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FoamPRO 2002 Installation And Operation Manual

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Form 825
02/02
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 by Hypro Corporation • 375 Fifth Avenue NW • New Brighton, MN • (651) 766-6300 • FAX (651) 766-6614
S y s t e m s
2001, 2002
and
2002HP
INSTALLATION AND
OPERATION MANUAL
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Installation and Operation Manual
Unit
Serial
Number
S y s t e m s
S y s t e m s
2001 and 2002
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 by Hypro Corporation • 375 Fifth Avenue NW • New Brighton, MN • (651) 766-6300 • FAX (651) 766-6614 Menu...

  • Page 2: Table Of Contents

    WARRANTY ......................BACK PAGE NOTE TO SYSTEM INSTALLER IMPORTANT: Please provide a copy of the FoamPro manual to the end user of the equipment. For additional manuals, contact Hypro Corporation by FAX (651) 766-6614 or call (651) 766-6300. Ask for Form No. 825.

  • Page 3: Safety

    1. Do not pump at pressures higher than the 10. CAUTION: Be sure that the electrical maximum recommended pressure (400 psi source of power for the 2001 and 2002 units are 12 volt, the 2001/24 and 2002/24 are [28 BAR]).

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

    The basic Foam concentrate is injected directly into the FoamPro 2001 and 2002 systems are shown in water stream on the discharge side of the water Figure 1. The systems will accurately deliver pump.

  • Page 5: System Component Description

    (The flowmeter is a required component and 1. DIGITAL DISPLAY CONTROL MODULE must be ordered separately. When ordering the 2. MOLDED CABLES 2001 or 2002, specify the flowmeter size based 3. FOAM PUMP ASSEMBLY on end use requirements. The flowmeters are 4. INSTRUCTION PLATE available with 1-1/2 NPT x 1"...
  • Page 6 S y s t e m s S y s t e m s 2001 and 2002 Installation and Operation Manual SYSTEM ACCESSORIES AVAILABLE Polypropylene Foam Tank(s) Electronic Dual Tank System with 8 gallon, Automatic Flush P/N 1530-0005 Provides automatic 8 second flush of...

  • Page 7: Installer Supplied Parts

    Installation and Operation Manual INSTALLER SUPPLIED PARTS The FoamPro 2001 and 2002 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 2001 12 VDC requires 41 amps; 2002 or 2002HP 12 VDC requires 56 amps; CAUTION: Always disconnect the ground 2001 24 VDC requires 22 amps; straps and control cables from the Digital 2002 or 2002HP 24 VDC requires 30 amps.

  • Page 9: Installation Planning

    FoamPro unit can best be installed the operators panel. onto a particular apparatus. Figure 2 shows the...
  • Page 10 It is required to use flexible abrasion during operation of the foam system. hose when making the hose connections to the FoamPro 2001 and 2002. DO NOT hard pipe Protect the foam pump base unit from excessive the system.
  • Page 11 Mounting Vertical [13 mm] inside diameter and be rated at Mounting 400 psi [28 BAR] for 2001/2002 models or 600 psi [41 BAR] for 2002HP models minimum Figure 5. Foam Pump Mounting Position working pressure or maximum discharge pressure of the fire pump.
  • Page 12 [28 BAR] minimum) (600 psi [41 BAR] for 2002HP models). E. FLOWMETER(S) The FoamPro System 2001 and 2002 are designed to accept flow reading signals from the FoamPro paddlewheel style flowmeter. Proper flowmeter sizing is critical to system accuracy. Select a flowmeter size based on actual flows required, not standard pipe sizes.
  • Page 13 Installation and Operation Manual FOAMPRO PADDLEWHEEL FLOWMETERS The FoamPro paddlewheel style flowmeter FoamPro Main Waterway Check Valve. A fittings are specially designed tees that make separate injection point is not possible for each inspection and maintenance of the flow sensor discharge.
  • Page 14 3. Energize FoamPro 2000 and allow electric motor driven foam pump to run until discharge is clear. 4. Shut off FoamPro 2000 system by depressing the Main Waterway FOAM button on the Digital Display Control Module.

  • Page 15: Electrical Equipment Installation

    14) for proper hookup of each of the flow even with the master circuit breaker off. electrical components. Complete molded cable sets are provided with each FoamPro system to • DO NOT cut molded cables. make all the necessary connections. The •...
  • Page 16 S y s t e m s 2001 and 2002 Installation and Operation Manual HYPRO Figure 14. FoamPro 2001 Electrical Wiring Diagram • Do not mount radio transmitter or transmitter • CAUTION: Always disconnect the ground cables in direct or close contact with the straps and control cables from the Digital FoamPro unit.
  • Page 17 (see Figure 15). 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 18 S y s t e m s S y s t e m s 2001 and 2002 Installation and Operation Manual the other cable end to the motor driver box on the foam pump/motor base assembly (see Figure 16). Check low level sensor operation after installation using a powered test light.
  • Page 19 The FoamPro Install clamp-on beads at the locations indicated 2001 and 2002 systems are no different — the in Figure 19. Slide the beads as close as better the power supply, the better the FoamPro possible to the connectors on the cable.
  • Page 20 S y s t e m s S y s t e m s 2001 and 2002 Installation and Operation Manual FLOWMETER AND CABLES The flowmeter tee must be grounded. If metal piping is used, sufficient grounding may be present. However, Victaulic joints, plastic pipe...

  • Page 21: Making Sure Everything Is Working Right

    S y s t e m s S y s t e m s 2001 and 2002 Installation and Operation Manual MAKING SURE EVERYTHING IS WORKING RIGHT Electrical ❑ Tank level sensor is connected and the connections are sealed from moisture.
  • Page 22 2001 and 2002 Installation and Operation Manual If you are still having difficulty priming the foam collect the output that will be coming from the pump in your FoamPro system, do the foam pump. following: • Put the system into “simulated flow mode”...

  • Page 23: Calibration And Setup

    • Enter the setup mode by pressing the SYSTEM SETUP PROCEDURES internal button on the left side of the FoamPro systems permit easy calibration of the controller. foam proportioning unit to assure accurate • Enter the diagnostics mode by pressing the operation.
  • Page 24 FOAM CONCENTRATE INJECTION RATE system is calibrated with an accurate flow When power is supplied to the FoamPro measuring device. Determine the water flow system, the foam concentrate injection rate in normally expected from that flowmeter memory will be the default injection rate setting.
  • Page 25 These Setup and Calibration procedures the actual concentrate injection may vary by as complete the adjustment of the system. The FoamPro system is now ready to be placed in much as 10%. When using the dual tank system, each foam concentrate should always service.
  • Page 26 The following procedures are it in a position to relieve at low pressure. provided if adjustment is necessary in field CAUTION: DO NOT run the FoamPro 2001 installation. DO NOT set the relief valve above or 2002 system more than one minute dead 400 psi [28 BAR].

  • Page 27: Operating Instructions

    The “ON” status lamp will flash If the flow decreases such that the required when foam is being injected. The FoamPro injection rate is less than the lowest rating of the system will monitor the water flows and control...
  • Page 28 S y s t e m s S y s t e m s 2001 and 2002 Installation and Operation Manual operator when the system is operating. A display will switch to the “%” display and show function is selected by pressing the grey the current percentage that is set, in any display “SELECT”...
  • Page 29 2001 and 2002 Installation and Operation Manual Normal Operation Summary How to Display Action 1. Turn FoamPro system on. 1. Operate the apparatus engine to develop hydraulic pressure. Turn the FoamPro Main Power circuit breaker switch on. HYPRO will appear display momentarily.
  • Page 30 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 31 Installation and Operation Manual Simulated Flow Operation The Simulated Flow function of the system allows the Warning: When operating the FoamPro in the operator to control the foam pump manually. The water Simulated Flow function, an outlet for the foam flow rate and the concentrate injection percentage rate concentrate injection must be provided.
  • Page 32 Turning the apparatus Master or Battery switch off will also turn off the Simulated Flow Function. The next time the power is turned on, the FoamPro will return to the original automatic default settings.

  • Page 33: Maintenance

    TANK HAS RUN DRY 2. With the fire pump flowing water from foam discharge and the FoamPro on observe the In some instances, the foam tank may run dry hose from the CAL/INJECT valve. while operating the FoamPro system. The foam 3.

  • Page 34: 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 35 S y s t e m s S y s t e m s 2001 and 2002 Installation and Operation Manual “Total Water” NOTE: ALWAYS REPLACE THE COVER SCREW AND O-RING TO KEEP WATER AND The value shown reflects the level of the DIRT FROM ENTERING THE DIGITAL liquid foam concentrate in the tank.

  • Page 36: Troubleshooting Guide

    No characters are displayed on the Note: The main switch is current limited digital display. to 41 amps for System 2001/12V DC; 56 amps for System 2002 & 2002HP/12V DC; 22 amps for System 2001/24V DC; 30 amps for System 2002/24V DC.
  • Page 37 S y s t e m s S y s t e m s 2001 and 2002 Installation and Operation Manual TROUBLESHOOTING GUIDE (Cont'd.) Symptom Probable Cause(s) Corrective Action System returns to standby mode Insufficient power supply. Inspect and correct power and ground while pumping or HYPRO appears connections, and wiring.

  • Page 38: Parts Identification

    S y s t e m s S y s t e m s 2001 and 2002 Installation and Operation Manual PARTS IDENTIFICATION FOR SYSTEM 2001 ¤ Read and Understand Operating Manual To Operator: Push red foam button. Light below switch will indicate unit is operating and will flash when foam is being injected.
  • Page 39 S y s t e m s S y s t e m s 2001 and 2002 Installation and Operation Manual PARTS IDENTIFICATION FOR SYSTEM 2002 ¤ Read and Understand Operating Manual To Operator: Push red foam button. Light below switch will indicate unit is operating and will flash when foam is being injected.

  • Page 40: Installation Drawings

    S y s t e m s S y s t e m s 2001 and 2002 Installation and Operation Manual INSTALLATION DRAWINGS Display Requires 3-7/8'' [98 mm] Dia. Hole 4.25 in. (108 mm) 3.50 in. (89 mm) 1.75 in.
  • Page 41 S y s t e m s S y s t e m s 2001 and 2002 Installation and Operation Manual FoamPro Flowmeter NOTES: Use CAUTION not to damage sensor during assembly. Use Loctite PST 565 or equivalent Teflon tape to seal pipe threads.
  • Page 42 S y s t e m s S y s t e m s 2001 and 2002 Installation and Operation Manual...
  • Page 43 S y s t e m s S y s t e m s 2001 and 2002 Installation and Operation Manual...

  • Page 44: Warranty

    WARRANTY Hypro Corporation, 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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