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FoamPRO AccuMax 3020 Installation And Operation Manual

Single-point injection systems
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Single-Point Injection Systems
Models 3020/3040/3060/3090/3150/3300
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 • 375 Fifth Avenue NW • New Brighton, MN 55112 USA • (651) 766-6300 • FAX (651) 766-6614
AccuMax
INSTALLATION AND
OPERATION MANUAL
Unit
Serial
Number
Form 903
Rev. B

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Summary of Contents for FoamPRO AccuMax 3020

  • Page 1 Proper use and good preventive maintenance will lengthen the life of your unit. ALWAYS INCLUDE THE UNIT SERIAL NUMBER IN CORRESPONDENCE. FoamPro • 375 Fifth Avenue NW • New Brighton, MN 55112 USA • (651) 766-6300 • FAX (651) 766-6614...

  • 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 Hypro by FAX 800-323-6496, web site www.foampro.com, or call (800) 533-9511. Request Form No. 903.

  • Page 3: Safety

    AccuMax SP Installation and Operation Manual Safety Before attempting to install a FoamPro AccuMax System, read all of the following safety precautions and follow carefully. The following special notices are used to notify and • Any electrical system has the potential to cause advise the user of this product of procedures that may sparks during service.
  • Page 4 Pay close attention to engine and transmission manufacturer drive CAUTION: Do not run the FoamPro system for more limitations. than one minute deadheaded against the pressure gauge as the foam pump could be damaged.

  • Page 5: A Quick Look At How The System Works

    The basic FoamPro system is shown in Figure 2-1. The Order optional system components listed in Section 3 to flowmeter measures the water flow and sends a signal accommodate system design and requirements.
  • Page 6 Installation and Operation Manual Figure 2-1 FoamPro 3000 System Layout...

  • Page 7: System Component Description

    5. Low-Tank Level Sensor (One required. Not found in Section 15. Up to four flowmeter sensors packaged with the unit. Order separately.) can be used with the FoamPro System when a 6. Hydraulic Control Driver MultiFlo interface is used.) 7. Calibrate/Inject Valve 12.
  • Page 8 FoamPro MultiFlo Interface The basic system requires at least one flowmeter to sense water flow in the discharge piping. The FoamPro MultiFlo Interface allows a total of four flowmeters to be used. The display will show the System Placard discharge flow on the selected flowmeter.

  • Page 9: Installer Supplied Parts

    Hydraulic Pump Drive Selection retrofit, all clearances must be taken into account. Consult PTO and chassis manufacturers to determine The foam pump for the FoamPro AccuMax SP system is dimensions and clearances required. powered by hydraulics. Power for the system comes...
  • Page 10 (31.8 mm) minimum for the 3090; 1-1/2” (38.1mm) for the 3150; and 2” (50.8mm) for the 3300 systems inside Ratings and data for the FoamPro AccuMax SP system diameter, rated at or above 400 PSI (28 BAR) working are based on operating with premium hydraulic fluids pressure.
  • Page 11 (at the main unit. The standard FoamPro AccuMax SP system waterway) due to static head pressure. The concentrate requires a minimum of 5 amperes at a voltage of 12 or check valve is included with each system (3/4”...

  • Page 12: Installation Planning

    Digital Display Control Module. practical to depict exactly how each FoamPro unit can Consideration must be given for routing the control best be installed onto a particular apparatus. Most of the...

  • Page 13: Foam Pump & Hydraulic Control Valve Installation

    [127] [83] [181] [248] Port A 1-1/16”-12 Straight Thd Port B O-Ring Port 1-1/6”-12 [114] Straight Thd Case Drain Port O-Ring Port 7/8”-14 UNC Straight Thd [64] O-Ring Port [10] Figure 6-1 FoamPro 3020 and 3040 Pump/Motor Assembly Installation Dimensions...
  • Page 14 [200] [251] [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. 1” Split Flange Boss O-ring Boss Case Drain 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...

  • Page 16: Hydraulic Plumbing Installation

    Hydraulic Power Source The fittings required to connect the hydraulic hoses to the FoamPro AccuMax SP foam pump motor and The hydraulic power for the FoamPro AccuMax SP hydraulic supply pump are SAE ORB (O-Ring Boss) system is supplied by a hydraulic pump mounted on the fittings with SAE JIC 37°...
  • Page 17 AccuMax SP Installation and Operation Manual Hydraulic Reservoir Hydraulic Oil Cooler The hydraulic reservoir for the system is to conform to An oil cooler is required in the hydraulic system to the description in Section 4 and to all SAE and DOT ensure proper oil temperature for optimum performance standards.

  • Page 18: Water And Foam Plumbing Component Installation

    Note that additional potential interferences. Figure 8-1 FoamPro AccuMax SP System Piping...
  • Page 19 This valve must be accessible by the pump maintain accuracy of the FoamPro system when using operator during normal operations. The valve is a 3- the FoamPro paddlewheel flowmeter in a tee or in the way directional control valve that selects where the FoamPro Manifold.
  • Page 20 (See Figure 8-4). Figure 8-2 Flowmeter Placement Most foam concentrates by nature mix with water very The FoamPro paddlewheel-style flowmeter fittings are quickly, so each discharge from a manifold will receive specially designed tees that make inspection and equal amounts of foam concentrate if the manifold is maintenance of the flow sensor easy.
  • Page 21 AccuMax SP Installation and Operation Manual Flowmeter Injection Port (Optional location on other side of Flowmeter) DON’T Injector Above Main Waterway Horizontal Plane Check Valve Drain Port Minimum length of nipple for Injector Below 2-1/2'' pipe is 12-1/2'' (318 mm). Horizontal Plane Refer to Table on Page 20 for recommended nipple lengths for...
  • Page 22 Installation and Operation Manual Drain Lines On apparatus with multiple drain lines, the drains Switch to disconnect Level Sensor when in from the foam solution discharge line should not be Outboard piped into a multi-drain system before the check Foam valves.

  • Page 23: Electrical Equipment Installation

    Foam Tank Low-Level Sensor Foam Flowmeter Large Beads Control Digital Display Cable Control Module Flowmeter Cable Hydraulic Pump DC Power + & - Small Beads Flowmeter Figure 9-1 FoamPro AccuMax SP Electrical Wiring Diagram...
  • Page 24 (red coded cable ends) from the hydraulic FoamPro Flowmeter pump valve driver box terminal (See Figure 9-2) to the If a single FoamPro paddlewheel-type flowmeter is to 5-pin connector on the back of the Digital Display be used, a molded cable is supplied which connects Control Module (See Figure 9-3).
  • Page 25 Refer to the MultiFlo Interface instructions for nipple attached to the top of the tank. Ensure the pipe installations requiring multiple FoamPro Flowmeters. nipple is rigid enough to withstand the force of the Figure 9-4 shows the connection of the flowmeters and sloshing foam when the vehicle is in motion.
  • Page 26 "extra" cable in the truck. power supply. The FoamPro AccuMax SP is not different Refer to the parts list in Section 15 for part numbers of - the better the power supply, the better the FoamPro will different size control and flowmeter cables. perform.
  • Page 27 AccuMax SP Installation and Operation Manual Hydraulic Motor-Driven Foam Pump Driver Box Modular Cable Large Beads Control Cable Wire Ties DON’T Control Large Cable Beads Flowmeter Cable Modular Cable Small Beads Figure 9-8 Extra Cable Storage Digital Display Control Module Flowmeter Figure 9-7 RFI/EMI Bead Installation Foam Discharge Flowmeters...
  • Page 28 Installation and Operation Manual Manual Override (Optional) The Manual Override option allows the operator to disengage the automatic proportioning system and control the foam pump manually. The manual override will allow the usage of the hydraulically-driven foam pump to deliver foam to the water lines.
  • Page 29 AccuMax SP Installation and Operation Manual The following procedure should be used when engaging this operation: 1. Turn off AccuMax Display Controller. 2. Turn the Manual Override switch to the ‘OFF’ position. The AccuMax displays should not be illuminated. 3. Close the 2-way manual foam control valve (not supplied) feeding the discharge line being used until it is about 1/4 of the way open.

  • Page 30: Make Sure Everything Is Working Right

    Installation and Operation Manual Make Sure Everything Is Working Right Hydraulic Supply (Refer to Sections 4 & 7) K Hydraulic pump is properly mounted to the PTO. K Hydraulic oil lines are properly routed and tight. K Filter(s) are installed and tight. K Oil reservoir is filled with correct fluid.
  • Page 31 CAL/INJECT valves back to the inject position. • If you are still having difficulty priming one or both of the foam pumps in your FoamPro system, do the following: 1. Make sure the foam concentrate tank shut-off valve is open.
  • Page 32 Installation and Operation Manual • Perform Steps 1 through 3 to wet the foam pumps to speed the priming operation. 1. Remove the pipe plug from the top of the gear pump. 2. Fill the pump with concentrate. 3. Replace the pipe plug. CAUTION: When pouring foam concentrate directly into the foam pump, the inlet strainer is...

  • Page 33: Calibration And Setup

    Cover Screw and O-ring to left of the Display Readout Panel on the Digital Display Control Module The FoamPro controller is factory defaulted to the dual (See Figure 11-1). tank option. If you are installing a remote start/stop...
  • Page 34 Foam Concentrate Injection Rate container is not available, a scale can be used to weigh When power is supplied to the FoamPro AccuMax SP the foam concentrate pumped. The total volume of foam system, the foam concentrate injection rate in memory concentrate pumped can then be calculated from this will be the default injection rate setting.
  • Page 35 Repeat this procedure as often as required to These Setup and Calibration procedures complete the yield the accuracy desired. adjustment of the system. The FoamPro system is now ready to be placed in service. Turn the CAL/INJECT valve back to the INJECT position.

  • Page 36: Operation Instructions

    ON status lamp will flash when foam is being injected. maximum rate and HI.FLO will flash on the digital The FoamPro system will monitor the water flows and display so that the operator realizes that the system control foam injection at the specified concentrate capacity is being exceeded and is running lean on foam injection rate.
  • Page 37 AccuMax SP Installation and Operation Manual Foam Percentage (%) If the flow decreases so the required injection rate is less than the lowest rating of the pump, the pump will When the concentrate percentage (%) is selected, the run at its minimum rate and LO.FLO will flash on the buttons will respectively increase or down display to let the operator know the system is running...
  • Page 38 Installation and Operation Manual Normal Operation Summary How to Action Display 1. Turn FoamPro system on. 1. Operate the apparatus engine to develop hydraulic pressure. Turn the FoamPro Main Power HYPRO circuit breaker switch on. HYPRO will appear on the display momentarily.
  • Page 39 The water flow rate through the foam discharge(s) will be displayed whether foam is being pumped or not. 8. Turn the FoamPro system off. 8. Turn the apparatus Master or Battery switch off. The system can also be turned off by using the circuit breaker switch on the valve driver box.
  • Page 40 Installation and Operation Manual Simulated Flow Operation Warning: When operating the FoamPro in the Simulated Flow function, an outlet for the foam The Simulated Flow function of the system allows the concentrate injection must be provided. Otherwise, operator to control the foam pump manually. The water...
  • Page 41 FOAM button.The foam pump will operate and foam concentrate will be discharged from the outlet tube. NOTE: FoamPro must be in Simulated Flow Mode. 5. Turn the Simulated Flow 5. Press both rate adjustment buttons at the same time.
  • Page 42 The pump is now primed and ready for normal operation. 6. Open foam concentrate tank shut-off valve. 5. If the fire pump is not running, place the FoamPro 7. Perform required maintenance checks on the system into the simulated flow mode and proceed FoamPro AccuMax SP.

  • Page 43: Maintenance

    Maintenance Procedures NOTE: Other types of hydraulic fluids are too viscous for proper load sense compensator 1. After each use: Flush FoamPro AccuMax SP foam operation. Do not mix hydraulic fluid types. pumps with fresh water (required if using other than Class A foam concentrate).

  • Page 44: Troubleshooting

    Installation and Operation Manual Troubleshooting Entering Diagnostic Mode value should be zero. This is a function test for the flowmeter. Removing the flowmeter sensor from its tee Diagnostic mode is entered by removing the Cover and spinning the paddlewheel should produce a reading Screw and O-ring on the right-hand side of the Digital other than zero on the display.
  • Page 45 AccuMax SP Installation and Operation Manual Foam Tank Low-Level Sensor Foam Flowmeter Large Beads Control Cable Flowmeter Cable To 12 or 24 VDC Small Beads Digital Display Control Module Flowmeter Figure 14-2 Electrical Wiring Diagram Symptom Probable Cause(s) Corrective Action Pump does not run.
  • Page 46 Installation and Operation Manual Symptom Probable Cause(s) Corrective Action Foam Flowmeter sensor Inspect wiring and connection Pump runs for 8 to 10 seconds circuit open. to foam flowmeter. then shuts down. ERR.HY may be flashed on display. Foam Flowmeter Check to ensure that the positioned incorrect.
  • Page 47 AccuMax SP Installation and Operation Manual Symptom Probable Cause(s) Corrective Action System returns to standby mode Poor ground to valve driver box. Make sure screws are tight and while pumping or HYPRO appears a good ground is maintained. momentarily while pumping. Low hydraulic oil pressure.
  • Page 48 Installation and Operation Manual Symptom Probable Cause(s) Corrective Action System cannot be calibrated. Calibration values selected are out Perform system reset as of range of system or setup memory described in Calibration Section is full. and recalibrate. Cannot enter Calibration Mode. Truck hydraulics and hydraulic valve Make sure hydraulic system is driver is not turned on.

  • Page 49: Specifications

    AccuMax SP Installation and Operation Manual Specifications...
  • Page 50 Installation and Operation Manual Hydraulic Fittings and Hose Specifications Connection Model Minimum Hose ID Pump Port Fitting Motor Port Fitting & Pressure Rating & Type 3020/3040 1” Suction #16 SAE O-Ring Hydraulic Reservoir to 3060 1” Suction #16 SAE O-Ring Hydraulic Charge 3090 1”...
  • Page 51 AccuMax SP Installation and Operation Manual Miscellaneous Standard Components Ref. Part No. Description Ref. Part No. Description 3320-0046 Check Valve 3020, 3040 3304-0027 Calibrate/Inject Valve 3020 - 3060 3320-0041 Check Valve 3060 3304-0026 Calibrate/Inject Valve 3090 3320-0047 Check Valve 3090 3304-0029 Calibrate/Inject Valve 3150 3304-0030...
  • Page 52 Installation and Operation Manual Parts Identification AccuMax SP Pump/Motor Assembly Ref. Part No. Description Qty. 8000-0075 Foam Pump - 3020 8000-0076 Foam Pump - 3040 8000-0077 Foam Pump - 3060 8000-0078 Foam Pump - 3090 8000-0079 Foam Pump - 3150 8000-0080 Foam Pump - 3300 2740-0014...
  • Page 53 AccuMax SP Installation and Operation Manual Cutout Dimensions for Display Control Module Display Requires 3-7/8'' (98 mm) Diameter Hole 1.04 3.50 2.70 4.25 26.3 68.7 88.9 4.25 3.50 88.9 #10 24 UNC x 7/16 DP (4) Holes for Mounting Cutout Dimensions for Instruction, System, System Spec.
  • Page 54 Installation and Operation Manual Flowmeter Specifications Sensor Assembly O-Rings 4.00* min. (102 mm) Retaining Ring NOTE #3 Female Pipe Threads 3.12* min. (79 mm) Grooved for pipe NOTES: 1. Use caution not to damage sensor during assembly. 2. Use Loctite ® PST or equivalent teflon tape to seal pipe threads.
  • Page 55 AccuMax SP Installation and Operation Manual Hydraulic Pump 3020 & 3040...
  • Page 56 Installation and Operation Manual Hydraulic Pump 3060...
  • Page 57 AccuMax SP Installation and Operation Manual Hydraulic Pump 3090, 3150...
  • Page 58 Installation and Operation Manual Hydraulic Pump 3300...
  • Page 59 AccuMax SP Installation and Operation Manual Notes...

  • Page 60: Warranty

    Styrofoam and other packaging materials, as it was received at your facility. FoamPro appreciates your attention in this matter, as we feel it will help us to serve you in a better fashion, while keeping the cost of the FoamPro product competitive.

This manual is also suitable for:

Accumax 3040Accumax 3060Accumax 3090Accumax 3150Accumax 3300

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