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Multi-Point Injection System
Models 3040, 3060, 3090, 3150, 3300
All quality FoamPro products are ruggedly designed, accurately machined, carefully assembled, thoroughly inspected
and tested. In order to maintain the high quality of your unit, and to keep it in a ready condition, it is important to follow
the instructions on care and operation. Proper use and good preventive maintenance will lengthen the life of your unit.
ALWAYS INCLUDE THE UNIT SERIAL NUMBER IN CORRESPONDENCE.
FoamPro • 26 Southern Blvd. • Nesconset, NY 11767 USA • 800-533-9511 • FAX 816-892-3178
AccuMax
INSTALLATION AND
OPERATION MANUAL
Unit
Serial
Number
Form 847
Rev. 11/14
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Table of Contents
Related Manuals for FoamPRO AccuMax 3040
Summary of Contents for FoamPRO AccuMax 3040
- Page 1 Proper use and good preventive maintenance will lengthen the life of your unit. ALWAYS INCLUDE THE UNIT SERIAL NUMBER IN CORRESPONDENCE. FoamPro • 26 Southern Blvd. • Nesconset, NY 11767 USA • 800-533-9511 • FAX 816-892-3178...
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Page 2: Table Of Contents
WARRANTY ....................Back Cover NOTE TO SYSTEM INSTALLERS IMPORTANT: Please provide a copy of the FoamPro manual to the end user of the equipment. For additional FoamPro manuals, contact by FAX 816-892-3178, web site www.foampro.com, or call 800-533-9511. Request Form No. 847. -
Page 3: Safety
Digital better as listed in Section 15, and are approved for mobile hydraulic system use. Display Control Module and all other FoamPro • Any electrical system has the potential to cause equipment before electric arc welding at any point sparks during service. - Page 4 CAUTION: Never attempt to cut or lengthen the molded cables. Doing so will result in RFI/EMI CAUTION: Do not run the FoamPro AccuMax 3000 interference. Contact the factory if molded cables system for more than one minute deadheaded of a different length are required.
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Page 5: A Quick Look At How The System Works
A basic diagram of the FoamPro system is shown in into its discharge line based on the input requirements Figure 2-1. The basic system is comprised of a master... - Page 6 Installation and Operation Manual Installation and Operation Manual Figure 2-1 FoamPro AccuMax Multi-Point System Layout...
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Page 7: System Component Description
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... - Page 8 Installation and Operation Manual Installation and Operation Manual System Accessories Available Stainless Steel Main Waterway Check Valve System Specification Placards with Drain Port System Placard System Part Number P/N 3320-0036 1-1/2" NPT thread P/N 6032-0050 3040 6032-0030 P/N 3320-0037 2" NPT thread 3060 6032-0032 P/N 3320-0038...
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Page 9: Installer Supplied Parts
Consult PTO and chassis manufacturers to determine Hydraulic Pump Drive Selection dimensions and clearances required. The foam pump for the FoamPro AccuMax MP system is powered by hydraulics. Power for the system CAUTION: The use of an accessory drive pad is... - Page 10 Fittings and hoses from the discharge of the foam pump Hydraulic Oil to the foam manifold must be supplied by the installer. Ratings and data for the FoamPro AccuMax MP Hoses and fittings are to be 1-1/2" (38.1 mm) minimum systems are based on operating with premium hydraulic for the 3040 thru 3150 systems and 2"...
- Page 11 Line Control assemblies, and any other apparatus or on the outside of the apparatus. FoamPro equipment before electric arc welding at any point on the apparatus. Failure to do so will One of those methods is to install check valves in all...
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Page 12: Installation Planning
Doing so will result in RFI/EMI plumbing and foam system configuration, it is not practical to depict exactly how each FoamPro AccuMax interference. Contact the factory if molded cables of Multi-Point system can best be installed onto a a different length are required. -
Page 13: Foam Pump And Hydraulic Control Valve Installation
Although the system is sealed and designed stresses of apparatus operation. Figures 6-1A thru to be resistant to the harsh environment of firefighting C provide the mounting dimensions for the FoamPro apparatus, a protected location with easy operator AccuMax foam pump and motor assemblies. - Page 14 [200] [251]9.9 [169] Motor Case Drain -10 SAE O-ring Port [191] [95] Figure 6-2 FoamPro 3060 Pump/Motor Assembly Installation Dimensions Port A 1.0625-12 SAE Str.Thd. O-ring Boss Case Drain 1" Split Flange Boss SAE J518 (Code 62) [83.6] Port B 1"...
- Page 15 [601] [229] 23.7 [304] [76] [259] 12.0 10.2 [191] [13] Figure 6-4 FoamPro 3150 Pump/Motor Assembly Installation Dimensions 1" SAE Split Flange 2X 1.0625 SAE Str.Thd. Port A Case Outlet [84] 1" SAE Split Flange [489] Port B [248] 19.2 [582] 22.9...
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Page 16: Hydraulic Plumbing Installation
Hydraulic Pump Hydraulic Motor Foam Pump/ Case Drain Motor Hydraulic Pump Assembly Upper Case Drain Motor Inlet Hydraulic Pump Bottom Case Drain Motor Return Figure 7-1 Simplified FoamPro AccuMax 3000 Hydraulic System Diagram (not to be used as a system schematic) - Page 17 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.
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Page 18: Water And Foam Plumbing Component Installation
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... - Page 19 Line Strainer CAUTION: Flexible hose connections are required between the major FoamPro components and the The line strainer provided with the FoamPro AccuMax main water system. Do not hard plumb the system. MP system is sized properly for most applications.
- Page 20 Select a flowmeter size based on actual flows required, not standard pipe sizes. Refer to the installation The FoamPro paddlewheel-style flowmeter fittings drawing in Section 15 for proper flowmeter sizing. are specially designed tees that make inspection and The flowmeters require that the amount of turbulence maintenance of the flow sensor easy.
- Page 21 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...
- Page 22 Installation and Operation Manual Installation and Operation Manual CAUTION: The usage of check valves or other apparatus water tank, resulting in contamination of the means isolation are not to be used as a substitute water tank with foam. A separate drain system should for proper flushing of apparatus lines after usage.
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Page 23: Electrical Equipment Installation
Complete molded cable sets are provided with each components. The last connections should be the FoamPro AccuMax MP System Module to make all the power cables to the Control Display Modules and necessary connections. - Page 24 Power (Yellow) terminals, it will cause system failure. Figure 9-2 Master and Line Control Display CAUTION: The cables shipped with each FoamPro system are tested at the factory with the unit. Improper handling and forcing connections may damage these cables and might result in other system damage.
- Page 25 AccuMax MP 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.
- Page 26 Installation and Operation Manual Installation and Operation Manual The side-mount foam tank low-level sensor must be color coded to keep them together during assembly. sealed with a suitable sealant to prevent concentrate Matching these color codes together will ensure the leakage.
- Page 27 Electrical devices can be damaged by a weak or erratic connector for power and ground power supply. The FoamPro AccuMax MP system is not Pin A + 12 or 24 VDC any different — the better the power supply, the better the system will perform.
- Page 28 The foam pump grounding, make sure radio cables and hardware are will maintain the set pressure in the manifold until the not located in the immediate area where the FoamPro system is switched to the ‘OFF’ position. AccuMax MP equipment is mounted.
- Page 29 AccuMax MP Installation and Operation Manual Installation and Operation Manual 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. •...
- Page 30 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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Page 31: Make Sure Everything Is Working Right
AccuMax MP 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. - Page 32 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. The Master Display will read HIFLO MASTER / FP.XXXX should appear for...
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Page 33: Calibration And Setup
The calibration process will make adjustments to the water flowmeters, the foam flowmeters, the foam Display control valves, and display readings. Area NOTE: FoamPro systems can be calibrated to any On/Off Mode Select unit of measure, i.e., U.S., Metric, Imperial, etc. Button... - Page 34 Installation and Operation Manual Installation and Operation Manual Line Configuration Mode position of the ball in these positions. When the display shows done, continue to the next step. Each discharge control circuit will require configuration. Depress the SELECT button until TOT CHEM The Line Control Display Module will be used to USED / 0.00 is displayed.
- Page 35 AccuMax MP Installation and Operation Manual Installation and Operation Manual PRESET RATE3 / X.X Depress the green I/O button and the display will operate the ball from closed to open and By using the up and down buttons, the last of return to close.
- Page 36 Increase or decrease the value on Wait for 15 to 30 seconds, and turn the power on. The the Line Control Display to match the value on FoamPro AccuMax 3000 system is now ready to be the Master Control Display. placed in service.
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Page 37: Operation Instructions
The control circuit will work seemlessly with The FoamPro AccuMax 3000 system will monitor the the rest of the system when required. water flows and control foam injection at the specified concentrate injection rate. - Page 38 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.
- Page 39 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. After a system check, the Master and Line display will read as shown.
- Page 40 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.
- Page 41 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.
- Page 42 7. Open foam concentrate tank shut-off valve. operation. 8. Perform required maintenance checks on the 5. If the fire pump is not running, place the FoamPro FoamPro AccuMax 3000 system. AccuMax 3000 system into the simulated flow mode and proceed with above steps.
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Page 43: Maintenance
Do not mix hydraulic fluid types. 1. After each use: It is recommended as good practice to flush the FoamPro AccuMax 3000 7. Bi-Annually: Change hydraulic oil filter. system foam pump after each use. The system... -
Page 44: Troubleshooting
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. - Page 45 AccuMax MP 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.
- Page 46 Installation and Operation Manual Installation and Operation Manual 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.
- Page 47 AccuMax MP 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.
- Page 48 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.
- Page 49 AccuMax MP 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.
- Page 50 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.
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Page 51: Specifications
AccuMax MP Installation and Operation Manual Installation and Operation Manual Specifications... - Page 52 Installation and Operation Manual Installation and Operation Manual Hydraulic Fittings and Hose Specifications Connection Model Minimum Hose ID Pump Port Fitting Motor Port Fitting & Pressure Rating & Type 3040 Suction #16 SAE O-Ring " Hydraulic Reservoir to 3060 Suction #16 SAE O-Ring "...
- Page 53 AccuMax MP Installation and Operation Manual Installation and Operation Manual Line Control Assembly Dimensions and Flow Capacities D" NPT Both Ends Note: Use the dimensions shown for the 3430-0626 for the 3430-0695 Low Flow Option Control Line. Part Number Flow Range Flowmeter Control Valve 3430-0769...
- Page 54 Installation and Operation Manual Installation and Operation Manual Parts Identification Pump/Motor Assembly 3040 2500-0026 3060 2500-0022 3090 2500-0022 3150 2500-0031 3300 2500-0031 3040 2740-0013 3060, 3090 2740-0009 3150, 3300 2740-0012 3040 thru 3300 2729-0007 3040 2740-0014 3060 2740-0008 3090, 3150, 3300 2740-0012 3040 8000-0076 3060 8000-0077 3090 8000-0078...
- Page 55 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 2660-0041 Foam Flowmeter: 1" - 3040 & 3060 2660-0042 Foam Flowmeter: 1-1/4" NPT - 3090 2660-0043 Foam Flowmeter: 1-1/2"...
- Page 56 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 3430-0626 Line Control Assembly " 3430-0627 Line Control Assembly " 3430-0628 1-1/4 Line Control Assembly "...
- Page 57 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.
- Page 58 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 Model 2660-0044 Insertion Flowmeter...
- Page 59 AccuMax MP Installation and Operation Manual Installation and Operation Manual Hydraulic Pump 3040...
- Page 60 Installation and Operation Manual Installation and Operation Manual Hydraulic Pump 3060...
- Page 61 AccuMax MP Installation and Operation Manual Installation and Operation Manual Hydraulic Pump 3090 and 3150...
- Page 62 Installation and Operation Manual Installation and Operation Manual Hydraulic Pump 3300...
- Page 63 AccuMax MP Installation and Operation Manual Installation and Operation Manual NOTES...
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Page 64: Warranty
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 one year from the date of shipment from the factory, to be free from defects in material and workmanship under normal use and service.
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