Summary of Contents for Safe Fleet FoamPro AccuMax 3040
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Form 847 Rev. 8/19 AccuMax Multi-Point Injection System Models 3040, 3060, 3090, 3150, 3300 INSTALLATION AND OPERATION MANUAL Unit Serial Number All quality FoamPro products are ruggedly designed, accurately machined, carefully assembled, thoroughly inspected and tested. In order to maintain the high quality of your unit, and to keep it in a ready condition, it is important to follow the instructions on care and operation.
Installation and Operation Manual Installation and Operation Manual TABLE OF CONTENTS SECTION PAGE SAFETY ........................... 3 A QUICK LOOK AT HOW THE SYSTEM WORKS ............5 SYSTEM COMPONENT DESCRIPTION ................ 7 INSTALLER SUPPLIED PARTS ..................9 INSTALLATION PLANNING ..................12 FOAM PUMP AND HYDRAULIC CONTROL VALVE INSTALLATION ......
AccuMax MP Installation and Operation Manual Installation and Operation Manual Safety Before attempting to install an AccuMax Multi-Point Injection System, read all of the following safety precautions and follow carefully. The following special notices are used to notify and advise •...
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Installation and Operation Manual Installation and Operation Manual WARNING: Always disconnect the ground straps, CAUTION: The foam tank low-level sensor must be electrical wires and control cables from the Digital utilized to protect the foam pump from dry running. Display Control Module and all other FoamPro Failure to do so will void warranty.
AccuMax MP Installation and Operation Manual Installation and Operation Manual A Quick Look At How The System Works The FoamPro AccuMax Multi-Point injection system is line display controller. The line controller displays and an electronically controlled, hydraulically driven, foam communicates the proper information to the master concentrate proportioning system designed to provide controller to ensure the proper amount of concentrate the wide range of foam concentrate injection rates...
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Installation and Operation Manual Installation and Operation Manual Figure 2-1 FoamPro AccuMax Multi-Point System Layout...
AccuMax MP Installation and Operation Manual Installation and Operation Manual System Component Description The following components are packaged with the standard FoamPro AccuMax Multi-Point system: Master Driver Control Master Control Display Hydraulic Supply Hydraulic Motor & Foam Pump Pump Assembly Foam Inlet Strainer Pressure Transducer...
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Installation and Operation Manual Installation and Operation Manual System Accessories Available Main Waterway Check Valve with Drain Port System Specification Placards Size/ Thread All Stainless Steel System Placard System Part Number 1-1/2" NPT P/N 3320-1001 P/N 6032-0050 3040 6032-0030 2" NPT P/N 3320-1002 3060 6032-0032...
AccuMax MP Installation and Operation Manual Installation and Operation Manual Installer Supplied Parts FoamPro AccuMax MP systems are provided with Other shaft configurations are available. Check with the major components and accessories required for FoamPro factory for other configurations that may be installation.
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Installation and Operation Manual Installation and Operation Manual positioned so that the flow to the reservoir is discharged below the normal fluid level, and also directed into Hydraulic Hoses and Fittings the interior of the reservoir for maximum dwell and High pressure hydraulic hoses and fittings are to be rated deaeration of the fluid.
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AccuMax MP Installation and Operation Manual Installation and Operation Manual ID of the pipe connection before the foam flowmeter of Drain lines must be provided from all water and foam each foam discharge assembly. Hoses and fittings are to solution piping components to prevent freezing in cold be rated at or above 400 PSI (28 BAR) working pressure.
Installation and Operation Manual Installation and Operation Manual Installation Planning Because of the potential differences in apparatus CAUTION: Never attempt to cut or lengthen the molded cables. Doing so will result in RFI/EMI plumbing and foam system configuration, it is not practical to depict exactly how each FoamPro AccuMax interference.
AccuMax MP Installation and Operation Manual Installation and Operation Manual Foam Pump/Motor Installation Hydraulic-Driven Foam Pump Assembly Choosing the Proper PTO The AccuMax systems are designed to be used with It is important to turn the hydraulic pump at the proper various gear type foam pumps currently in use in the speed to ensure that the correct hydraulic pressure is industry.
Installation and Operation Manual Installation and Operation Manual Hydraulic Plumbing Installation Figure 7-1 provides some recommended guidelines CAUTION: Use only approved petroleum-based hydraulic fluids as described in Section 4. Never for the location of the hydraulic system components. When making hydraulic component connections, mix fluid types.
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AccuMax MP Installation and Operation Manual Installation and Operation Manual Hydraulic Reservoir Hydraulic Supply Pump Connections The reservoir for the hydraulic system is to conform After completion of the mounting of all hydraulic system to the description in Section 4 and to all SAE and components, hose connections must be made.
Installation and Operation Manual Installation and Operation Manual Water and Foam Plumbing The following diagram (Figure 8-1) provides recommended guidelines for the installation of the system components that handle water, foam concentrate, and foam solution. Figure 8-1...
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AccuMax MP Installation and Operation Manual Installation and Operation Manual Line Strainer CAUTION: Flexible hose connections are required between the major FoamPro components and the The line strainer provided with the FoamPro AccuMax MP main water system. Do not hard plumb the system. system is sized properly for most applications.
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Installation and Operation Manual Installation and Operation Manual Horizontal Positioning Vertical Positioning Figure 8-4 Foam Flowmeter Positioning elbow or valve. Valves create severe turbulence when they are “gated down” as shown in Fig. 8-2. Figure 8-2 Flowmeter Placement 4. Try to mount the flowmeters in a position that is accessible for routine inspection and maintenance.
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AccuMax MP Installation and Operation Manual Installation and Operation Manual Foam Strainer Mounted Injection From Foam on Foam Pump Inlet Point Tank Appropriate Check ID Hose Valve Figure 8-5 Injector Fitting Placement for Multiple Discharge Check Valve From Fire Pump Injector Above Flush Water Shut-Off Valve Horizontal Plane...
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Installation and Operation Manual Installation and Operation Manual CAUTION: The usage of check valves or other water tank with foam. A separate drain system should means isolation are not to be used as a substitute be provided for the foam solution piping to prevent for proper flushing of apparatus lines after usage.
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AccuMax MP Installation and Operation Manual Calibration/Test Manifold ● Manifold is to be at least one pipe size larger than the largest Line Control assembly pipe size. It may be advantageous to install a Calibration/Test manifold into the AccuMax system for ease of calibration ●...
Installation and Operation Manual Installation and Operation Manual Electrical Equipment Installation Some Things to Keep in Mind Electrical Connections • Do not hookup the main power cables until all Follow the system electrical diagram (Figure 9-1) for connections are made to each of the electrical proper hookup of each of the electrical components.
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AccuMax MP Installation and Operation Manual Installation and Operation Manual NOTE: Do not mount radio transmitter or Local Bus Local Bus transmitter cables in direct or close contact with (Black) (Black) the FoamPro units. • Use care when installing molded cables. Count pins or check color codes before connecting.
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Installation and Operation Manual Installation and Operation Manual The connections for the foam flowmeter used on Hydraulic Pump Control Connection the 3300 system are shown in Fig. 9-10. The 3-pin The Hydraulic Pump Control cable is a purple-colored molded end connects to the Master Control Driver in the jacket cable with an orange molded end.
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AccuMax MP Installation and Operation Manual Installation and Operation Manual The side-mount foam tank low-level sensor must be Matching these color codes together will ensure the sealed with a suitable sealant to prevent concentrate compatibility of these components together. leakage. After installation, check operation of the side- mount foam tank low-level sensor with a powered test Line Control Display Module light.
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Installation and Operation Manual Installation and Operation Manual Line Water Flowmeter Connections Figure 9-10. The wiring on the power connection is: PIN A to + power, PIN B to ground. Be sure to install a 5 amp A FoamPro paddlewheel-type flowmeter is to be fuse to the + power supply.
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AccuMax MP Installation and Operation Manual CAUTION: Connecting other high power devices to the power or ground supply to the FoamPro system will cause component damage. The system will draw an approximate maximum of 5 Amperes and must be protected with a 10 Amp fuse in the main power line to the system and provides enough power and protection for all displays, drivers, and associated components.
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Installation and Operation Manual Installation and Operation Manual Solid State Contactor Option The usage of the optional solid state contactor is recommended to help protect the FoamPro system from excessive voltage surges that can take place in fire apparatus systems. The solid state contactor also has a higher life expectancy than mechanical relay options typically used for this application.
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AccuMax MP Installation and Operation Manual Installation and Operation Manual +12 or +24 VDC Extension Cable 2520-0134 Figure 9-11 Manual Override Schematic A manual means of metering foam into the waterway will need to be provided. This can be done using a few different methods as described.
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Installation and Operation Manual Installation and Operation Manual • Adding a separate foam manifold with a 3-way ball valve leading to individual foam metering ball valves to control the foam flow as shown. • There may be alternative methods to use for the plumbing for manual operation. Please check with the factory for assistance.
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AccuMax MP Installation and Operation Manual Installation and Operation Manual System Power Check Turn on the main power to the FoamPro AccuMax MP System and turn the Control Driver switches to the on position on both the master and line controllers. Check the display readouts.
Installation and Operation Manual Installation and Operation Manual Make Sure Everything Is Working Right Hydraulic Supply (Refer to Sections 4 & 7) Hydraulic pump is properly mounted to the PTO. Hydraulic oil lines are properly routed and tight. Filter(s) are installed and tight. Oil reservoir is filled with correct fluid.
AccuMax MP Installation and Operation Manual Installation and Operation Manual Calibration and Setup System Setup Procedures FoamPro AccuMax MP system permits easy calibration of the foam proportioning unit to assure accurate operation. The calibration process will make adjustments to the water flowmeters, the foam flowmeters, the foam Display control valves, and display readings.
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Installation and Operation Manual Installation and Operation Manual USING BYPASS / No This is to select the low end option. No means Depress the SELECT button until TOT CHEM USED this feature is disabled. To enable this feature, / 0.00 is displayed. Since any one of the lines needs to press the down button once and the display will be open to run the foam pump, pick one of the lines to read YES.
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AccuMax MP Installation and Operation Manual Installation and Operation Manual at least ½ gallon (1.9 liters). It should be noted that the Compare the readout on the Master Control Display with the value shown on the flowmeter more accurate the Master and “control” are, the better totalizer or with the volume collected in the calibration will be on the rest of the system.
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Installation and Operation Manual Installation and Operation Manual Line Water Flowmeter NOTE: It is critical that an accurate flow measuring NOTE: It is recommended when calibrating the device be used to measure water flow to calibrate the foam flowmeters to run a small volume of fluid, flowmeter(s).
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AccuMax MP Installation and Operation Manual System Reset During calibration procedures, it may be necessary to Cal/Inject return the system to the original factory default settings Valve on if errors are made and the system locks up. To return Foam Pump to the factory default values, enter calibration and setup mode as previously described.
Installation and Operation Manual Installation and Operation Manual Operation Instructions Normal System Operation If the flow decreases so the required injection rate is less than the lowest rating of the pump, the pump will Once the system has been set up and calibrated, run at its minimum rate and LO.FLO will flash on the operation is very simple and is controlled by the buttons display to let the operator know the system is running...
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AccuMax MP Installation and Operation Manual Installation and Operation Manual Display Messages RATE / XX: The display shows the accumulated water or foam solution rate being pumped. Several safety features are provided to protect the foam This totalized value is accumulated from the Line concentrate pump and the hydraulic drive system.
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Installation and Operation Manual Installation and Operation Manual Normal Operation Summary How to Display Action 1. Turn on system. 1. Operate the apparatus engine and Master engage PTO to hydraulic pump. Turn on the electrical power to the FoamPro PR/H2O RATE AccuMax 3000 system.
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AccuMax MP Installation and Operation Manual Installation and Operation Manual Normal Operation Summary How to Display Action 6. Read the total amount of foam 6. To read the total foam used on the Master concentrate used. Master Control Display, press the TOT CHM USED SELECT button until the display shows TOT CHM USED / X as shown.
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Installation and Operation Manual Installation and Operation Manual Simulated Flow Operation Warning: When operating the FoamPro AccuMax The Simulated Flow function of the system allows the 3000 system in the Simulated Flow function, an operator to control the line injection and foam pump outlet for the foam concentrate injection must manually.
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AccuMax MP Installation and Operation Manual Installation and Operation Manual Flushing Foam Pump Priming the Foam Pump when Foam Tank When returning the apparatus to ready condition after has Run Dry foam operations, the FoamPro foam pumps should be In some instances, the foam tank may run dry while flushed with fresh water.
Installation and Operation Manual Installation and Operation Manual Maintenance Maintenance Procedures 7. Bi-Annually: Change hydraulic oil filter. 3040 Filter 3800-0100 1. After each use: It is recommended as good 3060 thru 3300 3800-0101 practice to flush the FoamPro AccuMax 3000 system foam pump after each use.
AccuMax MP Installation and Operation Manual Installation and Operation Manual Troubleshooting The majority of troubleshooting can be done by the UP or DOWN button will select either the HIFLOW MSTR, the MASTER PUMP, or the BYPASS VALVE (if accessing the diagnostics mode. In this mode, it is possible to display the operating parameters of the selected) diagnostics.
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Installation and Operation Manual Installation and Operation Manual Pressing the SELECT button will allow diagnostics of Pressing the UP button will reveal the local the power supply voltage and display POWER SUPPLY bus firmware by displaying LOC BUS F/W / / XX.X.
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AccuMax MP Installation and Operation Manual Installation and Operation Manual Return to Suction Side of Foam Pump Figure 14-2 System Diagram mode. The display will read CHM PULS/SEC / XXX. Pressing the SELECT button will display the firmware This mode is also a running mode, and by pressing the version.
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Installation and Operation Manual Installation and Operation Manual Pressing the UP or DOWN button will place the Pressing the SELECT button again will enter the diagnostics in the DISCHG VALVE / dIAg mode. This control valve circuitry displaying the % of open condition mode will perform diagnostics on the Line Control of the control valve by displaying CNTRL OUTPUT / Driver.
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AccuMax MP Installation and Operation Manual Installation and Operation Manual Symptom Probable Cause(s) Corrective Action Engage Line Control. Pump does not run. Line Control not on. No change in message on Open discharge line to establish Line Control not requiring any foam Master Display.
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Installation and Operation Manual Installation and Operation Manual Symptom Probable Cause(s) Corrective Action Remove suction line and check Foam pump runs but no foam Obstruction in suction line. for loose liner or debris. Avoid all being pumped. unnecessary bends. Do not kink NO CHEM FLOW flashes on hose.
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AccuMax MP Installation and Operation Manual Installation and Operation Manual Symptom Probable Cause(s) Corrective Action Turn on main power switch on Nothing shows on any of the The main power switch is not on. apparatus. displays. One or more displays do not Cables not properly connected.
Installation and Operation Manual Installation and Operation Manual Specifications Specifications Contents The following section includes: ● Standard part information ► Standard part identification ................Pages 53 - 55 ► Standard part performance ..................Page 56 ► Standard part dimensional information ............Page 57 - 58 ►...
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AccuMax MP Installation and Operation Manual Installation and Operation Manual Line Control Assembly Dimensions and Flow Capacities D" NPT Both Ends Part Number Flow Range Flowmeter Control Valve 3430-0727 16 5/8" 7 3/16" 5" 1/2" NPT 2.6-26 GPM 2660-0058 2590-0026 3430-0627 18 3/4"...
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Installation and Operation Manual Installation and Operation Manual Standard Misc. Components Hydraulic Pump Operating Instruction Foam Relief Valve Line Waterway Flowmeter 3040 2500-0071 Placard 3300-0101 (See page 57) 3060 2500-0063 6032-0051 3090, 3150 2500-0030 3300 2500-0133 Hydraulic Pump Foam Pump Y Strainer Suction Filter Waterway Flowmeter Cable 3040...
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AccuMax MP Installation and Operation Manual Installation and Operation Manual Master Control Module Parts Ref. Part No. Description Qty. 2527-0080 Master Control Display 2527-0082 Master Control Driver 2660-0040 Foam Flowmeter: 3/4" - 3040 2660-0041 Foam Flowmeter: 1" - 3060 2660-0042 Foam Flowmeter: 1-1/4"...
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Installation and Operation Manual Installation and Operation Manual Line Control Module Parts Ref. Part No. Description Qty. 2527-0081 Line Control Display 2527-0083 Line Control Driver 3430-0727 1/2" Line Control Assembly 3304-0027 1" Calibrate / Inject Valve (Bushings included to 1/2") 3320-0029SS 3/4"Injection Check Valve (Bushings included to 1/2") 3430-0627...
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AccuMax MP Installation and Operation Manual Installation and Operation Manual Line Waterway Flowmeter Specifications Sensor Assembly O-Rings 4.00* min. (102 mm) 85° max. Retaining Ring see Note #3 Female Pipe Threads 3.12* min. (79 mm) Grooved for B Pipe NOTES: 1.
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Installation and Operation Manual Installation and Operation Manual Cutout Dimensions for Master and Line Control Display Module 5.56 Min 6.00 2.74 5.38 5.38 4.06 4.75 ø .21 (4) Holes For #10 Mounting Screws Cutout Dimensions for Instruction, System, System Spec. Placards Model 2660-0044 Insertion Flowmeter 4.25...
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AccuMax MP Installation and Operation Manual Installation and Operation Manual Hydraulic Pump 3040...
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Installation and Operation Manual Installation and Operation Manual Hydraulic Pump 3060...
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AccuMax MP Installation and Operation Manual Installation and Operation Manual Hydraulic Pump 3090 and 3150...
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Installation and Operation Manual Installation and Operation Manual Hydraulic Pump 3300...
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AccuMax MP Installation and Operation Manual Installation and Operation Manual Specifications for Fire Lion Pump Systems System Capacity Maximum Water Flow GPM (LPM) Foam Concentrate Rate 3040 3060 3090 3150 3300 4,000 (15,142) 6,000 (22,712) 9,000 (34,069) 15,000 (56,781) 30,000 (113,563) 1,333 (5,046) 2,000 (7,571) 3,000 (11,356)
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Installation and Operation Manual Installation and Operation Manual Fire Lion Hydraulic Fittings and Hose Specifications Connection Model Minimum Hose ID Pump Port Fitting Motor Port Fitting & Type & Pressure Rating 3040 1" Suction #16 SAE O-Ring 3060 1" Suction #16 SAE O-Ring Hydraulic Reservoir to Hydraulic Charge...
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Installation and Operation Manual 3090 – Trident Pump/Motor Assembly (P/N 3450-1044) 8.00 CASE DRAIN PORT SAE -10 ORB 12.51 9.25 2" VICTAULIC SUCTION PORT 2" VICTAULIC DISCHARGE PORT 5.63 CASE DRAIN PORT SAE -10 ORB PORT A 12.38 3/4" SPLIT FLANGE BOSS SAE J518 (CODE 62) PORT B 10.49...
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AccuMax MP Installation and Operation Manual 3300 – Trident Pump/Motor Assembly (P/N 3450-1046) SUCTION PORT DISCHARGE PORT 4" GROOVED VICTAULIC 4" GROOVED VICTAULIC 8.00 4.00 CASE DRAIN SAE -10 ORB 12.51 5.63 CASE DRAIN SAE -10 ORB 5.50 14.47 11.00 PORT A PORT B 1"...
Installation and Operation Manual Limited Warranty Fire Research Corp. (FRC), as supplier of FoamPro, warrants to the original purchaser, each new pump, system or other product of its own manufacture, for a period of two years from the date of shipment from the factory, to be free from defects in material and workmanship under normal use and service.