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FoamPRO 2002 Series Installation And Operation Manual

Electric motordriven, flow-based proportioning systems that measure water flow and then inject the proportional amount of foam concentrate to maintain the preset percentage
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Systems 2001, 2002,
2002HP and 2024
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
INSTALLATION AND
OPERATION MANUAL
Unit
Serial
Number
Form 829
6/16
1

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  • 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...

  • 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. 829.

  • Page 3: Safety

    System 2000 System 2000 Installation and Operation Manual Installation and Operation Manual Before attempting to install a FoamPro System 2001/2002/2024, Safety read all of the following safety precautions and follow carefully. 1. Do not pump at pressures higher than the 11.

  • Page 4: A Quick Look At How The System Works

    Installation and Operation Manual Installation and Operation Manual A Quick Look at How the System Works The FoamPro 2000 series systems are electric motor- Since foam is injected on the discharge side of the fire driven, flow-based proportioning systems that measure...

  • Page 5: System Component Description

    Installation and Operation Manual Installation and Operation Manual System Component Description STANDARD FOAMPRO 2000 SYSTEM EQUIPMENT 8. FoamPro Paddlewheel Flowmeter or Manifold The following components are packaged with the (The flowmeter is a required component and must FoamPro 2000 series: be ordered separately.
  • Page 6 2002 Series and larger only with interface to controller to controller CAFS Power-Link Remote Start/Stop Interfaces FoamPro system with CAF system Single Tank Flush Kits Both Internal and External flushing kits FoamPro MultiFlo Interface Dual Injection Management System Combines 2 to 4 flowmeters...

  • Page 7: Installer Supplied Parts

    Installation and Operation Manual Installer Supplied Parts The FoamPro 2000 series systems are provided with the major components and accessories required for installation. Due to differences in chassis and apparatus configurations, the installer must provide pipe, hoses, tubing, wire and fittings to satisfy installation requirements. The following paragraphs list the specifications for selection of these components.

  • Page 8: Installation Planning

    FoamPro unit can to the foam pump. The 2002 and 2024 systems can best be installed onto a particular apparatus. Figure be positioned with a suction lift not to exceed 6 ft (1.8...

  • Page 9: Plumbing Component Installation

    FoamPro 2000 series foam pump/motor base assembly. It is required to use flexible hose when making the hose connections to the FoamPro DON’T 2000 series. DO NOT hard pipe the system.
  • Page 10 Installation and Operation Manual Installation and Operation Manual Figure 4. FoamPro 2001/2002 Mounting Dimensions 11-3/8" 6-1/16" 22-3/4" 13/16" 11-7/8" 13-3/8" 33-9/16" 13/32" Mounting 16-1/8" Holes (4) Figure 4a. FoamPro 2024 Mounting Dimensions B. DISCHARGE RELIEF VALVE Protect the hoses and wiring from chafing and abrasion The discharge relief valve is installed on the outlet port during operation of the foam system.
  • Page 11 Valves create severe turbulence when they are D. LINE STRAINER “gated-down”. The line strainer that is provided with the FoamPro unit has 3/4-inch NPT female threaded ports for the 2001 & 2002 systems and 1-inch NPT female threaded ports for d.
  • Page 12 This fitting is not used priming without drawing foam into the piping. See if using a FoamPro Main Waterway Check Valve. A Figure 12. separate injection point is not possible for each discharge.
  • Page 13 4. Shut off FoamPro 2000 system by depressing the FOAM button on the Digital Display Control Module. I. FLUSHING SYSTEM Close flushing water supply valve.

  • Page 14: Electrical Equipment Installation

    Complete molded cable sets are provided with each disconnect switch, PTO or other device. FoamPro system to make all the necessary connections. • Provide at least the following amounts of electrical The cables are color coded and “indexed”...
  • Page 15 CAUTION: The cables shipped with each from the back of the operator panel to clear wires FoamPro unit are tested at the factory with and connectors. Make sure there is enough clearance that unit. Improper handling and forcing behind the operator’s panel for the cables.
  • Page 16 Installation and Operation Manual B. FLOWMETER(s) CONNECTIONS FOAMPRO FLOWMETER If a single FoamPro paddlewheel-type flowmeter is to be used, a molded cable that connects from the flowmeter to the 3 pin connector on the Digital Display Control Module is supplied.
  • Page 17 – the better the power supply, the better the system will perform. Following the instructions that follow will ensure the FoamPro system will perform at its best. Power and ground connections must come directly from the battery to the connections shown in figures 13 and 14.
  • Page 18 Bracket Assy Master Disconnect Switch, PTO Switch, Controller or Manual Switch Power Lead (+) Battery Common Power Connection for other FoamPro Accessories Relay, or Solid Common Ground Connection State Contactor for other FoamPro Accessories Appropriately Sized Amp Fuse or Breaker...
  • Page 19 F. SOLID STATE CONTACTOR (SSC) The usage of the optional solid state contactor (SSC) is recommended to help protect the FoamPro system from excessive voltage surges that can take place in fire apparatus systems. The SSC also has a higher life expectancy than mechanical relay options used for master switch applications.

  • Page 20: Making Sure Everything Is Working Right

    Installation and Operation Manual Making Sure Everything is Working Right Electrical • Tank level sensor is connected and the connections are sealed from moisture. • Digital Display Control Module connectors are correct and tight. • Cable connections at the motor driver box are correct and tight. •...
  • Page 21 (See Figure 23). Figure 22. Simulated Flow Indication • Engage the FoamPro system by pressing the red “FOAM” button. • Foam concentrate should begin flowing into the container. If concentrate is not being pumped, check first to make sure the foam pump is running.

  • Page 22: Calibration And Setup

    The display will show “Elec Setup” until START/STOP OPERATION any function button is pressed. The FoamPro controller is factory defaulted to the dual- tank option. If you are installing a remote start/stop Exit from Calibration and Setup mode is accomplished system, you must change the default setting for proper by pressing and releasing the switch again.
  • Page 23 Enter the Calibration and Setup Mode using the FOAM CONCENTRATE INJECTION RATE method previously described. Press the SELECT button When power is supplied to the FoamPro system, the to illuminate the light below TOTAL FOAM on the Digital foam concentrate injection rate in memory will be the Display Control Module.
  • Page 24 DO NOT set the relief valve above 400 concentrate can then be calculated from this weight. psi [28 BAR]. Start the FoamPro foam pump by pressing the red Perform this adjustment after the foam pump has been “FOAM” button. The foam pump will operate and pump primed.

  • Page 25: Operating Instructions

    The “ON” status lamp will flash when foam is being injected. The FoamPro system will monitor the If the flow decreases such that the required injection water flows and control foam injection at the specified rate is less than the lowest rating of the pump, the pump concentrate injection rate.

  • Page 26: Display Information

    Installation and Operation Manual DISPLAY INFORMATION FOAM PERCENTAGE (%) The five-digit display on the Digital Display Control When the concentrate percentage (%) is selected, the Module shows the value of the selected display function buttons will respectively increase or decrease or provides warnings to the operator when the system foam concentrate percentage.
  • Page 27 Installation and Operation Manual Normal Operation Summary Display Action How to 1. Operate the apparatus engine 1. Turn FoamPro system on. to develop hydraulic pressure. Turn the FoamPro Main Power circuit breaker switch on. FRC or HYPRO will appear on the display momentarily.
  • Page 28 8. Turn the apparatus Master or 8. Turn the FoamPro system off. Battery switch off. The system can also be turned off by using the circuit breaker switch on the valve driver box.
  • Page 29 System 2000 Installation and Operation Manual Warning: When operating the FoamPro in the Simulated Flow Operation 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 30 The pump is now primed and ready for normal foam concentrate flow quickly, the following procedure operation. can be used. 4. If the fire pump is not running, place the FoamPro into the simulated flow mode and proceed with above steps.

  • Page 31: Maintenance

    System 2000 Installation and Operation Manual Maintenance 1. Monthly: Inspect wiring, hoses, flowmeters and connections for tightness, corrosion, leaks and/or damage. 2. Monthly: Remove and clean the foam strainer screen(s). Flush as required. 3. Monthly: Check foam pump gear case oil level and refill as necessary with proper lubricant as described below.

  • Page 32: Troubleshooting

    Installation and Operation Manual Troubleshooting These FoamPro systems are designed to be easy to diagnose and service. There are several major components. Servicing the system involves isolation of the failed component and replacing it. There are no user serviceable internal components. Due to the reliable nature of modern electronics, most failures are traced to faulty cables or wiring problems.
  • Page 33 System 2000 Installation and Operation Manual Installation and Operation Manual NOTE: ALWAYS REPLACE THE COVER SCREW AND O-RING TO KEEP WATER AND DIRT FROM “Total Water” ENTERING THE DIGITAL DISPLAY CONTROL The value shown reflects the level of the liquid foam MODULE BECAUSE IT CAN CAUSE SERIOUS concentrate in the tank.

  • Page 34: Troubleshooting Guide

    Installation and Operation Manual TROUBLESHOOTING GUIDE Symptom Probable Cause(s) Corrective Action Pump runs but produces no flow. Pump is not primed. See Foam Pump Priming Check section on Page 19. Pump loses prime, chattering noise, Air leak in suction hose or inlet fittings. Remove suction hose and test for leaks by pressurizing pressure fluctuates.
  • Page 35 Repair or replace faulty components. ERR.SU on power up. Setup parameter memory is not functioning. Contact FOAMPRO for replacement. (NOTE: This unit will continue to operate using factory setup values.) Display shows “?” for flow. Flowmeter is sensing water flow, but the flow rate is Check flowmeter.

  • Page 36: Parts Identification

    Installation and Operation Manual Parts Identification for System 2001 (optional) Ref. Part No. Description Qty. Ref. Part No. Description Qty. 2341B-P-01 Foam Pump Assembly-2001 2910-0011 Clamp, Vinyl Coated 3300-0092 Relief Valve (Inc. brass tee fitting) 2530-0061 Capacitor (82,000uF) 3304-0025 Cal/Inject Valve 1510-0086 Mounting Bracket 2404-0271...
  • Page 37 System 2000 Installation and Operation Manual Parts Identification for System 2002 (optional) Ref. Part No. Description Qty. Ref. Part No. Description Qty. 2345B-P-08 Foam Pump Assy-2002 1510-0086 Mounting Bracket 2331B-P-01 Foam Pump Assy-2002HP 2404-0182 Injector Fitting (optional) 3300-0092 Relief Valve (Inc. brass tee fitting) 2510-0028 Tank Level Sensor (Vertical) 3304-0025...
  • Page 38 Installation and Operation Manual Parts Identification for System 2024 Ref. Part No. Description Qty. Ref. Part No. Description Qty. 2413B-P-01 Foam Pump Assy-2024 2527-0069 Driver Box 3300-0092 Relief Valve 2530-0097 Terminal Block 3304-0025 Cal/Inject Valve 2520-0107 Ground Strap 2404-0271 Reducer 2527-0031 Diode Block 2404-0272...

  • Page 39: Installation Drawings

    System 2000 Installation and Operation Manual Installation Drawings Display Requires 3-7/8’’ [98 mm] Dia. Hole 3.50 1.04 2.70 4.25 [88.9] [26.3] [68.7] [108] 4.25 3.50 [108] [88.9] #10 24UNC x 7/16 DP (4) Studs for Mounting Cutout Dimensions for Display Control Module 2x Mounting Location for Thru Holes or Tapped Holes or #4 Fastener...
  • Page 40 Installation and Operation Manual FoamPro Flowmeter Flowmeter Assembly 2660-0056 O-Rings 4.00* min. (102 mm) Retaining Pin 85° max. Note #3 Female Pipe Threads 3.12* min. (79 mm) Grooved for B Pipe NOTES: 1. Use CAUTION not to damage sensor during assembly.
  • Page 41 System 2000 Installation and Operation Manual NOTES...
  • Page 42 Installation and Operation Manual NOTES...
  • Page 43 System 2000 Installation and Operation Manual NOTES...

  • Page 44: Limited 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 two years 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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