to confirm the frequency is 65 Hz. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 30: Electrical Connections

    NB: Vehicle builder – use a 10 amp fuse in the supply line ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 31: Foam Tank Low Level Sensor

    Note: To ensure correct operation of the FoamLogix pump, all connections must be secure and pressure tight. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 32: Vehicle Design Considerations

    MUST NOT be used on CAFS discharges. Direction of rotation of the input drive flange is clockwise, when viewed on the gearbox. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 33: Installation And Initial Set-Up Foamlogix 2.1A

    Installation and Operation manual, part number 029-0021-68-0, supplied separately. For further information on the MDTII Manual Tank Selector, please see the separate manual supplied, part number 029-0020-40-0. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 34: Operation

    Ensure that there is sufficient foam agent in the tank(s). For FoamLogix 3.3 or 5.0 select tank A ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 35: Calibration Of Foamlogix

    The CAFS Smart Switch Panel is the primary component of the CAFS with compressor air-inject system. The Smart Switch Panel allows monitoring and control of the consistency of the discharged CAFS foam. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 36: Wet And Dry Buttons

    When the OPEN (or CLOSED) button is pressed the WET (or DRY) LEDs will be turned OFF. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 37: Open And Close Leds

    However, the scrubbing action of the foam on the hose wall tends to improve the foam quality. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 38: Foamlogix Control Panel

    Class B foam concentrate FLUSH – supplies clean water to flush out foam concentrate from the foam strainer and foam pump ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 39: Discharging Foam / Water Solution Only

    5. An indication of wet / dry foam condition is shown by the valve position LED indicator. When selecting DRY Foam increase the foam % level to 1% on the FoamLogix control. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 40: Overheat Shut Down

    A. For detailed flushing instructions, please refer to the FoamLogix Model 3.3/5.0 Description, Installation and Operation manual. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 41: Maintenance Schedule Pc2_/Pc1

    Replace the priming valve seals and diaphragm Manual Test the thermal relief valve Page 44 Compressor Maintenance Replace the oil separator element Manual ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 42: Maintenance Operations Pc2

    Do not clean the glass surfaces of the gauges with abrasive or solvent cleaners. These will cloud the glass surface. Use a mild detergent and water. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 43: Maintenance Operations Pc1_ / Pc2

    On later models the CAFS mixing manifold is fitted with two grease lines, these allow grease to be inserted from the front panel. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 44: Maintenance Operations Pc1_ / Pc2_ - Continued

    Open a pump discharge valve to permit cool water to enter the pump. The flow from the TRV should now cease. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 45: Maintenance Operations Compressor

    Please refer to the appropriate model FoamLogix Description, Installation and Operation manual to calibrate water flow and foam feedback characteristics. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 46: Fault Finding

    Do a Vacuum Test Do a Pressure Test Trace leaks, rectify and retest pump Suction is restored ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 47: Pump Operating Faults 2 - Excessive Pump Noise

    Reduce suction lift Has noise Continue using disappeared the pump Investigate further – possible mechanical problem ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 48: General Operating Faults - Cafs

    Chatter/ Depleted Refill foam tank Slugflow foam supply Foam % set Increase foam % too low setting ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 49: Air Injection Faults

    Is Foam Low Level Low Level Fill foam tank Switch to Switch verify if faulty Activated? Continued on next page ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 50 Replace interlock Check the air control module valve/pipework ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 51: Parts Lists

    FoamLogix Model 2.1A Description, Installation and Operation manual, part number 029-0020-74-0. FoamLogix Model 3.3/5.0 Description, Installation and Operation manual, part number 029-0020-68-0. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 52: Recommended Spares Kit For Bi-Annual Service

    Please exercise care when handling. It is at the customer’s discretion whether said items are carried as ‘off the shelf’ spares. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 53: Godiva

    INSTALLATION DRAWINGS – PC2_ WITH SMARTCAFS50 FOR OPTIONS OF DRIVE FLANGE, VALVES, SUCTION TUBE, CONTROL PANEL – CONTACT GODIVA Sheet 1 of 3 (based on PC2_3010) ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 54: Sheet 2 Of 3 (Based On Pc2_3010)

    Sheet 2 of 3 (based on PC2_3010) ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 55: Sheet 3 Of 3 (Based On Pc2_3010)

    Sheet 3 of 3 (based on PC2_3010) ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 56: Sheet 1 Of 3 (Based On Pc2_3010)

    INSTALLATION DRAWINGS – PC2_ WITH SMARTCAFS100 FOR OPTIONS OF DRIVE FLANGE, VALVES, SUCTION TUBE, CONTROL PANEL – CONTACT GODIVA Sheet 1 of 3 (based on PC2_3010) ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 57: Sheet 2 Of 3 (Based On Pc2_3010)

    Sheet 2 of 3 (based on PC2_3010) ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 58: Sheet 3 Of 3 (Based On Pc2_3010)

    Sheet 3 of 3 (based on PC2_3010) ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 59: Foam Concentrate Compatibility List

    FOAM CONCENTRATE COMPATIBILITY LIST ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 60 ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 61 ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

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