HALE FoamLogix 3.3 Installation And Operation Manual

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6/26/2003

FoamLogix

MODEL 3.3 AND 5.0 ROTARY GEAR

PUMP ELECTRONIC FOAM

PROPORTIONING SYSTEM

DESCRIPTION, INSTALLATION AND

Hale FoamLogix System Serial Number: _____________________________

Date Unit Placed in Service: _______________________________________

Fire Department: ________________________________________________

Engine Number: ________________________________________________

Calibration Factors:

Water Flow Factor: __________________________________________

Class A Foam Factor: ________________________________________

Class B Foam Factor: _______________________________________

NOTICE: This manual is divided into four sections for clarity and ease of use. Section I: DESCRIPTION; Provides an

introduction to the Hale foam proportioning system along with guidelines for designing and ordering a complete

system. Section II: INSTALLATION; Provides information to assist the OEM with installation and initial set-up of Hale foam

proportioning systems on an apparatus. Section III: SET-UP AND CALIBRATION; Is used by the installer and end user for

start-up and calibration of the Hale foam proportioning system. Section IV: OPERATION; Is primarily used by the

apparatus user for proper operation and maintenance of the Hale foam proportioning system. Each manual section

can be a stand alone section or can be used in conjunction with each other.

All Hale products are quality components: ruggedly designed, accurately machined, precision inspected, carefully assembled

and thoroughly tested. In order to maintain the high quality of your unit, and to keep it in a ready condition, it is important to

follow the instructions on care and operation. Proper use and good preventive maintenance will lengthen the life of your unit.

ALWAYS INCLUDE THE UNIT SERIAL NUMBER IN CORRESPONDENCE.

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HALE PRODUCTS, INC. l A Unit of IDEX Corporation l 700 Spring Mill Avenue l Conshohocken, PA 19428 l TEL: 610-825-6300 l FAX: 610-825-6440

OPERATION MANUAL

N I

Hale Products cannot assume responsibility for product failure resulting from improper

maintenance or operation. Hale Products is responsible only to the limits stated in the product

warranty. Product specifications contained in this material are subject to change without notice.

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Table of Contents

Summary of Contents for HALE FoamLogix 3.3

Page 1 ALWAYS INCLUDE THE UNIT SERIAL NUMBER IN CORRESPONDENCE. HALE PRODUCTS, INC. l A Unit of IDEX Corporation l 700 Spring Mill Avenue l Conshohocken, PA 19428 l TEL: 610-825-6300 l FAX: 610-825-6440 MANUAL P/N 029-0020-68-0, REV B, © 2003 HALE PRODUCTS, INC., PRINTED IN U.S.A.
Page 3: Table Of Contents
PARTS IDENTIFICATION ...................... IV-22 WARRANTY ......................... IV-28 System installer must provide two copies of this Hale Foam System Description, Installation and Operation Manual to the end user of the equipment. If additional manuals are required, contact Hale Products Inc. Communications Department at (610) 825-6300.
Page 5: Section I: Description
HALE PRODUCTS, INC. l A Unit of IDEX Corporation l 700 Spring Mill Avenue l Conshohocken, PA 19428 l TEL: 610-825-6300 l FAX: 610-825-6440 Hale Products cannot assume responsibility for product failure resulting from improper maintenance or operation.
Page 7: Safety
SAFETY Hale Foam systems are designed to provide reliable and safe foam concentrate injection. Before installing or operating a Hale Foam system read all safety precautions and follow carefully to ensure proper installation and personnel safety. 5. Do not mount radio transmitter or...
Page 8 When compatible with all foam concentrates installing the in-line strainer in systems equipped with Hale MDT ΙΙ or Hale MST to be used in the system. Use washers, lockwashers and capscrews made of make sure the in-line strainer/valve brass or 300 series stainless steel.
Page 9: System Description
As the motor rotates the pump, foam concentrate flows through the foam pump The heart of the Hale Foam system is an discharge to the one piece check valve/ electric motor driven rotary gear pump. injector fitting into the water discharge The pump is constructed of bronze and stream.
Page 10 The standard in-line The available Air Dual Tank (ADT) valve for strainer/valve assembly has a composite the Hale Foam system is an air operated nonmetallic housing with stainless steel foam tank selector valve that provides mesh strainer element. It is provided with a selection of foam concentrate dependent service shutoff valve, mounting bracket.
Page 11 ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM Components shown in Bold type above Ordering of Hale Foam systems is simple. represent the best value performance Using the current Hale FoamLogix Foam system. System components are shown in System Price List and Order Form helps the following system configuration section.
Page 12: System Specifications
ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM HALE FOAM SYSTEM SPECIFICATIONS Foam Pump................. Rotary Gear Positive Displacement Rated Foam Concentrate Output Model 3.3 ......................3.3 GPM (12 LPM) Model 5.0 ......................5.0 GPM (19 LPM) Maximum System Operating Pressure Model 3.3 ......................400 PSI (28 BAR) Model 5.0 ......................
Page 13 ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM MODEL 5.0: 25.37 IN. (644 MM) BYPASS HANDLE: BYPASS POSITION MODEL 3.3: 25.12 IN. (638 MM) MODEL 5.0: 24.74 IN. (628 MM) BYPASS HANDLE: INJECT POSITION MODEL 3.3: 24.94 IN. (622 MM) MODEL 5.0: 23.70 IN. (602 MM) MODEL 3.3: 23.45 IN.
Page 14: System Configuration
SYSTEM CONFIGURATION Hale Foam Proportioner System Model (Model 3.3 or Model 5.0) All Hale Foam systems include: Foam Pump/Motor Assembly, Control Unit, Control Cable and Check Valve/Injector Fitting Foam Pump/Motor Assembly (Shown with Bypass Valve when configured for MDT ΙΙ, MST or no tank selector option) Optional 6-Pin Extension Cable 16.5 Feet (P/N 013-2020-05-0)
Page 15 ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM Dual Foam Concentrate Tank System Options Panel Switch/Indicator Light Placard Assembly Optional Color Coded Air Connection Harness (P/N 507-0380-00-0) Foam Pump/Motor Assembly with Air Dual Tank (ADT) Selector (P/N 538-1640-02-0) Manual Dual Tank (MDT ΙΙ) Selector and Wiring Harness (P/N 538-1490-11-0) MDT ΙΙ...
Page 16 (¾ Inch NPT Threads. Use With Class A (1 Inch NPT Threads. Use With Class A and thin Class B Foam Concentrates) and Class B Foam Concentrates) Hale FS Series Strainers (Use When Strainer is Subjected to Flushing Water Pressure) Ι−10 Section I: Description...
Page 17 ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM Low Tank Level Sensor Options (One Low Tank Level Sensor is Required for Each Foam Tank) Side Mount Low Tank Level Sensor (P/N 200-2110-02-0) (½ Inch NPT Threaded Bushing to Mount From Outside Foam Tank) Brass Bottom Mount Low Tank Level Sensor (P/N 200-2110-04-0)
Page 18 ELECTRONIC FOAM PROPORTIONING SYSTEM Flowsensors Each Hale foam system requires a flowsensor to operate. Pipe size must be selected based on the minimum and maximum water flow in the foam capable discharge. Following is a list of pipe size and rated flow range along with flowsensor saddle clamp part number: In all instances a weld fitting may be substituted for the saddle clamp.
Page 19 ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM Check Valve Manifolds The check valve manifolds include Flowsensor, Check Valve/Injector fitting and single or dual waterway check valve flappers. End connections for the manifolds are 3 inch victaulic. SINGLE CHECK VALVE (SCV) MANIFOLD DUAL CHECK VALVE (DCV) MANIFOLD P/N 108893 P/N 108751...
Page 20 ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM Check Valves, Flanges and Gaskets 3 Inch "115" Check Valve 4 Inch "2433D" Check Valve (P/N 038-1570-00-0) (P/N 038-1570-04-0) Type 115 Flange Type 2433D Flange Use 3 and 2-½ inch NPT with 3 inch check valves. Also available with 1-½...
Page 21 ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM Elbows and Mini Manifold Close Fit Flanged Elbow Close Fit Flanged Elbow (P/N 098-0140-00-0) (P/N 098-0190-00-0) 115 flange inlet with 3 inch Victaulic outlet. 2433D flange inlet with 3 inch female NPT and 4 inch Victaulic outlet. Close Fit Flanged Elbow Close Fit Flanged Elbow (P/N 098-0050-00-0)
Page 22 BYPASS HOSE DISTRIBUTION CHECK VALVE INJECTOR FITTING HALE FLOWSENSOR PADDLE WHEEL MOUNTED IN SADDLECLAMP WATERWAY CHECK WATERWAY VALVE FOAM SOLUTION FIRE CHECK DISCHARGE(S) PUMP VALVE Figure 1-1. Hale Foam System Layout with Single Foam Concentrate Tank Ι−16 Section I: Description...
Page 23 PADDLE WHEEL CHECK VALVE MOUNTED IN INJECTOR SADDLECLAMP FITTING FIRE PUMP WATERWAY CHECK FOAM SOLUTION WATERWAY VALVE DISCHARGE(S) CHECK VALVE Figure 1-2. Hale Foam System Layout with Single Foam Concentrate Tank, MST and In- line Strainer/Valve Assembly Ι-17 Section I: Description...
Page 24 CORDSET HALE FITTING FLOWSENSOR PADDLE WHEEL MOUNTED IN SADDLECLAMP FIRE PUMP WATERWAY WATERWAY FOAM SOLUTION CHECK CHECK DISCHARGE(S) VALVE VALVE Figure 1-3. Hale Foam System Layout with Single Foam Concentrate Tank, MST and FS Series Strainer Ι−18 Section I: Description...
Page 25 PADDLE WHEEL FITTING MOUNTED IN FLOWSENSOR SADDLECLAMP CORDSET FIRE PUMP WATERWAY CHECK VALVE WATERWAY FOAM SOLUTION CHECK DISCHARGE(S) VALVE Figure 1-4. Hale Foam System Layout with Dual Foam Concentrate Tanks, MDT ΙΙ and In- line Strainer/Valve Assembly Ι-19 Section I: Description...
Page 26 FITTING PADDLE WHEEL CORDSET MOUNTED IN SADDLECLAMP WATERWAY CHECK WATERWAY FOAM SOLUTION VALVE CHECK DISCHARGE(S) VALVE FIRE PUMP Figure 1-5. Hale Foam System Layout with Dual Foam Concentrate Tanks, MDT ΙΙ and FS Series Strainer Assembly Ι−20 Section I: Description...
Page 27 HALE HOSE FLOWSENSOR PADDLE WHEEL MOUNTED IN SADDLECLAMP FIRE PUMP WATERWAY FOAM SOLUTION CHECK WATERWAY DISCHARGE(S) VALVE CHECK VALVE Figure 1-6. Hale Foam System Layout with Dual Foam Concentrate Tanks, ADT and In- line Strainer/Valve Assemblies Ι-21 Section I: Description...
Page 28 WATER SUPPLY FLOWSENSOR PADDLE WHEEL MOUNTED IN SADDLECLAMP FIRE PUMP FOAM SOLUTION WATERWAY WATERWAY DISCHARGE(S) CHECK CHECK VALVE VALVE Figure 1-7. Hale Foam System Layout with Dual Foam Concentrate Tanks, ADT and FS Series Strainer Assemblies Ι−22 Section I: Description...
Page 29: Section Ii: Installation
HALE PRODUCTS, INC. l A Unit of IDEX Corporation l 700 Spring Mill Avenue l Conshohocken, PA 19428 l TEL: 610-825-6300 l FAX: 610-825-6440 Hale Products cannot assume responsibility for product failure resulting from improper maintenance or operation.
Page 31: Safety
ELECTRONIC FOAM PROPORTIONING SYSTEM SAFETY Hale FoamLogix systems are designed to provide reliable and safe foam concentrate injection. Before installing or operating a Hale FoamLogix system read all safety precautions and follow carefully to ensure proper installation and personnel safety.
Page 32 When brass or 300 series stainless steel. installing the in-line strainer in systems equipped with Hale MDT ΙΙ or Hale MST 12. When making wire splice connections make sure they are properly insulated make sure the in-line strainer/valve...
Page 33: Apparatus Installation Planning
(ADT valve is an optional part of foam foam system configuration make it pump) Manual dual tank (MDT ΙΙ) selector valve impractical to show exactly how each Hale FoamLogix system is installed on a particular Manual single tank (MST) selector valve apparatus. The information contained in...
Page 34 Hale Clearance must be provided behind the MDT ΙΙ or Hale MST make sure the in-line panel to allow for hose connections to the strainer/valve assembly is in the hose on strainer.
Page 35: Installer Supplied Component Recommendations
RECOMMENDATIONS concentrate flow during foam pump Due to the many differences in apparatus operation. configuration and apparatus design requirements the Hale FoamLogix system RECOMMENDED COMPONENTS: installer must supply components such as Hose: PVC, Kuriyama Kuri-Tec K7130 mounting brackets, piping, hoses, fittings series and some electrical wiring.
Page 36 Use fittings working pressure. made of brass or 300 series stainless steel compatible with all foam concentrates. Hale 3 inch "115" flange type check valves (Hale P/N 038-1570-00-0) can be used for RECOMMENDED COMPONENTS: most installations on pumps with "115" style...
Page 37 FoamLogix system. used in the system. Primary power must be supplied from the When the Hale ADT, Hale MDT ΙΙ or Hale MST main apparatus battery to the distribution is installed a check valve is provided box on the foam pump and motor integral to the flushing water line assembly.
Page 38 3.3, cable lengths up to 6 feet (1.8 meters) ammeter is installed on the apparatus it is require minimum 4 AWG type SGX (SAE necessary to install a power filter kit (Hale P/ J1127) battery cable. Use solder lugs on N 546-1870-00-0) on the Hale FoamLogix cable ends with a 5/16 inch (8 mm) foam pump.
Page 39: Foam Pump Mounting
When the Hale FoamLogix system is The base of the foam pump and motor ordered with the ADT option, the operating assembly has predrilled mounting holes.
Page 40 6.02 IN. (153 MM) 9.43 IN. (240 MM) ½ INCH NPT INJECT HOSE CONNECTION ¾ INCH NPT SUCTION HOSE CONNECTION 2.58 IN. (66 MM) ½ INCH NPT BYPASS HOSE CONNECTION Figure 2-3. Hale FoamLogix Installation Envelope Dimensions ΙΙ-10 Section II: Installation...
Page 41 0.38 IN. (10 MM) DIA. THRU HOLE 14.06 IN. 0.75 IN. (4 PLACES) (357 MM) (19 MM) 15.56 IN. (395 MM) Figure 2-5. Hale FoamLogix Foam Pump and Motor Assembly Base Plate Dimensions and Mounting Hole Locations ΙΙ-11 Section II: Installation...
Page 42: Plumbing Component Installation
ELECTRONIC FOAM PROPORTIONING SYSTEM PLUMBING COMPONENT INSTALLATION Hale FoamLogix System plumbing diagrams are located at the end of this manual section. The diagrams provide recommended guidelines for the installation of system components that handle water, foam concentrate and foam solution. The sequence in which the plumbing installation is completed depends on the individual installation.
Page 43 Hale 4 inch check requirements during operation. Refer to the flowsensor selection chart in Section Ι of this valves, Hale 2433 flanges and 4 inch pipe. manual for proper pipe size for flow range desired. WATERWAY CHECK VALVES...
Page 44 The downstream piping length is not as critical but there should be a short of the Hale FoamLogix system. length of straight pipe with no fittings or valves immediately after the flowsensor paddlewheel.
Page 45 ADT are ½ inch NPT and Align the paddlewheel indexing pin to the on the Hale MDT ΙΙ and Hale MST they are ¼ indexing hole in the spacer, secure using inch NPT. The system installer must provide four ¾...
Page 46 (Refer to figure 2-12) pressure. When installing the in-line strainer in systems equipped with Hale MDT ΙΙ or Hale MST make sure the in-line 2. Refer to the diagram in figure 2-13 and mark 4 holes for mounting the foam strainer/valve assembly is in the hose on the inlet side of the valve.
Page 47 ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM 1-1/4 INCH NPT X 1-1/4 2 INCHES (51 mm) MINIMUM INCH HOSE BARB STRAINER CLEARANCE ABOVE FOR (Use on each end for Class VALVE OPERATION MOUNTING B foam concentrates) BRACKET FOAM FOAM CONCENTRATE CONCENTRATE OUTLET INLET...
Page 48 ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM inlet of the Hale MDT ΙΙ, Hale MST or foam concentrate pump or correct fitting on Hale ADT. FS SERIES STRAINER When a pressurized water flush is provided LOOKING FROM BACK OF STRAINER Figure 2-14.
Page 49 7. Install the hose from the strainer outlet to The holes for the FS15 strainer mounting the inlet of the Hale FoamLogix foam screws are 9/32 inch (7 mm) and the pump or selector valve.
Page 50 BYPASS HOSE CONNECTION INJECTOR FITTING A bypass port is provided on the discharge side of the Hale ADT or a 1/4 turn bypass valve is mounted on the discharge of the HALE MANIFOLD, 1 INCH NPT foam pump when the ADT option is not...
Page 51 ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM foam tank or to assist in priming of the foam pump. The hose from the BYPASS port must ACORN NUT be long enough to reach a container HANDLE outside the truck. This hose must be coiled for storage when not in use.
Page 52 ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM indicated in figure 2-21. A color coded be substituted. Make sure the air brake decal attached to the ADT valve assembly tubing selected has the proper DOT along with an optional color coded air hose approval.
Page 53 ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM AIR OUT A (GREEN) TANK A AIR IN INDICATOR (BLACK) SELECTOR SWITCH TANK B ELECTRICAL HARNESS INDICATOR AIR OUT B (RED) ADT PANEL PLACARD SIDE VIEW PANEL PLACARD ASSEMBLY ¼ INCH O.D. AIR HOSE OR AIR HARNESS ASSEMBLY...
Page 54: System Plumbing Diagrams
Due to variations in apparatus configuration and individual component locations, lengths of hoses and piping is not provided. The material described and component sizes are those which will provide optimum performance of a Hale FoamLogix system. These diagrams are intended as guidelines to assist the system installer with selection of hoses and fittings along with the connections required.
Page 55 OUTSIDE DIAMETER RATED AT HOSE 500 PSI (34 BAR) HALE FLOWSENSOR PADDLE WHEEL MOUNTED IN SADDLECLAMP FIRE PUMP FOAM SOLUTION WATERWAY WATERWAY DISCHARGE(S) CHECK CHECK VALVE VALVE Hale FoamLogix System Plumbing Diagram with Single Foam Concentrate Tank ΙΙ-25 Section II: Installation...
Page 56 INCH INSIDE DIAMETER FIRE PUMP HALE FOAM SOLUTION FLOWSENSOR WATERWAY DISCHARGE(S) PADDLE WHEEL CHECK WATERWAY MOUNTED IN VALVE CHECK SADDLECLAMP VALVE Hale FoamLogix System Plumbing Diagram with Single Foam Concentrate Tank, MST and In-line Strainer/Valve Assembly ΙΙ-26 Section II: Installation...
Page 57 AT 500 PSI (34 BAR) HOSE FIRE PUMP HALE FLOWSENSOR WATERWAY FOAM SOLUTION WATERWAY CHECK PADDLE WHEEL DISCHARGE(S) CHECK MOUNTED IN VALVE VALVE SADDLECLAMP Hale FoamLogix System Plumbing Diagram with Single Foam Concentrate Tank, MST and FS Series Strainer ΙΙ-27 Section II: Installation...
Page 58 AT 500 PSI (34 BAR) FIRE PUMP HALE WATERWAY FLOWSENSOR CHECK FOAM SOLUTION PADDLE WHEEL WATERWAY VALVE DISCHARGE(S) MOUNTED IN CHECK SADDLECLAMP VALVE Hale FoamLogix System Plumbing Diagram with Dual Foam Concentrate Tanks, MDT ΙΙ and In-line Strainer/Valve Assembly ΙΙ-28 Section II: Installation...
Page 59 INCH INSIDE DIAMETER FIRE PUMP HALE WATERWAY FLOWSENSOR CHECK PADDLE WHEEL FOAM SOLUTION WATERWAY VALVE MOUNTED IN CHECK DISCHARGE(S) SADDLECLAMP VALVE Hale FoamLogix System Plumbing Diagram with Dual Foam Concentrate Tanks, MDT ΙΙ and FS Series Strainer Assembly ΙΙ-29 Section II: Installation...
Page 60 INCH INSIDE DIAMETER CONNECTION FITTING HALE FLOWSENSOR PADDLE WHEEL MOUNTED IN SADDLECLAMP FIRE PUMP WATERWAY WATERWAY FOAM SOLUTION CHECK CHECK DISCHARGE(S) VALVE VALVE Hale FoamLogix System Plumbing Diagram with Dual Foam Concentrate Tanks, ADT and In-line Strainer/Valve Assemblies ΙΙ-30 Section II: Installation...
Page 61 INCH INSIDE DIAMETER HALE FLOWSENSOR PADDLE WHEEL MOUNTED IN SADDLECLAMP FIRE PUMP WATERWAY FOAM SOLUTION WATERWAY CHECK DISCHARGE(S) CHECK VALVE VALVE Hale FoamLogix System Plumbing Diagram with Dual Foam Concentrate Tanks, ADT and FS Series Strainer Assemblies ΙΙ-31 Section II: Installation...
Page 62 ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM ΙΙ-32 Section II: Installation...
Page 63: Electrical Installation
The resulting in possible system failure. Hale FoamLogix system is designed to be installed with a minimum of electrical • The cables shipped with each Hale connections. Complete electrically...
Page 64 (See figure 2-22 for CAUTION: Foam tank low level sensors mounting dimensions). The display requires must be utilized to protect the Hale 7 inches (178 mm) minimum clearance from FoamLogix from dry running. Failure to...
Page 65 ELECTRONIC FOAM PROPORTIONING SYSTEM ACCESSORY CONNECTOR (Plug inserted at factory when single tank installed.) (Connection made at factory when Hale MDT II or Hale ADT option installed.) (Field connection required at installation when Hale MST option installed.) CONTROL UNIT CABLE CONNECTION...
Page 66 ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM BOTTOM MOUNT LOW LEVEL SENSOR TOP MOUNT LOW LEVEL SENSOR INSTALLATION OPTION 1. The bottom mount foam tank low level sensor must be mounted into the bottom of the foam tank. The sensor, as supplied, is threaded into a bushing that has 1 inch NPT SIDE MOUNT TYPICAL...
Page 67 ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM 1.44 in. CAUTION: Use mounting hardware that (37 mm) is compatible with all foam 0.72 in. (18 mm) concentrates to be used in the system. Use washers, lockwashers and capscrews made of brass or 300 series stainless steel.
Page 68 4) Install a new ½ compression ferrule on the end of the tube. Carefully thread A connector kit (Hale P/N 546-1780-00-0) is the sensor wire through the tube included that contains a Packard assembly and attach the ¼ FNPT x ½...
Page 69 When the Hale FoamLogix system is installed the A-B switch box. using a Hale ADT or Hale MDT ΙΙ connect 3. Connect the lead from Tank A to the the low tank level sensors using the following...
Page 70 RFI emitted by this connection. A stud labeled NEG (—) is located on the distribution box to attach the chassis ground strap to the Hale FoamLogix system. (See figure 2-24) When making the ground strap connections make...
Page 71 ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM ensure proper grounding. The #6-32 UNC REMOTE ACTIVATION SWITCH screw that holds the spade terminal to the Choose a location in the apparatus flowsensor tee can be used to attach the personnel compartment for mounting the ground strap to the tee (refer to figure 2-11).
Page 72 ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM cutout and secure to panel using the #10-24 UNC x ½ inch long screws and #10-24 UNC nuts provided. NOTE: When making cable connection make sure the cable is routed by the shortest most direct route. A maximum of 40 feet (12 meters) of remote cable may be used.
Page 73: System Electrical Diagrams
MAXIMUM 18 INCHES (457 mm) LONG BATTERY CABLE FOR CABLE LENGTH UP TO 6 FEET. FOR CABLE LENGTH OVER 6 FEET REFER TO TABLE 2-2 FOR PROPER GAUGE WIRE. HALE FOAMLOGIX SYSTEM (NO TANK OPTION) CONTROL CONTROL LOW TANK LEVEL SENSORS...
Page 74 FOR CABLE LENGTH OVER 6 FEET REFER TO TABLE GROUND STRAP 2-2 FOR PROPER GAUGE WIRE. USE 1-¼ INCH WIDE FLAT BRAIDED GROUND STRAP MAXIMUM 18 INCHES (457 mm) LONG HALE FOAMLOGIX SYSTEM WITH MDT ΙΙ LOW TANK LEVEL SENSORS CONTROL USE MINIMUM 16 AWG TYPE CONTROL...
Page 75: Start-Up Checklist
Splices in wires sealed from moisture using adhesive filled heat shrink tubing. q Hale FoamLogix system ON/OFF switch on the distribution box is in the ON position. q If installed, ADT, MST or MDT ΙΙ electrical connections correct.
Page 76: System Installer Start-Up
ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM SYSTEM INSTALLER START-UP When energizing the Hale FoamLogix system at the system installer facility for the first time the following procedures shall be used. INITIAL SYSTEM POWER CHECK Observe the display on the control unit...
Page 77 Figure 2-33. Simulated Flow Display MDT ΙΙ or MST place the selector in the FLUSH position. "FLUSH" should alternate Depress ON button to energize Hale with "0" on the control unit display. Once FoamLogix system. Observe the proper operation is verified place the...
Page 78 ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM with setting of user specified default simulated flow and concentrate injection rates should be accomplished upon delivery to the end user using actual end user specified foam concentrates and default values. ΙΙ-48 Section II: Installation...
Page 79: Section Iii: Set-Up And Calibration
HALE PRODUCTS, INC. l A Unit of IDEX Corporation l 700 Spring Mill Avenue l Conshohocken, PA 19428 l TEL: 610-825-6300 l FAX: 610-825-6440 Hale Products cannot assume responsibility for product failure resulting from improper maintenance or operation.
Page 81: Safety
ELECTRONIC FOAM PROPORTIONING SYSTEM SAFETY Hale FoamLogix systems are designed to provide reliable and safe foam concentrate injection. Before installing or operating a Hale FoamLogix system read all safety precautions and follow carefully to ensure proper installation and personnel safety.
Page 82 When brass or 300 series stainless steel. installing the in-line strainer in systems equipped with Hale MDT ΙΙ or Hale MST 12. When making wire splice connections make sure they are properly insulated make sure the in-line strainer/valve...
Page 83: Installation And Delivery Checklist
ELECTRONIC FOAM PROPORTIONING SYSTEM INSTALLATION AND DELIVERY CHECKLIST After the Hale FoamLogix system has been installed the following check list should be used to verify installation and ensure proper system set-up when apparatus is delivered to the end user. Use procedures in referenced manual sections.
Page 84: Initial End User Set-Up
FOAM, TOTAL FOAM and all bargraph LEDs INITIAL POWER-UP will light along with "88888" for several seconds. "HALE CLASS 1 2002" followed by the software revision level (r x.x) will scroll across the display while the system checks itself followed by the flow display. The flow...
Page 85 Display will show “S” at the left most position to indicate the simulated flow (See figure 3-2). 4. Engage the Hale FoamLogix system by pressing the red ON button. The left LED Figure 3-2. Simulated Flow Display on the horizontal bargraph will illuminate to indicate the system is on.
Page 86: User Calibration
é é ê é to ensure they remain together. If the Hale FoamLogix system is properly installed, further calibration WILL NOT be necessary until delivery to customer. The system is RESTORE FACTORY DEFAULT VALUES...
Page 87 "CALIB" Figure 3-3. Entering Calibration Mode WATER FLOWSENSOR CALIBRATION NOTE: The flowsensor is calibrated at Hale Products Inc. and matched to the control unit. If the system is installed properly only minor adjustments should be necessary to flowsensor reading. Figure 3-4. Flowsensor Calibration Display ΙΙΙ-7...
Page 88 “S 150”. and the foam concentrate injection rate cannot be set. FOAM CONCENTRATE INJECTION RATE When the Hale FoamLogix system power is FOAM PUMP FEEDBACK CALIBRATION turned on, the foam concentrate injection NOTE: Foam pump feedback is rate in memory will be the default injection calibrated at Hale Products Inc.
Page 89 ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM TANK SELECTOR (TANK A) TANK SELECTOR (TANK A) TANK SELECTOR (TANK B) Figure 3-8. Foam Pump Feedback TANK SELECTOR (TANK B) Calibration Display Figure 3-7. Foam Concentrate Injection Rate Default Value Set Display NOTE: If an accurate calibrated concentrates.
Page 90 Class A FOAM PUMP FEEDBACK The above procedures complete CALIBRATION FACTOR: ____________ verification and adjustment of the system. The Hale FoamLogix system is now ready to Class B FOAM PUMP FEEDBACK be placed in service. CALIBRATION FACTOR: ____________ ΙΙΙ-10...
Page 91 During normal installation and operation the relief valve will not require adjustment. If adjustment is necessary in field installation contact Hale Products Inc for Relief Valve Service bulletin. ELECTRIC MOTOR...
Page 92 ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM Section III: Set-up and Calibration...
Page 93 HALE PRODUCTS, INC. l A Unit of IDEX Corporation l 700 Spring Mill Avenue l Conshohocken, PA 19428 l TEL: 610-825-6300 l FAX: 610-825-6440 Hale Products cannot assume responsibility for product failure resulting from improper maintenance or operation.
Page 95: Safety
ELECTRONIC FOAM PROPORTIONING SYSTEM SAFETY Hale FoamLogix systems are designed to provide reliable and safe foam concentrate injection. Before installing or operating a Hale FoamLogix system read all safety precautions and follow carefully to ensure proper installation and personnel safety.
Page 96 When control unit, foam discharge multiplexing installing the in-line strainer in systems equipped with Hale MDT ΙΙ or Hale MST display unit) will void warranty. 12. Use mounting hardware that is make sure the in-line strainer/valve...
Page 97: Operating Instructions
Upon initial power up of the apparatus the concentrate into the discharge stream. The Hale FoamLogix system will go to the bargraph will light when foam is being standby mode upon completion of a self injected and indicate system capacity.
Page 98 The display shows the current flow rate example the display may show "9.5" of water or foam solution per minute in indicating 9.5 gallons of foam Hale flowsensor monitored discharges. (See figure 4-2) TANK A SELECTED Figure 4-2. Stand-By/Flow Mode Display...
Page 99 All bargraph LEDs light and the Several safety features are incorporated rightmost LED flashes warning the operator into the Hale FoamLogix system to protect that the system capacity is being exceeded the foam concentrate pump, electric motor and is running "lean" on foam concentrate and apparatus wiring while maintaining percentage.
Page 100 These modes will not function while in FLUSH mode. Low Foam Tank Level Figure 4-5. Flush Display The Hale FoamLogix foam pump is interlocked with the foam concentrate tank detected the display will show “no A” or level switch(es). If the tank is empty, the “no b”, the pump will stop, and the leftmost...
Page 101 (See figure 4-7) Figure 4-7. Priming Error Display High Ambient Temperature In the event the Hale FoamLogix system is operating in an environment of excessive ambient temperature the display will show “hiGh” to indicate this situation (see figure Figure 4-8.
Page 102: Normal Operation Summary
ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM NORMAL OPERATION SUMMARY OPERATION ACTION DISPLAY Energize System Energize apparatus and turn FoamLogix power switch to INITIAL STARTUP SELF DIAGNOSTICS Select foam tank If System equipped with dual foam tanks place selector to STANDBY DISPLAY proper tank.
Page 103 ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM OPERATION ACTION DISPLAY Change injection rate Press é or ê and hold for 2 seconds. Release once desired rate is set. Press and release é or ê. Read injection rate Display will show injection rate and return to selected function after 2 seconds.
Page 104: Simulated Flow Operation
ON. operation or manually controlling foam 4. When the Hale FoamLogix is in the injection if the flowsensor malfunctions. The standby mode, FLOW LED lit, depress and release the é and ê buttons at the factory default simulated flow rate is 150 GPM (568 LPM).
Page 105 ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM 10. Place the bypass valve to the INJECT position. Secure bypass hose in the appropriate compartment. 11. Return apparatus to normal ready condition. Section IV: Operation IV-11...
Page 106: Tank Selection With Dual Tank System
The following procedures are provided for operation of the Hale FoamLogix system with a Hale ADT or Hale MDT ΙΙ Selector 2. Flip the Hale ADT toggle switch down or turn the Hale FoamLogix MDT ΙΙ handle until installed.
Page 107: Flushing Hale Foamlogix
When returning the apparatus to ready condition after foam operations using class B foam, the Hale FoamLogix foam pump 3. Place the Hale ADT, MDT ΙΙ or MST to the must be flushed because some Class B FLUSH position. foam concentrates deteriorate rapidly.
Page 108: Operation With Remote On/Off Switch
The foam pump is designed to MDT ΙΙ is in the TANK A position and the pump liquid. When the fire pump is running Hale MST is in the FOAM TANK position the foam pump may not pump efficiently when apparatus is placed in ready against 100 to 150 PSI (7 to 10 BAR) back condition.
Page 109: Maintenance
ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM MAINTENANCE MAINTENANCE PROCEDURES 1. After each use: Flush Hale FoamLogix foam pump if Class B foam concentrate was used and return to Class A. 2. After each use: Inspect wiring, hoses, flowsensors, and connections for tightness, corrosion, leaks and/or damage.
Page 110: Troubleshooting
Hale FoamLogix. receiving pulses from the flowsensor. These q Hale FoamLogix power switch located LEDs help to ease tracing of power supply on the distribution box is in the ON faults and eliminates some of the guesswork position.
Page 111 4. If there is no indication of water flow on control unit display troubleshoot flowsensor using procedures outlined in chart 4-3. 5. If water flow can be established turn Hale FoamLogix system ON to flow foam. Observe foam pump discharge, if foam is NOT flowing refer to foam pump troubleshooting chart 4-4.
Page 112 ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM Chart 4-1. Hale FoamLogix System Troubleshooting START ENERGIZE THE APPARATUS FOR NORMAL OPERATION AND SUPPLY POWER TO PUMP OPERATOR PANEL IS FOAMLOGIX CONTROL UNIT ILLUMINATED? PROCEED TO POWER SUPPLY TROUBLESHOOTING CHART 4-2 ENGAGE APPARATUS WATER PUMP AND ESTABLISH WATER FLOW.
Page 113 ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM Chart 4-2. Power System Troubleshooting START PROCEED TO CHART CONTROL UNIT 4-1 SYSTEM ILLUMINATED? TROUBLESHOOTING. IS POWER INDICATOR CHECK CONTROL CABLE LED ON DISTRIBUTION INTEGRITY AND REPLACE CABLE BOX ON? IF NECESSARY TURN SWITCH TO OFF FOR 30 IS POWER ISOLATION SECONDS TO RESET CIRCUIT SWITCH ON?
Page 114 ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM Chart 4-3. HPF Flowsensor Troubleshooting START ESTABLISH WATER FLOW IS WATER IN ACCORDANCE WITH FLOWING? APPARATUS OPERATING PROCEDURES IS FLOWSENSOR REPLACE PADDLEWHEEL PADDLEWHEEL FLOWSENSOR JAMMED? BE FREED? PROCEED TO IS CONTROL UNIT POWER SUPPLY DISPLAY LIGHTED? TROUBLESHOOTING CHART 4-2...
Page 115 FLOWING? APPARATUS OPERATING PROCEDURE FOR ADDITIONAL IS CONTROL UNIT IS CONTROL UNIT DEPRESS ASSISTANCE CONTACT ON LED ON LED CONTROL UNIT NEAREST HALE SERVICE ILLUMINATED? ILLUMINATED? ON BUTTON CENTER IS FOAM PUMP CONTROL UNIT MOTOR BARGRAPH INDICATES OPERATING? FOAM FLOW?
Page 116: Parts Identification
ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM PARTS IDENTIFICATION FOAM PUMP ASSEMBLY PART NUMBER DESCRIPTION UNIT 501-3120-15-0 (MODEL 3.3) FM 3.3 PUMP ASSY (12 VOLT DC MOTOR) 501-3120-24-0 (MODEL 3.3) FM 3.3 PUMP ASSY (24 VOLT DC MOTOR) 501-3130-15-0 (MODEL 5.0) FM 5.0 PUMP ASSY (12 VOLT DC MOTOR) 501-3130-24-0 (MODEL 5.0) FM 5.0 PUMP ASSY (24 VOLT DC MOTOR) 501-3110-00-0...
Page 117 ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM Section IV: Operation IV-23...
Page 118 ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM ADDITIONAL FOAMLOGIX SYSTEM COMPONENTS PART NUMBER DESCRIPTION UNIT 038-1790-00-0 CHECK VALVE INJECTOR 101-1630-12-0 FOAM SYSTEM DIAGRAM NAMEPLATE (SINGLE TANK) 107064 CONTROL UNIT 110-1703-06-0 012-1440-00-0 TEE HANDLE 012-0450-00-0 HANDLE COVER 018-1003-43-0 SCREW #10-24 X 3/8 IN LG 101-1630-01-0 BYPASS PLACARD 038-1810-00-0...
Page 119 ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM FOAMLOGIX FLOWSENSOR PART NUMBER DESCRIPTION UNIT 102714 PADDLE WHEEL 4842010 SADDLE CLAMP (2 INCH) 4843010 SADDLE CLAMP (2-1/2 INCH) 4844010 SADDLE CLAMP (3 INCH) 4846010 SADDLE CLAMP (4 INCH) 4845010 SADDLE CLAMP (5 INCH) 082-3060-00-0 WELD FITTING (STAINLESS STEEL) 309020...
Page 120 ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM HALE FOAMLOGIX AIR DUAL TANK VALVE (ADT) PART NUMBER DESCRIPTION UNIT 538-1640-00-0 ADT VALVE ASSEMBLY (INCLUDES ITEMS MARKED BELOW) 010-0660-00-0 INLET LINE STRAINER 012-1430-00-0 "PULL TO BYPASS" KNOB 018-1222-12-0 SCREW ¼-20 X 2-¼ IN LG...
Page 121 ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING SYSTEM Section IV: Operation IV-27...
Page 122: Warranty
— Any notice to HALE must be in writing, identifying the Product (or component) claimed defective and circumstances surrounding its failure; — HALE reserves the right to physically inspect the Product and require Buyer to return same to HALE’S plant or other Authorized Service Facility;...

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